Bipolar plate sealing structure and monitoring method thereof

Abstract

The invention discloses a bipolar plate sealing structure and a monitoring method thereof.The bipolar plate sealing structure comprises bipolar plates, water sealing lines are arranged on the bipolar plates, sealing gaskets are arranged between the adjacent bipolar plates, and first-stage sealing is formed by pressing the bipolar plates and the water sealing lines; a fixing ring is arranged on the outer side of the sealing gasket, and a plurality of first pressure sensors and second pressure sensors are arranged on the fixing ring; the first pressure sensor is arranged on the contact surface of the fixing ring and the bipolar plate and is used for monitoring the pressing force and uniformity of the bipolar plate during pressing; the second pressure sensor is arranged on the inner ring surface of the fixing ring and is used for monitoring the sealing state of the bipolar plate during operation. By arranging the fixing ring and the pressure sensor on the outer side of the sealing gasket, real-time monitoring on the pressing force and the sealing state is realized, and the device has the advantages that the pressing force and the uniformity during pressing of the bipolar plate and the sealing state during operation can be monitored in real time, so that the sealing reliability and the equipment safety are improved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of hydrogen production by water electrolysis, and particularly relates to a bipolar plate sealing structure and a monitoring method thereof. BACKGROUND

[0002] The hydrogen production by water electrolysis device has important application value in the fields of energy conversion, chemical production and transportation, and the sealing performance of the core component electrolytic cell directly relates to the stability and safety of system operation. In the working process of the electrolytic cell, elastic sealing gaskets are generally used between the bipolar plates to realize fluid isolation, but the structure is exposed to high temperature, high pressure and strong electrochemical corrosion for a long time, and the sealing gaskets are prone to defects such as compression permanent deformation, installation position deviation or material aging.

[0003] These defects cause small gaps in the sealing interface, and further cause electrolyte leakage, hydrogen and oxygen gas mutual penetration pollution, and in severe cases, may cause equipment corrosion, efficiency drop and even explosion risk. Especially during the bipolar plate assembly stage, it is difficult for the operator to accurately judge whether the compression force distribution is uniform and the total amount meets the standard during the compression process, and the traditional method only relies on experience or post-detection, and cannot feedback the compression state in real time; and during the equipment operation, there is no effective monitoring means for the degradation process of the sealing performance, and early leakage signs cannot be captured in time, so that the maintenance work is lagged, and the system reliability is significantly reduced. The existing technical solutions cannot integrate the compression force monitoring during the installation process and the sealing state monitoring during the operation process, so that the electrolytic cell faces the risk of sealing failure in the whole life cycle, and the overall safety margin is insufficient.

[0004] The existing technology needs to be improved in view of the above problems. SUMMARY

[0005] The purpose of the present application is to provide a bipolar plate sealing structure and a monitoring method, which can monitor the compression force and uniformity of the bipolar plate during compression and the sealing state during operation in real time, thereby improving the sealing reliability and equipment safety.

[0006] The above technical purpose of the present application is achieved by the following technical solutions:

[0007] A bipolar plate sealing structure, comprising a bipolar plate, a water seal line is arranged on the bipolar plate, a sealing gasket is arranged between adjacent bipolar plates, and a first level sealing is formed by compressing the bipolar plate and the water seal line;

[0008] A fixing ring is arranged on the outside of the sealing gasket, a plurality of first pressure sensors and second pressure sensors are arranged on the fixing ring;

[0009] The first pressure sensor is arranged on the contact surface between the fixing ring and the bipolar plate, and is used to monitor the compression force and uniformity of the bipolar plate during compression;

[0010] The second pressure sensor is arranged on the inner ring surface of the fixed ring, and is used for monitoring the sealing state of the bipolar plate during operation.

[0011] Further, the fixed ring is made of high-temperature-resistant and corrosion-resistant insulating material, including epoxy glass cloth board, polysulfone or polyphenylene sulfide.

[0012] Further, the bipolar plate is provided with a positioning structure for fixedly mounting the fixed ring, and the height of the fixed ring is equal to the height of the sealing gasket minus the pressing amount of the bipolar plate.

[0013] After the bipolar plate is pressed into place, the upper and lower surfaces of the bipolar plate and the fixed ring are tightly attached to form a second level of sealing.

[0014] Further, a plurality of first pressure sensors are uniformly distributed along the upper surface or the lower surface of the fixed ring, and a plurality of second pressure sensors are uniformly distributed along the inner ring surface of the fixed ring.

[0015] The first pressure sensor and the second pressure sensor are thin film pressure sensors, piezoresistive pressure sensors or fiber Bragg grating sensors.

[0016] The output ends of the first pressure sensor and the second pressure sensor are in communication connection with the receiving end arranged outside the bipolar plate.

[0017] Further, a temperature sensor is arranged on the contact surface between the fixed ring and the sealing gasket, which is used for monitoring the temperature of the sealing gasket during operation of the bipolar plate, to assist in judging the aging degree and sealing performance of the sealing gasket.

[0018] The application also provides a monitoring method for the bipolar plate sealing structure, which comprises the following steps:

[0019] S1. The sealing gasket is arranged between the water sealing lines of adjacent bipolar plates, and the fixed ring is arranged outside the sealing gasket;

[0020] S2. The adjacent bipolar plates are pressed until the upper and lower surfaces of the fixed ring are tightly attached to the bipolar plates, and in the pressed state of the bipolar plates, the sealing gasket forms a first level of sealing with the water sealing lines, and the upper and lower surfaces of the bipolar plates and the fixed ring form a second level of sealing.

[0021] S3. In the pressed state of the bipolar plates, the plurality of first pressure sensors output pressure values to the receiving end, and by checking the pressure values of each first pressure sensor and whether the pressure values are consistent, it is determined whether the bipolar plates are pressed into place.

[0022] S4. In the operation process of the bipolar plate, the second pressure sensor continuously outputs the pressure value to the receiving end, and whether the gas leakage to the inner ring surface of the fixed ring due to the failure of the first level sealing occurs is determined by checking whether the pressure value of the second pressure sensor increases.

