Polar and bipolar multicell panel-based design of proton exchange membrane fuel cells and electrolyzers and method for manufacturing

Abstract

There is provided a multicell panel fuel cell or electrolyzer comprising metallic plate components (1, 10), at opposing sides of the multicell panel fuel cell or the electrolyzer, structural polymer plate component (2) with joined to one or several proton exchange membrane (5) by a friction-based joining technique, and the outer metallic plate components (1, 10) joined to at least one common intermediate structural polymer plate component (2) by a friction-based joining technique.

Description

[0001] Polar and bipolar multicell panel-based design of proton exchange membrane fuel cells and electrolyzers and method for manufacturing

[0002] Field of invention

[0003] The field of invention relates to fuel cells and electrolyzers, especially to their design, more especially to polar and bipolar multicell panel-based design, more especially to multicell panel-based design of proton exchange membrane (PEM) fuel cells and electrolyzers and to a method for manufacturing them.

[0004] Background

[0005] The review of the prior art in the field of design of proton exchange membrane fuel cells and electrolyzers and method for manufacturing found the following contrasts with the present invention: US Patent 7,136,029 describes the method for assembling a PEM fuel cell stack, including the techniques for creating sealant layers that prevent gas crossover and leakage. US Patent 6,203,974 covers a method for manufacturing large-scale PEM fuel cells by integrating the components into a fuel cell stack. US Patent 8,247,125 focuses on developing a low-cost, highly efficient catalyst material using platinum alloys and other non-precious metals to reduce the cost of the PEM fuel cell. US Patent 8,505,831 describes an improved method for manufacturing the proton-exchange membrane itself, using more abundant materials such as polyphenylene sulfide-based polymers. US Patent 7,395,446 describes an innovative method for assembling a PEM fuel cell stack, including new sealing techniques and methods for enhancing the overall stack performance. US Patent 7,859,313 focuses on techniques for sealing and optimizing the operation of PEM fuel cell stacks under varying operational conditions. US Patent 10,287,124 focuses on a roll-to-roll process for the continuous manufacture of PEM fuel cell electrodes, which could greatly reduce the cost and complexity of large-scale production.

[0006] Summary of the inventionThe invention is defined by the features of the independent claims. Some embodiments are defined in the dependent claims.

[0007] According to a first aspect, there is provided a multicell panel fuel cell or electrolyzer comprising metallic plate components at opposing sides of the multicell panel fuel cell or the electrolyzer, structural polymer plate component with joined proton exchange membrane, PEM, fuel cell components, wherein the outer metallic plate components are joined to at least one common intermediate structural polymer plate component by a friction-based joining technique.

[0008] According to a second aspect, there is provided a method for a multicell panel fuel cell or electrolyzer, comprising providing outer metallic plate components and structural polymer plate components, installing proton exchange membrane, PEM, fuel cell components to the structural polymer plate components for forming a structural polymer plate components with integrated PEM fuel cell components, and joining the outer metallic plate components to at least one common structural polymer plate component with integrated PEM fuel cell components by a friction-based joining technique.

[0009] According to a third aspect, there is provided a wing of an airplane comprising an integrated multicell panel fuel cell or electrolyzer according to the first aspect.

[0010] According to a fourth aspect, there is provided a floor of a train or a truck comprising an integrated multicell panel fuel cell or electrolyzer according to the first aspect.

[0011] According to the fifth aspect, there is provided a wall of a civil construction comprising an integrated multicell panel fuel cell or electrolyzer according to the first aspect.

[0012] According to a sixth aspect, there is provided use of an integrated multicell panel fuel cell or electrolyzer according to the first aspect for a wing of an airplane.

[0013] According to a sixth aspect, there is provided use of an integrated multicell panel fuel cell or electrolyzer according to the first aspect for a floor of a train or a truck.According to a sixth aspect, there is provided use of an integrated multicell panel fuel cell or electrolyzer according to the first aspect for a wall of a civil construction.

[0014] List of figures

[0015] Figure 1 shows the integration of the multiple components in an exemplary case of a planar design of a polar MCP-FC / E panel sandwich system.

[0016] Figure 2 illustrates the sequence for assembly and manufacturing of the polar MCP-FC / E panel sandwich system.

[0017] Figure 3 shows the integration of the multiple components in a generic / exemplary case of a planar design of a bipolar MCP-FC / E panel sandwich system.

[0018] Figure 4 illustrates the manufacturing of the same system in Fig 3 in a three-dimensional panel shape.

[0019] Figure 5 shows the integration of the multiple components in a generic / exemplary case of a planar design of a bipolar MCP-FC / E panel sandwich system.

[0020] Figure 6 illustrates the manufacturing of the same system as in Fig 5.

