Separator for fuel cell, fuel cell and method of manufacturing fuel cell

Abstract

A separator for fuel cell includes a corrugated portion formed to have a corrugated cross section where a first groove that is concave to a first surface to form a flow path for a first fluid on the first surface and a second groove that is concave to a second surface opposite to the first surface to form a flow path for a second fluid on the second surface are arranged alternately and repeatedly. Each of the second grooves has at least one shallower groove section formed to have a less depth from the second surface than depth of a remaining groove section and provided to form a communication flow channel on the first surface side, which is arranged to communicate between two flow path spaces for the first fluid that are adjacent to each other across the shallower groove section.

1 - 30 . (canceled) 
     
     
         31 . A separator for fuel cell, comprising:
 a corrugated portion formed to have a corrugated cross section where a first groove that is concave to a first surface to form a flow path for a first fluid on the first surface and a second groove that is concave to a second surface opposite to the first surface to form a flow path for a second fluid on the second surface are arranged alternately and repeatedly, wherein   each of the second grooves has at least one shallower groove section formed to have a less depth from the second surface than depth of a remaining groove section and provided to form a communication flow channel on the first surface side, which is arranged to communicate between two flow path spaces for the first fluid that are adjacent to each other across the shallower groove section.   
     
     
         32 . The separator according to  claim 31 , wherein
 a combination of the first fluid and the second fluid is a combination of two out of a fuel gas, an oxidizing gas and a coolant.   
     
     
         33 . The separator according to  claim 31 , wherein
 the first fluid is a coolant.   
     
     
         34 . The separator according to  claim 31 ,
 the separator being formed in an approximately rectangular planar shape, wherein   a first opening for defining a manifold for the first fluid and a second opening for defining a manifold for the second fluid are formed in proximity to two outer circumferential sides that are opposed to each other across the corrugated portion of the separator.   
     
     
         35 . The separator according to  claim 31 , wherein
 the shallower groove section included in each of the second grooves is formed at a position aligned with the shallower groove section included in another adjacent second groove, and   the shallower groove section is formed to have a cross section with a larger curvature radius or a greater draft angle on a downstream side of flow of the first fluid in the communication flow channel than a curvature radius or a draft angle on an upstream side.   
     
     
         36 . The separator according to  claim 31 , wherein
 the shallower groove section included in each of the second grooves is formed at a position aligned with the shallower groove section included in another adjacent second groove, and   the shallower groove section is formed to have a cross section with a smaller curvature radius or a smaller draft angle on a downstream side of flow of the first fluid in the communication flow channel than a curvature radius or a draft angle on an upstream side.   
     
     
         37 . The separator according to  claim 33 , wherein
 the first surface of the corrugated portion is subjected to at least one of film-coating treatment to enhance corrosion resistance in a specific area of the first groove adjacent to the shallower groove section, water repellent treatment to enhance water repellency in the specific area of the first groove adjacent to the shallower groove section, and hydrophilic treatment to enhance hydrophilicity in the shallower groove section.   
     
     
         38 . The separator according to  claim 31 , wherein
 each of the second grooves has a plurality of the shallower groove sections,   each of the shallower groove sections included in each of the second grooves is formed at a position aligned with a shallower groove section included in another adjacent second groove, and   the first surface of the corrugated portion has a wall member that is formed on a downstream side of a deeper groove section that is a part of the second groove other than the shallower groove section in a flow direction of the first fluid in the communication flow channel to be located on an extension of a boundary wall between the deeper groove section and the shallower groove section, and a floor member that is formed on the downstream side of the shallower groove section to be located on an extension of a floor surface of the shallower groove section.   
     
     
         39 . The separator according to  claim 31 , wherein
 each of the second grooves has a plurality of the shallower groove sections,   each of the shallower groove sections included in each of the second grooves is formed at a position aligned with a shallower groove section included in another adjacent second groove, and   the first surface of the corrugated portion has a spacer located at a position in the first groove adjacent to a deeper groove section that is a part of the second groove other than the shallower groove section to fill a space.   
     
     
         40 . The separator according to  claim 31 , wherein
 each of the second grooves has a plurality of the shallower groove sections, which include a normal shallower groove section and a medium-depth shallower groove section having a greater depth than that of the normal shallower groove section,   each of the shallower groove sections included in each of the second grooves is formed at a position aligned with a shallower groove section included in another adjacent second groove, and   the medium-depth shallower groove section included in each of the second grooves is located at a position opposed to the normal shallower groove section included in the adjacent second groove.   
     
     
         41 . The separator according to  claim 31 , wherein
 each of the second grooves has a plurality of the shallower groove sections, and   a boundary wall between a deeper groove section that is a part of the second groove other than the shallower groove section and the shallower groove section that is adjacent to the deeper groove section on a downstream side of flow of the second fluid in the flow path for the second fluid in each of the second grooves is inclined, such that a position nearer to the second surface is located on a lower stream side of the flow of the second fluid.   
     
     
         42 . The separator according to  claim 41 , wherein
 the plurality of shallower groove sections included in each of the second grooves are arranged, such that the shallower groove section located on a lower stream side of the flow of the second fluid in the flow path for the second fluid has a greater depth and a greater width in a flow direction of the second fluid.   
     
     
         43 . The separator according to  claim 31 , wherein
 the corrugated portion includes multiple different types of shallower groove sections having different depths.   
     
     
         44 . The separator according to  claim 31 , wherein
 each of the second grooves has a plurality of the shallower groove sections, and   a boundary wall between a deeper groove section that is a part of the second groove other than the shallower groove section and the shallower groove section that is adjacent to the deeper groove section on a downstream side of flow of the second fluid in the flow path for the second fluid in each of the second grooves is inclined, such that a position farther from the second surface is located on a lower stream side of the flow of the second fluid.   
     
