Fuel Cell Header Isolating Terminal Plates From Corrosive Fluids

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Solution Overview

Problem

Fuel cell terminal plates experience corrosion due to contact with humid gaseous reactants and coolant, leading to reduced lifespan and contamination, necessitating expensive protective coatings that are sensitive and have limited lifespan.

Innovation Solution

Incorporating electrically non-conductive headers with fluid passageways that route reactants and coolant through the fuel cell stack without contacting the terminal plates, preventing corrosion and eliminating the need for costly coatings.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If terminal plates are used to conduct electrical current and allow fluid stream passage, then electrical conductivity and fluid transport are achieved, but corrosion occurs due to contact between humid fluid streams and the terminal plate

Engineering Contradiction:

Improveterminal plate corrosion resistanceVSAvoidcorrosion from humid fluid contact

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent introduces a header as an intermediary component that is sealingly engaged with the fuel cell stack and passes through the terminal plate. This header creates a fluid tight barrier that prevents direct contact between the humid fluid streams and the terminal plate, thereby eliminating the corrosion pathway while maintaining both electrical conductivity and fluid transport functions

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent segments the fluid transport function from the electrical conduction function by using separate components: the terminal plate handles electrical conduction while the header handles fluid transport. This segmentation allows each component to be optimized for its specific function without being compromised by the other, preventing corrosion of the terminal plate

Inventive Principle:

Principle #1Segmentation

2Reliability

If expensive protective coatings are applied to terminal plates to prevent corrosion, then corrosion resistance is improved, but manufacturing cost increases and the coatings are sensitive to damage

Engineering Contradiction:

Improveterminal plate corrosion protectionVSAvoidmanufacturing cost and complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The header acts as a protective intermediary that physically separates the terminal plate from corrosive fluid environments. This eliminates the need for expensive protective coatings on the terminal plate, reducing manufacturing costs while providing reliable corrosion protection that is not sensitive to minor damage

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent uses a relatively simple, inexpensive header component to protect the more critical and expensive terminal plate. The header can be a simpler, less expensive component that sacrificially protects the terminal plate, eliminating the need for costly coatings on the terminal plate itself

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

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

Prevents corrosion of terminal plates, reduces manufacturing costs, and allows for the use of more desirable coatings for improved current collection, while maintaining fluid tight communication paths and accommodating thermal expansion.

Implementation Method 1

Methodology Applied

Scientific EffectPhysical isolation: Physical Containment

Implementation Method 2

The header has a fluid transport passageway that allows the fluid stream to flow to or from the fuel cell stack through the opening in the terminal plate

Methodology Applied

Scientific EffectFluid transport through passageways:

Implementation Method 3

The header is sealingly engaged with the fuel cell stack

Methodology Applied

Scientific EffectSealing:

Implementation Method 4

accommodating thermal expansion

Methodology Applied

Scientific EffectThermal expansion accommodation: Thermal Expansion

Data Source

PatentUS7704626B2Isolated and insulated stack end unit inlet/outlet manifold headers

Publication Date: 2010.04.27 GM GLOBAL TECHNOLOGY OPERATIONS LLC

AI summary

The present invention isolates the fluid streams flowing into and out of a fuel cell stack from the terminal plates so that the fluid streams and terminal plates do not come into contact with one another. The prevention of the fluid streams from contacting the terminal plate eliminates corrosion concerns associated with the terminal plate. The present invention accomplishes this isolation through the use of headers having fluid passageways therein that route the fluid streams in and/or out of the fuel cell stack while preventing contact between the fluid streams and the terminal plate.