[0023] Further, the application also provides a monitoring method including a pre-warning analysis step, which performs:

[0024] The historical and real-time assembly compression force data of the first pressure sensor and the historical and real-time sealing cavity pressure data of the second pressure sensor are collected, and time series trend analysis is performed, and a sealing performance degradation model is established through algorithm processing;

[0025] When the sealing performance degradation model outputs that the sealing performance will soon drop to the preset failure threshold, a proactive warning signal is generated before the sealing completely fails.

[0026] As can be seen from the above, the bipolar plate sealing structure and the monitoring method provided by the application realize real-time monitoring of the compression compression force and the sealing state by arranging the fixed ring and the pressure sensor outside the sealing gasket, have the advantages that the compression compression force and the uniformity during the compression of the bipolar plate can be monitored in real time, and the sealing state during the operation can be monitored in real time, thereby improving the sealing reliability and the equipment safety.

[0027] In summary, the application has the following advantages:

[0028] 1. Double sealing design, the first sealing formed by the water seal line and the sealing gasket and the second sealing formed by the fixed ring form multiple protection, significantly improve the sealing reliability of the electrolytic cell, and avoid leakage caused by single gasket failure. At the same time, the assembly process is monitored in real time, and the first pressure sensor can detect the compression force and the distribution uniformity in real time during the assembly process. For example, the system can identify that the compression force at a certain position is lower than the design value, and an alarm prompt is issued, so that the installation quality is controllable and detectable.

[0029] 2. Active safety during operation, the second pressure sensor can sense the small pressure change (such as >0.02MPa) inside the fixed ring caused by leakage in real time during operation, which is more sensitive than manual inspection or traditional flow monitoring. This method realizes the change from passive repair to active protection. In addition, the application scheme can be applied to various hydrogen production systems such as alkaline electrolytic cell (ALK), proton exchange membrane electrolytic cell (PEM), and anion exchange membrane electrolytic cell (AEM). The fixed ring material and the sensor type can be optimized according to different systems.

[0030] 3.The application not only reduces the system operation and maintenance cost by reducing leakage accidents, prolonging the service life of gaskets and reducing unplanned maintenance, but also realizes life prediction and early warning. Through data acquisition and trend analysis, the aging rate of the gasket can be judged. When the pressure fluctuation frequency of the sensor rises significantly, maintenance can be performed in advance to reduce the risk of unplanned downtime. The total life cycle cost is reduced. BRIEF DESCRIPTION OF DRAWINGS

[0031] Figure 1 is a schematic diagram of the pre-positioning of the bipolar plate sealing structure described in the application.

[0032] Figure 2 is a schematic diagram of the bipolar plate sealing structure after compression described in the application.

[0033] Figure 3 is a schematic diagram of the fixed ring and the first pressure sensor described in the application.

[0034] Figure 4 is a schematic diagram of the fixed ring and the second pressure sensor described in the application.

[0035] Figure 5 is a flowchart of the detection method of the bipolar plate sealing structure described in the application. DETAILED DESCRIPTION

[0036] In order to make the technical means, creative features, purposes and effects realized by the application easy to understand, the application will be further described below in combination with the drawings and specific embodiments.

[0037] As shown in Figures 1 to 4 , the bipolar plate sealing structure proposed by the application includes a bipolar plate 101, a water seal line 102 is arranged on the bipolar plate 101, a sealing gasket 201 is arranged between adjacent bipolar plates 101, and a first-stage seal is formed by compressing the bipolar plate 101 and the water seal line 102; a fixed ring 301 is arranged on the outside of the sealing gasket 201, a plurality of first pressure sensors 401 and second pressure sensors 402 are arranged on the fixed ring 301; the first pressure sensors 401 are arranged on the contact surface of the fixed ring 301 and the bipolar plate 101, which are used to monitor the compression force and uniformity of the bipolar plate 101 during compression; the second pressure sensors 402 are arranged on the inner ring surface of the fixed ring 301, which are used to monitor the sealing state of the bipolar plate during operation.

[0038] In order to facilitate understanding, some key terms in the present embodiment are explained as follows:

[0039] The bipolar plate 101, as the core component of the electrolytic cell, is usually made of conductive material, used to separate the electrolyte flow channel and the gas flow channel, and conduct electric current.

[0040] Water seal line 102, which generally refers to a groove structure arranged on the surface of bipolar plate 101 for cooperating with sealing gasket 201 to form a seal.

[0041] Sealing gasket 201, which is generally made of elastic material, is arranged between adjacent bipolar plates 101 to achieve fluid sealing through compression deformation.

[0042] Fixed ring 301, which generally refers to a ring structure, is arranged outside sealing gasket 201 to support the sensor and assist in sealing.

[0043] First pressure sensor 401 is used to sense and output the pressure value on its contact surface.

[0044] Second pressure sensor 402 is used to sense and output the pressure value of its environment.

[0045] The bipolar plate sealing structure of the embodiment is provided with water seal line 102 on bipolar plate 101. Water seal line 102 can be designed as a groove structure on the surface of bipolar plate 101 for accommodating part of sealing gasket 201 to enhance positioning and sealing effect.

[0046] Sealing gasket 201 is arranged between adjacent bipolar plates 101 and forms a first level seal by compressing bipolar plate 101 and water seal line 102. Specifically, sealing gasket 201 can be placed between adjacent bipolar plates 101 and aligned with water seal line 102 on bipolar plate 101. When bipolar plate 101 is compressed, sealing gasket 201 is compressed and its material is elastically deformed, thereby filling the small gap between water seal line 102 and bipolar plate 101 to form an initial fluid sealing barrier. For example, sealing gasket 201 can be made of elastic materials such as rubber, fluororubber or silicone rubber to adapt to different working temperatures and medium environments.

[0047] Further, fixed ring 301 is arranged outside sealing gasket 201. Fixed ring 301 can be placed outside sealing gasket 201. Fixed ring 301 can be made of polymer materials, composite materials or metal materials, and its shape can be circular, oval or ring-shaped customized according to the geometric shape of bipolar plate 101. The installation of fixed ring 301 can be achieved by simple placement, or connected with bipolar plate 101 or other structures of electrolytic cell through adhesion, buckling, etc.

