Segmented Fuel Cell Manifolds for Pressure Drop Reduction
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Solution Overview
Problem
Current fuel cell technologies face limitations in achieving high current and volume power density, with issues related to pressure drop, oxygen utilization, phase change, and water management, especially under dynamic and load-modulating conditions.
Innovation Solution
The fuel cell design incorporates multiple segmented active areas with distinct fuel, oxidant, and coolant manifolds, allowing for independent media distribution and exit within each segment, reducing pressure drop and enhancing uniform temperature management, thereby increasing average cell voltage and power density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the active area of a fuel cell is increased to achieve higher power density, then the volume power density increases, but the pressure drop across the cell increases and oxygen utilization decreases
Solution Approach 1:
The fuel cell active area is divided into multiple smaller segments, each with its own inlet manifolds for fuel, oxidant, and coolant. This segmentation allows fresh media to be supplied to each segment independently, reducing the pressure drop across individual flow paths while maintaining a large total active area for high power density
2Power
If the active area of a fuel cell is increased to achieve higher power density, then the volume power density increases, but oxygen utilization and cell voltage decrease
Solution Approach 1:
The fuel cell is segmented into multiple active areas with separate inlet manifolds, ensuring fresh oxidant is supplied to each segment. This maintains high oxygen concentration and utilization efficiency across the entire active area, preventing voltage loss that would occur in a single large cell where oxygen depletion occurs along the flow path
3Stress or pressure
If the active area is segmented into multiple smaller areas, then pressure drop reduces and oxygen utilization improves, but the device complexity increases
Solution Approach 1:
Multiple functions are merged into the flow field structures, which serve as both gas distribution manifolds and coolant channels. This integration reduces the number of separate components needed while achieving the benefits of segmentation for pressure drop reduction and improved oxygen utilization
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 design enables power density increases to 6-7 kW/L, simplifies manufacturing, and allows for the use of a blower instead of a compressor, improving durability and flexibility in cell dimensions without performance loss.
Implementation Method 1
Fuel (normally hydrogen) passes through one surface of the membrane and oxidant (normally air) on the other side where electro-chemical reaction occurs to produce electricity and water as by-product
Implementation Method 2
Each flow field structure comprises at least three fuel manifolds, at least three oxidant manifolds and at least three coolant manifolds. The fuel cell comprises at least two active areas and wherein at least one fuel manifold, at least one oxidant manifold and at least one coolant manifold is arranged between the at least two active areas
Implementation Method 3
the 'reversable open circuit voltage' of a hydrogen fuel cell is defined by the 'Nernst' equation, where voltage of a cell is in direct correlation with partial pressure of oxygen. This means, utilisation and reduction of oxygen inside a cell leads to lower cell voltage
Data Source
AI summary
A fuel cell including at least one membrane, at least one anode electrode layer, at least one cathode electrode layer, at least two gas diffusion layers and at least two flow field structures. The at least one membrane is arranged between one anode electrode layer and one cathode electrode layer, forming a membrane electrode assembly and defining an active area. One gas diffusion layer is arranged adjacent to each electrode layer. One flow field structure is arranged adjacent to each gas diffusion layer. Each flow field structure includes at least three fuel manifolds, at least three oxidant manifolds and at least three coolant manifolds. The fuel cell includes at least two active areas and in that at least one fuel manifold, at least one oxidant manifold and at least one coolant manifold is arranged between the at least two active areas.