ELECTRODE MATERIAL AND ELECTRODE FOR OPERATING-MEDIUM DISTRIBUTION IN A FUEL CELL

Abstract

An electrode material (1) for a fuel cell (50), comprising a planar body (11) made of an electrically conductive foam having an open and continuous porosity for at least one operating medium of the fuel cell (50), wherein the planar body (11) has a top side (12) and a bottom side (13), and wherein the thickness (14) of the material across all points (12a, 12a′) on the surface of the top side (12), measured in each case between a point (12a, 12a′) on the surface of the top side (12) and the point (13a, 13a′) opposite this point (12a, 12a′) on the surface of the bottom side (13), varies by at least 10%. An electrode (2) for a fuel cell (50), comprising a planar body (21) made of an electrically conductive foam having an open and continuous porosity for at least one operating medium of the fuel cell (50), wherein the planar body (21) has a top side (22) and a bottom side (23), and wherein the top side (22), and/or the bottom side (23), has regions (22a, 23a) in which the porosity of the planar body (11) is reduced by at least 10%. A fuel cell (50) comprising the electrode (2). A method for production.

Claims

1. An electrode material (1) for a fuel cell (50), the electrode material comprising a plate-like body (11) composed of an electrically conductive foam with an open and continuous porosity for at least one operating medium of the fuel cell (50), wherein the plate-like body (11) has an upper side (12) and an underside (13) and wherein the thickness (14) of the material, measured between a point (12a, 12a′) on the surface of the upper side (12) and the point (13a, 13a′), situated opposite said first-mentioned point (12a, 12a′), on the surface of the underside (13), varies across all of the points (12a, 12a′) on the surface of the upper side (12) by at least 10%.

2. The electrode material (1) as claimed in claim 1, wherein the thickness of the material varies across all points (12a, 12a′) on the surface of the upper side (12) by at most 50%.

3. The electrode material (1) as claimed in claim 1, wherein the porosity of the foam is between 40% and 80%.

4. The electrode material (1) as claimed in claim 1, wherein the upper side (12) tapers in the form of a wedge toward the underside (13), and/or wherein the underside (13) tapers in the form of a wedge toward the upper side (12).

5. The electrode material (1) as claimed in claim 1, wherein the upper side (12), and/or the underside (13), has elongate elevations (15) and/or depressions (16), which define channel-like structures on the upper side (12), or on the underside (13).

6. An electrode (2) for a fuel cell (50), the electrode comprising a plate-like body (21) composed of an electrically conductive foam with an open and continuous porosity for at least one operating medium of the fuel cell (50), wherein the plate-like body (21) has an upper side (22) and an underside (23) and wherein the upper side (22), and/or the underside (23), has regions (22a, 23a) in which the porosity of the plate-like body (11) is reduced by at least 10%.

7. The electrode (2) as claimed in claim 6, wherein the porosity is reduced by deformation in the regions (22a, 23a) with reduced porosity.

8. The electrode (2) as claimed in claim 6, wherein the porosity is reduced by at most 50% in the regions (22a, 23a) with the reduced porosity.

9. The electrode (2) as claimed in claim 6, wherein the regions (22a, 23a) with the reduced porosity delimit channel-like structures (24) in the upper side (22), or in the underside (23).

10. The electrode (2) as claimed in claim 9, wherein the channel-like structures (24) transition into material recesses (26) in the surface of the upper side (22) and/or in the surface of the underside (23).

11. The electrode (2) as claimed in claim 10, wherein the material recesses (26) are arranged in that side (23, 22) of the electrode (2) which faces away from the side (22, 23) which comprises the regions (22a, 23a) with reduced porosity.

12. The electrode (2) as claimed in claim 10, wherein the material recesses (26) reach to a maximum depth that is between 10% and 40% of the maximum material thickness of the electrode (2).

13. The electrode (2) as claimed in claim 6, wherein the porosity increases or decreases monotonously along at least one direction (25) along the surface of the upper side (22) or along the surface of the underside (23).