[0048] On this basis, a plurality of first pressure sensors 401 and second pressure sensors 402 are arranged on the fixed ring 301. The plurality of first pressure sensors 401 and second pressure sensors 402 can be integrated or mounted on the surface or inside of the fixed ring 301. For example, the sensors can be fixed at preset positions of the fixed ring 301 by adhesives, or embedded by means of grooving, drilling or the like on the fixed ring 301, and the number of sensors can be configured according to monitoring requirements.

[0049] The first pressure sensors 401 are arranged on the contact surface of the fixed ring 301 and the bipolar plate 101, which are used to monitor the pressing force and uniformity of the bipolar plate 101 during pressing. When the bipolar plate 101 is pressed, the first pressure sensors 401 will sense the pressure acting on them and output pressure signals. By collecting and analyzing these pressure signals, the pressing force of the bipolar plate 101 during pressing can be obtained. In addition, by comparing the output values of the first pressure sensors 401 at different positions, the uniformity of the pressing force can be evaluated to determine whether the bipolar plate 101 is uniformly pressed.

[0050] The second pressure sensors 402 are arranged on the inner ring surface of the fixed ring 301, which are used to monitor the sealing state of the bipolar plate during operation. The second pressure sensors 402 can be mounted on the inner ring surface of the fixed ring 301 facing the sealing gasket 201. During normal operation of the electrolytic cell, if the first-stage sealing fails, for example due to gasket aging, damage or insufficient compression, causing electrolyte or gas leakage, these leakage will enter the space between the sealing gasket 201 and the fixed ring 301, causing pressure changes in this area. The second pressure sensors 402 can detect this abnormal pressure rise in real time by monitoring the pressure in this area, thereby determining whether the first-stage sealing has failed.

[0051] The bipolar plate sealing structure of the present embodiment realizes dual monitoring of the installation process and operation process of the electrolytic cell by arranging a fixed ring outside the sealing gasket and integrating first pressure sensors and second pressure sensors. The first pressure sensors can monitor the pressing force and uniformity of the bipolar plate during pressing in real time, effectively avoiding sealing failure caused by insufficient or uneven pressing. The second pressure sensors continuously monitor the sealing state during operation, timely detecting leaks caused by gasket aging or damage, significantly improving the sealing reliability and system safety of the electrolytic cell.

[0052] In some embodiments of the present application described above, a fixed ring is used to arrange pressure sensors and assist in sealing. However, during implementation, the fixed ring may undergo material degradation in high temperature, high pressure and corrosive environments, leading to sensor failure or reduced sealing performance.

[0053] To this end, the application further proposes that the fixing ring 301 is made of high-temperature-resistant and corrosion-resistant insulating material, including epoxy glass cloth board, polysulfone or polyphenylene sulfide.

[0054] Specifically, the high-temperature-resistant material used by the fixing ring 301 refers to a material that can maintain stable physical structure and chemical properties under the high-temperature environment generated by the operation of the electrolytic cell, and is not prone to softening, decomposition, deformation or strength reduction, thereby ensuring the structural integrity and dimensional accuracy of the fixing ring 301. Corrosion-resistant material refers to a material that can effectively resist the corrosion of corrosive media such as electrolyte and water vapor, avoiding the deterioration of material performance due to chemical reaction or physical dissolution, thereby maintaining its long-term reliability. Insulating material refers to a material with excellent electrical insulation properties, which can effectively prevent current conduction, prevent electrochemical corrosion, and protect the pressure sensor integrated on the fixing ring 301 from electrical signal interference or damage. As a specific example, the material can include epoxy glass cloth board, polysulfone or polyphenylene sulfide. Among them, the epoxy glass cloth board as a composite material combines the high strength of glass fiber and the excellent adhesion, chemical resistance and electrical insulation of epoxy resin, so that it can still maintain good mechanical and electrical properties in high temperature and corrosive environment. Polysulfone as a high-performance engineering plastic, its characteristics are high glass transition temperature and heat distortion temperature, at the same time, it has good hydrolysis resistance, acid and alkali resistance and excellent electrical insulation, suitable for long-term work in hot and corrosive medium. Polyphenylene sulfide as another high-performance thermoplastic material, it is known for its excellent heat resistance, chemical corrosion resistance (especially to many organic solvents and strong acids and bases), inherent flame retardance, and excellent mechanical strength and electrical insulation, which can meet the harsh requirements of electrolytic cell under extreme working conditions.

[0055] By selecting high-temperature-resistant and corrosion-resistant insulating materials to manufacture the fixed ring 301, the application effectively solves the problem of material degradation of the fixed ring 301 caused by high temperature, high pressure and corrosive environment during long-term operation of the electrolytic cell. Specifically, the high-temperature-resistant property ensures that the fixed ring 301 can maintain its structural stability and dimensional accuracy at high temperatures, avoiding the influence of thermal deformation on its function as a second-level seal and the supporting effect on the first pressure sensor 401 and the second pressure sensor 402. The corrosion-resistant property enables the fixed ring 301 to resist the corrosion of corrosive media such as electrolyte, preventing material performance degradation and thus ensuring the long-term reliability of the fixed ring 301. The insulating property further avoids damage to the fixed ring 301 itself caused by electrochemical corrosion and effectively isolates the interference of the electric field inside the electrolytic cell on the first pressure sensor 401 and the second pressure sensor 402 integrated on the fixed ring 301, ensuring that the sensors can monitor the pressing force and sealing state stably and accurately for a long time. Therefore, this scheme significantly improves the durability of the bipolar plate sealing structure under harsh working conditions and the reliability of the monitoring system, thereby ensuring the long-term stable operation and safety of the electrolytic cell.

[0056] In some of the above-mentioned schemes of the application, the fixed ring is used to set the pressure sensor and assist in sealing, however, during implementation, if the installation position and height of the fixed ring are not accurate, it may cause the fixed ring to not be properly close when the bipolar plate is pressed, resulting in inaccurate sealing or sensor monitoring.

