Unitary Separator Plate and Frame for Electrochemical Cells
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Solution Overview
Problem
There is a need for cost-effective separator plates and cell frames that can maintain intimate contact between electrochemical cell components under varying operational pressures over long periods, particularly in high-pressure applications.
Innovation Solution
The development of a separator plate with curvilinear protrusions and a frame with bridging elements that support water and gas passageways, allowing for reliable assembly and integration of individual parts in the electrochemical cell stack, while being formed from a single sheet of material using hydroforming, reducing manufacturing and labor costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional separator plates and cell frames are used, then assembly is simpler, but manufacturing cost and labor cost increase, and reliability under high pressure decreases
Solution Approach 1:
The patent combines the separator plate and cell frame into a single unitary component made from one piece of metal forming. This integration eliminates the need for separate manufacturing and assembly of two distinct parts, reducing manufacturing complexity and labor costs while maintaining the structural functions of both components under high-pressure operation
Solution Approach 2:
The unitary separator plate/frame structure performs multiple functions simultaneously: it acts as a separator plate to maintain cell component spacing, provides frame-like structural support for the electrochemical cell, and ensures intimate contact between components through its integrated design. This multi-functionality reduces the total number of parts needed
2Productivity
If traditional multi-part separator plates and frames are used, then manufacturing flexibility is higher, but device complexity and assembly time increase
Solution Approach 1:
The patent merges the separator plate and cell frame into one integrated unitary component. This consolidation reduces the number of discrete parts from two to one, simplifying the assembly process and eliminating the need for separate assembly steps, thereby improving productivity while reducing device complexity
3Adaptability or versatility
If unitary separator plate and frame are used, then manufacturing cost decreases, but adaptability to different operational pressures may be limited
Solution Approach 1:
The patent employs hydroforming technology to manufacture the unitary separator plate/frame, which allows for precise control of geometric parameters and structural characteristics during the forming process. This manufacturing method enables the creation of optimized structures that can adapt to varying operational pressures while maintaining cost-effectiveness through a single-piece construction
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 solution provides a cost-effective and reliable unitary separator plate and cell frame that supports the electrochemical cell structure under pressure, facilitating efficient fluid flow and assembly, thereby enhancing the performance and longevity of the cell stack.
Implementation Method 1
formed from a single sheet of material using hydroforming
Data Source
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AI summary
A separator plate and a frame member for an electrochemical cell are provided. The separator plate includes a plurality of protrusions extending therefrom to define a flow field. A pair of end features arranged along opposite sides of the flow field, each end feature extending substantially the length of the flow field. A periphery portion is provided having a first set of openings and a second set of openings. Wherein the plurality of protrusions and pair of end features extend from a plane defined by the periphery portion. The frame member includes features for facilitating assembly and reducing the risk of an over constrained condition. The frame member further having ports divided by a bridge member to support the frame member under operating pressures.