Humidifier Stack Plate Assembly for Sealing and Channel Stability

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Solution Overview

Problem

Current humidifier designs for fuel cell systems face challenges in assembly and sealing, particularly in maintaining tightness and stability of stack plates under compressive forces, which affects the efficiency of water transfer and pressure loss.

Innovation Solution

A stack plate device with alternately stacked first and second plates, each with peripheral frames and interlocking connecting elements, including nubs and gaskets, to ensure a form and friction fit, along with a semi-permeable layer separating exhaust gas and supply air flow channels, providing a cross-flow arrangement and maintaining channel height stability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional stack plates are used without interlocking connecting elements, then the device complexity is lower, but the reliability of maintaining tightness and stability under compressive forces deteriorates

Engineering Contradiction:

Improvetightness and stability of stack platesVSAvoidstructure of stack plates

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The stack plate device is divided into multiple individual stack plates that can be assembled separately. Each stack plate is a discrete component with integrated connecting elements, allowing modular assembly while maintaining structural integrity through the interlocking nubs and gaskets between adjacent plates.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The connecting elements (nubs and gaskets) are integrated directly into the stack plate structure itself, merging the sealing and mechanical connection functions into the stack plates. This eliminates the need for separate sealing components and simplifies the overall assembly process while ensuring reliable tightness under compression.

Inventive Principle:

Principle #5Merging (Combining)

2Reliability

If stack plates are compressed to maintain sealing, then the tightness improves, but the settling and operational pressure loss increase

Engineering Contradiction:

Improvesealing tightnessVSAvoidpressure loss

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The gaskets are designed to be compressible, allowing dynamic adjustment under operating conditions. The interlocking connecting elements provide a stable framework that maintains consistent compression forces on the gaskets, ensuring continuous sealing while accommodating thermal expansion and operational variations without excessive settling.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The design changes the compression parameter distribution by using interlocking nubs that localize and distribute compressive forces evenly across the gasket interfaces. This prevents excessive localized compression that would lead to settling, while maintaining sufficient overall compression for sealing, thereby reducing pressure loss.

Inventive Principle:

Principle #35Parameter changes

3Manufacturing precision

If multiple stack plates are assembled without alignment features, then the assembly process is simpler, but the manufacturing precision and consistent channel height are compromised

Engineering Contradiction:

Improvechannel height consistencyVSAvoidassembly process

Core Design Contradiction:

Manufacturing precisionVSEase of operation

Solution Approach 1:

Alignment features such as ribs and grooves are pre-formed on the stack plates during manufacturing. These features automatically guide and position adjacent plates correctly during assembly, cushioning against misalignment and ensuring consistent channel heights without requiring complex assembly procedures or additional alignment tools.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

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 configuration enhances assembly efficiency, maintains tightness, and ensures consistent water transfer and pressure control, reducing settling and operational pressure loss, while allowing for cost-effective and reliable manufacturing.

Implementation Method 1

water vapor from the exhaust air of a fuel cell system is transferred to the supply air with several flat semi-permeable layers, e.g. water-permeable membranes

Methodology Applied

Scientific EffectPermeation: Permeation

Implementation Method 2

The stack plates (100, 200) are connected to one another by means of connecting elements (140, 240; 152) in an interlocking manner

Methodology Applied

Scientific EffectFriction: Friction

Data Source

PatentUS20240282988A1Stack plate and stack plate device for humidifier

Publication Date: 2024.08.22 MANN HUMMEL GMBH

AI summary

A stack plate device for a humidifier for a fuel cell system includes first stack plates and second stack plates being stacked one on top of each other alternately in a stacking direction, top sides of the first stack plates facing bottom sides of the second stack plates, top sides of the second stack plates facing bottom sides of the first stack plates, and each of the first stack plates and the second stack plates comprising a peripheral frame that encloses a through-opening and has an inflow region and an outflow region. First flow channels and second flow channels are formed in the first stack plates and the second stack plates and formed transversely to one another, the first flow channels and second flow channels being separated by moisture-permeable layers.