Electrochemical Element Stack Assembly With Separated Gas Passages
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Solution Overview
Problem
Conventional electrochemical element stacks require extensive manual effort and high costs due to the need for precise sealing and alignment of many metal substrates, leading to increased production time and reduced reliability.
Innovation Solution
The electrochemical element stack is designed with a simplified configuration using conductive plate-like supports with internal passages, gas-permeable portions, and penetrating passages, allowing for separate flow of gases and reducing the need for individual sealing between elements, enabling easier assembly and production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If many metal substrates are stacked in a sealed manner to form air passages and fuel gas passages, then the electrochemical element stack can generate electrical power through electrochemical reactions, but the production cost greatly increases and production time extends due to the need for extensive manual sealing and alignment work
Solution Approach 1:
The patent divides the complex sealed structure into separate functional components: metal substrates provide structural support and electrical connection, while separate sealing structures (gaskets or sealing layers) provide the gas-tight seals. This segmentation allows each component to be manufactured and prepared independently, then assembled together, dramatically reducing the manual sealing and alignment work required in conventional stacked designs.
Solution Approach 2:
The patent introduces intermediary sealing structures (gaskets or sealing layers) that mediate between the metal substrates. These sealing components simplify the assembly process by providing pre-formed sealing surfaces that require minimal alignment, replacing the need for precise manual sealing between multiple metal substrate interfaces.
2Reliability
If many metal substrates are firmly fixed in a sealed manner, then gas-tightness and electrical connection reliability are improved, but the number of man-hours and extreme care required during production increases
Solution Approach 1:
The patent separates the sealing function from the structural metal substrates by introducing dedicated sealing components. This segmentation maintains reliable gas-tightness and electrical connections while simplifying assembly, as the sealing components can be designed with self-aligning features or standardized interfaces that reduce the need for extreme care during assembly.
Solution Approach 2:
The sealing structures are designed to perform their sealing function automatically upon assembly without requiring extensive manual adjustment or alignment. The sealing components may include self-centering features or elastic properties that enable them to self-adjust to minor variations in substrate positioning, reducing the need for operator skill and time.
3Ease of operation
If a conventional stacked configuration with multiple substrates is used, then air and fuel gas passages are defined, but the cost of producing the electrochemical element stack greatly increases
Solution Approach 1:
The patent merges multiple functions into fewer components. The metal substrates simultaneously provide structural support, electrical conduction, and mechanical spacing, while the sealing components provide both gas-tight sealing and define the gas passages. This functional merging reduces the total number of parts and assembly steps compared to conventional designs where each function is provided by separate components.
Solution Approach 2:
The metal substrates are designed to serve multiple functions: they provide structural support for the electrochemical elements, conduct electricity between elements, maintain spacing between stacked components, and work with sealing structures to define gas passages. This multi-functionality reduces the number of separate components needed, lowering manufacturing cost and 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 configuration significantly reduces production costs and time while maintaining reliability by allowing for easy handling and assembly of electrochemical elements, enhancing the efficiency and durability of the electrochemical element stack.
Implementation Method 1
a gas-permeable portion through which gas is permeable between the internal passage, which is located inside the plate-like support, and the outside
Implementation Method 2
electrochemical output such as electrical power is generated through a reaction between the air and the fuel gas in the electrochemical reaction portion
Data Source
AI summary
An electrochemical element stack that includes a plurality of stacked electrochemical elements, each of the electrochemical elements including a plate-like support provided with an internal passage. The plate-like support includes: a gas-permeable portion through which gas passes between the internal passage located inside the plate-like support and the outside; an electrochemical reaction portion covering the gas-permeable portion; and a first penetrated portion forming a supply passage through which fuel gas flows from the outside of the plate-like support to the internal passage. The plate-like supports of two adjacent electrochemical elements are opposed, an outer face of the first electrochemical element on which the electrochemical reaction portion is arranged is electrically connected to an outer face of the second electrochemical element on which the electrochemical reaction portion is not arranged, and a flowing portion through which air flows along the two adjacent outer faces is formed between the two outer faces.