Electrolyser Cell Seal Structure for High-Pressure Stack Reliability
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Solution Overview
Problem
Current industrial electrolyzer devices face challenges in maintaining tightness and reliability due to the failure of existing seals under high clamping forces and pressures, limiting the number of cells per stack and resulting in lower performance compared to fossil fuel-based hydrogen production.
Innovation Solution
The use of annular core seals with elastomer-based casings and specific rib configurations that provide improved mechanical strength, resistance to leaks, and electrical insulation, allowing for larger stacks with increased clamping forces and pressures without buckling or leakage issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stress or pressure
If current seal designs are used with high clamping forces to maintain tightness under high pressure, then sealing reliability deteriorates due to seal failure, but increasing clamping force is necessary to withstand operating pressures
Solution Approach 1:
The seal comprises a composite structure with a metallic core providing mechanical strength and pressure resistance, combined with an elastomer envelope providing sealing flexibility and compliance. This composite design allows the seal to withstand high operating pressures while maintaining reliability, as the metal core bears the mechanical load and the elastomer ensures continuous sealing contact.
Solution Approach 2:
Different regions of the seal have specialized functions: the metallic core provides structural integrity and pressure resistance, while the elastomer envelope provides sealing contact and compliance with mating surfaces. The through-openings in the core allow fluid passage while the elastomer covers these openings to prevent leakage. This local specialization of properties enables the seal to simultaneously handle high pressure and maintain reliable sealing.
2Productivity
If a large number of cells are stacked together to reduce costs and size, then device complexity increases and seal failure risk increases, but maximizing cells per stack is sought to reduce manufacturing and operation costs
Solution Approach 1:
The composite seal structure with metallic core and elastomer envelope provides enhanced mechanical strength and durability for use in large stacks. The metal core resists deformation under high clamping forces required for multi-cell stacks, while the elastomer maintains sealing effectiveness throughout the stack height, enabling reliable operation with maximum cells per stack.
Solution Approach 2:
The seal design incorporates specific geometric parameters including the configuration of through-openings, rib structures, and the thickness ratio between metal core and elastomer envelope. These parameter optimizations enable the seal to withstand the cumulative pressures and clamping forces in large stacks, maintaining reliability while enabling high cell density configurations.
3Reliability
If complex assembly designs with many separate parts are used to achieve tightness, then manufacturing precision requirements increase and assembly errors increase, but tightness is necessary to prevent leaks under high pressure
Solution Approach 1:
The seal integrates multiple functions into a single component: the metallic core provides structural support and pressure resistance, the elastomer envelope provides sealing contact, and the integrated through-openings with elastomer coverage provide both fluid passage and leak prevention. This merged design eliminates the need for multiple separate sealing parts, reducing assembly complexity while maintaining tightness under high pressure.
4Stress or pressure
If high clamping forces are applied to maintain seal tightness under high pressure, then creep phenomena increase and seal degradation accelerates, but high clamping force is necessary to prevent leaks
Solution Approach 1:
The metallic core has high creep resistance and maintains its shape under sustained clamping forces, while the elastomer envelope accommodates minor dimensional changes and maintains sealing contact. This composite structure distributes the clamping force burden, reducing creep deformation compared to pure elastomer seals, thereby extending seal lifetime under high clamping conditions.
Solution Approach 2:
The seal design places the creep-resistant metallic core in regions experiencing highest mechanical stress and clamping forces, while using elastomer in regions requiring compliance and sealing contact. The rib structures and through-opening configurations are locally optimized to distribute stresses and minimize creep-induced degradation, extending the operational life of the seal under high clamping forces.
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 enables the construction of larger, more efficient electrolyser stacks with reduced risks of degradation and leakage, enhancing the reliability and ecological acceptability of hydrogen production while reducing manufacturing and assembly complexities.
Implementation Method 1
The elastomer has greater deformability than metal. The core stiffens the seal and improves its mechanical strength while the elastomer deforms on contact and improves sealing.
Implementation Method 2
The core stiffens the seal and improves its mechanical strength
Implementation Method 3
Creep phenomena are also particularly reduced by the use of such gaskets.
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
A seal for an electrolyser cell and an electrolyser cell provided with such a seal. A seal (100) for an electrolyser cell comprising a core (101) and a shell (201). The core (101) is generally annular and has two faces mutually opposite each other in a thickness direction and at least two openings (111, 113). The two openings (111, 113) are through-openings in the thickness direction and are substantially diametrically opposed to each other. The shell (201) at least partially covers the two faces, leaving the two openings (111, 113) at least partially free. The shell (201) has at least one first rib (203) extending over a first (103) of the two faces according to a contour enclosing an inner edge (107) of the core (201) and the two openings (111, 113) in such a way as to allow a fluid to circulate between the two faces in the thickness direction.