Fuel Cell Resin Frame Inclined Surface Gap Reduction
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Solution Overview
Problem
The existing resin frame equipped membrane electrode assemblies for fuel cells have inefficiencies due to gaps formed inside the inner peripheral end of the resin frame member, which reduce power generation efficiency.
Innovation Solution
A resin frame equipped membrane electrode assembly with an inner peripheral end formed in a quadrangular annular shape and featuring an inclined surface that narrows inward from the center to the edges, reducing the gap between the electrolyte membrane and electrodes, achieved through laser processing of the resin film.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If an inclined surface is formed at the inner peripheral end of the resin frame member, then the gap between the electrolyte membrane and electrode is reduced, but the production time increases due to additional processing steps
Solution Approach 1:
The patent combines the inclined surface formation with the existing laser cutting process by adjusting the laser beam irradiation angle. Instead of adding a separate processing step, the laser beam is irradiated at an angle of 45 degrees or more relative to the normal direction of the inner peripheral end during the cutting operation, thereby forming the inclined surface and the cut edge in a single integrated process.
Solution Approach 2:
The patent changes the laser beam irradiation angle parameter from the conventional normal direction to an angle of 45 degrees or more relative to the normal direction of the inner peripheral end. This parameter modification enables the laser to perform both cutting and inclined surface formation simultaneously, resolving the contradiction between precision and production time.
2Ease of manufacture
If the inner peripheral end has a quadrangular shape, then the resin frame member is easy to manufacture, but a gap is formed inside the inner peripheral end reducing power generation efficiency
Solution Approach 1:
The patent addresses the gap problem by introducing a dimensional change through the inclined surface. The inner peripheral end transitions from a simple quadrangular cross-section to a form with an inclined surface, where the width of the inclined surface is gradually reduced from the center toward both ends. This dimensional modification eliminates the gap while preserving the quadrangular annular overall shape for ease of manufacture.
3Reliability
If the width of the inclined surface is gradually reduced from the center toward both ends, then the gap is minimized and power generation area is maximized, but the laser processing complexity increases
Solution Approach 1:
The patent employs the self-service principle by utilizing the natural characteristics of laser beam irradiation at an angle. When the laser beam irradiates the inner peripheral end at an angle of 45 degrees or more, the gradual reduction in inclined surface width from center to ends is achieved automatically through the laser's interaction with the material, without requiring complex positioning or multiple processing steps. The laser processing head simply needs to move along the inner peripheral end while maintaining the angled irradiation.
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 enhances power generation efficiency by increasing the power generation area and reduces production time in the laser processing step, improving overall production efficiency.
Implementation Method 1
a laser processing step of irradiating the inner peripheral end with a laser beam (L) emitted from the laser emission port disposed at the center of the opening to thereby form the inclined surface at the inner peripheral end
Data Source
AI summary
A resin frame member is produced by using a method of producing a resin frame member for a fuel cell. An inner peripheral end of the resin frame member includes an inclined surface formed over the entire periphery thereof. The inclined surface is inclined inward from one surface of the resin frame member toward the other surface of the resin frame member. The width of the inclined surface is gradually reduced from the center toward both ends of each side part of the inner peripheral end in a direction in which the side part of the inner peripheral end extends.