Electrochemical Cell Diffusion Layer with High-Pressure Water Punching
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Solution Overview
Problem
Existing methods for producing diffusion layers in electrochemical cells, such as laser punching, are limited in their ability to create a high number of holes efficiently and quickly, which affects the performance and efficiency of the cells.
Innovation Solution
Hydraulic punching, specifically water punching, is used to create a diffusion layer with several million holes by applying high pressures of at least 10,000 bar, using a foil clamped between dies with through and blind holes, ensuring uniform hole formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If laser punching is used to create holes in the diffusion layer, then the production process can be automated, but the number of holes that can be created efficiently is limited
Solution Approach 1:
The patent employs hydraulic punching using water at high pressure (at least 10,000 bar) to create holes in the diffusion layer. This hydraulic approach allows simultaneous creation of several million holes through the foil, dramatically increasing productivity compared to laser punching while maintaining automation. The high-pressure water jet efficiently pierces the metallic foil without the time constraints of sequential laser processing.
2Strength
If the foil thickness is increased to improve durability, then the mechanical strength increases, but the ability to pierce holes effectively decreases
Solution Approach 1:
The patent specifies that the metallic foil should have a maximum thickness of 0.2 mm to optimize the balance between mechanical strength and piercability. This parameter optimization allows the high-pressure water jet (at least 10,000 bar) to effectively create holes while maintaining sufficient structural integrity of the diffusion layer.
3Productivity
If the hole diameter is reduced to increase perforation rate, then more holes can be created, but the manufacturing precision required increases
Solution Approach 1:
The hydraulic punching method using high-pressure water (at least 10,000 bar) enables precise control of hole diameter while maintaining high productivity. The water jet naturally forms uniform cylindrical holes with maximum diameter of 20 μm through the metallic foil, achieving both high perforation rate and manufacturing precision simultaneously.
Solution Approach 2:
The patent emphasizes creating homogeneous perforations with uniform characteristics throughout the diffusion layer. The hydraulic punching process produces consistent cylindrical holes with maximum diameter of 20 μm and homogeneous distribution, ensuring uniform media supply across the entire surface area of the electrochemical cell.
4Productivity
If hydraulic punching is used to increase the number of holes, then the perforation rate increases, but the complexity of the production process increases
Solution Approach 1:
The patent utilizes hydraulic punching with water, leveraging the availability of water as a simple and inexpensive medium. The process requires a pressure vessel capable of generating at least 10,000 bar pressure, but avoids complex laser systems or specialized equipment, thereby increasing productivity while keeping the production process relatively simple and cost-effective.
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 method significantly increases the perforation rate and homogeneity of holes, enhancing media supply and performance of electrochemical cells while reducing production time and costs.
Implementation Method 1
Hydraulic punching is still a very fast production process... hydraulic punching is carried out as water punching... Pressure Increase
Implementation Method 2
The foil is clamped between a first die and a second die during punching... This applies pressure to each subsequent hole in the foil so that all holes are pierced accordingly
Data Source
AI summary
A method for producing a diffusion layer (5, 6) for an electrochemical cell, wherein the diffusion layer consists of a foil (5a, 6a) in which a plurality of holes are made by means of hydraulic punching.