Conductive Bipolar Plate Channels for Low Water Accumulation
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Solution Overview
Problem
Current bipolar plates in fuel cells and electrolysers face challenges in efficiently distributing reaction gases and managing pressure loss, with existing channel structures unable to form small contact surfaces that minimize water accumulation and reduce electrical resistance effectively.
Innovation Solution
A distributor structure, specifically a bipolar plate, is designed as an injection-molded part with a channel structure that minimizes contact points with the polymer membrane, using a graphite-plastic material mixture or electrically conductive coating, and incorporates a bearing surface for reliable sealing and reduced electrical resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional stamping methods are used to create channel structures with 1-2 mm dimensions, then manufacturing is simpler, but water accumulation increases and contact surfaces with the membrane are too large
Solution Approach 1:
The patent applies parameter changes by transitioning from traditional stamping to injection molding, enabling the creation of channel structures with dimensions below 0.5 mm (specifically 0.1-0.3 mm). This parameter change in manufacturing method allows for smaller contact surfaces with the membrane, reducing water accumulation while maintaining manufacturing feasibility through injection molding technology.
Solution Approach 2:
The patent utilizes porous or microstructured contact surfaces in the channel structure that interact with the membrane. These microstructured surfaces minimize actual contact area while maintaining structural integrity, allowing water to be efficiently removed through the porous pathways rather than accumulating on large flat contact surfaces.
2Object-affected harmful factors
If channel structure size is reduced to minimize water accumulation, then water management improves, but manufacturing complexity increases
Solution Approach 1:
The patent merges the channel structure with the bipolar plate into a single integrated component manufactured by injection molding. This combining of functions allows complex microstructured channel geometries (with dimensions 0.1-0.3 mm) to be produced in one manufacturing step without requiring separate assembly operations, thus reducing water accumulation while managing manufacturing complexity through process integration.
3Loss of energy
If contact points with polymer membrane are minimized, then pressure loss reduces and water accumulation decreases, but electrical conductivity may be affected
Solution Approach 1:
The patent applies local quality by creating distinct zones within the channel structure: minimal contact points (0.1-0.3 mm dimensions) with the membrane in the flow channels to reduce water accumulation and pressure loss, while maintaining adequate contact in the bipolar plate regions for electrical conductivity. This spatial differentiation of contact characteristics allows simultaneous optimization of fluid flow and electrical properties.
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 enhances power density, reduces pressure loss, and improves overall efficiency by minimizing water accumulation and optimizing flow, while allowing for more design flexibility and improved corrosion resistance.
Implementation Method 1
The bipolar plates distribute reaction gases uniformly over the active area
Implementation Method 2
conduct electrons from the gas diffusion layers into the next cell
Implementation Method 3
Liquid water or water vapor produced as a reaction product, and product gases from the cell, are carried away
Implementation Method 4
heat is dissipated from the catalyst layer into coolant
Data Source
AI summary
The invention relates to a distributor structure (12, 20), particularly a bipolar plate for a stack structure (10) of a fuel cell or of an electrolyser. The distributor structure (12, 20) comprises a channel structure (48) that interacts with at least one polymer membrane (16). The distributor structure (12, 20) is designed as a plastic part (40) that has electrically conductive properties.