Integrated manifold endplate composite structure for dual fuel cell stacks

Abstract

This utility model relates to an integrated manifold-type endplate composite structure for dual-stack fuel cells. The structure includes an upper endplate, a lower endplate, and a manifold assembly connecting the two. The upper and lower endplates are identical and interchangeable, each containing internal fluid channels leading to the fuel cell core. The manifold assembly contains a three-cavity flow channel, which communicates with the fluid channels within the endplates, forming a complete integrated flow channel system for uniformly distributing reactants and coolant between the upper and lower fuel cell cores. The endplates and manifold assembly employ a composite structure combining a metal skeleton and PPS injection molding, providing both structural strength and insulation performance. This utility model, through its integrated design, solves the problems of uneven reactant distribution, complex structure, and difficult assembly in dual-stack fuel cells, offering advantages such as compact structure, uniform load distribution, high reliability, and ease of assembly and maintenance.

Description

Technical Field

[0001] This utility model belongs to the field of fuel cell structure, specifically relating to an integrated manifold endplate composite structure for dual fuel cell stacks. Background Technology

[0002] As a highly efficient and clean power generation unit, fuel cells are finding increasingly diverse applications, leading to ever-increasing demands on output power. Parallel connection of two fuel cell stacks (hereinafter referred to as "dual stacks") is an effective technical solution for improving fuel cell power. However, simply combining two independent stacks into a dual stack structure presents significant challenges in reactant distribution and system integration, rendering traditional single-stack design approaches inapplicable. Specifically, existing "simple replication of a single stack" dual stack structures, such as... Figure 1 and Figure 2 As shown, the main inherent defects are as follows: 1. The system is redundant, with low integration and reliability. This design completely separates the upper and lower stacks, providing two independent sets of end plates (see reference). Figure 1-2 Upper end plate 11, lower end plate 12), insulating plate (reference) Figure 2 Upper insulating plate 71, lower insulating plate 72) and fluid manifold (see reference) Figure 1-2 (The openings in the upper and lower end plates). This simple stacking results in a loose system structure, numerous components, and a large volume. More importantly, the fluid communication between the upper and lower stacks relies on complex external piping, which not only increases the system's size and weight but also introduces numerous connection and sealing points, greatly increasing the risk of fluid (especially hydrogen) leakage and reducing the overall reliability of the system.

[0003] 2. Uneven distribution of reactants affects performance and lifespan. To achieve connectivity between the common interface of the two reactors and the interfaces of the upper and lower reactors, the "single-reactor replication" scheme relies on external piping for flow splitting and merging. Due to spatial constraints, the external piping leading to the upper and lower reactors inevitably differs in physical path length, bending angle, and flow resistance. This asymmetry in the flow path results in an uneven distribution of hydrogen, air, and coolant between the two reactors, leading to unbalanced loads, inconsistent output power, and uneven temperature fields. Over long-term operation, this significantly impacts the power generation efficiency and stability of the entire dual-reactor system and shortens its lifespan.

[0004] 3. Poor assembly and maintainability The numerous independent components and external piping make the assembly process cumbersome and complex, resulting in low production efficiency. When a single fuel cell stack malfunctions and needs repair or replacement, a large number of intricate external connections must be disassembled, making the maintenance process time-consuming, labor-intensive, and extremely difficult to maintain.

[0005] Therefore, the dual-stack structure, which is "simple replication of a single stack," cannot meet the requirements of high-performance fuel cell systems for compactness, reliability, and durability due to its inherent problems such as low integration, uneven distribution, and poor maintainability. Utility Model Content

[0006] The purpose of this invention is to provide an integrated manifold-type endplate composite structure for dual-stack fuel cells to overcome the aforementioned technical defects.

[0007] To address the aforementioned technical problems, this utility model provides an integrated manifold-type endplate composite structure for a dual-stack fuel cell, wherein the dual-stack fuel cell includes an upper core and a lower core, and the integrated manifold-type endplate composite structure includes: An upper end plate is disposed on the end face of the upper core, and a fluid channel leading to the upper core is formed inside the upper end plate; A lower end plate is disposed on the end face of the lower core, and a fluid channel leading to the lower core is formed inside the lower end plate; The upper end plate and the lower end plate have the same structure and can be interchanged; The integrated manifold endplate composite structure also includes: The manifold assembly is fastened to the upper end plate and the lower end plate. The manifold assembly has a three-cavity flow channel inside, which is interconnected with the fluid channel to form an integrated flow channel system for uniformly distributing reactants and coolant to the upper core and the lower core.

[0008] According to the integrated manifold-type endplate composite structure for dual fuel cell stacks, both the upper endplate and the lower endplate include: The end plate frame is made of metal and has at least two flow channel clearance grooves. And, a fluid channel formed by filling and molding the flow channel clearance groove through injection molding process; The fluid channel includes multiple fluid branch channels, which are configured to communicate with corresponding fluid interfaces of the upper core or the lower core, respectively.

