Fuel Cell Separator Self-Alignment via Interlocking Protrusions
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional fuel cell separators require two types of plates with different thicknesses due to double-side injection molding, leading to misalignment issues during assembly and increased manufacturing complexity, which affects production efficiency and quality.
Innovation Solution
A fuel cell separator design featuring self-aligning first and second separator plates with protrusions and gaskets that regulate assembly positions, allowing for the use of plates with uniform thickness and reducing misalignment, while enabling efficient assembly and alignment of anode and cathode separators.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If double-side injection molding is used to produce separator plates with gaskets on both sides, then the separator plate can be manufactured in one process, but the separator plate becomes thick and difficult to deform, and misalignment occurs during assembly
Solution Approach 1:
The separator plate is divided into a first separator plate and a second separator plate with different thicknesses. The first separator plate has a first gasket on one side, while the second separator plate has a second gasket on the other side. This segmentation allows each plate to be optimized for its specific function, with thinner plates that can be more easily deformed and aligned during assembly, while still achieving the benefit of gaskets on both sides of the separator assembly.
Solution Approach 2:
The first separator plate and second separator plate are designed with asymmetric thicknesses to accommodate the different requirements of each side of the fuel cell stack. This asymmetric design allows the thinner plates to be more flexible and easier to align during the spot welding process, reducing misalignment issues while maintaining the advantage of integrated gasket manufacturing through injection molding.
2Manufacturing precision
If two kinds of separator plates with different thicknesses are used, then misalignment is reduced and self-alignment is enabled, but the device complexity increases
Solution Approach 1:
The first separator plate with its gasket and the second separator plate with its gasket are combined in an alternating stacked arrangement to form the complete separator assembly. This merging of two simpler components achieves the alignment benefits of different thicknesses while maintaining manufacturing efficiency through integrated injection molding processes for each plate type.
Solution Approach 2:
Each separator plate type serves multiple functions: structural separation, gas distribution, and sealing through its integrated gasket. The alternating arrangement of the two plate types creates a universal assembly pattern that can be replicated throughout the fuel cell stack, simplifying the overall design while achieving precise alignment through the self-aligning property of the different thicknesses.
3Ease of manufacture
If conventional thick separator plates are used for double-side injection molding, then manufacturing is simplified, but the separator plate cannot be easily deformed for alignment
Solution Approach 1:
The separator assembly is segmented into two distinct plate types with different thicknesses, allowing the thinner plates to be deformed more easily for alignment during assembly while still being manufacturable through injection molding. This segmentation resolves the conflict between manufacturing simplicity and deformability by optimizing each plate's thickness for its specific operational requirements.
Data Source
AI summary
A fuel cell separator includes a first separator plate and a second separator plate for an anode or a cathode. The first and second separator plates are adjacent to each other for assembly in a fuel cell stack. A first protrusion is formed at an edge portion of the first separator plate and protrudes toward the second separator plate arranged facing the first separator plate. A second protrusion is formed at an edge portion of the second separator plate and protrudes toward the first separator plate arranged facing the second separator plate. With the first and second separator plates adjacent to each other, since side surfaces of the first and second protrusions push each other, assembly positions of the first and second separator plates are regulated. The first and second protrusions are arranged such that opposing side surfaces thereof are spaced from each other. A third gasket is arranged in a gap between the first and second protrusions.