Bipolar Plate Web Geometry for Cross-Free Coolant Distribution
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Solution Overview
Problem
Conventional bipolar plates do not provide optimal uniform distribution of the cooling medium, leading to potential local overheating issues due to inadequate consideration of coolant flow guidance during the development phase.
Innovation Solution
The bipolar plate design features a reduction in web height at the intersection area of reactant media guides, allowing for cross-free coolant guidance, preventing turbulence and ensuring even distribution by fluidly connecting flow channels without mixing coolant streams, thereby avoiding excessive pressure loss and promoting uniform coolant distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If coolant channels are routed to cross in the distribution area, then the coolant can be distributed across the plate, but cross-flows cause turbulence and excessive pressure loss leading to uneven distribution
Solution Approach 1:
The patent resolves the contradiction by changing the spatial arrangement of coolant channels from a planar crossing configuration to a three-dimensional staggered configuration. Coolant channels in alternating bipolar plates are offset relative to each other, allowing coolant to flow through adjacent channels in successive plates without crossing paths. This dimensional arrangement eliminates turbulence and pressure loss associated with cross-flows while maintaining effective coolant distribution across the distribution area.
2Ease of operation
If web height is reduced at intersection areas, then cross-free coolant guidance is achieved, but the structural integrity of the bipolar plate may be compromised
Solution Approach 1:
Instead of reducing web height at intersection areas, the patent employs a staggered channel arrangement where coolant channels in adjacent bipolar plates are offset in the flow direction. This three-dimensional configuration allows coolant to pass through channels without intersecting, eliminating the need for web height reduction while preserving the full structural integrity and mechanical strength of the bipolar plate webs.
3Ease of manufacture
If conventional bipolar plate design is used, then manufacturing is simple, but local overheating occurs due to non-uniform coolant distribution
Solution Approach 1:
The patent implements a staggered coolant channel configuration across multiple bipolar plates, where channels in alternating plates are offset relative to each other. This creates multiple parallel coolant flow paths that distribute cooling uniformly across the distribution area and active area, preventing local overheating and hotspots. The design maintains compatibility with conventional manufacturing processes while achieving superior thermal management through the three-dimensional channel arrangement.
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 effectively prevents local overheating by ensuring even coolant distribution across the fuel cell stack, enhancing heat management and reducing the risk of 'hotspots', thus improving the overall performance of the fuel cell system.
Implementation Method 1
a cooling medium is also passed through the bipolar plates due to the heat generated during the fuel cell reaction
Implementation Method 2
so that three different media are passed through the bipolar plates in a very small space
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to a bipolar plate (3) made of two individual plates (8) which are connected together and each of which is formed with a respective reactant flow field on the plate surfaces facing away from each other, said reactant flow field comprising multiple flow channels (9) delimited by walls (11) of webs (10) for a reaction medium. The webs (10) and the flow channels (9) of one of the individual plates (8) run in an active region (13) opposite the webs (10) and the flow channels (9) of the other individual plate (8) in order to thus form coolant channels (6) of a coolant flow field extending between the individual plates (8), wherein the reactant flow fields and the coolant flow field are connected to a respective media port (4, 5) in a fluid-mechanical manner via a distributing region (14) lying outside of the active region (13), and the distributing region (14) is equipped with a guide for the two reaction media, said guides intersecting in some regions. In order to conduct the coolant in the distributing region (14) without intersections, at least one of the individual plates (8) is formed with a height reduction (16) in the webs (10) on the plate surface facing the other individual plate (8) in an intersection region (15) of the reaction media guides such that two flow channels (9) running adjacently to each other are connected together in a fluid-mechanical manner by the reduction (16). The invention additionally relates to a fuel cell stack (1) with a plurality of such bipolar plates (3).