Separator Design for Fuel Battery Stack Deformation Control
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Solution Overview
Problem
Conventional separators composed of two thin metal plates are prone to deformation under pressure in the lamination direction, which can cause the cooling medium flow channel to be closed, compromising the integrity of the fuel battery stack.
Innovation Solution
A separator design featuring two flat plate members with oxidation gas and fuel gas flow channels on one side and a cooling medium flow channel on the opposite side, utilizing through holes and passage parts to maintain the cooling medium flow channel structure even under pressure, with projections and gasket lines to prevent deformation and ensure flow channel integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If two thin metal plates are used to construct the separator, then weight reduction and miniaturization are achieved, but the separator becomes prone to deformation under pressure in the lamination direction
Solution Approach 1:
The separator is divided into multiple through holes that penetrate both plate members, creating segmented flow channels for the cooling medium. This segmentation allows the structure to maintain integrity while using thinner plates, as the through holes provide defined pathways that prevent complete collapse under pressure.
Solution Approach 2:
The invention introduces a third dimension by creating through holes that penetrate both plate members in the lamination direction. This dimensional change allows the cooling medium to flow through the separator thickness, providing structural support that prevents deformation while maintaining thin plate construction.
2Reliability
If the separator is deformed by pressure in the lamination direction, then the cooling medium flow channel may be closed, but using thicker plates to prevent deformation increases weight
Solution Approach 1:
The separator structure is designed in advance with through holes and passage parts that pre-establish the cooling medium flow paths. This preliminary structural arrangement ensures that even under pressure, the flow channels remain open because the through holes provide defined geometric constraints that prevent collapse.
Solution Approach 2:
The separator is constructed as a composite structure with two different plate members (first plate member and second plate member) joined together. This composite construction provides enhanced structural integrity and deformation resistance compared to a single plate, allowing the use of thinner materials while maintaining flow channel integrity.
3Strength
If conventional cutting work is used to process conductive carbon sheets, then separator plates with high rigidity are obtained, but manufacturing complexity and time increase
Solution Approach 1:
The invention replaces the conventional mechanical cutting process with a forming process that creates the separator structure directly. Instead of cutting conductive carbon sheets, the separator is formed by joining two plate members with integrated through holes and passage parts, eliminating complex cutting operations while maintaining structural integrity.
Data Source
AI summary
An example separator includes: a flat plate-shaped first plate member; a flat plate-shaped second plate member joined with the first plate member; an oxidation gas flow channel wall, which forms a flow channel of oxidation gas; a fuel gas flow channel wall, which forms a flow channel of fuel gas; a cooling medium flow channel wall, which forms a flow channel of a cooling medium; a first through hole, which penetrates the first plate member and the second plate member; a second through hole, which penetrates the first plate member and the second plate member; a first cooling medium passage part; a second cooling medium passage part; one projection, which is formed on at least one of the first cooling medium passage part and the second cooling medium passage part; and another projection, which is formed at a position corresponding to the one projection.