Fuel Cell Separator-Integrated Gasket With Rubber-Blocking Protrusions
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Solution Overview
Problem
Conventional separator-integrated gaskets for fuel cells face productivity issues due to liquid rubber flowing down from beads during the manufacturing process, resulting in defective products with irregular size and shape, especially when the liquid rubber has low viscosity or the intended height is high.
Innovation Solution
Incorporating a pair of protrusions on either side of the bead in the separator main body to block liquid rubber, ensuring it maintains a regular size and shape during curing, and optionally providing auxiliary protrusions for additional blocking stages.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If liquid rubber is applied to the bead to form the gasket, then the gasket is formed with the intended shape, but the liquid rubber may flow downward resulting in defective products
Solution Approach 1:
The protrusions are formed on the separator main body before applying the liquid rubber. These protrusions serve as preliminary structural features that guide and constrain the liquid rubber during application, preventing it from flowing downward before curing. This preliminary structural preparation ensures the liquid rubber maintains its intended shape without requiring additional control measures during the application process.
2Ease of manufacture
If the liquid rubber has low viscosity to improve application, then the gasket can be formed more easily, but the liquid rubber flows down more easily causing defects
Solution Approach 1:
The separator main body is given non-uniform local structures in the form of protrusions at specific locations where liquid rubber application occurs. These localized protrusions create specific constraints only where needed, allowing the liquid rubber to flow and spread easily in permitted areas while being contained in areas where shape precision is critical. This local structural modification enables both easy application and precise shape control.
3Reliability
If the intended gasket height is increased to enhance sealing property, then the sealing performance is improved, but the liquid rubber flows down more easily resulting in defects
Solution Approach 1:
The protrusions are pre-formed on the separator main body to establish containment boundaries before liquid rubber application. When forming gaskets with increased height for enhanced sealing, these preliminary protrusion structures prevent the liquid rubber from flowing downward during the filling process, allowing the gasket to achieve the required height without defect formation. This eliminates the need to reduce gasket height as a compromise, maintaining both sealing performance and productivity.
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 configuration enhances the productivity of separator-integrated gaskets by maintaining the liquid rubber's intended shape and size, reducing the likelihood of defects and preventing gasket peeling during compression.
Implementation Method 1
The gasket is formed when the liquid rubber is cured
Implementation Method 2
The surface tension of the liquid rubber applied to the bead 510 maintains the shape formed when the liquid rubber is applied
Data Source
AI summary
A separator-integrated gasket with improved productivity includes a separator main body for a fuel cell and an elastic gasket formed integrally with the separator main body. The separator main body includes a bead and a pair of protrusions located on opposite sides of the bead to block the liquid rubber applied to the bead. The gasket is formed when the liquid rubber is cured.