PolyMET Bipolar Plate Conductive Pathways for Low-Corrosion Fuel Cells
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Solution Overview
Problem
Conventional PEM fuel cell stacks face challenges with weight, corrosion, and current leakage due to the limitations of existing materials used in mono-polar plates and coolants, which affect the efficiency and durability of the fuel cells.
Innovation Solution
The PolyMET plate is designed using a polymeric material with in-plane and through-plane conductive pathways, providing high mechanical strength, low weight, and electrical conductivity while minimizing corrosion and eliminating current leakage through strategic placement of conductive materials, thus enhancing the power-to-weight ratio and operational efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If graphite is used as monopolar plate material, then corrosion resistance and low surface contact resistance are improved, but mechanical strength and density are worsened
Solution Approach 1:
The patent uses a composite material consisting of metal substrate (providing mechanical strength) combined with conductive polymer coating (providing corrosion resistance and electrical conductivity). This composite structure resolves the contradiction by integrating the advantages of both materials while eliminating their individual disadvantages.
2Strength
If polymer composite is used in graphite monopolar plate, then mechanical strength is improved, but electrical conductivity is worsened
Solution Approach 1:
The patent changes the material parameters by selecting specific conductive polymers with high electrical conductivity and optimizing the coating thickness and composition. This allows achieving both improved mechanical strength from the polymer matrix and maintained electrical conductivity through proper parameter selection.
3Strength
If metallic monopolar plate is used, then mechanical stability and electrical conductivity are improved, but corrosion resistance is worsened
Solution Approach 1:
The patent applies a conductive polymer coating on the metal substrate to create a composite structure where the metal provides mechanical stability and the polymer coating provides corrosion resistance, thus resolving the contradiction between mechanical stability and corrosion resistance.
4Temperature
If coolant with high electrical conductivity is used, then heat removal efficiency is improved, but current leakage through coolant is worsened
Solution Approach 1:
The patent extracts the electrical conductivity function from the coolant system by using electrically insulating polymer materials for the monopolar plates. This separates the thermal management function (coolant) from the electrical conduction function (polymer plates), allowing the coolant to be electrically insulating while maintaining heat removal efficiency through proper channel design.
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 PolyMET plate achieves a significant reduction in weight and corrosion, eliminates current leakage, and improves the power density of PEM fuel cells, making them more suitable for transportation applications by maintaining optimal electrical and thermal conductivity.
Implementation Method 1
a through-plane conductive pathway formed of a solid conductive material extending between the first surface and second surface, such that the through-plane conductive pathway is electrically coupled to the in-plane conductive pathways
Implementation Method 2
The primary functions of mono-polar plates are: It provides mechanical strength and supports the membrane electrode assembly
Implementation Method 3
In fuel cell stack, the heat generated as a by-product due to electrochemical reactions must be taken away from the stack to maintain the desired temperature inside the cells. Coolant is used to remove the heat from the stack by getting circulated in a closed loop.
Implementation Method 4
Coolant is used to remove the heat from the stack by getting circulated in a closed loop
Implementation Method 5
PEM fuel cells are of prime interest in transportation applications due to their relatively high efficiency and low pollutant emissions
Data Source
AI summary
The present subject matter pertains to PolyMET plate for a Proton Exchange Membrane fuel cell where the PolyMET plate includes a body made of a polymeric material and comprise a first surface and a second surface opposite to the first surface. Furthermore, the PolyMET plate includes a plurality of in-plane conductive pathways on the first surface defining a reaction area on the first surface, where the plurality of in-plane conductive pathways is formed as a coating of conductive material on the first surface. Moreover, the PolyMET plate also includes a through-plane conductive pathway formed of a solid conductive material extending between the first surface and second surface, such that the through-plane conductive pathway is electrically coupled to the in-plane conductive pathways.