A fuel cell stack, a method of assembly, a fuel cell module and a vehicle

Abstract

This application discloses a fuel cell stack, assembly method, fuel cell module, and vehicle, which can increase the mounting spacing of connectors and improve the structural strength of connectors. The fuel cell stack includes a low-voltage wiring harness, a core with tabs, and a connector assembly electrically connected to the tabs. The core includes several stacked individual cells, with odd-numbered and / or even-numbered individual cells in the core having tabs, each tab forming the tab row. The connector assembly connects to the tabs of the odd-numbered and / or even-numbered individual cells in the core. Because a single connector assembly connects only odd-numbered or even-numbered individual cells, the mounting spacing of the connectors can be increased by at least double, ensuring sufficient wall thickness for the connectors and thus improving their structural strength. At least one connector assembly is electrically connected to the low-voltage wiring harness, enabling different inspection schemes.

Description

Technical Field

[0001] This application belongs to the field of fuel cell stack technology, specifically relating to a fuel cell stack, assembly method, fuel cell module, and vehicle. Background Technology

[0002] A proton exchange membrane fuel cell (PEMFC) is a power generation device that uses hydrogen as fuel to directly convert chemical energy into electrical energy. The high energy density, fast start-up speed, low operating temperature, and pollution-free byproducts of fuel cells make them potentially valuable for applications in the new energy vehicle sector. A fuel cell stack typically consists of hundreds of membrane electrode assemblies (MEAs), bipolar plates, and seals stacked together. These are secured by end plates, insulating plates, and current collectors, which collect output energy and isolate high voltage. The end plates are fastened together using straps, tie rods, and screws. Inside the fuel cell stack, the reactant gases (hydrogen and air) and coolant are distributed to each cell through a main pipe on the bipolar plates. Therefore, the size of the main pipe directly affects the flow resistance of the three chambers of the stack. Inside each cell, hydrogen and air are evenly distributed through the anode and cathode channels, respectively, and transferred to the MEAs. Inside the MEAs, under the action of catalysts on both sides of the proton exchange membrane, an electrochemical reaction occurs in the anode and cathode reaction media, converting chemical energy into electrical energy.

[0003] During normal use, the performance of a proton exchange membrane fuel cell is related to adverse operating conditions such as excessive dryness, excessive moisture, or lack of gas in the intake system, as well as mechanical damage, which in turn affects the voltage of each individual cell. Therefore, it is necessary to collect the voltage signal of each individual fuel cell and send it to the fuel cell system controller. By monitoring the voltage signals of each individual cell, the operating status of the fuel cell can be determined, and corresponding control operations can be performed. Specifically, this is done by using a voltage monitoring device (CVM) to monitor the voltage of each bipolar plate.

[0004] The bipolar plate and the CVM are primarily connected via a voltage monitoring connector. During connection, the bipolar plate is first inserted into the connector, and then the signal or electrical energy is transmitted to the CVM via a low-voltage wiring harness for data and energy conversion. With technological advancements, the volumetric power density of the fuel cell stack is gradually increasing, and the spacing between the bipolar plates is gradually decreasing. This requires a corresponding reduction in the outer wall thickness of adjacent voltage monitoring connectors, which leads to a decrease in connector strength. Summary of the Invention

[0005] To address the aforementioned technical issues, this application provides a fuel cell stack, assembly method, fuel cell module, and vehicle, which can achieve various inspection methods such as single-cell inspection and double-cell inspection, thereby increasing the mounting spacing of the connectors and improving the structural strength of the connectors.

[0006] The technical solution adopted to achieve the purpose of this application is a fuel cell stack, including a low-voltage wiring harness, a stack core with tabs, and a connector assembly electrically connected to the tabs. The stack core includes a plurality of stacked single cells, and the odd-numbered and / or even-numbered single cells in the stack core are provided with tabs, and each tab constitutes the tab array. The connector assembly is connected to the tabs of the odd-numbered and / or even-numbered single cells in the stack core, and at least one of the connector assemblies is electrically connected to the low-voltage wiring harness.

[0007] In some embodiments, both odd-numbered and even-numbered cells in the core are provided with tabs, with the tabs of the odd-numbered cells forming a first tab row and the tabs of the even-numbered cells forming a second tab row.

[0008] In some embodiments, both the first and second tabs are connected to the connector assembly, and at least one of the connector assemblies is electrically connected to the low-voltage wiring harness.

