Flexible Fuel Cell Stack Enclosure for EMI and Thermal Management

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Solution Overview

Problem

Existing electrochemical fuel cell stack enclosures often fail to provide adequate insulation against electromagnetic interference (EMI) and environmental conditions, require costly and heavy components, and do not effectively compensate for stack expansion and contraction or build tolerances.

Innovation Solution

A fuel cell system incorporating a flexible enclosure in sealing contact with end plates to resist environmental elements and a rigid enclosure to limit EMI and heat transfer, with the flexible enclosure accommodating stack expansion and contraction, and the rigid enclosure constructed from multiple sections that can be crimped together for improved sealing and accessibility.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a steel sleeve with multiple fasteners and seals is used to enclose the fuel cell stack, then structural strength and sealing are improved, but weight and cost increase

Engineering Contradiction:

Improvesealing performanceVSAvoidenclosure weight

Core Design Contradiction:

ReliabilityVSWeight of stationary object

Solution Approach 1:

The patent replaces the traditional rigid steel sleeve enclosure with a flexible membrane enclosure that has selective permeability. The flexible membrane includes a first portion that is substantially impermeable to gases and a second portion that is substantially permeable to water vapor, eliminating the need for heavy steel structures while maintaining sealing performance and enabling water vapor transmission.

Inventive Principle:

Principle #30Flexible shells and thin films

2Reliability

If multiple fasteners and environmental seals are used in the enclosure, then sealing against environmental conditions is improved, but device complexity increases

Engineering Contradiction:

Improveenvironmental sealingVSAvoidenclosure structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines multiple sealing functions into a single integrated flexible membrane structure. The membrane simultaneously provides environmental sealing, EMI shielding, and water vapor permeability through its selective permeability design, eliminating the need for separate fasteners, gaskets, and seals that would increase structural complexity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The flexible membrane is constructed as a composite material structure with regions of different permeability properties. The membrane includes a first portion impermeable to gases and a second portion permeable to water vapor, creating a multi-functional barrier that simplifies the overall enclosure design while maintaining multiple protective functions.

Inventive Principle:

Principle #40Composite materials

3Object-affected harmful factors

If a rigid steel sleeve enclosure is used, then EMI insulation is improved, but adaptability to stack expansion and contraction decreases

Engineering Contradiction:

ImproveEMI insulationVSAvoidaccommodation of stack expansion

Core Design Contradiction:

Object-affected harmful factorsVSAdaptability or versatility

Solution Approach 1:

The patent replaces the rigid steel sleeve with a dynamic flexible membrane enclosure that can expand and contract with the fuel cell stack during operation. The flexible membrane maintains EMI shielding effectiveness while adapting to thermal expansion and operational variations of the stack, eliminating the mismatch problems associated with rigid enclosures.

Inventive Principle:

Principle #15Dynamics

4Reliability

If conventional enclosures with multiple components are used, then sealing is improved, but manufacturing cost increases

Engineering Contradiction:

Improvesealing performanceVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent uses a flexible membrane that can be formed as a single integrated component with varying permeability regions, replacing the need for multiple separate sealing components, gaskets, and fasteners. This reduces material costs, assembly complexity, and manufacturing steps while maintaining effective sealing performance.

Inventive Principle:

Principle #30Flexible shells and thin films

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 provides effective insulation against EMI and environmental conditions, reduces material costs, and accommodates stack expansion and contraction, while allowing for easy disassembly and cleaning of the fuel cell system.

Implementation Method 1

The membrane includes a first portion that is substantially impermeable to gases and a second portion that is substantially permeable to water vapor

Methodology Applied

Scientific EffectSelective permeability: Semipermeable Membrane

Implementation Method 2

provides effective insulation against EMI

Methodology Applied

Scientific EffectElectromagnetic shielding: Faraday Cage

Implementation Method 3

limit EMI and heat transfer

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentUS9577284B2Fuel cell stack enclosure

Publication Date: 2017.02.21 GM GLOBAL TECHNOLOGY OPERATIONS LLC

AI summary

A fuel cell device including a fuel cell stack with a flexible enclosure.