[0009] According to the integrated manifold endplate composite structure for dual stacks of fuel cells, the at least two flow channel clearance slots include a first flow channel clearance slot and a second flow channel clearance slot. The plurality of fluid branch channels include a first empty inlet branch channel, a first coolant inlet branch channel, and a first hydrogen outlet branch channel located in the first flow channel clearance groove, and a second empty outlet branch channel, a second coolant outlet branch channel, and a second hydrogen inlet branch channel located in the second flow channel clearance groove.

[0010] According to the integrated manifold endplate composite structure for dual fuel cell stacks, an insulating layer is coated on the surface of the endplate skeleton by injection molding. The insulating layer has through holes to allow the multiple fluid channels to communicate with the corresponding fluid interfaces of the upper core or the lower core. The insulating layer forms the mounting plane for the end plate skeleton to engage with the end face of the upper core or the lower core. According to the integrated manifold endplate composite structure for dual fuel cell stacks, the manifold assembly includes at least a first manifold assembly. The first manifold assembly includes: The first manifold frame is made of metal and is fastened and attached to the first area of ​​the upper end plate and the lower end plate. The first manifold frame has a first cavity clearance groove. And, a first cavity flow channel formed by encapsulating the first cavity clearance groove through injection molding; The first cavity flow channel includes a plurality of first cavity branch channels, which are configured to communicate with a plurality of fluid branch channels within the first flow channel clearance groove.

[0011] According to the integrated manifold endplate composite structure for dual stacks of fuel cells, the plurality of first cavity branch channels include a first air inlet cavity branch channel, a first coolant inlet cavity branch channel, and a first hydrogen outlet cavity branch channel to form a three-cavity channel. The first air inlet cavity branch channel is interconnected with the first air inlet branch channel; The first coolant inlet cavity branch channel is interconnected with the first coolant inlet branch channel; The first hydrogen outlet cavity branch channel is interconnected with the first hydrogen outlet branch channel.

[0012] According to the integrated manifold endplate composite structure for dual fuel cell stacks, the manifold assembly further includes a second manifold assembly. The second manifold assembly includes: The second manifold frame is made of metal and is fastened and attached to the second area of ​​the upper end plate and the lower end plate. The second manifold frame has a second cavity clearance groove. And, a second cavity flow channel formed by encapsulating the second cavity clearance groove through an injection molding process; The second cavity flow channel includes a plurality of second cavity branch channels, which are configured to communicate with a plurality of second fluid branch channels within the second flow channel clearance groove.

[0013] According to the integrated manifold endplate composite structure for dual stacks of fuel cells, multiple second cavity branch channels include a second cavity outlet branch channel, a second coolant outlet branch channel, and a second hydrogen inlet branch channel to form a three-cavity channel. The second empty cavity branch channel is interconnected with the second empty branch channel; The second coolant outlet cavity branch channel and the second coolant outlet branch channel are interconnected; The second hydrogen inlet cavity branch channel is interconnected with the second hydrogen inlet branch channel.

[0014] According to the integrated manifold endplate composite structure for dual stacks of fuel cells, the fluid channel, the first cavity flow channel, and the second cavity flow channel are tubular or semi-tubular structures. For the first cavity flow channel and the second cavity flow channel, which have a semi-tubular structure, a cover plate is placed on their manifold skeleton to form a closed flow channel. The first manifold frame is covered with a first cover plate, and the second manifold frame is covered with a coolant outlet cover plate and a hydrogen inlet cover plate respectively.

[0015] The beneficial effects of this utility model are as follows: By directly integrating the complex hydrogen, air, and coolant three-chamber flow channels within the upper and lower end plates and manifold frame, the numerous external pipes, connectors, and auxiliary supports required to connect the upper and lower stack cores in traditional dual-stack structures are completely eliminated. This reduces redundant connectors, the number of parts, and the use of raw materials, making the entire fuel cell dual-stack assembly more compact.

[0016] Through meticulous flow channel layout design, the structure ensures a high degree of symmetry and consistency in the fluid paths (including length, bends, and cross-sectional area) from the common interface to the corresponding interfaces of the upper and lower cores. This ensures that the upper and lower cores receive almost identical reactants (hydrogen and air) and coolant supplies, resulting in uniform workloads for both cores. This balanced load avoids localized hot spots or performance degradation.

[0017] Employing an integrated composite structure of "metal skeleton and injection molding," the system minimizes external connectors, eliminating most external connection points and sealing surfaces that could lead to fluid (especially flammable and explosive hydrogen) leakage. The manifold assembly acts as a structural beam connecting the upper and lower end plates, forming a robust frame structure that enhances the overall mechanical strength and rigidity of the assembly, providing stronger resistance to vibration and impact.

