Field of the Invention
This invention relates to bipolar plate assemblies for fuel cells and particularly for solid polymer electrolyte fuel cells intended for applications requiring high power density.
Description of the Related Art
Fuel cells such as solid polymer electrolyte or proton exchange membrane fuel cells electrochemically convert reactants, namely fuel (such as hydrogen) and oxidant (such as oxygen or air), to generate electric power. Solid polymer electrolyte fuel cells generally employ a proton conducting, solid polymer membrane electrolyte between cathode and anode electrodes. A structure comprising a solid polymer membrane electrolyte sandwiched between these two electrodes is known as a membrane electrode assembly (MEA). In a typical fuel cell, flow field plates comprising numerous fluid distribution channels for the reactants are provided on either side of a MEA to distribute fuel and oxidant to the respective electrodes and to remove by-products of the electrochemical reactions taking place within the fuel cell. Water is the primary by-product in a cell operating on hydrogen and air reactants. Because the output voltage of a single cell is of order of 1 V, a plurality of cells is usually stacked together in series for commercial applications in order to provide a higher output voltage. Fuel cell stacks can be further connected in arrays of interconnected stacks in series and/or parallel for use in automotive applications and the like.
Along with water, heat is a significant by-product from the electrochemical reactions taking place within the fuel cell. Means for cooling a fuel cell stack is thus generally required. Stacks designed to achieve high power density (e.g. automotive stacks) typically circulate liquid coolant throughout the stack in order to remove heat quickly and efficiently. To accomplish this, coolant flow fields comprising numerous coolant channels are also typically incorporated in the flow field plates of the cells in the stacks. The coolant flow fields may be formed on the electrochemically inactive surfaces of the flow field plates and thus can distribute coolant evenly throughout the cells while keeping the coolant reliably separated from the reactants.
Bipolar plate assemblies comprising an anode flow field plate and a cathode flow field plate which have been bonded and appropriately sealed together so as to form a sealed coolant flow field between the plates are thus commonly employed in the art. Various transition channels, ports, ducts, and other features involving all three operating fluids (i.e. fuel, oxidant, and coolant) may also appear on the inactive side and other inactive areas of these plates. The operating fluids may be provided under significant pressure and thus all the features in the plates have to be sealed appropriately to prevent leaks between the fluids and to the external environment. A further requirement for bipolar plate assemblies is that there is a satisfactory electrical connection between the two plates. This is because the substantial current generated by the fuel cell stack must pass between the two plates.
In order to obtain the greatest power density possible, developers of fuel cells strive to make the fuel cell stacks smaller, and particularly by reducing the thickness of the numerous bipolar plates in the stack. In that regard, the plates making up the assembly are preferably metallic and are typically produced by stamping or forming the desired features into sheets of appropriate metal materials (e.g. certain corrosion resistant stainless steels). Two or more stamped sheets are then typically welded together so as to appropriately seal all the fluid passages from each other and from the external environment. Additional welds may be provided to enhance the ability of the assembly to carry electrical current, particularly opposite the active areas of the plates. Metallic plates may however be bonded and sealed together using adhesives. Corrosion resistant coatings are also often applied before or after assembly.
Numerous designs for metallic bipolar plate assemblies have been proposed in the art. For instance, U.S. Pat. No. 7,419,738 discloses a variety of embodiments in which at least two of the plates have a common seal element of polymer material which is injected onto the plates and by which the plates are at least partially joined to one another. The arrangement makes it possible to reduce the number individual parts necessary for assembling the fuel cell arrangement with a comparatively small number of working steps. At the same time, the seal element can mechanically fix the plates without engaging in significant additional measures. By way of the seal element, it is possible to achieve not only sealing between the individual modules, but also sealing between the individual plates of a module. Numerous variations for the specific configuration of the connection of the plates by way of the seal element are possible.
In another example, US2009/0253022 discloses a seal structure for forming a substantially fluid tight seal between a unitized electrode assembly (UEA) and a plate of a fuel cell system, the seal structure including a sealing member formed in one fuel cell plate, a seal support adapted to span feed area channels in an adjacent fuel cell plate, and a seal adapted to cooperate with a UEA disposed between the fuel cell plates, the sealing member, and the seal support to form a substantially fluid tight seal between the UEA and the one fuel cell plate. The seal structure militates against a leakage of fluids from the fuel cell system, facilitates the maintenance of a velocity of a reactant flow in the fuel cell system, and a cost thereof is minimized. In this disclosure however, the sealing member itself in the vicinity of the seal is not well supported.
Further still, EP2696418 discloses another approach for a sealing assembly that has improved mechanical properties. The seal assembly is designed so that the reaction forces between the sealing element and surround are so small that damage of the groove and/or adjacent components is avoided. The sealing assembly comprises a plate having at least one step-shaped bead, the bead having at least one counter bead lying within the bead with a counter bead base and at least one counter bead flank, where a profiled sealing element having at least one sealing lip is positioned on the opposite bead base with certain specific characteristics.
Notwithstanding the many developments to date, there remains a need for greater improvement in power density from fuel cell stacks, and particularly for automotive applications. This invention fulfills these needs and provides further related advantages.
A bipolar plate assembly with integrated seal for a fuel cell is disclosed which comprises a subassembly comprising a formed metal cathode plate bonded to a formed metal anode plate. On at least a first one of the plates, two raised continuous ridges are formed on the outward surface of and around the perimeter of this first plate, thereby creating a channel to contain the seal. In this design, a substantial portion (e.g. greater than ½) of the channel area on the inward surface of this first plate is in direct contact with and supported by the other, second, plate. The channel and hence the seal are thus well supported during molding and under compression in the assembled fuel cell. A seal is integrated to the subassembly in which the seal comprises a sealing pad within the channel and on the outward surface of the first plate. A sealing bead may optionally be included on the outward surface of the sealing pad within the channel of the first plate.
