Fuel cell module and manufacturing method therefor

Abstract

A fuel cell module (100), comprising a porous substrate (10), a first electrode layer (20), an electrolyte layer (30), and a second electrode layer (40). The porous substrate (10) is conductive, the porous substrate (10) has a tubular shape, and the porous substrate (10) comprises a tubular body (11); the first electrode layer (20) is located on the tubular body (11) of the porous substrate (10); the electrolyte layer (30) is located on the surface of the side of the first electrode layer (20) distant from the tubular body (11); and the second electrode layer (40) is located on the surface of the side of the electrolyte layer (30) distant from the first electrode layer (20). The fuel cell module (100) has a simple structure, and can achieve the purposes of reducing design complexity and increasing energy density per unit volume.

Description

Fuel cell module and method of manufacturing the same TECHNICAL FIELD

[0001] The present application relates to a battery module, in particular to a fuel cell module and a method of manufacturing the same. BACKGROUND

[0002] In recent years, various countries are actively developing a fuel cell which can be applied to the field of electric vehicles to solve the problem of greenhouse gas generated by gasoline vehicles, thereby reducing the demand and use of oil.

[0003] In detail, the fuel cell generates electricity through an electrochemical reaction, has the characteristics of high efficiency and low pollution, and enables electric vehicles to replace gasoline vehicles. The stack, as the core technology of the fuel cell, has a bipolar plate which can provide support and uniform distribution of gas. Of course, the performance of the bipolar plate directly affects the volume, power and service life of the stack. TECHNICAL PROBLEM

[0004] Through the practice of relevant technical personnel, several technical problems of the bipolar plate are found, which are described as follows:

[0005] 1. High design complexity: During actual manufacturing, the bipolar plate needs to cooperate with other components of the stack, so the design complexity is increased, and the overall manufacturing cost is also high.

[0006] 2. Low energy density per unit volume: Because the stack must be separated by the bipolar plate, increasing the number of bipolar plates is necessary to increase the capacity of the fuel cell, thereby increasing the volume of the fuel cell. In this way, the volume and storage energy of the fuel cell cannot be considered.

[0007] In summary, if the design complexity of the fuel cell can be reduced without affecting the operation of the fuel cell, the overall manufacturing cost can be further reduced, and the energy density per unit volume can be increased. It is a great innovation in the field of fuel cell technology. Therefore, the present application proposes a technical solution to solve the above problems to improve the defects of the prior art. TECHNICAL SOLUTION

[0008] The main purpose of the present application is to provide a fuel cell module with a simple structure to reduce the design complexity and improve the energy density per unit volume.

[0009] The foregoing objects are not exclusive of one another. The objects derived from the specification, claims, drawings, or the like, which can be inferred by those skilled in the art, are also included in the objects of the present application. Therefore, the objects of the present application are not limited to the foregoing enumerated objects.

[0010] To achieve the foregoing objects, the present application provides a fuel cell module, which comprises a porous substrate, a first electrode layer, an electrolyte layer, and a second electrode layer. The porous substrate has electrical conductivity, and the porous substrate has a tubular shape. The porous substrate has a tube body, a first connecting portion, and a second connecting portion. The first connecting portion and the second connecting portion are respectively located at opposite ends of the porous substrate, and the tube body is located between the first connecting portion and the second connecting portion. The first electrode layer is located on the tube body of the porous substrate. The electrolyte layer is located on a side surface of the first electrode layer away from the tube body. The second electrode layer is located on a side surface of the electrolyte layer away from the first electrode layer.

[0011] In an embodiment of the present application, a current collecting layer is further included. The current collecting layer has a mesh shape, and the current collecting layer is located on a side surface of the second electrode layer away from the electrolyte layer.

[0012] In an embodiment of the present application, a first conductive connecting unit, a first insulating connecting unit, and a second conductive connecting unit are further included. The first conductive connecting unit is arranged on the first connecting portion. The first insulating connecting unit is arranged on the second connecting portion. The second conductive connecting unit is arranged on the first insulating connecting unit.

