Profiled Cell Assembly for Fuel Cell Layer Interlocking
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Solution Overview
Problem
In fuel cell systems and electrolyzers, the existing cell assemblies face challenges in achieving a robust and intimate connection between the catalyst layer and the microporous layer due to differences in surface roughness, leading to delamination, poor electrical contacting, and water accumulation, which limits current and power densities.
Innovation Solution
The cell assembly features profiled catalyst and microporous layers with differing surface roughness, allowing them to interlock and form a continuous, robust contact area, preventing delamination and enhancing mechanical force distribution through the use of a binder and potentially including electrically conductive and stiffening components, thereby improving contact and reducing water accumulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the microporous layer and catalyst layer are pressed together during stacking, then contact area is improved, but delamination occurs due to surface roughness mismatch
Solution Approach 1:
The patent profiles the microporous layer to create specific surface geometries (protrusions and recesses) that change the surface parameters from flat to structured. This profiling enables the rougher microporous layer to mechanically interlock with the smoother catalyst layer, resolving the delamination issue while maintaining connection stability under compression.
Solution Approach 2:
The patent introduces curved and irregular surface features through profiling the microporous layer. The protrusions and recesses create a non-planar surface that complements the catalyst layer topology, enabling intimate contact through mechanical interlocking rather than flat pressing, thus preventing delamination while improving connection strength.
2Reliability
If pressure is applied during stacking, then electrical conductivity is improved, but water accumulation occurs in cavity areas
Solution Approach 1:
The profiling of the microporous layer creates a controlled surface topology with protrusions and recesses that eliminates large flat cavity areas where water would accumulate. The structured surface allows pressure to be distributed more evenly while maintaining electrical contact through the protrusion-catalyst layer interface, preventing both contact loss and water trapping.
3Ease of manufacture
If the GDL fleece is pressed irregularly, then assembly is achieved, but flat assembly cannot be obtained
Solution Approach 1:
The patent applies profiling to the microporous layer to create a predetermined surface geometry that compensates for the irregular GDL fleece. The structured surface with protrusions and recesses allows the assembly to achieve functional contact while accommodating the inherent irregularities of the GDL, transforming the manufacturing approach from requiring flatness to utilizing controlled roughness.
Data Source
AI summary
The presented invention relates to a cell assembly (100) for the controlled guiding of reactive fluids, wherein: the cell assembly (100) comprises a membrane (101), which has a first side and a second side opposite from the first side; on each of the first side and the second side, a catalyst layer (103) and a microporous layer (105) are disposed; the microporous layer (105) and/or the catalyst layer (103) of at least one side is profiled in such a way that the surface roughness of the catalyst layer (103) differs from the surface roughness of the microporous layer (105), so that the catalyst layer (103) and the microporous layer (105) fit together in parts.