Bipolar Separator Perforated Sheet Cooling Optimization
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Solution Overview
Problem
The geometry of the cooling liquid passage in bipolar separators is not optimal, leading to inefficiencies and increased weight due to excessive cooling liquid volume, as it is dependent on fuel and oxidant channel configurations.
Innovation Solution
A bipolar separator with a perforated sheet forming through-grooves between flat polar plates allows independent optimization of fluid flows, reducing the volume of cooling liquid by adjusting the sheet thickness and groove geometry, and using straight channels for the cooling liquid to minimize transit time and volume.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the bipolar separator uses stamped polar plates with distribution channels, then the fuel and oxidant flow paths are formed, but the cooling liquid passage geometry becomes non-optimal and the cooling liquid volume increases
Solution Approach 1:
The bipolar separator is segmented into multiple functional layers: first and second polar plates for fuel/oxidant distribution, and a separate perforated sheet with through-grooves dedicated to cooling liquid flow. This segmentation allows each layer to be optimized for its specific function without compromising others, resolving the conflict between manufacturing ease and cooling liquid volume optimization.
Solution Approach 2:
The perforated sheet acts as an intermediary element between the polar plates, providing a dedicated structure for cooling liquid passage. The through-grooves in the perforated sheet create optimal cooling channels independent of the fuel and oxidant channel configurations, thereby reducing excessive cooling liquid volume while maintaining effective cooling.
2Device complexity
If the cooling liquid passage is formed by interstitial spaces between stamped polar plates, then the structure is simple, but the passage geometry is dependent on fuel and oxidant channel dimensions and is not optimal
Solution Approach 1:
The cooling liquid passage function is segmented from the fuel/oxidant distribution function by introducing a dedicated perforated sheet layer. This allows the cooling channels to be independently designed with optimal geometry (straight through-grooves) rather than being constrained by the interstitial spaces between stamped polar plates.
Solution Approach 2:
The cooling liquid passage is moved from the interstitial space dimension (between plates) to the through-thickness dimension (via through-grooves in the perforated sheet). This dimensional change enables straight, optimized cooling paths that are independent of the planar channel configurations for fuel and oxidant.
3Productivity
If spacers are inserted between polar plates to create cooling passages, then the cooling liquid flow is improved, but the flow section increases and the system volume increases
Solution Approach 1:
The perforated sheet functions as a thin film structure that provides dedicated through-groove channels for cooling liquid flow. Unlike bulky spacers, the thin perforated sheet maintains effective cooling liquid flow while minimizing the increase in system volume, as it integrates within the existing bipolar separator thickness.
Solution Approach 2:
The perforated sheet provides localized cooling channels only where needed, with through-grooves positioned strategically to create optimal cooling paths. This localized approach improves cooling liquid flow efficiency without unnecessarily increasing the overall system volume, unlike universal spacer insertion.
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 configuration optimizes the flow and volume of all fluids, reducing the cooling liquid volume and weight while maintaining efficient cooling, without increasing flow speed or pump power.
Implementation Method 1
ducts used for the passage of the cooling liquid... This heat tends to increase the temperature of the fuel cell stack when it operated... allowing the cooling liquid to flow in straight channels between the two polar plates
Data Source
AI summary
The invention relates to a bipolar separator (17) including a first (33) and a second (35) polar plate each comprising an inner surface and an outer surface in which at least one distribution channel (53, 55) is formed, the channels formed in the outer surfaces of the first and the second polar plate enabling fuel and oxidizer, respectively, to flow. The bipolar separator further includes an inner layer (29) provided to be sandwiched and compressed between the substantially planar inner surfaces of the first (33) and the second (35) polar plate, so as to form a laminated structure. The inner layer is formed by a perforated sheet comprising a group of through-grooves that form branchless channels, the ends of which lead, respectively, to two manifolds such that the coolant is able to flow between the first (33) and the second (35) polar plate.