[0018] Employing a modular design, the upper and lower stack components can be assembled independently, and end plates, manifolds, and other parts are molded in one piece using a composite injection molding process. The final assembly process is simplified to the assembly of several large modules, greatly reducing the steps of bolt tightening and pipe connection, resulting in high assembly efficiency and good consistency. When a single stack fails, the upper and lower stack components can be quickly separated for replacement or repair; the upper and lower end plates are designed identically, achieving universal interchangeability of parts.

[0019] To make the above-mentioned contents of this utility model more obvious and understandable, preferred embodiments are described below in detail with reference to the accompanying drawings. Attached Figure Description

[0020] Figure 1 This is a structural diagram of a fuel dual-fuel stack in the background technology.

[0021] Figure 2 yes Figure 1 The exploded diagram.

[0022] Figure 3 This is an assembly drawing of an integrated manifold endplate composite structure for dual fuel cell stacks.

[0023] Figure 4 This is a schematic diagram of the three-chamber flow channel inside the manifold assembly (upper and lower end plates are not shown).

[0024] Figure 5 yes Figure 3 The exploded diagram.

[0025] Figure 6-1 It is a front view of the upper or lower end plate.

[0026] Figure 6-2 It is a rear view of the upper or lower end plate.

[0027] Figure 7-1 yes Figure 6-1 The exploded diagram.

[0028] Figure 7-2 yes Figure 6-2 The exploded diagram.

[0029] Figure 8-1 This is the front view of the first manifold component.

[0030] Figure 8-2 This is the rear view of the first manifold component.

[0031] Figure 9-1 yes Figure 8-1 The exploded diagram.

[0032] Figure 9-2 yes Figure 8-2 The exploded diagram.

[0033] Figure 10-1 This is a front view of the first cover plate.

[0034] Figure 10-2 This is the rear view of the first cover plate.

[0035] Figure 11-1 This is a first-view view of the second manifold assembly.

[0036] Figure 11-2 This is a second-view diagram of the second manifold assembly.

[0037] Figure 12-1 yes Figure 11-1 The exploded diagram.

[0038] Figure 12-2 yes Figure 11-2 The exploded diagram.

[0039] Figure 13-1 This is a front view of the coolant outlet cover.

[0040] Figure 13-2 This is a rear view of the coolant outlet cover.

[0041] Figure 14-1 This is a front view of the hydrogen inlet cover.

[0042] Figure 14-2 This is a rear view of the hydrogen inlet cover.

[0043] Figure 15 It is an assembly drawing of the upper and lower cores, upper and lower end plates, and the first / second manifold assembly.

[0044] Figure 16 It is an assembly drawing of the upper and lower cores and the upper and lower end plates.

[0045] Explanation of reference numerals in the attached figures: 11. Upper end plate; 12. Lower end plate; 21. End plate frame; 211. First flow channel clearance groove; 212. Second flow channel clearance groove; 22. Fluid channel; 221. First air inlet branch channel; 222. First coolant inlet branch channel; 223. First hydrogen outlet branch channel; 224. Second coolant outlet branch channel; 225. Second air outlet branch channel; 226. Second hydrogen inlet branch channel; 23. Insulating layer; 31. Upper core; 32. Lower core; 4. First manifold assembly; 41. First manifold frame; 42. First cavity clearance groove; 43. First cavity flow channel; 431. First air inlet cavity branch channel; 432. First coolant inlet cavity branch channel; 433. First hydrogen outlet cavity branch channel; 44. First cover plate; 5. Second manifold assembly; 51. Second manifold frame; 52. Second cavity clearance groove; 53. Second cavity flow channel; 531. Second cavity outlet branch channel; 532. Second coolant outlet cavity branch channel; 533. Second hydrogen inlet cavity branch channel; 54. Coolant outlet cover plate; 55. Hydrogen inlet cover plate; 61. Upper stack of outer shell; 62. Lower stack of outer shell; 71. Upper stack of insulating boards; 72. Lower stack of insulating boards; 81. Common air intake interface; 82. Common air outlet interface; 83. Common coolant inlet interface; 84. Common coolant outlet interface; 85. Common hydrogen inlet interface; 86. Common hydrogen outlet interface. Detailed Implementation

[0046] The following specific embodiments illustrate the implementation of this utility model. Those skilled in the art can easily understand other advantages and effects of this utility model from the content disclosed in this specification.

[0047] It should be noted that, in this utility model, the upper, lower, left, and right in the figure are regarded as the upper, lower, left, and right of the integrated manifold endplate composite structure for dual stacks of fuel cells described in this specification.

[0048] Exemplary embodiments of the present invention are now described with reference to the accompanying drawings. However, the present invention may be embodied in many different forms and is not limited to the embodiments described herein. These embodiments are provided to fully and completely disclose the present invention and to fully convey its scope to those skilled in the art. The terminology used in the exemplary embodiments shown in the drawings is not intended to limit the present invention. In the drawings, the same units / elements are referred to by the same reference numerals.

