Composite plate for fuel cell
The endplate for fuel cells, featuring a composite structure and porous dielectric core, addresses weight and stability issues, offering lightweight, stable, and safe fuel cell assemblies with improved leak-tight connections and electrical insulation.
Patent Information
- Application Number
- JP2024096235
- Authority / Receiving Office
- JP · JP
- Patent Type
- Applications
- Current Assignee / Owner
- Priority Date
- 2023-06-13
- Filing Date
- 2024-06-13
- Publication Date
- 2024-12-25
AI Technical Summary
Fuel cells for aircraft are challenging due to weight considerations and the need for stability under varying physical conditions, leading to bulky cell arrangements.
The endplate for fuel cells is designed with a first fiber composite structure for in-plane structural tensile strength, a second fiber composite structure for electrical insulation and media leakage protection, and a porous dielectric core for torsional and bending stiffness, forming a lightweight and stable sandwich plate.
The endplate provides enhanced stability, reduced weight, and improved leak-tight connections while maintaining electrical isolation, allowing operation across a wide temperature range and achieving up to 50% weight savings compared to traditional methods.
Smart Images
Figure 2024178945000001_ABST
Abstract
Description
[Technical field]
[0001] The present invention relates to end plates, fuel cells, energy supply systems, and methods for manufacturing end plates for cell assemblies. [Background technology]
[0002] Fuel cells, which convert chemical energy into electrical energy, can be deployed to power a wide range of vehicle systems. However, certain vehicle systems, such as aircraft, are difficult to deploy fuel cells in due to weight considerations. Another aspect associated with fuel cells in aircraft is the requirement for stability to withstand possible physical conditions that may occur during operation of the aircraft, which can result in bulky battery arrangements. Summary of the Invention [Problem to be solved by the invention]
[0003] Therefore, there may be a need for improved fuel cells that are highly stable, low weight, and widely deployable. [Means for solving the problem]
[0004] The object of the present invention is solved by the subject matter of the independent claims, further embodiments are incorporated in the dependent claims. It should be noted that the aspects of the present invention described below also apply to end plates, fuel cells and methods for manufacturing end plates for cell assemblies.
[0005] According to the invention, an end plate for a fuel cell is provided. The end plate comprises a first layer forming an outer end plate layer, a second layer forming an abutment layer for a cell assembly of the fuel cell, and a core between the first and second layers. The outer end plate layer comprises a first fiber composite structure providing structural tensile strength in the plane direction of the outer end plate layer and forming a support structure for the abutment layer and the core. The abutment layer comprises a second fiber composite structure providing structural tensile strength in the plane direction of the abutment layer. The abutment layer provides electrical insulation for the abutting cell assembly, and the abutment layer also provides leakage protection of the medium during operation of the fuel cell. The first fiber composite structure comprises a first fiber material and the second fiber composite structure comprises a second fiber material different from the first material. The core is provided as a sandwich core between the outer end plate layer and the abutment layer. The core, together with the outer end plate layer, provides torsional and / or bending rigidity to the end plate. The core comprises a porous structure of a dielectric material including a plurality of volumes, the porous structure providing compressive strength. The outer end plies and the abutment plies are each connected in layers to the core, thereby forming a sandwich plate.
[0006] The effect is that the end plates provide greater stability with less weight.
[0007] The advantage is that it provides a lightweight, stable and safe end plate for the battery assembly.
[0008] Advantageously, the end plates provide low thermal expansion.
[0009] As an advantage, a more leak-tight connection of the end plate to the fuel cell is established.
[0010] The advantage is that fewer parts are provided to form the end plate.
[0011] As an advantage, the core cell is electrically isolated.
[0012] The advantage is that it can control a wide range of temperatures, from -60 degrees Celsius to 180-200 degrees Celsius.
[0013] The advantage is that it can save up to 50% weight compared to traditional methods.
[0014] According to one example, the first fiber composite structure comprises carbon fiber and the second fiber composite structure comprises glass fiber.
[0015] According to one example, the porous structure comprises a honeycomb structure.
[0016] According to one example, at least 50% of the pore volume contains filler. Preferably, the filled and unfilled pore volume is evenly distributed throughout the porous structure.
[0017] According to the invention, there is also provided a fuel cell. The fuel cell comprises a plurality of fuel cells arranged as a cell assembly, a bottom plate and a top plate, at least one fastening element, and a plurality of current collectors. The cell assembly is arranged between the bottom plate and the top plate. The at least one fastening element secures the bottom plate and the top plate relative to each other such that the cell assembly is fixedly held between the bottom plate and the top plate. The plurality of current collectors are arranged between the cell assembly and the bottom plate and / or the top plate. At least one of the bottom plate and the top plate is provided as an end plate according to any one of the previous examples. The end plate faces the cell assembly with an abutment layer.
[0018] An added benefit is that it provides a lightweight, stable and safe battery assembly.