[0021] Figure 7 illustrates a polar MCP-FC / E panel sandwich system 9 containing a single fuel cell / electrolyzer with four multicells.

[0022] Figure 8 illustrates a polar MCP-FC / E panel sandwich system 9 containing a single fuel cell / electrolyzer with two multicells.

[0023] Figure 9 illustrates an exemplary irregular-shaped planar polar MCP-FC / E panel sandwich system 9 containing six fuel cell / electrolyzers with one cell each.Figure 10 illustrates the manufacturing of the similar system as in Fig 1.

[0024] Figure 11 illustrates an exemplary polar / bipolar MCP-FC / E panel sandwich system 9 containing two single fuel cells / electrolyzers with four multicells each.

[0025] Figure 12 illustrates an exemplary planar polar / bipolar MCP-FC / E panel sandwich system 9 containing six single fuel cells / electrolyzers with four multicells each.

[0026] Figure 13 illustrates the same system in Fig 12 but containing six times six (equal to thirty-six) fuel cells / electrolyzers.

[0027] Figure 14 illustrates the same system in Fig 12 but each of the six fuel cells / electrolyzers with one cell only.

[0028] Figure 15 shows the extension of the exemplary case of a planar design of a MCP-FC / E panel sandwich system 9 presented in Fig. 3.

[0029] Figure 16 shows the extension of the exemplary case of a planar design of a bipolar MCP-FC / E panel sandwich system 9 presented in Fig. 5.

[0030] Figure 17 illustrates the same system as in Fig. 16 but with the several bipolar metallic components 10, with one cell each.

[0031] Figure 18 illustrates the same system as in Fig. 1 , for different shapes, of one polar MCP-FC / E panel sandwich system 9, with each single fuel cell / electrolyzer with one cell each.

[0032] Figure 19 illustrates the same system as in Fig. 12, in a stack of 4 layers of polar / bipolar MCP-FC / E panel sandwich system 9 separated by an insulation layer 8.Figure 20 shows a structural integration of an MCP-FC / E panel sandwich system 9 in the floor of a train / tram vehicle.

[0033] Figure 21 shows a structural integration of an MCP-FC / E panel sandwich system 9 in an aeronautic vehicle.

[0034] Figure 22 shows a structural integration of an MCP-FC / E panel sandwich system 9 in a truck vehicle.

[0035] Figure 23 shows a structural integration of an MCP-FC / E panel sandwich system 9 in a wall of a civil construction.

[0036] Figure 24 illustrates a polar MCP-FC / E panel sandwich system 9, with the two polar metallic components 1 joint to the structural polymer plate component.

[0037] Detailed Description

[0038] Operation of fuel cells and electrolyzers is a set of integrated multiphysical phenomena, including electrochemical reactions, gas and liquid flows, electrical circuits, heat generation and flow, structural integrity and reliability of sensitive materials. The existing / conventional PEM based fuel cells and electrolyzers design and manufacturing / assembling processes have not evolved at same pace of other sub-systems, and as result the PEM based fuel cells and electrolyzers are heavy systems difficult to integrate and with low structural and operational reliability. The multimaterial components’ system and manufacturing techniques to produce an PEM-based electrolyzers is similar to the ones from PEM based fuel cells.

[0039] There is perceived need and market for a proton exchange membrane (PEM) based fuel cells and eletrolyzers with simplified design and with better sealing and joining solution of the multi-material components’ system (system of multiple components made of different materials). This growth is pushed by the need of alternative source of energy, due to increase in existing resource scarcity and mainly due to extreme environmental regulations dictating thateconomic growth must rely on more environmentally friendly and efficient processes. As part of larger energy systems, the Fuel cells are the ideal environment friendly alternative solution to internal combustion (IC) engines and other conventional energy conversion technologies, and electrolyzers are an efficient solution for storage of energy harvest from renewable sources e.g. wind, solar and waves.

[0040] A fuel cell is a device that converts chemical potential energy (energy stored in molecular bonds) into electrical energy. A PEM based fuel cell uses hydrogen gas (H2) and oxygen gas (O2) as fuel. The products of the reaction from the cell are water, electricity, and heat. This is a big improvement over internal combustion engines, coal and hydrocarbon-based power plants, and nuclear power plants, all of which produce harmful by-products. Since O2 is readily available in the atmosphere, we only need to supply the fuel cell with H2 which can come from an electrolyzer system.

