Integrated MEA with WVT Region for Fuel Cell Humidification

Solution Overview

Problem

Traditional fuel cell systems require external water vapor transfer units to humidify reactant gases, increasing system size and cost due to separate components, which is particularly problematic in space-constrained applications like vehicles.

Innovation Solution

An integrated membrane electrode assembly (MEA) with a built-in water vapor transfer (WVT) region is manufactured by simultaneously coating specific layers onto a substrate, including a microporous layer, catalyst layer, and membrane ionomer layers, with optional support layers, and heat treating before assembly, allowing for internal moisture transfer within the MEA.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If an external water vapor transfer unit is used to humidify reactant gases, then the fuel cell can maintain optimal humidity levels, but the system size and complexity increase

Engineering Contradiction:

Improvehumidity controlVSAvoidsystem complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines the water vapor transfer function with the membrane electrode assembly by integrating a water vapor transfer region directly into the MEA structure. This merging eliminates the need for separate external humidification units, thereby maintaining optimal humidity levels while reducing system complexity and size.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The membrane electrode assembly is designed to perform multiple functions: electrochemical energy conversion in the active area and water vapor transfer in the WVT region. This multi-functionality allows the MEA to both generate electricity and humidify reactant gases internally, eliminating the need for dedicated external humidification equipment.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If an external water vapor transfer unit is used to humidify reactant gases, then the fuel cell can maintain optimal humidity levels, but the system cost increases

Engineering Contradiction:

Improvehumidity controlVSAvoidsystem cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent combines the water vapor transfer function with the membrane electrode assembly by integrating a water vapor transfer region directly into the MEA structure. This merging eliminates the need for separate external humidification units, thereby maintaining optimal humidity levels while reducing system complexity and size.

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If separate components are used for water vapor transfer, then the humidification function can be performed, but the packaging space increases

Engineering Contradiction:

Improvehumidification functionVSAvoidpackaging space

Core Design Contradiction:

ReliabilityVSVolume of moving object

Solution Approach 1:

The patent combines the water vapor transfer function with the membrane electrode assembly by integrating a water vapor transfer region directly into the MEA structure. This merging eliminates the need for separate external humidification units, thereby maintaining optimal humidity levels while reducing system complexity and size.

Inventive Principle:

Principle #5Merging (Combining)

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 integration reduces system size and cost by eliminating the need for external humidification units, enhancing fuel cell performance and longevity by maintaining optimal humidity levels within the fuel cell stack.

Implementation Method 1

simultaneously coating a microporous layer (MPL), a catalyst-containing layer, and a first membrane ionomer layer onto the substrate

Methodology Applied

Scientific EffectCoating/Deposition: Deposition (physical)

Implementation Method 2

heat treating the coated substrate formed by the substrate and a plurality of layers

Methodology Applied

Scientific EffectHeat treatment: Heat Treatment

Implementation Method 3

an integrated water vapor transfer (WVT) region wherein certain layers of the MEA are simultaneously stripe-coated

Methodology Applied

Scientific EffectWater vapor transfer: Diffusion

Data Source

PatentUS10680266B2Method of manufacturing an integrated water vapor transfer device and fuel cell-II

Publication Date: 2020.06.09 GM GLOBAL TECHNOLOGY OPERATIONS LLC

AI summary

The present disclosure provides a method for manufacturing an integrated MEA, the method includes the following steps: (1) providing a substrate having an AA region and a WVT region; (2) simultaneously coating a microporous layer, a catalyst layer, and a first membrane ionomer layer onto the substrate; (3) applying an optional membrane support layer to the first membrane ionomer layer in the AA region and the WVT region; (4) applying an optional second membrane ionomer layer; (5) heating treating a coated substrate; and (6) assembling the coated substrate to a companion coated substrate.