Composite CDI Electrode Lamination to Prevent Pore Blockage
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing capacitive deionization electrodes suffer from reduced deionization efficiency due to pore blockage by binders in the slurry, poor mechanical properties, environmental unfriendliness from organic solvent use, and limited commercial viability due to high costs.
Innovation Solution
A manufacturing method involving the formation of ion exchange resin layers on both surfaces of microporous membranes, which are then stacked and compressed onto a carbon electrode layer, reducing organic solvent use and enhancing mechanical and chemical resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the carbon electrode layer is coated with slurry including ion exchange resin powder, then the ion exchange membrane layer is formed, but the binder and organic solvent permeate into pores of the carbon electrode layer reducing deionization efficiency
Solution Approach 1:
The patent divides the manufacturing process into two separate stages: first forming the ion exchange resin layer on a porous substrate independently, then assembling it with the carbon electrode layer in a second stage. This segmentation prevents the binder and organic solvent from permeating into the carbon electrode pores, maintaining deionization efficiency while still achieving ion exchange membrane layer formation.
2Reliability
If the carbon electrode layer is coated with slurry including ion exchange resin powder, then the ion exchange membrane layer is formed, but the process uses excessive amount of organic solvent reducing environmental friendliness
Solution Approach 1:
The patent extracts the ion exchange resin layer formation process from the carbon electrode coating process. By forming the ion exchange resin layer on a porous substrate separately using minimal or no organic solvent, and then assembling it with the carbon electrode layer, the invention eliminates the harmful effect of excessive organic solvent usage while maintaining ion exchange membrane layer formation.
3Reliability
If the ion exchange membrane layer is formed by coating slurry on carbon electrode layer, then the membrane layer is attached, but the electrode shows poor mechanical properties causing breakage and secession
Solution Approach 1:
The patent performs preliminary action by forming the ion exchange resin layer on the porous substrate separately before assembly with the carbon electrode layer. This preliminary formation allows the porous substrate to provide its full mechanical support function, preventing breakage and secession issues that occur when the ion exchange membrane layer is formed directly on the carbon electrode layer which lacks sufficient mechanical strength.
4Reliability
If the ion exchange membrane layer is formed by coating slurry on carbon electrode layer, then the membrane layer is attached, but the electrode has shortened lifespan due to poor chemical resistance
Solution Approach 1:
The patent employs composite materials by combining a porous substrate with ion exchange resin layers on both surfaces, then assembling this composite structure with the carbon electrode layer. The porous substrate provides chemical resistance and structural stability, while the ion exchange resin layers provide the necessary ion exchange functionality, resulting in an electrode with extended lifespan and improved chemical resistance.
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 method results in high deionization efficiency, improved mechanical properties, and reduced environmental impact, facilitating mass-production and commercialization with cost-effectiveness.
Implementation Method 1
forming ion exchange resin layers on surfaces of microporous membranes
Implementation Method 2
stacking and combining an electrode sheet on one surface of the second unit, wherein the electrode sheet comprises a current collector and a carbon electrode layer formed on at least one surface of the current collector, wherein a composite microporous membrane of the second unit is stacked on and compressed onto the carbon electrode layer
Data Source
Figure [D1]
Figure [D2]
Figure [D3]
AI summary
The present invention relates to a manufacturing method of a composite capacitive desalination electrode which can increase the desalination efficiency and as a new structure with more excellent mechanical and chemical resistance. The present invention also relates to a composite capacitive desalination electrode and assembly. According to the present invention, the manufacturing method of a composite capacitive desalination electrode comprises the following steps: a) forming a composite microporous membrane by forming an ion exchange resin layer on a surface of the microporous membrane; and b) forming the composite microporous membrane prepared in the step a) on both sides of an electrode sheet, thereby producing a first unit including the composite microporous membrane and the electrode sheet. The steps are performed in a single process line by an in-line continuous process.