Bipolar Plate With Resilient Conduction Member for Shorter Current Paths

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Solution Overview

Problem

Alkaline fuel cell stacks with monopolar designs have long electron current paths and limited surface area for edge electrical connections, which hinder efficient energy transfer and increase material usage.

Innovation Solution

The electrochemical cell employs a bipolar design with resilient electrical conduction members, comprising flow plates, bipolar plates, and electrodes, where the conduction members reduce electron travel distance and enhance connection surface area, utilizing a compressible metal mesh for efficient current and fluid flow.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If a monopolar cell design is used, then the structure is simpler, but the electron current path becomes very long (up to half a metre)

Engineering Contradiction:

Improvecell structure complexityVSAvoidelectron current path length

Core Design Contradiction:

Device complexityVSLength of moving object

Solution Approach 1:

The patent inverts the conventional monopolar design by implementing a bipolar cell configuration where adjacent cells are oriented with the same polarity, allowing electrons to flow directly between adjacent cells through bipolar plates rather than traveling through the entire stack length. This inversion of the current path topology reduces the electron travel distance from half a metre to a minimal distance between adjacent cell surfaces.

Inventive Principle:

Principle #13The other way round (Inversion)

2Device complexity

If a monopolar design is used, then fewer components are needed, but the surface area for edge electrical connections is limited

Engineering Contradiction:

Improvenumber of componentsVSAvoidsurface area for electrical connections

Core Design Contradiction:

Device complexityVSArea of stationary object

Solution Approach 1:

The patent transitions from edge-based electrical connections in monopolar designs to face-based connections in bipolar designs. By utilizing the entire surface area of the bipolar plates as electrical connection interfaces rather than limited edge contacts, the connection surface area is dramatically increased, enabling more efficient current distribution and reduced contact resistance.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Reliability

If resilient electrical conduction members are compressed between bipolar plate and electrode, then electrical contact is improved, but mechanical stress is applied to components

Engineering Contradiction:

Improveelectrical contact reliabilityVSAvoidmechanical stress on components

Core Design Contradiction:

ReliabilityVSStress or pressure

Solution Approach 1:

The patent employs resilient electrical conduction members with flexible, compressible structures that can deform under compression to maintain reliable electrical contact between the bipolar plate and electrode. These flexible conduction members accommodate mechanical stress through elastic deformation, ensuring continuous electrical connection while distributing the applied pressure to prevent damage to rigid components.

Inventive Principle:

Principle #30Flexible shells and thin films

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

This design significantly reduces electron travel distance between cells and increases electrical connection surface area, improving energy transfer efficiency and reducing material usage while minimizing shunt currents and corrosion.

Implementation Method 1

the resilient electrical conduction member is compressed between the bipolar plate and the electrode, so that the electrical contacts are held against the electrically conductive surface of the bipolar plate and the electrode

Methodology Applied

Scientific EffectElasticity: Elasticity

Implementation Method 2

the resilient electrical conduction member has a first side that is in electrically conductive contact with the bipolar plate and a second side that is in electrically conductive contact with the electrode, such as to allow an electric current to flow between the bipolar plate and the electrode

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Data Source

PatentUS20240088406A1Bipolar plate and resilient conduction member

Publication Date: 2024.03.14 AFC ENERGY

AI summary

An electrochemical cell (3) for use in a fuel cell stack (1) comprising a resilient electrical conduction member sub-assembly (10, 16) having a first flow plate (5, 9), a second flow plate (6, 8) and a bipolar plate (11, 22). A fluid chamber (17, 19) is created by the first flow plate (5, 9), the second flow plate (6, 8), the bipolar plate (11, 22) and an electrode (13, 18) and has an inflow duct (59, 63) and an outflow duct (61, 65). A resilient electrical conduction member (15, 20) is located within the fluid chamber (17, 19) so that in use, a fluid can flow between the inflow duct (59, 61) and the outflow duct (61, 65). The resilient electrical conduction member (15, 20) is in electrically conductive contact with the bipolar plate (11, 22) and with the electrode (13, 18) via a plurality of electrical contacts (51) and the resilient electrical conduction member (15, 20) is compressed between the bipolar plate (11, 22) and the electrode (13, 18).