14. The electrode (2) as claimed in claim 6, the electrode comprising a pressed or rolled electrode material (1), the electrode material comprising a plate-like body (11) composed of an electrically conductive foam with an open and continuous porosity for at least one operating medium of the fuel cell (50), wherein the plate-like body (11) has an upper side (12) and an underside (13) and wherein the thickness (14) of the material, measured between a point (12a, 12a′) on the surface of the upper side (12) and the point (13a, 13a′), situated opposite said first-mentioned point (12a, 12a′), on the surface of the underside (13), varies across all of the points (12a, 12a′) on the surface of the upper side (12) by at least 10%.

15. The electrode (2) as claimed in claim 14, produced by pressing of the electrode material (1) between a first, planar pressing surface and a second, topographically structured pressing surface, or by rolling between a first, purely cylindrical roller and a second roller that is topographically structured on its cylinder shell, wherein the topographical structuring of the second pressing surface, or of the second roller, corresponds to the material recesses (26).

16. The electrode material (1) as claimed in claim 1, wherein, at least in partial regions, the average pore size is between 100 μm and 400 μm.

17. A fuel cell (50) with an anode space (50a), a cathode space (50b) and an electrolyte (53), which separates the anode space (50a) from the cathode space (50b), wherein the anode space (50a) and the cathode space (50b) are respectively delimited on the side facing away from the electrolyte (53) by an end plate or bipolar plate (51, 52), and wherein an electrode (2) as claimed in claim 6 is arranged between at least one end plate or bipolar plate (51, 52), on one side, and the electrolyte (53), on the other side, such that the end plate or bipolar plate (51, 52) interacts with those regions (22a) of the electrode (2) in which the porosity is reduced in order to form a distributing structure (54, 55) for at least one operating medium of the fuel cell (50).

18. The fuel cell (50) as claimed in claim 17, wherein the end plate or bipolar plate (51, 52) additionally interacts with material recesses (26) of the electrode (2) in order to form the distributing structure (54, 55).

19. A method for producing an electrode material (1) as claimed in claim 1, wherein the plate-like body (11) is cut off from a block (1a) of the electrically conductive foam, wherein a cutting tool (3) in wire form is moved in a uniform basic movement (31) through the block (1a), and wherein the variation of the thickness (14) is introduced by virtue of a movement (32) of the cutting tool (3) perpendicular to said basic movement (31) being modulated onto the basic movement (31).

20. The method as claimed in claim 19, wherein complete cuts through the block (1a) with modulated basic movement (31+32) and unmodulated basic movement (31) are performed in alternation.

21. A method for producing an electrode (2) as claimed in claim 6, the method comprising providing an electrode material (1) comprising a plate-like body (11) composed of an electrically conductive foam with an open and continuous porosity for at least one operating medium of the fuel cell (50), wherein the plate-like body (11) has an upper side (12) and an underside (13) and wherein the thickness (14) of the material, measured between a point (12a, 12a′) on the surface of the upper side (12) and the point (13a, 13a′), situated opposite said first-mentioned point (12a, 12a′), on the surface of the underside (13), varies across all of the points (12a, 12a′) on the surface of the upper side (12) by at least 10%, and at least temporarily compressing the electrode material (1) in terms of its thickness by at least 20% and at most 60%.

22. The method as claimed in claim 21, wherein the electrode material (1) is, for the compression, loaded with a pressure between 200 N/cm.sup.2 and 3000 N/cm.sup.2.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0039] In the figures:

[0040] FIGS. 1a and 1b show exemplary embodiments of the electrode material 1;

[0041] FIGS. 2a, 2b and 2c show exemplary embodiments of the electrode 2, obtainable by pressing or rolling of the electrode materials 1 shown in FIG. 1;

[0042] FIG. 3 shows an exemplary embodiment of the electrode 2 with two different gradations of a reduced porosity;

[0043] FIG. 4 shows the exemplary production of a body 11 of the electrode material 1 from a block 1a of the electrically conductive foam;

[0044] FIGS. 5a and 5b show the exemplary production of a multiplicity of bodies 11, 11′ with minimal material loss;

[0045] FIG. 6 shows an exemplary embodiment of a fuel cell 50 with exemplary electrodes 2.

