Edge-Densified Porous Metal Substrates for Welded Electrochemical Cells
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Solution Overview
Problem
Conventional porous metal substrates used in metal-supported electrochemical cells are prone to deformation and sealing issues during welding or diffusion bonding, limiting the assembly of robust and durable cell stacks due to mismatched coefficients of thermal expansion and non-uniform compression.
Innovation Solution
A reinforced porous metal substrate with a densified metal reinforcement member along its perimeter, enabling weld sealing or diffusion bonding, which provides structural strength and a site for bonding, allowing for the construction of a backbone-structured electrochemical cell stack with improved durability and power density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional porous metal substrate is used for metal-supported electrochemical cell, then the cell can be constructed with porous metal support, but the substrate is prone to deformation and cave-in during welding or diffusion bonding process
Solution Approach 1:
The invention uses a composite structure consisting of a porous metal substrate combined with a densified metal reinforcement member. The porous substrate provides necessary porosity for electrochemical function, while the densified reinforcement member provides structural strength and resistance to deformation during welding. This composite approach allows the cell to maintain both manufacturability through welding and structural integrity.
2Productivity
If porous metal substrate with high porosity is used, then the electrochemical performance is improved, but the substrate becomes prone to cave in and deformation during welding
Solution Approach 1:
The invention applies local quality by having different regions of the metal substrate with different properties. The central region maintains high porosity (20-50 vol%) for optimal electrochemical performance, while the perimeter region incorporates a densified metal reinforcement member with lower porosity to provide structural stability during welding. This spatial differentiation of material properties resolves the contradiction between electrochemical performance and welding reliability.
3Weight of moving object
If weld sealing or diffusion bonding is employed for stack assembly, then the stack weight is reduced and power output is improved, but the porous metal substrate deforms during the bonding process
Solution Approach 1:
The composite structure of porous substrate plus densified reinforcement member enables the use of weld sealing or diffusion bonding for stack assembly. The densified reinforcement member acts as a bonding interface that can withstand the thermal and mechanical stresses of welding without deforming, while the porous substrate maintains its shape and functionality. This allows realization of lighter stacks with higher power output through elimination of gaskets and glass seals.
4Reliability
If conventional joining methods with gaskets and glass seals are used, then sealing is achieved, but the stack becomes heavier and has reduced power output
Solution Approach 1:
The invention extracts and eliminates the need for gaskets and glass seals from the stack assembly by implementing weld sealing or diffusion bonding directly on the densified metal reinforcement member. This removal of auxiliary sealing components reduces stack weight and increases power output while maintaining reliable sealing through the metallurgical bond created during welding or diffusion bonding.
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 solution enhances the durability and thermal cycling capability of electrochemical cell stacks, reduces the need for ceramic and glass seals, and increases power density by allowing for the assembly of lighter, more robust stacks with improved vibration resistance.
Implementation Method 1
a densified metal reinforcement member disposed along at least a portion of a perimeter of one side of the porous metal substrate
Data Source
AI summary
This invention pertains to a reinforced porous metal substrate that finds utility in a backbone-structured metal-supported electrochemical cell and to methods of fabricating the reinforced porous metal substrate. In another aspect, this invention pertains to a backbone-structured metal-supported electrochemical cell repeat unit constructed by weld sealing or diffusion bonding the reinforced porous metal substrate to a metal frame. In another aspect, this invention pertains to an electrochemical cell and stack.