[0013] In an embodiment of the present application, a first airtight layer and a second airtight layer are further included. The first airtight layer is fixed between the first conductive connecting unit and the tube body. The second airtight layer is fixed between the second conductive connecting unit and the tube body.

[0014] In an embodiment of the present application, the second electrode layer and the first connecting portion have a first spacing along an axis of the porous substrate.

[0015] In an embodiment of the present application, a third conductive connecting unit is further included. The third conductive connecting unit has a hollow shape. The number of fuel cell modules is two. The two fuel cell modules are parallel to each other. The third conductive connecting unit is connected between the two fuel cell modules.

[0016] In an embodiment of the present application, a housing is further included. The housing has a containing space. The two fuel cell modules are arranged in the containing space. The first conductive connecting unit and the third conductive connecting unit of the two fuel cell modules are exposed outside the housing.

[0017] In an embodiment of the present application, the housing has an inlet and an outlet, the inlet and the outlet are in communication with the accommodation space and the outside of the housing, the inlet and the outlet are located between the first conductive connecting unit and the third conductive connecting unit, the inlet is located adjacent to the third conductive connecting unit, and the outlet is located adjacent to the first conductive connecting unit.

[0018] In an embodiment of the present application, the housing has a cooling unit, the cooling unit is located in the accommodation space, and the cooling unit is located adjacent to the two fuel cell modules.

[0019] In an embodiment of the present application, a manufacturing method is provided, which comprises:

[0020] providing a porous substrate;

[0021] forming a first electrode layer on a side surface of the porous substrate away from the tube body;

[0022] forming an electrolyte layer on a side surface of the first electrode layer away from the tube body; and

[0023] forming a second electrode layer on a side surface of the electrolyte layer away from the first electrode layer.

[0024] In an embodiment of the present application, a mesh current collecting layer is formed on a side surface of the second electrode layer away from the electrolyte layer.

[0025] In an embodiment of the present application, a metal layer is formed on the porous substrate.

[0026] In an embodiment of the present application, the first electrode layer is formed on the tube body by coating.

[0027] In an embodiment of the present application, the second electrode layer is formed on the electrolyte layer by coating.

[0028] Therefore, the fuel cell module of the present application can achieve the energy storage purpose with a simple structure, which greatly reduces the design complexity and the manufacturing cost. In addition, more fuel cell modules can be accommodated in the same volume, thereby achieving the purpose of improving the energy density per unit volume. BRIEF DESCRIPTION OF DRAWINGS

[0029] The present application will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0030] FIG. 1 is a perspective view of a fuel cell module according to an embodiment of the present application, particularly showing the appearance of the fuel cell module.

[0031] FIG. 2 is a sectional view of a fuel cell module according to an embodiment of the present application (I), particularly showing the structure of the fuel cell module.

[0032] Figure 3 is a cross-sectional view of a fuel cell module according to an embodiment of the present application, particularly showing a first electrode layer, an electrolyte layer, and a second electrode layer under a high magnification microscope.

[0033] Figure 4 is a side view of a fuel cell module according to another embodiment of the present application, particularly showing a third conductive connection unit connecting two porous substrates.

[0034] Figure 5 is a schematic diagram of a fuel cell module according to yet another embodiment of the present application, particularly showing a fuel cell module performing an electrolysis process.

[0035] Figure 6 is a schematic diagram of a fuel cell module according to yet another embodiment of the present application, particularly showing a fuel cell module performing a power generation process.

[0036] Figure 7 is a flowchart of a manufacturing method according to an embodiment of the present application.

[0037] Figure 8 is a flowchart of a manufacturing method according to another embodiment of the present application.

