Bipolar Sheet with Polymeric Frame for Membrane Electrochemical Generator
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Solution Overview
Problem
Existing membrane electrochemical generators face issues with weight and complexity due to the use of metal bipolar sheets, leading to increased costs, fragility, leakage risks, difficult assembly, lack of electrical insulation, and thermal power dispersion.
Innovation Solution
The design incorporates metal bipolar sheets with a central metallic body integrated into a polymeric frame, which serves as a sealing gasket and distributes reactants and coolant, reducing the number of components and seals, and enhancing electrical insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal bipolar sheets are used in membrane electrochemical generators, then electrical conductivity and structural strength are improved, but weight and device complexity increase significantly
Solution Approach 1:
The bipolar sheet is divided into two distinct parts: a metallic body for electrical conductivity and strength, and a polymeric frame for sealing and distribution functions. This segmentation allows each component to be optimized for its specific function while reducing overall weight compared to traditional solid metal bipolar sheets.
Solution Approach 2:
The bipolar sheet combines metal and polymeric materials into a single integrated component. The metallic body provides electrical conductivity and mechanical strength, while the polymeric frame provides sealing and distribution functions, creating a composite structure that optimizes both performance and weight characteristics.
2Adaptability or versatility
If multiple separate components (bipolar sheets, sealing gaskets, distributors) are used, then functional requirements are met, but assembly complexity and leakage risks increase
Solution Approach 1:
The sealing gasket and current distributor functions are merged into the polymeric frame of the bipolar sheet. This integration reduces the number of separate components and assembly steps while maintaining all necessary functions, thereby reducing assembly complexity and potential leakage points.
Solution Approach 2:
The polymeric frame performs multiple functions simultaneously: it provides sealing to prevent gas leakage, distributes reactants through integrated channels, and supports the metallic body. This multi-functionality eliminates the need for separate components for each function.
3Power
If traditional metal bipolar sheets are used, then electrical conductivity is maintained, but electrical insulation to the external environment is lacking
Solution Approach 1:
The composite structure uses the polymeric frame as an electrical insulator that surrounds and isolates the conductive metallic body from the external environment, particularly from the coolant. This provides necessary electrical insulation while maintaining the conductivity needed for electrochemical reactions within the cell.
4Temperature
If metal components are used in contact with coolant within longitudinal manifolds, then thermal management is achieved, but shunt currents and corrosion risks increase
Solution Approach 1:
The polymeric frame acts as an intermediary between the metallic body and the coolant. It allows thermal management by conducting heat away from the reaction cell while preventing direct contact between the metal and coolant, thereby eliminating shunt currents and corrosion risks.
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 achieves a 30% weight reduction, simplifies assembly, reduces leakage risks, improves component alignment, and minimizes thermal power dispersion while maintaining electrical insulation.
Implementation Method 1
An ion-exchange membrane separating the anode from the cathode compartment allows the continuous flow of H+ ions from the anode to the cathode compartment while hindering the passage of electrons
Implementation Method 2
a frame (111) made of polymeric material... The frame (111) is also provided with a multiplicity of holes (150) for housing tie-rods... presenting first and second openings (111a1, 111a2) for the passage of the gaseous reactants... first and second openings (111b1, 111b2) for the discharge of the reaction products
Implementation Method 3
The bipolar sheets (102) are formed by a central metallic body (110), with dimensions slightly exceeding those of the active area of the reaction cells (101), integrated in a frame (111) made of polymeric material... achieving a 30% weight reduction
Implementation Method 4
The frame (111) presents first and second openings (111a1, 111a2) for the passage of the gaseous reactants, respectively fuel and oxidant, first and second openings (111b1, 111b2) for the discharge of the reaction products optionally mixed with exhausts
Implementation Method 5
The electrochemical generator (1) of the prior art may also comprise a multiplicity of cooling cells (20) interposed between the reaction cells (2). The cooling cells (20), deputed to coolant flowing, contain a conductive element equivalent to the above disclosed collectors (7) and directed in this case to establish the electric continuity between two adjacent bipolar sheets while increasing the thermal exchange coefficient
Data Source
AI summary
The present invention relates to a membrane electrochemical generator (100) characterised by improved electrical insulation and reduced volume. The membrane electrochemical generator (100) is fed with gaseous reactants and comprises a multiplicity of reaction cells (101) assembled in a filter-press configuration. Each of said reaction cells (101) is delimited by a pair of bipolar sheets (102), formed by a metallic central body (110) integrated in a frame (111) made of polymeric material. The polymeric material may be of the thermoplastic or thermosetting type and the frame (111) is laid on the metallic central body (110) by moulding.