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The original Ni current collectors, due to their low yield strength, deformed under high pressure into the low pressure coolant channels molded into the back of each cell. This caused internal leaks in the SFIVBM The material specification was cPanged from a fully annealed Ni to hard Ni which was suffi cientfor4140kN/m (600psi)waterelectrolysis-cerloperatidn. " Insulation Plate with Internal Cooling. A new insulation plate with an integral liquid-cooling compartment was designed, fabricated and installed The cooling channel was added to provide a thermal environment for the top end cell similar to that of the other cells in a module. The new insulation plate design is shown in Figure 13 The cooling path was machined into the back of the plate requiring the addition of a large O-ring groove around the channel to contain the liquid coolant. Square Cathodes The cathodes developed previously had the four corners cut off to facilitate mounttg5 of the bipolar polar current collector connection screws (see Figure 10). The requirement for the removal of the cathode corners was eliminated by closer tolerancing of the screw mounting holes. A new electrode configuration was designed and is shown in Figure 14. Correction of Cell Frame Warpage The original SFWEM cells showed signs of warpage following injection molding and cooldown In order to( e the cell frames individually each frame was annealed in a hot air oven. Subsequent injection mold design improvements performed at LSI derived the use of cored out channels in thick areas of a cell frame. This provided more even cross sections and allowed the plastic to cool uniformly, resulting in flatter parts A literature search suggested that addiyjjal warpage improvements are possible if the molding conditions are adjusted. For polysulfone parts, high injection molding forces are required for every portion of projected areg of the molded part. Based on the size of the SFWEM cell design, a 1 6 x 10 kg (180 ton) injection molding machine is needed. Previous frames were formed on a much smaller machine, resulting in low injection flow rates This allowed the plastic to cool prematurely and cause undue stresses, resulting cell frame warpage. To produce the additional frames required under the program an alternate injection vendor with a larger machine was identified. Several modifications to the mold supports had to be incorporated to allow the use of the larger injection molding machine. Parts were successfully molded using the corrected molding technique and the frames could be used without the costly annealing process O-Rings with Reduced Compression Set. The design of the SFIVEM includes double O-ring sealing around all H2 cavities for increased reliability. To keep the overall size of the cell to a minimum, O-rings had to be selected which were of non-standard size. 36 LieSystems, J1c.PDF Image | STATIC FEED WATER ELECTROLYSIS PROCESS
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