Fuel Cell Plate Bonding via Injection Molded Seal
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Solution Overview
Problem
Existing methods for securing and sealing fuel cell plates in fuel cell stack assemblies often require multiple manufacturing steps and may not provide a robust, single-step solution for bonding and sealing multiple components effectively.
Innovation Solution
A method involving the use of a bond film secured to fuel cell plates using thermal energy from an injection molded seal, where the bond film is melted and cured during the injection molding process to unite the plates and seal interfaces between components in a single step.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple separate manufacturing steps are used for bonding and sealing fuel cell plates, then each step can be optimized independently, but the overall manufacturing time and process complexity increase
Solution Approach 1:
The patent combines bonding and sealing operations into a single integrated manufacturing step. A seal member with integrated bonding functionality is applied to the fuel cell plate, allowing both sealing and bonding to occur simultaneously during one molding process, thereby improving productivity without sacrificing bonding and sealing quality.
Solution Approach 2:
The seal member is designed to perform multiple functions: sealing the interface between fuel cell plates and bonding the plates together. This multi-functional component eliminates the need for separate bonding and sealing operations, resolving the contradiction between manufacturing precision and productivity.
2Productivity
If a single-step bonding and sealing method is used, then manufacturing efficiency improves, but the process complexity and difficulty of achieving reliable bonding increase
Solution Approach 1:
The invention segments the complex bonding and sealing function into distinct modular components: a seal member with specific geometric features (flange, sealing surface, bonding surface) and fuel cell plates with designated bonding areas. This segmentation simplifies the overall process by making each component's function clear and manageable, reducing process complexity while maintaining high productivity.
Solution Approach 2:
The seal member is designed with different local properties: a flange for positioning, a sealing surface for sealing, and a bonding surface for bonding. Each local region is optimized for its specific function, allowing the single-step process to achieve reliable results without excessive complexity.
3Strength
If bond film is used to secure fuel cell plates, then bonding strength is improved, but additional materials and processing steps are required
Solution Approach 1:
The bonding function is merged into the seal member itself. The seal member includes a bonding surface with bonding agents or adhesive layers integrated directly onto it, eliminating the need for separate bond films or adhesive applications. This reduces the number of components while maintaining strong bonding between fuel cell plates.
Solution Approach 2:
The seal member is designed to perform bonding as part of its primary sealing function. The bonding agents are pre-applied to the bonding surface, allowing the seal member to secure the fuel cell plates automatically during the molding process without requiring additional bonding steps or separate bond film materials.
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 allows for efficient bonding and sealing of fuel cell components in a single manufacturing step, enhancing the structural integrity and reducing processing time by using thermal energy from the injection molded seal to melt and cure the bond film, thereby improving the sealing and bonding of fuel cell plates.
Implementation Method 1
melting the bond film using thermal energy from an injection molded seal
Implementation Method 2
melting the bond film using thermal energy from an injection molded seal
Data Source
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Figure 4
AI summary
An example method of securing a bond film to a fuel cell component includes positioning the bond film adjacent the fuel cell component and melting the bond film using thermal energy from an injection molded seal.