Fuel Cell Gasket Welded to Gas Diffusion Layer
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The assembly of fuel cells is complex due to the need for precise handling and sealing of thin layers, including gas diffusion layers and gaskets, which can interfere with gas flow and sealing properties.
Innovation Solution
A fuel cell sub-assembly comprising a gasket with a peripheral seal and a gas diffusion layer, where the gasket is welded to the gas diffusion layer at specific points, allowing for secure bonding without interfering with gas flow and sealing, and optionally including a channel for fluid connection, facilitating unimpeded gas flow and simplified assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the gas diffusion layer is securely bonded to the gasket, then the assembly reliability is improved, but the gas flow properties may be compromised
Solution Approach 1:
The patent applies welding only at specific connection points rather than across the entire interface between the gas diffusion layer and gasket. This localized bonding approach secures the assembly while leaving the central aperture open for unimpeded gas flow, thus resolving the contradiction between assembly reliability and gas flow properties.
Solution Approach 2:
The weld acts as an intermediary bonding mechanism that connects the gasket and gas diffusion layer at discrete points. This intermediary connection provides structural reliability without creating a continuous barrier that would interfere with gas diffusion, unlike a fully bonded interface would.
2Reliability
If multiple thin layers are precisely assembled, then the sealing properties are improved, but the assembly complexity increases
Solution Approach 1:
The patent combines the gas diffusion layer and gasket into a single pre-assembled sub-assembly unit with integrated welding. This merging reduces the number of separate assembly steps in the overall fuel cell manufacturing process, as the sub-assembly is installed as one unit rather than requiring separate positioning and bonding of multiple thin layers.
Solution Approach 2:
The gas diffusion layer is pre-positioned within the central aperture of the gasket and pre-welded to it before integration into the complete fuel cell assembly. This preliminary assembly action ensures proper positioning and sealing properties are achieved beforehand, simplifying the final assembly process.
3Reliability
If the gas diffusion layer is positioned within the central aperture, then the sealing effectiveness is improved, but the gas flow paths may be obstructed
Solution Approach 1:
The gas diffusion layer is positioned within the central aperture of the gasket, and welding is applied locally at connection points rather than across the entire aperture. This localized approach maintains sealing effectiveness at the connection points while leaving the central region open for gas flow.
4Object-generated harmful factors
If additional spacing tabs are used to maintain spacing, then the gas flow is improved, but the assembly complexity and manufacturing steps increase
Solution Approach 1:
The patent removes the need for separate spacing tabs by integrating the spacing function into the welded connection structure itself. The weld creates a fixed connection that maintains appropriate spacing between components, eliminating the need for additional spacing hardware and simplifying manufacturing.
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 solution simplifies the manufacturing and assembly of fuel cells by securely bonding the gas diffusion layer and gasket without compromising sealing, ensuring efficient gas flow and reducing the need for additional spacing tabs, thus enhancing the overall efficiency and reliability of the fuel cell sub-assembly.
Implementation Method 1
The weld, which may comprise an ultrasonic weld or a laser weld
Implementation Method 2
The weld, which may comprise an ultrasonic weld or a laser weld
Implementation Method 3
The diffusion layer is of a porous material to allow the fuel or oxidant to diffuse therethrough
Data Source
AI summary
A fuel cell sub-assembly (100) comprising; a gasket (101) comprising a peripheral seal (102) for a fuel cell assembly, the peripheral seal defining a central aperture (103) of the gasket; a gas diffusion layer (104) for providing diffused gases to a proton exchange membrane (503) of a fuel cell, the gas diffusion layer (104) located within the central aperture; wherein at at least one convection point (105, 106), an inside facing surface (107) of the peripheral seal of the gasket is welded to a corresponding outward facing surface (108) of the gas diffusion layer (104).