3D Separator Plate Structure for Uniform Electrochemical Cell Flow
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Solution Overview
Problem
Existing electrochemical cell units, particularly solid oxide fuel cell (SOFC) and solid oxide electrolyser cell (SOEC) units, face issues with suboptimal fluid distribution due to conventional separator plates, leading to reduced power density and hydrogen production efficiency.
Innovation Solution
A selectively shaped three-dimensional (3D) separator plate with dimpled protrusions on both sides and a varying mid-plane region is used, allowing for tailored fluid flow rates across the electrochemically active cell region without channels, thereby improving fluid distribution and thermal management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conventional separator plates are used, then the structure is simple and manufacturing is easy, but fluid distribution is suboptimal leading to reduced power density
Solution Approach 1:
The separator plate transitions from a conventional flat two-dimensional structure to a three-dimensional structure with varying mid-plane height. This dimensional change enables the creation of fluid distribution zones that control flow rates across different regions of the electrochemically active cell region, optimizing fluid distribution and thereby improving power density without adding separate distribution systems.
Solution Approach 2:
The separator plate incorporates regions with different mid-plane heights, creating local variations in fluid flow characteristics. By selectively shaping different zones of the separator plate, the invention achieves tailored fluid distribution where specific areas receive optimized flow rates, directly enhancing power density in high-performance regions while maintaining structural integrity.
2Productivity
If conventional separator plates are used, then manufacturing is straightforward, but additional fluid distribution systems are required
Solution Approach 1:
The invention merges the separator plate function with the fluid distribution function into a single integrated component. The three-dimensional separator plate structure performs both separation and fluid distribution tasks simultaneously, eliminating the need for separate fluid distribution systems and thereby improving hydrogen production efficiency while reducing overall system complexity.
Solution Approach 2:
The separator plate is designed to perform multiple functions: it separates cell units, manages fluid distribution, controls flow rates, and provides thermal management. This multi-functional design eliminates the need for additional dedicated components, streamlining the system and enhancing productivity by improving fluid distribution efficiency across the cell unit.
3Temperature
If conventional separator plates are used, then thermal management is insufficient, but adding cooling systems increases complexity
Solution Approach 1:
The separator plate integrates thermal management capabilities directly into its structure. The three-dimensional design with varying mid-plane heights creates channels and zones that facilitate heat dissipation, allowing the separator plate to perform both its primary separation function and thermal cooling function simultaneously, thereby improving temperature control without adding separate cooling systems.
Data Source
AI summary
An electrochemical cell unit and stack includes a separator plate overlying a cell layer. The separator plate has a selectively shaped three-dimensional region that overlies at least part of an electrochemically active cell region. In that three-dimensional region the separator plate has been deformed into a first plurality of outwardly extending dimpled protrusions that define the height of a first fluid volume on a first side of the separator plate, and a second plurality of outwardly extending dimpled protrusions that define the height of a second fluid volume on a second side of the separator plate. A mid-plane region is disposed between the protrusions and the mid-plane region is so shaped as selectively to vary its height in at least one direction across the active cell region such that the interrelated respective heights of the first and second fluid volumes are correspondingly increased and decreased as a result.