[0019] According to the invention there is also provided an energy supply system. The energy supply system comprises a fluid reservoir, a fluid supply and a fuel cell as described in the previous example. The fluid reservoir is configured to supply a fluid to the fuel cell via the fluid supply. The fluid supply is configured to be connected to the fuel cell. The fluid supply is configured to supply the fluid and to exhaust exhaust gases. An end plate of the fuel cell is configured to provide access and connections for the fluid supply and electrical connections to the fuel cell. The fuel cell is configured to provide energy from the fluid by its electrical connections through the end plate.
[0020] There is also provided in accordance with the present invention a method for manufacturing an end plate for a battery assembly, the method comprising: - providing a first layer forming an outer endplate layer; - providing a second layer forming an abutment layer for the battery assembly; - providing a core between the first layer and the second layer. The outer end plate layer comprises a first fiber composite structure providing structural tensile strength in the plane direction of the outer end plate layer and forming a support structure for the abutment layer and the core. The abutment layer comprises a second fiber composite structure providing structural tensile strength in the plane direction of the abutment layer. The abutment layer provides electrical insulation for the abutting cell assembly, and also provides leakage protection of the medium during operation of the fuel cell. The first fiber composite structure comprises a first fiber material and the second fiber composite structure comprises a second fiber material different from the first material. The core is provided as a sandwich core between the outer end plate layer and the abutment layer. The core, together with the outer end plate layer, provides torsional and / or bending rigidity to the end plate. The core comprises a porous structure of a dielectric material including a plurality of volumes, the porous structure providing compressive strength. The outer end plate layer and the abutment layer are each connected in layers to the core, thereby forming a sandwich plate. The current collector is bonded to an abutment layer which is formed to overlap the edges of the current collector, thereby forming a sandwich plate.
[0021] According to one aspect, a novel approach to constructing fuel cells using carbon fiber technology is provided. Carbon fiber has the welcome properties of high tensile strength, low weight, and can be manufactured as a fiber composite structure. However, it lacks stiffness, electrical insulating capability, and leak tightness to fluid media. However, since carbon fiber can be used to manufacture composite materials, these properties can be added to the composite material by other materials. As an example, stiffness and insulation can be provided by materials such as reinforced paper or cellulose, for example, as in a paper honeycomb structure. Leak tightness can be provided by other materials that bond to a stiff and insulating material such as paper, as for example GFRP does. All these materials interact together and reinforce each other as part of the structural framework of the fuel cell. The structural framework provides a highly stable fuel cell with low weight or mass.
[0022] These and other aspects of the invention will be apparent from and elucidated with reference to the embodiment(s) described hereinafter.
[0023] Exemplary embodiments of the invention are described below with reference to the following drawings: [Brief description of the drawings]
[0024] [Figure 1] 1 illustrates a schematic cross-section of an example end plate for a fuel cell. [Diagram 2] 2 shows a schematic diagram of an example of the porous structure of the core of FIG. 1. [Diagram 3] 1A and 1B show schematic views of the abutment layer of an example end plate having a media port and a submerged current collector. [Figure 4A] 13A shows a schematic cross section through the area where the media port side cover block abuts three layers of an example end plate. [Figure 4B] 1 shows a schematic cross-section of an example end plate with an immersed current collector. [Diagram 5] 1 shows a schematic of an example of a fuel cell with end plates as bottom and top plates. [Figure 6]1 illustrates a schematic diagram of an example of an energy supply system that deploys a fuel cell; [Figure 7] 1 illustrates the basic steps of a method for manufacturing end plates for a battery assembly. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0025] Certain embodiments will now be described in more detail with reference to the accompanying drawings. In the following description, similar drawing reference numbers are used for similar elements in different drawings. Matters defined in the description, such as detailed configurations and elements, are provided to aid in a comprehensive understanding of the exemplary embodiments. Also, well-known functions or configurations will not be described in detail, as they would obscure the embodiments with unnecessary details. Furthermore, expressions such as "at least one of," when preceding a list of elements, modify the entire list of elements, and do not modify individual elements of the list.
[0026] FIG. 1 shows a schematic cross-section of an example of an end plate 10 for a fuel cell. The end plate 10 comprises a first layer forming an outer end plate layer 12, a second layer forming an abutment layer 14 for a cell assembly of the fuel cell, and a core 16 between the first and second layers. The outer end plate layer 12 comprises a first fiber composite structure providing structural tensile strength in the plane of the outer end plate layer 12 and forming a support structure for the abutment layer 14 and the core 16. The abutment layer 14 comprises a second fiber composite structure providing structural tensile strength in the plane of the abutment layer 14. The abutment layer 14 provides electrical insulation for the abutting cell assembly and also provides leakage protection for the medium during operation of the fuel cell. The first fiber composite structure comprises a first fiber material 18 and the second fiber composite structure comprises a second fiber material 20 different from the first material. The core 16 is provided between the outer endplate layer 12 and the abutment layer 14 as a sandwich core 16. The core 16, together with the outer endplate layer 12, provides torsional and / or bending stiffness to the endplate 10. The core 16 comprises a porous structure 22 of dielectric material containing a plurality of volumes, the porous structure 22 providing compressive strength. The outer endplate layer 12 and the abutment layer 14 are each connected in layers (24) to the core 16, thereby forming a sandwich plate.
