Flat Fuel Cell Assembly Conductive Net Bonding
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Solution Overview
Problem
Conventional fuel cell connecting structures face issues with non-uniform force distribution, increased resistance, and reduced assembling density, particularly in portable devices, due to the use of screws and metal nets that do not closely contact the anode and cathode, leading to reduced output voltage and inefficient fuel cell stacks.
Innovation Solution
The use of conductive nets coated with precious metals and bonded to the anode and cathode of a membrane electrode assembly using a b-stage thermosetting adhesive, which increases conductivity and simplifies the assembly process, allowing for a more compact and efficient fuel cell stack configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If screws are used to assemble the fuel cell components, then the components are mechanically connected, but the force distribution becomes non-uniform and resistance increases
Solution Approach 1:
The patent replaces the mechanical screw connection system with a chemical bonding system using conductive adhesive. The adhesive is applied between the bipolar plate and the gas diffusion layer, creating a uniform chemical bond that eliminates the non-uniform force distribution and contact resistance issues associated with mechanical screw connections.
Solution Approach 2:
The patent uses composite conductive adhesive material that combines bonding functionality with electrical conductivity. This composite material serves dual purposes: providing mechanical attachment like screws while simultaneously ensuring uniform electrical contact and low resistance, thereby resolving the contradiction between mechanical connection strength and electrical conductivity.
2Strength
If screws are used for assembly, then components are securely connected, but the assembling density is reduced by 30-50%
Solution Approach 1:
The patent extracts and removes the screw components from the fuel cell assembly, eliminating the need for additional fastening holes and mechanical connection structures. This extraction of the mechanical fastening system directly increases the assembling density by removing the space-consuming elements while maintaining connection strength through adhesive bonding.
3Reliability
If metal nets are used to connect anode and cathode, then electrical connection is established, but the contact is not close and resistance increases
Solution Approach 1:
The patent replaces the mechanical metal net structure with a chemical adhesive bonding system. The adhesive fills and eliminates air gaps between the bipolar plate and gas diffusion layer, creating intimate molecular-level contact that ensures uniform electrical connection throughout the entire interface area, thereby achieving both reliable electrical connection and manufacturing precision.
4Power
If conventional stacked fuel cell assembly is used, then fuel cells are connected in series, but the structure is not suited for portable devices
Solution Approach 1:
The patent transitions from the conventional vertical stacked configuration to a horizontal planar arrangement. By changing the spatial dimension from vertical stacking to horizontal layering, the fuel cell assembly becomes suitable for portable devices while maintaining the series connection capability for achieving required output voltage.
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
This solution enhances the conductivity and stability of the fuel cell assembly, increases the effective reaction area, and reduces the cost of fabrication by providing a reliable and efficient method for connecting fuel cells in series, addressing the limitations of existing technologies in terms of power density and assembly complexity.
Implementation Method 1
bonded to the anode and cathode of a membrane electrode assembly using a b-stage thermosetting adhesive
Implementation Method 2
heat pressing, which not only improves conductivity between the metal nets and carbon layers
Implementation Method 3
conductive nets attached thereto to transfer electrons
Implementation Method 4
conductive nets coated with precious metals
Data Source
AI summary
A connecting structure of a flat fuel cell assembly. The assembly includes a plurality of fuel cells, each of which has a membrane electrode assembly with an anode, a proton exchange membrane and a cathode combined. Two conductive nets are attached to the surfaces of the anode and the cathode of each membrane electrode assembly by thermosetting adhesive and heat pressing to collect and transmit electrons.