[0049] Unless otherwise stated, the terms used herein (including technical terms) have their common meaning as understood by one of ordinary skill in the art. Furthermore, it is understood that terms defined in commonly used dictionaries should be understood to have a meaning consistent with the context of their relevant field, and not to be interpreted as having an idealized or overly formal meaning.

[0050] The front face, as referred to below, is the end face that is away from the upper and lower cores, while the rear face is the end face that is close to the upper and lower cores.

[0051] This embodiment relates to an integrated manifold-type endplate composite structure for a dual-stack fuel cell, comprising an upper core 31 and a lower core 32. The upper core 31 is installed within an upper stack housing 61, and the lower core 32 is installed within a lower stack housing 62. Please refer to... Figure 3The integrated manifold-type endplate composite structure includes an upper endplate 11, a lower endplate 12, and a manifold assembly. The manifold assembly includes a first manifold assembly 4 and a second manifold assembly 5.

[0052] An upper end plate 11 is disposed on the end face of the upper core 31, and a fluid channel 22 leading to the upper core 31 is formed inside the upper end plate 11. A lower end plate 12 is disposed on the end face of the lower core 32, and a fluid channel 22 leading to the lower core 32 is formed inside the lower end plate 12.

[0053] The fluid channel 22 embedded inside the plate body leads directly to the corresponding interface of the upper core 31 or lower core 32 that it is connected to, providing the most direct flow path for reactants and coolant to enter or leave the core.

[0054] Among them, such as Figure 16 As shown, the upper end plate 11 and the lower end plate 12 have the same structure and are interchangeable, realizing the generalization and interchangeability of parts, which greatly improves the assembly and subsequent maintainability.

[0055] The manifold assembly is fastened to the upper end plate 11 and the lower end plate 12. The manifold assembly has a three-cavity flow channel inside, which is interconnected with the fluid channel 22 to form an integrated flow channel system for uniformly distributing reactants and coolant to the upper core 31 and the lower core 32.

[0056] For the layout of the integrated flow channel system, please refer to Figure 4 (This system does not include upper core 31 and lower core 32). As shown in the figure, Figure 4 Three sets of flow channels are arranged on the left side: Air intake common interface 81: Air enters through this interface and is evenly divided into two paths at the split point, which are respectively guided to the air inlets of the upper core 31 and the lower core 32 to achieve uniform air distribution.

[0057] Coolant inlet common interface 83: Coolant enters from this interface and is evenly divided into two paths at the split point, which are respectively guided to the coolant inlets of the upper core 31 and the lower core 32 to achieve uniform distribution of coolant.

[0058] Hydrogen outlet common interface 86: The residual hydrogen and water remaining after the electrochemical reaction in the upper core 31 and lower core 32 are brought together at the merging point and then exported through this interface.

[0059] Figure 4 Three sets of flow channels are also arranged on the right side: Air outlet common interface 82: The moist air (mainly composed of nitrogen, unreacted oxygen and water generated in the reaction) discharged from the upper core 31 and lower core 32 after the reaction is combined at the merging point and then jointly discharged through this interface.

[0060] Coolant outlet common interface 84: The heated coolant flowing from the upper core 31 and the lower core 32 merges at the merging point and is then discharged through this common interface.

[0061] Hydrogen inlet common interface 85: Hydrogen enters through this interface and is evenly divided into two paths at the split point, which are respectively guided to the hydrogen inlets of the upper core 31 and the lower core 32 to achieve uniform distribution of hydrogen.

[0062] It should be noted that, since the flow channel where the air outlet common interface 82 is located needs to meet the drainage function, its merging point is lower than the air outlet on the lower core 32, so as to avoid water accumulation in the flow channel where the air outlet common interface 82 is located.

[0063] Similarly, since the flow channel where the hydrogen outlet common interface 86 is located needs to meet the drainage function, its merging point is lower than the hydrogen outlet on the lower core 32 to avoid water accumulation in the flow channel where the hydrogen outlet common interface 86 is located.

[0064] The above-mentioned diversion points and merging points, namely Figure 4 The fluid confluence points of the flow channels where the various common interfaces are located.

[0065] Therefore, the three-chamber flow channel does not work independently, but is interconnected with the fluid channels 22 inside the upper end plate 11 and the lower end plate 12. It is responsible for receiving hydrogen, air and coolant from the common interface, and then distributing them evenly to the upper core 31 and the lower core 32 through the reasonable layout and precise flow distribution of the internal flow channels. At the same time, it also efficiently collects and discharges water, unreacted gas and heated coolant generated by the reactor.

[0066] Because the integrated flow channel system was planned and optimized in an integrated manner during the design phase, its flow channel direction, length, and resistance were designed to be symmetrical, thus ensuring, from a physical structure perspective, that the fluid paths to the upper core 31 and the lower core 32 are basically consistent. This consistency of physical paths is the guarantee for achieving uniform distribution of reactants between the two reactors, ensuring balanced load, stable operation, and synchronized lifespan of the two reactors.

[0067] The aforementioned three-chamber flow channel refers to the channel through which hydrogen, coolant, and air flow.