[0027] An "end plate" may also be referred to as a cover, lid, cap, upper shell, end plate, top cover, cask cover, aft end cover, end plate, panel, disk, board, sheet slab outer end plate, compression plate, or support structure.
[0028] In one example, as depicted later in FIG. 5, the end plates 10 represent the structural framework for structural stability of the cell assembly.
[0029] A "battery assembly" may also be referred to as a battery component or a battery stack.
[0030] A "fuel cell" may also be referred to as a component that converts the chemical energy of a fuel into electrical energy. A fuel cell may be powered by any substance that provides energy, such as a fuel.
[0031] "Battery component" or "battery assembly" refers to an assembly of individual plates, not shown in FIG. 1, that form a channel to the fuel and conduct electrical energy.
[0032] A "fuel" may also be referred to as a fluid or a medium.
[0033] In one example, the fuel is hydrogen.
[0034] In one example, the fuel is a hydrocarbon.
[0035] In one example, the fuel includes nitrogen.
[0036] In one example, the fuel is air.
[0037] A "layer" may also be referred to as a sheet, a slab, a component, or a coat.
[0038] The term "first layer" or "outer end plate layer" may be understood to be the surface of end plate 10 facing outwardly, opposite the battery component or battery assembly, that is not shown in FIG. 1 and that is not in contact with the battery stack or electronic connections, current collectors, or other elements of the battery component or battery assembly that conduct electrical current.
[0039] The term "second layer" or "contact layer" may be understood as the face of the end plate 10 facing the cell assembly. It is in contact with the cell stack arrangement of the fuel cell. The second layer may be understood as the connection of the end plate 10 to a cell component or cell assembly.
[0040] The "first layer" or "outer endplate layer" and the "second layer" or "abutment layer" may also be referred to as layers.
[0041] The term "fiber composite structure" refers to a matrix that contains fibers. The fibers have a certain length, direction, connection to each other, pattern or distribution in the matrix that can be described as a structure. The fibers are not shown in FIG. 1.
[0042] In one example, the matrix is a polymer or resin.
[0043] The term "structural tensile strength" refers to the stress that a layer can withstand while being stretched or pulled before breaking.
[0044] The term "in-plane" refers to the direction parallel to the largest surface of a layer.
[0045] The term "torsional strength" refers to the stress (resistance to twisting motion) that a layer can withstand while twisting before breaking.
[0046] The term "flexural strength" relates to the stress (resistance to deformation) that a layer can withstand while being deformed before breaking.
[0047] The term electrical insulation can also be referred to as isolation or electrical isolation.
[0048] The term "electrically insulating" refers to the property of a layer, not shown in FIG. 1, that prevents the conduction of any electrical current.
[0049] In one example, the end plate 10 comprises a first layer comprising a fibrous material to provide tensile strength. The fibrous material also provides electrical conductivity. Electrical conductivity is undesirable for a fuel cell end plate as it may cause the end plate 10 to short to the fuel cell. Thus, although not shown in FIG. 1, the electrically conducting fuel cell components, cell assemblies, etc. are separated or electrically insulated from the first layer by a second layer, abutment layer 14 and a cover. The second layer and cover comprise a dielectric material that provides insulation from the fuel cell electronics.
[0050] The term "leak-tight" refers to the property of forming a barrier to fluids, i.e. media from the fuel cell, that cannot be overcome by penetrating the respective layers by channels, cracks or pores not shown in FIG.
[0051] In one example, the second layer, the abutment layer 14, is leak-tight to the medium.
[0052] The term "fibrous material" relates to any solid material that forms an elongated structure.
[0053] In one example, the fibrous material includes a mixture of different types of fibers, not shown in FIG.
[0054] The term "different" refers to the properties of the fiber materials of the first and second layers, which differ in terms of chemical or physical properties, for example the first layer comprises carbon fibers and the second layer comprises glass fibers.
[0055] In one example, the first fiber composite structure comprises conductive fibers and the second fiber composite structure comprises non-conductive fibers, i.e. dielectric fibers.
[0056] The term "sandwich" refers to the positioning of the core 16 relative to the first and second layers, such that the core 16 is between the first and second layers, whereby the first layer covers one surface of the core 16 and the second layer covers the other surface of the core 16. As shown in Figure 1, the core 16 separates the first layer from the second layer.
[0057] The term "porous structure" refers to a plurality of hollow structures, i.e., pores, channels, tunnels, recesses, lumens and networks, within the core 16 that reinforce the inner surface of the core 16 and provide space for the volume within the core 16, the volume not including the material of the core 16, which is not shown in FIG. 1.
[0058] In one example, the core 16 provides a high ratio of insulation and structural rigidity to the end plate 10. This is accomplished by maximizing the interconnection provided by the pore wall material relative to the volume filled by the pores.
[0059] The term "volumes" refers to spaces within the core 16 structure that are not filled by the core 16 material.
[0060] "Compressive strength" can also be referred to as the ability to resist pressure.
