Fuel Cell Gas Diffusion Layer Patterned Water Repellent Coating

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Solution Overview

Problem

Conventional gas diffusion layers for fuel cells experience reduced pore size and compromised gas diffusion and water discharge performance due to the clogging effect of water repellents in both the microporous and macroporous layers, which deteriorates their water-repellent properties.

Innovation Solution

A gas diffusion layer is manufactured using a fiber-type water repellent or water repellent applied in a designated pattern, with an apparatus that includes a conveyor and nozzles to coat the base sheets, allowing for precise control of the water repellent application to prevent pore reduction and enhance water-repellent performance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If water repellent is applied to the macroporous layer using a dipping process, then water-repellent property is improved, but pore size is reduced due to clogging

Engineering Contradiction:
Improvewater-repellent propertyVSAvoidpore size
Core Design Contradiction:
ReliabilityVSVolume of moving object

Solution Approach 1:

The patent applies water repellent selectively to specific regions rather than uniformly across the entire macroporous layer. By using a coating head that deposits water repellent only in certain areas, the patent maintains water-repellent properties where needed while preserving pore size and gas diffusion pathways in other regions, thus resolving the contradiction between water repellency and pore size maintenance

Inventive Principle:
Principle #3Local quality

Solution Approach 2:

The patent uses partial action by applying water repellent to only a portion of the macroporous layer surface rather than the entire surface. This selective application provides sufficient water-repellent performance for water discharge while avoiding excessive water repellent accumulation that would clog pores and reduce gas diffusion performance

Inventive Principle:
Principle #16Partial or excessive action

2Reliability

If water repellent content is increased to improve water-repellent property, then water-repellent performance is enhanced, but gas diffusion performance and water discharge performance decrease

Engineering Contradiction:
Improvewater-repellent performanceVSAvoidgas diffusion performance
Core Design Contradiction:
ReliabilityVSProductivity

Solution Approach 1:

The patent implements local quality by concentrating water repellent application in specific regions rather than distributing it uniformly across the entire macroporous layer. This localized approach ensures adequate water-repellent performance in areas where water discharge is needed while maintaining high gas diffusion performance in areas where water repellent is not applied, thus resolving the contradiction between water-repellent performance and gas diffusion performance

Inventive Principle:
Principle #3Local quality

Solution Approach 2:

The patent applies partial action by using a controlled amount of water repellent in specific areas rather than applying excessive water repellent throughout the entire layer. This partial application achieves the necessary water-repellent effect for effective water discharge while avoiding the performance degradation that would result from excessive water repellent content affecting gas diffusion

Inventive Principle:
Principle #16Partial or excessive action

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

The solution effectively maintains pore size and improves water-repellent and discharge performance by applying a fiber-type water repellent in a pattern that prevents clogging, enhancing the durability and water balance of fuel cell unit cells.

Implementation Method 1

a nozzle disposed around the conveyer to coat the transferring base sheet with a water repellent in a fiber type or desired pattern

Methodology Applied
Scientific EffectCoating: Coatings

Implementation Method 2

coating the base sheet with a water repellent as a fiber type or in a desired pattern through a nozzle, thereby preventing a reduction in sizes of pores

Methodology Applied
Scientific EffectHydrophobic effect: Hydrophobe

Data Source

PatentUS11374233B2Gas diffusion layer for fuel cells and apparatus and method for manufacturing the same
Publication Date: 2022.06.28 HYUNDAI MOTOR CO LTD
  • US11374233B2 patent drawing
  • US11374233B2 patent drawing
  • US11374233B2 patent drawing

AI summary

An apparatus for manufacturing a gas diffusion layer for fuel cells includes: a conveyer transferring a base sheet for a macroporous layer of the gas diffusion layer in one direction before water repellent coating; a nozzle disposed around the conveyer to coat the transferring base sheet with a water repellent in a fiber type or desired pattern; and a nozzle transfer unit combined with an upper end of the nozzle to transfer the nozzle along a desired trajectory.