Electrochemical Cell Inter-Connector Warping with Differential Oxide Layers
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Solution Overview
Problem
The inter-connector in electrochemical cells, due to its protrusions and recesses, is difficult to warp through processing such as stamping, which affects its contact with other components.
Innovation Solution
The inter-connector is designed with a body and two oxide layers of varying thickness and thermal expansion coefficients, allowing it to be warped by thermal stress, with the first oxide layer being smaller or larger than the body depending on the desired direction of warping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the inter-connector includes protrusions and recesses formed by processing such as embossing or slitting, then the inter-connector can serve as a channel for raw material gas supply, but it becomes difficult to warp the inter-connector by processing such as stamping
Solution Approach 1:
The inter-connector is divided into multiple regions with different oxide layer thicknesses (first oxide layer and second oxide layer), creating segments with different thermal expansion characteristics. This segmentation allows the body to warp in specific directions while maintaining the protrusions and recesses for gas supply channels.
Solution Approach 2:
The invention changes the physical parameters of different regions by controlling oxide layer thickness. The first and second oxide layers have different thicknesses, creating parameter variations that enable controlled warping through thermal stress while preserving the gas supply channel structure.
2Reliability
If the inter-connector is warped to ensure contact with contacted objects, then contact reliability is improved, but the presence of protrusions and recesses prevents effective warping
Solution Approach 1:
The invention utilizes thermal expansion differences between the oxide layers and the body material. By heating the inter-connector, the oxide layers expand at different rates due to their different thicknesses, generating internal thermal stress that causes the body to warp into the desired shape for reliable contact.
Solution Approach 2:
The inter-connector is constructed as a composite structure with the body and multiple oxide layers. This composite design allows the different materials to have different thermal expansion coefficients, enabling controlled warping through thermal treatment while maintaining the structural integrity needed for contact reliability.
3Shape
If oxide layers of different thicknesses are applied to the body, then thermal stress can be generated to warp the inter-connector, but the manufacturing process becomes more complex
Solution Approach 1:
The oxide layers are applied with different thicknesses in different local regions of the inter-connector. The first oxide layer has a different thickness than the second oxide layer, creating local quality variations that generate controlled thermal stress and enable precise warping in specific directions.
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 configuration enables reliable contact with adjacent cells by warping the inter-connector, ensuring effective electrical connection and gas flow in electrochemical cells.
Implementation Method 1
the first and second oxide layers are different in thickness from each other; hence, the inter-connector can be warped by a thermal stress generated therein
Data Source
AI summary
The present inter-connector includes a body, a first oxide layer, and a second oxide layer. The body includes a first principal surface and a second principal surface. The second principal surface is opposite to the first principal surface. The first oxide layer is disposed on the first principal surface. The second oxide layer is disposed on the second principal surface. The second oxide layer is different in thickness from the first oxide layer.