[0068] The reactants are hydrogen and air, and the coolant is water or other cooling medium that meets the required function.

[0069] according to Figure 4 It can be seen that there is a certain gap between two adjacent flow channels, and these gaps will be... Figure 5 The solid material shown is used for filling, which ensures uniform distribution of the flow channels while also satisfying the structural sealing between the flow channels.

[0070] like Figure 6-1As shown, both the upper end plate 11 and the lower end plate 12 include an end plate frame 21 and a fluid channel 22.

[0071] The end plate frame 21 is made of metal and has at least two flow channel clearance grooves.

[0072] In some embodiments, the end plate frame 21 is made of aluminum alloy, such as aluminum alloy 6061-T6.

[0073] At least two flow channel clearance slots include a first flow channel clearance slot 211 and a second flow channel clearance slot 212, see Figure 7-1 .

[0074] The fluid channel 22 is formed by filling and molding the flow channel clearance groove through injection molding process.

[0075] The fluid channel 22 includes multiple fluid branch channels, which are configured to communicate with the corresponding fluid interfaces of the upper core 31 or the lower core 32, respectively.

[0076] Continue reading Figure 7-1 The multiple fluid branch channels include a first air inlet branch channel 221, a first coolant inlet branch channel 222, and a first hydrogen outlet branch channel 223 located in the first flow channel clearance groove 211, and a second air outlet branch channel 225, a second coolant outlet branch channel 224, and a second hydrogen inlet branch channel 226 located in the second flow channel clearance groove 212.

[0077] In some embodiments, the shapes and structures of the first air inlet branch channel 221, the first coolant inlet branch channel 222, the first hydrogen outlet branch channel 223, and the second air outlet branch channel 225, the second coolant outlet branch channel 224, and the second hydrogen inlet branch channel 226 are as follows: Figure 7-1 As shown, the shape and structure of these fluid channels are not limited to this, and can be modified according to actual needs so that they can ultimately achieve uniform distribution of reactants and coolant.

[0078] Please see Figure 6-2 An insulating layer 23 is applied to the surface of the end plate frame 21 by injection molding. The insulating layer 23 has through holes to allow multiple fluid channels to connect with the corresponding fluid interfaces of the upper core 31 or the lower core 32. The insulating layer 23 forms the mounting plane for the end face of the end plate frame 21 to join with the end face of the upper core 31 or the lower core 32, and serves as an insulating barrier between the upper core 31 or the lower core 32 and the end plate frame 21. In some embodiments, both the fluid channel 22 and the insulating layer 23 are made of polyphenylene sulfide (PPS). Figure 7-1 and Figure 7-2 It forms a composite structure with the end plate skeleton 21 through injection molding, which serves as an insulating barrier between the reactants and the coolant and the end plate skeleton 21.

[0079] In the injection molding process, molten PPS is injected into the mold, simultaneously covering the surface of the end plate frame 21 and filling the runner clearance groove thereon. After the PPS material cools and solidifies, a cavity is formed in the runner clearance groove as a fluid channel 22, while a flat insulating layer 23 is formed on the surface of the end plate frame 21 facing the core.

[0080] Thus, the PPS composite plays a dual key role: (1) forming a flow channel, constituting a fluid channel 22 integrated with the endplate skeleton 21, used to guide the reactants and coolant. (2) achieving insulation, forming a reliable insulating barrier layer between the endplate skeleton 21 and the end face of the upper core 31 or lower core 32, which serves to insulate the reactants, coolant and the metal endplate skeleton 21, prevent possible electrochemical corrosion, and ensure the electrical safety of the system.

[0081] Please see Figure 8-1 The manifold assembly includes at least a first manifold assembly 4, which includes a first manifold skeleton 41 and a first cavity flow channel 43.

[0082] The first manifold frame 41 is made of metal. Please refer to... Figure 3 , Figure 5 and Figure 15 The first manifold frame 41 is fastened and attached to the first region of the upper end plate 11 and the lower end plate 12, the first region referring to... Figure 3 , Figure 5 The area where the first manifold assembly 4 is located, that is, the left side in the figure, or the left half of the upper end plate 11 and the lower end plate 12.

[0083] In some embodiments, the first manifold frame 41 is made of aluminum alloy, such as aluminum alloy 6061-T6.

[0084] like Figure 9-1 As shown, the first manifold frame 41 has a first cavity clearance groove 42.

[0085] Please combine Figure 8-1 , Figure 8-2 and Figure 9-1 The first cavity flow channel 43 is formed by encapsulating the first cavity clearance groove 42 through an injection molding process.

[0086] The first cavity flow channel 43 includes multiple first cavity branch channels, which are configured to communicate with multiple fluid branch channels in the first flow channel clearance groove 211.

[0087] Multiple first cavity branch channels are symmetrically distributed based on the symmetry center of the respective reaction fluid interface of the upper and lower cores to achieve uniform fluid distribution within the multiple first cavity branch channels.

