Resin Frame Penetration Bonding for Fuel Cell Sealing
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Solution Overview
Problem
Existing fuel cell assembly production methods face issues with gas leakage and increased stack thickness due to incomplete melting of the resin frame, leading to denaturation of the electrolyte membrane and potential breakage during stacking.
Innovation Solution
A fuel cell assembly design where the resin frame has a recess and housing hole structure, allowing the resin to penetrate into the electrodes without heat-welding, and using an adhesive or elastomer for bonding to prevent gaps and protrusions, ensuring secure integration and preventing membrane damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the resin frame is heat-welded to the electrolyte membrane, then bonding strength is improved, but the electrolyte membrane becomes denatured and damaged due to heat
Solution Approach 1:
The patent introduces a porous member (gas diffusion layer) as an intermediary between the resin frame and the electrolyte membrane. The resin frame is bonded to the porous member instead of directly to the electrolyte membrane, preventing heat damage while maintaining bonding strength. This intermediary layer absorbs the thermal impact and protects the sensitive membrane.
Solution Approach 2:
The patent extracts the electrolyte membrane from the direct bonding interface by positioning it adjacent to but not in contact with the resin frame. The bonding is performed between the resin frame and the porous member, separating the bonding function from the membrane to eliminate heat-related damage.
2Reliability
If the resin frame is melted and introduced into the gas diffusion layer, then bonding is achieved, but the resin frame does not melt sufficiently leading to gas leakage
Solution Approach 1:
The patent modifies the bonding parameters by using a porous member with controlled porosity and structure that facilitates resin penetration at lower temperatures. The porous structure allows the resin to be introduced effectively without requiring complete melting, achieving reliable sealing while simplifying the manufacturing process.
3Strength
If the resin frame is heat-welded to the electrolyte membrane, then bonding is achieved, but the welded portion deteriorates in strength due to swelling and shrinkage
Solution Approach 1:
The porous member serves as a protective intermediary that prevents direct thermal bonding to the electrolyte membrane. This eliminates the denaturation and strength deterioration caused by heat welding, ensuring long-term bonding durability even under swelling and shrinkage conditions.
4Strength
If the resin frame protrudes from the membrane electrode assembly, then bonding is achieved, but the stack thickness increases
Solution Approach 1:
The patent designs the resin frame structure to nest within or align with the boundaries of the membrane electrode assembly. The bonding portion is contained within the assembly dimensions, preventing protrusion and maintaining compact stack thickness while achieving reliable bonding through the porous member interface.
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 prevents gas leakage, maintains membrane integrity, and prevents an increase in stack thickness by ensuring a secure and even integration of the resin frame with the electrodes, enhancing sealing properties and durability.
Implementation Method 1
the upper surface is heated and pressed in the vicinity of the housing hole 32. A portion of the resin frame 11 is softened (or melted) and is made flowable by heating
Implementation Method 2
a portion of the resin frame 11 is softened (or melted) and is made flowable by heating, such that the softened material penetrates into the gas diffusion layer 28
Implementation Method 3
the introduced melt is cooled and solidified
Data Source
AI summary
The present invention relates to a fuel cell assembly and method of manufacturing same, and a bonding part manufacturing method and device. For instance, in a resin frame, a depression part is subsidence formed from a lower-end face toward an upper-end face, and a housing hole is pass-through formed from a top surface of the depression part toward the upper-end face. For instance, the depression part, a cathode-side electrode and an electrolyte film are housed, and in such a circumstance, an anode-side electrode is housed in the housing hole. A portion of the resin frame permeates a gas diffusion layer which configures the anode-side electrode and is a porous body. Via the permeated site, the resin frame and the gas diffusion layer (anode-side electrode) are integrally bonded.