Fuel Cell Humidifier Membrane Coating for Low-Handling Assembly

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Solution Overview

Problem

Existing fuel cell humidifier units face challenges in maintaining balanced water levels, leading to issues like flooding or dehydration, and the fabrication process is costly due to excessive handling and potential damage of ionomer membranes.

Innovation Solution

The ionomer membrane is directly coated onto a separator roll just before cutting, minimizing handling and eliminating the need for a backer layer, thereby reducing waste and enhancing durability through secure attachment using ePTFE support layers.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If the ionomer membrane is handled extensively during fabrication, then the membrane can be assembled into the humidifier unit, but the membrane is prone to damage and crossover

Engineering Contradiction:

Improvemembrane assemblyVSAvoidmembrane integrity

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The ionomer membrane is coated onto the separator roll at the final stage of separator fabrication, just before cutting into individual separators. This preliminary positioning of the membrane eliminates the need for separate handling and assembly steps, directly resolving the contradiction by reducing handling while enabling complete assembly.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The ionomer membrane is combined with the separator by coating it directly onto the separator roll surface. This merging of the membrane with the separator structure creates an integrated component that eliminates separate assembly steps and reduces handling, thereby improving both manufacturability and membrane reliability.

Inventive Principle:

Principle #5Merging (Combining)

2Reliability

If a backer layer is used to support the ionomer membrane, then the membrane is protected during handling, but material waste increases and cost increases

Engineering Contradiction:

Improvemembrane protectionVSAvoidmaterial waste

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

The backer layer is completely removed from the structure. Instead of using a backer for support, the ionomer membrane is coated directly onto the separator roll and remains attached to the separator itself, eliminating material waste while maintaining membrane protection through its integrated positioning.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The separator itself serves as the permanent support structure for the ionomer membrane, replacing the need for a separate backer layer. This eliminates the waste associated with disposable backers while the durable separator provides ongoing support and protection.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Loss of substance

If the ionomer membrane is coated directly onto the separator roll, then handling is minimized and waste is reduced, but the membrane requires secure attachment

Engineering Contradiction:

Improvemembrane wasteVSAvoidmembrane attachment

Core Design Contradiction:

Loss of substanceVSStrength

Solution Approach 1:

The mechanical attachment method is replaced by direct coating of the ionomer membrane onto the separator roll surface. The coating process creates a secure bond between the membrane and separator without requiring additional mechanical fastening systems, thereby reducing waste while ensuring strong attachment.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 approach results in more durable and cost-effective water-permeable membrane assemblies with improved water permeability, reducing the risk of membrane damage and waste, while maintaining optimal hydration levels in fuel cells.

Implementation Method 1

The separator is formed continuously as a roll with a pair of planar porous layers and a support spaced apart by elongated strings placed between them

Methodology Applied

Scientific EffectMechanical support:

Implementation Method 2

The exchange of humidity is generally accomplished in the WVT unit by using an ionomer membrane disposed between adjacent high humidity and low humidity fluid flowpaths

Methodology Applied

Scientific EffectWater vapor permeation: Permeation

Implementation Method 3

the ionomer membrane layer is affixed thereto with minimum risk of ionomer membrane layer damage. In one form of the invention, the ionomer membrane layer can be coated directly onto a separator roll

Methodology Applied

Scientific EffectCoating: Coatings

Data Source

PatentUS8657266B2Separator roll membrane coating for fuel cell humidifier

Publication Date: 2014.02.25 GM GLOBAL TECHNOLOGY OPERATIONS LLC

AI summary

A water vapor transfer unit with separator plates and a method of making the same. In such an assembly, an ionomer coating that facilitates moisture transfer from a moisture-rich flowpath to a moisture-deficient flowpath and an underlying separator may both be prepared from continuous, roll-based methods. The ionomer may be applied to a separator assembly as the last processing step such that the handling of the fragile membrane is kept to a minimum.