Co-Extrusion Die for Multilayer Cell Layers With Precise Thickness Control
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Solution Overview
Problem
Current manufacturing processes for electrochemical cells, such as electrolysis cells and batteries, are costly and labor-intensive due to the use of excessive expensive materials like platinum and Nafion, with traditional methods requiring multiple steps and high material quantities.
Innovation Solution
A co-extrusion die is used to produce a multilayer extrusion comprising component layers of an electrochemical cell, allowing for the simultaneous extrusion of a polymeric membrane layer between metallic layers and electrode layers, reducing the number of manufacturing steps and material usage through controlled pressure adjustment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional multi-step manufacturing processes are used for membrane electrode assemblies, then each layer can be separately controlled and assembled, but the manufacturing cost increases and production time extends
Solution Approach 1:
The patent combines multiple separate manufacturing steps (extrusion of membrane, electrodes, and GDL layers) into a single co-extrusion process. The multi-layer extrusion die simultaneously produces all layers in one continuous operation, eliminating sequential assembly steps while maintaining precise layer control through independent channel design and pressure regulation for each material stream.
Solution Approach 2:
The extrusion die is segmented into multiple independent channels, each dedicated to a specific layer material (membrane, electrode, GDL). This segmentation allows separate control of each material stream through individual pressure regulation systems and channel geometries, enabling precise thickness and composition control for each layer while producing them simultaneously.
2Adaptability or versatility
If larger quantities of expensive materials are used to accommodate manufacturing processes, then process flexibility is improved, but material cost increases
Solution Approach 1:
The patent employs parameter changes by regulating the pressure of each material stream independently during co-extrusion. By adjusting pressure parameters for each channel, the process can accommodate different material viscosities, flow rates, and thickness requirements without changing the fundamental co-extrusion process or requiring excess materials for process flexibility.
3Ease of manufacture
If multiple manual steps are used for coating, drying, heating, and pressing layers, then each step can be optimized independently, but labor intensity and manufacturing complexity increase
Solution Approach 1:
The patent merges coating, drying, heating, and pressing operations into a single co-extrusion and consolidation step. The multi-layer structure is formed directly in the extruded state with layers already bonded together, eliminating the need for separate manual coating, drying, heating, and pressing steps that would otherwise be required for each layer assembly.
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
This approach streamlines the manufacturing process, reducing costs by 44% for membrane electrode assemblies and overall system costs by 7%, while maintaining quality and enhancing catalyst utilization and layer uniformity.
Implementation Method 1
A plurality of channels are configured to separately transport and shape the plurality of fluids from the plurality of inlet ports to a merge section, such that the plurality of fluids flow together in the merge section to form the multilayer extrusion. A thickness of each layer within the merge section is controllable by adjustment of a pressure of the plurality of pressurized fluids.
Implementation Method 2
A plurality of channels are configured to separately transport and shape the plurality of fluids from the plurality of inlet ports to a merge section, such that the plurality of fluids flow together in the merge section to form the multilayer extrusion comprising a polymeric membrane layer disposed between and in contact with a first metallic layer and a second metallic layer.
Data Source
AI summary
A co-extrusion die is configured to produce a multilayer extrusion comprising component layers of an electrochemical cell. The die comprises a plurality of inlet ports configured to receive a plurality of pressurized fluids comprising at least a first metallic ink, a second metallic ink, and a polymeric ink. A plurality of channels are configured to separately transport and shape the plurality of fluids from the plurality of inlet ports to a merge section, such that the plurality of fluids flow together in the merge section to form the multilayer extrusion comprising a polymeric membrane layer disposed between and in contact with a first metallic layer and a second metallic layer. A thickness of each layer within the merge section is controllable by adjustment of a pressure of the plurality of pressurized fluids. An outlet port is configured to output the multilayer extrusion onto a substrate.