Elastomeric Cell Frame for Fuel Cells
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Solution Overview
Problem
Existing fuel cell manufacturing processes require separate adhesive and sealing members for bonding bipolar plates and integrated frames, increasing material and manufacturing costs, and posing challenges in maintaining a hermetic reaction area and preventing water leakage.
Innovation Solution
An elastomeric cell frame is integrated using a pair of sheet-type elastomeric frames thermally bonded without adhesives, forming channels for reaction gas and coolant flow, which eliminates the need for separate adhesives and sealing members, and is bonded to a membrane-electrode assembly and gas diffusion layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If adhesive members and sealing members are used to bond bipolar plates and integrated frames, then bonding strength and hermetic sealing are improved, but material costs and manufacturing complexity increase
Solution Approach 1:
The patent combines the sealing function and bonding function into a single integrated frame structure made of thermoplastic elastomer. The elastomeric frame serves both as the bonding component that attaches the membrane electrode assembly and gas diffusion layers, and as the sealing component that maintains hermetic enclosure, eliminating the need for separate adhesive members and sealing members.
Solution Approach 2:
The integrated frame made of thermoplastic elastomer performs multiple functions simultaneously: it provides structural support, creates hermetic sealing, and enables bonding of components. This multi-functional design replaces the traditional multi-component system (adhesive + sealing member + frame), reducing both material costs and manufacturing complexity while maintaining reliability.
2Manufacturing precision
If separate adhesive members are used for bonding, then bonding precision can be improved, but material costs and manufacturing time increase
Solution Approach 1:
The bonding function is integrated into the frame structure itself through the thermoplastic elastomer material properties. The frame is molded with specific geometric features that directly bond to the membrane electrode assembly and gas diffusion layers, eliminating the need for separate adhesive application steps while maintaining bonding precision.
Solution Approach 2:
The bonding surfaces and geometric features are pre-formed during the frame molding process. The thermoplastic elastomer frame is manufactured with integrated bonding interfaces that require no additional preparation or adhesive application, allowing direct assembly and reducing manufacturing time while preserving bonding precision.
3Reliability
If multiple separate components (adhesive, sealing member, frame) are used, then functional performance can be optimized, but material costs increase
Solution Approach 1:
The patent merges multiple functional components into a single integrated frame made of thermoplastic elastomer. This eliminates the need for separate adhesive members and sealing members, reducing the total quantity of materials required while maintaining all necessary functions including bonding, sealing, and structural support.
Solution Approach 2:
The thermoplastic elastomer frame serves multiple functions simultaneously - structural support, hermetic sealing, and component bonding - replacing what would traditionally require multiple separate components. This multi-functionality reduces material costs while preserving functional performance.
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 solution reduces material costs, prevents electrical shorts and corrosion, allows for a compact stack design, simplifies the stacking process, and improves bonding precision, leading to reduced defective rates and increased productivity.
Implementation Method 1
an elastomeric frame in which a pair of sheet-type elastomeric frames is disposed on a bottom portion and a top portion of an edge portion of the insert and is integrated by thermal bonding outside the insert
Data Source
AI summary
An elastomeric cell frame for a fuel cell in which a membrane electrode assembly and gas diffusion layers are formed using a pair of sheet-type elastomeric frames without a specific adhesive member and in which channels for the flow of reaction gas and coolant are formed, may include an insert formed by bonding a pair of gas diffusion layers to both sides of a membrane electrode assembly and an elastomeric frame.