[0057] To this end, the application further proposes that the bipolar plate 101 is provided with a positioning structure for fixedly installing the fixed ring 301, and the height of the fixed ring 301 is equal to the height of the sealing gasket 201 minus the pressing amount of the bipolar plate 101; after the bipolar plate 101 is pressed into place, the bipolar plate 101 and the upper and lower surfaces of the fixed ring 301 are tightly attached to form a second-level seal.

[0058] Specifically, the positioning structure for fixedly installing the fixed ring 301 on the bipolar plate 101 is designed to ensure that the fixed ring 301 can be accurately placed and kept stable during installation, avoiding displacement or deflection when the bipolar plate 101 is pressed. The positioning structure can be implemented in various forms, for example, a ring-shaped groove matching the shape of the fixed ring 301 can be machined on the surface of the bipolar plate 101, so that the fixed ring 301 can be embedded therein, thereby achieving accurate radial and axial positioning; or a plurality of positioning pin holes can be provided on the bipolar plate 101, and corresponding positioning pins can be provided on the fixed ring 301, and the position of the fixed ring 301 is guided and fixed by the cooperation of the pins and the pin holes.

[0059] The height of the fixed ring 301 is designed to be equal to the height of the sealing gasket 201 minus the compression amount of the bipolar plate 101. This size relationship is crucial, as it ensures that the fixed ring 301 can be in contact with the upper and lower surfaces of the bipolar plate 101 at the same time when the bipolar plate 101 is fully compressed in place. If the fixed ring 301 is too high, it will hinder the full compression of the bipolar plate 101, resulting in insufficient compression of the sealing gasket 201 and affecting the first level of sealing effect; if the fixed ring 301 is too low, there will be a gap between the fixed ring 301 and the bipolar plate 101 after the bipolar plate 101 is compressed in place, which cannot form an effective second level of sealing. Therefore, through accurate calculation and manufacturing, the ideal contact of the fixed ring 301 in the compressed state is ensured.

[0060] When the bipolar plate 101 is compressed in place, the bipolar plate 101 and the fixed ring 301 are tightly attached to the upper and lower surfaces, thereby forming a second level of sealing. This tight attachment forms an additional physical barrier that works in conjunction with the first level of sealing formed by the sealing gasket 201 and the water seal line 102 to improve the reliability of the entire sealing structure.

[0061] Through the above technical solutions, the positioning structure for fixing and installing the fixed ring 301 is provided on the bipolar plate 101, effectively solving the problem of inaccurate positioning of the fixed ring 301 during installation, ensuring the accuracy and stability of its position. At the same time, by accurately controlling the height of the fixed ring 301 to be equal to the height of the sealing gasket 201 minus the compression amount of the bipolar plate 101, it is ensured that the fixed ring 301 can be tightly attached to the upper and lower surfaces of the bipolar plate 101 when the bipolar plate 101 is compressed in place, thereby forming a reliable second level of sealing. This design not only avoids the risk of sealing failure caused by inaccurate installation of the fixed ring 301, but also ensures that the first pressure sensor 401 and the second pressure sensor 402 can accurately monitor the compression force and sealing state, significantly improving the overall reliability and safety of the bipolar plate sealing structure.

[0062] In some of the above schemes of the present application, a pressure sensor is used to monitor the compression force when the bipolar plate is compressed and the sealing state when it is running. However, due to uneven distribution of sensors, unclear types or lack of communication connection, the monitoring data may not be comprehensive, the accuracy may be insufficient, or real-time transmission may be impossible, thereby affecting the accurate judgment and timely warning of the sealing performance.

[0063] To this end, the application further proposes that a plurality of first pressure sensors 401 are uniformly distributed along the upper surface or lower surface of the fixed ring 301, and a plurality of second pressure sensors 402 are uniformly distributed along the inner ring surface of the fixed ring 301; the first pressure sensors 401 and the second pressure sensors 402 are thin-film pressure sensors, piezoresistive pressure sensors or fiber Bragg grating sensors; the output ends of the first pressure sensors 401 and the second pressure sensors 402 are in communication connection with the receiving end arranged outside the bipolar plate 101.

[0064] Specifically, in order to ensure comprehensive and accurate monitoring of the pressing force and its uniformity during pressing of the bipolar plate 101, a plurality of first pressure sensors 401 are designed to be uniformly distributed along the upper surface or lower surface of the fixed ring 301. This uniform distribution can be manifested as multiple first pressure sensors 401 arranged at equal angles along the circumferential direction of the fixed ring 301, for example, one sensor is arranged at every certain angle to cover the entire contact surface.

[0065] At the same time, in order to realize dead-angle-free monitoring of the sealing state of the bipolar plate 101 during operation, a plurality of second pressure sensors 402 are uniformly distributed along the inner ring surface of the fixed ring 301. This generally means that multiple second pressure sensors 402 are arranged at equal distances or equal angles along the circumferential direction of the inner ring surface of the fixed ring 301, ensuring effective coverage of the entire inner ring surface where leakage may occur. These sensors can be designed in a miniaturized form to be directly integrated on the inner wall of the fixed ring 301, or a sensor array can be directly manufactured on the inner ring surface through thin-film printing technology, in order to improve the sensitivity and reliability of monitoring.

[0066] Further, considering the particularity of the electrolytic cell working environment, the first pressure sensors 401 and the second pressure sensors 402 are selected to be thin-film pressure sensors, piezoresistive pressure sensors or fiber Bragg grating sensors. Thin-film pressure sensors utilize the principle of resistance or capacitance change of thin-film materials under pressure, and have the characteristics of small size, fast response, high precision and good stability. Piezoresistive pressure sensors are based on the piezoresistive effect of semiconductor materials, and have the advantages of high sensitivity, good linearity and easy integration. Fiber Bragg grating sensors utilize the periodic variation of gratings in optical fibers to modulate the wavelength of light, and measure pressure by monitoring the drift of reflected light wavelength. Its unique anti-electromagnetic interference, high temperature resistance, corrosion resistance and long distance transmission capability make it perform well in harsh working conditions. In addition to the above types, capacitive pressure sensors or resonant pressure sensors can also be considered, which also have the advantages of high sensitivity, low power consumption or high precision, long-term stability, etc., and can ensure the accuracy and reliability of monitoring data in high temperature, high pressure and corrosive environments.

