Fuel Cell Plate Seal With Integrated Support
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Solution Overview
Problem
Existing fuel cell seals are costly and sensitive to dimensional and environmental variations, leading to reduced fluid velocity and potential blockages in fuel cell stacks, which affect performance and electrical output.
Innovation Solution
A seal assembly for fuel cell systems featuring elongated sealing members and seal supports that form a fluid-tight seal, allowing for consistent fluid flow and accommodating misalignment, while minimizing material and tooling costs by using existing plate material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If prior art seals are used, then sealing function is achieved, but cost increases and sensitivity to dimensional variation worsens
Solution Approach 1:
The seal support is integrated with the fuel cell plate structure, merging two previously separate components (seal support and plate) into a unified structure. This integration eliminates the need for separate seal supports, reducing part count, manufacturing complexity, and cost while improving dimensional stability by using the plate's inherent structural properties.
Solution Approach 2:
The fuel cell plate is designed to serve multiple functions: it provides structural support, defines flow fields, and integrates the seal support function. By making the plate multi-functional, the patent eliminates the need for dedicated seal support components, thereby reducing manufacturing cost and sensitivity to dimensional variations.
2Reliability
If tortuous flow path is used, then sealing is improved, but fluid velocity decreases and blockage risk increases
Solution Approach 1:
The seal assembly is segmented into distinct functional zones: a seal support region integrated with the plate and a seal engagement region that interfaces with the seal. This segmentation allows the fluid flow path to be optimized separately from the sealing function, enabling straighter flow paths that maintain velocity while still achieving effective sealing through the dedicated seal engagement structures.
Solution Approach 2:
The seal support structure acts as an intermediary element that mediates between the plate structure and the seal. It provides a stable mounting surface for the seal while minimizing interference with the fluid flow path, thereby maintaining fluid velocity and reducing blockage risk while ensuring reliable sealing.
3Reliability
If complex seal assembly is used, then sealing reliability improves, but manufacturing complexity increases
Solution Approach 1:
The seal support is merged with the fuel cell plate structure, combining what were previously separate components into a unified structure. This merger simplifies the overall assembly by reducing part count and eliminating the need for separate seal support manufacturing, while maintaining sealing reliability through integrated design features.
Solution Approach 2:
The seal support is made homogeneous with the plate material and manufacturing process, using the same material and formation methods (e.g., stamping, molding) as the plate itself. This homogeneity simplifies manufacturing by using existing processes and materials, reducing assembly complexity, while ensuring compatible thermal and mechanical properties for reliable sealing.
Data Source
AI summary
A seal structure is disclosed for forming a substantially fluid tight seal between a UEA and a plate of a fuel cell system, the seal structure including a sealing member formed in one fuel cell plate, a seal support adapted to span feed area channels in an adjacent fuel cell plate, and a seal adapted to cooperate with a UEA disposed between the fuel cell plates, the sealing member, and the seal support to form a substantially fluid tight seal between the UEA and the one fuel cell plate. The seal structure militates against a leakage of fluids from the fuel cell system, facilitates the maintenance of a velocity of a reactant flow in the fuel cell system, and a cost thereof is minimized.