Gas-Diffusion Layer Columns Replace Hardware Springs in Fuel Cells

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Solution Overview

Problem

Fuel-cell stacks face challenges with compression properties and structural design, often relying on heavy hardware springs that increase weight and induce voltages.

Innovation Solution

A membrane-electrode assembly with gas-diffusion layers featuring columnar structures on both sides of the membrane, which act as a spring under compression, replacing the need for hardware springs and enhancing structural integrity, while bipolar plates are designed to be flat on one side for reduced production costs and improved support.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stress or pressure

If hardware springs are used for compression in fuel-cell stacks, then compression properties are improved, but weight increases significantly

Engineering Contradiction:

Improvecompression propertiesVSAvoidweight

Core Design Contradiction:

Stress or pressureVSWeight of moving object

Solution Approach 1:

The patent removes hardware springs from the fuel-cell stack design entirely. Instead, the compression function is transferred to the columnar structures integrated into the gas-diffusion layers, which provide spring action through their deformable geometry without requiring separate mechanical spring components.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent combines the compression function with the gas-diffusion layers by integrating columnar structures directly into them. These columns serve dual purposes: enabling gas diffusion and providing spring action for compression, thereby eliminating the need for separate hardware springs.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 3:

The columnar structures in the gas-diffusion layers act as flexible elements that can deform under compression. Their geometry allows them to function as springs through elastic deformation, replacing rigid hardware springs with flexible, integrally-formed structures.

Inventive Principle:

Principle #30Flexible shells and thin films

2Stress or pressure

If hardware springs are used for compression, then compression properties are improved, but induced voltages increase

Engineering Contradiction:

Improvecompression propertiesVSAvoidinduced voltages

Core Design Contradiction:

Stress or pressureVSObject-generated harmful factors

Solution Approach 1:

The patent removes hardware springs that generate harmful induced voltages during compression. The columnar structures in the gas-diffusion layers provide compression without the electromagnetic interference problems associated with metallic spring components.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The columnar structures are designed as sacrificial or consumable elements that can deform and provide compression without generating harmful voltages. They serve their compression function through geometric deformation rather than metallic elasticity, avoiding electromagnetic issues.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Strength

If columnar structures are added to gas-diffusion layers, then structural integrity is improved, but device complexity increases

Engineering Contradiction:

Improvestructural integrityVSAvoiddevice complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent merges the structural support function with the gas-diffusion function by integrating columnar structures into the gas-diffusion layers. This eliminates the need for separate support structures, thereby improving structural integrity without significantly increasing overall device complexity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The columnar structures serve multiple functions simultaneously: they provide structural support, enable gas diffusion, and act as springs for compression. This multi-functionality improves structural integrity while avoiding the need for additional dedicated components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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

This design improves compression properties, reduces weight, and minimizes induced voltages, resulting in a more robust and cost-effective fuel-cell stack with increased structural integrity.

Implementation Method 1

By means of the columns of the gas-diffusion layer, a spring action under compression is, advantageously, achieved

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS11495813B2Membrane electrode assembly, fuel cell stack, and vehicle comprising such a fuel cell stack

Publication Date: 2022.11.08 AUDI AG

AI summary

Embodiments of the invention relate to a membrane-electrode assembly comprising a membrane structure with an anode layer, a cathode layer, and a membrane layer, wherein the membrane layer is positioned between the anode layer and the cathode layer. The membrane-electrode assembly furthermore comprises an anode-side gas-diffusion layer arranged on the anode layer and a cathode-side gas-diffusion layer arranged on the cathode layer. Furthermore, at least one of the anode-side gas-diffusion and the cathode-side gas-diffusion layers has a structure on the side facing away from the membrane structure. According to some embodiments, the structure comprises a plurality of columns for forming a laterally-open flow field, wherein the columns have support surfaces for supporting a bipolar plate.