[0088] Combination Figure 9-1 and Figure 9-2 The system comprises multiple first cavity branch channels, including a first air inlet branch channel 431, a first coolant inlet branch channel 432, and a first hydrogen outlet branch channel 433, forming a three-cavity flow channel. Specifically, the first air inlet branch channel 431 is interconnected with the first air inlet branch channel 221, the first coolant inlet branch channel 432 is interconnected with the first coolant inlet branch channel 222, and the first hydrogen outlet branch channel 433 is interconnected with the first hydrogen outlet branch channel 223.

[0089] In some embodiments, the shape and structure of the first air inlet cavity branch channel 431, the first coolant inlet cavity branch channel 432, and the first hydrogen outlet cavity branch channel 433 are as follows: Figure 9-1 and Figure 9-2 As shown, the shape and structure of these fluid branch channels are not limited to this, and can be modified according to actual needs so that they can ultimately achieve uniform distribution of reactants and coolant.

[0090] Please see Figure 11-1 , Figure 11-2 , Figure 12-1 , Figure 12-2 The manifold assembly also includes a second manifold assembly 5, which includes a second manifold frame 51 made of metal.

[0091] In some embodiments, the second manifold frame 51 is made of aluminum alloy, such as aluminum alloy 6061-T6.

[0092] Please combine Figure 3 , Figure 5 and Figure 15 The second manifold frame 51 is fastened and attached to the second region of the upper end plate 11 and the lower end plate 12. The second region refers to... Figure 3 , Figure 5 The area where the second manifold assembly 5 is located, that is, the right side in the figure, or the right half of the upper end plate 11 and the lower end plate 12.

[0093] like Figure 12-1 , Figure 12-2 As shown, the second manifold frame 51 has a second cavity clearance groove 52.

[0094] Please combine Figure 11-1 and Figure 12-1 ,as well as Figure 11-2 and Figure 12-2 The second cavity flow channel 53 is formed by encapsulating the second cavity clearance groove 52 through an injection molding process.

[0095] The second cavity flow channel 53 includes multiple second cavity branch channels, which are configured to communicate with multiple second fluid branch channels within the second flow channel clearance groove 212.

[0096] Multiple second cavity branch channels are symmetrically distributed based on the symmetry center of the respective reaction fluid interface of the upper and lower cores to achieve uniform fluid distribution in the multiple second cavity branch channels.

[0097] Combination Figure 12-1 and Figure 12-2 The system comprises multiple second cavity branch channels, including a second cavity outlet branch channel 531, a second coolant outlet branch channel 532, and a second hydrogen inlet branch channel 533, forming a three-cavity flow channel. Specifically, the second cavity outlet branch channel 531 is interconnected with the second cavity outlet branch channel 225, the second coolant outlet branch channel 532 is interconnected with the second coolant outlet branch channel 224, and the second hydrogen inlet branch channel 533 is interconnected with the second hydrogen inlet branch channel 226.

[0098] In some embodiments, the shape and structure of the second cavity outlet branch channel 531, the second coolant outlet branch channel 532, and the second hydrogen inlet branch channel 533 are as follows: Figure 12-1 and Figure 12-2 As shown, the shape and structure of these fluid branch channels are not limited to this, and can be modified according to actual needs so that they can ultimately achieve uniform distribution of reactants and coolant.

[0099] At this point, the fluid channels 22 within the upper end plate 11 and lower end plate 12, together with the first cavity flow channel 43 and the second cavity flow channel 53 within the manifold assembly, form an integrated flow channel system. The specific structure of this integrated flow channel system can be found in [reference needed]. Figure 4 .

[0100] In some embodiments, the fluid channel 22, the first cavity flow channel 43, and the second cavity flow channel 53 are tubular or semi-tubular structures.

[0101] In some embodiments, such as Figures 8-1 to 12-2 As shown, the first cavity flow channel 43 and the second cavity flow channel 53 are semi-tubular. For the first cavity flow channel 43 and the second cavity flow channel 53, which are semi-tubular, a cover plate is placed on their manifold skeleton to jointly enclose and form a closed flow channel. Please refer to [link / reference] for details. Figure 5 .

[0102] Please continue reading. Figure 5 A first cover plate 44 is fitted onto the first manifold frame 41. The structure of the first cover plate 44 is as follows: Figure 10-1 and Figure 10-2 As shown, a half-tube is also correspondingly opened on the rear end face of the first cover plate 44, so as to be snapped and spliced ​​on the half-tube type first cavity flow channel 43 to form a complete flow channel.

[0103] The first cover plate 44 is injection molded or machined from polyphenylene sulfide (PPS) material and is used to provide structural strength and insulation between flow channels.

