Composite Bipolar Plate Joining by Localized Peripheral Heating
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Solution Overview
Problem
Existing methods for joining bipolar plates made of composite material in electrochemical devices are lengthy, complex, and often require additional materials, leading to increased thickness and weight, which is undesirable for integration into vehicles or aircraft.
Innovation Solution
A system and method for joining bipolar plates using localized heating and pressure to melt the polymer resin in the peripheral portion, without affecting the central conductive portion, allowing for rapid and reliable assembly without additional materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If elastomer seal is added to peripheral area of bipolar plates for joining, then sealing reliability is improved, but manufacturing complexity and production time increase significantly
Solution Approach 1:
The invention extracts the sealing function from a separate elastomer component and integrates it directly into the bipolar plate structure through peripheral grooves. The bipolar plate itself becomes the sealing element, eliminating the need for separate elastomer seals and reducing manufacturing steps.
Solution Approach 2:
The invention merges the structural function of the bipolar plate with the sealing function by creating peripheral grooves that directly form sealing channels. This combines two previously separate functions (structural support and sealing) into a single integrated component.
2Productivity
If resistive welding process is used to join composite panels, then joining speed is improved, but the process is not applicable to bipolar composite sheets due to conductive particles being carried away by molten resin
Solution Approach 1:
The invention applies different properties to different parts of the bipolar plate: the central area maintains high conductive particle concentration for electrical conductivity, while the peripheral area with grooves provides sealing functionality. This local differentiation allows each zone to optimize its specific function without compromising the other.
3Reliability
If large number of conductive particles are incorporated in composite material to ensure high conductivity, then electrical conductivity is improved, but plate thickness increases to 3-5 mm which increases device size and mass
Solution Approach 1:
The invention creates a porous-like structure in the peripheral area through grooves and channels that allow fluid passage while maintaining structural integrity. This reduces material usage in non-critical areas while preserving conductivity in the central active area where conductive particles are concentrated.
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 method enables fast, reliable, and cost-effective joining of thin bipolar plates with preserved conductivity and mechanical properties, reducing production time and complexity while maintaining the integrity of the electrochemical device.
Implementation Method 1
a heating element having a peripheral shape and configured to perform heating according to a peripheral heating zone on the peripheral portion of the first bipolar plate so as to melt the matrix
Data Source
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AI summary
The invention relates to a system (S) for securing a first bipolar plate (1A) and a second bipolar plate (1B), each bipolar plate comprising an electrically conductive central portion (2A, 2B) and an electrically conductive peripheral portion (3A, 3B), the securing system (S) comprising a first assembly device (4) configured to be in contact with the first bipolar plate and a second assembly device (5) configured to be in contact with the second bipolar plate, the first assembly device (4) comprising a heating member which has a peripheral shape and is configured to heat a peripheral heating zone on the peripheral portion (3A) of the first bipolar plate (1A).