Bipolar Plate Assembly Sealing Without Adhesives or Welding
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Solution Overview
Problem
The existing methods for sealing bipolar plates in fuel cell assemblies are time-consuming and costly, particularly in the manufacturing process of fuel cell stacks, where precise sealing is required between half cells and across fuel cell assemblies.
Innovation Solution
The use of frame members with protuberances and recesses that deform the bipolar plates and proton exchange membrane to form seals, providing a cooperative sealing mechanism that can be integrated into the forming process of the bipolar plates, allowing for efficient sealing without the need for additional sealants in certain configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If adhesive bonding or welding is used to seal bipolar plates, then sealing reliability is improved, but manufacturing time and cost increase
Solution Approach 1:
The patent replaces chemical bonding (adhesive) or thermal bonding (welding) with a mechanical sealing system. Frame members with integrated sealing features mechanically clamp and seal the bipolar plates through compression and geometric interlocking, eliminating the need for adhesive bonding or welding processes.
Solution Approach 2:
The frame members are designed with self-contained sealing features (protrusions, recesses, and compression surfaces) that automatically create seals when assembled. The sealing action is inherent to the assembly process itself, requiring no separate sealing operation or additional materials.
2Reliability
If adhesive bonding or welding is used to seal bipolar plates, then sealing reliability is improved, but manufacturing cost increases
Solution Approach 1:
The patent replaces chemical bonding (adhesive) or thermal bonding (welding) with a mechanical sealing system. Frame members with integrated sealing features mechanically clamp and seal the bipolar plates through compression and geometric interlocking, eliminating the need for adhesive bonding or welding processes.
Solution Approach 2:
The sealing function is integrated into the frame members themselves rather than requiring separate, expensive sealing materials like adhesives or welding consumables. The frame members serve as both structural components and sealing elements, reducing material costs.
3Manufacturing precision
If separate sealing processes are used for bipolar plates, then sealing precision is improved, but assembly complexity increases
Solution Approach 1:
The patent combines the sealing function with the frame member structure itself. The frame members include integrated sealing features (protrusions, recesses, compression surfaces) that perform both structural support and sealing functions simultaneously, eliminating separate sealing processes and reducing assembly complexity.
Solution Approach 2:
The frame members are designed to perform multiple functions: providing structural support, enabling mechanical assembly, and creating seals. This multi-functionality integrates what would otherwise be separate processes into a single unified system.
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 approach enables faster and more cost-effective assembly of fuel cell stacks by providing a reliable sealing mechanism that reduces manufacturing time and costs, while maintaining the integrity of the fuel cell's electrical and fluid distribution functions.
Implementation Method 1
The first side protuberance of the first frame member deforms the portion of the anode plate and the portion of the cathode plate into the second side recess of the second frame member forming a seal therebetween
Data Source
AI summary
A bipolar plate assembly includes a first frame member, a second frame member, and a membrane electrode assembly. The first frame member has a first side and a second side. The first side has a first side protuberance. The second frame member includes a first side and a second side. The second side has a second side recess. The membrane electrode assembly has an anode plate and a cathode plate. A portion of the membrane electrode assembly is disposed between the first frame member and the second frame member. The portion of the membrane electrode assembly has a juxtaposition of the anode plate and the cathode plate. The first side protuberance of the first frame member deforms the portion of the membrane electrode assembly into the second side recess of the second frame member.