Embossed Contacting Plate for Fuel Cell Electrical Connectivity
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Solution Overview
Problem
Conventional electrochemical systems experience high ohmic losses and sealing issues due to the use of metallic current leads and polymer end plates with metal cover plates, which lead to unreliable long-term sealing under temperature variations.
Innovation Solution
An electrochemical system design featuring a metallic electrical conductor integrated with a contacting plate and separator plate half, bonded media-tight, which reduces ohmic losses and incorporates a sealing device between the end plate and contacting plate to accommodate thermal expansion, ensuring reliable sealing and improved electrical connectivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a metallic current lead and gas diffusion layer are used to establish electrical connection between the end plate and cover plate, then electrical connectivity is achieved, but high ohmic losses occur
Solution Approach 1:
The patent combines the electrical conductor and contacting plate into a single integrated component. The metallic electrical conductor is directly connected to the contacting plate, eliminating the gas diffusion layer interface and reducing contact resistance. This merging of functions reduces ohmic losses while maintaining reliable electrical connectivity.
Solution Approach 2:
The contacting plate acts as an intermediary component between the end plate and the electrical conductor. It provides a stable, low-resistance electrical connection path while mechanically connecting the polymer end plate to the metal stack cover plate, thereby reducing overall ohmic losses in the electrical connection path.
2Adaptability or versatility
If polymer end plates and metal cover plates are used together, then structural requirements are met, but sealing reliability deteriorates under temperature variations
Solution Approach 1:
The patent explicitly addresses thermal expansion differences between polymer and metal materials. The sealing device is designed to accommodate the different thermal expansion coefficients of the polymer end plate and metal contacting plate/stack cover plate assembly, maintaining sealing reliability across temperature variations through controlled deformation or compliance mechanisms.
Solution Approach 2:
The system uses composite material construction with polymer end plates and metal contacting plates/stack cover plates. Each material is selected for its specific properties (polymer for electrical insulation and structural support, metal for electrical conductivity and mechanical strength), and the sealing device bridges these different material properties to achieve reliable sealing.
3Reliability
If conventional sealing devices are used between polymer end plates and metal cover plates, then initial sealing is achieved, but sealing longevity deteriorates under thermal cycling
Solution Approach 1:
The sealing device incorporates dynamic characteristics that allow it to adapt to thermal cycling. It can deform, expand, or contract in response to temperature changes, maintaining continuous sealing contact between the polymer end plate and metal components throughout the operational temperature range, thereby extending sealing longevity.
Solution Approach 2:
The sealing device is pre-designed with compliance features that anticipate thermal expansion and contraction. It includes built-in flexibility or cushioning mechanisms that absorb thermal stresses before they can damage the seal, preventing premature failure and extending the service life of the sealing system under thermal cycling conditions.
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 solution significantly reduces ohmic losses and enhances the sealing device's longevity by allowing the metallic electrical conductor to be in one piece or directly in contact with the contacting plate, and by using a sealing device that can accommodate thermal expansion, thus improving the overall efficiency and reliability of the electrochemical system.
Implementation Method 1
ohmic losses that occur along the electrical connection between the contacting plate and the outside of the system and are caused, for example, by contact voltages and/or fritting voltages, are significantly reduced
Implementation Method 2
significantly different expansions and contractions occur during the heating and cooling of the electrochemical system
Data Source
AI summary
An electrochemical system is described having an end plate, a stack cover plate adjacent to the end plate and at least one metallic electrical conductor. The stack cover plate has an electrically conductive contacting plate adjacent to the end plate and an electrically conductive separator plate half facing away from the end plate. The contacting plate and the separator plate half are connected to each other electrically and media-tight. The metallic electrical conductor extends to an outside of the electrochemical system. The metallic electrical conductor and the contacting plate are in one piece or the metallic electrical conductor contacts the contacting plate directly. The contacting plate and the separator plate half are bonded to each other.