Contoured Fuel Cell End Plate for Compression Force Distribution
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Solution Overview
Problem
Traditional fuel cell stacks face challenges in evenly distributing compression forces across different areas, leading to uneven loads and potential damage due to changing conditions like temperature and pressure, and existing solutions are costly and complex.
Innovation Solution
The design of a contoured end plate unit with multiple planar regions and a current collector that can be affixed to specific areas, allowing for tailored compression force distribution by varying the height difference between regions to match specific requirements of the fuel cell stack.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a traditional flat end plate is used to compress the fuel cell stack, then the structure is simple and manufacturing is easy, but the compression force is unevenly distributed across different areas leading to potential damage
Solution Approach 1:
The end plate is divided into multiple planar regions (first planar region, second planar region, third planar region) with different heights, where each region applies a different compression force to different areas of the fuel cell stack. The first planar region applies higher compression force to the active area while the second and third regions apply lower compression force to the seal areas, thereby achieving localized quality control of compression force distribution.
2Reliability
If the compression force is increased to ensure electrical contact, then the electrical contact is improved, but the electrolyte, electrodes, or electrical interconnect may be damaged
Solution Approach 1:
The end plate design applies higher compression force only to the active area (first planar region) where electrical contact is needed, while applying lower compression force to the seal areas (second and third planar regions). This localized differentiation ensures adequate electrical contact without excessively compressing and damaging the electrolyte, electrodes, or electrical interconnect.
3Reliability
If a contoured end plate design with multiple planar regions is used to distribute compression force evenly, then the compression force distribution is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The end plate is segmented into multiple planar regions (first planar region, second planar region, third planar region) with different heights, where each segment serves a specific function in the compression force distribution. This segmentation allows the complex function of differential compression to be achieved through a relatively simple structural division that can be manufactured using conventional techniques.
4Reliability
If the compression force is increased to ensure seal contact, then the seal integrity is improved, but the gas flow over the fuel cell may be impeded
Solution Approach 1:
The end plate design applies lower compression force to the seal areas (second and third planar regions) compared to the active area, thereby maintaining adequate seal integrity without excessively compressing the fuel cell components. This localized differentiation ensures that the seal remains intact while preserving sufficient gas flow channels over the fuel cell.
Data Source
AI summary
An end plate unit for use in a fuel cell stack in an electric vehicle is provided wherein the end plate includes an outer surface, an inner surface disposed opposite the outer surface and a current collector. The inner surface defines at least a first region and a second region which is spaced apart from and substantially parallel to the first region. The current collector may be affixed to the inner surface.