Fuel Cell Membrane Edge Fixing via Injection Molding Presser
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Solution Overview
Problem
Conventional solid polymer electrolyte fuel cells face issues with cross-leakage due to inadequate binding between the polymer electrolyte membrane and the frame, leading to reduced performance and potential membrane damage during the injection molding process.
Innovation Solution
A manufacturing method involving a first frame member and a second mold to securely fix the electrolyte membrane edge during injection molding, using presser members to prevent membrane separation and ensure integral bonding between the frame members, thereby enhancing the binding property and reducing cross-leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the polymer electrolyte membrane is bound to the frame using adhesives, then the binding between the membrane and frame is achieved, but the performance of the polymer electrolyte membrane deteriorates due to volatile components of the adhesives
Solution Approach 1:
The invention extracts and eliminates the adhesive component from the binding system, replacing it with a mechanical pressing method during injection molding. This removes the source of volatile components that deteriorate membrane performance while achieving the necessary binding between the polymer electrolyte membrane and frame through direct mechanical contact and resin encapsulation.
Solution Approach 2:
The invention replaces the chemical bonding mechanism (adhesives) with a mechanical bonding mechanism (pressing and injection molding). The membrane is mechanically secured between the frame and the injected resin, eliminating chemical interactions that could harm the membrane while achieving secure attachment through physical forces.
2Strength
If a mechanical cramp is used to bind the polymer electrolyte membrane to the frame, then the binding is achieved, but cross-leak from fine clearance between the membrane and frame occurs
Solution Approach 1:
The invention merges the binding function with the sealing function into a single integrated process. The injection molding operation simultaneously binds the membrane to the frame and fills the interface region with resin material, eliminating fine clearances that would allow cross-leak while achieving mechanical attachment.
Solution Approach 2:
The injected resin material acts as an intermediary substance that fills the gap between the membrane and frame. This resin mediator eliminates fine clearances that cause cross-leak while also providing binding strength, serving dual functions of sealing and attachment without requiring separate mechanical cramps.
3Strength
If injection molding is used to form the frame with the electrolyte membrane inside, then the adhesion between frame and membrane is enhanced, but the membrane may float and separate during the injection process
Solution Approach 1:
The invention performs preliminary positioning and securing of the electrolyte membrane before the injection molding process begins. The membrane is pre-arranged in the correct position within the mold cavity and temporarily secured, ensuring it remains stable during the subsequent high-pressure resin injection that enhances adhesion.
Solution Approach 2:
The invention applies preliminary counter-actions to prevent the harmful effect of membrane floating. By securing the membrane in position before injection and using mold design features that constrain membrane movement, the system counteracts the floating tendency caused by resin pressure before it can cause separation.
4Strength
If the electrolyte membrane is arranged in the center of the frame thickness, then the membrane is supported, but cross-leak from clearance between membrane and frame periphery occurs
Solution Approach 1:
The invention merges the support function and sealing function by using the same injection molding process to both support the membrane in the center of the frame and seal the peripheral clearance. The injected resin simultaneously provides structural support and eliminates leakage paths at the periphery.
Solution Approach 2:
The injected resin material serves as an intermediary that fills and seals the peripheral clearance between the membrane and frame. This resin mediator prevents cross-leak at the periphery while allowing the membrane to remain positioned in the center of the frame thickness for optimal support.
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 method effectively suppresses cross-leakage and ensures stable support of the polymer electrolyte membrane, improving the overall performance and reliability of the fuel cell by preventing membrane separation and damage during the molding process.
Implementation Method 1
pressing and fixing a part of the edge of the electrolyte membrane member to the first frame member by a presser member mounted on the second mold
Implementation Method 2
injecting a molding resin material into a resin flow passage to fill the resin material in the resin flow passage in the condition where the electrolyte membrane member is fixed by the presser member
Implementation Method 3
curing the filled resin material to form a second frame member which is bound to the first frame member integrally in the resin flow passage
Data Source
AI summary
In a manufacturing method for an electrode-membrane-frame assembly in a fuel cell, a first frame member and an electrolyte membrane member are arranged in a first mold for injection molding such that the edge of the electrolyte membrane member is arranged on the first frame member, a second mold is arranged to form a resin flow passage for forming a second frame member which is in contact with the first frame member by interposing the electrolyte membrane member, and a part of the edge of the electrolyte membrane member is pressed and fixed to the first frame member by a presser member mounted on the second mold and a molding resin material is injected into the resin flow passage to form a second frame member.