Micro-Channel Electrode Structure for High-Throughput Desalination
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Solution Overview
Problem
There is a need for inexpensive, efficient, and high-throughput methods and devices for enabling electrochemical reactions between an electrolyte and an electrode, particularly in applications like water desalination, where existing technologies are energy-intensive and costly.
Innovation Solution
A three-dimensional micro-channel structure is created by forming electrode and fluid micro-channels in a common step, with the electrode extending into the micro-channel intersection without occluding the fluid channel, and filled with conductive material, allowing for increased flow rates and improved energy efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional electrochemical devices are used, then electrochemical reactions can occur, but energy consumption is high and throughput is low
Solution Approach 1:
The patent transitions from planar two-dimensional electrode structures to three-dimensional micro-channel structures with vertical electrodes extending into fluid channels. This dimensional change increases the electrode-fluid interaction surface area and reaction volume, thereby improving throughput and energy efficiency simultaneously
Solution Approach 2:
The device is divided into multiple segmented micro-channels with individual electrodes in each segment. This segmentation allows parallel processing of multiple fluid streams, increasing overall throughput while maintaining efficient electrochemical reactions in each compact segment
2Manufacturing precision
If complex multi-step manufacturing processes are used, then precise micro-channel structures can be formed, but manufacturing cost increases
Solution Approach 1:
The patent combines multiple manufacturing operations into a single integrated molding process. The mold cavity includes integrated features for forming both the fluid micro-channels and electrode structures in one step, eliminating the need for separate fabrication steps and reducing manufacturing complexity and cost
Solution Approach 2:
The mold is pre-configured with electrode holders, fluid channel geometries, and gating systems before the molding process begins. This preliminary preparation of the mold structure enables the complex micro-channel features to be formed automatically during the single-shot molding process, reducing manufacturing steps
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
The solution enables increased flow rates of the liquid electrolyte, improved energy efficiency, and reduced manufacturing costs, enhancing electrochemical reactions and scalability.
Implementation Method 1
curing the curable layer to form an imprinted cured layer
Implementation Method 2
exposing the developable material with an electrode pattern, the electrode pattern including the electrode micro-channel and extending from the electrode micro-channel into the micro-channel intersection without occluding the fluid micro-channel; developing the exposed developable material to remove the developable material from the electrode pattern
Data Source
AI summary
A method of making a micro-channel electrode structure includes providing a curable layer and imprinting the curable layer to form an electrode micro-channel and a fluid micro-channel in a common step. The electrode micro-channel intersects the fluid micro-channel to form a micro-channel intersection. The curable layer is cured to form an imprinted cured layer. Both the electrode and the fluid micro-channels are filled with a developable material that is exposed with an electrode pattern including the electrode micro-channel and extending from the electrode micro-channel into the micro-channel intersection without occluding the fluid micro-channel. The exposed developable material is developed to remove the developable material from the electrode pattern and the electrode micro-channel and the micro-channel intersection corresponding to the electrode pattern are at least partly filled with a conductive material. At least a portion of the remaining developable material is removed from the fluid micro-channel.