1. Field of the Invention
The present invention relates to a fuel cell, and more particularly, to a fuel cell having a stack structure in which a plurality of unit cells are stacked on top of one another.
2. Description of the Related Art
A fuel cell stack has a stack of unit cells each having an electrolyte membrane, a pair of electrodes disposed on both sides of the electrolyte membrane, and a pair of separators disposed outside the electrodes. In such a fuel cell stack, a fuel gas is supplied to the anode of each unit cell through a fuel gas supply manifold. Similarly, an oxidant gas is supplied to the cathode of each unit cell through an oxidant gas supply manifold. The manifolds extend in the stacking direction through the fuel cell stack. Each separator has an outer peripheral portion through which through-holes are formed, and the through-holes define the manifolds when the unit cells are stacked on top of one another. In such a unit cell, a seal member is often interposed between the paired separators to prevent leakage of the fuel gas and oxidant gas. For example, Japanese Patent Application Publication No. 2003-223903 (JP-A-2003-223903) discloses a unit cell having seal members provided around through-holes of separators and around a power generating part thereof.
In such a fuel cell stack, a fastening load may be applied in the stacking direction of the fuel cell stack to improve the sealability of the seal members and to prevent deterioration of cell function due to poor electrical contact in the fuel cell stack. For example, a fastening load can be applied in the stacking direction of the fuel cell stack by providing end plates at both ends of the stack and fastening nuts threaded on tension rods extending through the four corners of the end plates.
As shown in
The present invention provides an fuel cell separators having edges that are not deformed or broken by a fastening load in the stacking direction.
A first aspect of the present invention relates to a fuel cell. The fuel cell has a stack of unit cells each having an electrolyte membrane, a pair of electrodes disposed on both sides of the electrolyte membrane, and a pair of separators disposed outside the paired electrodes. In the fuel cell, a fastening load is applied in the stacking direction to maintain the stacked state of the stack. The fuel cell has through-holes formed through outer peripheral portions of the separators that allow at least a reactant gas to flow through the separators; and support members disposed between the pairs of separators for supporting the fastening load in areas with no through-holes on the outer peripheral portions of the separators.
The fuel cell described above may further include seal members formed along at least part of the edges of the through-holes. The support members may be formed integrally with the seal members.
In the fuel cell, the support members are located in areas with no through-holes on the outer peripheral portions of the separators. The fuel cell has seal members provided around the through-holes, through which a reactant gas flows, and the seal members also support separators between the separators. When the positions of the seal members are shifted when the separators are pressed from both sides, bending stress is exerted on the separators. In the fuel cell according to the first aspect of the present invention, the separators are less likely to be bent because the edges of the separators are supported by the support members. Therefore, in the case of metal separators, the separators do not bent until the edges of the separators come into contact with each other to cause an electrical short circuit. In the case of carbon separators, the separators may be prevented from developing cracks at locations where the seal members are misaligned relative to each other.
The seal members may be implemented in various forms such as seal gaskets, seal gasket-integrated MEAs, and adhesive seals. The seal members may be formed around the through-holes, or the seal member may be omitted at positions where the through holes are communicated with reaction gas passages. By providing seal members as described above the flow of reactant gas is not interfered with.
In the fuel cell according to the first aspect of the present invention, because the support members are formed integrally with the seal members, the number of parts can be reduced and the assembly of the fuel cell stack can be facilitated.
In the fuel cell according to the first aspect of the present invention, the pairs of separators, the seal members and the support members do not form an enclosed space.
Here, the enclosed space have no openings for communication with other spaces. For example, it can be thought of a case where, when closed regions (for example, rectangular regions) are formed by the seal members formed around the through-holes and the support members formed integrally with the seal members, closed spaces are formed by the separators, the support members and the seal members when the support members are disposed between the pairs of separators.
In the fuel cell according to the first aspect of the present invention, the pairs of separators, the seal members and the support members do not form an enclosed space. Therefore, the following effect is achieved. For example, when closed spaces are formed by the separators, support members, and seal members, the air in the closed spaces may expand because of self heating and flow beyond the seal members and support member to the side of the through-holes while the fuel cell is operating. Then, the sealability of the seal members formed around the through-holes deteriorates and the reactant gas flows through the through-holes and may leak to the outside. However, according to the fuel cell of the present invention, because a closed space is not formed, the force which causes gas to move beyond the seal members formed around the through-holes is not generated. Therefore, deterioration of sealability is prevented.