[0009] In some embodiments, the odd-numbered or even-numbered individual cells in the core are provided with tabs.

[0010] In some embodiments, the core has a sealing structure at at least one end along the stacking direction; the sealing structure includes at least one dummy membrane electrode and at least one electrode plate unit alternately stacked; the dummy membrane electrode is a membrane electrode structure with a sealing ring and unable to undergo electrochemical reactions, and the electrode plate unit has tabs; the connector assembly is electrically connected to both the tabs of the core and the tabs of the sealing structure.

[0011] In some embodiments, the connector assembly includes at least two connectors arranged sequentially along a stacking direction; the connector includes at least two rows of connection positions, each row having two or more connection positions, the connection positions in the at least two rows being staggered, and the spacing between connection positions in the same row being the same.

[0012] In some embodiments, the connector includes two rows of connection positions; each row of connection positions contains four or more connection positions; the spacing D between each connection position in the same row is 4d, where d is the inter-plate spacing between two adjacent single cells.

[0013] In some embodiments, the connector has a recess at a first end along the stacking direction and a protrusion at a second end that mates with the recess.

[0014] In some embodiments, the connector connected to the low-voltage harness is an integral part of the low-voltage harness.

[0015] In some embodiments, the single cell includes stacked bipolar plates and membrane electrodes; the bipolar plates are fabricated from a substrate, and the substrate has two tabs, which are respectively located on two opposite sides of the substrate.

[0016] In some embodiments, the two electrodes are staggered or centrally symmetrically distributed; the two electrodes are located on the two short sides of the substrate, respectively.

[0017] Based on the same inventive concept, this application also provides an assembly method for the above-mentioned fuel cell stack, comprising the following steps:

[0018] One of the tabs in a substrate with two tabs is cut off to obtain a bipolar plate, wherein the tabs of the odd-numbered bipolar plates and the tabs of the even-numbered bipolar plates are distributed on different sides of the bipolar plate.

[0019] Assemble the fuel cell stack; during the assembly process, the odd-numbered bipolar plates or the even-numbered bipolar plates are rotated 180° and then stacked, and the stacked bipolar plates form the first tab and the second tab.

[0020] Connect the connector assembly with the low-voltage wiring harness and the connector assembly without the low-voltage wiring harness to the first electrode row and the second electrode row, respectively, to obtain the fuel cell stack.

[0021] Based on the same inventive concept, this application also provides another assembly method for the above-mentioned fuel cell stack, comprising the following steps:

[0022] At least one tab in the substrate is cut off to obtain a bipolar plate, wherein: the bipolar plate with odd numbering or the bipolar plate with even numbering has the tab;

[0023] Assemble the fuel cell stack; during the assembly process, the odd-numbered bipolar plates or the even-numbered bipolar plates are rotated 180° and then stacked, and the stacked bipolar plates form a row of tabs.

[0024] The connector assembly with the low-voltage wiring harness is connected to the tab array to obtain the fuel cell stack.

[0025] Based on the same inventive concept, this application also provides a fuel cell module, including a low-voltage inspection device and at least one of the above-mentioned fuel cell stacks, wherein the low-voltage inspection device is electrically connected to the low-voltage wiring harness.

[0026] Based on the same inventive concept, this application also provides a vehicle including at least one of the above-described fuel cell stacks; or including the above-described fuel cell module.

[0027] As can be seen from the above technical solution, the fuel cell stack provided in this application includes a low-voltage wiring harness, a stack core with tabs, and a connector assembly electrically connected to the tabs. The stack core includes several stacked single cells. The single cells in the stack core can be numbered sequentially along the stacking direction. Unlike the prior art where the stack core only has one row of tabs, in the fuel cell stack provided in this application, the odd-numbered and / or even-numbered single cells in the stack core are provided with tabs, and each tab constitutes a tab row. That is to say, the tab row in the stack core is composed of either purely odd-numbered single cells or purely even-numbered single cells. If both odd-numbered and even-numbered single cells are provided with tabs, the position of the tab row formed by the tabs of the odd-numbered single cells is different from the position of the tab row formed by the tabs of the even-numbered single cells.

