Stacked Porous Fuel Cell Separator for 3D Flow Path Formation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for producing porous separators for fuel cells are complex, time-consuming, and difficult to mass-produce due to their intricate shapes, leading to high costs and inefficiencies.
Innovation Solution
A method involving the stacking of porous pattern structures with unit holes of regular shapes and controlled angular relationships to form a three-dimensional flow path pattern, allowing for the simple and efficient production of porous separators with complex shapes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If traditional etching or stamping processing methods are used to prepare porous separators, then the separator can be formed with complex shapes, but the manufacturing cost and preparation time increase significantly
Solution Approach 1:
The porous separator is divided into multiple thin porous pattern structures stacked together. Each individual layer has a simpler structure that is easier to manufacture, while the stacked combination creates the desired complex three-dimensional flow path pattern. This segmentation allows each layer to be produced more easily through simple forming processes rather than attempting to create the entire complex structure in a single piece using traditional etching or stamping methods.
Solution Approach 2:
The invention transitions from creating complex two-dimensional patterns in a single plane to stacking multiple simpler two-dimensional porous pattern structures in the third dimension. By arranging multiple layers with different orientations and patterns, the complex three-dimensional flow paths are formed through the stacking arrangement rather than through complex in-plane patterning, thereby simplifying the manufacturing of each individual layer.
2Manufacturing precision
If traditional processing methods are used to create minute and various shapes in porous separators, then the required precision can be achieved, but mass production becomes difficult due to forming limitations
Solution Approach 1:
By segmenting the complex precise structure into multiple simpler porous pattern layers, each layer can be manufactured with standard precision using simple forming processes. The cumulative effect of stacking these precisely aligned layers achieves the overall minute and various shapes required, while enabling mass production through standardized layer manufacturing and assembly processes.
Solution Approach 2:
The invention moves the complexity from the two-dimensional in-plane patterns to the three-dimensional stacking arrangement. This allows each individual layer to be manufactured with conventional precision using simple forms, while the precise control of layer stacking, thickness, and orientation achieves the required minute and various three-dimensional shapes, thereby enabling mass production.
3Ease of manufacture
If a single thick porous structure is used, then the separator can be formed simply, but the fuel distribution performance and electrochemical performance deteriorate
Solution Approach 1:
The single thick porous structure is segmented into multiple thin porous pattern structures stacked together. Each thin layer maintains simplicity in formation, while the stacked arrangement creates complex three-dimensional flow paths that enhance fuel distribution performance. The multiple layers provide better reactant distribution, improved mass transport, and enhanced electrochemical performance compared to a single thick structure, while each individual layer remains simple to manufacture.
Data Source
Figure 1A~1B
Figure 1C~2A
Figure 2B~2C
AI summary
An exemplary embodiment of the present invention provides a method of preparing a porous separator for a fuel cell, the method including: preparing a plurality of porous pattern structures, each of which includes a plurality of regularly repeated unit holes and in which a center axis is set to pass through a center of one unit hole and a center of another unit hole adjacent to the one unit hole; and preparing a porous separator by stacking the plurality of porous pattern structures, in which in the preparing of the porous separator, a center axis of one porous pattern structure and a center axis of another porous pattern structure adjacent to the one porous pattern structure are spaced apart from each other or intersect to form an angle of larger than 0° but lower than 90°.