Ceramic Spacer Sealing for Thermal-Stable Oxygen Purifier Stacks

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Solution Overview

Problem

Traditional methods for purifying oxygen gas are energy and resource-intensive, and existing on-site oxygen generation technologies are costly and inefficient, particularly for producing high-purity oxygen.

Innovation Solution

A ceramic-based electrochemical stack system that includes a terminal plumbing assembly to manage thermal expansion mismatch between metal and ceramic components, enabling efficient oxygen concentration and pressurization with reduced energy consumption.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If traditional cryogenic air separation is used to produce high-purity oxygen, then oxygen purity is improved, but energy consumption and cost increase significantly

Engineering Contradiction:

Improveoxygen purityVSAvoidenergy consumption

Core Design Contradiction:

Measurement precisionVSUse of energy by moving object

Solution Approach 1:

The patent changes the operating temperature parameter from cryogenic conditions to moderate temperatures (below 100°C), enabling high-purity oxygen production without the excessive energy consumption of traditional cryogenic methods. The ceramic membrane separation process achieves this by operating at temperatures that avoid phase changes while maintaining separation efficiency.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces the mechanical cryogenic distillation system with a ceramic membrane-based separation system. This substitution eliminates the need for complex cryogenic equipment, compressors, and distillation columns, thereby reducing energy consumption while maintaining high oxygen purity through selective gas permeation.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Device complexity

If ceramic spacers are not used in the electrochemical stack, then device complexity is reduced, but thermal expansion mismatch causes structural failure

Engineering Contradiction:

Improvestack structure complexityVSAvoidstructural integrity

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The patent introduces ceramic spacers as intermediary components between metal end plates and ceramic membranes. These spacers act as mediators that accommodate thermal expansion differences, preventing direct stress transmission that would cause structural failure. The spacers absorb differential expansion without compromising the integrity of connected components.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent explicitly addresses thermal expansion by using ceramic spacers with thermal expansion coefficients matched to the ceramic membranes. This allows the stack structure to accommodate temperature changes during operation without generating damaging stresses, thereby maintaining structural integrity in the electrochemical oxygen generation system.

Inventive Principle:

Principle #37Thermal expansion

3Reliability

If on-site oxygen generation is implemented, then supply reliability is improved, but production cost increases

Engineering Contradiction:

Improveoxygen supply reliabilityVSAvoidproduction cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent enables hospitals and facilities to generate their own oxygen on-site using electrochemical cells with ceramic membranes. This self-service approach eliminates dependence on external oxygen tanks and delivery systems, ensuring continuous supply reliability. The system uses readily available materials and moderate operating conditions to keep production costs manageable while providing uninterrupted oxygen supply.

Inventive Principle:

Principle #25Self-service

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The system produces high-purity oxygen gas efficiently and cost-effectively, eliminating the need for cryogenic containers and oxygen cylinders, and is suitable for on-demand use.

Implementation Method 1

a ceramic membrane that separates oxygen from other gases

Methodology Applied

Scientific EffectSelective permeation: Semipermeable Membrane

Implementation Method 2

electrochemical stack system that includes a terminal plumbing assembly to manage thermal expansion mismatch between metal and ceramic components, enabling efficient oxygen concentration

Methodology Applied

Scientific EffectElectrochemical separation: Electrophoresis

Implementation Method 3

enabling efficient oxygen concentration and pressurization with reduced energy consumption

Methodology Applied

Scientific EffectGas compression: Compression

Implementation Method 4

terminal plumbing assembly to manage thermal expansion mismatch between metal and ceramic components

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Data Source

PatentUS20260078511A1Ceramic spacers for electrochemical stack of ceramic oxygen purifier

Publication Date: 2026.03.19 AMERICAN OXYGEN LLC

AI summary

Systems for oxygen concentration and pressurization. An assembly includes a first ceramic wafer, a second ceramic wafer, and a ceramic spacer disposed in between the first ceramic wafer and the second ceramic wafer. The assembly is such that the ceramic spacer is attached to the first ceramic wafer with a first glass-ceramic seal, and the ceramic spacer is attached to the second ceramic wafer with a second glass-ceramic seal. The assembly is such that at least one of the first glass-ceramic seal or the second glass-ceramic seal is a gastight seal after undergoing two or more sintering cycles.