[0028] Compared with existing technologies, the fuel cell stack provided in this application connects the connector assembly to the tabs of odd-numbered and / or even-numbered individual cells in the stack core. This allows a single connector assembly to connect only odd-numbered or even-numbered individual cells, increasing the connector mounting distance by at least double and ensuring sufficient wall thickness to improve structural strength. Furthermore, by electrically connecting different connector assemblies to the low-voltage wiring harness, different inspection schemes can be implemented. For example, by connecting only the connectors to the tab rows of odd-numbered individual cells, the fuel cell stack can achieve a "two-cell-one-inspection" scheme, while the connectors not connected to the low-voltage wiring harness are used for insulation between the tabs. If all connectors are connected, the fuel cell stack can achieve a "single-cell-one-inspection" scheme. Attached Figure Description

[0029] Figure 1 This is a schematic diagram of the structure of the fuel cell stack of Embodiment 1 of this application.

[0030] Figure 2 This is a schematic diagram of the core structure of the fuel cell stack according to Embodiment 1 of this application.

[0031] Figure 3 for Figure 2 An enlarged view of the tabs of the reactor core.

[0032] Figure 4 for Figure 2 A schematic diagram of the bipolar plates in a single cell with an odd-numbered core.

[0033] Figure 5 for Figure 2 A schematic diagram of the bipolar plates in a single cell with an even-numbered core.

[0034] Figure 6This is a connection structure diagram of the tab array and connector assembly of the fuel cell stack in Embodiment 1 of this application.

[0035] Figure 7 This is a schematic diagram of the substrate used to form the bipolar plate of the fuel cell stack of Embodiment 1 of this application.

[0036] Figure 8 This is a schematic diagram of the core structure of the fuel cell stack of Embodiment 2 of this application.

[0037] Figure 9 for Figure 8 An enlarged view of the tabs of the reactor core.

[0038] Figure 10 for Figure 8 A schematic diagram of the bipolar plates in a single cell with an odd-numbered core.

[0039] Figure 11 for Figure 8 A schematic diagram of the bipolar plates in a single cell with an even-numbered core.

[0040] Figure 12 This is a structural block diagram of the fuel cell module of Embodiment 5 of this application.

[0041] Figure 13 This is a structural block diagram of the vehicle according to Embodiment 6 of this application.

[0042] Figure 14 This is a diagram showing the connection structure of the tab bar and connector assembly in the prior art.

[0043] Explanation of reference numerals in the attached drawings: 100-Fuel cell stack; 110-Inlet end plate; 120-Inlet end insulation plate; 130-Inlet end manifold; 140-Core; 141-Bipolar plate; 142-Taper; 143-Base plate; 144-Taper row; 1441-First tab row; 1442-Second tab row; 150-Blind end manifold; 160-Blind end insulation plate; 170-Blind end plate assembly; 171-Blind end plate; 172-Disc spring support plate; 180-Fastening assembly; 190-Connector assembly; 191-Connector; 192-Connection position. Detailed Implementation

[0044] To enable those skilled in the art to better understand this application, the technical solution of this application will be described in detail below with reference to the accompanying drawings and specific embodiments.

[0045] In related technologies, fuel cell stack inspection typically employs a "single-piece, one-piece" inspection scheme. Connectors are generally arranged in a single row, with each connector's connection point continuously inserted into the bipolar plates. As the spacing between bipolar plates decreases, the required outer wall thickness of adjacent voltage inspection connectors must also decrease, leading to a reduction in connector strength. Furthermore, from an inspection function perspective, due to the presence of the connector's outer frame, the thickness of the outer frame is significantly greater than the spacing between the bipolar plates. This prevents current inspection devices from simultaneously detecting the voltage of the two outermost bipolar plates of adjacent connectors. Figure 14 As shown, the first connector A and the second connector B can only detect the voltage of the first bipolar plate a and the third bipolar plate c, but cannot detect the voltage of the second bipolar plate b (located between the last inspection connection position of the first connector A and the first inspection connection position of the second connector B).

[0046] Therefore, this application provides a fuel cell stack, assembly method, fuel cell module, and vehicle, which can realize various inspection methods such as single-cell inspection and double-cell inspection, thereby increasing the mounting spacing of the connectors and improving the structural strength of the connectors. This solves, to a certain extent, the technical problems existing in the aforementioned related technologies. The present application will be described in detail below with reference to the accompanying drawings and specific embodiments:

[0047] Example 1:

[0048] This application provides a fuel cell stack 100, including a low-voltage wiring harness, a stack core 140 with tabs 144, and a connector assembly 190 electrically connected to the tabs 144. The stack core 140 includes a plurality of stacked individual cells. Each individual cell includes a membrane electrode assembly (MEA) and a bipolar plate 141. The MEA and bipolar plate 141 generally have the same outline, are parallel to each other, and are stacked along the normal direction of their respective planes. Each individual cell is also stacked along the same direction. In a fuel cell, the end closer to the reaction medium input is defined as the inlet end, and the end farther from the reaction medium input is defined as the blind end. Correspondingly, each individual cell is stacked sequentially along the inlet end-blind end (or blind end-inlet end) direction. Therefore, in this embodiment, the term "stack direction" refers to the inlet end-blind end (or blind end-inlet end) direction.