[0038] Legend of Reference Numerals

[0039] 100: fuel cell module

[0040] 1: fuel

[0041] 2: power supply module

[0042] 3: product

[0043] 4: oxidizer

[0044] 5: load

[0045] 10: porous substrate

[0046] 11: tube body

[0047] 12: first connection portion

[0048] 13: second connection portion

[0049] 20: first electrode layer

[0050] 30: electrolyte layer

[0051] 40: second electrode layer

[0052] 50: current collector layer

[0053] 60a: first conductive connection unit

[0054] 60b: second conductive connection unit

[0055] 60c: third conductive connection unit

[0056] 70: first insulating connecting unit;

[0057] 80a: first airtight layer;

[0058] 80b: second airtight layer;

[0059] 90: metal layer;

[0060] 200: housing;

[0061] 210: accommodating space;

[0062] 220: inlet;

[0063] 230: outlet;

[0064] 240: cooling unit;

[0065] 300: manufacturing method;

[0066] C: axis;

[0067] D1: first distance;

[0068] D2: second distance. Best mode of the present application

[0069] To facilitate the central idea of the present application as indicated in the above column, the present application is expressed in specific embodiments. The various components in the embodiments are depicted in the proportions, sizes, deformation amounts or displacement amounts suitable for illustration, rather than in the proportions of actual components. It is hereby stated.

[0070] The exemplary embodiments of the present application are described in detail below with reference to the accompanying drawings, and the technical principles of the present application are not intended to be limited to the specific disclosed embodiments, and the scope of protection of the present application only covers the claims, covering alternatives, modifications and equivalents.

[0071] Please refer to FIGS. 1 to 7, in the embodiments of the present application, the present application provides a fuel cell module 100, which comprises a porous substrate 10, a first electrode layer 20, an electrolyte layer 30 and a second electrode layer 40.

[0072] Please refer to FIGS. 1 and 2, the porous substrate 10 is electrically conductive and in a tubular shape; in the present embodiment, the tube diameter R of the porous substrate 10 is between 1 mm and 5 mm, and the length of the porous substrate 10 is between 40 mm and 80 mm. The porous substrate 10 has a tube body 11.

[0073] In one embodiment of the present application, the porous substrate 10 has a first connecting portion 12 and a second connecting portion 13. The first connecting portion 12 and the second connecting portion 13 are respectively located at two opposite ends of the porous substrate 10. The first connecting portion 12 can be an anode or a cathode, and the second connecting portion 13 can be an anode or a cathode. The tube body 11 is located between the first connecting portion 12 and the second connecting portion 13. In this way, the energy can be outputted to the outside of the fuel cell module 100 by simply connecting the first connecting portion 12 and the second connecting portion 13.

[0074] Please refer to FIG. 2, the first electrode layer 20 is located on the tube body 11 of the porous substrate 10. In detail, the first electrode layer 20 is located between the first connecting portion 12 and the second connecting portion 13, and the first electrode layer 20 entirely covers the tube body 11 of the porous substrate 10.

[0075] The electrolyte layer 30 is located on a side surface of the first electrode layer 20 away from the tube body 11. The electrolyte layer 30 entirely covers the first electrode layer 20.

[0076] The second electrode layer 40 is located on a side surface of the electrolyte layer 30 away from the first electrode layer 20. The second electrode layer 40 entirely covers the electrolyte layer 30, and the first electrode layer 20, the electrolyte layer 30 and the second electrode layer 40 respectively have a hollow cylindrical shape. In addition, as shown in FIG. 2, the second electrode layer 40 and the first connecting portion 12 have a first spacing D1 along an axis C of the porous substrate 10. The first spacing D1 can be 1, 2, 3, 4, 5, 6, 7, 8, 9 or 10 millimeters, so as to reduce the short circuit of the fuel cell module 100.

[0077] In one preferred embodiment of the present application, the fuel cell module 100 further comprises a current collecting layer 50 having a conductive property. In this embodiment, the material of the current collecting layer 50 can be metal. The current collecting layer 50 has a mesh shape, and has a gas permeable property. The current collecting layer 50 is located on a side surface of the second electrode layer 40 away from the electrolyte layer 30. The current collecting layer 50 entirely covers the second electrode layer 40, so as to increase the conductive ability of the fuel cell module 100.