[0061] "Structural rigidity" can also be referred to as the stiffness of a component or its resistance to deformation.
[0062] The term "in-plane" refers to the direction parallel to the fiber orientation or parallel to the largest plane.
[0063] The term "out of plane" refers to the direction perpendicular to the fiber orientation or perpendicular to the largest surface. The term "layered" refers to the way in which the layers are interconnected with each other. The layers are interconnected or stacked with each other via their largest surface, i.e. such that the largest surface or face of the first layer abuts the largest outer surface or face of the core 16. The fibers of the fiber composite structure of the first and second layers run in a planar direction, parallel to the largest surface of the layers.
[0064] The fiber structures of the first and second layers, not shown in FIG. 1, extend parallel to the largest face of the core 16 .
[0065] In one example, the first layer and the second layer are attached to the core 16 by adhesive forces.
[0066] In one example, a connecting layer, such as an adhesive, is provided between the core 16 and the adjacent, ie, neighboring, first and second layers.
[0067] In one example, not shown in FIG. 1, the adhesion is created by heating the matrix material of the first and second layers and then pressing the first and second layers against the core 16 .
[0068] In one example, the interconnections between the surfaces of the first and second layers and the core 16 are configured to form a three-layer combination that combines the properties of the tensile strength of the first layer, the stiffness and electrical insulation of the core 16, and the electrical insulation and leak tightness of the second layer.
[0069] In one example, a composite material as shown in FIG. 1 is produced.
[0070] In one example, a synergy between the first layer, the second layer and the core 16 is a common low thermal expansion between all three components combined into a composite material.
[0071] In one example, an overall low thermal expansion composite material is provided.
[0072] In one example not shown in FIG. 1, the first fiber composite structure comprises carbon fiber and the second fiber composite structure comprises glass fiber.
[0073] In one example, carbon fibers offer high tensile strength.
[0074] In one example, the carbon fibers are electrically conductive and the core 16 comprising the dielectric material and the second layer comprising glass fibers electrically insulates the carbon fibers from the electronic current of the battery assembly.
[0075] Thus, although not shown in FIG. 1, the first layer may be conductive while the second layer is non-conductive, i.e., a dielectric.
[0076] Advantageously, a carbon fibre reinforced battery assembly can be provided.
[0077] In one example, the first fiber composite structure is CFRP.
[0078] In one example, the second fiber composite structure is GFRP with E-glass or S-glass fibers.
[0079] Figure 2 shows a schematic of one example of the porous structure 22 of the core 16 of Figure 1. The porous structure 22 provides a plurality of volumes as pore volumes 26 and pore walls 28.
[0080] Optionally, but preferably, the openings of the pores 30 in the pore structure open towards the outer endplate layer 12 and the abutment layer 14 .
[0081] Optionally, but preferably, the pore walls 28 extend across the outer endplate layer 12 and the abutment layer 14 .
[0082] The term "pore volume" refers to the total volume of all the pores, not the pore volume of a single pore.
[0083] In one example, the pores are open exclusively at the greatest surface of the core 16 .
[0084] In another example, not shown in FIG. 2, the pores are open exclusively at the sides of the core 16 .
[0085] In one example, the pore walls 28 extend vertically from one largest surface of the core 16 to the other largest surface of the core 16 .
[0086] In one example, not shown in FIG. 2, pore walls 28 extend vertically from one side of core 16 to the other side of core 16.
[0087] In one example, the pore walls 28 and the pores include a variety of shapes and the pore walls 28 have a variety of thicknesses.
[0088] In one example, the pore axes intersect within the core 16 .
[0089] In one example, not shown in FIG. 2, a portion of the matrix material of the first and second layers is incorporated into the pore openings to improve bond strength.
[0090] In one example, a portion of the fibers of the first and second layers are recessed within the openings of the pores.
[0091] In one example, the foam structure comprises, for example, an open cell structure or a closed cell structure.
[0092] In the example of FIG. 2, the porous structure 22 comprises a honeycomb structure 32 .
[0093] In one example, the pore walls 28 include a hexagonal shape.
[0094] In one example, the hexagonal pore walls 28 extend vertically from the first layer to the second layer.
[0095] In one example, not shown in FIG. 2, the pore openings of the honeycomb structure 32 are covered with a sheet of core 16 material to improve the stability of the honeycomb structure 32.
[0096] In one example, the shape and geometry of the pores varies within the pore structure.
[0097] In one example, not shown in FIG. 2, the core 16 comprises cellulose.
[0098] In one example, a honeycomb structure made from a cellulosic material, such as a paper honeycomb structure 32, is provided.
[0099] The term "cellulose" can also be referred to as paper.
[0100] In one example, not shown in FIG. 2, the cellulose includes additional materials to enhance tensile strength and / or stiffness.
[0101] In one example, the cellulose includes additional materials to enhance tensile strength and / or stiffness when the cellulose is wet.
[0102] In one example, the surface of the cellulosic core 16 is pretreated to improve adhesion to carbon or glass fibers, ie, CFRP or GFRP.
