Fuel Cell Jet Array Manifold for Uniform Gas Distribution
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Solution Overview
Problem
Fuel cells face performance limitations due to non-uniform air supply leading to flooding, which impairs air and hydrogen transfer, resulting in reduced output power and durability issues, especially during high current demands and low power states.
Innovation Solution
A fuel cell system with a stack of cells, air and hydrogen manifolds, a jet array with tubular bodies and orifices, and a controller to manage air and hydrogen distribution, including a jet stream-generating compressor and valve system to ensure uniform flow and prevent flooding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the rotational speed of the air compressor is increased to increase the flow rate of air for high output power, then the flow rate of air is improved, but power consumption spikes and overall efficiency decreases
Solution Approach 1:
The air supply system is segmented into multiple independent control zones using a manifold with multiple outlets and controllable valves. Each outlet can be independently regulated to optimize air distribution, allowing the system to maintain required flow rates without uniformly increasing compressor speed, thus reducing overall power consumption.
Solution Approach 2:
The system dynamically adjusts the opening degree of individual manifold outlets based on real-time operating conditions and stack cell status. This dynamic control enables precise air flow regulation matched to actual demand, preventing excessive power consumption while maintaining adequate air supply for output power requirements.
2Reliability
If the flow rate of air is increased to remove water and prevent flooding, then flooding is suppressed, but power consumption increases and membrane durability deteriorates due to drying
Solution Approach 1:
The manifold system provides localized air flow control to specific stack regions based on their individual water management needs. By adjusting outlet openings locally rather than increasing overall air flow system-wide, the system prevents flooding in affected areas without causing excessive drying elsewhere, thereby avoiding membrane durability issues and reducing unnecessary power consumption.
Solution Approach 2:
The system incorporates feedback control by monitoring stack cell status and water distribution patterns, then adjusting manifold outlet openings accordingly. This feedback mechanism enables precise water management that prevents flooding without requiring excessive air flow increases, thus maintaining low power consumption and protecting membrane durability.
3Reliability
If the flow rate of air is increased to prevent flooding, then flooding is suppressed, but the membrane dries out and durability deteriorates
Solution Approach 1:
The manifold enables differentiated air distribution to various stack regions, allowing each area to receive appropriate air flow for its specific water management requirements. This local control prevents flooding in water-prone areas while avoiding over-drying in other regions, thereby preserving membrane durability without sacrificing flooding prevention.
4Productivity
If non-uniform air supply occurs, then flooding happens in specific cells, but output power decreases dramatically
Solution Approach 1:
The air supply system is divided into multiple independently controllable outlets in the manifold, each serving specific stack cells. This segmentation allows precise regulation of air flow to each region, ensuring uniform distribution across all cells and preventing localized flooding that would otherwise cause dramatic output power decreases.
Solution Approach 2:
The system dynamically adjusts individual outlet openings based on real-time stack operating conditions and water distribution patterns. This dynamic control ensures uniform air supply to all cells under varying conditions, preventing flooding-related performance losses and maintaining stable output power.
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 achieves uniform air, hydrogen, and cooling water distribution, suppresses flooding, and manages faulty cells, ensuring consistent output power and preventing membrane deterioration, suitable for cold startup and long-term vehicle operation without durability issues.
Implementation Method 1
a jet array including a tubular body inserted in the air manifold or the hydrogen manifold and a plurality of orifices formed in the tubular body and arranged in a longitudinal direction of the tubular body
Data Source
AI summary
A fuel cell including a stack in which a plurality of cells are stacked includes an air manifold and a hydrogen manifold on a first side and a second side of the stack, respectively, a jet array including a tubular body inserted in the air manifold or the hydrogen manifold and a plurality of orifices formed in the tubular body and arranged in a longitudinal direction of the tubular body, a pump or a valve for supplying air or hydrogen to the jet array; and a controller that operates the pump or the valve.