Corrugated PEM Fuel Cell Structure for Higher Power Density
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Solution Overview
Problem
Existing proton exchange membrane fuel cells (PEMFCs) face limitations in power density due to their traditional plate-and-frame structure, which restricts reaction area utilization and complicates water and gas management, leading to high production costs and limited power density improvements.
Innovation Solution
A corrugated fuel cell design with inclined anode and cathode channels and ribs, integrated with a corrugated membrane electrode assembly, allowing for increased reaction area and improved water and gas distribution, while maintaining manufacturing ease and reducing contact resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a traditional plate-and-frame structure is adopted, then manufacturing convenience and assembly simplicity are improved, but power density and reaction area utilization are limited
Solution Approach 1:
The patent applies corrugated (wavy) structures to the bipolar plates instead of traditional flat plates. This curvature increases the reaction area of the membrane electrode assembly within the same volume, thereby improving power density while maintaining manufacturability through standard forming processes
Solution Approach 2:
The invention transitions from a two-dimensional flat plate structure to a three-dimensional corrugated structure by adding vertical undulations to the bipolar plates. This dimensional change increases the effective reaction area without significantly increasing the footprint or complicating assembly
2Area of stationary object
If a tubular fuel cell design is adopted, then reaction area is increased, but liquid coolant circulation and manufacturing cost are compromised
Solution Approach 1:
The patent uses corrugated bipolar plates with wave-like structures to increase reaction area, avoiding the complex tubular geometry while achieving similar area expansion benefits. This approach maintains compatibility with standard planar manufacturing processes
Solution Approach 2:
The corrugated bipolar plate structure simultaneously serves multiple functions: increasing reaction area, providing mechanical support, and enabling coolant flow channels within the same component, eliminating the need for separate tubular structures
3Strength
If an arc-shaped fuel cell design is adopted, then mechanical properties are improved, but power density increase is limited
Solution Approach 1:
The patent employs corrugated structures with optimized wave parameters (amplitude, wavelength, frequency) that simultaneously enhance mechanical strength through geometric reinforcement and maximize reaction area to improve power density
4Productivity
If a corrugated structure is adopted, then power density is improved, but manufacturing complexity increases
Solution Approach 1:
The patent uses regular, periodic corrugated patterns that can be manufactured using standard forming processes, avoiding irregular complex geometries while achieving significant power density improvements through increased reaction area
Data Source
AI summary
The invention relates to a single corrugated fuel cell and a cell stack. The single cell comprises an anode plate, a cathode plate, and a membrane electrode assembly; the anode plate is of a corrugated structure and a plurality of anode channels and anode ribs are arranged on the anode plate in parallel; the cathode plate is of a corrugated structure engaged with the anode plate and a plurality of cathode channels and cathode ribs are arranged on the cathode plate in parallel; the membrane electrode assembly is arranged between the anode plate and the cathode plate. The single cell presents a corrugated structure in a width direction of the channel. A plurality of single cells are stacked in sequence to form a fuel cell stack. Compared with the prior art, the invention significantly increases the reaction area per unit volume of the fuel cell through the corrugated structural design, thereby improving the power density of the fuel cell. In addition, the present invention has little change to the existing processing and manufacturing technology, and thus has high production feasibility.