[0041] Operation of fuel cells and electrolyzers is a set of integrated multi-physical phenomena, including electrochemical reactions, gas and liquid flows, electrical circuits, heat generation and flow, structural integrity and reliability of sensitive materials. The existing / conventional PEM based fuel cells and electrolyzers design and manufacturing / assembling processes have not evolved at same pace of other subsystems, and as result the PEM based fuel cells and electrolyzers are heavy systems difficult to integrate and

[0042] with low structural and operational reliability. The multi-material components’ system and manufacturing techniques to produce an PEM-based electrolyzers is similar to the ones from PEM based fuel cells.

[0043] The Multicell Panel Fuel Cell I Electrolyzer (MCP-FC / E) consists of a panel sandwich system and aims to be the next generation of PEM based fuel cells / electrolyzers with new design enabled by a set of dedicated manufacturing techniques, which enables to produce PEM based fuel cell / electrolyzer in a panel encompassing one, or several cells (the multicell panel) without depending on mechanical fasteners for load-bearing and gastight joining between the multi-material components’ system.MCP-FC / E is enabled by a set of modern friction-based processing and manufacturing techniques, such as the through slot extrusion joining (TSEJ) to join metallic components to structural polymer components, static-shoulder friction-stir welding (SSFSW) to join structural polymer components to PEM, and friction stir channeling (FSC) to create subsurface channels for thermal management in the metallic components.

[0044] This set of modern friction-based processing and manufacturing techniques provides solutions for sealing and joining of the multi-material components’ system composing the PEM based fuel cells and eletrolyzers. The new multicell panel-based design of proton exchange membrane fuel cells and electrolyzers and method for manufacturing discards the dependence of previous / conventional designs on the sealing of gases and liquids on mechanical fasteners providing heavy compression force between the multicomponents and many gaskets that hamper the reliable operation of previous / conventional PEM based fuel cells and eletrolyzers.

[0045] The design of current conventional fuel cell and electrolyser had made it even more complex because of problem cited as below:

[0046] - Large and heavy: The use of structurally resistant end plates, complex mechanical clamping with multiple bolts / fasteners, washer, springs, nuts (electrically insulated) , long gaskets at all interfaces for sealing, heavy Cu bus plates, tubes and connectors for gas and liquid flow makes the final assembled unit very heavy and large.

[0047] - Difficult to assure sealing during assembling: The current design of the fuel cell depends on structural end plates on either side compressed under high load, which is then fastened with large number of fasteners to get the required sealing for the stack.

[0048] - Low reliability: The use of gasket along with other fuel cell component under high stress under chemical and thermal environment decrease the durability of the gasket, which then effect the reliability of the whole cell because a small defect / damage of any of the many elements (e.g. gaskets,graphite bipolar plates) leads to relaxation of the clamping force and compromise the sealing of whole stack and can stop its operation due to leakage

[0049] - Graphite bipolar plates are problem: The existing design use the bipolar plates are mostly made of graphite, which is brittle, difficult to machine and expensive. Graphite undergoes carbon corrosion producing CO2 and leading to fracture. There is a great need for a suitable replacement material.

[0050] - Not recyclable: The maximum components currently used in the fuel cells are not fully recyclable.

[0051] - Inefficient thermal management: The current design of thermal management fully depends on the compression sealing of the coolant, which are very prone to leakage.

[0052] The following reference numbers are used for the following parts in the Figures of this application:

[0053] 1 - Outer polar panel metallic component;

[0054] 1 a - Gas and fluid inlet in polar panel metallic component 1 ;

[0055] 1 b - Gas and fluid outlet feature in polar panel metallic component 1 ;

[0056] 1 c - Diffusion channel feature in polar panel metallic component 1 ;

[0057] 2 - Structural polymer plate component joint to PEM manufactured as an example via SSFSW;

[0058] 2a -Structural polymer plate component with open cells for PEM insert;

[0059] 2b -Rib of structural polymer plate component;

[0060] 3 - Multibody rigid extrusion die system for gas-tight TSEJ joints enabling the TSEJ joint 6;

[0061] 3a - Outer extrusion die component;

[0062] 3b - Inner extrusion die component;

[0063] 4 - Path of the TSEJ joint, along the slot, or aperture, formed by the multibody rigid extrusion die system 3 defining;

[0064] 5 - Proton exchange membrane;

[0065] 6 - TSEJ joint;7 - Subsurface channels for thermal management in the polar panel metallic component 1 and bipolar panel metallic component 10 manufactured as an example via Friction Stir Channeling;

[0066] 8 - Electrical and thermal insulation layer;

[0067] 9 - Polar / bipolar MCP-FC / E panel sandwich system.

[0068] 9a -Intermediate step of producing the MCP-FC / E, panel sandwich, with only one polar / bipolar metallic component 1 , and missing the opposite polar / bipolar metallic component 1 ;

[0069] 10 - Outer bipolar panel metallic component

[0070] 10a - Gas and fluid inlet in bipolar panel metallic component 10;

[0071] 10b - Gas and fluid outlet feature in bipolar panel metallic component 10; 10c- Diffusion channel feature in bipolar panel metallic component 10.

