Fuel Cell Membrane Module Assembly With Integrated Frame Sealing
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Solution Overview
Problem
The existing manufacturing process of proton-exchange membrane fuel cell units is complex and inefficient, with low material utilization and high waste generation due to the use of multiple frames and separate seal formation on bipolar plates.
Innovation Solution
A simplified membrane module design featuring a multilayer membrane with a single layer of frames on either side, connected by an elastomeric seal, which simplifies assembly and reduces material waste, and a manufacturing method that integrates layers and forms the elastomeric seal through injection molding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If two frames are used to hermetically connect the intermediate diffusion layers, catalyst layers, and proton exchange membrane, then sealing reliability is improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent merges the sealing function from separate frame structures into a single elastomeric seal component that integrates with the bipolar plate. This single seal component replaces the need for two separate frames, reducing structural complexity while maintaining hermetic sealing of the membrane electrode assembly and diffusion layers.
Solution Approach 2:
The elastomeric seal serves multiple functions simultaneously: it provides hermetic sealing, structural support, and mechanical connection between components. This multi-functional design eliminates the need for separate frame structures, simplifying the overall device while ensuring reliable sealing.
2Manufacturing precision
If seals are formed separately on bipolar plates, then sealing precision is improved, but manufacturing time and process complexity increase
Solution Approach 1:
The patent combines the seal formation process with the bipolar plate manufacturing into a single integrated step. The elastomeric seal is formed directly on the bipolar plate surface, eliminating separate seal formation operations and reducing overall manufacturing time while maintaining precise sealing through the integrated process.
Solution Approach 2:
The elastomeric seal is pre-formed on the bipolar plate during manufacturing, preparing the sealing structure in advance. This preliminary action ensures precise seal positioning and geometry are achieved during the initial manufacturing process, eliminating the need for subsequent separate seal formation steps.
3Reliability
If multiple frames and separate seal formation are used, then sealing effectiveness is improved, but material utilization decreases and waste increases
Solution Approach 1:
The patent merges multiple separate components (frames and seals) into a single integrated elastomeric seal structure that is formed directly on the bipolar plate. This integration reduces the total material required for sealing and structural support, minimizing material waste while maintaining effective sealing of the fuel cell assembly.
Solution Approach 2:
The integrated elastomeric seal design eliminates excess material that would be present in separate frame and seal structures. By forming the seal directly on the bipolar plate, the design uses only the necessary amount of material for sealing and support functions, reducing material discard and improving utilization efficiency.
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 design enhances material utilization, reduces processing complexity, and minimizes waste, making the fuel cell unit easier to manufacture and assemble while maintaining effective sealing.
Implementation Method 1
an elastomeric seal connecting the multilayer membrane with the first frame and the second frame
Data Source
AI summary
A membrane module and a manufacturing method thereof, a fuel cell unit and a fuel cell package are disclosed. The membrane module includes (i) a multilayer membrane, (ii) a first frame and a second frame substantially located on opposite sides of the multilayer membrane on the plane in which the multilayer membrane is located, and (iii) an elastomeric seal connecting the multilayer membrane with the first frame and the second frame. The fuel cell unit has a simplified structure and is more convenient to manufacture.