106Electric Vehicle Technology Explained,
Second EditionFigure 5.16An example of a fairly large PEMFC system. Four separate fuel cell stacks can be seen. Each consists of 160 cells in series. (Reproduced by kind permission of MAN Nutzfahrzeuge
AG. This is the fuel cell stack from the bus shown in Figure 5.2, and is made by Siemens.)
most promising options are discussed elsewhere, such as in Ruge and B¨uchi (2001).
It is certainly the case now, and will be for many years, that the bipolar plate makes a major contribution to the cost of a fuel cell, as well as its size and its weight.
Anyone who has
made fuel cells knows that leaks are a major problem. If the path of hydrogen through a stack using internal manifolding (as in Figure 5.15) is imagined, the possibilities for the gas to escape are many. The gas must reach the edge of every porous electrode – so the entire edge of every electrode is a possible escape route, both under and over the edge gasket. Other likely trouble spots are the joins between each and every bipolar plate.
In addition, if there is the smallest hole in any of the electrolyte, a serious leak is certain.
The result is that a fuel cell is quite a difficult system to manufacture, requiring parts that are complex to form rapidly and cheaply. Very
careful assembly is required, and each fuel cell stack consists of a large number of components. The system has a very low level of fault tolerance.
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