[0072] FIG. 1 shows the integration of the multiple components in an exemplary case of a planar design of a polar MCP-FC / E panel sandwich system 9 with two polar metallic components 1, at opposite sides, acting as polar plates where one is a cathode and the opposite one is an anode, and the polar MCP-FC / E panel sandwich system 9 contains a single fuel cell / electrolyzer with four multicells. The four multicells are rectangular.

[0073] FIG. 2 illustrates the sequence for assembly and manufacturing of the polar MCP-FC / E panel sandwich system 9 presented in Fig. 1. First step A shows details on both sides of the polar panel metallic component 1 with subsurface channels for thermal management manufactured as an example via FSC 7. The step B depicts the installation of the four proton exchange membranes 5 in the structural polymer plate component joint to PEM, with the gas-tight joints manufactured as an example via SSFSW forming the one structural polymer plate component with PEM integrated 2; The step C presents the intermediate step 9a where one polar metallic components 1 is joint to the structural polymer plate component with PEM integrated 2, containing four multicells in one polar MCP-FC / E, panel sandwich, with the joint between 1 and 2 manufactured via TSEJ 6; The step D shows the joining of the second polar metallic component 1 to the 9a completing the polar MCP-FC / E panel sandwich system 9 of one fuel cell / eletrolyzer containing four multiple cells.FIG. 3 shows the integration of the multiple components in a generic / exemplary case of a planar design of a bipolar MCP-FC / E panel sandwich system 9 with one bipolar metallic components 10, on one side of the structural polymer plate component with PEM integrated 2 and at opposite sides two polar metallic components 1, and the MCP-FC / E panel sandwich system 9 contains two fuel cells / electrolyzers, where each one contain four multicells.

[0074] FIG. 4 illustrates the manufacturing of the same system in Fig 3 in a three-dimensional panel shape.

[0075] FIG. 5 shows the integration of the multiple components in a generic / exemplary case of a planar design of a bipolar MCP-FC / E panel sandwich system 9 with two bipolar metallic components 10, at opposite sides, acting as bipolar plates and the bipolar MCP-FC / E panel sandwich system 9 contains two fuel cells / electrolyzers, where each one contains four multicells. The eight multicells are rectangular.

[0076] FIG. 5 shows the integration of the multiple components in a generic / exemplary case of a planar design of a bipolar MCP-FC / E panel sandwich system 9 with two polar metallic components 10, at opposite sides, acting as bipolar plates and the bipolar MCP-FC / E panel sandwich system 9 contains one fuel cells / electrolyzers, where each one contains eight multicells. The eight multicells are rectangular.

[0077] FIG. 6 illustrates the manufacturing of the same system in Fig 5 in a three-dimensional panel shape.

[0078] FIG. 7 illustrates a polar MCP-FC / E panel sandwich system 9 containing a single fuel cell / electrolyzer with four multicells similar to the system in Fig. 1 but where the four square shaped multicells are replaced by four triangular shaped multicells. The multicells are triangular.FIG. 8 illustrates a polar MCP-FC / E panel sandwich system 9 containing a single fuel cell / electrolyzer with two multicells, where the two multicells are shaped as semi-circles.

[0079] FIG. 9 illustrates an exemplary irregular shaped planar polar / bipolar MCP-FC / E panel sandwich system 9 containing six fuel cells / electrolyzers with one cell each, sharing the same structural polymer plate component joint to six PEM units 2.

[0080] FIG. 10 illustrates the manufacturing of the similar system in Fig 1 in a tridimensional panel shaped as “L”, and the polar MCP-FC / E panel sandwich system 9 contains a single fuel cell / electrolyzer with eight multicells.

[0081] FIG. 11 illustrates an exemplary polar / bipolar MCP-FC / E panel sandwich system (9) containing two single fuel cells / electrolyzers with four multicells each, sharing the same structural polymer plate component joint to PEM units 2, that is shaped as “L”.

[0082] FIG. 12 illustrates an exemplary regular planar polar / bipolar MCP-FC / E panel / sandwich system 9 containing six fuel cells / electrolyzers with four multicells each, sharing the same structural polymer plate component joint to PEM units 2. Polar metallic components 1 may be electrically connected between them in different combinations allowing to design in final voltage and current delivered by the MCP-FC / E panel / sandwich system 9.

[0083] FIG. 13 illustrates the same system in Fig 12 but containing six times six (equal to thirty-six) fuel cells / electrolyzers.

