Fuel Cell Sensor Integration for Accurate Internal State Measurement
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Solution Overview
Problem
Conventional fuel cell measurement techniques require complex assembly processes that can damage sensors and lead to inaccurate measurements due to potential displacement, increasing the fuel cell thickness and necessitating structural changes.
Innovation Solution
A fuel cell design incorporating sensors on separators or a frame member with integrated wiring, covered by insulating films, allowing for easy and accurate measurement of internal state quantities without altering the cell's thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a sensor such as a thermocouple is disposed between a separator having a normal structure and a membrane electrode assembly, then the internal state quantity of the fuel cell can be measured, but the assembly process becomes complicated and the sensor may be damaged or displaced
Solution Approach 1:
The sensor is integrated directly into the separator structure, merging the measurement function with the structural component. The sensor arrangement regions are formed as integral parts of the separator, eliminating the need for separate sensor housing and simplifying assembly while ensuring proper sensor positioning for accurate internal state measurement
Solution Approach 2:
The sensor arrangement regions are pre-formed during separator manufacturing with appropriate thickness variations and sensor positioning features. This preliminary preparation allows sensors to be easily installed in correct positions during assembly, preventing displacement and damage while maintaining measurement precision
2Measurement precision
If a cover body is arranged on the cathode side to measure internal temperature, then the sensor can be disposed, but the fuel cell thickness increases and the structure needs significant change
Solution Approach 1:
The sensor integration is merged into the existing separator structure rather than adding a separate cover body. The sensor arrangement regions are formed within the separator thickness, utilizing the existing structural space and avoiding any increase in overall fuel cell thickness while enabling internal temperature measurement
3Measurement precision
If a sensor is disposed between separator and membrane electrode assembly, then internal environment can be measured, but the operator may damage the thin metal wire for the thermocouple during assembly
Solution Approach 1:
Sensor arrangement regions with appropriate thickness and structural support are pre-formed during separator manufacturing. This preliminary preparation provides mechanical protection to the sensor and its connections during assembly, preventing damage to thin metal wires while enabling accurate internal environment measurement
Solution Approach 2:
The separator structure with varied thickness in sensor arrangement regions provides cushioning and protection to the sensor before assembly is complete. This preliminary protective structure prevents damage during the assembly process while maintaining measurement capability
Data Source
AI summary
A fuel cell includes sensors. Each sensor includes: a sensor portion provided on at least one of separators, a frame member, and an electrolyte membrane; and a wiring portion connected to the sensor portion and extending to an outer peripheral portion of one of the separators or an outer peripheral portion of a membrane electrode assembly. The sensor further includes a base insulating film covering a sensor arrangement region; wiring patterns laminated on the base insulating film; and a covering insulating film covering the wiring patterns and portions of the base insulating film not covered with the wiring patterns.