Fuel Cell Separator Weld Layout for Sealing Pressure Retention
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Solution Overview
Problem
The uniformity of reaction force across the bead portions of fuel cell separators is challenging due to variations in stiffness caused by through-holes, embossed portions, and ribs, leading to excessive heat input at weld meeting points, which can reduce the sealing property.
Innovation Solution
Form the weld meeting points at high-stiffness areas away from the bead portions to prevent thermal contraction and maintain the required surface pressure for sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a metal substrate is used as a fuel cell separator, then electrical conductivity and mechanical strength are improved, but susceptibility to stress cracking and corrosion increases
Solution Approach 1:
The patent applies composite materials by coating a metal substrate with a porous layer comprising a porous inorganic backbone and an organic-inorganic composite coating. This composite structure combines the high strength and electrical conductivity of metal with the corrosion and stress cracking resistance of ceramic and polymer materials, resolving the contradiction between mechanical strength and reliability.
Solution Approach 2:
The patent uses porous materials by forming a porous inorganic backbone layer and an organic-inorganic composite porous coating on the metal substrate. The porous structure provides pathways for reactant gas flow while maintaining mechanical integrity and providing barrier protection against corrosion and stress cracking, thus improving reliability without sacrificing strength.
2Use of energy by moving object
If a metal substrate is used as a fuel cell separator, then electrical conductivity is improved, but corrosion resistance deteriorates
Solution Approach 1:
The patent applies composite materials by coating a metal substrate with a porous layer comprising a porous inorganic backbone and an organic-inorganic composite coating. This composite structure combines the high strength and electrical conductivity of metal with the corrosion and stress cracking resistance of ceramic and polymer materials, resolving the contradiction between mechanical strength and reliability.
Solution Approach 2:
The patent uses porous materials by forming a porous inorganic backbone layer and an organic-inorganic composite porous coating on the metal substrate. The porous structure provides pathways for reactant gas flow while maintaining mechanical integrity and providing barrier protection against corrosion and stress cracking, thus improving reliability without sacrificing strength.
3Reliability
If organic-inorganic composite porous coating is applied, then corrosion and stress cracking resistance are improved, but manufacturing complexity increases
Solution Approach 1:
The patent applies segmentation by dividing the protective coating into two distinct functional layers: a porous inorganic backbone layer and an organic-inorganic composite porous coating layer. This segmented structure allows each layer to perform its specific function (structural support and corrosion/stress cracking protection) while simplifying the overall manufacturing process through sequential application of standardized layers.
Solution Approach 2:
The patent applies parameter changes by controlling the pore size, porosity, and compositional parameters of each coating layer to optimize both protective performance and manufacturability. By adjusting these parameters within defined ranges, the patent achieves reliable stress cracking and corrosion resistance without requiring overly complex multi-layer or gradient structures.
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
Prevents reduction in sealing property by ensuring consistent bead height and maintaining high reaction force through strategic weld placement at high-stiffness areas.
Implementation Method 1
a porous coating layer covering the surface of the metal substrate and having a water retention function
Implementation Method 2
an anodized layer formed on a metal substrate
Implementation Method 3
a porous inorganic backbone and an organic-inorganic composite coating formed on the porous inorganic backbone
Data Source
Figure 1~2
Figure 3
Figure 4
AI summary
Provided is a manufacturing method of a fuel cell separator and a fuel cell separator that can prevent a reduction of a sealing property. The manufacturing method of the fuel cell separator includes an overlaying step of overlaying a first metal separator (21) and a second metal separator (22) together, the first metal separator (21) and the second metal separator (22) each including a flat portion (30) and a bead portion (31) protruding from the flat portion (30), a welding step of welding along the bead portion (31) overlaid flat portions (30), and in the welding step, a weld meeting point (Z) where welded portions meet is formed at an area which is away from the bead portion (31) and/or which is to be a high stiffness part (U) with a high stiffness on a welding path.