[0084] Fig. 14 illustrates the same system in Fig 12 but each of the six fuel cells / electrolyzers with one cell only.

[0085] Fig. 15 shows the extension of the exemplary case of a planar design of an MCP-FC / E panel sandwich system 9 presented in Fig. 3, with several bipolar metallic components 10 on one side of the structural polymer plate componentwith PEM integrated 2, and at opposite sides two polar metallic components 1 , forming a sequence of fuel cells / electrolyzer where each has four multicells. The lines of hydrogen and oxygen / air are also represented. The areas of the bipolar metallic components 10, contacting the Proton exchange membrane 5, acting as anode and cathode are represented as red and green, respectively. Fig. 15 shows the extension of the exemplary case of a planar design of a MCP-FC / E panel sandwich system 9 presented in Fig. 13, where the outer polar panel metallic components 1 can be electrically connected to transform the MCP-FC / E panel system into a bipolar and the feeding of gas can be integrated and combined for the multiple cells.

[0086] Fig. 16 shows the extension of the exemplary case of a planar design of a bipolar MCP-FC / E panel sandwich system 9 presented in Fig. 5, with several bipolar metallic components 10, with four multicells each, at opposite sides, forming a sequence of fuel cells / electrolyzer where each has four multicells. The lines of hydrogen and oxygen / air are also represented. The areas of the bipolar metallic components 10, contacting the Proton exchange membrane 5, acting as anode and cathode are represented as red and green, respectively.

[0087] FIG. 17 illustrates the same system as in Fig. 16 but with the several bipolar metallic components 10, with one cell each.

[0088] FIG. 18 illustrates the same system as in Fig. 1, for different shapes, of one polar MCP-FC / E panel sandwich system 9, with each single fuel cell / electrolyzer with one cell each.

[0089] Fig. 19 illustrates the same system as in Fig. 12, in a stack of 4 layers of polar / bipolar MCP-FC / E panel sandwich system 9 separated by an insulation layer 8. Fig. 19 illustrates the same system as in Fig. 12, in a stack of 4 layers of polar / bipolar MCP-FC / E panel sandwich system 9, which may be in direct contact by an insulation layer 8.

[0090] Fig. 20 structural integration of an MCP-FC / E panel sandwich system 9 in the floor of a train / tram vehicle.Fig. 21 illustrates a structural integration of an MCP-FC / E panel sandwich system 9 in an aeronautic vehicle.

[0091] Fig. 22 illustrates a structural integration of an MCP-FC / E panel sandwich system 9 in a truck vehicle.

[0092] Fig. 23 illustrates structural integration of an MCP-FC / E panel sandwich system 9 in a civil construction.

[0093] Fig. 24 illustrates a polar MCP-FC / E panel sandwich system 9, with the two polar metallic components 1 joint to the structural polymer plate component with PEM integrated 2 via the TSEJ 6. The circular TSEJ 6 path is visible on the outer metallic component 1.

[0094] As illustrated in the Figs, and throughout this application, a panel structure of MCP-FC / E is provided. The panel structure enables to connect and combine multiple electrode polar systems side by side, in the same layer, instead of a stack or series of layers, as previously. Each electrode polar system may include one or multiple PEM cells. Smaller PEM cells enable higher maximum pressure operation. The panel structures may integrated and utilized in surfaces over bi- or tridimensional space, since their dimensions are merely length and width, with very small height or thickness compared to the length and width.

[0095] MCP-FC / E consists of a panel sandwich system that can be planar (two-dimensional) or three-dimensional. The panel sandwich system encompasses one, or a stack of multiple cells, where occurs the electrochemical phenomenon of conversion of the hydrogen and oxygen into electricity and water, in the case of fuel cells, or the opposite conversion, in the case of electrolyzers. The panel sandwich system is made of outer metallic plate (or panel) components, that operate as polar, or bipolar, plates. The outer metallic plates are joined to at least one common intermediate structural polymer plate component. The joining of the outer metallic plate components to theintermediate structural polymer plate components is made by a friction-based joining technique, such as, through slot extrusion joining (TSEJ), with or without rigid extrusion dies. The intermediate structural polymer plate components consist of a plate with through open cells to be occupied by PEM component. The joining between the structural polymer plate components and the PEM component is made by a friction-based joining technique, such as, static-shoulder friction stir welding (SSFSW). Each of the PEM component is made of a synthetic polymer membrane, with ionic properties, and with both sides partially coated by a catalyst and gas diffuser layer compound. The structural polymer plate components electrically insulate the contact between the opposite side outer metallic plate components. Each of the outer metallic plate components are designed to closely surround the structural polymer plate components and inserts into the cells contacting with their side of the catalyst and gas diffuser layer compound coating of the PEM component, in each cell.

