Photocurable Fuel Cell Sealant Sheet for Bubble-Free Hydrogen Sealing
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Solution Overview
Problem
Existing photocurable resin sealing agents for fuel cells suffer from air bubble incorporation during screen printing, leading to reduced adherence to the electrolyte membrane and increased hydrogen gas permeability, which compromises the efficiency and reliability of solid polymer fuel cells.
Innovation Solution
A photocurable sheet-shaped sealing agent comprising urethane (meth)acrylate, phenoxy resin, and a photopolymerization initiator, with specific molecular weight ranges and glass transition temperatures, is used to create a cured product with enhanced adherence and low hydrogen gas permeability, utilizing a three-layer structure and UV curing for improved sealing between fuel cell components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If photocurable resin is printed on the surface of separator by screen printing, then sealing function is provided, but air bubbles easily get mixed in and adherence to the member is reduced
Solution Approach 1:
A release film is introduced as an intermediary carrier between the photocurable resin and the separator. The resin is applied on the release film surface rather than directly on the separator, preventing air bubble entrapment while ensuring proper adherence through controlled release film separation. This mediator approach resolves the contradiction by decoupling the application process from the bonding process.
Solution Approach 2:
The sealing structure is segmented into three distinct components: the separator, the release film carrier, and the photocurable resin layer. This segmentation allows each component to perform its specific function independently - the release film enables clean resin application without air bubbles, while the separator provides the structural base, and the resin provides the sealing function.
2Reliability
If photocurable resin is printed on the surface of separator, then sealing structure is formed, but hydrogen gas permeability increases
Solution Approach 1:
The molecular weight of the urethane (meth)acrylate is controlled within a specific range (20,000-100,000), and the glass transition temperature of the phenoxy resin is optimized (50-120°C). These parameter changes create a cured product with appropriate density and crosslinking structure that reduces hydrogen gas permeability while maintaining sealing functionality.
Solution Approach 2:
The sealing agent uses a composite formulation combining urethane (meth)acrylate with phenoxy resin. This composite material structure creates a dense crosslinked network upon curing that effectively blocks hydrogen gas permeation while providing the necessary sealing properties. The synergistic combination of these two resin systems resolves the gas permeability issue.
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 solution achieves excellent adherence to the electrolyte membrane and significantly reduces hydrogen gas permeability, ensuring better sealing efficiency and maintaining the performance of solid polymer fuel cells by preventing gas leakage and mixing.
Implementation Method 1
a component (C): a photopolymerization initiator
Data Source
AI summary
One embodiment of the present invention aims to provide a photocurable sheet-shaped sealing agent having adherence to an electrolyte membrane and a hydrogen gas barrier. A photocurable sheet-shaped sealing agent for fuel cell, comprising a component (A): urethane (meth)acrylate, a component (B): a phenoxy resin, and a component (C): a photopolymerization initiator.