Electrochemical Reactor Flow Guide Printing for Deeper Channels
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Solution Overview
Problem
Existing methods for manufacturing fluidic circuits in fuel cells are limited by the maximum print height of 200 μm, which restricts channel depth and width, leading to inefficiencies due to pressure drops and high production costs.
Innovation Solution
A method using two mesh screens with specific opening configurations to superimpose patterns, allowing for pyramidal printing of fluidic circuits with a shape ratio greater than 1, enabling channels deeper than 200 μm and reducing the width of the tooth/channel step.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a single mesh screen is used for screen-printing, then the manufacturing process is simple, but the channel depth is limited to maximum 200 μm
Solution Approach 1:
The printing process is segmented into multiple sequential steps using different mesh screens. First, a base layer is printed with a first mesh screen, then additional layers are printed with a second mesh screen that has smaller opening dimensions. This segmentation allows achieving channel depths exceeding 200 μm by building up material in controlled stages, resolving the contradiction between manufacturing precision and device complexity.
Solution Approach 2:
The invention transitions from single-layer printing to multi-layer superimposed printing. By adding the vertical dimension of layer stacking with progressively smaller opening dimensions, the channel depth is enhanced beyond the 200 μm limit of single-screen printing, while maintaining systematic control over the printing process.
2Loss of energy
If the channel width is reduced to improve performance, then pressure drops decrease, but the manufacturing precision becomes more difficult to achieve
Solution Approach 1:
The channel width control is achieved through segmented printing with multiple mesh screens having progressively smaller opening dimensions. This allows precise control of the tooth/channel step width by selecting appropriate screen combinations, enabling narrow channels that reduce pressure drops while maintaining manufacturability through systematic multi-step printing.
Solution Approach 2:
The invention changes the opening dimension parameters of the mesh screens across different printing steps. By using a second mesh screen with smaller opening dimensions than the first, the process achieves finer width precision for the channels and teeth, allowing optimization of hydraulic performance while maintaining manufacturing feasibility.
3Manufacturing precision
If the shape ratio of ribs is increased to enable deeper channels, then the channel depth increases, but the structural stability may be compromised
Solution Approach 1:
The rib structure is built segmentally through multiple printing layers with different opening dimensions. Each layer contributes to the overall rib height and stability, creating a pyramidal or stepped structure that maintains structural integrity while achieving greater depths. The segmented construction allows optimization of the shape ratio without compromising strength.
Solution Approach 2:
The invention uses multi-dimensional layering to achieve deep channels while maintaining rib stability. By stacking material in controlled vertical layers with progressively refined dimensions, the process creates stable rib structures with enhanced depth, transforming the single-dimension depth problem into a multi-dimensional construction solution.
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 approach enables the production of fluidic circuits with enhanced channel depth and reduced width, improving efficiency and reducing production costs while maintaining mechanical and electrical integrity.
Implementation Method 1
printing a first layer of a first electrically-conductive ink by screen-printing using a first mesh screen
Data Source
AI summary
The invention relates to a method for manufacturing at least one flow-guide (1, 1′) for an electrochemical reactor, comprising the following steps:a) Providing a substrate (10),b) Providing a first mesh screen (11) comprising openings (111) configured to form a first pattern (21) of ribs (211) of a first flow-guide (1),c) Providing a second mesh screen (12) comprising openings (121) configured to form a second pattern (22) of ribs (221) of the first flow-guide (1).The invention uses a mesh screen printing technique to produce fluidic circuits with a large channel depth and with an aspect ratio equal to or greater than 1.