[0067] In addition, in order to realize real-time acquisition and remote management of monitoring data, the output ends of the first pressure sensor 401 and the second pressure sensor 402 are in communication connection with the receiving end arranged outside the bipolar plate 101. This communication connection can be realized in a wired manner, or wireless manner, such as a sensor integrated micro wireless transmission module, which transmits data to the receiving end through wireless communication technologies such as Bluetooth, Wi-Fi, Zigbee or LoRa, which is suitable for scenes with difficult wiring or flexible deployment. For the fiber Bragg grating sensor, the output end is directly connected to the external optical spectrum demodulator through an optical fiber to realize the transmission and demodulation of the optical signal. The receiving end can be a separate microcontroller unit, which integrates data acquisition, storage and preliminary processing functions, and is connected to the central monitoring system through a higher level network interface, thereby ensuring real-time transmission and remote monitoring of monitoring data, facilitating timely analysis of the sealing state.

[0068] Through the above technical solutions, the present application effectively solves the problems of uneven distribution of sensors, unclear types or lack of communication connection in the prior art, which leads to incomplete monitoring data, insufficient precision or inability to transmit in real time. Specifically, the plurality of first pressure sensors 401 are evenly distributed along the upper surface or lower surface of the fixed ring 301, ensuring that the compression force and its uniformity are comprehensively and dead-angle-free monitored during the compression process of the bipolar plate 101, avoiding the risk of sealing failure caused by uneven local stress, thereby significantly improving the installation quality and reliability of the first-stage sealing. At the same time, the plurality of second pressure sensors 402 are evenly distributed along the inner ring surface of the fixed ring 301, so that the pressure change in the sealing cavity can be monitored in real time and comprehensively during the operation of the bipolar plate 101, and once the first-stage sealing fails to cause gas leakage, it can be quickly and accurately detected, providing a reliable basis for early warning. In addition, high-stability and high-sensitivity sensor types such as thin-film pressure sensors, piezoresistive pressure sensors or fiber Bragg grating sensors are selected to ensure the accuracy and reliability of the monitoring data under harsh working conditions such as high temperature, high pressure and corrosion. Finally, by connecting the output ends of the first pressure sensor 401 and the second pressure sensor 402 to the receiving end arranged outside the bipolar plate 101, real-time transmission and remote monitoring of monitoring data are realized, so that the operator can obtain sealing state information in a timely manner, and respond and handle potential problems quickly, thereby greatly improving the safety, reliability and maintainability of the bipolar plate sealing structure during installation and operation.

[0069] In some of the above schemes of the present application, the fixed ring is used to install pressure sensors to monitor the compression force and sealing state. However, during implementation, the sealing gasket is prone to thermal aging and deformation due to the long-term operation of the electrolytic cell in a high-temperature environment, but there is a lack of direct monitoring means for the temperature of the gasket, which makes it impossible to timely evaluate the aging degree and potential sealing failure risk.

[0070] To this end, the application further proposes that a temperature sensor is arranged on the contact surface between the retaining ring 301 and the gasket 201, which is used to monitor the temperature of the gasket 201 during the operation of the bipolar plate, so as to assist in judging the aging degree and sealing performance of the gasket 201.

[0071] Specifically, the temperature sensor is a device that can sense temperature and convert it into a measurable electrical signal. The temperature sensor can be implemented in various forms, for example, a thermistor can be selected, whose resistance value will change regularly with the change of temperature, and the corresponding temperature can be calculated by measuring the resistance value; or a thermocouple can be used, which uses the thermoelectric power generated by the temperature difference of two different metal conductors when connected to measure the temperature. In addition, considering the integration and accuracy, a thin film temperature sensor can also be used, which is directly integrated or attached to the contact surface to achieve closer fitting and faster response. By arranging the temperature sensor on the contact surface between the retaining ring 301 and the gasket 201, it is ensured that the sensor can directly and closely exchange heat with the gasket 201, so as to obtain the real-time temperature information closest to the body of the gasket 201, effectively avoiding the errors and lags that may be caused by indirect measurement through other media.

[0072] Through the above technical solution, the temperature sensor can continuously and accurately monitor the actual working temperature of the gasket 201 during the operation of the bipolar plate 101. Since high temperature is one of the main factors that accelerate the aging and performance degradation of the gasket material, the real-time temperature data can directly reflect the thermal load borne by the gasket 201. By analyzing these temperature data, such as monitoring the abnormal rise of temperature or the long time in high temperature state, the aging degree of the gasket 201 can be effectively assisted to be judged. When the temperature data indicates that the gasket 201 may be performance declined due to thermal aging, the system can identify the potential sealing failure risk in advance, so as to take preventive measures before the sealing completely fails. This not only makes up for the shortcomings of relying only on the pressure sensor to monitor the sealing state, but also, together with the first pressure sensor 401 and the second pressure sensor 402, builds a more comprehensive and intelligent sealing monitoring system. The first pressure sensor 401 and the second pressure sensor 402 are mainly used to monitor the pressing force and gas leakage, while the temperature sensor provides early warning information from the perspective of material aging, so that the entire sealing structure has higher reliability and safety during installation, operation and maintenance. In this way, the early warning capability of the system can be significantly enhanced, the service life of the electrolytic cell can be prolonged, and the operation risk caused by sealing failure can be reduced.

[0073] Currently, water electrolysis hydrogen production devices are widely used in energy, chemical industry and transportation fields. The electrolytic cell as a core component, its sealing performance directly affects the stability and safety of the system operation. In the existing electrolytic cell, gaskets are usually used to seal between bipolar plates. However, due to the long-term work of the electrolytic cell in high temperature, high pressure and electrochemical corrosion environment, the gasket is prone to problems such as insufficient compression, uneven installation, aging deformation, etc., resulting in electrolyte leakage, gas cross contamination, and even safety accidents. In the prior art, there is a lack of a structure and method that can effectively monitor the compression force during the installation of the electrolytic cell and real-time monitor the sealing state during operation, thereby resulting in insufficient reliability and safety of the electrolytic cell.