[0078] Please refer to Fig. 3, the present application observes the first electrode layer 20, the electrolyte layer 30 and the second electrode layer 40 by high magnification microscope. The average thickness of the first electrode layer 20 is between 15 microns and 35 microns, for example, 15, 17, 19, 21, 23, 25, 27, 29, 31, 33 and 35 microns. The average thickness of the electrolyte layer 30 is between 80 microns and 100 microns, for example, 80, 82, 84, 86, 88, 90, 92, 94, 96, 98 and 100 microns. The average thickness of the second electrode layer 40 is between 20 microns and 40 microns, for example, 20, 22, 24, 26, 28, 30, 32, 34, 36, 38 and 40 microns.

[0079] Please refer to Figs. 2 and 4, the fuel cell module 100 further comprises a first conductive connecting unit 60a, a second conductive connecting unit 60b and a first insulating connecting unit 70.

[0080] The first conductive connecting unit 60a is disposed on the first connecting portion 12, and the first conductive connecting unit 60a is in contact with the first electrode layer 20. Further, the first conductive connecting unit 60a is combined with the outer thread of the first connecting portion 12 by the inner thread of the first conductive connecting unit 60a, so as to complete the disposition of the first conductive connecting unit 60a.

[0081] The first insulating connecting unit 70 is used for insulation. The first insulating connecting unit 70 is disposed on the second connecting portion 13, and the first insulating connecting unit 70 is in contact with the first electrode layer 20 and the electrolyte layer 30. The second conductive connecting unit 60b is disposed on the first insulating connecting unit 70, and the second conductive connecting unit 60b is in contact with the second electrode layer 40 and the current collecting layer 50, or only in contact with the current collecting layer 50. The first insulating connecting unit 70 is combined with the outer thread of the second connecting portion 13 by the inner thread of the first insulating connecting unit 70, and the second conductive connecting unit 60b is combined with the outer thread of the first insulating connecting unit 70 by the inner thread of the second conductive connecting unit 60b, so as to complete the disposition of the second conductive connecting unit 60b and the first insulating connecting unit 70.

[0082] Further, the first conductive connecting unit 60a and the second conductive connecting unit 60b can be conductive adapters, and the first insulating connecting unit 70 can be an insulating adapter.

[0083] The fuel cell module 100 further comprises a first airtight layer 80a and a second airtight layer 80b. The first airtight layer 80a is sealed between the first conductive connecting unit 60a and the pipe body 11, and the second airtight layer 80b is sealed between the second conductive connecting unit 60b and the pipe body 11. In this way, the fuel 1 is prevented from leaking from the gap between the pipe body 11 and the first conductive connecting unit 60a, and the gap between the pipe body 11 and the second conductive connecting unit 60b.

[0084] The present application further comprises a third conductive connecting unit 60c. The third conductive connecting unit 60c is hollow, so as to provide a passage for the fuel 1 to pass through. The fuel cell module 100 is in the number of two, and the two fuel cell modules 100 are parallel to each other. The two fuel cell modules 100 have a second spacing D2 along the direction of the vertical axis C. The second spacing D2 can be 0.5, 1.0, 1.5, 2.0, 2.5, 3.0 mm, etc. The third conductive connecting unit 60c is connected between the two fuel cell modules 100.

[0085] Please refer to FIG. 4, the two porous substrates 10 and the third conductive connecting unit 60c are in a U shape, and the two first conductive connecting units 60a are located on the same side of the porous substrate 10, which is more conducive to the arrangement and assembly of the porous substrate 10. In addition, this method can also increase the reaction path of the fuel 1, so that the fuel 1 can react more effectively.

[0086] Please refer to FIG. 5, the fuel cell module 100 further comprises a housing 200. The housing 200 has a receiving space 210. The two fuel cell modules 100 are arranged in the receiving space 210, and the first conductive connecting unit 60a and the third conductive connecting unit 60c of the two fuel cell modules 100 are exposed outside the housing 200, so as to carry out electrolysis reaction.

[0087] In a preferred embodiment of the present application, the housing 200 has an inlet 220 and an outlet 230. The inlet 220 and the outlet 230 communicate the receiving space 210 and the outside of the housing 200. The inlet 220 and the outlet 230 are located between the first conductive connecting unit 60a and the third conductive connecting unit 60c. The inlet 220 is arranged adjacent to the third conductive connecting unit 60c, and the outlet 230 is arranged adjacent to the first conductive connecting unit 60a.

