Humidifier Stack Plate Assembly With Integrated Membrane Sealing
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Solution Overview
Problem
Existing methods for manufacturing stack plates in humidifiers for fuel cell stacks require additional manufacturing steps and bonding agents to achieve leak-tight sealing and stackability, which complicates the process and increases costs.
Innovation Solution
The method involves using a semipermeable membrane as a bonding element, integrated with a plastic frame and gasket, allowing for a single-step manufacturing process that combines separation, sealing, and stackability functions, using materials like glass fibre reinforced polypropylene or polyamide for the frame and silicone rubber or polyurethane for the gasket.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional manufacturing steps and bonding agents are used to achieve leak-tight sealing and stackability, then sealing reliability is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines the sealing function and bonding function into a single integrated gasket structure. The gasket is formed as one piece that simultaneously provides leak-tight sealing between stack plates and bonding to attach the membrane to the frame, eliminating the need for separate sealing elements and bonding agents. This reduces manufacturing steps while maintaining sealing reliability.
Solution Approach 2:
The gasket is designed to perform multiple functions simultaneously: it provides sealing between stack plates, bonds the membrane to the frame, and maintains structural integrity. This multi-functional design eliminates the need for separate components for each function, reducing device complexity and manufacturing cost while ensuring reliable sealing.
2Strength
If multiple bonding agents and additional manufacturing steps are used, then bonding strength is improved, but manufacturing time and cost increase
Solution Approach 1:
The gasket integrates bonding and sealing functions into a single component that is applied in one manufacturing step. The gasket material itself provides the bonding strength needed to attach the membrane to the frame while simultaneously providing sealing, eliminating multiple bonding steps and reducing manufacturing time.
Solution Approach 2:
The gasket is designed to perform bonding without requiring additional bonding agents. The material composition and structural design of the gasket itself provide the necessary bonding strength, allowing it to bond the membrane to the frame through its inherent properties rather than requiring separate bonding materials and processes.
3Reliability
If separate sealing components and bonding agents are used, then sealing effectiveness is improved, but the number of components and assembly steps increase
Solution Approach 1:
The patent merges the sealing component and bonding agent into a single integrated gasket. This gasket structure provides both the sealing function to prevent leaks between stack plates and the bonding function to attach the membrane to the frame, reducing the number of components from multiple separate elements to one unified component.
Solution Approach 2:
The gasket is designed as a universal component that performs multiple functions: sealing between stack plates, bonding the membrane to the frame, and maintaining structural integrity. This single multi-functional component replaces what would otherwise require multiple separate components, simplifying the overall device structure.
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
This approach reduces manufacturing complexity and costs by eliminating the need for additional steps and agents, while ensuring leak-tight sealing and efficient moisture transfer between channels.
Implementation Method 1
separation between water of exhaust gases of a fuel cell stack and supply air for the fuel cell stack with membrane elements which are stacked together to create a sufficient effective area for the separation
Implementation Method 2
the gasket is bonded to the second side opposing the first side at least in the some areas where the semipermeable membrane is supported by the plastic frame arranged on the first side
Data Source
AI summary
A method of manufacturing a stack plate of a humidifier, comprises providing a semipermeable membrane that is airtight but permeable to moisture, depositing a plastic layer forming a plastic frame to a first side of the semipermeable membrane so that the semipermeable membrane is arranged over a fluid passage of the plastic frame, and depositing a gasket layer forming a gasket to a second side of the semipermeable membrane, the gasket being for sealing the stack plate against another stack plate, and the second side opposing the first side at least in some areas where the semipermeable membrane is supported by the plastic frame on the first side.