The support members may be adhesives.
The adhesive may be a silicone, epoxy resin, epoxy-modified silicone, olefin, or olefin-modified silicone.
The support members may be seal gaskets.
The support members may have gas impermeability, elasticity, and heat resistance.
In the fuel cell according to the first aspect of the present invention, because the support members comprise an adhesive, each of the unit cells is integrated into a unitary body. Therefore, when a plurality of unit cells are stacked, the fuel cell stack may be easily assembled with high accuracy as compared to the case where the separators, electrodes, electrolyte membranes and so on are stacked individually.
The foregoing and further features and advantages of the invention will become apparent from the following description of example embodiments with reference to the accompanying drawings, wherein like numerals are used to represent like elements and wherein:
The best mode for carrying out the present invention is described in the following order: A First embodiment, B. Second embodiment, C. Third embodiment, D. Fourth embodiment, E. Modification.
A. First embodiment: A1. Configuration of fuel cell stack:
In the fuel cell stack 100, an end plate 10, an insulating plate 20, a current collecting plate 30, a plurality of unit cells 40a, a current collecting plate 50, an insulating plate 60, and an end plate 70 are stacked in the stated order from one end to the other. These members have supply ports, discharge ports, and passages (not shown) to allow hydrogen as fuel gas, air as oxidant gas, and coolant to flow through the fuel cell stack 100. The hydrogen is supplied from a hydrogen tank (not shown). The air and the coolant are pressurized and supplied by pumps (not shown). A coolant separator (not shown) each having a coolant passage through which coolant flows is interposed between every five unit cells 40a.
The fuel cell stack 100 has tension plates 80. In the fuel cell stack 100, a pressure is applied in the stacking direction of the stack structure. As a result, deterioration of cell performance due to poor electrical contact in the fuel cell stack 100 can be prevented and the sealing performance of seal members is ensured. The tension plates 80 are secured to the end plates 10 and 70 at both ends of the fuel cell stack 100 by bolts 82 in the fuel cell stack 100. As a result, the unit cells 40a are fastened by a prescribed fastening force in the stacking direction.
The end plates 10 and 70, and the tension plates 80 are made of a metal, such as steel, to ensure rigidity. The insulating plates 20 and 60 are made of an insulating material such as rubber or resin. The current collecting plates 30 and 50 are made of a gas-impermeable conductive material such as dense carbon or copper plate. Each of the current collecting plates 30 and 50 has an output terminal (not shown) so that the electric power generated in the fuel cell stack 100 may be output.
Next the unit cell 40a will be described with reference to
The unit cell 40a is integrated into a unitary body by an adhesive Ba applied on the anode side separator 41a and the cathode side separator 47a. The lines of adhesive Ba (areas indicated by oblique hatching) are described below with reference to
Similarly, on the cathode side separator 47a, the adhesive Ba is applied continuously along all four edges thereof as shown in
The lower edge of the anode side separator 41a and the upper edge of the cathode side separator 47a are bonded to each other as shown in
When a plurality of unit cells 40a constituted as described above are stacked on top of each other to form a fuel cell stack 100, the hydrogen supply through-holes 412i and 472i form a hydrogen supply manifold (not shown) extending through the fuel cell stack 100 in the stacking direction. Similarly, the hydrogen discharge through-holes 412o and 472o form a hydrogen discharge manifold (not shown), the air supply through-holes 414i and 474i form an air supply manifold (not shown), the air discharge through-holes 414o and 474o form an air discharge manifold (not shown), the coolant supply through-holes 416i and 476i form a coolant supply manifold (not shown), and the coolant discharge through-holes 416o and 476o form a coolant discharge manifold (not shown). Hydrogen supplied from the hydrogen tank (not shown) to the fuel cell stack 100 is distributed into the hydrogen passages 412p of the unit cells 40a through the hydrogen supply manifold and supplied to the anodes 43. Hydrogen that is not consumed in the electrode reaction is discharged from the fuel cell stack 100 through the hydrogen discharge manifold. Similarly, air from the atmosphere outside the fuel cell stack 100 pressurized and supplied to the fuel cell stack 100 by a pump (not shown) is distributed through the air passages 474p of the unit cells 40a through the air supply manifold and supplied to the cathodes 45. Air that is not consumed in the electrode reaction is discharged from the fuel cell stack 100 through the air discharge manifold. Coolant supplied to the fuel cell stack 100 is distributed to a plurality of coolant separators through the coolant supply manifold and flows through the coolant passages therein to cool the unit cells. After that, the coolant is discharged from the fuel cell stack 100 through the coolant discharge manifold.
