Fuel Cell Separator Mechanical Fastening Assembly

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Solution Overview

Problem

Conventional fuel cell separator assembly methods, such as spot-welding, result in poor welding-surface contact due to metal burrs and spring-back phenomena, leading to reduced yield and air-tightness issues, along with increased costs and time for trimming and washing processes.

Innovation Solution

A mechanical fastening method using tunnel-shaped fastening parts and insert parts on the separators, eliminating the need for welding and addressing the issues of ion elution and corrosion resistance by ensuring secure and durable assembly.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If spot-welding is used to integrate separators, then assembly is achieved, but welding-surface contact is poor due to metal burrs and spring-back phenomena, reducing yield and air-tightness

Engineering Contradiction:

Improveassembly methodVSAvoidair-tightness

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent replaces the welding process (thermal/mechanical system) with a mechanical fastening system using fastening parts that physically interlock separators. This substitution eliminates the spring-back and metal burr issues inherent in welding, achieving both ease of manufacture and reliable air-tightness through precise mechanical engagement.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces fastening parts as intermediary components between separators. These fastening parts serve as mediators that ensure proper contact and alignment of separator surfaces without requiring direct welding, thereby solving the air-tightness problem while maintaining manufacturing efficiency.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of manufacture

If spot-welding is used to integrate separators, then assembly is achieved, but trimming and washing processes are required, increasing costs and time

Engineering Contradiction:

Improveassembly methodVSAvoidprocessing time

Core Design Contradiction:

Ease of manufactureVSLoss of time

Solution Approach 1:

The fastening parts are designed with pre-formed geometric shapes that enable direct mechanical assembly without requiring preliminary trimming or washing operations. The separators and fastening parts are manufactured with precise dimensions that allow immediate engagement, eliminating time-consuming post-processing steps.

Inventive Principle:

Principle #10Preliminary action

3Reliability

If mechanical fastening with fastening parts is used, then assembly is achieved without welding, but new structural design is required

Engineering Contradiction:

ImprovedurabilityVSAvoidstructural design

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent divides the fastening function into separate fastening parts distinct from the separators themselves. This segmentation allows the fastening mechanism to be independently optimized and manufactured, reducing the complexity of modifying the entire separator structure while achieving improved durability through reliable mechanical connection.

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS11600841B2Separator assembly for fuel cell and fuel cell stack including same

Publication Date: 2023.03.07 HYUNDAI MOTOR CO LTD

AI summary

A separator assembly for a fuel cell includes a first separator having tunnel-shaped fastening parts formed on a plurality of points of an edge area thereof, and a second separator having insert parts formed at positions corresponding to each of the fastening parts of the first separator on an edge area thereof to be inserted into the fastening parts, wherein the insert parts of the second separator are inserted into the fastening parts of the first separator to assemble the first separator and the second separator.