[0074] For this purpose, see Figure 5 The application provides a monitoring method for the installation and use process of a bipolar plate sealing structure, comprising the following steps:

[0075] S1. The sealing gasket 201 is arranged between the water seal lines 102 of adjacent bipolar plates 101, and the fixing ring 301 is arranged outside the sealing gasket 201. In specific implementation, the sealing gasket 201 is made of an elastic material such as fluororubber or silicone rubber, is pre-cut into an annular structure matched with the water seal line 102, and is accurately placed on the water seal line 102 of the bipolar plate 101; the fixing ring 301 is made of a ring-shaped support body of stainless steel or corrosion-resistant engineering plastic, is fixed on the radial outer side of the sealing gasket 201 through a positioning groove or an adhesive, and ensures that the fixing ring 301 maintains a preset distance from the sealing gasket 201 to provide a stable platform for sensor installation.

[0076] S2. The adjacent bipolar plates 101 are pressed together until the upper and lower surfaces of the fixing ring 301 are tightly attached to the bipolar plates 101. During the pressing process, the pressure is gradually applied by a hydraulic press, so that the sealing gasket 201 is elastically compressed and deformed, tightly fills the small gap between the water seal line 102 and the bipolar plate 101, and forms a first-level seal; at the same time, the upper and lower surfaces of the fixing ring 301 are completely attached to the bipolar plates 101 to form a second-level seal structure, and the redundant sealing design provides a physical basis for the monitoring function of the pressure sensor, and ensures the integrity of the sealing interface during the pressing process.

[0077] S3. When the bipolar plate 101 is pressed together, several first pressure sensors 401 will output pressure values ​​to the receiving end. The first pressure sensors 401 are pre-embedded in the contact area of ​​the upper and lower surfaces of the fixing ring 301. When the bipolar plate 101 is pressed together, the sensors sense the pressure distribution on the contact surface in real time. The receiving end obtains the values ​​of each first pressure sensor 401 through the data acquisition system. By comparing the value magnitude and distribution uniformity, if all sensor readings reach the preset threshold and the deviation is less than 10%, it is determined that the bipolar plate 101 is pressed together in place. Otherwise, the clamping force needs to be adjusted and the plates need to be pressed together again, thereby ensuring the sufficiency and uniformity of the clamping force during the installation process.

[0078] S4. During the operation of the bipolar plate 101, several second pressure sensors 402 continuously output pressure values ​​to the receiving end. The second pressure sensors 402 are installed on the inner ring surface of the fixed ring 301, facing the sealing gasket 201. When the electrolytic cell is working normally, this area is in a low-pressure state. If the first-stage seal fails due to gasket aging or damage, the leaked hydrogen or oxygen will enter the inner ring surface space of the fixed ring 301, causing a local pressure increase. The receiving end monitors the value changes of the second pressure sensors 402 in real time. When an abnormal increase in pressure is detected, it immediately determines that a gas leak has occurred, triggers the safety warning system, and prevents the leak from expanding.

[0079] This embodiment integrates the fixing ring 301 with the first pressure sensor 401 and the second pressure sensor 402 at specific locations. This enables real-time monitoring and uniformity determination of the clamping force during installation and continuous monitoring of the sealing status during operation. Specifically, during the pressing process, the distributed monitoring of the first pressure sensor 401 ensures the uniformity of the clamping force distribution, avoiding insufficient or uneven compression caused by reliance on experience in traditional installation methods. During operation, the second pressure sensor 402 dynamically tracks the pressure on the inner ring surface of the fixing ring 301, enabling early identification of first-stage seal failure and timely warning of gas leakage risks. This technical solution effectively solves the technical challenge of lacking dual monitoring in electrolyzers under high temperature, high pressure, and corrosive environments, significantly improving sealing reliability and system safety, and providing technical assurance for the stable operation of the water electrolysis hydrogen production unit.

[0080] In some of the embodiments described above in this application, a monitoring method is proposed to monitor the sealing status in real time. However, in its implementation, it lacks the ability to predict the degradation of sealing performance and cannot provide proactive warnings before the seal completely fails.

[0081] In response, this application further proposes that the above-mentioned monitoring method also includes an early warning analysis step, which is performed as follows: historical and real-time assembly clamping force data of the first pressure sensor 401 and historical and real-time sealing cavity pressure data of the second pressure sensor 402 are collected and time-series trend analysis is performed. A sealing performance degradation model is established through algorithm processing. When the sealing performance degradation model outputs an indication that the sealing performance is about to drop to a preset failure threshold, an active early warning signal is generated before the seal completely fails.

[0082] This early warning analysis step aims to predict future trends in sealing performance through in-depth mining and analysis of historical and real-time data, thereby providing early warnings before potential failures occur. Its role is to transform traditional passive fault response into proactive preventative maintenance, significantly improving system reliability and safety. Specifically, collecting historical and real-time assembly clamping force data of the first pressure sensor 401 refers to continuously recording and storing the clamping force values ​​measured by the first pressure sensor 401 during the pressing process of the bipolar plate 101 and during operation. This data can be stored in local memory, such as non-volatile memory or solid-state drives, or it can be transmitted via network to a remote server or cloud platform for centralized management and analysis. By collecting this data, the pressing state of the bipolar plate 101 at different points in time can be comprehensively reflected, providing a basis for subsequent performance evaluation and degradation prediction. Simultaneously, collecting historical and real-time sealing cavity pressure data of the second pressure sensor 402 refers to continuously acquiring and recording the internal pressure values ​​of the sealing cavity monitored by the second pressure sensor 402 during the operation of the bipolar plate 101. This data can also be stored in a local data recording unit, such as an embedded memory chip, or transmitted to a central control system or data center via a wireless communication module (such as Wi-Fi, Bluetooth, or cellular network). By collecting this data, the sealing integrity of the gasket 201 can be dynamically monitored, and abnormal pressure caused by sealing failure can be detected in a timely manner, providing key evidence for the analysis of sealing performance degradation.