With this design, ducts traversing the seal region can advantageously be formed for various fuel cell fluids without affecting the functioning of the seal. A duct or ducts can be formed between the bonded cathode and anode plates and traverse a span under both of the two raised continuous ridges of the first plate.
In certain embodiments, the integrated seal can be provided on both sides of the bipolar plate assembly. For instance, the subassembly can comprise at least one through-hole within the channel and which passes through both the bonded cathode and anode plates. The integrated seal can then be provided such that a portion fills the through-hole and also such that a sealing pad is provided on the outward surface of the second plate. It can be advantageous to employ a plurality of through-holes within the channel for this purpose. In such embodiments, the sealing pad on the outward surface of the second plate can be flat. Further, a curl can be introduced in the periphery of the through-hole or through-holes in order to better anchor the integrated to the subassembly.
In other embodiments, a similar second channel may be provided in the second plate. That is, the second plate in the subassembly can also comprise two raised continuous ridges on the outward surface and around the perimeter, thereby creating a second channel around the perimeter of the second plate. Here too, a substantial portion (e.g. greater than ½) of the area of the second channel on the inward surface of the second plate is in direct contact with and supported by the first plate. And again, the second channel and associated seal are thus well supported during molding and under compression in the assembled fuel cell.
Such bipolar plate assemblies with integrated seals are suitable for use in fuel cells, and particularly solid polymer electrolyte fuel cells and stacks thereof, for high power density applications (e.g. automotive).
The aforementioned bipolar plate assemblies with integrated seals can be manufactured by providing a metal cathode plate and a metal anode plate, forming two raised continuous ridges on the outward surface of and around the perimeter of a first one of the cathode and anode plates, to thereby create a channel around the perimeter of the first plate. The first plate is bonded to the second plate to form a subassembly in which a substantial portion of the area of the channel on the inward surface of the first plate is in direct contact with and supported by the second one of the cathode and anode plates. Then, a first mold is sealingly engaged to the apices of the two raised continuous ridges of the first plate, liquid sealant is injected into the first mold, and the liquid sealant is cured within the engaged first mold.
In embodiments comprising one or more through-holes in the subassembly, the through-hole, or holes, is formed such that it is within the channel and passes through the bonded first and second plates. This step can be accomplished either before or after the plates are bonded together. A second mold is also sealingly engaged to the outward surface of the second plate. And liquid sealant is injected into both the first and second molds (via direct connection to either the first or second mold or both), which is then cured within the engaged first and second molds.
These and other aspects of the invention are evident upon reference to the attached Figures and following detailed description.
In this specification, words such as “a” and “comprises” are to be construed in an open-ended sense and are to be considered as meaning at least one but not limited to just one.
Herein, in a quantitative context, the term “about” should be construed as being in the range up to plus 10% and down to minus 10%. “Formed” refers to the process of making or fashioning a component into a certain shape or form. With regards to forming a metal plate, typically this involves a stamping or pressing process.
The present design for a bipolar plate assembly with integrated seal provides a channel in which to mold and locate the seal, as well as desirable support for the channel during molding and while under compression in the assembled fuel cell.
Bipolar plate assembly 1 comprises formed metal first plate 2 bonded to formed metal second plate 12 (below first plate 2 and not visible in
An exemplary fuel cell stack in which to use the invention is a solid polymer electrolyte fuel cell stack intended for automotive purposes. Such stacks would comprise a series stack of generally rectangular, planar fuel cells that are separated by a number of bipolar plate assemblies 1. The membrane electrodes assemblies of the fuel cells would be located within the electrochemically active regions 8. Each sealing pad 4 in a bipolar plate assembly would then seal to the second plate in the adjacent bipolar plate assembly in the stack.
For comparison,
Yet another variant of the invention is shown in
The inventive bipolar plate assemblies with integrated seals can be manufactured by obtaining appropriate metal cathode and anode plate blanks and then forming two raised continuous ridges on the outward surface of and around the perimeter one or both of the plates to create the desired channels around the perimeter of the plate or plates. Other desired features, such as ducts and flow fields, also are formed into the plates. The two plates are then bonded together to form a subassembly. Importantly by design, after bonding, a substantial portion of the area of the formed channel on the inward surface of the relevant plate is in direct contact with and supported by the other plate. Note that the supporting region in the other plate does not need to be in the plane of the rest of the plate (e.g. as illustrated in
Once the metal plate subassembly has been prepared, the seal can be integrated thereto by molding an appropriate sealant (e.g. silicone) to the subassembly. For instance, a first mold can be sealingly engaged to the apices of the two raised continuous ridges of the plate comprising the channel, liquid sealant can then be injected into the first mold and afterwards the liquid sealant is cured within the engaged first mold.
If it is desired that the integrated seal have sealing pads formed on both sides of the bipolar plate subassembly, through-holes are also formed in the plates (e.g. as shown in
All of the above U.S. patents, U.S. patent application publications, U.S. patent applications, foreign patents, foreign patent applications and non-patent publications referred to in this specification, are incorporated herein by reference in their entirety.
While particular elements, embodiments and applications of the present invention have been shown and described, it will be understood, of course, that the invention is not limited thereto since modifications may be made by those skilled in the art without departing from the spirit and scope of the present disclosure, particularly in light of the foregoing teachings. Such modifications are to be considered within the purview and scope of the claims appended hereto.
Filing Document | Filing Date | Country | Kind |
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PCT/IB2015/001510 | 9/2/2015 | WO | 00 |
Number | Date | Country | |
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62053128 | Sep 2014 | US |