Honeycomb structure and method for production of said structure

• US 7,115,336 B2
• Filed: 02/17/2003
• Issued: 10/03/2006
• Est. Priority Date: 02/19/2002
• Status: Expired due to Fees

• Current Assignee: Commissariat a L'Energie Atomique (French Alternative Energies and Atomic Energy Commission)
• Original Assignee: Commissariat a L'Energie Atomique (French Alternative Energies and Atomic Energy Commission)
• Inventors: Revol, Stephane
• Primary Examiner(s): Zimmerman, John J.
• Application Number:
  US10/503,589
• Publication Number:
  US 20050221150A1
• Time in Patent Office: 1,324 Days
• Field of Search: None
• US Class Current: 429/434
• CPC Class Codes: B22F 10/28 Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
• CPC Class Codes: B22F 3/1103 with particular physical characteristics
• CPC Class Codes: F28F 13/003 by using permeable mass, perforated or porous materials F28F13/18 takes precedence
• CPC Class Codes: H01M 8/0206 Metals or alloys
• CPC Class Codes: H01M 8/0247 characterised by the form characterised by a channel configuration H01M8/0258
• CPC Class Codes: H01M 8/0258 characterised by the configuration of channels, e.g. by the flow field of the reactant or coolant
• CPC Class Codes: H01M 8/0267 having heating or cooling means, e.g. heaters or coolant flow channels
• CPC Class Codes: H01M 8/0271 Sealing or supporting means around electrodes, matrices or membranes
• CPC Class Codes: Y02E 60/50 Fuel cells
• CPC Class Codes: Y02P 10/25 Process efficiency
• CPC Class Codes: Y02P 70/50 Manufacturing or production processes characterised by the final manufactured product
• CPC Class Codes: Y10T 428/12361 having aperture or cut
• CPC Class Codes: Y10T 428/12479 Porous [e.g., foamed, spongy, cracked, etc.]

Abstract

The invention concerns an alveolar structure (1) comprising at least one alveolar zone (2a, 2b) partially delimited by an associated leak tight surface (4a, 4b) . According to the invention, each alveolar zone (2a, 2b) is formed of a plurality of metallic layers (8) superimposed parallel to the associated leak tight surface (4a, 4b), each metallic layer (8) comprising a network of passages (10) opening out on either side of said metallic layer (8).

The invention further concerns a method for manufacturing said alveolar structure (1)

Application to fuel cells and heat exchangers.

Claims

1. A bipolar plate for a fuel cell comprising:

at least two alveolar zones juxtaposed with a common base plate, each zone being partially delimited by an associated leak tight surface of the common base plate,

wherein each alveolar zone is formed of a plurality of metallic layers superimposed parallel to the associated leak tight surface, each metallic layer comprising a network of passages opening out on either side of said each metallic layer.

2. The bipolar plate according to claim 1, integrated in a fuel cell.

3. The bipolar plate according to claim 1, integrated in a fuel cell with an integrated exchanger.

4. The bipolar plate according to claim 1, integrated in a heat exchanger.

5. A method of manufacturing an alveolar structure including at least one alveolar zone partially delimited by an associated leak tight surface.

wherein each alveolar zone is formed of a plurality of metallic layers superimposed parallel to the associated leak tight surface, each metallic layer comprising a network of passages opening out on either side of said each metallic layer, wherein each metallic layer is formed by:

depositing a layer of metallic powder;

partially solidifying by laser the layer of deposited metallic powder, leading to formation of solidified parts and non-solidified parts, the solidified parts defining a perimeter of the network of passages of the metallic layer.

6. A method according to claim 5, wherein for each alveolar zone, the metallic layers are formed successively, the associated leak tight surface constituting a support for a first of the metallic layers to be formed, the solidified and non- solidified parts of any metallic layer formed constituting a support for following of the metallic layers to be formed.

7. A method according to claim 5, wherein for each alveolar zone, when all of the metallic layers have been formed, the network of passages of the metallic layers are obtained by eliminating the non-solidified parts of the metallic layers.

8. A method according to claim 5, wherein the partially solidifying by laser of a layer of deposited metallic powder is also capable of making the solidified parts obtained integral with the solidified parts of the metallic layer on which they are lying.

9. A method according to claim 5, wherein the partially solidifying by laser of the first layer of deposited metallic powder is also capable of making the solidified parts obtained integral with the associated leak tight surface on which they are lying.

10. A method according to claim 5, wherein the metallic layers are composed of a material chosen from among stainless steels, aluminium and its alloys, including Ni—

Cr, and a mixture of at least two of the aforementioned elements.

11. A method according to claim 10, wherein the metallic layers comprise at least one binder.

12. A method according to claim 10, wherein the at least one binder comprises bronze.