Solid Rubber Seal for Fuel Cell Electrode Integration
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Solution Overview
Problem
Conventional proton-exchange membrane fuel cell gasket structures face issues with low mechanical strength, difficulty in controlling liquid rubber impregnation, and risk of electrolyte membrane deformation during injection molding, leading to poor sealability and laborious assembly processes.
Innovation Solution
Integration of an electrode member and separator using an adhesive rubber member with high tensile strength and adhesiveness, formed from solid rubber, which seals the peripheral edge portion and allows for easier assembly and inspection, eliminating the need for separate adhesives and reducing the risk of membrane deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If liquid rubber is used as the seal member in conventional gasket structures, then the seal member can be easily molded, but the mechanical strength and tensile strength of the seal member become insufficient
Solution Approach 1:
The patent changes the material parameter from liquid rubber to solid rubber, which fundamentally alters the mechanical properties while maintaining moldability. Solid rubber provides sufficient tensile strength and elasticity to withstand electrolyte membrane expansion and contraction, resolving the strength deficiency of liquid rubber seal members.
2Ease of manufacture
If liquid rubber is poured into the peripheral edge portion of the electrode member, then the seal member can be formed, but the liquid rubber excessively impregnates the porous gas diffusion layer
Solution Approach 1:
The patent changes the physical state parameter of the rubber material from liquid to solid form. Solid rubber can be precisely positioned and controlled during the molding process, preventing excessive impregnation of the gas diffusion layer while ensuring adequate sealing at the peripheral edge portion.
3Ease of manufacture
If liquid rubber injection molding is performed, then the seal member can be integrated with the electrode member, but the electrolyte membrane deforms due to injection pressure
Solution Approach 1:
The patent changes the injection method by using solid rubber instead of liquid rubber. Solid rubber molding applies lower injection pressure, preventing deformation of the thin electrolyte membrane while still achieving integration of the seal member with the electrode member through the same molding process.
4Ease of manufacture
If silicone rubber is used as the seal member, then the seal member can be easily molded, but the adhesiveness and acid resistance become insufficient
Solution Approach 1:
The patent employs solid rubber materials with composite properties that simultaneously provide adhesiveness, acid resistance, and moldability. The solid rubber formulation is designed to adhere to both the electrode member and separator while resisting degradation in the acidic fuel cell environment, overcoming the limitations of silicone rubber.
Data Source
AI summary
A fuel cell module includes: an electrode member having a membrane electrode assembly, which is formed from an electrolyte membrane and a pair of electrode catalyst layers that is disposed on both sides of the electrolyte membrane in the thickness direction, and having a pair of porous layers disposed on both sides of the membrane electrode assembly in the thickness direction; a separator disposed layered on the electrode member so as to contact at least one of the porous layers; and an adhesive rubber member sealing a peripheral edge portion of the electrode member, wherein the electrode member and the separator are integrated by the adhesive rubber member, and a tensile product of the adhesive rubber member is 1,500 MPa·% or more.