Fuel Cell Metal Separator Frame Bonding via Concavo-Convex Mold
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Solution Overview
Problem
The existing method of integrally molding a resin frame to the outer edge of a metal separator for fuel cells is prone to separation and deformation, leading to potential insulation issues due to the generation of rubber burrs and the thinness of the metal separator, which requires extensive manual labor for burr removal and poses risks to electric insulation.
Innovation Solution
A metal mold with a concavo-convex shape on the metal separator and strategically positioned gate portions to increase contact area and reduce deformation, ensuring the resin frame remains integrated and minimizing exposure of the metal separator's edge during resin molding, thereby preventing separation and deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a concavo-convex shape is provided to the outer edge portion of the metal separator to prevent resin frame separation, then the contact area between metal separator and resin frame is increased, but the metal separator may be deformed by resin molding material injecting pressure
Solution Approach 1:
The patent applies local quality by providing the concavo-convex shape only at the outer edge portion of the metal separator where bonding is needed, while keeping the rest of the separator flat and dimensionally stable. This localized modification increases contact area for bonding without causing overall deformation of the thin metal separator during molding.
Solution Approach 2:
The concavo-convex shape is pre-formed on the metal separator before the resin molding process. This preliminary action prepares the bonding surface in advance, allowing the resin to flow into the concave portions and mechanically interlock with the metal separator, thereby preventing separation without requiring additional force during molding that could cause deformation.
2Volume of moving object
If the metal separator is made extremely thin to achieve compact fuel cell structure, then the fuel cell size is reduced, but the metal separator becomes prone to deformation under external force
Solution Approach 1:
The patent transitions from a two-dimensional flat bonding surface to a three-dimensional concavo-convex surface at the outer edge. This dimensional change increases the bonding contact area and creates mechanical interlocking features that enhance the structural stability of the thin metal separator without increasing its overall thickness or compromising the compact fuel cell design.
3Manufacturing precision
If manual burr removal is performed to remove rubber burrs from molded products, then the quality of the molded product is improved, but a significant number of man hours are required
Solution Approach 1:
The patent converts the potentially harmful rubber burrs into a beneficial bonding mechanism. Instead of removing excess rubber material, the design allows the rubber to form a concavo-convex shape that mechanically interlocks with the resin frame. This eliminates the need for manual burr removal while actually improving the bonding strength between components.
Data Source
AI summary
A method of manufacturing a plate with an insulating frame by using a metal mold. The plate includes an outer edge portion having a concavo-concave shape, and the metal mold includes a plurality of gate portions for injecting a molding material that forms the frame. The gate portions of the metal mold are at locations that correspond to the concave portions of the metal plate such that when the molding material is injected into the metal mold, an injection pressure of the molding material that can deform the metal plate will not deform the metal plate to an extent that deteriorates insulation resistance that is provided by the frame.