PCB-Laminated Fuel Cell Board With Decoupled Coolant Flow
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Solution Overview
Problem
In fuel cell stacks, the combined flow of coolant and reactant fluids leads to increased coolant flow rates that reduce moisture levels, affecting ionic conductivity and overall efficiency, as they are typically circulated together to supply reactants and remove heat.
Innovation Solution
The design decouples coolant and reactant fluid flows by arranging fuel cell boards such that coolant fluid is directed only to the anode side and reactant fluid only to the cathode side, allowing independent control of flow rates, pressures, and compositions, using printed circuit board (PCB) technology for modular and efficient fluid management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If coolant and reactant fluids are circulated together through the same channels, then heat removal efficiency is improved, but moisture levels at the cathode decrease affecting ionic conductivity
Solution Approach 1:
The patent divides the fluid circulation system into separate channels: one channel for coolant flow and another for reactant fluid flow. This segmentation allows independent control of each fluid's flow rate and path, preventing the coolant from removing excessive moisture from the cathode while still achieving effective heat removal.
Solution Approach 2:
The patent introduces separate flow channels as intermediary structures that mediate between the coolant and reactant fluids. These channels act as physical barriers that prevent direct interaction between the two fluids, allowing each to perform its function independently without interfering with the other's performance.
2Temperature
If coolant flow rate is increased to improve cooling, then heat removal is enhanced, but moisture loss at the cathode increases
Solution Approach 1:
By segmenting the flow paths into separate channels for coolant and reactant fluids, the system can increase coolant flow rate for improved cooling without causing moisture loss at the cathode, since the coolant no longer flows through the cathode region where moisture is needed.
Solution Approach 2:
The patent extracts the coolant flow path from the reactant fluid channel, removing the harmful effect of coolant-induced moisture loss while preserving the beneficial cooling effect. The coolant channel is taken out as a separate entity that can be optimized independently.
3Device complexity
If combined fluid flow is used to simplify channel structure, then device complexity is reduced, but independent control of flow rates is lost
Solution Approach 1:
The patent segments the fluid distribution system into separate channels for coolant and reactant fluids. While this increases structural complexity compared to a single combined channel, it enables independent control of flow rates, pressures, and compositions for each fluid type, providing greater operational flexibility and adaptability.
Solution Approach 2:
The separate channel design allows dynamic adjustment of flow rates for coolant and reactant fluids independently. Each channel can be controlled according to real-time operational requirements, enabling the system to adapt to varying load conditions and optimize performance under different operating scenarios.
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 decoupling enhances fuel cell efficiency by maintaining desired humidity levels at the cathodes, allowing for higher coolant flow rates while preventing moisture loss, thereby improving power density and reducing parasitic power requirements.
Implementation Method 1
an ion permeable membrane, which comprises an ion-permeable membrane sandwiched between two electrode layers
Implementation Method 2
Catalyst layers adjacent to the electrodes increase the rate of and efficiency of the reactions at the electrodes
Implementation Method 3
A fuel cell (e.g. a solid-polymer-electrolyte fuel cell) is an electrochemical device which generates electrical energy and heat from a reactant or oxidant (e.g. pure oxygen or air) and a fuel (e.g. hydrogen or a hydrogen-containing mixture)
Implementation Method 4
a coolant fluid (e.g. air or water) that circulates within the stack
Data Source
AI summary
The present disclosure provides a fuel cell comprising at least one fuel cell board (200), (400). Each fuel cell board (200), (400) comprises a Membrane Electrode Assembly (MEA) (113) comprising at least one ion permeable membrane, at least one anode, and at least one cathode, wherein each or all anodes are arranged on a first surface of the ion permeable membrane and each or all cathodes are arranged on a second surface of the ion permeable membrane. Each fuel cell board (200), (400) also comprises a first printed circuit board (PCB) layer (101), (401) comprising at least one first fluid path. Each fuel cell board also comprises a second PCB layer comprising (102), (402) at least one second fluid path. The MEA (113) is located between the first PCB layer (101), (401) and the second PCB layer (102), (402) so that the at least one first fluid path is arranged adjacent to each or all of the cathodes such that an oxidisable fluid flows to each or all of the cathodes of the at least one fuel cell board (200), (400) and so that the at least one second fluid path is arranged adjacent to each or all of the anodes such that a reducible fluid flows to the each or all of the anodes of the at least one fuel cell board (200), (400). The MEA (113), the first PCB layer (101). (401) and the second PCB layer (102), (402) are laminated together to form the fuel cell board (200), (400).