[0049] The single cells in the core 140 with odd and / or even numbers are provided with tabs 142, and each tab 142 constitutes a tab row 144; the connector assembly 190 is connected to the tabs 142 of the single cells with odd and / or even numbers in the core 140, and at least one connector assembly 190 is electrically connected to the low voltage wiring harness.

[0050] If each cell in the core 140 is numbered sequentially along the stacking direction, there will be odd-numbered cells and even-numbered cells. In related technologies, the tabs 142 of odd-numbered cells and even-numbered cells are arranged in the same row, that is, the core 140 has only one row of tabs 144. However, in the fuel cell stack 100 provided in this application, the tabs 142 of odd-numbered cells and even-numbered cells in the core 140 are arranged in separate rows. In other words, odd-numbered and / or even-numbered cells are provided with tabs 142, and each tab 142 constitutes a tab row 144. In other words, the tab array 144 in the core 140 is composed of either odd-numbered or even-numbered single cells. If both odd-numbered and even-numbered single cells are provided with tabs 142, then the tabs 142 of the odd-numbered single cells constitute the first tab array 1441, and the tabs 142 of the even-numbered single cells constitute the second tab array 1442, and the first tab array 1441 and the second tab array 1442 are in different positions. This difference in position can be that the first tab array 1441 and the second tab array 1442 are located on the same side of the single cell but with a certain distance between them; or that the first tab array 1441 and the second tab array 1442 are located on different sides of the single cell, thus resulting in different positions.

[0051] In the fuel cell stack 100 provided in this application, the tabs 142 of the odd-numbered and / or even-numbered single cells in the stack core 140 are arranged in separate rows. Therefore, a single connector assembly 190 connects only the odd-numbered or even-numbered single cells, doubling the mounting distance of the connectors 191 and ensuring that the connectors 191 have sufficient wall thickness, thereby improving their structural strength. On the other hand, by electrically connecting different connector assemblies 190 to the low-voltage wiring harness, different inspection schemes can be implemented. For example, if only the connectors 191 connected to the tab rows 144 of the odd-numbered single cells are wired, the fuel cell stack 100 can implement a "two-cell-one-inspection" inspection scheme, while the connectors 191 not connected to the low-voltage wiring harness are used for insulation between the tabs 142; if all connectors 191 are wired, the fuel cell stack 100 can implement a "single-cell-one-inspection" inspection scheme.

[0052] See details Figures 2 to 5In this embodiment, both odd-numbered and even-numbered single cells in the core 140 are provided with tabs 142. The tabs 142 of the odd-numbered single cells form a first tab row 1441, and the tabs 142 of the even-numbered single cells form a second tab row 1442. Specifically, the tabs 142 are all disposed on the short side of the bipolar plate 141 of the single cell, and in the core 140, the first tab row 1441 and the second tab row 1442 are located on the same short side, and the first tab row 1441 and the second tab row 1442 have a certain distance between them, which is required to meet the space requirements for arranging two connector assemblies 190.

[0053] Specifically, based on the different positions of the tabs 142 of odd-numbered single cells and even-numbered single cells, two specifications of bipolar plates 141 can be set: one for bipolar plates 141 used as odd-numbered single cells, such as... Figure 4 As shown; another type of bipolar plate 141 used for single cells with even-numbered designations, such as Figure 5 As shown. The two specifications of bipolar plates 141 can be fabricated using separate molds.

[0054] In some embodiments, to reduce mold costs and improve product versatility, the bipolar plates 141 of different specifications are processed from the same substrate 143. For example... Figure 7 As shown, the substrate 143 has two tabs 142, which are located on opposite sides of the substrate 143. For ease of wiring, it is preferable to place one tab 142 on each of the two short sides of the substrate 143. The two tabs 142 of the substrate 143 are staggered and not centrally symmetrical; that is, there is a certain distance between the position of the first tab 142 and the position of the second tab 142 after rotating 180°. If the two tabs 142 of the substrate 143 are denoted as m and n, and the positions of tabs m and n after rotating 180° are denoted as M and N, then: cutting off tab m of the substrate 143 yields a bipolar plate 141 for a single cell with odd-numbered designations, as shown below. Figure 4 As shown; by cutting away the tab n of the substrate 143, the bipolar plate 141 of the even-numbered single cell can be obtained, as shown. Figure 5 As shown.

