Elastomeric Fuel Cell Frame Integrally Bonds Components
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Solution Overview
Problem
Conventional fuel cell manufacturing processes require separate adhesive and sealing members, leading to increased material and manufacturing costs, and are prone to corrosion and deformation issues due to metal separators, which are also difficult to handle.
Innovation Solution
An elastomeric cell frame made of thermoplastic elastomer (TPE) integrally bonds a membrane electrode assembly, gas diffusion layer, and separator without a separate adhesive member, featuring manifold through-holes and thermal bonding to eliminate the need for separate adhesive and sealing members, reducing material usage and enhancing durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional integrated frame uses adhesive agent to bond frame and insert, then bonding is achieved, but material cost and manufacturing cost increase
Solution Approach 1:
The patent removes the adhesive agent from the bonding process by extracting its function. The elastomeric frame itself is designed to provide bonding through its material properties and structural design, eliminating the need for separate adhesive materials while maintaining bonding strength between the frame, insert, and separator.
Solution Approach 2:
The elastomeric frame acts as an intermediary component that provides both structural support and bonding function. Its elastic material properties enable it to serve as a mediator that bonds the rigid frame and insert together, as well as providing sealing, without requiring additional adhesive materials.
2Reliability
If separate adhesive member and sealing member are used, then bonding and sealing are achieved, but device complexity increases
Solution Approach 1:
The patent merges the functions of the frame, insert, separator, adhesive member, and sealing member into a single integrated elastomeric frame structure. This multi-functional design eliminates the need for separate components, reducing device complexity while maintaining reliable bonding and sealing performance through the frame's inherent material properties.
Solution Approach 2:
The elastomeric frame is designed as a universal component that simultaneously performs multiple functions: structural support, bonding between components, sealing against gas leakage, and alignment guidance. This multi-functionality reduces the total number of components needed in the fuel cell assembly.
3Productivity
If metal separator with manifold part is used, then gas flow is achieved, but corrosion occurs during long-term operation
Solution Approach 1:
The patent replaces the durable but corrosion-prone metal separator with an elastomeric frame that, while potentially having different longevity characteristics, provides superior corrosion resistance. The elastomeric material is inherently resistant to chemical corrosion from fuel cell operating conditions, ensuring long-term reliability without the corrosion issues of metal components.
4Volume of stationary object
If thin plate metal separator is used to reduce volume, then compactness is achieved, but outer manifold part becomes liable to deformation due to external impact
Solution Approach 1:
The patent employs an elastomeric frame that utilizes the properties of flexible materials to provide both compactness and impact resistance. The elastomeric material can deform elastically under external impact and return to its original shape, providing inherent shock absorption and impact resistance while maintaining a compact fuel cell structure without requiring thick rigid plates.
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 and manufacturing costs, prevents corrosion and deformation, and simplifies the stacking process while maintaining airtightness and stability of the fuel cell stack.
Implementation Method 1
integrally bonds a membrane electrode assembly, a gas diffusion layer, and a separator without a separate adhesive member by using a sheet-shaped elastomeric frame made of a thermoplastic elastomer (TPE)
Data Source
AI summary
An elastomeric cell frame for a fuel cell includes an insert in which a membrane electrode assembly and a pair of gas diffusion layers disposed on both surfaces of the insert have been bonded; a separator assembly disposed on one of the surfaces of the insert while a pair of separators is configured to face each other; and a sheet-shaped elastomeric frame disposed to surround a rim of the insert and a rim of the separator assembly and a side surface thereof in outside regions of the insert and the separator assembly, and integrally bonded with the rim of the insert and the rim of the separator assembly by thermal bonding.