Fuel Cell Separator Elastic Deformation Joining
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Solution Overview
Problem
The existing methods for manufacturing fuel cell separators often result in non-ideal contact surfaces due to manufacturing errors, leading to gaps and defective joins, which increase contact resistance and decrease power generation performance.
Innovation Solution
A method involving the stacking of separator plates with protruding portions that are pressed against each other using elastic deformation of bent portions to ensure a strong and uniform join, improving the junction state through laser welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional welding methods are used to join separator plates, then the manufacturing process is simple, but the junction state is poor due to gaps caused by manufacturing errors and surface irregularities
Solution Approach 1:
The separator plate is pre-formed with bent portions and protruding portions before the joining process. These structural features are prepared in advance to enable automatic pressing and gap elimination during the joining operation, improving junction state without requiring complex real-time control systems
Solution Approach 2:
The invention replaces conventional complex welding or mechanical fastening systems with a simpler pressing mechanism that utilizes the elastic deformation of bent portions. The protruding portions automatically press against the opposing separator plate surface during joining, eliminating gaps through elastic-mechanical action rather than complex mechanical systems
2Reliability
If separator plates are joined without pressing protruding portions, then the manufacturing process is fast, but contact resistance increases due to insufficient contact between junction portions
Solution Approach 1:
The bent portions and protruding portions are designed to automatically perform the pressing function during the joining process itself. The structural features enable the separator plate to self-press against the opposing plate through elastic deformation, eliminating the need for separate pressing operations or additional actuators, thus maintaining high manufacturing speed while reducing contact resistance
Solution Approach 2:
The invention changes the physical state of the bent portions from rigid to elastically deformable. This parameter change allows the protruding portions to apply varying pressing forces during joining, ensuring adequate contact pressure to reduce contact resistance while maintaining a simple and fast manufacturing process
3Manufacturing precision
If the junction portion is not pressed against the separator plate, then the joining process is simple, but gaps form between plates leading to defective joins
Solution Approach 1:
The bent portions and protruding portions are pre-formed into the separator plate structure before joining. This preliminary action ensures that when the plates are brought together, the protruding portions automatically engage and press against the opposing plate surface, eliminating gaps without requiring complex pressing mechanisms
Solution Approach 2:
The protruding portions act as intermediary elements between the two separator plates. These protruding features transmit the pressing force from one plate to the other through elastic deformation of the bent portions, ensuring intimate contact at the junction interface without requiring direct complex pressing mechanisms
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 approach enhances the joint strength and reduces contact resistance between separator plates, thereby improving the power generation performance of fuel cells by ensuring a more effective and uniform contact.
Implementation Method 1
the first junction portion is pressed against the first separator plate by elastic deformation of a first bent portion that is bent between the first junction portion and the first protruding portion
Implementation Method 2
joining the first junction portion to the first separator plate while the first junction portion is being pressed against the first separator plate
Data Source
AI summary
A method of manufacturing a fuel cell separator, includes: stacking a first separator plate and a second separator plate having first and second protruding portions so that the first and second protruding portions protrude in a direction away from the first separator plate, the first and second protruding portions being adjacent to both sides of a first junction portion to be joined to the first separator plate; pressing the first and second protruding portions toward the first separator plate so that the first junction portion is pressed against the first separator plate; and joining the first junction portion to the first separator plate while the first junction portion is being pressed against the first separator plate, wherein in the pressing, the first junction portion is pressed against the first separator plate by elastic deformation of a first bent portion bent between the first junction portion and the first protruding portion.