Fuel cell bipolar plate design for reduced corrosion potential

Patent metadata

Field	Value
Publication number	US-12482834-B2
Application number	US-202217877513-A
Country	US
Kind code	B2
Filing date	Jul 29, 2022
Priority date	Jul 29, 2022
Publication date	Nov 25, 2025
Grant date	Nov 25, 2025

Abstract

A fuel cell system includes: a first fuel cell; a second fuel cell; a cathode configured to receive a positive charge from the first fuel cell and the second fuel cell; an anode disposed apart from the cathode and configured to receive a negative charge from the first fuel cell and the second fuel cell; a manifold enclosing the anode and the cathode; coolant disposed within the manifold and surrounding the cathode and the anode; and a seal disposed between the cathode and the anode so as to prevent the coolant from leaking into the first fuel cell, wherein the cathode includes a seal portion disposed adjacent to the seal and a remaining portion separated from the seal by the seal portion, and wherein the remaining portion of the cathode is configured to be non-parallel with the anode so as to reduce shunt current at the seal portion.

First claim

What is claimed is:

1 . A fuel cell system comprising:
a first fuel cell; a second fuel cell electrically connected in series with said first fuel cell; a cathode configured to receive a positive charge from said first fuel cell and said second fuel cell; an anode disposed apart from said cathode and configured to receive a negative charge from said first fuel cell and said second fuel cell; a manifold enclosing said anode and said cathode; coolant disposed within said manifold and surrounding said cathode and said anode; and a seal disposed between said cathode and said anode so as to prevent said coolant from leaking into said first fuel cell, wherein said cathode includes a seal portion disposed adjacent to said seal and a remaining portion separated from said seal by said seal portion, and wherein said remaining portion of said cathode is configured to be non-parallel with said anode so as to reduce shunt current at said seal portion.

2 . The fuel cell system of claim 1 , wherein said remaining portion of said cathode includes a parallel portion that is parallel with said anode and a rising step portion that is not parallel with said anode.

3 . The fuel cell system of claim 2 ,
wherein said parallel portion is disposed a first distance from said anode and said rising step portion is disposed at a second distance from said anode, wherein said first distance is greater than said second distance, and wherein said rising step portion connects said parallel portion with said seal portion.

4 . The fuel cell system of claim 1 ,
wherein said remaining portion of said cathode is curved such that at least one portion of said remaining portion is disposed a first distance from said anode and said seal portion is disposed at a second distance from said anode, and wherein said first distance is less than said second distance.

5 . The fuel cell system of claim 1 ,
wherein said anode includes an anode seal portion disposed adjacent to said seal and an anode remaining portion separated from said seal by said anode seal portion, and wherein said remaining portion of said cathode is configured to be non-parallel with said anode remaining portion.

6 . The fuel cell system of claim 1 , wherein said remaining portion of said cathode includes an end that is bent toward said anode.

7 . A method of making a fuel cell system, said method comprising:
forming a first fuel cell; forming a second fuel cell electrically connected in series with the first fuel cell; forming a cathode configured to receive a positive charge from the first fuel cell and the second fuel cell; forming an anode disposed apart from the cathode and configured to receive a negative charge from the first fuel cell and the second fuel cell; forming a seal between the cathode and the anode; enclosing the anode and the cathode with a manifold; and disposing coolant within the manifold and so as to surround the cathode and the anode, wherein the seal prevents the coolant from leaking into the first fuel cell, wherein said forming the cathode comprises forming the cathode so as to include a seal portion disposed adjacent to the seal and a remaining portion separated from the seal by the seal portion, and wherein said forming the cathode comprises forming the remaining portion so as to be non-parallel with the anode so as to reduce shunt current at the seal portion.

8 . The method of claim 7 , wherein said forming the cathode comprises forming the remaining portion so as to include a parallel portion that is parallel with the anode and a rising step portion that is not parallel with the anode.

9 . The method of claim 8 ,
wherein said forming the remaining portion comprises forming the parallel portion so as to be disposed a first distance from the anode, wherein the rising step portion is disposed at a second distance from the anode, wherein the first distance is greater than the second distance, and wherein said forming the remaining portion comprises forming the rising step portion so as to connect the parallel portion with the seal portion.

10 . The method of claim 7 ,
wherein said forming the cathode comprises forming the remaining portion to be curved such that at least one portion of the remaining portion is disposed a first distance from the anode, wherein the seal portion is disposed at a second distance from said anode, and wherein the first distance is less than the second distance.

11 . The method of claim 7 ,
wherein said forming the anode comprises forming the anode so as to include an anode seal portion disposed adjacent to the seal and an anode remaining portion separated from the seal by the anode seal portion, and wherein said forming the cathode comprises forming remaining portion so as to be non-parallel with the anode remaining portion.

12 . The method of claim 7 , wherein said forming the cathode comprises forming the remaining portion so as to include an end that is bent toward the anode.

13 . A fuel cell system including a fuel cell, an anode, a cathode, a manifold surrounding said anode and said cathode, the improvement comprising:
wherein said cathode includes a seal portion and a remaining portion, wherein said remaining portion of said cathode is configured to be non-parallel with said anode so as to reduce shunt current at said seal portion, wherein said remaining portion of said cathode includes a parallel portion that is parallel with said anode and a rising step portion that is not parallel with said anode, wherein said parallel portion is disposed a first distance from said anode and said rising step portion is disposed at a second distance from said anode, wherein said first distance is greater than said second distance, and wherein said rising step portion connects said parallel portion with said seal portion.

14 . A fuel cell system including a fuel cell, an anode, a cathode, a manifold surrounding said anode and said cathode, the improvement comprising:
wherein said cathode includes a seal portion and a remaining portion,
wherein said remaining portion of said cathode is configured to be non-parallel with said anode so as to reduce shunt current at said seal portion,
wherein said remaining portion of said cathode is curved such that at least one portion of said remaining portion is disposed a first distance from said anode and said seal portion is disposed at a second distance from said anode, and
wherein said first distance is less than said second distance.

15 . A fuel cell system including a fuel cell, an anode, a cathode, a manifold surrounding said anode and said cathode, the improvement comprising:
wherein said cathode includes a seal portion and a remaining portion,
wherein said remaining portion of said cathode is configured to be non-parallel with said anode so as to reduce shunt current at said seal portion,
wherein said anode includes an anode seal portion disposed adjacent to a seal and an anode remaining portion separated from said seal by said anode seal portion, and
wherein said remaining portion of said cathode is configured to be non-parallel with said anode remaining portion.

16 . The fuel cell system of claim 13 , wherein said remaining portion of said cathode includes an end that is bent toward said anode.

Assignees

• Toyota Eng & Mfg North America
• Toyota Motor Co Ltd

Inventors

• Tambo Tomoki
• Dede Ercan
• Zhou Yuqing

Classifications

• H01M8/2485

  Arrangements for sealing external manifolds; Arrangements for mounting external manifolds around a stack · CPC title

• Y02E60/50

  Fuel cells · CPC title

• H01M8/2404

  Processes or apparatus for grouping fuel cells · CPC title

• H01M8/0247

  characterised by the form (characterised by a channel configuration H01M8/0258) · CPC title

• H01M8/0271

  Sealing or supporting means around electrodes, matrices or membranes · CPC title