[0096] The zones of the outer metallic plate components, that are inserted inside each cell contacting the catalyst and gas diffuser layer compound, has a machined gas diffusion open channel pattern to conduct the flow of the fluids, namely the hydrogen and oxygen gases and water, wetting uniformly each side of the catalyst and gas diffuser layer compound of the PEM component. The outer metallic plate components can integrate a sub-surface channel, accommodating a fluid for thermal management of the fuel cells / electrolyzer system made by a friction-based joining technique, such as, friction stir channeling (FSC).

[0097] The load-bearing capacity of the MCP-FC / E panel sandwich system is provided by the integrated contributions from the outer metallic plate components and the intermediate structural polymer plate components joined together. To design complex panel shapes and design the electrical circuit, i.e. the voltage and current, each outer metallic plate component can be joined to more than one intermediate structural polymer plate component, and each intermediate structural polymer plate component can be joined to more than one outer metallic plate component. The outer metallic plate componentsoperate as bipolar elements providing the electric conductive media for communication between the multiple cells. The multi-dimensional shape of is provided by the coherent shaping of the outer metallic plate components and the intermediate structural polymer plate components.

[0098] The friction-based joining techniques provide gas-tight joints between all the sub-components, namely defining the individual cells electrochemical domain of operation. The outer metallic plate components have inlets, outlets and channel features for receiving and conducting the gases and liquids between the multiple cells, and between the outside and inside.

[0099] Two main distinctive new features of the MCP-FC / E panel sandwich system for PEM-based fuel cells and electrolyzers are:

[0100] - MCP-FC / E enables structural integration of the panel sandwich system in the targeted structural application, e.g. the wing of an airplane, the floor of a train or a truck, the wall of a civil construction unit such as a house or industrial building. Nowadays, the integration solutions demand a separate specific volume for installing the stack of fuel cells.

[0101] - The multicell character of the MCP-FC / E system enables designs with very small size cells that allows internal pressure operation higher than any present solution and even electrochemical hydrogen compression when working as an electrolyzer.

[0102] The MCP-FC / E manufacturing process is enabled by a set of modern frictionbased processing and manufacturing techniques is following sequence / step: - Step 1: A static-shoulder friction stir welding (SSFSW) to join structural polymer components (2) to PEM (5), outcome (A)

[0103] - Step 2: The through slot extrusion joining (TSEJ) to join each metallic components (1) to both sides of structural polymer components (2), outcome (D)

[0104] The parameters controlling the process of MCP-FC / E, design and method for manufacturing are the following:

[0105] 1. Number of multicells in each fuel cell / eletrolyzer unit2. Shape of the individual multicells

[0106] 3. Number of outer polar / bipolar panel metallic components (1 ) / (10) in the polar / Bipolar MCP-FC / E panel sandwich system (9)

[0107] 4. Shape of the outer polar / bipolar panel metallic components (1 ) / (10) in the polar / Bipolar MCP-FC / E panel sandwich system (9)

[0108] 5. Material and thickness of the outer metallic plate components (1 );

[0109] 6. Material and thickness of the intermediate structural polymer plate component (2)

[0110] 7. Material and thickness of the PEM

[0111] 8. Manufacturing method parameters, through slot extrusion joining (TSEJ) to join metallic components to structural polymer components, 9. Manufacturing method parameters, static-shoulder friction stir welding (SSFSW) to join structural polymer components to PEM

[0112] 10. Manufacturing method parameters, friction stir channeling (FSC) to create subsurface channels for thermal management in the metallic components

[0113] MCP-FC / E is enabled by a set of modern friction-based processing and manufacturing techniques, such as the through slot extrusion joining (TSEJ) to join metallic components to structural polymer components, static-shoulder friction stir welding (SSFSW) to join structural polymer components to PEM, and friction stir channeling (FSC) to create subsurface channels for thermal management in the metallic components. This set of modern friction-based processing and manufacturing techniques provides solutions for sealing and joining of the multi-material components’ system composing the PEM based fuel cells and eletrolyzers.

[0114] The new multicell panel-based design of proton exchange membrane fuel cells and electrolyzers and method for manufacturing discards the dependence of previous / conventional designs on the sealing of gases and liquids on mechanical fasteners providing heavy compression force between the multicomponents and many gaskets that hamper the reliable operation of previous / conventional PEM based fuel cells and eletrolyzers.MCP-FC / E panel sandwich system solves various existing problems, of existing PEM Fuel Cells and electrolysers by making its manufacturing process more sophisticated. MCP-FC / E is enabled by a set of modem friction-based processing and manufacturing techniques,

[0115] - Dedicated solution for joining and sealing fuel cell or elctrolysers. Such as the through slot extrusion joining (TSEJ) to join metallic components to structural polymer components, static-shoulder friction-stir welding (SSFSW) to join structural polymer components to PE.