[0088] As shown in FIG. 5, for example, if the present application wants to carry out the electrolysis process, the fuel 1, such as deionized water, can be input from one of the first connecting parts 12 and the inlet 220. The two first conductive connecting units 60a and the third conductive connecting unit 60c are coupled to a power supply module 2. During the electrolysis process, the fuel 1 in the tube body 11 passes through the holes of the porous substrate 10, and is guided to the first electrode layer 20, the electrolysis layer 30 and the second electrode layer 40 for reaction. If the first connecting part 12 is an anode, the product 3 generated by the fuel cell module 100, such as oxygen and hydrogen, is output from the other first connecting part 12, and the hydrogen and the un-electrolyzed water are output from the outlet 230.

[0089] Please refer to Fig. 6, another example is provided. If the application is to generate electricity, fuel 1 is inputted from one of the first connecting parts 12 and outputted from another first connecting part 12. The inlet 220 is inputted with oxidant 4. The two first conductive connecting units 60a and the third conductive connecting unit 60c are coupled to a load 5. During the electricity generation process, the oxidant 4 and water are outputted from the outlet 230.

[0090] Further, the shell 200 has a cooling unit 240. The cooling unit 240 is located in the accommodation space 210. The cooling unit 240 is adjacent to the two fuel cell modules 100. For example, the cooling unit 240 is wrapped around the two second electrode layers 40. In this embodiment, the cooling unit 240 cools the fuel cell modules 100 by water cooling.

[0091] Please refer to Figs. 7 and 8, in an embodiment of the application, a manufacturing method 300 is provided. The manufacturing method 300 comprises the following steps:

[0092] Step S1: providing a porous substrate 10.

[0093] Step S2: forming a first electrode layer 20 on a tube body 11 of the porous substrate 10. The first electrode layer 20 is formed on the tube body 11 by coating.

[0094] Step S3: forming an electrolyte layer 30 on a side surface of the first electrode layer 20 away from the tube body 11.

[0095] Step S4: forming a second electrode layer 40 on a side surface of the electrolyte layer 30 away from the first electrode layer 20. The second electrode layer 40 is formed on the electrolyte layer 30 by coating.

[0096] Please refer to Fig. 8, in a preferred embodiment of the application, a step S5 is provided after the step S4. Step S5: forming a mesh current collecting layer 50 on a side surface of the second electrode layer 40 away from the electrolyte layer 30, so as to increase the conductivity of the fuel cell module 100.

[0097] In a preferred embodiment of the application, a step S6 is provided between the step S1 and the step S2. Step S6: forming a metal layer 90 on the porous substrate 10, i.e. the metal layer 90 entirely covers the porous substrate 10, so as to increase the conductivity of the porous substrate 10. The metal layer 90 is formed on the porous substrate 10 by electroplating. Further, the metal layer 90 is made of copper.

[0098] In summary, the application has the following technical features:

[0099] 1. The present application can reduce the complexity of the design of the fuel cell module 100, thereby reducing the overall manufacturing cost, and improving the energy density per unit volume, without affecting the operation of the fuel cell module 100.

[0100] 2. The present application can further increase the conductivity of the fuel cell module 100 by covering the second electrode layer 40 with the current collecting layer 50.

[0101] 3. The first and second airtight layers 80a and 80b can avoid the gap between the pipe body 11 and the first and second conductive connection units 60a and 60b, so that the fuel 1 cannot leak out of the gap.

[0102] 4. The present application can further facilitate the arrangement and assembly of the plurality of porous substrates 10 by combining the two porous substrates 10 with the third conductive connection unit 60c. In addition, the present application can increase the reaction path of the fuel 1, so that the fuel 1 can react more effectively.

[0103] 5. Since the fuel cell module 100 generates heat during the reaction process, the present application is provided with a cooling unit 240 to cool the fuel cell module 100.

