Fuel Cell Membrane Humidifier Assembly for Airtight Low-Turbulence Flow

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Solution Overview

Problem

Conventional membrane humidifiers for fuel cells have complex structures, leading to high manufacturing costs, reduced durability, and compromised airtight properties due to exposed elements and lengthy assembly processes, as well as issues with air turbulence and thermal expansion differences in hollow fiber membrane bundles.

Innovation Solution

A membrane humidifier design featuring a simple assembly structure with two housings, reduced air turbulence through controlled flow paths, and enhanced airtight properties using a cartridge with polycarbonate and polyurethane materials, along with a module clamp for improved maintenance efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a conventional membrane humidifier structure is used, then the humidification function is achieved, but the structure becomes complicated and manufacturing cost increases

Engineering Contradiction:

Improvehumidification functionVSAvoidstructure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The device is divided into two independent housings (first housing and second housing) that are coupled together, with each housing containing specific flow path functions. This segmentation simplifies the overall structure by separating functions into distinct modules while maintaining the humidification capability through the membrane cartridge system.

Inventive Principle:

Principle #1Segmentation

2Reliability

If a conventional dispersed flow path structure is used, then the humidification process is achieved, but durability is reduced due to air turbulence

Engineering Contradiction:

Improvehumidification processVSAvoiddurability

Core Design Contradiction:

ReliabilityVSDuration of action of stationary object

Solution Approach 1:

Instead of using a dispersed flow path structure that creates turbulence, the patent employs a centralized flow path design where air flows through a defined route via the membrane cartridge. This inverted approach to flow path design eliminates turbulence and improves durability by providing a stable, controlled flow environment.

Inventive Principle:

Principle #13The other way round (Inversion)

3Reliability

If conventional assembly methods with multiple partition parts are used, then the hollow fiber membrane is assembled, but assembly time increases and productivity decreases

Engineering Contradiction:

Improveassembly completenessVSAvoidassembly speed

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent merges multiple assembly operations into a single integrated process. The membrane cartridge is assembled as one complete unit and then installed as a single component into the coupled housings, eliminating the need for separate assembly operations for each partition part. This merging of assembly steps significantly reduces assembly time and improves productivity.

Inventive Principle:

Principle #5Merging (Combining)

4Ease of operation

If elements are exposed to outside space in conventional designs, then access is easier, but airtight properties are degraded

Engineering Contradiction:

ImproveaccessibilityVSAvoidairtight properties

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The membrane cartridge and flow path elements are nested within the enclosed housings, creating a sealed internal environment. The first and second housings are coupled together to form a closed system that maintains airtight properties while still allowing access to the membrane cartridge for maintenance or replacement through designed access points.

Inventive Principle:

Principle #7Nested doll (Nesting)

5Strength

If potting material with different thermal expansion coefficients is used, then bonding is achieved, but potting separation occurs due to thermal expansion differences

Engineering Contradiction:

Improvebonding strengthVSAvoidpotting stability

Core Design Contradiction:

StrengthVSStability of the object's composition

Solution Approach 1:

The patent addresses thermal expansion issues by selecting potting materials whose thermal expansion coefficients are matched to the housing and membrane materials. This parameter matching prevents potting separation caused by differential thermal expansion, maintaining both bonding strength and long-term stability under varying temperature conditions.

Inventive Principle:

Principle #35Parameter changes

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 results in a cost-effective, durable, and efficient membrane humidifier with simplified assembly, reduced air turbulence, and improved maintenance, enhancing the performance and longevity of fuel cell systems.

Implementation Method 1

the membrane humidifier is configured to humidify the dry air stream using the wet flow passing through the hollow fiber membrane cartridge

Methodology Applied

Scientific EffectHumidification: Evaporation

Implementation Method 2

a flow distributing cartridge holes to minimize a dead space of a hollow fiber membrane

Methodology Applied

Scientific EffectFluid distribution:

Data Source

PatentUS12107303B1Membrane humidifier for fuel cells

Publication Date: 2024.10.01 DS FILTER CO LTD

AI summary

A membrane humidifier for a fuel cell is disclosed. The membrane humidifier for a fuel cell includes a first housing (10) including a humidity inlet port (12) suctioning a wet flow thereinto and a dry air outlet port (14) discharging dry air, and a second housing (80) correspondingly coupled to the first housing, and including a humidity outlet port discharging a wet flow and a dry air inlet port suctioning dry air.