IMAT Ceramic Oxygen Module Assembly
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Solution Overview
Problem
Current oxygen generating systems are unable to produce high-pressure oxygen above 1800 psi and are susceptible to leakage due to the use of spherical joints, which are expensive and prone to failure.
Innovation Solution
The development of an Integrated Manifold and Tube (IMAT) module design where ceramic elements are injection molded with electrically conductive coatings, forming a series-parallel array of tubes that are sealed together to create a modular electrochemical device capable of generating high-pressure oxygen, reducing the number of connections and eliminating the need for spherical joints.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If spherical joints are used to connect IMAT modules to metal tubes, then the system can be assembled, but leakage occurs and the joints become expensive
Solution Approach 1:
The patent merges the manifold and tube into a single integrated ceramic component, eliminating the need for separate spherical joints and metal tube connections. The IMAT module integrates the gas collection manifold and outlet tube as one piece, reducing connection points and eliminating leakage issues associated with spherical joints.
Solution Approach 2:
The patent extracts the metal tube and spherical joint components from the system and replaces them with an integrated ceramic structure. By removing these separate components, the design eliminates the leakage problems and reduces assembly complexity while maintaining the necessary gas transport function.
2Productivity
If multiple separate IMAT modules are used, then oxygen generating capacity increases, but assembly complexity and leakage risk increase
Solution Approach 1:
The patent combines multiple IMAT modules into a single integrated unit where the manifold and tube are formed as one piece. This merging reduces the number of separate components that need to be assembled, thereby reducing assembly complexity while maintaining the ability to generate high volumes of oxygen through multiple electrochemical cells.
3Reliability
If spherical joints and metal tubes are used, then the system can deliver oxygen, but the cost increases
Solution Approach 1:
The patent merges multiple components (manifold, tube, and electrochemical cells) into a single integrated ceramic structure that can be manufactured as one piece. This eliminates the need for expensive spherical joints and metal tube assemblies, reducing manufacturing costs while maintaining system functionality.
Solution Approach 2:
The patent removes the expensive metal tube and spherical joint components from the system, replacing them with an integrated ceramic design. This extraction of problematic components directly reduces manufacturing cost while preserving the oxygen delivery function through the integrated ceramic structure.
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 allows for the efficient generation of high-pressure oxygen while minimizing leakage and assembly complexity, enabling more modules to be integrated in the same oven size with improved structural integrity and reduced costs.
Implementation Method 1
oxygen can be removed from more complex gasses, such as air, by an electrochemical process of ionizing the oxygen molecules, transporting the oxygen ions through a solid electrolyte and reforming the oxygen molecules on an opposite electrolyte surface
Implementation Method 2
transporting the oxygen ions through a solid electrolyte
Implementation Method 3
An electrical potential is applied to a suitable catalyzing electrode coating applied to the surface of the electrolyte which is porous to oxygen molecules and which acts to disassociate oxygen molecules into oxygen ions at its interface with the electrolyte
Data Source
AI summary
An ionically conductive ceramic element includes a central unit (703). The central unit (703) is composed of a plurality of integrated manifold and tube modules (IMAT) (22) joined end to end along a central axis (A). Each IMAT module (22) has a tube support portion (804) and a plurality of tubes (802) extending from the first surface (803). The tubes (802) each have a closed end (805) and an open end. The second surface (807) is at least partially open to the atmosphere. The open ends of the tubes (802) are open to the atmosphere through the second surface (807). An interior space (830) is formed in the interior of the IMAT (22) for collecting a desired product gas. A collection tube (710) is operable joined with a first end (714) of the central unit (703) for transporting the desired product gas collected in the interior space (730) of the connected IMAT modules (22).