Corrugated Bipolar Plate Assembly for PEM Fuel Cell Cooling
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Solution Overview
Problem
Existing methods for manufacturing aluminum bipolar plates for proton exchange membrane fuel cells face challenges such as difficulty in simultaneously stamping complex flow, sealing, and fluid-cooling features, insufficient strength, misalignment, and uneven temperature distribution, leading to suboptimal performance.
Innovation Solution
The introduction of a corrugated insert, such as a lightweight aluminum foil or mesh, between anode and cathode plates to form a cooling flow field, decoupling the formation of anode, cathode, and cooling flow fields, enhancing strength and stability, and optimizing cooling and temperature distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If stamped cooling channels are used in bipolar plates, then cooling efficiency is improved, but manufacturing complexity and difficulty increase significantly
Solution Approach 1:
The bipolar plate is segmented into multiple functional layers: a base plate with simplified cooling channels, a flow field plate with reactant distribution channels, and a gasket layer. This segmentation allows each layer to be manufactured separately with optimized features, then assembled together, resolving the contradiction by distributing manufacturing complexity across multiple simple components rather than one complex stamped plate
Solution Approach 2:
The flow field plate is nested within the assembly between the base plate and MEA, with cooling channels in the base plate and flow fields in the separate plate. This nested structure allows complex functions (cooling + reactant distribution) to be achieved through layered simplicity, where each nested layer contributes one primary function manufactured with standard processes
2Adaptability or versatility
If complex flow field features, sealing features, bonding features and fluid-cooling features are stamped simultaneously on the same plate, then integration is improved, but manufacturing feasibility deteriorates
Solution Approach 1:
Different features are segmented into different plates: cooling channels in the base plate, flow fields in the flow field plate, sealing in the gasket. This segmentation makes each manufacturing step feasible using standard stamping processes, while the final assembly achieves full feature integration
Solution Approach 2:
The base plate serves multiple universal functions: structural support, cooling channel housing, and electrical connection. The flow field plate provides reactant distribution and sealing surfaces. This multi-functionality assignment simplifies manufacturing by giving each component a focused set of features that can be stamped with standard tooling
3Area of stationary object
If plate size is increased to address larger applications, then application scope is improved, but structural strength and feature stability deteriorate
Solution Approach 1:
The large bipolar plate assembly is segmented into a base plate, flow field plate, and gasket layer. This segmentation allows each component to be manufactured at optimal sizes with adequate strength, then assembled into a large-area configuration that maintains structural integrity through the layered construction and bonding features
Solution Approach 2:
The bipolar plate assembly uses composite construction with aluminum base plate, stainless steel flow field plate, and elastomeric gasket. This composite structure combines the lightweight thermal conductivity of aluminum with the strength and corrosion resistance of stainless steel, enabling large-area plates to maintain structural strength while addressing larger applications
4Strength
If braising or welding is used for bonding plates, then bonding strength is improved, but manufacturing precision and alignment deteriorate
Solution Approach 1:
Alignment features such as locating pins, recesses, and protrusions are preliminarily formed in the base plate and flow field plate during manufacturing. These pre-formed alignment features guide the bonding process, ensuring precise alignment is maintained during braising or welding, thus resolving the contradiction by preparing the assembly for strong bonding without sacrificing precision
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
The corrugated insert improves heat transfer, stability, and temperature uniformity, enabling robust, corrosion-resistant bipolar plates suitable for mass production and commercial applications, reducing the need for additional compression springs and optimizing cooling efficiency.
Implementation Method 1
The embodiments of the current application use an insert as a turbulator and stiffening feature to replace stamped cooling channels in a bipolar plate. The insert functions as a cooling flow field... promotes better heat transfer
Implementation Method 2
The insert functions as a cooling flow field and separates the anode and cathode of different cells... optimizing cooling and temperature distribution
Data Source
AI summary
A proton exchange membrane fuel cell bipolar plate (PEM FC BPP) assembly is provided. The PEM FC BPP assembly includes a cathode plate, an anode plate, and an insert. The insert is positioned between the cathode plate, an anode plate; and is comprised of a metal, a composite, a foil, a mesh, or a combination thereof, the insert includes at least one corrugated structure having peaks provided from 1-10 mm apart. The at least one corrugated structure is bonded to the anode and cathode plates at, at least one of its peaks and troughs. The disclosure also includes an electric device which includes the PEM FC BPP with cooling insert and where the electric device includes an electric vertical take-off and landing (eVTOL) aircraft.