Electrolysis Module Resin-Molded Structure Reducing Part Count
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Solution Overview
Problem
Conventional pipe-type electrolysis modules face challenges such as high manufacturing costs, space constraints, non-uniform current distribution, and inefficiencies due to large part numbers and complex assembly, as well as issues with scale formation and reduced electrode lifespan.
Innovation Solution
The electrolysis module features a reduced size design with a metal-coated inner electrode for improved current flow, a resin-molded structure for safety and reduced parts, and both inner and outer surfaces of bipolar electrodes used for electrolysis, ensuring uniform current distribution and efficient electrolysis performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional pipe-type electrolysis cells are used with multiple parts and complex assembly, then electrolysis function is achieved, but manufacturing cost increases and device complexity increases
Solution Approach 1:
The patent combines multiple separate components (electrode, insulating spacer, connection structures) into an integrated molded structure. The insulating spacer is molded directly onto the electrode, eliminating the need for separate assembly steps and reducing the total number of parts while maintaining the electrolysis function.
Solution Approach 2:
The molded structure serves multiple functions simultaneously: the electrode provides electrical conduction for electrolysis, the integrated insulating spacer provides electrical insulation and structural support, and the unified design simplifies assembly. This multi-functionality reduces both part count and manufacturing complexity.
2Productivity
If conventional pipe-type electrolysis cells with large size are used, then adequate electrolysis capacity is achieved, but installation space requirement increases
Solution Approach 1:
The patent transitions from a conventional two-dimensional electrode surface to a three-dimensional molded structure where the electrode extends in multiple spatial dimensions. This allows increased electrolysis surface area within a compact volume, improving capacity while reducing installation space requirements.
3Productivity
If conventional electrode design with non-uniform current distribution is used, then electrolysis occurs, but reaction uniformity decreases and heat generation increases
Solution Approach 1:
The molded structure incorporates locally optimized electrode geometry and insulating features that ensure uniform current distribution across different regions of the electrode surface. This local quality control prevents current concentration in specific areas, improving reaction uniformity and reducing localized heat generation.
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 design enhances electrolysis efficiency, reduces manufacturing costs, and minimizes space requirements while maintaining performance, allowing for easier maintenance and installation in constrained spaces, with improved reaction uniformity and reduced heat generation.
Implementation Method 1
a metal-coated inner electrode for improved current flow
Implementation Method 2
when DC power is applied between terminals of an anode and a cathode to cause electrolysis while sea water flows along the surfaces of the inner pipe and the outer pipe, sodium hypochlorite is produced
Implementation Method 3
a resin-molded structure for safety and reduced parts
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
Disclosed is an electrolysis module including: an electrolysis unit module including a plurality of pipe-type electrolysis cells connected in series with each other; a molding case surrounding the periphery of the electrolysis unit module to protect the electrolysis module; a cell guide member installed in the molding case to support the electrolysis unit module; a power cable having a first end connected to the electrolysis unit module and a second end extending to an outside through the molding case; and a resin layer formed by filling the inside of the molding case to cover the outer surface of the electrolysis unit module disposed in the molding case.