Fuel Cell Flow Field Plates Without Transition Regions
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Solution Overview
Problem
Conventional fuel cell flow field plates with transition regions lead to non-uniform flow distribution, reduced power density, and increased complexity in design and manufacturing, due to the need for intricate transition regions to align oxidant and fuel inlet and outlet ports with channels, which affects overall fuel cell performance and operational efficiency.
Innovation Solution
Designing fuel cell assemblies with flow field plates that reduce or eliminate transition regions by aligning inlet and outlet ports directly with channel inlets and outlets, and using sculpted connectors and feed-plates to ensure uniform flow distribution across the active area, allowing for channels with varying cross-sectional areas along their length to improve flow management and reduce the area occupied by transition regions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If transition regions are included in flow field plates to align ports with channels, then flow distribution can be managed, but the device complexity and manufacturing difficulty increase significantly
Solution Approach 1:
The patent removes the transition region component entirely from the flow field plate design. Instead of including transition regions within the plate, the invention uses externally attached sculpted connectors that perform the flow distribution function, thereby simplifying the plate itself to only contain straight channels without complex transition zones.
Solution Approach 2:
The flow distribution function is segmented into separate components: the flow field plate contains only straight channels, while the sculpted connectors (attached to inlet/outlet ports) handle the flow distribution. This segmentation allows each component to be optimized independently and simplifies manufacturing.
2Reliability
If transition regions are designed to align ports with channels, then fluid flow can be directed properly, but the active area of the fuel cell is reduced
Solution Approach 1:
The invention moves the flow distribution function from the planar dimension (within the plate's active area) to the vertical/three-dimensional dimension by using sculpted connectors that attach to the inlet and outlet ports. This allows flow distribution to occur in the connector geometry rather than consuming active area on the plate surface.
3Power
If conventional flow field plates with transition regions are used, then port alignment is achieved, but power density is reduced due to non-uniform flow distribution
Solution Approach 1:
The sculpted connectors provide localized flow distribution optimization at the inlet and outlet ports, creating uniform flow entry into the channels without requiring the entire plate to have complex geometry. This local quality approach improves overall flow uniformity and power density.
4Ease of manufacture
If transition regions are eliminated and ports are aligned directly with channels, then manufacturing is simplified, but flow distribution uniformity may be compromised
Solution Approach 1:
The sculpted connectors act as intermediary components that mediate between the simple straight channels of the flow field plate and the port requirements. These connectors provide the necessary flow distribution function without requiring the plate itself to have complex transition regions, thus maintaining manufacturing simplicity while ensuring flow uniformity.
Data Source
AI summary
In some embodiments, fuel cell assemblies can include fuel cell flow field plates with reduced, if not eliminated, transition regions. In some embodiments, methods and apparatus can reduce, if not eliminate, the area occupied by transition regions on a fuel cell plate in a fuel cell assembly. In some embodiments, the fuel cell stacks can include an oxidant inlet assembly including a sculpted oxidant inlet connector, and a feed-plate with a sculpted opening. In some embodiments, the fuel cell stacks can include an oxidant outlet assembly including a feed-plate with a sculpted opening, and a sculpted oxidant outlet connector.