Humidifier Stack Plate With Membrane-Bonded Frame and Gasket
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing humidifier technologies for fuel cell stacks face challenges in achieving leak-tight bonding between stack plates without additional manufacturing steps, bonding agents, or mechanical connections, while ensuring separation and sealing functions.
Innovation Solution
A method involving a semipermeable membrane integrated as a bonding element between a plastic frame and a gasket, allowing for a single-step manufacturing process that combines separation, sealing, and stackability, using materials like glass fibre reinforced polypropylene and polyurethane foam.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If steel sheets including membrane are assembled together and overmolded with liquid silicone rubber to achieve sealing functionality, then sealing reliability is improved, but device complexity and manufacturing steps increase
Solution Approach 1:
The patent combines the membrane element and gasket into a single integrated stack plate component. The gasket is formed as an integral part of the stack plate body, eliminating the need for separate assembly steps and additional bonding agents. This merging of components achieves sealing functionality while reducing manufacturing complexity.
Solution Approach 2:
The stack plate is designed to perform multiple functions simultaneously: it provides structural support, houses the membrane element for moisture separation, and incorporates the gasket for sealing. This multi-functionality eliminates the need for separate sealing components and assembly steps, resolving the contradiction between reliability and device complexity.
2Reliability
If additional bonding agents and mechanical bonding connections are used to achieve leak-tight bonding, then bonding reliability is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The gasket is formed as an integral part of the stack plate body through a single injection molding process. This eliminates the need for additional bonding agents and mechanical connections, achieving leak-tight bonding while reducing manufacturing steps and cost.
Solution Approach 2:
The injection molding process itself creates the bonding between the gasket and stack plate body. The material flows and bonds during the molding process, making the manufacturing process self-sufficient without requiring additional bonding steps or external agents.
3Reliability
If separate assembly steps and additional bonding agents are used, then sealing function is achieved, but manufacturing time and productivity are reduced
Solution Approach 1:
The stack plate and gasket are manufactured as a single integrated component in one injection molding cycle. This eliminates multiple assembly steps and bonding operations, achieving sealing function while significantly reducing manufacturing time and improving productivity.
Solution Approach 2:
The gasket structure is pre-formed as an integral part of the stack plate during the injection molding process. This preliminary formation of the sealing structure eliminates the need for subsequent assembly steps, reducing manufacturing time while ensuring proper sealing function.
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 cost, enabling efficient moisture transfer and leak-tight assembly of humidifier stacks with integrated sealing and stackability, using a semipermeable membrane as a bonding agent.
Implementation Method 1
providing a semipermeable membrane (10) to be arranged over a fluid passage (50) of a plastic frame (22) and arranged between the plastic frame (22) and a gasket (32)
Implementation Method 2
depositing a plastic layer (20) forming the plastic frame (22) to a first side (12) of the semipermeable membrane (10)... the plastic frame (22) being bonded to the first side (12) of the semipermeable membrane (10)
Implementation Method 3
depositing a gasket layer (30) forming the gasket (32) to a second side (14) of the semipermeable membrane (10)... the gasket (32) is bonded to the second side (14) opposing the first side (12)
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A method of manufacturing a stack plate (100, 102) of a humidifier, in particular for a fuel cell stack, comprises providing a semipermeable membrane (10) to be arranged over a fluid passage (50) of a plastic frame (22) and arranged between the plastic frame (22) and a gasket (32), depositing a plastic layer (20) forming the plastic frame (22) to a first side (12) of the semipermeable membrane (10), and depositing a gasket layer (30) forming the gasket (32) to a second side (14) of the semipermeable membrane (10), the second side (14) opposing the first side (12) at least in some areas (38) where the semipermeable membrane (10) is supported by the plastic frame (22) on the first side (12).