     
         45 . The separator according to  claim 44 , wherein
 the second surface of the shallower groove sections in each of the second grooves is subjected to hydrophilic treatment to enhance hydrophilicity.   
     
     
         46 . The separator according to  claim 31 , wherein
 each of the second grooves has a plurality of the shallower groove sections, and   a boundary wall between a deeper groove section that is a part of the second groove other than the shallower groove section and the shallower groove section included in each of the second grooves has a part inclined at a predetermined angle to a flow direction of the first fluid in the communication flow channel.   
     
     
         47 . The separator according to  claim 46 , wherein
 each of the shallower groove sections included in each of the second grooves is arranged at a position shifted by a predetermined distance in a direction orthogonal to the flow direction of the first fluid in the communication flow channel, from position of the shallower groove section included in another adjacent second groove.   
     
     
         48 . The separator according to  claim 31 , wherein
 each of the second grooves has a plurality of the shallower groove sections, and   each of the shallower groove sections included in each of the second grooves is formed at a position shifted by a predetermined distance in a direction orthogonal to a flow direction of the first fluid in the communication flow channel, from position of the shallower groove section included in another adjacent second groove.   
     
     
         49 . The separator according to  claim 31 , wherein
 each of the second grooves has a plurality of the shallower groove sections, and   a deeper groove section included in the second groove that is a part of the second groove other than the shallower groove section has a larger diameter along a flow direction of the first fluid in the communication flow channel than diameter along the flow direction of the first fluid of the shallower groove section.   
     
     
         50 . A fuel cell, comprising:
 a power generation layer including an electrolyte membrane, an anode formed on one side of the electrolyte membrane and a cathode formed on the other side of the electrolyte membrane; and   the separators according to  claim 31  that are placed across the power generation layer.   
     
     
         51 . The fuel cell according to  claim 50 , further comprising:
 a detector configured to determine that a pressure loss in the flow path for the first fluid is less than a predetermined threshold value and thereby detect an abnormality in the flow path for the first fluid, wherein   the first fluid is a coolant.   
     
     
         52 . A method of manufacturing a fuel cell, the fuel cell comprising: a power generation layer including an electrolyte membrane, an anode formed on one side of the electrolyte membrane and a cathode formed on the other side of the electrolyte membrane; and the separators according to  claim 33  that are placed across the power generation layer, the method comprising the steps of:
 exposing the first surface of the first groove in the separator to a coolant; and 
 stacking the separator and the power generation layer, after the exposing step. 
 
     
     
         53 . A fuel cell, comprising:
 a plurality of power generation layers, each including an electrolyte membrane, an anode formed on one side of the electrolyte membrane and a cathode formed on the other side of the electrolyte membrane;   the separator according to  claim 31  that is located on an anode side of each of the power generation layers; and   a second separator in a flat plate-like shape that is located on a cathode side of each of the power generation layers.   
     
     
         54 . The fuel cell according to  claim 53 , wherein
 the separator is manufactured by press-forming a plate-like member, and   the second separator is formed to have a less thickness than thickness of the plate-like member used for manufacturing the separator.   
     
     
         55 . The fuel cell according to  claim 53 , further comprising:
 a seal formed to seal between the separator and the second separator opposed to the separator without intervention of the power generation layer at least at a position where the separator has concavity and convexity and arranged to adhere to the separator and to be pressed against the second separator, so as to ensure sealing.   
     
     
         56 . The fuel cell according to  claim 55 ,
 the fuel cell being manufactured by alternately stacking a first cell including an even number of the power generation layers and a second cell including an odd number of the power generation layers, wherein   the seal is provided on the first cell but is not provided on the second cell, prior to stacking of the first cell and the second cell to manufacture the fuel cell.   
     
     
         57 . A fuel cell, comprising:
 a plurality of power generation layers, each including an electrolyte membrane, an anode formed on one side of the electrolyte membrane and a cathode formed on the other side of the electrolyte membrane;   the separator according to  claim 31  that is located on an anode side of each of the power generation layers;   a second separator in a flat plate-like shape that is located on a cathode side of each of the power generation layers;   a first seal formed to seal between the separator and the second separator opposed to the separator without intervention of the power generation layer; and   a second seal formed to seal between the anode side and the cathode side at an edge of each of the power generation layers, wherein   at least one of the separator and the power generation layer has a tunnel flow path-forming member to form a tunnel flow path that runs under a seal line formed by the first seal and communicates between a flow path space for the second fluid and a flow path space opposed to the flow path space for the second fluid across the first seal, and   the tunnel flow path-forming member is located inside of the second seal along a planar direction of the power generation layer.   
     
     
         58 . The fuel cell according to  claim 57 , wherein
 the tunnel flow path-forming member includes a third groove that is formed in the separator and is concave to the second surface, and   the third groove is formed to have a less depth than depth of the deeper groove section included in the second groove.   
     
     
         59 . The fuel cell according to  claim 57 , wherein
 the tunnel flow path-forming member includes a thin-walled part that has a surface of the power generation layer opposed to the separator and recessed from surface of a remaining part of the power generation layer.   
     
     
         60 . The fuel cell according to  claim 57 , wherein
 the separator has a plurality of the tunnel flow path-forming members, and   the plurality of the tunnel flow path-forming members are arranged, such that the tunnel flow path-forming member located at a lowermost position in a direction of gravity in use of the fuel cell is extended to a location nearest to the flow path space for the second fluid.