Fuel Cell Humidifier End Cap Shroud for Low-Adhesive Potting

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Solution Overview

Problem

Current humidification systems for fuel cells rely on expensive adhesives and require molds for assembly, which can lead to out-gassing and unsightly bubbles.

Innovation Solution

Replacing adhesive end caps with pre-formed plastic shrouds that match the inner geometry of the mold, allowing the adhesive to flow around the fiber ends, thus reducing adhesive usage and eliminating the need for molds, while providing a functional exterior finish.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If adhesive end caps are used to fix the fiber membrane bundle, then the fibers are stabilized and fixed at both sides of the housing, but the adhesive cost increases and molds are required for assembly

Engineering Contradiction:

Improvefiber stabilizationVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent replaces expensive adhesive end caps with disposable crimped metal sleeves that are inexpensive to manufacture and eliminate the need for costly adhesive materials and mold tooling

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The patent extracts and removes the adhesive material and mold requirements from the manufacturing process by using self-contained crimped sleeves that provide all necessary fixation functions without requiring external adhesives or molding equipment

Inventive Principle:

Principle #2Taking out (Extraction)

2Reliability

If adhesive is used to pot the fiber ends, then the fibers are fixed and encapsulated, but out-gassing occurs causing unsightly bubbles

Engineering Contradiction:

Improvefiber fixationVSAvoidbubbles

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The patent replaces adhesive with crimped metal sleeves that do not undergo chemical curing reactions, thereby eliminating out-gassing and bubble formation while providing secure mechanical fixation of the fiber ends

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The patent replaces the chemical bonding mechanism of adhesive with a mechanical crimping system that physically secures the fiber ends through deformation of the metal sleeve, avoiding chemical reactions that produce gas

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Manufacturing precision

If molds and tooling are used to pour and cure adhesive, then the end caps are formed with proper geometry, but additional equipment and process complexity are required

Engineering Contradiction:

Improveend cap geometryVSAvoidtooling requirements

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent uses simple, inexpensive crimped metal sleeves that achieve proper geometry through controlled deformation during crimping, eliminating the need for expensive precision molds and complex tooling equipment

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The patent pre-forms the metal sleeves with the necessary geometric features before assembly, allowing the crimping operation to simply secure the pre-prepared components without requiring complex in-situ forming equipment

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS20240173674A1Fuel cell humidification potting adhesive shroud

Publication Date: 2024.05.30 PARKER HANNIFIN CORP

AI summary

A separation and/or humidification element that employs fibrous hollow membrane tubes is provided, which may be used for water vapor transfer between different gas streams in a fuel cell application, such as to humidify the reaction gas. At least one and typically two composite end caps encapsulate ends of a bundle of the fibrous hollow membrane tubes. Each composite end cap comprises adhesive (e.g. epoxy) and a preform such as a plastic annular shroud.