Fuel Cell End Plate Anti-Bending Plate Injection Molding
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Solution Overview
Problem
Conventional integral metal inserts in fuel cell end plates face challenges such as difficulty in injection molding due to material reduction structures, long manufacturing times, and limitations in using different materials for weight reduction and strength improvement, along with bending issues during the injection molding process.
Innovation Solution
A sandwich insert with multiple stacked plates and an anti-bending plate is used, where the anti-bending plate is coupled to the sandwich insert and injection molded to prevent bending caused by resin pressure, allowing for weight reduction and improved manufacturing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If an integral metal insert is manufactured through machining for high strength, then strength is improved, but manufacturing time increases and weight reduction becomes difficult
Solution Approach 1:
The metal insert is divided into multiple stacked plates (first plate, second plate, third plate) that can be manufactured separately and then assembled. This segmentation allows each plate to be manufactured more efficiently while maintaining the overall structural integrity and strength requirements of the insert.
Solution Approach 2:
The invention uses a composite structure combining multiple metal plates with different functions - the first plate provides structural support, the second plate contains flow fields, and the third plate provides additional support. This composite approach allows optimization of each component for its specific function while reducing overall manufacturing complexity and time.
2Weight of moving object
If material reduction structures are applied to metal inserts for weight reduction, then weight is reduced, but injection molding becomes difficult and manufacturing precision deteriorates
Solution Approach 1:
By segmenting the insert into multiple plates, weight reduction can be achieved by optimizing the thickness and material distribution of each individual plate. The stacked structure allows for strategic material placement only where needed for structural support, avoiding unnecessary material in non-critical areas.
Solution Approach 2:
Different regions of the insert are designed with different material properties and thicknesses based on local requirements. Critical load-bearing areas use thicker plates or higher strength materials, while non-critical areas use thinner plates, achieving weight reduction without compromising overall precision and functionality.
3Weight of moving object
If a sandwich insert structure is used for weight reduction, then weight is reduced, but bending occurs during injection molding due to resin pressure
Solution Approach 1:
The sandwich structure is divided into multiple discrete plates that can be independently optimized. By stacking multiple thinner plates rather than using a single thick plate, the structure achieves weight reduction while the distributed arrangement provides better resistance to bending forces during injection molding.
Solution Approach 2:
The plates are pre-assembled into a stable stacked configuration before injection molding. This preliminary assembly ensures proper alignment and structural integrity, allowing the sandwich structure to resist resin pressure effectively during the molding process while maintaining weight reduction benefits.
4Weight of moving object
If multiple stacked plates are used in a sandwich insert, then weight reduction and material versatility are improved, but device complexity increases
Solution Approach 1:
While the insert is segmented into multiple plates, each plate is designed with simple, standardized geometries that are easy to manufacture. The segmentation allows for modular assembly and disassembly, reducing the overall complexity of manufacturing and maintenance compared to a single complex integral structure.
Solution Approach 2:
The multiple plates are designed to perform different functions within a unified structure - structural support, flow distribution, and electrical conduction. This multi-functionality reduces the need for separate components, actually simplifying the overall device architecture while achieving weight reduction and material versatility.
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
The anti-bending plate effectively supports the sandwich insert during injection molding, preventing bending and enabling efficient mass production while allowing for the use of different materials for enhanced strength and weight reduction.
Implementation Method 1
an anti-bending plate that is in close contact with a surface of an injection mold are coupled to a surface of the sandwich insert opposite to where a resin pressure is directly applied in an injection molding
Implementation Method 2
a plastic injection molded body is injection molded, so that the sandwich insert to which the resin pressure can be applied within the injection mold is supported by the anti-bending plate
Data Source
AI summary
Disclosed is an end plate for a fuel cell including an anti-bending plate, in which an anti-bending plate is assembled with an insert having a sandwich structure and the insert is injection molded, thereby easily preventing the insert from being bent due to an injection molding pressure. In the disclosed end plate, a sandwich insert including two or more stacked plates each having a specific shape is manufactured, and an anti-bending plate is coupled to the sandwich insert and then is injection molded, thereby easily preventing the sandwich insert from being bent due to a resin pressure in the injection molding process, contrary to a conventional integral metal insert.