Interlocking Stack Plate Assembly for Fuel Cell Humidifier Sealing
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Solution Overview
Problem
Existing humidifier systems for fuel cell systems face challenges in efficient assembly and sealing of stack plates, leading to potential leaks and pressure loss, which affect water transfer and overall system performance.
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, ensures a form and friction fit, maintaining channel height and preventing excessive deflection, while a semi-permeable layer separates flow channels for cross-flow arrangement, enhancing sealing and turbulence.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional stacking methods are used without interlocking connecting elements, then assembly is simpler, but sealing reliability deteriorates due to potential leaks and pressure loss
Solution Approach 1:
The connecting elements integrate multiple functions into a single component: mechanical interlocking for structural stability, sealing surfaces for leak prevention, and positioning features for alignment. This merging of functions resolves the contradiction by achieving reliable sealing without proportionally increasing assembly complexity.
Solution Approach 2:
The connecting elements act as intermediary components between adjacent stack plates, providing a dedicated interface for both mechanical connection and sealing. This intermediary structure resolves the contradiction by creating a specialized connection zone that handles both structural and sealing requirements.
2Manufacturing precision
If stack plates are stacked without interlocking connecting elements, then manufacturing is less complex, but assembly precision deteriorates leading to misalignment and settling
Solution Approach 1:
The connecting elements incorporate preliminary positioning features such as alignment pins, guide surfaces, and pre-configured sealing surfaces that ensure correct alignment during assembly. This preliminary action resolves the contradiction by pre-establishing the precise geometric relationships needed for proper stacking.
Solution Approach 2:
The interlocking connecting elements are designed to self-align and self-position during assembly through features like tapered guides, spring-loaded components, or cam mechanisms. This self-service capability resolves the contradiction by achieving high assembly precision without requiring complex external alignment procedures.
3Stability of the object's composition
If conventional stacking without interlocking elements is used, then the structure is simpler, but stability deteriorates due to excessive deflection and settling
Solution Approach 1:
The connecting elements may combine different materials with complementary properties, such as rigid structural components for stability and compliant sealing materials for adaptation. This composite approach resolves the contradiction by achieving structural stability through material properties rather than complex geometric arrangements.
Solution Approach 2:
The connecting elements incorporate dynamic characteristics such as elasticity, damping, or controlled flexibility to accommodate thermal expansion, pressure variations, and assembly tolerances. This dynamic design resolves the contradiction by maintaining structural stability under varying conditions without requiring overly rigid or complex structures.
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 provides a cost-effective, reliable, and efficient assembly process with improved sealing and water transfer rates, minimizing pressure loss and ensuring consistent performance by maintaining channel height and preventing settling of the composite structure.
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
Implementation Method 2
The peripheral frames comprise one or more connecting elements and the connecting elements of adjacent stack plates are arranged in an interlocking manner
Implementation Method 3
ensures a form and friction fit, maintaining channel height and preventing excessive deflection
Data Source
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AI summary
The invention relates to a stack plate device (400) for a humidifier (1000), in particular for a fuel cell system, the stack plate device (400) including a plurality of first and second stack plates (100, 200) being stacked one on top of each other alternately in a stacking direction (500), with each stack plate (100, 200) comprising a peripheral frame (120, 220), wherein at least first and second groups of flow channels (410, 420) are formed in the stacked stack plates (100, 200), the flow channels (410, 420) being formed transversely to one another and being separated by semi-permeable layers (110, 210), in particular moisture-permeable layers (110, 210). The peripheral frames (120, 220) comprise one or more connecting elements (140, 240; 152) and the connecting elements (140, 240; 152) of adjacent stack plates are arranged in an interlocking manner.