Fuel Cell Separator Resin Molding via Anti-Deformation Pins
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Solution Overview
Problem
The existing methods for producing fuel cell separators with resin molding at the peripheral edge are costly, time-consuming, and lack high connection strength and size precision, as they require separate production and adhesive application of resin members, which can lead to separation issues due to inadequate bonding.
Innovation Solution
A resin molding method where a resin mold region with through holes and a front end region is set in a die, allowing resin to be injected and molded, engaging with the through holes to prevent separation and enhance connection strength, using anti-deformation pins to support the front end region and improve deformation prevention, enabling simultaneous molding and connection with high precision and cost-effectiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If adhesive is used to connect resin member to separator, then connection is achieved, but production cost increases and connection strength is limited
Solution Approach 1:
The patent merges the resin member production and separator assembly into a single integrated molding process. The resin member is molded directly onto the separator in one operation, eliminating the need for separate production and adhesive bonding steps. This integration reduces production cost while achieving strong mechanical connection through direct bonding of the resin to the separator surface.
Solution Approach 2:
The patent extracts the adhesive from the connection process and replaces it with direct mechanical bonding. By removing the adhesive layer and using a molding process that directly bonds the resin member to the separator, the connection strength is improved while eliminating the cost and complexity associated with adhesive application and curing.
2Strength
If adhesive is used to connect resin member to separator, then connection is achieved, but production time increases due to adhesive hardening
Solution Approach 1:
The patent combines the resin member formation and separator assembly into a single continuous molding operation. The resin member is molded directly onto the separator without interruption, eliminating the time required for adhesive application and hardening. This integrated process significantly reduces production time while maintaining strong connection through direct mechanical bonding.
3Ease of manufacture
If resin is molded only at peripheral edge portion of separator, then molding is simplified, but connection strength is insufficient and resin member may separate
Solution Approach 1:
The patent extends the resin molding from a two-dimensional peripheral edge application to a three-dimensional structure that includes vertical protrusions and recesses. The resin member is molded to form engagement portions that protrude toward the opposing surface of the separator, creating mechanical interlocking in the vertical dimension. This dimensional extension significantly improves connection strength while maintaining molding feasibility.
4Strength
If overall of separator is molded by resin, then connection strength is maximized, but deformation of separator occurs during injection
Solution Approach 1:
The patent segments the resin molding into two distinct regions: a first region at the peripheral edge portion and a second region at the inner portion of the separator. This segmentation allows the resin to be molded in a controlled manner that prevents excessive pressure on the separator during injection. The segmented approach maintains strong connection while preventing deformation and preserving size accuracy.
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 method achieves a strong, cost-effective, and precise connection of the resin member to the fuel cell separator, improving connection strength and reducing production time while maintaining high size accuracy, as demonstrated by the comparison with adhesive-based methods.
Implementation Method 1
a die set process that the resin mold region of the fuel cell separator is set in the die such that the front end region is held by a pair of anti-deformation pins of the die
Implementation Method 2
a resin filling process that a resin is filled in the die, wherein the resin is molded on the resin mold region of the fuel cell separator so as to be filled in the through hole
Implementation Method 3
the resin is molded on the resin mold region of the fuel cell separator so as to be filled in the through hole, and a resin member is thereby molded on the resin mold region so as to extend outward from the edge
Data Source
AI summary
The present invention provides a resin molding method for fuel cell separator. The fuel cell separator includes: a resin mold region formed inward a predetermined distance from an edge; a through hole formed at the resin mold region; and a front end region formed between the through hole and the edge at the resin mold region. The resin molding method includes: a die set process that the resin mold region of the fuel cell separator is set in the die such that the front end region is held by a pair of anti-deformation pins of the die; and a resin filling process that a resin is filled in the die, wherein the resin is molded on the resin mold region of the fuel cell separator so as to be filled in the through hole, and a resin member is thereby molded on the resin mold region so as to extend outward from the edge.