Fuel Cell De-mineralizer Etching Network Flow Distribution
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Solution Overview
Problem
Conventional de-mineralizers for fuel cell systems face issues with ion resin leakage and inefficient flow rate distribution of cooling water due to defects in the welding process of the mesh network, leading to reduced filtering efficiency and increased differential pressure.
Innovation Solution
The de-mineralizer employs an etching network with fine holes of varying sizes or distributions in a cylindrical shape, supported by a frame, to prevent ion resin leakage and enhance cooling water flow rate distribution, using a thin plate member with non-etched portions for spot welding and injection molding to improve the structural integrity and flow efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a mesh network is used to support the ion resin in the cartridge assembly, then the ion resin can be contained and supported, but welding defects occur during manufacturing causing ion resin leakage
Solution Approach 1:
The patent extracts the welding process entirely by replacing the mesh network with a meshless porous support structure. This eliminates the welding step that causes manufacturing defects while maintaining the ion resin containment function through the porous structure's physical architecture rather than welded joints.
Solution Approach 2:
The patent replaces the mechanical welding system with a porous material structure. Instead of joining mesh wires through welding, the support function is achieved through the inherent porosity and structural integrity of the porous material, substituting a mechanical connection system with a material property-based system.
2Reliability
If conventional mesh network structure is used in the cartridge assembly, then ion resin can be supported, but flow rate distribution of cooling water becomes inefficient and differential pressure increases
Solution Approach 1:
The patent employs a meshless porous support structure instead of a conventional mesh network. The porous material provides uniform flow distribution through its interconnected pore structure, allowing cooling water to pass evenly while supporting the ion resin, thereby reducing differential pressure and improving flow rate distribution efficiency.
Solution Approach 2:
The porous support structure provides locally optimized flow paths throughout the cartridge assembly. The uniform distribution of pores ensures that cooling water flows evenly across all regions, creating local flow conditions that collectively achieve efficient overall flow rate distribution and reduced pressure differential.
3Shape
If welding process is used to assemble the mesh network, then the mesh structure can be formed, but manufacturing complexity and cost increase
Solution Approach 1:
The patent removes the welding process from the manufacturing sequence by using a meshless porous support structure. The porous structure can be manufactured as a single integrated component through techniques like sintering or foam formation, eliminating the need for separate welding operations to assemble mesh networks.
Solution Approach 2:
The patent merges the support function and the structural form into a single porous material component. Instead of assembling separate mesh wires through welding, the entire support structure is formed as one integrated porous element, simplifying manufacturing and reducing process complexity.
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 solution effectively prevents ion resin leakage, improves cooling water flow rate distribution, reduces differential pressure, and increases the durability and filtering efficiency of the de-mineralizer, while simplifying the metal mold and reducing costs.
Implementation Method 1
the de-mineralizer serves to remove metal ions from the cooling water discharged after circulating through the fuel cell stack
Data Source
AI summary
A de-mineralizer for a fuel cell includes a cartridge assembly including an external outer cartridge and an internal inner cartridge installed inside a housing filled with ion resin, wherein at least one of the inner cartridge and the outer cartridge includes an etching network formed with a plurality of fine holes, in which at least one of a size and distribution of the fine holes are formed differently depending on the respective positions based on a vertical flow direction of the cooling water, and a frame formed on an outer circumferential surface of the etching network to support the etching network.