Segmented Electrode Fluid Channels for Scalable Electrochemical Treatment
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Solution Overview
Problem
Existing electrochemical treatment devices are limited to small scales and face challenges in scalability, leading to long process times and health hazards due to drippage and off-gases, especially when treating larger components.
Innovation Solution
A scalable electrochemical treatment device with integrated multiple fluid supply and return channels in a single electrode, allowing for uniform treatment and non-drippage by optimizing fluid flow distribution and suction, utilizing modern manufacturing techniques like additive manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single fluid inflow and outflow system is used in electrochemical treatment devices, then the device structure is simple, but the device is limited to small scales and cannot treat larger surfaces efficiently
Solution Approach 1:
The electrode is divided into multiple segments with separate fluid supply channels and fluid return channels. Each segment has its own inlet and outlet ports, allowing the device to treat larger surfaces by distributing electrolyte flow across multiple zones simultaneously, thus scaling up productivity without proportionally increasing complexity.
2Area of stationary object
If the distance between central electrode holes and peripheral exhaust is increased to treat larger areas, then the treatment area is enlarged, but the device inevitably drips and process time increases
Solution Approach 1:
By segmenting the electrode into multiple zones with local supply and return channels, the effective fluid transport distance is reduced in each segment while maintaining a large overall treatment area. This allows parallel processing across multiple zones, enlarging the treatment area without increasing process time.
3Object-affected harmful factors
If too much suction is applied to maintain non-drippage, then drippage is prevented, but the porous media does not receive uniform supply of inflow fluid
Solution Approach 1:
Multiple distributed return channels are placed throughout the electrode structure, creating localized suction zones that maintain appropriate flow dynamics in each segment. This prevents drippage locally without creating excessive suction that would disrupt uniform fluid supply to the porous media across the entire treatment surface.
4Area of stationary object
If in-tank processing is used for large articles, then large surfaces can be treated, but large process tanks and associated equipment are required
Solution Approach 1:
The treatment system is segmented into a portable electrode device that can be applied directly to large articles without requiring immersion in a large tank. The electrode itself contains the fluid distribution network, eliminating the need for extensive external tank infrastructure while maintaining the ability to treat large surfaces.
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
Enables efficient electrochemical treatment of large components in any orientation without drippage, reducing process time and health risks, and avoiding the need for large tanks.
Implementation Method 1
A porous pad (10) is coupled to the electrode section for contacting a substrate to be treated and receives the treatment fluid via the plurality of treatment fluid supply ports
Implementation Method 2
the plurality of fluid return ports remove spent and excess treatment fluid and gases from the substrate, the surrounding air, and the porous pad
Implementation Method 3
electrochemical treatment of a surface in any orientation
Data Source
AI summary
An electrochemical treatment system includes a treatment fluid supply manifold, a fluid return manifold, and an electrode section connected to the treatment fluid supply manifold. A plurality of treatment fluid supply ports feed fluid through or across the electrode and a plurality of fluid return ports proximate the treatment fluid supply ports are connected to the fluid return manifold. A porous pad is coupled to the electrode section for contacting a substrate to be treated and receives the treatment fluid via the plurality of treatment fluid supply ports. The plurality of fluid return ports remove spent and excess treatment fluid and gases from the substrate, the surrounding air, and the