[0083] After acquiring this data, time-series trend analysis is required. This involves performing statistical and mathematical analysis on the collected historical and real-time data over time to identify patterns, trends, periodicities, or outliers in the data's changes over time. For example, moving averages and exponential smoothing can be used to smooth the data and reveal long-term trends; or Fourier transforms and wavelet analysis can be used to identify periodic components in the data. Furthermore, statistical models such as regression analysis and autoregressive integral moving average (ARIMA) models can be used to predict future data trends. This analysis helps to understand the evolution of sealing performance over time, laying the foundation for establishing accurate degradation models. Based on this, a sealing performance degradation model is established through algorithmic processing. This involves using machine learning algorithms or statistical modeling methods, based on the results of time-series trend analysis, to construct a mathematical model that can quantify the degree of sealing performance degradation and predict its future state. For example, machine learning algorithms such as support vector machines (SVM) and neural networks (NN) can be used to learn complex patterns in historical data and predict the degradation trajectory of sealing performance; or statistical methods such as Gaussian process regression and Weibull distribution can be used to describe the lifespan distribution and degradation process of components. This model can transform sensor data into an assessment of the health of the seal, thereby enabling a quantitative prediction of the risk of seal failure.

[0084] Ultimately, when the sealing performance degradation model outputs an indication that the sealing performance is about to decline to a preset failure threshold, an active warning signal is generated before complete seal failure. This means that when the sealing performance indicators predicted by the model (e.g., the rate of decrease in clamping force, the rate of increase in sealing cavity pressure, etc.) reach or exceed a preset critical value, the system automatically triggers an alarm or notification. This preset failure threshold is determined based on experience, experimental data, or safety standards, representing the boundary between acceptable and unacceptable sealing performance. The warning signal can take various forms, such as audible and visual alarms, SMS notifications, emails, and pop-ups on the control interface, aiming to remind operators or maintenance teams to take timely intervention measures, such as arranging maintenance or replacement of components, thereby avoiding production interruptions or safety accidents caused by complete seal failure.

[0085] Through the above technical solution, this application further optimizes the monitoring method for the installation and use of bipolar plate sealing structures, shifting from passive monitoring to proactive early warning. By continuously collecting historical and real-time assembly clamping force data from the first pressure sensor 401 and historical and real-time sealing cavity pressure data from the second pressure sensor 402, and conducting in-depth time-series trend analysis, the dynamic changes in the clamping state and sealing integrity of the sealing gasket 201 can be comprehensively grasped. Based on this, a sealing performance degradation model is established through algorithm processing, which can accurately predict the trajectory of sealing performance decline. When the model predicts that the sealing performance is about to reach the preset failure threshold, the system can generate a proactive early warning signal in time before the seal completely fails. This allows maintenance personnel to obtain sufficient early warning time before a failure occurs, thereby carrying out planned maintenance or replacement, avoiding downtime losses, safety risks, and environmental pollution caused by sudden seal failure. Compared with solutions that only perform real-time monitoring, this application significantly improves the reliability and safety of electrolytic cell operation by introducing an early warning analysis step, realizing a shift from fault response to fault prevention, greatly extending the service life of the equipment and reducing operating costs.

[0086] The following example will provide a more detailed explanation of the above technical solution:

[0087] During the assembly of a water electrolysis hydrogen production device, the bipolar plates of the electrolyzer need to be sealed. First, a sealing gasket 201 is placed between adjacent bipolar plates 101, specifically at the water seal line 102 on the bipolar plate 101. Next, a retaining ring 301 is placed on the outside of the sealing gasket 201. This retaining ring 301 is made of a high-temperature and corrosion-resistant insulating material, such as epoxy fiberglass cloth. The bipolar plate 101 has a positioning structure for fixing the retaining ring 301, ensuring accurate positioning. The height of the retaining ring 301 is precisely designed to be equal to the height of the sealing gasket 201 minus the expected compression amount of the bipolar plate 101.

[0088] On the fixed ring 301, a plurality of first pressure sensors 401 are evenly distributed along its upper and lower surfaces, while a plurality of second pressure sensors 402 are evenly distributed along its inner ring surface. These sensors are all thin-film pressure sensors, and their output terminals are communicatively connected to a receiving terminal disposed outside the bipolar plate 101. In addition, a temperature sensor is provided on the contact surface between the fixed ring 301 and the sealing gasket 201 for monitoring the temperature of the sealing gasket 201.

[0089] During the installation phase of the electrolytic cell, the first pressure sensors 401 activate when adjacent bipolar plates 101 begin to press together. These sensors, located on the contact surface between the fixing ring 301 and the bipolar plates 101, monitor the clamping force and its uniformity during the pressing process in real time. The receiving end displays the pressure values ​​output by each first pressure sensor 401. By observing these values, operators can determine whether the bipolar plates 101 are properly pressed together and whether the clamping force is uniform. For example, if the pressure value in a certain area is low, it indicates insufficient clamping force in that area, requiring adjustment. Once the bipolar plates 101 are properly pressed together, the sealing gasket 201 and the water seal line 102 form a first-level seal, while the upper and lower surfaces of the bipolar plates 101 and the fixing ring 301 are tightly fitted, forming a second-level seal. This real-time, visualized clamping force monitoring solves the problem of seal failure caused by insufficient gasket compression or uneven installation in existing technologies, improving installation quality and reliability.

