Fuel Cell Separator Assembly Bead Seal Deformation Control

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Solution Overview

Problem

Fuel cell stacks face challenges in maintaining airtightness and durability due to the deformation of bead seals under surface pressure, which increases production costs and reduces the efficiency of gas and coolant flow.

Innovation Solution

A separator assembly with a protruding bead seal on one separator and an arched bulge on the opposing separator, combined with a gasket and sealing agent, is used to enhance airtightness and durability while reducing production costs by dispersing surface pressure and maintaining fluid flow paths.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If a bead seal is used to provide sealing between separators, then manufacturing cost is reduced and ease of manufacture is improved, but the bead seal deforms under surface pressure causing loss of airtightness

Engineering Contradiction:

Improveease of manufactureVSAvoidairtightness

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent applies beforehand cushioning by providing a bulge structure on one separator that corresponds to the bead seal location on the opposing separator. This bulge acts as a pre-positioned cushioning element that absorbs and distributes the surface pressure before it can deform the bead seal, thereby maintaining airtightness while preserving the cost advantages of bead seal manufacturing

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

2Reliability

If surface pressure is applied to compress the stack, then airtightness is improved through gasket compression, but the bead seal deforms reducing durability

Engineering Contradiction:

ImproveairtightnessVSAvoiddurability

Core Design Contradiction:

ReliabilityVSDuration of action of stationary object

Solution Approach 1:

The bulge structure serves as a beforehand cushioning element that is already in position to absorb surface pressure during stack compression. This prevents the bead seal from deforming under compression forces, thereby maintaining both airtightness and durability over the long term operation of the fuel cell stack

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Reliability

If multiple gaskets are arranged between separators to ensure airtightness, then sealing performance is improved, but production cost increases

Engineering Contradiction:

ImproveairtightnessVSAvoidproduction cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent merges the sealing function with the separator structure itself by integrating the bulge feature directly into the separator body. This combines the structural support function of the separator with the sealing function that would otherwise require separate gasket components, thereby maintaining airtightness while reducing production costs through part consolidation

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS11658313B2Separator assembly for fuel cell and fuel cell stack including same

Publication Date: 2023.05.23 HYUNDAI MOTOR CO LTD

AI summary

A separator assembly for a fuel cell includes: a first separator having a protruding bead seal providing a seal; a second separator joined to the first separator to be integrated therewith and having an arched bulge protruding in the same direction as the bead seal at a location corresponding to a location where the bead seal is formed; a gasket provided on a concave surface of the bulge of the second separator at the location where the bulge is formed, the concave surface being opposite to a convex surface of the bulge; and a sealing agent applied to a convex surface of the bead seal of the first separator at the location where the bead seal is formed.