Fuel Cell Stack Seal Structure for Single-Step Fluid Routing Assembly
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Solution Overview
Problem
Existing fuel cell stack designs require multiple process steps and complex assembly processes for fluid connections, leading to increased manufacturing complexity and potential damage to seals due to overlapping weld lines, especially when using injection molding.
Innovation Solution
A stack structure with spacer elements positioned between inner seal portions, allowing for single-step injection molding of process fluid seals and providing stable support for weld seams, while ensuring reliable fluid routing through through-openings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If injection molding is used to attach seals to bipolar plates, then manufacturing efficiency is improved, but weld lines overlap seal lines causing seal damage
Solution Approach 1:
The patent introduces spacer elements that extend in the stacking direction (z-dimension) to create a three-dimensional support structure. This dimensional addition allows the seal attachment area to be elevated above the bipolar plate surface, separating it from the weld line intersection zone and preventing seal damage while maintaining injection molding efficiency
Solution Approach 2:
The spacer elements act as intermediary components between the bipolar plates and the seals. These spacers provide a dedicated attachment surface for seal bonding while being positioned away from the weld lines, thus mediating between the conflicting requirements of efficient seal attachment and seal protection from weld damage
2Manufacturing precision
If multiple process steps are used for fluid connections, then manufacturing precision is improved, but assembly complexity increases
Solution Approach 1:
The patent combines multiple functions into the spacer elements: they provide structural support, create fluid routing passages, and serve as attachment surfaces for seals. This merging of functions reduces the number of separate components and assembly steps while maintaining the precision needed for fluid connections
3Ease of operation
If seal lines are arranged orthogonally offset from stacking direction, then media routing is improved, but bipolar plate design becomes asymmetric requiring rotation
Solution Approach 1:
The spacer elements extend in the stacking direction (z-dimension) to provide seal attachment surfaces, allowing seal lines to be positioned without compromising bipolar plate symmetry. This vertical dimensionality enables straightforward media routing while maintaining symmetric bipolar plate design that simplifies manufacturing and assembly
Data Source
AI summary
The present invention relates to a stack structure (10) for an electrochemical energy converter (80), comprising bipolar plates (11), membrane electrode units (12), a process fluid routing structure (13) for routing process fluid in a stacking direction (14), frame seals (15), which are respectively attached to the membrane electrode unit (12) in an edge region of a membrane electrode unit (12), process fluid seals (16) for sealing an edge area of the process fluid routing structure (13), wherein the process fluid seals (16) each comprise an inner seal portion (18), which, viewed in a transverse direction (19), is positioned between the process fluid routing structure (13) and the membrane electrode units (12), edge seals (17) for sealing an edge region of the frame seals (15) and/or an edge region of the bipolar plates (11), and spacer elements (20), positioned and/or configured in the stacking direction (14) between two inner seal portions (18) and each having a through-opening (21) for routing process fluid in the transverse direction (19) from the process fluid routing structure (13) to the respective membrane electrode unit (12). The invention further relates to a method of manufacturing such a stack structure (10).