Fuel Cell Separator Masking for Gasket Cross-Linking

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Solution Overview

Problem

The formation of a gasket on a fuel cell stack separator often results in surface contamination due to foreign substances, leading to increased contact resistance, which deteriorates the performance and quality of the fuel cell stack.

Innovation Solution

A method involving physical or chemical masking of the separator's surface, except for the region where the gasket is formed, to prevent contamination during the gasket cross-linking process, using a masking jig or masking coating layer to protect the surface from external substances and environments.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a gasket is formed and cross-linked on the separator surface, then the sealing function is improved, but the separator surface becomes contaminated with foreign substances, increasing contact resistance

Engineering Contradiction:

Improvesealing functionVSAvoidsurface contamination

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The separator surface is pre-treated with a coating layer before gasket formation to prevent contamination during the cross-linking process. This preliminary protective action ensures that when foreign substances are generated during gasket cross-linking, they do not directly contaminate the separator surface, thus maintaining low contact resistance while achieving reliable sealing.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

A coating layer is introduced as an intermediary between the separator surface and the gasket material. This intermediate layer acts as a barrier that prevents direct contact between foreign substances generated during gasket cross-linking and the separator surface, thereby resolving the contradiction between achieving reliable sealing and preventing surface contamination.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Manufacturing precision

If the separator surface is coated to reduce contact resistance, then electrical conduction is improved, but the surface becomes more susceptible to contamination during gasket formation

Engineering Contradiction:

Improvecontact resistanceVSAvoidsurface contamination

Core Design Contradiction:

Manufacturing precisionVSObject-affected harmful factors

Solution Approach 1:

The separator surface is pre-coated with a protective layer before the gasket formation process. This preliminary coating ensures that when foreign substances are generated during gasket cross-linking, they are prevented from contaminating the separator surface, thereby maintaining the electrical conduction properties achieved by the initial coating while protecting against subsequent contamination.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

A thin film coating layer is applied to the separator surface to create a protective barrier. This flexible thin film prevents foreign substances generated during gasket formation from directly contacting the separator surface, thus preserving the low contact resistance properties while protecting against contamination.

Inventive Principle:

Principle #30Flexible shells and thin films

3Manufacturing precision

If foreign substances are present on the separator surface, then the effective area for electric conduction is reduced, but the gasket forming process is necessary for sealing

Engineering Contradiction:

Improveeffective area for electric conductionVSAvoidsealing function

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

A coating layer is introduced as an intermediary between the separator surface and the gasket material. This intermediate layer prevents foreign substances generated during gasket cross-linking from directly contaminating the separator surface, thereby maintaining the effective area for electric conduction while still enabling the gasket to perform its sealing function.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The separator surface is pre-coated before gasket formation to protect the effective area for electric conduction. This preliminary protective measure ensures that when the gasket is formed and cross-linked, foreign substances do not reduce the effective conduction area, while the gasket still achieves reliable sealing.

Inventive Principle:

Principle #10Preliminary action

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 effectively reduces contact resistance and minimizes defects in the separator, enhancing the performance and quality of the fuel cell stack by preventing contamination and maintaining low contact resistance.

Implementation Method 1

masking a surface of the separator except for a region of the surface of the separator on which the gasket is formed; and inserting the partially masked separator into a chamber to cross-link the gasket

Methodology Applied

Scientific EffectPhysical barrier (masking): Physical Containment

Implementation Method 2

a gasket which is formed and processed in advance, form a gasket on a separator using a liquid gasket material, etc.

Methodology Applied

Scientific EffectCross-linking: Chemical Bonding

Data Source

PatentUS10128479B2Method for manufacturing separator of fuel cell stack

Publication Date: 2018.11.13 HYUNDAI MOTOR CO LTD

AI summary

A method for manufacturing a separator of a fuel cell stack includes: forming a gasket on the separator of the fuel cell stack; masking a surface of the separator except for a region of the surface of the separator on which the gasket is formed; and inserting the partially masked separator into a chamber to cross-link the gasket.