Composite Fuel Cell End Plate for Lightweight Stiff Sealing
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Solution Overview
Problem
Fuel cells for aircraft face challenges in achieving high stability, low weight, and wide deployability due to weight constraints and the need to withstand various physical conditions during operation, with existing end plates often being bulky and lacking in rigidity, electrical insulation, and leak-tightness.
Innovation Solution
The end plate is composed of a first fibre composite structure for structural tensile strength, a second fibre composite structure for electrical insulation and leak-tightness, and a porous dielectric core for compressive strength, all laminated together to form a sandwich plate with enhanced torsional and bending stiffness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If conventional end plates are used to ensure stability and withstand physical conditions, then stability and strength are improved, but weight increases and deployability is reduced
Solution Approach 1:
The end plate is constructed as a composite structure with three distinct layers: an outer end plate layer with first fibre composite structure for tensile strength, an abutting layer with second fibre composite structure for electrical insulation and leak-tightness, and a core with porous structure providing compressive strength. This composite approach allows each layer to contribute specific properties, achieving high stability while minimizing weight compared to conventional homogeneous end plates.
2Strength
If conventional end plates are used to ensure structural integrity, then strength is improved, but weight increases by up to 50%
Solution Approach 1:
The end plate is segmented into three functional layers, each optimized for specific mechanical properties. The outer end plate layer with first fibre composite structure handles tensile loads, the core with porous structure handles compressive loads, and the abutting layer provides additional structural support. This segmentation allows each component to be optimized for its specific function, achieving high structural integrity with reduced overall weight.
Solution Approach 2:
Each layer of the end plate is designed with specific local qualities: the outer end plate layer uses first fibre composite structure optimized for tensile strength, the core uses porous structure optimized for compressive strength, and the abutting layer uses second fibre composite structure optimized for electrical insulation and leak-tightness. This local optimization of material properties ensures maximum structural efficiency with minimum weight.
3Stability of the object's composition
If conventional end plates are used to ensure stability, then stability is improved, but device complexity increases
Solution Approach 1:
The end plate merges multiple functions into a single integrated component. The three layers are laminated together to form one cohesive end plate structure that simultaneously provides mechanical strength, electrical insulation, leak-tightness, and thermal management. This merging eliminates the need for separate components for each function, reducing overall device complexity while maintaining high stability.
Solution Approach 2:
The end plate is designed as a multi-functional component where the same structure performs multiple roles: structural support, electrical insulation, fluid sealing, and thermal management. The abutting layer provides both structural support and electrical insulation, while the porous core provides both mechanical support and thermal management. This universality reduces the number of separate components needed, simplifying the overall device.
4Reliability
If conventional end plates are used to ensure leak-tightness and electrical insulation, then reliability is improved, but weight increases
Solution Approach 1:
The abutting layer is specifically designed with second fibre composite structure that provides localized electrical insulation and leak-tightness properties where needed, without adding unnecessary weight to the entire end plate. This targeted approach ensures reliability for electrical insulation and sealing functions while minimizing overall weight.
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 a lightweight, stable, and secure end plate with improved leak-tightness and electrical insulation, allowing operation across a wide temperature range (-60 to 200°C) while reducing weight by up to 50% compared to conventional methods.
Implementation Method 1
The core comprises a porous structure of a dielectric material comprising a plurality of volumes, the porous structure providing compressive strength
Implementation Method 2
The outer end plate layer and the abutting layer are each connected to the core in a laminar manner, such that a sandwich plate is formed
Data Source
Figure 1~2
Figure 3~4B
Figure 5~6
AI summary
The present invention relates to an end plate for a fuel cell. In order to provide for an improved fuel cell with a high stability, low weight and wide range of deployability an end plate (10) for a fuel cell is provided. The end plate comprises a first layer forming an outer end plate layer (12), a second layer forming an abutting layer (14) for a cell assembly of the fuel cell and a core (16) between the first layer and the second layer. The outer end plate layer comprises a first fibre composite structure providing structural tensile strength in a plane orientation of the outer end plate layer and forming a supporting structure to the abutting layer and the core. The abutting layer comprises a second fibre composite structure providing structural tensile strength in a plane orientation of the abutting layer. The abutting layer provides an electrical insulation for the abutting cell assembly, the abutting layer also providing a leak-tightness for media during operation of the fuel cell. The first fibre composite structure comprises a first fibre material (18) and the second fibre composite structure comprises a second fibre material (20) that is different than the first material. The core is provided as a sandwich core between the outer end plate layer and the abutting layer. The core along with the outer end plate layer provides the torsional and/or bending stiffness to the end plate. The core comprises a porous structure (22) of a dielectric material comprising a plurality of volumes, the porous structure providing compressive strength. The outer end plate layer and the abutting layer are each connected to the core in a laminar manner (24), such that a sandwich plate is formed.