Fuel Cell Separator With Integrated Gasket Preventing Deformation

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Solution Overview

Problem

Conventional methods for manufacturing separators with integrated gaskets for fuel cells often result in deformation of the separator and overflow of the gasket due to flow resistance during the injection process, leading to poor airtightness and durability issues.

Innovation Solution

A method involving a slide core divided into multiple parts is used to form a separator with a burring part and a gasket, where the gasket is bonded to the separator using a molten resin, and the second gasket part is bent and not bonded to the separator, with a fastening hole for the burring part, allowing for improved moldability and airtightness by preventing deformation and burr overflow.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If the separator is molded using a conventional insert injection method, then the gasket can be integrated with the separator, but the separator may be deformed or gasket burr may overflow due to flow resistance

Engineering Contradiction:

Improvegasket integrationVSAvoidseparator deformation and gasket burr overflow

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The mold is divided into multiple sections including a fixed core, a movable core, and a slide core that can move horizontally. The gasket molding process is segmented into different stages where the slide core moves to form the gasket shape, allowing the resin to flow in a controlled manner and preventing both separator deformation and gasket burr overflow while achieving integrated manufacturing

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention introduces a dynamic molding process where the slide core moves horizontally during the injection process. This dynamic adjustment allows the mold cavity to adapt to the resin flow, reducing flow resistance and preventing gasket burr overflow while maintaining separator integrity throughout the molding process

Inventive Principle:

Principle #15Dynamics

2Reliability

If the gasket is made thicker to improve sealing, then the airtightness of the fuel cell stack is improved, but the device size and pitch increase

Engineering Contradiction:

ImproveairtightnessVSAvoidgasket height and stack size

Core Design Contradiction:

ReliabilityVSVolume of moving object

Solution Approach 1:

The gasket is designed as a thin, flexible rubber component that is injected into a precisely formed mold cavity. The flexibility of the rubber material allows it to provide effective sealing at reduced thickness, while the precise mold geometry ensures consistent gasket dimensions and proper fit with the separator, achieving both compact size and reliable airtightness

Inventive Principle:

Principle #30Flexible shells and thin films

3Volume of moving object

If the gasket is made thinner to reduce device size, then the fuel cell stack is miniaturized, but the airtightness and sealing performance deteriorate

Engineering Contradiction:

Improvegasket heightVSAvoidsealing performance

Core Design Contradiction:

Volume of moving objectVSReliability

Solution Approach 1:

The invention optimizes multiple parameters including gasket thickness, rubber material properties, injection pressure, and mold temperature to achieve the desired sealing performance in a thin gasket. By carefully controlling these parameters, the gasket provides adequate sealing force and airtightness while maintaining reduced thickness for compact fuel cell stack design

Inventive Principle:

Principle #35Parameter changes

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 enhances the productivity of the separator manufacturing process, reduces the gasket height, miniaturizes the fuel cell stack, and improves the durability and airtightness of the fuel cell by preventing deformation and burr overflow, while maintaining the gasket's sealing performance.

Implementation Method 1

cooling the molten resin to form the separator integrated with the gasket

Methodology Applied

Scientific EffectCooling: Cooling

Implementation Method 2

cooling the molten resin to form the separator integrated with the gasket

Methodology Applied

Scientific EffectPhase change: Phase Change

Implementation Method 3

moving a slide core, which is disposed horizontally, in a mold closing direction to assemble a cavity in a preset shape

Methodology Applied

Scientific EffectFriction: Friction

Data Source

PatentUS20230066335A1Separator integrated with gasket for fuel cell and method for manufacturing the same

Publication Date: 2023.03.02 HYUNDAI MOTOR CO LTD

AI summary

A separator with integrated gasket including a first gasket part bonded to a separator by seating the separator formed with a burring part on a lower core, moving and assembling a mold including a slide core, and injecting molten resin into a cavity and then cooling it, and a second gasket part bent from the first gasket part and not bonded to the separator may be molded and taken out. The fastening part and the burring part may be fitted and fastened by rotating the second gasket part of the taken-out separator with the integrated gasket.