[0103] In one example, not shown in FIG. 2, the paper foam structure comprises, for example, an open cell structure or a closed cell structure.
[0104] In one example, side covers are provided on the core 16 to provide a seal for the fuel. Optionally, the side covers also extend to the lateral end faces of the first and second outer layers. The side covers, which may also be referred to as end covers, side covers, or terminal side covers, are not shown in FIG. 2 but are shown as side cover blocks in FIG. 4A.
[0105] In one example, the side covers provide a leak tight seal for hydrogen.
[0106] In one example, the side covers prevent fuel from entering the pores of the porous structure 22 .
[0107] Optionally, the side covers are provided as L-shaped covers that overlap the edge portions of the abutment layer 14 .
[0108] In one example, the core 16 construction includes wood, such as balsa wood or bamboo.
[0109] In one example, the core 16 includes a flame retardant material.
[0110] 2, the core 16 further comprises reinforcing elements 34. The reinforcing elements are configured to structurally strengthen the pores.
[0111] In one example, a fitting is provided to support the pore wall 28 .
[0112] In one example, some pore walls 28 include thicker core 16 material.
[0113] In one example, the first and second layers reinforce the pore structure of the core 16 .
[0114] 2, the reinforcing elements 34 are provided as filler material 36, which fills at least a portion of the pore volume 26 of the core 16. The filler material 36 is configured to provide compressive strength, structural rigidity, and electrical insulation.
[0115] The term "filler" refers to a substance that, while a low viscosity fluid, conforms its shape to the pore walls 28 and pore volume 26 and then changes into a solid material or a very high viscosity fluid.
[0116] In one example, the filler 36 adheres to the pore walls 28 .
[0117] The term "filler" can also be referred to as filling.
[0118] In one example, not shown in FIG. 2, the filler 36 includes a resin mixed with chopped glass fibers (chopped fibers).
[0119] In one example, the filler 36 further includes a dielectric fibrous material that provides electrical insulation.
[0120] In one example, the filler material 36 provides the pores themselves.
[0121] In a further option of FIG. 2, at least 50% of the pore volume 26 comprises filler material 36 .
[0122] Further optionally, and preferably, the filled pore volume 38 and unfilled pore volume 40 are evenly distributed throughout the porous structure 22 .
[0123] In one example, less than 50% of the pore volume 26 comprises filler 36, such as, for example, 20, 30, or 40%.
[0124] In another example, all of the pore walls 28 are in contact with the filler material 36 .
[0125] In another example, all of the pores are filled with the filler material 36 .
[0126] In one example, the pore volume 26 of the pore is half filled with the filler material 36 .
[0127] In one example, not shown in FIG. 2, the filling of the pore volume 26 of the pores with the filler material 36 varies from pore to pore.
[0128] In one example, the filler material 36 fills the pores so that the pore walls 28 are covered with the filler material 36, but there is a smaller pore volume 26 inside the filled pores.
[0129] In another example, the pores are completely filled with the filler material 36 .
[0130] In one example, the filled pores are located in certain predefined areas of the core 16 .
[0131] In one example, not shown in FIG. 2, filler material 36 lurking through the pore openings facilitates adhesion of the first and second layers to the core 16 .
[0132] In one example, the filler 36 is the matrix material of the fiber composite structure of the first and second layers.
[0133] In one example, the packing material 36 prevents fluids, such as hydrogen, from entering the pore volume 26 .
[0134] In one example, not shown in FIG. 2, the first fiber composite structure of the outer endplate layer 12 includes symmetric fiber layers including fiber orientations of 0, ±45, and 90 degrees.
[0135] Optionally and preferably, the first fiber composite structure renders the outer endplate layer 12 quasi-isotropic.
[0136] In one example, the fibers are randomly distributed from layer to layer.
[0137] 3 shows a schematic view of an abutment layer 14 of an example end plate 10 having a media port and a submerged current collector. At least one media port 42 is provided in a side portion 44 of the abutment layer 14 for supplying fuel to the cell assembly. Although not visible in FIG. 3, the at least one media port 42 extends to the opposing surface of the outer end plate layer 12.
[0138] FIG. 4A shows a schematic cross section of the area where the side cover block of the media port 42 abuts three layers of an example end plate.
[0139] Optionally, but preferably, a side cover block 46 is provided having at least one cavity (48) forming at least one media port 42 running laterally through the end faces of the core 16 and the outer end layer 12. The side cover block 46 is also shown in FIG.
[0140] The term "media port" refers to a cable guide or channel for guiding supplies through the end plate 10 to the fuel cell.
[0141] The term "side portion" refers to the minor surface, i.e., the side, of the first layer or second layer or core 16. The side portion 44 cuts the fibers of the first and second layers.
[0142] The term “side cover block” refers to a type of veneer that blocks fluid access to the side portions 44 of the end plates 10 , ie, prevents fluids such as hydrogen from entering the pore structure of the core 16 .
[0143] In one example, a cover layer is provided that comprises a resin layer that seals the side portions 44 of the endplate 10 to prevent fluid from leaking into the endplate 10 .
