Gas Diffusion Layer Integrated Seal for Fuel Cell Alignment

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Solution Overview

Problem

Existing fuel cell stack assembly methods face challenges with misaligned gaskets causing leaks and increased assembly time due to the use of separate die-cut or molded rubber gaskets, which can lead to stack failure and broken bipolar plates.

Innovation Solution

The integration of manifold seals directly onto the gas diffusion layers, allowing for a single molding tool to produce MEA assemblies with aligned seal beads, facilitating easier assembly and eliminating misalignment issues by orienting duplicate gas diffusion layers 180 degrees offset around a membrane layer.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If separate die-cut or molded rubber gaskets are used for sealing, then sealing function is provided, but misalignment occurs causing leaks and stack failure

Engineering Contradiction:

Improvesealing reliabilityVSAvoidgasket alignment precision

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The patent merges the gasket function directly into the gas diffusion layer by integrating a seal bead structure into the GDL itself. The seal bead is formed as an integral part of the GDL through molding, eliminating the need for separate gasket components. This integration ensures precise alignment between the seal and the bipolar plate openings, preventing leaks and misalignment issues while maintaining reliable sealing.

Inventive Principle:

Principle #5Merging (Combining)

2Reliability

If separate gaskets are used for sealing, then sealing function is provided, but assembly time increases significantly

Engineering Contradiction:

Improvesealing functionVSAvoidstack assembly speed

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The seal bead is integrated into the gas diffusion layer as a single molded component, combining the GDL and gasket functions into one piece. This eliminates the need for separate gasket installation steps, reducing assembly time and increasing stack assembly productivity while maintaining effective sealing.

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If separate gaskets are used for sealing, then sealing function is provided, but risk of broken bipolar plates increases

Engineering Contradiction:

Improvesealing functionVSAvoidbipolar plate damage

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

By integrating the seal bead into the gas diffusion layer, the patent eliminates separate gasket components that could misalign and exert uneven forces on bipolar plates. The integrated seal ensures proper positioning and distributes sealing forces evenly, reducing the risk of damaging bipolar plates during assembly and operation.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS9496578B2Gas diffusion layer with integrated seal for use in a fuel cell

Publication Date: 2016.11.15 FREUDENBERG NOK GEN PARTNERSHIP

AI summary

A membrane electrode assembly is provided for use in a fuel cell and utilizes an external manifold and seal structure which are molded directly to the gas diffusion layers. The integrated manifold and gas diffusion layers are formed as duplicate components which can be oriented 180 degrees offset to one another to create the MEA assembly with a catalyst coated membrane disposed therebetween. The integrated manifold and seal structures can be held together by heat pressing or other known connection techniques.