Screen Printed Sealing Gasket for Fuel Cell Bipolar Plates
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Solution Overview
Problem
The existing methods for manufacturing fluidic circuits in fuel cells, particularly proton exchange membrane fuel cells, face challenges such as complex production processes, high costs, convexity issues that complicate sealing, and difficulties in reducing the thickness and weight of bipolar plates, which impact the volume and mass energy density of the fuel cells.
Innovation Solution
A method involving a substrate with first ribs that form grooves for the seal, allowing for the deposition of a sealing material with a thickness greater than the ribs, enabling the production of seals with desired thickness and shape factors through screen printing, and ensuring mechanical retention during assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional machining or forming methods are used to manufacture fluidic circuits in bipolar plates, then the sealing can be achieved, but the manufacturing process becomes complex and production costs increase
Solution Approach 1:
The patent replaces traditional mechanical machining and forming methods with a screen printing process to create fluidic circuits and sealing structures. The printing method uses a mesh screen and ink to deposit conductive material patterns directly onto the bipolar plate surface, eliminating complex mechanical tooling and multi-step manufacturing processes while achieving the same sealing and fluid distribution functions
Solution Approach 2:
The patent changes the manufacturing approach from mechanical removal or deformation of material to additive deposition of conductive ink. By controlling ink viscosity, screen mesh size, and printing parameters, the process achieves precise control over fluidic circuit geometry and sealing structure thickness, simplifying manufacturing while maintaining reliability
2Reliability
If traditional forming methods are used to create fluidic circuits, then sealing structures can be formed, but convexity issues arise that complicate the sealing process
Solution Approach 1:
The patent transitions from creating three-dimensional convex sealing structures through forming to depositing sealing material in a controlled thin layer through screen printing. The printing process deposits ink that is then cured to form a planar sealing structure, eliminating convexity issues that complicate traditional sealing while maintaining sealing effectiveness through precise material placement
3Reliability
If thicker bipolar plates are used to accommodate traditional sealing methods, then sealing can be achieved, but the weight and volume energy density are negatively impacted
Solution Approach 1:
The patent uses a thin film approach by depositing sealing material as a controlled thin layer through screen printing rather than relying on thick plate structures. The printed sealing layer, cured after deposition, provides effective sealing while minimizing additional thickness and weight, thereby preserving the energy density of the fuel cell system
4Manufacturing precision
If screen printing is used to deposit sealing material with thickness greater than ribs, then the desired seal thickness and shape are achieved, but additional manufacturing steps are required
Solution Approach 1:
The patent combines the sealing material deposition with the existing screen printing process used for creating fluidic circuits. The same mesh screen and printing infrastructure are utilized to deposit both the conductive ink for fluidic circuits and the sealing material, merging two functions into a single integrated manufacturing step that maintains productivity while achieving precise seal thickness control
Data Source
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Figure 6A~7B
AI summary
The present invention relates to a substrate 10 comprising a first face 101 on which a first flow guide 1 for an electrochemical reactor extends, or a substrate 10 comprising a first face 101 intended to be aligned with a first flow guide 1 of a plate 20 for an electrochemical reactor. The substrate comprises, on its first face, a sealing gasket 50 around a region referred to as the region of interest 1000 of the first face, which is intended to be sealed. The substrate further comprises at least two first ribs 71 and 72 configured to form at least one groove in which the sealing gasket 50 extends, said sealing gasket having a thickness strictly greater than the thicknesses of the first ribs. The present invention also relates to a method for manufacturing such a substrate.