[0116] - Dedicated efficient solution for thermal management of polar and bipolar plates enabled by friction stir channeling (FSC) to create subsurface channels for thermal management in the metallic components.

[0117] - The new multicell panel-based design of proton exchange membrane fuel cells and electrolyzers and method for manufacturing discards the dependence of previous / conventional designs on the sealing of gases and liquids on mechanical fasteners providing heavy compression force between the multi-components and many gaskets that hamper the reliable operation of previous / conventional PEM based fuel cells and eletrolyzers.

[0118] MCP-FC / E enables structural integration of the panel sandwich system in the targeted structural application, e.g. the wing of an airplane, the floor of a train or a truck, the wall of a civil construction unit such as a house or industrial building. Nowadays, the integration solutions demand a separate specific volume for installing the stack of fuel cells.

[0119] - The multicell character of the MCP-FC / E system enables designs with very small size cells that allows internal pressure operation higher than any present solution and even electrochemical hydrogen compression when working as an electrolyzer.

[0120] - All this friction based joining techniques can be fully automated hence enabling efficient manufacturing and easing manufacturing scaling.

Claims

Claims1. A multicell panel fuel cell or electrolyzer comprising- metallic plate components (1 , 10), at opposing sides of the multicell panel fuel cell or the electrolyzer,- structural polymer plate component (2) with joined to one or several proton exchange membrane (5) by a friction-based joining technique, and- the outer metallic plate components (1, 10) joined to at least one common intermediate structural polymer plate component (2) by a friction-based joining technique.

2. A multicell panel fuel cell or electrolyzer according to the claim 1, wherein the metallic plate components (1, 10) are outer components and the at least one structural polymer plate components (2) are intermediate components.

3. A multicell panel fuel cell or electrolyzer according to the claim 1 or 2, wherein the one or multiple proton exchange membranes (5) are inserted in the open cell cavities of a structural polymer plate component (2a) and with a rib of structural polymer plage component (2b) all components are joined forming a structural polymer plate component (2).

4. A multicell panel fuel cell or electrolyzer according to any one of the preceding claims, the outer metallic plate components (1, 10) act as polar plates where one is a cathode and the opposite one is an anode.

5. A multicell panel fuel cell or electrolyzer according to any one of the preceding claims, wherein the outer metallic plate components (1, 10) are configured to operate as polar or bipolar components.

6. A multicell panel fuel cell or electrolyzer according to any one of the preceding claims, comprising one or a stack of multiple cells, where occurs the electrochemical phenomenon of conversion of the hydrogen and oxygen into electricity and water in case of fuel cell; or the opposite conversion of the electricity and water into hydrogen and oxygen in case of electrolyzer.

7. A multicell panel fuel cell or electrolyzer according to any one of the preceding claims, comprising one or more polar fuel cells or electrolyzers system, of which each comprises one cell or multicells.

8. A multicell panel fuel cell or electrolyzer according to any one of the preceding claims, wherein the outer metallic plate components (1, 10) are joined to at least one common structural polymer plate component (2) by a through slot extrusion joining, TSEJ.

9. A multicell panel fuel cell or electrolyzer according to any one of the preceding claims, wherein the PEM fuel cell components (5) are joined to the structural polymer plate components (2a) and to the rib of the structural polymer plate component (2b) by a friction-based joining technique.

10. A multicell panel fuel cell or electrolyzer according to the claim 9, wherein the friction-based joining technique is a static-shoulder friction stir welding, SSFSW.

11. A multicell panel fuel cell or electrolyzer according to any one of the preceding claims, wherein the multicells are shaped as squares, triangulars, hexagons, circles and / or semi-circles.

12. A multicell panel fuel cell or electrolyzer according to any one of the preceding claims, wherein each outer metallic plate component (1, 10) is joined to more than one structural polymer plate components (2).

13. A multicell panel fuel cell or electrolyzer according to any one of the preceding claims, wherein each structural polymer plate component (2) is joined to more than one outer metallic plate components (1 , 10).

14. A multicell panel fuel cell or an electrolyzer according to any one of the preceding claims, wherein the structural polymer plate components (2) are configured to electrically insulate contact between the outer metallic plate components (1, 10).

15. A multicell panel fuel cell or electrolyzer according to any one of the preceding claims, wherein each PEM fuel cell component (5) is made of a synthetic polymer membrane, with ionic properties, and with both sides partially coated by a catalyst and gas diffuser layer compound.

