Membrane-to-Frame Fixation for Leak-Safe Cell Stack Sealing
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Solution Overview
Problem
Existing methods for securing membranes to frames, such as in battery cells, often fail to provide a durable and tight connection, especially when materials are incompatible, leading to issues like electrolyte mixing and short-circuiting due to inadequate sealing.
Innovation Solution
A method involving the creation of a fixation area with a first zone for integral bonding between frame members and a second zone for mechanical deformation of the membrane, allowing for secure attachment without destroying the membrane, using techniques like ultrasonic welding or mechanical compression.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding is used to join frame members, then a strong and durable connection is achieved, but the process becomes complex or unfeasible when the materials are incompatible
Solution Approach 1:
The fixation area is divided into two distinct zones: a first zone where frame members are integrally bonded together through welding, and a second zone where the membrane is mechanically deformed and secured. This segmentation allows each zone to use the most appropriate fixation method for its specific requirements, resolving the contradiction between achieving strong connections and managing material incompatibility.
Solution Approach 2:
Different fixation methods are applied to different locations within the fixation area. The first zone uses integral bonding (welding) for strong frame member connection, while the second zone uses mechanical deformation for membrane attachment. This local differentiation of quality and method allows compatible materials to be welded while accommodating incompatible materials through mechanical means in specific areas.
2Ease of manufacture
If adhesive bonding or mechanical clamping is used to secure incompatible materials, then the connection is feasible, but the adhesive must withstand harsh environments or the mechanical forces may cause destruction
Solution Approach 1:
The fixation area is segmented into zones with different fixation mechanisms. The first zone provides integral bonding for reliable frame connection, while the second zone uses mechanical deformation for membrane attachment. This eliminates the need for adhesives to withstand harsh environments, as the membrane is mechanically secured in the second zone where environmental exposure is most severe.
Solution Approach 2:
The fixation area acts as an intermediary zone between the frame members and the membrane. Within this area, the first zone provides structural bonding while the second zone provides mechanical attachment, serving as a transition region that accommodates the incompatible materials without requiring direct bonding between them. This intermediary structure allows each material to be treated with the most appropriate method.
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 method provides a durable and secure attachment of membranes to frames, preventing leakage and short-circuiting by combining integral bonding and mechanical deformation, even with incompatible materials, thus ensuring reliable operation in environments like battery cells.
Implementation Method 1
The first and second frame members may be integrally bonded together, for example, by an ultrasonic welding process
Implementation Method 2
Creating the second zone comprises mechanically deforming the membrane between the first frame member and the second frame member
Data Source
Figure 1a~1b
Figure 2a~3a
Figure 3b
AI summary
The present invention provides a method of fixing a membrane between a first frame member and a second frame member, the membrane having at least one property conferring incompatibility for fixing it to the first and second frame members. The method comprises: creating a fixation area comprising a first zone and a second zone, wherein creating the first zone comprises integrally bonding the first frame member to the second frame member, and wherein creating the second zone comprises mechanically deforming the membrane between the first frame member and the second frame member. There is also provided a cell stack and a use of an ion-exchange membrane in the disclosed cell stack.