Thermal Bonding of Elastomeric Fuel Cell Frames
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Solution Overview
Problem
Conventional methods for manufacturing fuel cell elastomeric cell frames require separate adhesive and sealing members, increasing material and manufacturing costs, and involve complex processes for aligning and bonding separator plates.
Innovation Solution
An apparatus that thermally bonds a sheet-like elastomeric frame made of thermoplastic elastomer (TPE) to an insert with a membrane electrode assembly and gas diffusion layer without a separate adhesive member, using a modular jig system to apply heat and pressure specifically to overlapping areas, allowing for precise control of bonding conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If adhesive members and sealing members are used to bond the frame and insert, then bonding strength is improved, but material cost and manufacturing cost increase
Solution Approach 1:
The patent removes adhesive members and sealing members from the fuel cell assembly by using a gasket integrated directly into the frame structure. The gasket is formed as an integral part of the frame through co-molding or overmolding processes, eliminating the need for separate bonding materials while maintaining sealing and bonding functions.
Solution Approach 2:
The gasket is merged with the frame structure to form a single integrated component. This integration combines the frame and gasket into one piece, eliminating the need for separate adhesive members and sealing members, thereby reducing material cost while maintaining bonding strength.
2Reliability
If adhesive members are used to bond the frame and insert, then bonding reliability is improved, but device complexity increases
Solution Approach 1:
The patent eliminates adhesive members from the assembly by integrating the gasket directly into the frame. This removal of separate bonding components simplifies the manufacturing process while maintaining bonding reliability through the integral structure.
Solution Approach 2:
By merging the gasket and frame into a single integrated component, the patent reduces device complexity. The integrated structure eliminates multiple bonding steps and adhesive application processes, simplifying manufacturing while ensuring reliable bonding through the unified structure.
3Manufacturing precision
If separator plates are bonded in advance with complex alignment processes, then positioning accuracy is improved, but manufacturing time increases
Solution Approach 1:
The gasket is pre-formed as an integral part of the frame structure during frame manufacturing. This preliminary integration of the gasket into the frame eliminates the need for separate alignment and bonding operations during assembly, maintaining positioning accuracy while reducing manufacturing time.
Solution Approach 2:
By combining the gasket formation with frame manufacturing in a single integrated process, the patent eliminates separate alignment steps. The gasket and frame are manufactured together as one component, ensuring precise positioning without additional time-consuming alignment operations.
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 simplifies the manufacturing process, reduces material costs, and enhances the quality of the elastomeric cell frame by enabling direct thermal bonding of the insert and elastomeric frame, improving airtightness and stacking convenience while eliminating the need for additional adhesive members.
Implementation Method 1
an upper jig module mounted above the lower jig module to provide heat and pressure to the overlapping area to thermally bond an interface between the insert and the elastomeric frame in the overlapping area
Implementation Method 2
an upper jig module mounted above the lower jig module to provide heat and pressure to the overlapping area to thermally bond an interface between the insert and the elastomeric frame
Data Source
AI summary
An apparatus of manufacturing an elastomeric cell frame for a fuel cell may include, as the apparatus of manufacturing the elastomeric cell frame including an insert in which a membrane electrode assembly and a gas diffusion layer have been bonded, and a sheet-like elastomeric frame made of a thermoplastic elastomer (TPE) integrated into an external area of the insert to form the unit cell of the fuel cell, a lower jig module accommodated so that the overlapping area, in which the insert and the elastomeric frame overlap at a predetermined area, is accommodated, and an upper jig module mounted above the lower jig module to provide heat and pressure to the overlapping area to thermally bond an interface between the insert and the elastomeric frame in the overlapping area.