A2. Effect: The effect of the fuel cell stack 100 according to this embodiment is described below with reference to
In the fuel cell stack of the related art, when the load points where pressures are applied to the separators from both sides in areas with no through-holes on the outer peripheral portions of the separators are displaced relative to each other, bending stress is exerted on the separators and the separators may be bent (
B. Second embodiment: B1. Configuration of fuel cell stack: The configuration of a fuel cell stack of a second embodiment is similar to that of the fuel cell stack 100 of the first embodiment with the exception of the lines of adhesive Bb in unit cells 40b and hence description of similar features will not repeated. The lines of adhesive Bb (areas indicated by oblique hatching in
As in the case of the first embodiment, when a pressurizing load is applied to the anode side separator 41b and the cathode side separator 47b with an MEA 48 interposed therebetween so that the lower edge of the anode side separator 41b and the upper edge of the cathode side separator 47b are bonded to each other and the upper edge of the anode side separator 41b and the lower edge of the cathode side separator 47b are bonded to each other as shown in
B2. Effect: In the fuel cell stack of this embodiment, the adhesive Bb is applied along the upper and lower edges of the separators 41b and 47b in the areas with no through-holes on the outer peripheral portions of the separators 41b and 47b. Thus, even if the lines of adhesive Bb pressing the separators 41b and 47b from both sides are displaced relative to each other in the areas with no through-holes, the separators are not bent because the edges of the separators 41b and 47b are supported by the adhesive Bb as in the first embodiment. Therefore, deformation in the outer peripheral portions of the separators may be prevented.
When the adhesive Bb is applied as in the first embodiment, for example, closed regions surrounded by the lines of adhesive Bb are formed at the corners of the separators 41b and 47b. Then, when the anode side separator 41b and the cathode side separator 47b are bonded to each other to form an integrated unit cell 40b, closed spaces (indicated as O in
However, in the fuel cell of this embodiment, the adhesive Bb applied along the upper and lower edges of the anode side separator 41b and the adhesive Bb applied around the through-holes 412i, 412o, 414i, and 414o are not connected to each other. Similarly, the adhesive Bb applied along the upper and lower edges of the cathode side separator 47b and the adhesive Bb applied around the through-holes 472i, 472o, 474i and 474o are not connected to each other. That is, the adhesive Bb, which functions as a support member, and the adhesive Bb, which functions as a seal member, do not form a closed region. Thus, when an anode side separator 41b and a cathode side separator 47b are bonded to each other to form an integrated unit cell 40b, any closed space containing air is not formed in the unit cell 40b. Therefore, the adhesive Bb applied around the through-holes can be prevented from being broken and its function as seal members cannot be impaired.
C. Third embodiment: C1. Configuration of fuel cell stack: The configuration of a fuel cell stack according to a third embodiment is similar to that of the fuel cell stack 100 of the first embodiment with the exception of the lines of adhesive Bc in unit cells 40c and hence description of the similar features will not be repeated. The lines of adhesive Bc (areas indicated by oblique hatching in
The lower edge of the anode side separator 41c and the upper edge of the cathode side separator 47c are bonded to each other as in the first embodiment as shown in
C2. Effect: In the fuel cell stack of this embodiment, the adhesive Bc is applied in spots along the upper and lower edges of the separators 41c and 47c to the areas with no through-holes on the outer peripheral portion of the separators 41c and 47c. Thus, even if the lines of adhesive Bc pressing the separators 41c and 47c from both sides are displaced relative to each other in the areas with no through-holes, the separators are not bent because the edges of the separators 41c and 47c are supported by the adhesive Bc as in the first embodiment. Therefore, deformation in the outer peripheral portions of the separators may be prevented.
