Fuel Cell Separator Adhesive Coating for Corrosion and Burr Prevention
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Solution Overview
Problem
Conventional fuel cell separators experience corrosion and burr formation due to exposed edges in corrosive environments, which reduces durability and requires additional finishing processes, affecting manufacturing efficiency.
Innovation Solution
Coating a resin adhesive, such as screen adhesive, on the entire or portion of the separator surface, including edges, to prevent exposure and absorption of pressing forces during injection molding, ensuring the gasket is molded with the adhesive covering the edges, thus preventing corrosion and burr formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the gasket is not formed on the edges of the separator during injection molding, then the injection molding process is simpler and faster, but the separator edges are exposed to corrosive environments causing corrosion and reduced durability
Solution Approach 1:
The adhesive is coated on the separator edges before the injection molding process begins. This preliminary action ensures that when the gasket is molded, the adhesive is already in position to cover and protect the separator edges, preventing corrosion without requiring additional post-processing steps
Solution Approach 2:
The adhesive serves as an intermediary layer between the separator and the corrosive environment. It is coated on the separator edges and then covered by the gasket during injection molding, creating a protective barrier that prevents direct contact between the separator edges and corrosive substances while maintaining the simplicity of the injection molding process
2Manufacturing precision
If the injection mold applies pressure directly to the separator edges during gasket molding, then the gasket is properly formed, but burrs are generated on the separator surface requiring additional finishing processes
Solution Approach 1:
The adhesive acts as an intermediary layer between the injection mold and the separator edges. When the injection mold applies pressure to form the gasket, the adhesive absorbs and distributes this pressing force, preventing direct contact that would cause burrs while still ensuring proper gasket formation
Solution Approach 2:
The adhesive is applied in advance to the separator edges to provide a cushioning layer that will absorb the pressing force during injection molding. This beforehand cushioning prevents the generation of burrs by softening the impact and distributing the pressure, eliminating the need for subsequent burr removal processes
3Ease of manufacture
If the separator edges are exposed to maintain simple manufacturing, then manufacturing is easier, but corrosion occurs reducing separator durability
Solution Approach 1:
The adhesive is coated on the separator edges before assembly, providing preliminary protection against corrosion. This preliminary action ensures that the separator edges are protected from the start, extending service life without complicating the manufacturing process
Solution Approach 2:
The adhesive serves as a protective intermediary layer on the separator edges that are necessarily exposed during manufacturing. This layer prevents direct contact between the metal separator and corrosive environments, maintaining both manufacturing simplicity and long-term durability
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
Enhances corrosion resistance and productivity by maintaining the separator's integrity and eliminating the need for burr removal processes, ensuring consistent air-tightness and extended durability.
Implementation Method 1
the pressing force of an injection mold when the injection mold clamps the edges of the separator by applying a pressure is absorbed by the adhesive
Implementation Method 2
an adhesive coated on a surface of the separator where the gasket is to be injection molded, and an adhesive coated on a surface of the edges of the separator
Data Source
AI summary
The present invention provides a fuel cell separator with a gasket and a method for manufacturing the same, which can prevent corrosion of the separator and improve corrosion resistance of the separator. In particular, the present invention provides a fuel cell separator with a gasket and a method for manufacturing the same, in which an adhesive is coated on the entire or partial surface of the separator, preferably by screen printing. A process of integrally molding a gasket to the separator is then performed such that the edges of the separator are not exposed to the outside after the injection molding process but, rather, are coated with the resin adhesive. The present invention thereby prevents corrosion of the separator, improves corrosion resistance of the separator, and prevents formation of burrs during the injection molding process.