DETAILED DESCRIPTION

[0046] FIG. 1a shows a first exemplary embodiment of the electrode material 1 in a schematic sectional drawing. The plate-like body 11 of the electrode material 1 has an upper side 12 and an underside 13. The underside 13 is planar, and the upper side 12 has an undulating structure. The thickness 14 of the material, measured in each case between a point 12a or 12a′ on the upper side 12 and a point 13a or 13a′, situated opposite said point 12a or 12a′, on the underside 13 is variable owing to said structuring. There are thus elevations 15, and in this example also depressions 16, in the upper side 12 of the electrode material 1.

[0047] FIG. 1b shows a second exemplary embodiment of the electrode material 1 in a schematic sectional drawing. Here, the underside 13 of the plate-like body 11 is in turn planar, whereas the upper side 12 tapers in the form of a wedge toward the underside 13. The thickness 14 of the plate-like body 11 thus decreases continuously from left to right.

[0048] FIGS. 2a and 2b show a first exemplary embodiment of the electrode 2, obtainable for example by pressing or rolling of the electrode material 1 shown in FIG. 1a. FIG. 2a shows a schematic plan view, and FIG. 2b shows a schematic sectional drawing.

[0049] The electrode 2 has a plate-like body 21, which has originated, for example by at least partial plastic deformation, from the plate-like body 11 of the electrode material 1. The plate-like body 21 has an upper side 22 and an underside 23 (not visible in FIG. 2a). The elevations 15 (visible in FIG. 1a) in the electrode material 1, after the pressing, become regions 22a with reduced porosity in the upper side 22, because the material contained in the elevations 15 must escape inward into the body 21. Said regions 22a pose an increased flow resistance to a through-flowing operating medium for a fuel cell 50. The intermediate spaces between said regions 22a define channel-like structures 24 in the upper side 22. During the operation of the fuel cell 50, the plate-like body 21 of the electrode 2 can accommodate more operating medium, and transport said operating medium more quickly, in said regions 24 than in the regions 22a. Also shown in FIG. 2b are material recesses 26 into which the channel-like structures 24 transition. Here, the material recesses 26 are situated in the underside 23 of the electrode, that is to say in that side of the electrode 2 which faces away from the regions 22a with reduced porosity.

[0050] FIG. 2c shows a second exemplary embodiment of the electrode 2, obtainable for example by pressing or rolling of the electrode material 1 shown in FIG. 1b. Here, the acting force is distributed more uniformly over the upper side 12 and the underside 13 of the plate-like body 11 of the electrode material 1. The plate-like body 21 of the electrode 2 that is thus obtained therefore has, both on its upper side 22 and on its underside 23, a respective region 22a and 23a with reduced porosity. The depth to which said region respectively extends into the interior of the plate-like body 21 is determined by how much material must escape into said interior. For example, in the case of the pressing or rolling of the wedge-like body 11 of the electrode material 1 as shown in FIG. 1b, there is the tendency, visible in FIG. 2c, that the regions 22a and 23a at the left edge of the body 21 of the electrode 2 that is formed project deeper into said body than at the right edge. Furthermore, within the regions 22a and 23a, the exact magnitude of the porosity increases monotonously along the direction 25 from left to right.

[0051] FIG. 3 shows a third exemplary embodiment of the electrode 2 in a schematic sectional drawing. Said electrode 2 can be obtained for example by virtue of two bodies 11 of electrode materials 1 of the type shown in FIG. 1a being laid with the elevations 15 in the upper sides 12 thereof one on top of the other, specifically so as to be rotationally offset with respect to one another by 90°, and by virtue of said arrangement subsequently being rolled or compressed. All elevations 15 are then, analogously to the transition from FIG. 1a to FIGS. 2a and 2b, converted in each case into regions 22a with reduced porosity, with the difference that there are horizontal and vertical regions 22a of said type. The qualitatively most important difference is however that the intersection points of the elevations 15 are converted into regions 22a′ with even more greatly reduced porosity.