In addition, in the fuel cell stack of this embodiment, the adhesive Bc which functions as a seal member and the adhesive Bc which functions as a support member for supporting the fastening load exerted on the separators do not form any closed region. Thus, when the anode side separator 41c and the cathode side separator 47c are bonded to each other to form an integrated unit cell 40c, any closed space containing air is not formed in the unit cell 40c as in the second embodiment. Therefore, the adhesive Bc applied around the through-holes may be prevented from being broken and its function as a seal member is not impaired.
In addition, in the fuel cell stack of this embodiment, because the adhesive Bc is applied in spots on the anode side separator 41c and the cathode side separator 47c except for the areas around the receiving part 418 and around the through-holes, the amount of the adhesive Bc can be reduced. Therefore, the cost and weight of the fuel cell stack can be decreased.
D. Fourth embodiment: D1. Configuration of fuel cell stack: The configuration of a fuel cell stack of a fourth embodiment is similar to that of the fuel cell stack 100 of the first embodiment with the exception of the configuration of unit cells 40d and hence description of similar features will not repeated. The configuration of the unit cell 40d in this embodiment is described below with reference to
The anode side separator 41d is a flat plate having a generally square planar shape and has the same through-holes as those of the seal gasket 49 through the outer peripheral portion thereof as in the case of the anode side separator 41a of the first embodiment. The anode side separator 41d also has groove-like hydrogen passages 412p (
A unit cell 40d is formed by interposing a seal gasket-integrated MEA 489 between an anode side separator 41d and a cathode side separator 47d as shown in
D2. Effect: The seal gasket-integrated MEA of the fuel cell stack according to the related art has ribs formed around the MEA and around the through-holes. When a fuel cell stack is formed, the separators are pressed from both sides by the ribs. The positions of the ribs located on both sides of the separators may be shifted relative to each other when the unit cells are stacked, and the ribs may be deformed by gas pressure while the fuel cell stack is operating. Then, the load points where pressures are applied to the separators from both sides may be displaced relative to each other. When the load points where pressures are applied to the separators from both sides are displaced relative to each other, bending stress is exerted on the separators. This may cause cracks to develop in carbon separators.
In the fuel cell stack of this embodiment, however, linear ribs R are formed along the upper and lower edges of the seal gasket 49. Thus, even if the ribs R pressing the separators 41d and 47d from both sides are misaligned relative to each other, the separators are not bent because the edges of the separators are supported by the ribs R which function as support members. Therefore, cracks in the outer peripheral portions of the separators are prevented from forming.
E. Modification: Although an example in which an adhesive is used as support members is shown in the first and second embodiments described above, a seal gasket may be used instead. Although an example in which an adhesive is applied in spots as support members is shown in the third embodiment, spherical or columnar members may be used instead.
Although an example in which each separator has support members extending continuously along all four edges thereof (first embodiment), an example in which each separator has support members extending along two opposite edges thereof (second embodiment), and an example in which each separator has support members provided in spots along two opposite edges thereof (third embodiment) are shown in the above embodiments, the support members are not limited to the above but may be in other forms in the present invention. For example, L-shaped support members may be formed at the corners of the separators, or support members may be formed in the shape of broken lines along the edges of the separators.
While the invention has been described with reference to what are considered to be example embodiments thereof, it is to be understood that the invention is not limited to the described embodiments or constructions. On the contrary, the invention is intended to cover various modifications and equivalent arrangements. In addition, while the various elements of the described invention are shown in various example combinations and configurations, other combinations and configurations, including more, less or only a single element, are also within the scope of the appended claims.
Number | Date | Country | Kind |
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2006-207595 | Jul 2006 | JP | national |
Filing Document | Filing Date | Country | Kind | 371c Date |
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PCT/IB07/02168 | 7/30/2007 | WO | 00 | 1/30/2009 |