Fuel Cell Separator Laser Ablation for Resin Bonding
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Solution Overview
Problem
In fuel cell manufacturing, it is difficult to bond separators to resin members with high adhesive strength due to reflective and non-absorbing glossy metal surfaces, leading to peeling issues under pressure from gases or refrigerants.
Innovation Solution
A manufacturing method involving a laser application step to remove carbon films from metal plates, exposing the metal surfaces and allowing for high-temperature removal of dirt, followed by bonding the separators to resin members within the exposed ranges, ensuring strong adhesion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a carbon film covers the separator surface, then the separator can be bonded to resin members, but the adhesive strength is insufficient and bonding parts peel off under pressure
Solution Approach 1:
The patent removes the carbon film from the separator surface in the bonding region, extracting the problematic layer that prevents strong adhesion. This allows direct bonding between the metal separator and resin member, achieving high adhesive strength while maintaining the carbon film's protective function in non-bonding areas.
Solution Approach 2:
The patent applies different surface conditions to different regions of the separator: the carbon film is removed only in the bonding region where strong adhesion is needed, while maintaining the carbon film coverage in other regions where protection and electrical conductivity are required. This local differentiation resolves the contradiction between bonding strength and overall separator performance.
2Ease of manufacture
If the separator surface is left glossy without carbon film, then laser beam can be applied to remove dirt, but the laser beam is easily reflected and cannot sufficiently remove dirt
Solution Approach 1:
The patent applies a carbon film to the separator surface before the laser treatment step. This preliminary action of adding the carbon film layer enables the subsequent laser beam to effectively remove dirt, as the carbon film absorbs the laser energy and facilitates dirt removal, while the film is later removed only in bonding regions.
3Strength
If the carbon film is removed to expose metal plate for bonding, then high adhesive strength is achieved, but the metal plate surface may have dirt that interferes with bonding
Solution Approach 1:
The patent performs laser beam treatment to remove dirt from the separator surface before the bonding process. This preliminary cleaning action ensures that when the carbon film is subsequently removed and bonding is performed, the metal surface is free from dirt and other contaminants that would interfere with adhesion, thus achieving high adhesive strength.
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 method effectively bonds separators to resin members with high adhesive strength, preventing peeling and enhancing the durability of fuel cell components.
Implementation Method 1
a laser beam is applied to a carbon film of a separator including a metal plate and the carbon film covering a surface of the metal plate such that the metal plate is exposed by removing the carbon film within an application range of the laser beam
Implementation Method 2
The carbon film easily absorbs the laser beam. Accordingly, in the laser application step, the temperature of the carbon film within the application range easily increases, so that the carbon film can be easily removed
Implementation Method 3
The carbon film easily absorbs the laser beam. Accordingly, in the laser application step, the temperature of the carbon film within the application range easily increases, so that the carbon film can be easily removed. Further, the temperature of the carbon film easily increases, and therefore, in a case where dirt is attached on the surface of the metal plate, the dirt is removed together with the carbon film.
Data Source
AI summary
A manufacturing method for manufacturing a fuel cell includes a laser application step and a bonding step. In the laser application step, a laser beam is applied to a carbon film of a separator including a metal plate and the carbon film covering a surface of the metal plate such that the metal plate is exposed by removing the carbon film within an application range of the laser beam. In the bonding step, the separator is bonded to a resin member within a range including at least part of a range where the metal plate is exposed.