[0090] After the electrolyzer is put into operation, the second pressure sensor 402 begins to work continuously. These sensors are located on the inner ring surface of the fixed ring 301 and are used to monitor the sealing status of the bipolar plates during operation. Under normal operating conditions, if the first-stage seal is intact, the second pressure sensor 402 should output a low or stable pressure value. If the first-stage seal fails due to gasket aging, deformation, or other reasons, causing gas or electrolyte to leak to the inner ring surface of the fixed ring 301, the pressure value of the second pressure sensor 402 will immediately increase. By continuously monitoring the pressure value of the second pressure sensor 402, the receiving end can determine in real time whether a leak has occurred. This real-time monitoring mechanism effectively solves the problem in existing technologies where the sealing status of the electrolyzer is difficult to monitor in real time, leading to leaks, cross-contamination of gases, and even safety accidents.

[0091] Meanwhile, a temperature sensor on the contact surface between the retaining ring 301 and the sealing gasket 201 continuously monitors the temperature of the sealing gasket 201. This temperature data helps determine the degree of aging and sealing performance of the sealing gasket 201.

[0092] In addition, the system collects historical and real-time assembly clamping force data from the first pressure sensor 401 and historical and real-time sealing cavity pressure data from the second pressure sensor 402, and performs time-series trend analysis. Through algorithmic processing, a sealing performance degradation model is established. When the sealing performance degradation model outputs an indication that the sealing performance is about to decline to a preset failure threshold, the system generates an active warning signal before the seal completely fails. This early warning analysis step allows maintenance personnel to intervene before the seal fails, avoiding sudden failures and further improving the stability and safety of the electrolytic cell operation. Compared with existing technologies, this solution not only provides effective monitoring of the installation process and real-time monitoring of the operation process, but also achieves proactive maintenance through an early warning mechanism, significantly improving the reliability and safety of the electrolytic cell.

[0093] In this document, the terms "upper," "lower," "front," "back," "left," "right," "top," "bottom," "inner," "outer," "vertical," and "horizontal," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only used for the clarity of expressing the technical solution and for the convenience of description, and therefore should not be construed as limiting the present invention.

[0094] In this document, the terms “comprising,” “including,” or any other variations thereof are intended to cover non-exclusive inclusion, which includes not only the elements listed but also other elements not expressly listed.

[0095] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of the invention. Various changes and modifications can be made to the invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of the present invention as claimed. The scope of protection of this invention is defined by the appended claims and their equivalents.

Claims

1. A bipolar plate sealing structure, comprising a bipolar plate (101) provided with a water seal line (102), a sealing gasket (201) arranged between adjacent bipolar plates (101) and a first level of sealing formed by pressing the bipolar plate (101) and the water seal line (102); characterized in that A fixing ring (301) is arranged outside the sealing gasket (201), and a plurality of first pressure sensors (401) and second pressure sensors (402) are arranged on the fixing ring (301); The first pressure sensors (401) are arranged on the contact surface of the fixing ring (301) and the bipolar plate (101), and are used to monitor the pressing force and uniformity of the bipolar plate (101) during pressing; The second pressure sensors (402) are arranged on the inner ring surface of the fixing ring (301), and are used to monitor the sealing state of the bipolar plate during operation.

2. The bipolar plate sealing structure according to claim 1, characterized in that, The fixing ring (301) is made of high-temperature-resistant and corrosion-resistant insulating material, including epoxy glass cloth board, polysulfone or polyphenylene sulfide.

3. The bipolar plate sealing structure according to claim 1, wherein The bipolar plate (101) is provided with a positioning structure for fixing and installing the fixing ring (301), and the height of the fixing ring (301) is equal to the height of the sealing gasket (201) minus the pressing amount of the bipolar plate (101); after the bipolar plate (101) is pressed in place, the upper and lower surfaces of the bipolar plate (101) and the fixing ring (301) are tightly attached to form a second level of sealing.

4. The bipolar plate sealing structure according to claim 1, wherein A plurality of first pressure sensors (401) are uniformly distributed along the upper surface or lower surface of the fixing ring (301), and a plurality of second pressure sensors (402) are uniformly distributed along the inner ring surface of the fixing ring (301); The first pressure sensors (401) and the second pressure sensors (402) are thin film pressure sensors, piezoresistive pressure sensors or fiber Bragg grating sensors; The output ends of the first pressure sensors (401) and the second pressure sensors (402) are communicatively connected to the receiving end arranged outside the bipolar plate (101).

5. The bipolar plate sealing structure according to claim 1, wherein A temperature sensor is arranged on the contact surface of the fixing ring (301) and the sealing gasket (201), which is used to monitor the temperature of the sealing gasket (201) during operation of the bipolar plate, to assist in judging the aging degree and sealing performance of the sealing gasket (201).

6. A method of monitoring a seal structure of a bipolar plate, characterized by, The method comprises the following steps: S1. Arranging the sealing gasket (201) between the water seal lines (102) of adjacent bipolar plates (101), and arranging the fixing ring (301) outside the sealing gasket (201); S2. Pressing the adjacent bipolar plates (101) until the upper and lower surfaces of the fixing ring (301) are tightly attached to the bipolar plates (101), and in the pressed state of the bipolar plates (101), the sealing gasket (201) and the water seal line (102) form a first level of sealing, and the upper and lower surfaces of the bipolar plate (101) and the fixing ring (301) are tightly attached to form a second level of sealing; S3. In the pressing state of the bipolar plate (101), the first pressure sensors (401) output pressure values to the receiving end. By checking the pressure values of each first pressure sensor (401) and whether the pressure values are consistent, it is determined whether the bipolar plate (101) is pressed into place. S4. In the running process of the bipolar plate (101), the second pressure sensors (402) continuously output pressure values to the receiving end. By checking whether the pressure values of the second pressure sensors (401) are rising, it is determined whether gas leakage to the inner ring surface of the fixed ring (301) due to failure of the first-stage seal occurs.

7. The method of monitoring of a bipolar plate seal structure according to claim 6, characterized in that, It also includes a pre-warning analysis step, which performs: Collecting historical and real-time assembly compression force data of the first pressure sensors (401) and historical and real-time sealing cavity pressure data of the second pressure sensors (402), and performing time series trend analysis to establish a sealing performance degradation model through algorithm processing; When the sealing performance degradation model outputs a prediction that the sealing performance will soon drop to a preset failure threshold, a proactive warning signal is generated before the sealing completely fails.

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