Thermally Conductive Sub-Gasket for PEM Fuel Cell Heat Dissipation

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Solution Overview

Problem

In proton exchange membrane fuel cells, unintended catalyst particles can generate thermal energy that elevates the temperature of polymer sub-gaskets to their melt temperature, leading to premature failure and mixing of anode and cathode streams.

Innovation Solution

A sub-gasket design incorporating a structural component with a thermally conductive layer that dissipates heat energy, positioned between the cathode or anode layer and the ion-conducting membrane, to prevent overheating and maintain the integrity of the fuel cell.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a polymer sub-gasket is used in the fuel cell, then it provides adequate sealing and structural support during normal operation, but it is vulnerable to thermal degradation and melting when exposed to thermal energy from catalyst particles

Engineering Contradiction:

Improvesealing performanceVSAvoidthermal degradation

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The sub-gasket is constructed as a composite structure with an inner polymer layer providing sealing and an outer thermal management layer (metal or ceramic) providing thermal resistance. This composite design allows the gasket to maintain sealing performance while resisting thermal degradation from catalyst particles.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The thermal management layer is positioned in advance to shield the polymer sealing layer from thermal energy generated by catalyst particles. This protective layer acts as a thermal barrier that prevents heat from reaching the polymer material before it can cause degradation or melting.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

2Loss of energy

If the sub-gasket material has high thermal conductivity to dissipate heat, then thermal energy from catalyst particles is better managed, but the polymer material becomes more susceptible to reaching melt temperature

Engineering Contradiction:

Improvethermal energy dissipationVSAvoidmelt temperature

Core Design Contradiction:

Loss of energyVSTemperature

Solution Approach 1:

The sub-gasket uses a composite structure with an inner polymer layer and an outer thermal management layer. The thermal management layer has high thermal conductivity to dissipate heat away from the polymer, while the layered structure ensures heat must traverse multiple interfaces, preventing rapid temperature rise in the polymer material.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The solution addresses thermal management by adding a dimensional layer (the thermal management layer) rather than relying solely on the polymer's intrinsic thermal properties. This layered approach creates a thermal pathway that extends heat dissipation across multiple dimensions and interfaces.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Loss of energy

If a thermal management layer is added to the sub-gasket, then thermal energy dissipation is improved, but the device complexity increases

Engineering Contradiction:

Improvethermal energy managementVSAvoidsub-gasket structure

Core Design Contradiction:

Loss of energyVSDevice complexity

Solution Approach 1:

The thermal management layer is merged with the sub-gasket structure to form an integrated component. Rather than being a separate assembly, the thermal management layer is bonded or laminated directly to the polymer layer, creating a single multi-functional component that provides both sealing and thermal management.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The sub-gasket is designed as a composite material structure where the thermal management layer and polymer layer are combined into a single integrated component. This composite approach allows multiple functions (sealing, structural support, thermal management) to be achieved within a unified structure.

Inventive Principle:

Principle #40Composite materials

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

Effectively dissipates thermal energy, preventing sub-gasket melting and maintaining the separation of anode and cathode streams, thus enhancing the reliability and longevity of the fuel cell.

Implementation Method 1

a thermally conductive layer adhered to the outer region of the sub-gasket... the thermally conductive layer is tailored to dissipate heat energy

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS9911988B2Subgasket design to dissipate thermal energy generated from catalytic combustion experienced in a PEM fuel cell

Publication Date: 2018.03.06 GM GLOBAL TECHNOLOGY OPERATIONS LLC

AI summary

A fuel cell component includes a sub-gasket including a structural component and a thermally conductive layer. The sub-gasket defines a central opening while the structural component includes a first side and a second side. The sub-gasket also has an inner portion proximate to the central opening and an outer portion. The inner portion is positioned between the cathode layer outer edge and the ion-conducting membrane outer edge or between the anode layer outer edge and the ion-conducting membrane outer edge. Finally, the thermally conductive layer contacts the second side of the structural component. Advantageously, the thermally conductive layer dissipates locally generated heat caused by unintended particles falling on the sub-gasket.