Polymeric Coating Bipolar Plate for Fuel Cell Sealing
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Solution Overview
Problem
The complexity and cost of manufacturing and assembly in fuel cell systems are increased due to the need for separate components for sealing, corrosion protection, and electrical insulation in bipolar plates, which hinders the commercialization of hydrogen as an energy carrier and the sustainability of a hydrogen economy.
Innovation Solution
A bipolar plate with a polymeric coating that serves as an electrical insulator, seal, and corrosion protection layer, reducing the need for multiple components and simplifying the manufacturing process by using a frame and base with a polymeric coating that can deform to create seals and withstand high pressures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate components are used for sealing, corrosion protection, and electrical insulation in bipolar plates, then reliable sealing and protection are achieved, but manufacturing complexity and assembly cost increase
Solution Approach 1:
The patent combines sealing, corrosion protection, and electrical insulation functions into a single polymeric coating layer applied to the bipolar plate. This eliminates the need for separate sealing components and multiple protective layers, reducing manufacturing complexity while maintaining reliable sealing and protection functions.
Solution Approach 2:
The polymeric coating serves multiple functions simultaneously: it provides sealing against gas leakage, corrosion protection for the bipolar plate, and electrical insulation to prevent short circuits. This multi-functional design simplifies the overall structure and reduces the number of components needed.
2Reliability
If multiple separate components are used for bipolar plate functions, then each function can be optimized independently, but assembly time and manufacturing cost increase
Solution Approach 1:
The patent integrates corrosion protection, sealing, and electrical insulation into a single polymeric coating that is applied directly to the bipolar plate surface. This eliminates the need for assembling multiple separate components, significantly improving assembly speed and productivity while maintaining reliable corrosion protection.
3Reliability
If traditional sealing components are used in bipolar plates, then sealing is provided, but the number of parts and assembly steps increase
Solution Approach 1:
The patent extracts the sealing function from separate mechanical sealing components (such as gaskets or O-rings) and integrates it directly into the polymeric coating on the bipolar plate. This eliminates the need for separate sealing parts while maintaining effective sealing performance.
Solution Approach 2:
The sealing function is merged with the polymeric coating that also provides corrosion protection and electrical insulation. This consolidation reduces the total number of components from multiple separate parts to a single integrated coating layer.
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
The polymeric coating reduces manufacturing and assembly complexity, lowers material costs, and enhances the robustness of the electrochemical cell by providing reliable sealing and corrosion protection, enabling efficient and cost-effective hydrogen management.
Implementation Method 1
a polymeric coating applied to at least one of the frame and the base... The polymeric coating may be an electrical insulator for the electrochemical cell, a seal for sealing one or more zones of the electrochemical cell
Implementation Method 2
The polymeric coating may be an electrical insulator for the electrochemical cell
Implementation Method 3
The polymeric coating may be an electrical insulator for the electrochemical cell, a seal for sealing one or more zones of the electrochemical cell, and a corrosion protection later of the electrochemical cell
Data Source
AI summary
The present disclosure is directed to a bipolar plate of an electrochemical cell. The bipolar plate may have a frame and a base. The bipolar plate may also have a polymeric coating applied to at least one of the frame and the base. The present disclosure is also directed to a method of assembling a bipolar plate for an electrochemical cell. The method may include compressing a frame and a base of the bipolar plate, at least one of the frame and the base has a polymeric coating. The polymeric coating may be an electrical insulator for the electrochemical cell, a seal for sealing one or more zones of the electrochemical cell, and a corrosion protection later of the electrochemical cell.