Advancements in sealing technologies for PEMFC

Sealing reliability between neighboring cells in proton exchange membrane fuel cell stacks is essential in order to prevent reactant gas leaks and achieve the 5,000–8,000 hour operational lifetimes needed for commercial viability. Inter-cell sealing technologies are examined in this review, including deterioration mechanisms, integration techniques, materials selection, structural design, and current advancements. The durability, mechanical characteristics, and chemical stability of silicon rubber, ethylene-propylene-diene monomer, and fluoroelastomers under fuel cell working conditions are assessed. Along with accelerated testing techniques, important degradation mechanisms such as acidic hydrolysis, compression set, stress relaxation, and heat cycling damage are examined. UV-curable adhesives, multi-layer frame designs, and ultrasonic welding (achieving up to 93% reduction in sealing assembly cycle time) are examples of recent innovations that show promise for improved durability and lower manufacturing costs. To get around present constraints, future directions that prioritize nanocomposite materials, digital twins, in-situ monitoring, and intelligent assembly processes are suggested.