Coplanar Bipolar Plate Channels for Fuel Cell Cooling
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Solution Overview
Problem
Conventional bipolar plates in fuel cell assemblies face challenges such as increased size and complexity due to the need for additional coolant channels, compromised cooling efficiency, and high manufacturing costs, while also struggling with uniform fluid distribution and pressure drop issues.
Innovation Solution
A bipolar plate design featuring coplanar fluid flow channels formed between corrugated plates, allowing for reduced thickness and optimized coolant, fuel, and oxidant flow, with serpentine and interdigitated channel configurations to ensure uniform flow and efficient cooling, and the use of gaskets for sealing and manifold integration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If dedicated coolant channels are provided within the bipolar plate to improve cooling efficiency, then cooling performance is improved, but device complexity and overall size increase
Solution Approach 1:
The patent merges the coolant channels with the corrugated plate structure by forming channels between the corrugations of mating plates. This integration eliminates the need for separate coolant channel components, reducing device complexity while maintaining effective cooling through the bipolar plate.
Solution Approach 2:
The corrugated plates serve multiple functions: they provide structural support, create fluid flow channels for both coolant and reactants, and enable thermal management. This multi-functionality reduces the number of separate components needed, thereby reducing device complexity while maintaining cooling efficiency.
2Length of stationary object
If coplanar fluid flow channels are provided between corrugated plates, then plate thickness is reduced, but manufacturing precision requirements increase
Solution Approach 1:
The bipolar plate is segmented into multiple corrugated plates that are mated together. Each plate is manufactured separately with standard thickness, and the corrugations provide self-aligning features that facilitate precise positioning. This segmentation allows for easier manufacturing while achieving the reduced overall thickness through the layered construction.
Solution Approach 2:
The corrugated plates feature curved, wave-like structures that provide mechanical interlocking and self-alignment when plates are mated together. This geometric feature naturally guides the plates into proper alignment during assembly, reducing the need for high-precision manufacturing while ensuring accurate channel positioning.
3Manufacturing precision
If serpentine and interdigitated channel configurations are used, then fluid distribution uniformity is improved, but device complexity increases
Solution Approach 1:
The serpentine and interdigitated channel patterns are merged with the corrugated plate structure itself. The channels are formed by the corrugations of mating plates, so the complex flow patterns are achieved through the geometric arrangement of simple, standardized plate components rather than through complex internal channel machining.
Data Source
AI summary
The invention relates to bipolar plates for electrochemical fuel cell assemblies, and in particular to configurations of bipolar plates allowing for multiple fluid flow channels for the passage of anode, cathode and coolant fluids. Embodiments disclosed include a bipolar plate (10) for an electrochemical fuel cell assembly, comprising: a first plurality of fluid flow channels (13) extending across a first face of the bipolar plate between first inlet and outlet ports (18a, 18b) at opposing ends of the bipolar plate; a second plurality of fluid flow channels (22) extending across a second opposing face of the bipolar plate between second inlet and outlet ports (21a, 21b) at opposing ends of the bipolar plate; and a third plurality of fluid flow channels (14) extending between third inlet and outlet ports (19a, 19b) at opposing ends of the bipolar plate, the third plurality of fluid flow channels provided between first and second corrugated plates (11, 12) forming the first and second opposing faces of the bipolar plate, wherein the first, second and third fluid flow channels are coplanar.