Anode Support Member and Bipolar Separator for Fuel Cell Assembly
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Solution Overview
Problem
Conventional anode support members in molten carbonate fuel cells fail to provide sufficient mechanical support for the anode electrode, leading to waviness and insufficient electrical contact, while also being unable to effectively prevent electrolyte creepage to the reforming catalyst, resulting in catalyst poisoning and reduced fuel cell efficiency.
Innovation Solution
A bipolar separator plate with a non-wettable electrolyte barrier, such as a weld bead or coating of Ni or Cu, applied to limited portions of the outer surface, combined with an anode support member that includes a high porosity reticulated foam and a wire mesh, providing mechanical support and reducing electrolyte creepage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a conventional anode support member (perforated plate, wire mesh, or porous sintered powder) is used, then the structure provides some mechanical support, but it fails to provide sufficient mechanical support leading to anode electrode waviness and insufficient electrical contact
Solution Approach 1:
The anode support member is constructed as a composite structure combining a rigid perforated plate substrate with a porous sintered powder coating layer. The perforated plate provides fundamental mechanical strength and structural stability, while the porous sintered powder layer (made from nickel, copper, or their alloys) provides enhanced surface area, electrical conductivity, and mechanical compliance. This composite architecture resolves the contradiction by integrating both structural support and electrical contact functions in a single component, preventing anode waviness while ensuring reliable electrical contact.
2Device complexity
If conventional anode support members are used, then the structure is simple, but it is unable to effectively prevent electrolyte creepage to the reforming catalyst, resulting in catalyst poisoning
Solution Approach 1:
The anode support member incorporates a porous sintered powder coating layer with controlled porosity and pore size distribution. This porous structure creates a tortuous path that physically impedes electrolyte creepage toward the reforming catalyst while still allowing fuel gas permeation and maintaining electrical conductivity. The porous layer acts as a diffusion barrier that reduces electrolyte access to the catalyst, preventing catalyst poisoning without requiring complex additional barrier structures.
3Object-affected harmful factors
If the anode support member uses non-wettable materials (nickel, copper), then electrolyte creepage is reduced, but manufacturing cost increases due to material selection and coating processes
Solution Approach 1:
The invention utilizes nickel or copper materials and their alloys, which inherently possess non-wettable properties toward molten carbonate electrolyte. By selecting base metals with natural hydrophobic characteristics and controlling the sintering parameters (temperature, time, atmosphere) to achieve optimal pore structure and surface properties, the design achieves effective electrolyte creepage prevention using cost-effective materials. The sintering process parameters are optimized to create the right balance between porosity, density, and surface energy to maximize creepage resistance while minimizing material and processing costs.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enhances mechanical support for the anode electrode, improves electrical contact, and significantly reduces electrolyte creepage to the reforming catalyst, thereby prolonging catalyst life and maintaining fuel cell efficiency while reducing manufacturing costs.
Implementation Method 1
a bipolar separator plate with a protective coating on the plate or on portions of the plate forming wet seal regions. Such protective coating is typically formed from Al or Al/Fe... Non-wettable materials used to form such anode support members typically include nickel, copper or other materials which are stable in the fuel-reducing atmosphere
Implementation Method 2
an anode support member that includes a high porosity reticulated foam and a wire mesh
Implementation Method 3
a steam reforming catalyst is placed within the fuel cell stack to allow direct use of hydrocarbon fuels such as methane, coal gas, etc.
Data Source
Figure 1~2
Figure 3A~4
Figure 5
AI summary
An anode support for supporting an anode electrode in a fuel cell assembly in which the anode support has a first support member formed of a porous non-wettable material and a second support member abutting and joined with the second member and having a plurality of through openings. Also disclosed is a bipolar separator having an electrolyte barrier over predetermined limited portions of its outer surface so as to prevent or retard electrolyte creeping.