Fuel Cell Stack Seal Arrangement With Compression Protection

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Solution Overview

Problem

Existing fuel cell technologies fail to adequately withstand high forces, such as those encountered during vehicle accidents or earthquakes, leading to potential damage and safety issues.

Innovation Solution

A seal arrangement for fuel cell stacks that includes a seal element and a compression protection unit to prevent irreversible deformation during high forces, featuring a corrugation element and multi-layer compression protection zones to absorb and distribute forces along the plate stack longitudinal axis.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional seal arrangements are used in fuel cell stacks, then the structure is simple and easy to manufacture, but the seal element is vulnerable to irreversible deformation under high forces such as during vehicle accidents or earthquakes

Engineering Contradiction:

Improvewithstand high forcesVSAvoidseal arrangement structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The seal arrangement is divided into distinct functional components: a seal element for sealing and compression protection units for force absorption. Each component is optimized for its specific function, allowing the seal element to remain simple while the compression protection units provide the necessary force resistance through their structured design

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Compression protection units are positioned adjacent to the seal element to provide preemptive protection against high forces. These units are designed to deform preferentially under compression, absorbing impact forces before they can reach and damage the seal element, thus cushioning the seal element in advance against irreversible deformation

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

2Duration of action of stationary object

If compression protection units are added to protect the seal element, then the durability under high forces is improved, but the manufacturing complexity increases

Engineering Contradiction:

Improvedurability under high forcesVSAvoidseal arrangement production

Core Design Contradiction:

Duration of action of stationary objectVSEase of manufacture

Solution Approach 1:

The compression protection units incorporate corrugation elements with wave-like structures that provide high compression resistance through geometric design rather than material thickness. This allows the protection units to be manufactured from thin, flexible materials using standard forming processes, maintaining ease of manufacture while achieving superior durability

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The seal arrangement combines different material properties in the compression protection units, using materials that offer both structural integrity and controlled deformability. This composite approach allows the units to withstand high forces while remaining manufacturable through conventional techniques

Inventive Principle:

Principle #40Composite materials

3Reliability

If the seal element is made more robust to withstand high forces, then the protection against irreversible deformation is improved, but the sealing effectiveness may be compromised due to increased stiffness

Engineering Contradiction:

Improveprotection against irreversible deformationVSAvoidsealing effectiveness

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The system separates the sealing function from the force protection function into two distinct components: the seal element maintains its original compliant, precision-sealing design while the compression protection units provide the robust force resistance. This segmentation allows each component to be optimized for its specific function without compromise

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The compression protection units act as intermediary elements between external high forces and the seal element. They absorb and dissipate impact forces through controlled deformation, preventing these forces from being transmitted to the seal element and thus protecting the precision sealing interface from damage

Inventive Principle:

Principle #24Intermediary (Mediator)

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

The seal arrangement effectively protects the seal element from irreversible deformation, ensuring durability and safety of the fuel cell stack under high force conditions.

Implementation Method 1

compression protection unit for protecting the seal element in relation to irreversible deformation during compression of the plate stack arrangement along a plate stack longitudinal axis

Methodology Applied

Scientific EffectCompression: Compression

Implementation Method 2

compression protection unit... to absorb and distribute forces

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS20260005279A1Seal arrangement and plate stack arrangement

Publication Date: 2026.01.01 EKPO FUEL CELL TECH GMBH

AI summary

A seal arrangement for sealing a space in a plate stack arrangement, wherein the plate stack arrangement can be, for example, a fuel cell stack or part of a fuel cell stack, and the space can be a space lying therein, wherein the seal arrangement comprises the following: a seal element for delimiting the space in at least one direction, and a compression protection unit for protecting the seal element in relation to irreversible deformation during compression of the plate stack arrangement along a plate stack longitudinal axis.