Insulated Separator Segmentation for High Voltage Fuel Cell Stacks

Solution Overview

Problem

Conventional fuel cell stacks face challenges in maintaining high output voltage while keeping current low, which increases manufacturing costs and reduces efficiency due to the large reaction area and limited number of cells, leading to cooling issues and increased weight and volume of drive units.

Innovation Solution

A fuel cell stack design with a separator structure where two or more reaction areas are connected in an insulated manner using an insulating material, reducing the number of stacked cells and manufacturing processes, and improving the efficiency of drive components by maintaining high output voltage and low current.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If a separator with a large reaction area and single module design is used, then assembly is facilitated and size is reduced, but output voltage becomes low and current becomes high

Engineering Contradiction:

Improveassembly easeVSAvoidoutput voltage

Core Design Contradiction:

Ease of operationVSPower

Solution Approach 1:

The separator is divided into multiple reaction areas (first reaction area and second reaction area) that are electrically insulated from each other. This segmentation allows multiple reaction areas to be connected in series, increasing the output voltage while maintaining a compact single-module structure that facilitates assembly.

Inventive Principle:

Principle #1Segmentation

2Ease of manufacture

If a separator with a large reaction area and single module design is used, then manufacturing cost is reduced, but drive unit efficiency decreases and cooling problems occur

Engineering Contradiction:

Improvemanufacturing costVSAvoiddrive unit efficiency

Core Design Contradiction:

Ease of manufactureVSLoss of energy

Solution Approach 1:

The separator is divided into multiple reaction areas (first reaction area and second reaction area) that are electrically insulated from each other. This segmentation allows multiple reaction areas to be connected in series, increasing the output voltage while maintaining a compact single-module structure that facilitates assembly.

Inventive Principle:

Principle #1Segmentation

3Power

If the number of stacked cells is increased to maintain high voltage, then output voltage increases, but manufacturing complexity and cost increase

Engineering Contradiction:

Improveoutput voltageVSAvoidnumber of stacked cells

Core Design Contradiction:

PowerVSDevice complexity

Solution Approach 1:

Multiple reaction areas are integrated into a single separator structure rather than requiring multiple separate cells to be stacked. The first and second reaction areas are connected in series through electrical insulation, achieving high voltage output within one module and reducing manufacturing complexity.

Inventive Principle:

Principle #5Merging (Combining)

4Power

If high current is used to compensate for low voltage, then output power is maintained, but efficiency of drive components decreases

Engineering Contradiction:

Improveoutput powerVSAvoiddrive component efficiency

Core Design Contradiction:

PowerVSLoss of energy

Solution Approach 1:

The separator is divided into multiple reaction areas (first reaction area and second reaction area) that are electrically insulated from each other. This segmentation allows multiple reaction areas to be connected in series, increasing the output voltage while maintaining a compact single-module structure that facilitates assembly.

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

This design enhances the productivity and cost-effectiveness of fuel cell stacks by reducing manufacturing costs, improving assembly efficiency, and facilitating vehicle mounting while maintaining high output voltage and low current levels.

Implementation Method 1

a separator having a structure in which two or more reaction areas are connected to each other in an insulated manner

Methodology Applied

Scientific EffectElectrical insulation: Electrical Resistance

Implementation Method 2

a polymer electrolyte membrane 11 capable of transporting hydrogen ions (protons)

Methodology Applied

Scientific EffectIon transport: Ion Exchange

Implementation Method 3

catalyst layers such as a cathode 12 and an anode 13, which are coated on both sides of the electrolyte membrane 11 such that hydrogen and oxygen react with each other

Methodology Applied

Scientific EffectCatalysis: Catalysis

Implementation Method 4

an oxidation reaction of hydrogen occurs to produce hydrogen ions (protons) and electrons

Methodology Applied

Scientific EffectOxidation reaction: Oxidation

Implementation Method 5

the hydrogen ions and electrons transmitted from the anode 13 react with the oxygen-containing air to produce water

Methodology Applied

Scientific EffectReduction reaction: Reduction

Implementation Method 6

a gas diffusion layer (GDL) 16

Methodology Applied

Scientific EffectGas diffusion: Diffusion

Implementation Method 7

channels 22 each located between the lands 21 and serving as a passage of the fuel such as hydrogen and air (oxygen)

Methodology Applied

Scientific EffectFluid flow: Convection

Data Source

PatentUS9472824B2Fuel cell stack

Publication Date: 2016.10.18 HYUNDAI MOTOR CO LTD

AI summary

Disclosed is a fuel cell stack using a separator in which two or more reaction areas are connected in an insulated manner. Further, a gas diffusion layer, a membrane electrode assembly and the like are sequentially stacked on each reaction area of the separator, and the reaction areas are connected in series to configure a single stack module thereby increasing the voltage generated in the fuel cell stack and maintain the current at a low level.