Fuel Cell Stack Separator Bonding for Coolant Leak Prevention
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing fuel cell stack design, where protrusion portions are adhered by adhesive, is prone to displacement due to external impacts, leading to reduced sealing properties and leakage in the cooling liquid flow path.
Innovation Solution
A fuel cell stack design where the protrusion portions of the first separator are adhered to a wider flat surface of the second separator using a pressure-sensitive adhesive sheet, ensuring secure bonding even under external impacts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If protrusion portions are adhered to each other by adhesive in the existing design, then the cooling liquid flow path can be formed, but displacement due to external impacts occurs and sealing property is reduced
Solution Approach 1:
The invention applies different surface characteristics to different parts of the separator: the protrusion portion maintains its original surface properties for adhesive bonding, while the flat surface is specifically designed with a larger area to provide a stable bonding base. This local differentiation ensures that the protrusion portions remain securely positioned without displacement under external impacts, resolving the contradiction between sealing property and position stability.
Solution Approach 2:
The flat surface is pre-formed on the separator before the adhesive bonding process. This preliminary preparation of a wider bonding surface ensures that when adhesive is applied, the protrusion portions have a stable base to adhere to, preventing displacement before the adhesive even sets. This preliminary structural preparation addresses the position stability issue proactively.
2Ease of manufacture
If protrusion portions are adhered by adhesive, then cells can be stacked, but leakage occurs in the cooling liquid flow path when displacement happens
Solution Approach 1:
The invention creates a localized wider flat surface area on the separator specifically at the bonding region. This local expansion of the bonding surface provides a larger adhesive contact area, ensuring that even when cells are stacked and subjected to external impacts, the adhesive bond remains intact and prevents cooling liquid leakage, thus maintaining sealing integrity while enabling easy cell stacking.
Solution Approach 2:
The flat surface acts as an intermediary bonding interface between the protrusion portions of adjacent cells. By providing a wider, more stable surface for adhesive attachment, it mediates the connection between cells more effectively, preventing displacement and ensuring that the cooling liquid flow path remains sealed during cell stacking and operation.
3Strength
If protrusion portions are used for adhesive bonding, then cells can be adhered, but the sealing property is reduced when displacement occurs due to impact
Solution Approach 1:
The wider flat surface is pre-formed on the separator before adhesive application. This preliminary structural preparation creates a larger bonding area that distributes mechanical stresses more evenly when external impacts occur. The adhesive bonds to this pre-prepared wider surface, creating a stronger, more impact-resistant connection that maintains sealing properties under load.
Solution Approach 2:
The invention changes the geometric parameter of the bonding surface by making the flat surface wider than the protrusion portion base. This parameter change increases the adhesive bonding area and improves the mechanical strength of the joint, enabling the adhesive bond to withstand external impacts without failing and maintaining sealing integrity.
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 effectively prevents cooling liquid leakage by maintaining sealing integrity despite displacement, enhancing the adhesive's sealing properties and reducing the risk of fluid loss.
Implementation Method 1
A adhesive sheet adheres the first separator of the first cell and the second separator of the second cell. The protrusion portion is adhered to a flat surface of the second separator of the second cell by the adhesive sheet.
Data Source
AI summary
The cells of the fuel cell stack have an adhesive sheet between adjacent first cell and second cell. The pressure-sensitive adhesive sheet adheres the first separator of the first cell to the second separator of the second cell. The first separator of the first cell comprises ribs in the adhesive region of the adhesive sheet, the ribs being adhered to the flat surface of the second separator of the second cell by the adhesive sheet. The width of the flat surface is larger than the width of the rib base portion.