Fuel Cell Membrane Sealing via Integrated Separator Rubber Layers
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Solution Overview
Problem
Conventional solid polymer electrolyte fuel cells face challenges in maintaining consistent sealing of oxidant and fuel gas flow passages between separators, leading to potential leaks and power generation issues due to misalignment and complexity in assembly.
Innovation Solution
A novel cell design where the solid polymer electrolyte membrane is slightly larger than the electrodes, with separators having primary and secondary seal rubber layers to clamp the membrane fluid-tightly, ensuring accurate positioning and sealing without increasing parts or assembly steps, using metal separators for enhanced strength and conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate seal rubber components are added to improve sealing, then sealing reliability is improved, but device complexity and number of parts increase
Solution Approach 1:
The seal rubber layer is integrated directly into the separator structure, merging the sealing function with the separator component. This eliminates the need for separate seal rubber parts while maintaining effective sealing between the oxidant and fuel gas flow passages.
Solution Approach 2:
The separator is designed to perform multiple functions simultaneously: it acts as both a structural support element and a sealing component. The seal rubber layer formed on the separator's primary face provides sealing functionality while the separator itself maintains the cell structure and facilitates gas flow.
2Reliability
If separate seal rubber components are added to improve sealing, then sealing reliability is improved, but assembly complexity increases
Solution Approach 1:
The seal rubber layer is formed as an integral part of the separator during the separator manufacturing process. This merging of the sealing component with the separator eliminates additional assembly steps for installing separate seal rubber parts, simplifying the overall cell assembly process.
3Productivity
If the membrane/electrode assembly is made thinner to improve power density, then productivity is improved, but manufacturing precision becomes more difficult
Solution Approach 1:
The seal rubber layer acts as an intermediary element between the membrane/electrode assembly and the separator. It provides a compliant interface that compensates for minor misalignments and positioning errors, enabling accurate assembly even when handling thin membrane structures that are difficult to position precisely.
Solution Approach 2:
The seal rubber layer functions as a flexible film that can deform to accommodate variations in the positioning of the thin membrane/electrode assembly. This flexibility allows the seal to maintain effective sealing even when the membrane is difficult to handle and position with high precision during assembly.
4Length of moving object
If seal rubber layers are made thinner to reduce cell thickness, then length is improved, but strength decreases
Solution Approach 1:
The seal rubber layer is formed as a composite structure on the separator's primary face, combining the rubber material with the separator substrate. This composite construction provides enhanced strength and structural support while maintaining a thin overall profile, allowing the seal to withstand operational pressures without requiring increased thickness.
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 design achieves high sealing efficiency, prevents gas leaks, and simplifies assembly by ensuring accurate membrane positioning, while metal separators provide strength and heat resistance, improving the overall performance and reliability of the fuel cell.
Implementation Method 1
primary face seal rubber layers being affixed to outer peripheral edge portions of the primary faces of the first and second separators... whereby the outer peripheral edge portion of the solid polymer electrolyte membrane projecting outwardly beyond the fuel electrode and the oxidant electrode are held clamped fluid-tightly between the first and second separator by means of inner peripheral portions of the primary face seal rubber layers
Data Source
AI summary
A cell for use in a solid polymer electrolyte fuel cell, including a membrane electrode assembly including a fuel electrode and an oxidant electrode disposed on either side of a solid polymer electrolyte membrane, the assembly being sandwiched from either side by a first separator and a second separator to give a stacked construction. The first and second separator have a planar shape slightly larger than a solid polymer electrolyte membrane, with primary face seal rubber layers affixed to outer peripheral edge portions of primary faces of the first and second separator. Thus, an outer peripheral edge portion of the solid polymer electrolyte membrane projecting outwardly beyond the fuel and oxidant electrodes are held clamped fluid-tightly between the first and second separators by means of the primary face seal rubber layers of the first and second separators.