[0052] If the electrode 2 that is to be produced is, as shown in FIG. 3, rectangular and not square, then it is for example possible for two bodies 11 with the same rectangular dimensions but orientations of the elevations 15 offset with respect to one another by 90° to be produced by virtue of a block being cut from the electrically conductive foam alternately in each case in different directions. If the cuts are alternately made with a 90° offset with respect to one another with uniform and regular modulation, slices are produced, the upper side and underside of which have elevations 15 which are offset with respect to one another by 90°. In turn, a body which is structured on two sides is produced, as shown in FIG. 3.

[0053] Suitable variations, for example for rhomboidal flow fields, in which there are thus rhomboidally arranged zones of greater and lesser porosity, can be generated by virtue of the modulated cuts for generating the upper side and underside of the foam slices being performed at an angle between 0° and 90° with respect to one another.

[0054] The regions 22a′ with the even more greatly reduced porosity can, in a fuel cell 50, be used for example to realize regular points for the homogenization of the local reaction rates, at which water condenses, heat is conducted, or mechanical supporting points are formed, in targeted fashion.

[0055] FIG. 4 shows, by way of example, how bodies 11 of electrode materials 1 can be produced from a block 1a of an electrically conductive foam. A cutting tool 3 in wire form which extends perpendicular to the plane of the drawing is led through the block 1a in a basic movement 31 from top to bottom. Said basic movement 31 has a movement 32 perpendicular to it modulated thereon. By means of said further movement 32, it is for example possible for the elevations 15 and depressions 16 visible in FIG. 1a, or for example the wedge shape visible in FIG. 2b, to be introduced into the body 11. In the example shown in FIG. 4, the elevations 15 of the cut-off body 11 correspond to depressions 16 in the surface of the rest of the block 1a, and the depressions 16 of the cut-off body 11 correspond to elevations 15 in the surface of the rest of the block 1a. The preliminary work for the manufacture of the next body 11 has thus already been performed, which next body can be directly cut from the block 1a in the next working step.

[0056] FIG. 5 shows, by way of example, how a multiplicity of bodies 11, 11′ of electrode materials 1 can be produced, with minimal loss of material, from a block 1a of an electrically conductive foam. FIG. 5a shows how the block 1a can be divided into a multiplicity of similar bodies 11, 11′ of the type shown in FIG. 1a by means of alternate undulating and straight cuts. FIG. 5b shows how the block 1a can, by means of an alternating sequence of two different oblique cuts, be divided into a multiplicity of similar bodies 11, 11′, the upper sides and undersides of which respectively taper toward one another.

[0057] FIG. 6 shows an exemplary embodiment of a fuel cell 50. The fuel cell 50 has an anode space 50a and a cathode space 50b, which are separated from one another by an electrolyte 53. The anode space 50a is delimited by a first end plate 51, on one side, and the electrolyte 53, on the other side. The cathode space 50b is delimited by a second end plate 52, on one side, and the electrolyte 53, on the other side. Lateral or encircling seals are not shown in FIG. 6 for the sake of clarity.

[0058] In each case one example of the described electrode 2, in this case of the type illustrated in FIG. 2b, is arranged in the anode space 50a and in the cathode space 50b. The respective channel-like structures 24 outside the regions 22a in which the porosity is reduced interact with the respective end plate 51 or 52 in order to form distributing structures 54 or 55 for the operating media of the fuel cell 50.

[0059] Analogously to FIG. 2c, it is the case here that the channel-like structures 24 transition into material recesses 26 of the electrodes 2. Here, said material recesses 26 each face toward an end plate 51, 52 and extend parallel to the channel-like structures 24 perpendicular to the plane of the drawing. An operating medium supplied in the region of the end plate 51, 52 can thus firstly be distributed with a low pressure loss over the entire boundary surface between the end plate 51, 52 and the adjoining electrode 2. If the operating medium now moves within the plane of the drawing in the direction of the electrolyte 53, then it is subjected to a progressively increasing flow resistance proceeding from the material recesses.