[0144] In one example, the side cover block 46 is made of GFRP.
[0145] 4B shows a schematic cross-section of an example of an end plate 10 with an immersed current collector 50. The current collector 50 for connecting the cells of a battery assembly is provided at least partially embedded in the abutment layer 14. At least a portion of a surface (52) of the current collector 50 is exposed to face the battery assembly.
[0146] Optionally, but preferably, abutment layer 14 overlaps at least one side, indicated by dashed circle 51 in FIG. 4B, of current collector 50 providing an engagement mount 52 .
[0147] The term "current collector" refers to an element that receives or conducts electricity from the cell assembly of a fuel cell to an electrical conduit that carries electricity from the fuel cell.
[0148] In one example, the core 16 and second layer are configured to electrically insulate the current collector 50 from the first layer, ie, the carbon fiber.
[0149] In one example, an end plate 10 according to the previous example is provided. The first layer and the second layer are attached to the core 16 by adhesive forces. In addition, although not shown in FIG. 4B, the first layer and the second layer can also be bonded through adhesive forces in different areas, which provides increased strength and improved leak protection for the media.
[0150] In one example, the first layer and the second layer can be joined at different locations, with the core 16 material making up the remainder of the void volume between the first layer and the second layer.
[0151] FIG. 5 shows a schematic diagram of an example of a fuel cell 100 having end plates 10 as a bottom plate 106 and a top plate 108. The fuel cell 100 comprises a plurality of fuel cells 102 arranged as a cell assembly 104, a bottom plate 106 and a top plate 108, at least one fastening element 110, and a plurality of current collectors 112. The cell assembly 104 is arranged between the bottom plate 106 and the top plate 108. The at least one fastening element 110 fastens the bottom plate 106 and the top plate 108 relative to each other such that the cell assembly 104 is fixedly held between the bottom plate 106 and the top plate 108. The plurality of current collectors 112 are arranged between the cell assembly 104 and the bottom plate 106 and / or the top plate 108. At least one of the bottom plate 106 and the top plate 108 is provided as an end plate 10 according to any one of the previous examples and options. The end plate 10 faces the cell assembly 104 at an abutment layer 114 .
[0152] In one example, the end plates 106, 108 are attached to opposing connection portions of the battery assembly 104 at their connection interfaces.
[0153] In one example, end plates 106, 108 at either end of the cell assembly 104 are fastened together by fastening elements 110 to provide structural stability to the fuel cell.
[0154] In one example, electrical connection terminals are provided for connecting the battery assembly 104 to a load, such as an electric drive, an electrically operated component, an appliance, etc. The electrical connection terminals are connected to the plurality of current collectors 112.
[0155] In one example, the connection interfaces of the end plates 106, 108 are configured to fasten the end plates 106, 108 to the battery assembly 104 with fastening elements 110 and provide access to the electrical connections.
[0156] In one example, the lower plate 106 and the upper plate 108 are configured to be secured to one another by a shear force and / or a bending force and / or a torque force and / or a tension force and / or a preload force.
[0157] In the example of FIG. 5, the lower plate 106 and the upper plate 108 are both provided as the end plate 10 according to any one of claims 1 to 11.
[0158] 6 shows a schematic diagram of an example of an energy supply system 200 for deploying a fuel cell. The energy supply system 200 comprises a fluid reservoir 202, a fluid supply 204, and a fuel cell 206 according to any one of the previous examples and options. The fluid reservoir is configured to supply a fluid to the fuel cell 206 via the fluid supply. The fluid supply is configured to be connected to the fuel cell 206. The fluid supply is configured to supply a fluid and to exhaust exhaust gases. The end plates 106, 108 of the fuel cell 206 are configured to provide access and connections for the fluid supply and electrical connections to the fuel cell 206. The fuel cell 206 is configured to provide energy from the fluid by its electrical connections through the end plates 106, 108.
[0159] In one example, the energy supply system 200 is configured to provide energy to an aircraft during a mission.
[0160] In one example, the plate has media ports or channels to guide supplies to the battery assemblies 104. These ports and channels are covered by side covers, not shown in FIG. 6, to prevent materials from entering the interior of the end plate 10.
[0161] 7 illustrates the basic steps of a method 300 for manufacturing end plates 106, 108 for a battery assembly 104. The method includes: In a first step 302, a first layer is provided which will form the outer endplate layer 12. The outer endplate layer 12 comprises a first fibre composite structure which provides structural tensile strength in the plane of the outer endplate layer 12 and forms a support structure for the abutment layer 14 and the core 16. In a second step 304, the core 16 is provided between the first and second layers. The core 16 is provided as a sandwich core 16 between the outer endplate layer 12 and the abutment layer 14. The core 16, together with the outer endplate layer 12, provides torsional and / or bending stiffness to the endplate. The core 16 comprises a porous structure 22 of dielectric material containing a plurality of volumes, the porous structure 22 providing compressive strength. In a third step 306, a second layer is provided which forms the abutment layer 14 for the cell assembly 104. The first fiber composite structure comprises a first fiber material 18 and the second fiber composite structure comprises a second fiber material 20 different from the first material. The abutment layer 14 comprises a second fiber composite structure which provides structural tensile strength in the plane of the abutment layer 14. The abutment layer 14 provides electrical insulation for the abutting cell assembly 104 and also provides a leak-tightness of the medium during operation of the fuel cell 100. The outer end plate layer 12 and the abutment layer 14 are connected to the core 16 in layers 24, respectively, thereby forming a sandwich plate. The current collector 50 is bonded to the abutment layer 14, which is formed to overlap the edge of the current collector 50, thereby forming a sandwich plate.