[0104] 6. The present application can further increase the conductivity of the porous substrate 10 by forming the metal layer 90 completely on the porous substrate 10.

[0105] The foregoing effects do not hinder the existence of other effects. If the effects can be derived from the description, claims, or drawings of the specification, they are also included in the effects of the present application. Therefore, the effects of the present application are not limited to the foregoing enumerated effects.

[0106] The above examples are only used to illustrate the present application and are not intended to limit the scope of protection of the present application. Any modification or change that does not deviate from the spirit of the present application is intended to be within the scope of protection of the present application.

Claims

1. A fuel cell module characterized by The fuel cell module comprises: a porous substrate with electric conductivity, in a tubular shape, the porous substrate having a tube body, a first connecting portion and a second connecting portion, the first connecting portion and the second connecting portion being located at opposite ends of the porous substrate, the tube body being located between the first connecting portion and the second connecting portion; a first electrode layer located on the tube body of the porous substrate; an electrolyte layer located on a side surface of the first electrode layer away from the tube body; and a second electrode layer located on a side surface of the electrolyte layer away from the first electrode layer.

2. The fuel cell module of claim 1, wherein, The fuel cell module further comprises a current collector layer in a mesh shape, the current collector layer being located on a side surface of the second electrode layer away from the electrolyte layer.

3. The fuel cell module of claim 1, wherein, The fuel cell module further comprises a first electrically-conductive connecting unit, a first insulating connecting unit and a second electrically-conductive connecting unit, the first electrically-conductive connecting unit being arranged on the first connecting portion, the first insulating connecting unit being arranged on the second connecting portion, and the second electrically-conductive connecting unit being arranged on the first insulating connecting unit.

4. The fuel cell module of claim 3, wherein, The fuel cell module further comprises a first airtight layer and a second airtight layer, the first airtight layer being sealed between the first electrically-conductive connecting unit and the tube body, and the second airtight layer being sealed between the second electrically-conductive connecting unit and the tube body.

5. The fuel cell module of claim 4, wherein, The second electrode layer and the first connecting portion are in a first spacing along an axis of the porous substrate.

6. The fuel cell module of claim 5, wherein, The fuel cell module further comprises a third electrically-conductive connecting unit in a hollow shape, the number of the fuel cell modules being two, the two fuel cell modules being parallel to each other, and the third electrically-conductive connecting unit being connected between the two fuel cell modules.

7. The fuel cell module of claim 6, wherein, The fuel cell module further comprises a housing having a receiving space, the two fuel cell modules being arranged in the receiving space, and the first electrically-conductive connecting unit and the third electrically-conductive connecting unit of the two fuel cell modules being exposed outside the housing.

8. The fuel cell module of claim 7, wherein, The housing has an inlet and an outlet, the inlet and the outlet communicating the receiving space and the outside of the housing, the inlet and the outlet being located between the first electrically-conductive connecting unit and the third electrically-conductive connecting unit, the inlet being arranged adjacent to the third electrically-conductive connecting unit, and the outlet being arranged adjacent to the first electrically-conductive connecting unit.

9. The fuel cell module of claim 7, wherein, The housing has a cooling unit located in the receiving space, the cooling unit being arranged adjacent to the two fuel cell modules.

10. A method for manufacturing the fuel cell module according to claim 1, comprising: providing the porous substrate; forming the first electrode layer on the tube body of the porous substrate; forming the electrolyte layer on a side surface of the first electrode layer away from the tube body; and forming the second electrode layer on a side surface of the electrolyte layer away from the first electrode layer. forming a mesh-shaped current collector layer on a side surface of the second electrode layer away from the electrolyte layer.

11. The method of manufacturing a fuel cell module according to claim 10, wherein completely forming a metal layer on the porous substrate.

12. The method of manufacturing a fuel cell module according to claim 10, wherein The first electrode layer is formed on the tube body by coating.

13. The method of manufacturing a fuel cell module according to claim 10, wherein The second electrode layer is formed on the electrolyte layer by coating.

14. The method of fabricating a fuel cell module of claim 10, wherein, ​

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