Fuel Cell Sub-Gasket Flow Path to Prevent Clogging and Pressure Loss

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Solution Overview

Problem

Conventional fuel cell designs face issues with gas flow passage clogging and pressure drop due to deformation and complexity, particularly in resin-based connections between gas manifolds and the cell active area, leading to reliability and manufacturability challenges.

Innovation Solution

A fuel cell assembly with a sub-gasket frame and integrated flow-path that uses a network of wires to create a rigid passage for gases, minimizing pressure loss and eliminating deformation, which is simpler and easier to produce than existing designs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If resin-based connections are used between gas manifolds and cell active area, then the assembly is easier to manufacture, but the gas flow passage deforms and clogs after compression and fatigue

Engineering Contradiction:

Improveease of manufactureVSAvoidreliability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent changes the material parameter from resin to metal for the flow path component, which fundamentally alters the mechanical properties including rigidity, resistance to deformation, and fatigue resistance, thereby solving the reliability issue while maintaining manufacturability through metal forming processes

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention separates the flow path into a distinct metal component that is integrated into the assembly, rather than using resin to connect separate components. This segmentation allows each component to be optimized for its specific function while improving overall reliability

Inventive Principle:

Principle #1Segmentation

2Device complexity

If resin-based connections with cross-passing are used, then the design is simplified, but the gas flow passage clogs inevitably after thermal cycles and fatigue

Engineering Contradiction:

Improvedevice complexityVSAvoidreliability

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

Inventive Principle:

Principle #1Segmentation

3Ease of manufacture

If stamping or embossing is used on plates to create flow paths, then the gas passage is formed, but large pressure drop occurs within the assembly

Engineering Contradiction:

Improveease of manufactureVSAvoidpressure drop

Core Design Contradiction:

Ease of manufactureVSLoss of energy

Solution Approach 1:

The patent changes the manufacturing method from stamping/embossing (which creates sharp edges and constrictions) to a metal flow path component with optimized geometry that provides smooth transitions and larger flow areas, thereby reducing pressure drop while remaining manufacturable

Inventive Principle:

Principle #35Parameter changes

4Strength

If multiple bonding steps at high temperatures are used to assemble MEA and gas diffusion layer, then the components are securely bonded, but membrane deformation occurs and production speed is limited

Engineering Contradiction:

Improvebonding strengthVSAvoidproduction speed

Core Design Contradiction:

StrengthVSProductivity

Solution Approach 1:

The patent incorporates the flow path design into the plate structure itself during manufacturing, rather than adding it as a separate component requiring additional assembly steps. This preliminary integration eliminates subsequent bonding operations while maintaining structural integrity

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The invention merges the flow path function with the plate structure, eliminating the need for separate bonding steps between MEA, gas diffusion layer, and flow path components. This consolidation reduces both thermal cycling risks and assembly time

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS12148965B2Fuel cells

Publication Date: 2024.11.19 EH GRP ENG AG

AI summary

A fuel cell assembly includes an CCM layer with a sub-gasket frame around it to provide gas manifolds and sealant. A flow path is integrated on the sub-gasket in vicinity of the inlet and outlet manifolds that provides a passage for the gases to/from the active area. The flow path provides a rigid path without deforming or clogging the passage.