Bipolar Separator with Corrugated Element for Fuel Cell Stacks

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Solution Overview

Problem

The complexity and cost of assembling polymer membrane fuel cell stacks due to the need for multiple components and hydraulic seals, along with the challenge of maintaining hydration and thermal control, hinder the industrial adoption of this technology.

Innovation Solution

A bipolar separator with conductive sheets and a corrugated element for integrated thermal regulation, reactant distribution, and humidification, reducing the number of components and hydraulic seals by combining these functions into a single structure.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If multiple components (bipolar plates, gaskets, current collectors, membranes) are used to achieve adequate thermal control and hydration, then the fuel cell functions properly, but the assembly complexity and cost increase significantly

Engineering Contradiction:

Improvethermal control and hydration maintenanceVSAvoidnumber of components and assembly steps

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The bipolar separator integrates multiple previously separate components into a single structure. The conductive sheets provide both electrical conductivity and structural support, while the corrugated element combines thermal regulation channels with reactant distribution pathways. This merging eliminates the need for separate gaskets, current collectors, and dedicated cooling plates, thereby reducing assembly complexity while maintaining thermal control and hydration functions.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The bipolar separator performs multiple functions simultaneously: it provides electrical conductivity through conductive sheets, thermal regulation through corrugated cooling channels, reactant distribution through integrated flow paths, and structural support for the membrane assembly. This multi-functionality replaces what previously required multiple specialized components, reducing both part count and assembly complexity while maintaining all necessary fuel cell functions.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Temperature

If traditional bipolar plates with embedded cooling channels are used, then thermal control is achieved, but the plates become thick and heavy

Engineering Contradiction:

Improvethermal controlVSAvoidbipolar plate weight

Core Design Contradiction:

TemperatureVSWeight of stationary object

Solution Approach 1:

Instead of using thick plates with uniformly distributed cooling channels, the corrugated element provides cooling channels only in specific locations where thermal management is most needed. The corrugated structure creates localized cooling passages that efficiently remove heat from critical areas without requiring the entire plate to be thick, thereby reducing overall weight while maintaining effective thermal control.

Inventive Principle:

Principle #3Local quality

3Reliability

If separate humidification devices are added to maintain membrane hydration, then the membrane ionic conductivity is sufficient, but the system size and complexity increase

Engineering Contradiction:

Improvemembrane hydration and ionic conductivityVSAvoidsystem size

Core Design Contradiction:

ReliabilityVSVolume of stationary object

Solution Approach 1:

The bipolar separator integrates humidification functionality directly into its structure through the corrugated element design. The corrugated channels serve dual purposes: cooling the cell and distributing humidified reactants to the membrane. This integration eliminates the need for separate external humidification devices, reducing system volume while ensuring adequate membrane hydration for maintaining ionic conductivity.

Inventive Principle:

Principle #5Merging (Combining)

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 simplifies the assembly process, reduces the number of components, and effectively manages hydration and thermal control, leading to a more compact and efficient fuel cell stack.

Implementation Method 1

a bipolar separator delimited by a cathode sheet and an anode sheet... welded or metallurgically bonded through a conductive corrugated element... for integrated thermal regulation

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

at least one of which provided with fluid passage holes... for reactant distribution

Methodology Applied

Scientific EffectFluid flow through passages:

Implementation Method 3

for the humidification of the gaseous reactants... maintaining a high degree of hydration of the membrane during operation

Methodology Applied

Scientific EffectHumidification:

Implementation Method 4

for the withdrawal of the generated heat... integrated thermal regulation

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Data Source

PatentUS7794895B2Bipolar separator for fuel cell stack

Publication Date: 2010.09.14 NUVERA FUEL CELLS LLC

AI summary

It is described a bipolar separator for polymer membrane fuel cell stacks, delimited by two sheets provided with fluid passage holes connected by means of a corrugated element and comprising a passage section for a thermostatting liquid, which allows to achieve the withdrawal of heat from the adjacent cells and the humidification and distribution of gases with a single integrated piece, simplifying the assembly and the hydraulic sealing of the stack.