Fuel Cell Separator Integrally Molded Airtight Gasket
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing fuel cell separators face challenges in maintaining airtightness and supporting the stacked separators due to deformation of thin metal plates, leading to leaks of reactant gases and coolant, and require complex gasket structures and additional manufacturing processes.
Innovation Solution
Integrally injection-molding airtight gaskets on both surfaces of the separators to form a closed curve, with main and sub-lines between manifolds and flow fields to guide fluid flow and provide structural support, enhancing bonding strength and airtightness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a gasket is separately attached to the separator, then airtightness can be maintained, but the manufacturing process becomes complex and time-consuming
Solution Approach 1:
The gasket and separator are merged into a single integrated component through injection molding. The gasket material is injected directly onto the separator surface, forming a unified structure that eliminates the need for separate attachment processes while maintaining airtight sealing functionality.
Solution Approach 2:
The gasket is pre-formed during the separator manufacturing process itself. By injecting the gasket material onto the separator in the same manufacturing cycle, the airtight sealing structure is prepared in advance, eliminating subsequent assembly steps and reducing manufacturing complexity.
2Productivity
If thin metal plates are used for separators, then manufacturing time and cost are reduced, but deformation occurs leading to leaks
Solution Approach 1:
The separator structure becomes a composite system combining thin metal plate with elastomeric gasket material. The thin metal plate maintains manufacturing efficiency while the injected gasket material provides reinforcement and sealing functionality, preventing deformation-induced leaks.
Solution Approach 2:
The gasket material is selectively applied to specific regions of the separator where sealing and structural support are needed. This localized reinforcement strengthens critical areas without requiring the entire separator to be thicker, maintaining overall manufacturing efficiency.
3Reliability
If additional support structures are added to maintain airtightness, then reliability improves, but device complexity increases
Solution Approach 1:
The support function and sealing function are merged into the same gasket component. The elastomeric material provides both the airtight sealing barrier and the structural support needed to prevent separator deformation, eliminating the need for separate support structures.
Solution Approach 2:
The gasket component performs multiple functions simultaneously: it provides airtight sealing, structural support to prevent deformation, and fluid flow guidance. This multi-functionality reduces the number of separate components needed while maintaining reliability.
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 improves airtightness and structural stability, ensuring efficient fluid flow and reducing manufacturing complexity by integrating gaskets directly onto the separators, thus maintaining the integrity of the fuel cell stack.
Implementation Method 1
a gasket is integrally injection-molded on both surfaces of the separator
Data Source
AI summary
The present invention provides a fuel cell separator having an airtight gasket, in which a gasket is integrally injection-molded in a region that requires airtightness of a fuel cell separator to maintain airtightness of each flow field of the separator and to smoothly guide the fluid flow in each flow field.For this purpose, the present invention provides a fuel cell separator having an airtight gasket, which is integrally injection-molded on both surfaces of the separator to form a closed curve.