[0162] In one example of this method, side cover blocks 46, which form the gap to the media, are bonded to the sandwich panel during layer construction.
[0163] The term "side cover blocks" refers to blocks that are integrated into the sandwich during lamination.
[0164] The "side cover block" may consist of several layers of GFRP or may be used as a single solid block.
[0165] In one example, the media port 42 is formed through machining of the side cover block.
[0166] In one example, the outer edge of the end plate 10 is machined prior to adding the current collector 50 and the overlapping layer of GFRP to the abutment layer 14. This is to ensure a precise outer edge for positioning of the current collector 50.
[0167] In one example, a first fiber composite structure that provides structural tensile strength in the planar direction has different orientations.
[0168] In one example, the first fiber composite structure provides structural rigidity to the facing layer and the core.
[0169] In one example, the individual laminae, or fiber directions, of the outer endplate layer are connected to one another through an adhesive.
[0170] In an option of the method, the core includes cells that are partially filled with a filler material in combination with fibers that provide compressive strength to the structure.
[0171] In one example, the abutment layer is bonded to the core material through an adhesive.
[0172] In one example, the current collector 50 is provided as a recessed feature on the abutment layer that faces the cell assembly.
[0173] In one example, the current collector is bonded to an abutment layer and an additional single layer of a second fibrous material is formed overlapping an edge of the current collector, thereby forming a sandwich plate.
[0174] In one example, the additional monolayer is attached to the existing abutment layer and the outer edge of the current collector through an adhesive.
[0175] In one example, the outer edges of the sandwich plate, where the open cells of the core material are visible, are covered with a filler material to prevent moisture absorption.
[0176] It should be noted that the embodiments of the present invention are described with reference to different subject matters. In particular, some embodiments are described with reference to method type claims, whereas other embodiments are described with reference to apparatus type claims. However, a person skilled in the art will infer from the above description and the following description that, unless otherwise notified, any combination of features belonging to one type of subject matter, as well as any combination between features related to different subject matters, is also considered to be disclosed in the present application. However, all features can be combined to provide more synergistic effects than the simple sum of the features.
[0177] While the invention has been illustrated and described in detail in the drawings and the foregoing description, such illustration and description are to be considered illustrative or exemplary and not restrictive. The invention is not limited to the disclosed embodiments. Other variations to the disclosed embodiments can be understood and effected by those skilled in the art in practicing the claimed invention, from a study of the drawings, the disclosure, and the dependent claims.
[0178] In the claims, the word "comprising" does not exclude other elements or steps, and the indefinite article "a" or "an" does not exclude a plurality. A single processor or other unit may fulfill the functions of several items recited in the claims. The mere fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of these measures cannot be used to advantage. Any reference signs in the claims should not be interpreted as limiting their scope. [Explanation of symbols]
[0179] 10 End plate 12 Outer end plate layer 14 Contact layer 16 cores 18 First Fiber Material 20 Second Fiber Material 22 Porous structure 24 Layered 26 Pore volume 28 Pore Wall 30 pores 32 Honeycomb structure 34 Reinforcing elements 36 Filling material 38 Packed Pore Volume 40 Unfilled Pore Volume 42 Media Port 44 Lateral part 46 Side cover block 48 void 50 Current collector 51 dashed circle 52 Surface 52 Engagement Mount 100 fuel cell 102 Fuel Cell 104 Battery Assembly 106 Lower plate 108 Upper Board 110 Fastening elements 112 Current collector 114 Contact layer 200 Energy Supply System 202 Fluid Reservoir 204 Fluid supply 206 Fuel Cell 300 ways 302 First Step 304 Second Step 306 Third Step
Claims
1. An end plate (10) for a fuel cell, said end plate comprising: a first layer forming an outer endplate layer (12); a second layer forming an abutment layer (14) for the fuel cell cell assembly; a core (16) between the first layer and the second layer; Equipped with the outer end plate layer comprises a first fiber composite structure providing structural tensile strength in a plane direction of the outer end plate layer and forming a support structure for the abutment layer and the core; the abutment layer comprises a second fiber composite structure providing structural tensile strength in a plane direction of the abutment layer; the abutment layer provides electrical insulation for the abutting cell assemblies and also provides a leak tight seal for media during operation of the fuel cell; The first fiber composite structure comprises a first fiber material (18) and the second fiber composite structure comprises a second fiber material (20) different from the first material; The core is provided as a sandwich core between the outer end plate layer and the abutment layer; the core, together with the outer endplate layers, provides torsional and / or bending stiffness to the endplates; The core comprises a porous structure (22) of a dielectric material containing a plurality of volumes, the porous structure providing compressive strength; The outer end plate layers and the abutment layers are each connected to the core in a layered manner (24), thereby forming a sandwich plate. End plate (10).
