Humidifier Stack Seal Structure for Load-Resistant Membrane Support
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Solution Overview
Problem
Existing humidifier devices for fuel cell systems face challenges with premature failure due to high thermal and mechanical loads, complex manufacturing processes, and dimensional tolerance issues, which affect their operational reliability and efficiency.
Innovation Solution
A humidifier stack design featuring a membrane with a circumferentially extending seal that forms flow channels through compression with frame plates, eliminating the need for direct membrane-to-frame connections, and utilizing nonwoven layers for membrane protection and improved handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the membrane is directly connected to the frame plates (glued or welded), then the flow channels are formed, but the connection becomes a point of weakness under thermal and mechanical loads leading to premature failure
Solution Approach 1:
The invention separates the membrane from the frame plates, eliminating the direct connection that causes failure. The membrane is held in position by the clamping force of the plate stack rather than being permanently attached, dividing the structural support function from the sealing function.
Solution Approach 2:
The seal elements act as intermediaries between the membrane and frame plates, providing a compliant interface that accommodates thermal expansion and mechanical stress without transmitting damaging forces to the membrane connection points.
2Device complexity
If the membrane is directly connected to the frame plates, then the assembly is simplified, but the manufacturing process becomes complex and prone to failure requiring continuous quality controls
Solution Approach 1:
The plate stack structure itself provides the clamping force needed to hold the membrane in position through compression, eliminating the need for separate fastening mechanisms or complex attachment procedures. The system uses its own structural compression to secure the membrane.
3Quantity of substance
If up to 300 stack layers are comprised, then the humidifier stack provides sufficient moisture transfer surface, but the tolerances in the stacking direction add up leading to dimensional deviations in the millimeter range
Solution Approach 1:
The invention introduces dynamic adjustment capability through the compression force application, allowing the stack to self-adjust and compensate for tolerance accumulations. The compressive force enables the structure to adapt to dimensional variations rather than requiring precise fixed dimensions.
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 enhances thermal and mechanical robustness, simplifies manufacturing, reduces failure risks, and improves durability and cost-effectiveness, enabling disturbance-free operation over extended periods.
Implementation Method 1
The membrane permits a moisture transfer from a fluid flow guided in the moist gas channel to a fluid flow guided in the dry gas channel
Implementation Method 2
moisture from a moist exhaust air flow coming from the fuel cell is supplied to this dry air flow
Implementation Method 3
The flow channel seal sections seal now relative to a neighboring frame plate in order to form one of the flow channels
Data Source
AI summary
A humidifier stack for a humidifier device includes frame plates following each other in a stacking direction in a plate stack including a dry gas channel and a moist gas channel, and a membrane separating the dry gas channel and the moist gas channel, the membrane enabling a moisture transfer from a fluid flow being guided in the moist gas channel to a fluid flow being guided in the dry gas channel. The humidifier stack further includes an at least partially circumferentially extending seal fixedly connected to the membrane, the at least partially circumferentially extending seal including flow channel seal sections disposed along circumferential edges of a moisture transfer surface of the membrane at a first surface of the membrane.