[0104] Please continue reading. Figure 5 A coolant outlet cover 54 and a hydrogen inlet cover 55 are correspondingly fitted onto the second manifold frame 51. The structure of the coolant outlet cover 54 is as follows: Figure 13-1 and Figure 13-2 As shown, a half-pipe is also correspondingly formed on the rear end face of the coolant outlet cover 54, which is snapped onto the half-pipe type second coolant outlet cavity branch channel 532 to form a complete flow channel. Similarly, the structure of the hydrogen inlet cover 55 is as follows: Figure 14-1 and Figure 14-2 As shown, a half-pipe is also correspondingly opened on the rear end face of the hydrogen inlet cover plate 55, so as to be snapped and spliced ​​on the half-pipe type second hydrogen inlet cavity branch channel 533 to form a complete flow channel.

[0105] It should be noted that the hydrogen inlet cover 55 is perpendicular to the upper end plate 11 or the lower end plate 12. Therefore, the front and rear end faces of the hydrogen inlet cover 55 are defined differently from other components. The front end face of the hydrogen inlet cover 55 refers to the end face facing the first manifold assembly 4, and the rear end face refers to the end face that is in close contact with the second hydrogen inlet cavity branch channel 533.

[0106] Both the coolant outlet cover 54 and the hydrogen inlet cover 55 are injection molded or machined from polyphenylene sulfide (PPS) material to provide structural strength and insulation between flow channels.

[0107] In summary, this invention fundamentally optimizes the spatial layout of the hydrogen, air, and coolant three-chamber circuits through a comprehensive and integrated design of the fuel cell stack's insulation structure, endplate structure, and fluid distribution manifold. This design ensures a highly consistent physical path for the fluid from the upper and lower cores to the common interface, thereby achieving uniform distribution of reactants and coolant between the two stacks. This characteristic guarantees that the upper and lower stacks maintain load balance and stable operation under different operating conditions, effectively improving the overall system's output performance and durability.

[0108] The aforementioned common interfaces refer to air intake common interface 81, air outlet common interface 82, coolant inlet common interface 83, coolant outlet common interface 84, hydrogen inlet common interface 85, and hydrogen outlet common interface 86.

[0109] The components of this invention, including the upper and lower end plates and the manifold assembly, all adopt a composite structure of "metal structural skeleton and PPS injection molding". This structure leverages the core advantages of both materials: the metal skeleton bears the main structural strength, rigidity, and pressure resistance requirements; while the PPS material utilizes its excellent electrical insulation, chemical corrosion resistance, and flowability to integrally form a complex insulating layer and internal flow channels. This design achieves lightweighting and functional integration while ensuring performance.

[0110] This invention rationally divides the interfaces between various functional components (such as between the upper and lower end plates and the manifold assembly, and between the manifold assembly and various cover plates) according to the flow channel direction. This modular division concept not only realizes the efficient arrangement of the flow channel in three-dimensional space, but also enables each independent component to adopt the most suitable processing technology (such as metal processing and plastic injection molding), greatly improving the manufacturability and production efficiency of the parts.

[0111] like Figure 15 As shown, the entire fuel cell dual-stack assembly adopts a modular, pre-assembled design. The upper stack assembly (upper end plate 11 and upper core 31), the lower stack assembly (lower end plate 12 and lower core 32), and the manifold assembly can all be assembled and tested as independent modules before final assembly. This process greatly simplifies the final assembly stage and improves assembly efficiency. In subsequent maintenance, if a single component fails, it can be replaced independently without disassembling the entire system, resulting in excellent maintainability.

[0112] The first manifold assembly 4 and the second manifold assembly 5 are fixedly connected between the upper and lower stack assemblies via their metal frames, forming a robust lateral support structure. This not only meets the strength requirements of the manifold itself, but also acts as a structural beam, effectively supplementing and enhancing the overall rigidity and strength of the end plates, thereby significantly improving the structural stability and reliability of the dual-stack assembly in the face of vibration, impact, and fluid pressure fluctuations.

[0113] In this invention, the upper and lower end plates of the double stack adopt the same design, realizing the standardization and commonality of components (see...). Figure 16 This effectively reduces manufacturing costs and supply chain management complexity. At the same time, the design greatly facilitates testing during prototyping and production. Figure 15 As shown, the upper and lower stack components can be assembled and tested independently. The standardized interfaces integrated on the upper and lower end plates can be directly used as test interfaces, which simplifies the testing process and improves the production cycle time.

[0114] Those skilled in the art will understand that the above embodiments are specific examples of implementing the present invention, and in practical applications, various changes can be made to them in form and detail without departing from the spirit and scope of the present invention.

Claims

1. An integrated manifold end plate composite structure for a fuel cell dual stack comprising an upper stack core (31) and a lower stack core (32), characterized by, The integrated manifold endplate composite structure includes: An upper end plate (11) is disposed on the end face of the upper core (31), and a fluid channel (22) leading to the upper core (31) is formed inside the upper end plate (11). The lower end plate (12) is disposed on the end face of the lower core (32), and a fluid channel (22) leading to the lower core (32) is formed inside the lower end plate (12). The upper end plate (11) and the lower end plate (12) have the same structure and can be interchanged; The integrated manifold endplate composite structure also includes: The manifold assembly is fastened to the upper end plate (11) and the lower end plate (12). The manifold assembly has a three-cavity flow channel inside, which is interconnected with the fluid channel (22) to form an integrated flow channel system for uniformly distributing reactants and coolant to the upper core (31) and the lower core (32).

