Fuel Cell Separator Segmentation for Gas Distribution

Solution Overview

Problem

Conventional fuel cell stacks face challenges in manufacturing performance due to narrow or wide channel intervals in the diffusion part, leading to compromised differential pressure and water discharge efficiency.

Innovation Solution

A fuel cell stack design where the diffusion channel height is adjusted to uniformly distribute reaction gas, with a reaction channel height greater than the diffusion channel, and a gas diffusion layer contacting both parts at different compression rates, maintaining water discharge performance while reducing differential pressure.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If the channel interval of the diffusion part is formed to be narrow, then the fuel cell separator improves distribution performance of reaction gas, but manufacturing performance of the separator is degraded

Engineering Contradiction:

Improvedistribution performance of reaction gasVSAvoidmanufacturing performance of the separator

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The separator is divided into two distinct parts: a diffusion part with a first channel interval optimized for gas distribution, and a reaction part with a second channel interval optimized for manufacturing. This segmentation allows each part to have different channel interval characteristics, resolving the contradiction between distribution performance and manufacturing ease.

Inventive Principle:

Principle #1Segmentation

2Ease of manufacture

If the channel interval of the diffusion part is formed to be wide, then the fuel cell separator has the improved manufacturing performance, but it may cause an increase in a differential pressure and a reduction in water discharge performance

Engineering Contradiction:

Improvemanufacturing performance of the separatorVSAvoidwater discharge performance

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The separator is divided into two distinct parts: a diffusion part with a first channel interval optimized for gas distribution, and a reaction part with a second channel interval optimized for manufacturing. This segmentation allows each part to have different channel interval characteristics, resolving the contradiction between distribution performance and manufacturing ease.

Inventive Principle:

Principle #1Segmentation

3Manufacturing precision

If the channel interval of the diffusion part is formed to be narrow, then the fuel cell separator improves distribution performance of reaction gas, but it may cause an increase in a differential pressure

Engineering Contradiction:

Improvedistribution performance of reaction gasVSAvoiddifferential pressure

Core Design Contradiction:

Manufacturing precisionVSStress or pressure

Solution Approach 1:

The separator is divided into two distinct parts: a diffusion part with a first channel interval optimized for gas distribution, and a reaction part with a second channel interval optimized for manufacturing. This segmentation allows each part to have different channel interval characteristics, resolving the contradiction between distribution performance and manufacturing ease.

Inventive Principle:

Principle #1Segmentation

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

Improves manufacturing performance and system efficiency by optimizing gas distribution and reducing differential pressure without compromising water discharge functionality.

Implementation Method 1

a gas diffusion layer configured to contact the separator at the diffusion part and the reaction part

Methodology Applied

Scientific EffectDiffusion: Diffusion

Implementation Method 2

The fuel cell system is an apparatus which directly converts energy of fuel into electrical energy. Further, the fuel cell system includes a pair of electrodes, i.e. an anode and a cathode, having an electrolyte disposed therebetween and obtains electricity and heat by an electrochemical reaction of ionized fuel gas.

Methodology Applied

Scientific EffectElectrochemical reaction: Fuel Cell

Implementation Method 3

a separator which comprises a diffusion part, as being provided with a diffusion channel, configured to distribute reaction gas and cooling water

Methodology Applied

Scientific EffectFluid flow:

Data Source

PatentUS11031609B2Fuel cell stack

Publication Date: 2021.06.08 HYUNDAI MOTOR CO LTD

AI summary

Disclosed herein is a fuel cell stack with improved manufacturing performance. The fuel cell stack includes: a separator that comprises a diffusion part, as being provided with a diffusion channel, configured to distribute reaction gas and cooling water and a reaction part, as being continuously formed from the diffusion part and provided with a reaction channel that has a height greater than that of the diffusion channel, configured to move reaction gas distributed from the diffusion part and generate electrons by a chemical reaction; and a gas diffusion layer configured to contact the separator at the diffusion part and the reaction part.