16. A multicell panel fuel cell or electrolyzer according to the preceding claim 13, wherein each of the outer metallic plate components (1, 10) are configured to closely surround the structural polymer plate components (2) and inserts into the cells contacting with their side of the catalyst and gas diffuser layer compound coating of the PEM fuel cell component (5), in each cell;or wherein each of the outer metallic plate components (1, 10) are configured to closely contact the surfaces of the structural polymer plate components (2) and inserts into the cells contacting with their side of the catalyst and gas diffuser layer compound coating of the PEM fuel cell component (5), in each cell.

17. A multicell panel fuel cell or electrolyzer according to any one of the preceding claims 15-16, comprising zones of the metallic plate components (1, 10), that are inserted inside each cell contacting the catalyst and gas diffuser layer compound, having a machined gas diffusion open channel pattern configured to conduct flow of fluids of hydrogen and oxygen gases and water, configured to wet uniformly each side of the catalyst and gas diffuser layer compound of the PEM component (5).

18. A multicell panel fuel cell or electrolyzer according to any one of the preceding claims, wherein the metallic plate components (1, 10) comprise at least one sub-surface channel for thermal management, the at least one sub-surface channel being made by a friction-based joining technique19. A multicell panel fuel cell or electrolyzer according to the claim 18, wherein the at least one sub-surface channel is being made by friction stir channeling, FSC.

20. A multicell panel fuel cell or electrolyzer according to any one of the preceding claims, wherein the outer metallic plate components (1, 10) operate as bipolar elements providing an electric conductive media for communication between the multiple fuel cells.

21. A multicell panel fuel cell or electrolyzer according to any one of the preceding claims, wherein the outer metallic plate components (1, 10) have inlets, outlets and channel features for receiving and conducting the gases and liquids between the multiple cells, and between the outside and inside of the multicell panel fuel cell or electrolyzer.

22. Method for a multicell panel fuel cell or electrolyzer, comprising- providing outer metallic plate components (1, 10) and structural polymer plate components (2a),- installing proton exchange membrane, PEM, fuel cell components (5) to the structural polymer plate components (2a) with a rib of structural polymer plate component (2b)for forming a structural polymer plate components (2) with integrated PEM fuel cell components, andjoining the outer metallic plate components (1, 10) to at least one common structural polymer plate component with integrated PEM fuel cell components (2) by a friction-based joining technique.

23. Method according to the claim 22, wherein the outer metallic plate components (1, 10) comprise sub-surface channels for thermal management.

24. Method according to any one of the preceding claims 23, wherein the sub-surface channels are made by friction stir channeling, FSC.

25. Method according to any one of the preceding claims 22-24, comprising joining the outer metallic plate components (1, 10), to the structural polymer plate components (2) by a through slot extrusion joining, TSEJ, technique.

26. Method according to any one of the preceding claims 22-25, comprising joining the structural polymer plate components (2a) to the PEM fuel cell components (5) by static-shoulder friction stir welding, SSFSW.

27. Method according to any one of the preceding claims 22-26, wherein each PEM fuel cell component (5) is made of a synthetic polymer membrane, with ionic properties, and with both sides partially coated by a catalyst and gas diffuser layer compound.

28. Method according to any one of the preceding claims 22-27, wherein each of the outer metallic plate components (1, 10) are configured to closely surround the structural polymer plate components (2) and inserts into the cells contacting with their side of the catalyst and gas diffuser layer compound coating of the PEM fuel cell component (5), in each cell.

29. Method according to any one of the preceding claims 22-28, comprising zones of the metallic plate components (1, 10), that are inserted inside each cell contacting the catalyst and gas diffuser layer compound, having a machined gas diffusion open channel pattern configured to conduct flow of fluids of hydrogen and oxygen gases and water, configured to wet uniformly each side of the catalyst and gas diffuser layer compound of the PEM component (5).

30. Method according to any one of the preceding claims 22-29, wherein the outer metallic plate components (1, 10) are operated as bipolar elements providing an electric conductive media for communication between the multiple fuel cells.

31. A wing of an airplane comprising an integrated multicell panel fuel cell or electrolyzer according to any one of the claims 1 -21.

32. A floor of a train or a truck comprising an integrated multicell panel fuel cell or electrolyzer according to any one of the claims 1-21.

33. A wall of a civil construction comprising an integrated multicell panel fuel cell or electrolyzer according to any one of the claims 1 -21.

34. Use of an integrated multicell panel fuel cell or electrolyzer according to any one of the claims 1 -21 in a wing of an airplane.

35. Use of an integrated multicell panel fuel cell or electrolyzer according to any one of the claims 1 -21 in a floor of a train or a truck.

36. Use of an integrated multicell panel fuel cell or electrolyzer according to any one of the claims 1-21 in a wall of a civil construction.

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