Expanded Metal Mesh for Fuel Cell Gas Flow Pressure Loss
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Solution Overview
Problem
The existing fuel cell systems experience increased pressure loss and reduced voltage stability due to the zigzag pattern of gas flow passages formed by expanded metal, leading to higher requirements for air compressors and hydrogen circulation pumps, and difficulties in discharging generated water.
Innovation Solution
Modifying the mesh shape of expanded metal to reduce pressure loss by altering the bond length and strand portion configuration, creating larger sectional areas for gas flow passages, and adjusting the shift direction and amount of trapezoids to optimize gas flow and water discharge.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a zigzag pattern of hexagonal mesh is used to form gas flow passages, then the gas flow passages can be formed by expanded metal, but the pressure loss increases and gas flow rate decreases
Solution Approach 1:
The patent changes the mesh pattern from a regular hexagonal zigzag arrangement to an asymmetric arrangement where the bond length and strand portion are specifically configured. This asymmetric design reduces the number of sharp turns in the gas flow path, thereby reducing pressure loss while maintaining manufacturability through expanded metal
Solution Approach 2:
The patent modifies the geometric parameters of the mesh, specifically the bond length and strand portion dimensions, to optimize gas flow characteristics. By adjusting these parameters, the gas flow passages achieve reduced pressure loss and improved flow rate while still being formable by expanded metal processing
2Productivity
If the mesh shape is modified to reduce pressure loss, then gas flow rate increases, but the structural strength of the expanded metal may be compromised
Solution Approach 1:
The patent optimizes the bond length and strand portion dimensions to achieve a balance between gas flow performance and structural strength. The modified mesh parameters are designed to reduce pressure loss while maintaining sufficient mechanical integrity of the expanded metal structure
Solution Approach 2:
The patent employs expanded metal as a composite structure that combines the mesh pattern with the metal material properties. This allows the gas flow passages to achieve improved flow characteristics while the metal matrix maintains the necessary structural strength
3Volume of moving object
If the gas flow passages have small sectional area, then the cell structure is compact, but generated water cannot be discharged smoothly
Solution Approach 1:
The patent modifies the mesh parameters to create gas flow passages with optimized sectional area that balances cell compactness and water discharge capability. The adjusted bond length and strand portion configuration provide sufficient passage area for smooth water removal while maintaining a compact cell structure
Data Source
AI summary
In a fuel cell having a cell structure in which a gas flow passage is formed by an expanded metal, a bond portion connecting a mesh of the expanded metal stands partially upright in a position where a bond length is shortened so as to form a part of a strand portion. Hence, in an opening formed by the mesh of the expanded metal, a surface area on which front and rear openings overlap in a direction increases when seen from an direction. Thus, a sectional area of gas flow passages constituted by a continuum in the direction of the openings overlapping in the direction increases. As a result, a gas flow flows without making repeated narrow turns, leading to a reduction in gas pressure loss.