Plastic Frame Assembly with Integrated Flow Channels for Fuel Cell Manifolds
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Solution Overview
Problem
Existing fuel cell stack assemblies face challenges in ensuring uniform fluid flow distribution, minimizing pressure drop across manifolds, precise alignment of fluid flow manifolds, reducing manufacturing complexity and costs, and optimizing the pitch of fuel cells while maintaining performance.
Innovation Solution
The use of flow plate and frame assemblies with anode and cathode frame members made from distinct materials, such as a rigid plastic and compressible sealing material, which are formed via 2K molding, allowing for precise alignment and fluid distribution through integrated flow channels and conduits, and enabling efficient assembly processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If continuous seals made from gasketing material are used around fluid flow plates, then alignment and fluid flow manifolding are provided, but misalignments occur at various points throughout the fuel cell stack assembly under high compression force
Solution Approach 1:
The sealing feature is merged into the rigid frame member itself through integral formation, eliminating the separate continuous seal. The frame member includes a sealing surface that directly contacts the fluid flow plate, combining structural support and sealing functions in one component.
Solution Approach 2:
The sealing interface is segmented into discrete contact points rather than a continuous seal. The rigid frame member has protrusions or features that create localized sealing contacts at specific locations, allowing precise positioning without relying on continuous material deformation.
2Ease of manufacture
If continuous seals are used for fluid flow manifolding, then fluid distribution is enabled, but secondary manufacturing steps are required which increase manufacturing costs and lead times
Solution Approach 1:
The sealing surface and fluid flow manifold features are merged into the rigid frame member through integral formation. The frame member simultaneously provides structural support, sealing, and fluid distribution pathways, eliminating the need for separate sealing components and assembly steps.
Solution Approach 2:
The rigid frame member performs multiple functions: structural support, sealing contact, and fluid flow distribution. The sealing surface and manifold features are integrated into the same component, reducing the total number of parts and manufacturing operations required.
3Loss of energy
If conventional fluid flow plates are used, then fluid flow channels are provided, but pressure drop across inlet manifolds is not minimized
Solution Approach 1:
The rigid frame member has varying local geometries optimized for different functions: wider manifold regions for fluid distribution and narrower channels for directed flow. The sealing surface geometry is locally optimized to maintain contact pressure while minimizing flow resistance.
Solution Approach 2:
The fluid flow paths transition from two-dimensional plate channels to three-dimensional manifold structures in the rigid frame member. This adds vertical dimensionality to the flow paths, allowing larger cross-sectional areas for fluid distribution and reduced velocity-induced pressure drops.
Data Source
AI summary
The present disclosure provides methods for forming flow plate and frame assemblies that comprise an anode frame member, a flow plate, and a cathode frame member with the flow plate retained between the anode and cathode frame members. The present disclosure also provides for flow plate and frame assemblies, fuel cell stacks containing a plurality of the flow plate and frame assemblies, and fuel cell systems containing the fuel cell stacks. A fluidly connected anode fluid pathway can be provided from an anode fluid inlet, through conduits in the anode frame member, onto an anode surface of the flow plate, and into anode flow channels.