Fuel Cell Electrode Frame Assembly Punching Method

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Solution Overview

Problem

The existing manufacturing methods for fuel cell electrode frame assemblies result in a large clearance between the frame and the diffusion layer, leading to increased cell size, cost, and potential damage to the electrolyte membrane, as well as early deterioration of cell performance due to incomplete adhesive filling.

Innovation Solution

A method and apparatus for manufacturing the electrode frame assembly where the diffusion layer and frame are punched out in a stacked state to match the shape of the frame's opening, eliminating placement tolerances and reducing the likelihood of slippage during conveyance, thereby downsizing the fuel cell and simplifying the manufacturing process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the opening size of the frame is made relatively larger to accommodate placement tolerances, then the diffusion layer can surely fit in the opening, but the clearance between the frame and diffusion layer becomes large (about 2 mm)

Engineering Contradiction:

Improvefitting reliabilityVSAvoidclearance size

Core Design Contradiction:

ReliabilityVSLength of moving object

Solution Approach 1:

The diffusion layer is placed on the frame in advance before punching, allowing the punching process to simultaneously create the opening and define the final precise fit, eliminating the need for large clearance to accommodate placement tolerances

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The punching process replaces the traditional mechanical placement and fitting process, using a single punching operation to simultaneously create the opening and achieve precise positioning, eliminating the need for large clearance

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Manufacturing precision

If the clearance between frame and diffusion layer is large, then the diffusion layer can accommodate placement tolerances, but the overall fuel cell size becomes significantly larger than the power generation area

Engineering Contradiction:

Improveplacement tolerance accommodationVSAvoidfuel cell area

Core Design Contradiction:

Manufacturing precisionVSArea of stationary object

Solution Approach 1:

The diffusion layer is placed on the frame before punching, allowing the punching process to simultaneously create the opening and achieve precise fit, eliminating the need for large clearance and reducing overall fuel cell area

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The opening creation and diffusion layer fitting processes are merged into a single punching operation, achieving both functions simultaneously and eliminating the need for separate fitting steps that would require large clearance

Inventive Principle:

Principle #5Merging (Combining)

3Manufacturing precision

If the clearance between frame and diffusion layer is large, then placement tolerances can be accommodated, but adhesive cannot completely fill the clearance, causing electrolyte membrane exposure and early deterioration

Engineering Contradiction:

Improveplacement tolerance accommodationVSAvoidcell performance durability

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

The diffusion layer is placed on the frame before punching, allowing the punching process to simultaneously create the opening and achieve precise fit, eliminating large clearance and ensuring complete adhesive filling

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS10090538B2Manufacturing method and manufacturing apparatus of electrode frame assembly for fuel cell

Publication Date: 2018.10.02 TOYOTA JIDOSHA KK

AI summary

The purpose is to suppress positional misalignment between the diffusion layer and the frame. The manufacturing method of an electrode frame assembly for fuel cell comprises the steps of: (a) placing a frame and a diffusion layer to be stacked on each other; and (b) punching out the diffusion layer and the frame in the stacked state to form in the frame an opening in a shape matching with the punched-out diffusion layer.