Fuel Cell Stack Storage Using CO Purge Against Carbon Corrosion

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Solution Overview

Problem

Fuel cell systems with carbon black particles as support for platinum nanoparticles face durability challenges due to carbon corrosion during extended inactivity or storage, as ambient oxygen can oxidize carbon black, leading to corrosion reactions.

Innovation Solution

A method involving the use of a premixed gas containing carbon monoxide is introduced to protect the carbon support in the fuel cell stack by flowing it through the stack, adsorbing CO onto platinum nanoparticles, thereby preventing oxidation and corrosion, and subsequent purging with ambient air to refresh the system before operation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If the fuel cell stack is stored in ambient air during extended inactivity, then the system remains accessible and easy to store, but carbon black particles undergo oxidation leading to corrosion and reduced durability

Engineering Contradiction:

ImproveStorage accessibilityVSAvoidCarbon support durability

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The patent applies the inert atmosphere principle by introducing a premixed gas containing carbon monoxide and hydrogen into the fuel cell stack during storage. The carbon monoxide acts as a protective agent that preferentially reacts with oxygen to form carbon dioxide, preventing oxidation of carbon black particles. This creates a chemically protective environment that maintains carbon support durability while allowing standard storage conditions.

Inventive Principle:

Principle #39Inert atmosphere (Inert environment)

Solution Approach 2:

The patent implements preliminary action by pre-saturating the fuel cell stack with a premixed gas containing carbon monoxide and hydrogen before storage begins. This preliminary gas introduction ensures that carbon monoxide is present in the stack to prevent oxidation reactions during the entire storage period, addressing the corrosion problem before it can occur during extended inactivity.

Inventive Principle:

Principle #10Preliminary action

2Object-affected harmful factors

If hydrogen is used to purge oxygen from the fuel cell stack during storage, then oxygen protection is provided, but carbon black oxidation can still occur through slow oxidation under oxygen atmosphere or rapid oxidation when hydrogen and oxygen are present together

Engineering Contradiction:

ImproveOxygen intrusion protectionVSAvoidCarbon corrosion reaction

Core Design Contradiction:

Object-affected harmful factorsVSObject-generated harmful factors

Solution Approach 1:

The patent applies the intermediary principle by introducing carbon monoxide as a mediating substance between oxygen and carbon black. The carbon monoxide preferentially reacts with oxygen to form carbon dioxide, acting as a sacrificial intermediary that protects the carbon black from oxidation. This resolves the contradiction by providing oxygen protection without creating the conditions for rapid carbon corrosion that occurs when hydrogen and oxygen are present together.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent converts the potentially harmful presence of oxygen into a beneficial protective mechanism. By introducing carbon monoxide, the oxygen that would otherwise cause carbon black oxidation is transformed into a controlled reaction that produces carbon dioxide and water, while the carbon monoxide itself acts as a protective barrier. The harmful oxygen intrusion is converted into a beneficial protective atmosphere.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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 approach effectively minimizes carbon corrosion during storage and shipping by stabilizing the carbon support, ensuring the longevity and reliability of the fuel cell system.

Implementation Method 1

Adsorbing CO onto platinum nanoparticles

Methodology Applied

Scientific EffectAdsorption: Adsorption

Implementation Method 2

in presence of Pt catalyst, acidic electrolyte, and O2

Methodology Applied

Scientific EffectCatalysis: Catalysis

Implementation Method 3

carbon black particles may be oxidized to CO2

Methodology Applied

Scientific EffectOxidation: Oxidation

Data Source

PatentUS20250023071A1Method and system for managing a fuel cell stack

Publication Date: 2025.01.16 GM GLOBAL TECHNOLOGY OPERATIONS LLC

AI summary

A fuel cell system and associated method of operation includes assembling a fuel cell stack including an exhaust valve, flowing a premixed gas containing carbon monoxide therethrough; and closing the exhaust valve, including prior to storage. Subsequently, the exhaust valve may be opened and a refresh operation may be executed to purge the carbon monoxide from the fuel cell stack.