Fuel Cell Frame-Gasket Integration for Separator Alignment

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Solution Overview

Problem

Conventional fuel cell manufacturing methods face issues with misalignment of separators and membrane electrode assemblies during stacking, leading to defects and reduced performance due to the use of adhesives and complex manufacturing processes, which result in physical damage and burrs.

Innovation Solution

Integration of a separator, gasket, and membrane electrode assembly into a single body using frame-gaskets with concave and convex portions for precise alignment, eliminating the need for adhesives and simplifying the manufacturing process by forming a single contiguous piece through injection molding.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If adhesives are used to assemble separators and membrane electrode assemblies, then assembly is enabled, but misalignment occurs and manufacturing complexity increases

Engineering Contradiction:

Improveassembly processVSAvoidalignment accuracy

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The gasket and frame are merged into a single integrated component through injection molding. The gasket is formed with built-in convex portions that fit into concave portions on the frame, creating a unified assembly unit that eliminates misalignment issues between separate adhesive-bonded components.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The convex portions on the gasket serve as intermediary alignment features that mediate between the gasket and frame. These protrusions fit into corresponding concave recesses on the frame, providing precise positional registration without requiring adhesives or complex alignment procedures.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If injection molding is used to produce integrated gaskets, then manufacturing efficiency is improved, but material leakage forms burrs increasing defect rates

Engineering Contradiction:

Improvemanufacturing efficiencyVSAvoidsurface quality

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The problematic gap between the separator and mold is eliminated by extracting the separator from the injection molding process. Instead of molding the gasket directly onto the separator surface, the gasket is molded separately and then assembled to the frame, removing the source of material leakage and burr formation.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The manufacturing process is segmented into distinct stages: gasket injection molding, frame preparation, and final assembly. This segmentation allows each component to be optimized independently - the gasket can be molded with precise dimensions without constraint from the separator geometry, eliminating burr formation while maintaining high productivity.

Inventive Principle:

Principle #1Segmentation

3Adaptability or versatility

If multiple separate components are assembled, then flexibility is maintained, but alignment errors decrease performance

Engineering Contradiction:

Improvecomponent flexibilityVSAvoidstacking alignment

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS9401516B2Fuel cell

Publication Date: 2016.07.26 HYUNDAI MOTOR CO LTD

AI summary

A fuel cell that includes a membrane electrode assembly having an electrolyte, an anode catalyst, and a cathode catalyst; and a plurality of frame-gaskets is provided. Each of the frame-gaskets may be disposed between an anode-side separator and the membrane electrode assembly or between a cathode-side separator and the membrane electrode assembly. Additionally, the membrane electrode assembly is provided with an aperture which is used to combine the membrane electrode assembly with the frame-gasket assembly.