Fuel Cell Separator Convex Protrusions for Seal Adhesion
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Solution Overview
Problem
Conventional fuel cell manufacturing processes often result in a significant reduction of adhesive layer thickness, leading to reduced adhesive force and non-uniform thickness, which can cause leakage of reactive gases or cooling mediums due to inadequate sealing between fuel cell separators.
Innovation Solution
Incorporating convex protrusions on the surfaces of separators that face the adhesive layers, with a harder core layer between them, to prevent excessive pressing and maintain adhesive layer thickness, and arranging these convexes in specific regions to distribute load effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the entire opposed surfaces of separators are pressed against the surface layers of the seal member, then the bonding area is maximized, but the thickness of the adhesive portion is significantly reduced
Solution Approach 1:
The separator surface is designed with convex portions that concentrate the pressing force at specific locations rather than distributing it uniformly across the entire surface. This local quality approach allows the adhesive layer to maintain its thickness in most areas while still achieving effective bonding at the convex contact points with the seal member.
Solution Approach 2:
The continuous pressing surface of the separator is segmented into multiple discrete convex portions. This segmentation prevents the uniform compression that would otherwise occur across the entire adhesive interface, thereby preserving the adhesive layer thickness while providing sufficient bonding through the distributed convex contact points.
2Strength
If the entire opposed surfaces of separators are pressed against the surface layers of the seal member, then the bonding strength is improved, but the thickness of the fuel cell becomes non-uniform
Solution Approach 1:
By concentrating bonding force at specific convex portions rather than applying uniform pressure across the entire surface, the design achieves sufficient adhesive strength at critical locations while preventing excessive compression that would cause non-uniform thickness variations in the overall fuel cell structure.
Solution Approach 2:
Instead of applying full pressing force across the entire separator surface, the convex portions provide partial action concentrated at key bonding points. This partial action is sufficient to achieve the required adhesive strength while avoiding the excessive compression that would lead to non-uniform fuel cell thickness.
3Stress or pressure
If the adhesive layer thickness is significantly reduced, then the pressing force is distributed over a larger area, but the adhesive force between the separator and seal member is reduced
Solution Approach 1:
The convex portions create local zones of high pressure that concentrate the pressing force, maintaining adequate adhesive force at the bonding interface. This local quality approach prevents the uniform pressure distribution that would otherwise require excessive total force and cause non-uniform thickness reduction.
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 configuration enhances the adhesive force and maintains uniform adhesive layer thickness, preventing leakage and ensuring effective sealing between fuel cell separators, even under stacking loads.
Implementation Method 1
The first separator includes a first opposed surface that is arranged to face the first adhesive layer and a first convex that is protruded from the first opposed surface in a direction toward the seal member to dent the first adhesive layer
Implementation Method 2
In a process of manufacturing the fuel cell, the surface layers of the seal member are melted and are then cured, so that opposed surfaces of the separators arranged to face the respective surface layers of the seal member adhere to the surface layers
Implementation Method 3
the surface layers of the seal member are melted and are then cured, so that opposed surfaces of the separators arranged to face the respective surface layers of the seal member adhere to the surface layers
Implementation Method 4
a core layer that is placed between the first adhesive layer and the second adhesive layer and is harder than the first adhesive layer and the second adhesive layer
Data Source
AI summary
A technique of reducing the possibility that the thickness of an adhesive layer in a seal member becomes non-uniform is provided. There is provided a fuel cell comprising a membrane electrode gas diffusion layer assembly; a seal member; and a first separator and a second separator arranged to place the diffusion layer assembly and the seal member therebetween. The seal member includes a first adhesive layer facing the first separator, a second adhesive layer facing the second separator, and a core layer that is placed between, and is harder than, the first and second adhesive layers. Each of the first and second separators includes an opposed surface that faces the corresponding adhesive layer and a convex protruded from the opposed surface in a direction toward the seal member. A circumference of the convex in the opposed surface adheres to the corresponding facing adhesive layer.