Non-planar Current Collectors for Fuel Cell Contact Force
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Solution Overview
Problem
Traditional fuel cell devices often provide limited contact force for internal components, such as electrodes, which can affect electrical conductivity and long-term reliability.
Innovation Solution
The fuel cell module design includes a membrane electrode assembly, gas diffusion layers, current collectors, and a fluid flow plate assembly with non-planar surfaces that are flattened to provide a contact force during assembly, enhancing electrical conductivity and reliability by ensuring a tight contact between components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional fuel cell devices are used with planar components, then the device structure is simple and easy to manufacture, but the contact force between internal components is limited, resulting in poor electrical conductivity and reduced reliability
Solution Approach 1:
The current collector is designed with a non-planar curved surface that applies contact force to the gas diffusion layer. The curvature allows the component to maintain pressure and improve electrical conductivity without requiring additional fastening mechanisms, thus improving reliability while keeping the overall structure relatively simple
2Reliability
If traditional fuel cell devices are used without biasing mechanisms, then the device is easier to assemble, but the contact force between components is insufficient, leading to increased contact impedance and reduced long-term reliability
Solution Approach 1:
The non-planar current collector serves a dual function: it collects current and simultaneously provides biasing contact force to the gas diffusion layer. This self-service approach eliminates the need for separate biasing mechanisms or complex assembly procedures, improving long-term reliability while maintaining ease of manufacture
Data Source
Figure 1
Figure 2A
Figure 2B
AI summary
A fuel cell module may include a membrane electrode assembly MEA (301) two gas diffusion layers (302), two current collectors (303,304), two sealing members (20), and a fluid flow plate assembly (10). The membrane electrode assembly may include at least one membrane for fuel cell reactions, and the two gas diffusion layers may be respectively coupled with the two opposite sides of the membrane electrode assembly. The fluid flow plate assembly is coupled with the membrane electrode assembly at a first side of the two opposite sides of the membrane electrode assembly. At least one of the two current collectors (303,304) has a non-planar surface protruding towards the MEA prior to an assembly of the membrane electrode assembly, the two gas diffusion layers, the two current collectors, and the two sealing members, and the non-planar surface is at least partially flattened when the assembly occurs.