Folded-Edge Bipolar Plate for Stable Flow Channels and Seals
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Solution Overview
Problem
In electrochemical cells, the relaxation of embossed channel structures over time leads to reduced flow cross-sections, increased pressure requirements, and impaired performance, particularly under high pressures and in systems with soft materials.
Innovation Solution
A metallic component with folded edges, where at least one free edge of the metallic layer is folded over onto itself to form fold layers, acting as deformation limiters for channels and sealing structures, thereby maintaining the dimensional stability of embossed flow channels and sealing elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If embossed channel structures are used in separator plates, then flow regions are created for media supply and discharge, but the channels relax over time under compression, reducing flow cross-sections and impairing cell performance
Solution Approach 1:
Deformation limiters are pre-installed in the separator plate at locations where channel relaxation would occur under compression. These limiters prevent the embossed channels from relaxing by providing mechanical support before compression sets in, thereby maintaining stable flow cross-sections throughout the operational life of the electrochemical cell
Solution Approach 2:
The deformation limiters act as intermediary elements between the embossed channel structures and the compressive forces applied during cell stack assembly. They absorb and distribute the compression forces, preventing direct transmission to the channel walls that would cause relaxation and maintain channel geometry stability
2Reliability
If sealing structures are embossed into the separator plate to seal flow regions, then sealing is achieved, but the embossed sealing structures relax under high compression forces, reducing sealing effectiveness
Solution Approach 1:
Deformation limiters are positioned adjacent to embossed sealing structures before compression occurs. These limiters provide pre-support that prevents the sealing structures from relaxing under high compression forces, ensuring that sealing effectiveness is maintained throughout the operational life of the cell
Solution Approach 2:
The deformation limiters serve as intermediary elements that absorb and distribute compression forces away from the embossed sealing structures. This prevents direct force transmission to the sealing beads, maintaining their dimensional stability and sealing effectiveness under high compression conditions
3Stability of the object's composition
If the thickness of the metallic separator layer is increased to provide more structural support, then channel and sealing structure stability improves, but the space available for flow channels and reactant supply is reduced
Solution Approach 1:
The separator plate is functionally segmented into different thickness zones: thinner regions in the flow channel areas to maximize flow cross-sections and reactant supply volume, and thicker regions at the edges and near sealing structures to provide structural support and prevent relaxation. This segmentation allows optimization of both flow capacity and structural stability without compromise
Data Source
AI summary
The present disclosure relates to a component of an electrochemical cell, in particular a separator plate or a cell frame of an electrochemical cell. Furthermore, the present disclosure also relates to a bipolar plate, an electrochemical cell and an electrochemical system such as a fuel cell, an electrolyzer or a redox flow battery. The component comprises a first metallic layer. Adjacent to at least one free edge of the first metallic layer, the first metallic layer is at least in sections folded over on itself one or more times thereby forming one or more folded layers, thereby increasing the thickness of the component by one or more than one layer thickness of the first metallic layer.