2. The integrated manifold-type endplate composite structure for dual-stack fuel cells according to claim 1, characterized in that, Both the upper end plate (11) and the lower end plate (12) include: The end plate frame (21) is made of metal and has at least two flow channel clearance grooves. And, a fluid channel (22) formed by filling and molding the flow channel clearance groove through injection molding process. The fluid channel (22) includes multiple fluid branch channels, which are configured to communicate with the corresponding fluid interfaces of the upper core (31) or the lower core (32), respectively.

3. The integrated manifold endplate composite structure for dual fuel cell stacks according to claim 2, characterized in that, The at least two flow channel clearance slots include a first flow channel clearance slot (211) and a second flow channel clearance slot (212); The plurality of fluid branch channels include a first empty inlet branch channel (221), a first coolant inlet branch channel (222), and a first hydrogen outlet branch channel (223) located in the first flow channel clearance groove (211), and a second empty outlet branch channel (225), a second coolant outlet branch channel (224), and a second hydrogen inlet branch channel (226) located in the second flow channel clearance groove (212).

4. The integrated manifold endplate composite structure for dual fuel cell stacks according to claim 3, characterized in that, An insulating layer (23) is applied to the surface of the end plate frame (21) by injection molding. The insulating layer (23) has through holes so that the multiple fluid channels can be connected to the corresponding fluid interfaces of the upper core (31) or the lower core (32); The insulating layer (23) forms the mounting plane for the end plate frame (21) to engage with the end face of the upper core (31) or the lower core (32).

5. The integrated manifold endplate composite structure for dual fuel cell stacks according to claim 4, characterized in that, The manifold assembly includes at least a first manifold assembly (4); The first manifold assembly (4) includes: The first manifold frame (41) is made of metal and is fastened and attached to the first area of ​​the upper end plate (11) and the lower end plate (12). The first manifold frame (41) has a first cavity clearance groove (42). And, a first cavity flow channel (43) formed by covering the first cavity clearance groove (42) by injection molding process; The first cavity flow channel (43) includes a plurality of first cavity branch channels, which are configured to communicate with a plurality of fluid branch channels in the first flow channel clearance groove (211).

6. The integrated manifold endplate composite structure for dual fuel cell stacks according to claim 5, characterized in that, The plurality of first cavity branch channels include a first air inlet cavity branch channel (431), a first coolant inlet cavity branch channel (432), and a first hydrogen outlet cavity branch channel (433) to form a three-cavity channel; The first air inlet cavity branch channel (431) is connected to the first air inlet branch channel (221); The first coolant inlet cavity branch channel (432) is connected to the first coolant inlet branch channel (222); The first hydrogen outlet cavity branch channel (433) is interconnected with the first hydrogen outlet branch channel (223).

7. The integrated manifold-type endplate composite structure for dual-stack fuel cells according to claim 6, characterized in that, The manifold assembly also includes a second manifold assembly (5); The second manifold assembly (5) includes: The second manifold frame (51) is made of metal and is fastened and attached to the second region of the upper end plate (11) and the lower end plate (12). The second manifold frame (51) has a second cavity clearance groove (52). And, a second cavity flow channel (53) formed by covering the second cavity clearance groove (52) by injection molding process; The second cavity flow channel (53) includes a plurality of second cavity branch channels, which are configured to communicate with a plurality of second fluid branch channels in the second flow channel clearance groove (212).

8. The integrated manifold endplate composite structure for dual fuel cell stacks according to claim 7, characterized in that, The plurality of second cavity branch channels include a second cavity outlet branch channel (531), a second coolant outlet branch channel (532), and a second hydrogen inlet branch channel (533) to form a three-cavity channel; The second empty cavity branch channel (531) is connected to the second empty branch channel (225); The second coolant outlet cavity branch channel (532) is connected to the second coolant outlet branch channel (224); The second hydrogen inlet cavity branch channel (533) is interconnected with the second hydrogen inlet branch channel (226).

9. The integrated manifold endplate composite structure for dual fuel cell stacks according to claim 8, characterized in that, The fluid channel (22), the first cavity flow channel (43), and the second cavity flow channel (53) are tubular or semi-tubular structures; For the first cavity flow channel (43) and the second cavity flow channel (53) which are semi-tubular structures, a cover plate is placed on their manifold skeleton to form a closed flow channel together; A first cover plate (44) is fitted onto the first manifold frame (41), and a coolant outlet cover plate (54) and a hydrogen inlet cover plate (55) are correspondingly fitted onto the second manifold frame (51).

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