2. the first fiber composite structure comprises carbon fiber; the second fiber composite structure comprises glass fibers; The end plate of claim 1 .
3. said porous structure providing a plurality of volumes as pore volumes (26) and pore walls (28); Preferably, the openings of the pores (30) of the pore structure open towards the outer end plate layer and the abutment layer; Preferably, the pore walls extend transversely to the outer end plate layer and the abutment layer. An end plate according to claim 1 or 2.
4. An end plate according to any one of claims 1 to 3, wherein the porous structure comprises a honeycomb structure (32).
5. An end plate according to any one of claims 1 to 4, wherein the core comprises cellulose.
6. The core further comprises a reinforcing element (34); The reinforcing element is configured to structurally strengthen the pore. An end plate according to any one of claims 1 to 5.
7. the reinforcing elements are provided as fillers (36), the fillers filling at least a portion of the pore volume of the core; The filler is configured to provide compressive strength, structural rigidity and electrical insulation. An end plate according to any one of claims 1 to 6.
8. at least 50% of the pore volume comprises the filler; Preferably, the filled pore volume (38) and the unfilled pore volume (40) are evenly distributed throughout the porous structure. An end plate according to any one of the preceding claims.
9. the first fiber composite structure of the outer endplate layer includes symmetric fiber plies including fiber orientations of 0, ±45, and 90 degrees; Preferably, the first fiber composite structure renders the outer endplate layer quasi-isotropic. An end plate according to any one of the preceding claims.
10. At least one media port (42) is provided in a side portion (44) of the abutment layer for supplying fuel to the cell assembly; the at least one media port extends to an opposing surface of the outer end layer; Preferably, a side cover block (46) is provided having at least one cavity (48) running laterally of the end faces of the core and the outer end plate layer forming the at least one media port. An end plate according to any one of the preceding claims.
11. a current collector (50) for connecting the cells of a battery assembly is provided at least partially embedded in the contact layer; At least a portion of the surface (52) of the current collector is exposed to face the battery assembly; Preferably, the abutment layer overlaps at least one side (dashed circle 51) of the current collector providing an engagement mount (52). An end plate according to any one of the preceding claims.
12. a plurality of fuel cells (102) arranged as a cell assembly (104); A lower plate (106) and an upper plate (108); At least one fastening element (110); A plurality of current collectors (112); A fuel cell (100) comprising: The battery assembly is disposed between a lower plate and an upper plate; the at least one fastening element secures the bottom plate and the top plate relative to one another such that the battery assembly is fixedly held between the bottom plate and the top plate; the plurality of current collectors are disposed between the battery assembly and the lower plate and the upper plate; At least one of the lower plate and the upper plate is provided as an end plate according to any one of claims 1 to 11, The end plate faces the battery assembly with an abutment layer (114). Fuel cell (100).
13. The lower plate and the upper plate are both provided as end plates according to any one of claims 1 to 11. The fuel cell of claim 12.
14. A fluid reservoir (202); A fluid supply (204); A fuel cell (206) according to claim 12 or 13; An energy supply system (200) comprising: the fluid reservoir is configured to supply fluid to the fuel cell via the fluid supply; the fluid supply is configured to be connected to the fuel cell; the fluid supply is configured to supply and discharge a medium; the end plates of the fuel cell are configured to provide access and connections for the fluid supplies and electrical outlets to the fuel cell; the fuel cell is configured to provide energy from the fluid via the electrical outlet through the end plate; An energy supply system (200).
15. A method (300) for manufacturing an end plate for a battery assembly, comprising: Providing a first layer forming an outer endplate layer (302), comprising: The outer endplate layer comprises a first fiber composite structure that provides structural tensile strength in the plane of the outer endplate layer and forms a support structure for the abutment layer and the core; Providing (304) the core between the first layer and the second layer, The core is provided as a sandwich core between the outer end plate layer and the abutment layer; the core, together with the outer endplate layers, provides torsional and / or bending stiffness to the endplates; The core comprises a porous structure of a dielectric material including a plurality of volumes, the porous structure providing compressive strength; Providing (306) a second layer forming an abutment layer for the battery assembly, the first fiber composite structure comprises a first fiber material and the second fiber composite structure comprises a second fiber material different from the first material; the abutment layer comprises the second fiber composite structure providing structural tensile strength in a plane direction of the abutment layer; the abutment layer provides electrical insulation for the abutting cell assemblies and also provides a leak tight seal for media during operation of the fuel cell; the outer end plate layers and the abutment layers are each layer-by-layer connected to the core, thereby forming a sandwich plate; A current collector is bonded to the abutment layer, the abutment layer being formed to overlap an edge of the current collector, thereby forming a sandwich plate (306); The method (300).