[0055] During the stacking process of bipolar plates 141, it is usually necessary to rotate two adjacent bipolar plates 141 by 180°. The reason is as follows: a single bipolar plate 141 consists of an anode plate and a cathode plate, and the flow channel structures of the anode plate and the cathode plate are different. In order to ensure sealing, the flow channels of adjacent anode plates and cathode plates need to be consistent. In the existing plate structure, the flow channel on the left side of the anode plate and the flow channel on the right side of the cathode plate are matched. Therefore, it is necessary to rotate two adjacent bipolar plates 141 by 180° to ensure that the flow channel on the left side of the anode plate of the bipolar plate 141 on the gas inlet side of the membrane electrode is aligned with the flow channel on the right side of the cathode plate of the bipolar plate 141 on the blind end side of the membrane electrode. Therefore, although the tabs 142 removed during the formation of the bipolar plate 141 are different, when the bipolar plate 141 is rotated 180°, the tabs 142 of the bipolar plates 141 of odd-numbered single cells will be located on the same side of the core 140 as the tabs 142 of the bipolar plates 141 of even-numbered single cells. That is, the position of tab m is on the same side of the core 140 as position N; the position of tab n is on the same side of the core 140 as position M. This ensures that after stacking, the core 140 can form two rows of tabs 144 on the same side: the first tab row 1441 and the second tab row 1442.

[0056] Connector assembly 190 is connected to the first tab 1441 and / or the second tab 1442. When only the first tab 1441 or the second tab 1442 is connected to connector assembly 190, insulation treatment is required for the second tab 1442 or the first tab 1441 without connector assembly 190. For example, an insulating sleeve can be installed on the second tab 1442 or the first tab 1441 without connector assembly 190 to achieve insulation between adjacent tabs 142. Since the outer shell of connector assembly 190 is made of insulating material except for the part in contact with the tabs 142 which is conductive, connector assembly 190 can achieve insulation between adjacent tabs 142 when connected to tabs 142. If a low-voltage harness is not installed on connector assembly 190, no signal will be output.

[0057] Therefore, please refer to Figure 6In this embodiment, both the first tab bar 1441 and the second tab bar 1442 are connected to connector assemblies 190, and at least one connector assembly 190 is electrically connected to the low-voltage wiring harness. Specifically, when one of the two connector assemblies 190 is electrically connected to the low-voltage wiring harness, the fuel cell stack 100 can implement a "two-cell-per-unit" inspection scheme, that is, the output inspection voltage is the total voltage of two adjacent single cells. When both connector assemblies 190 are electrically connected to the low-voltage wiring harness, the fuel cell stack 100 can implement a "single-cell-per-unit" inspection scheme, that is, the output inspection voltage is the voltage of a single cell. In other embodiments, if only part of the connectors in each connector assembly 190 are wired, the fuel cell stack 100 can implement inspection schemes such as "four-cell-per-unit" or "eight-cell-per-unit". The specific wiring method can be determined according to the inspection scheme of the fuel cell stack 100, and this application does not impose specific limitations.

[0058] For ease of assembly, in some embodiments, the connector assembly 190 connected to the low-voltage wiring harness is integrated with the low-voltage wiring harness as a single unit. That is, the connector assembly 190 has two specifications: one is a specification that integrates the low-voltage wiring harness, in which the two connection ports of the connector assembly 190 are connected to the tab 142 and the CVM, respectively; the other is a separate connector assembly 190, in which the two connection ports of the connector assembly 190 are connected to the tab 142 and the low-voltage wiring harness, respectively.

[0059] Considering factors such as cost, strength, versatility, and ease of installation, the number of connection positions 192 of a single connector 191 is typically less than 30, while the number of individual cells in a fuel cell stack 100 is generally more than 100. With technological advancements, the volumetric power density of fuel cell stacks is gradually increasing, and the number of individual cells in the stack core 140 is also increasing, for example, reaching 300-400 cells. Clearly, a single connector 191 cannot meet the low-voltage wiring requirements of the fuel cell stack. Therefore, the connector assembly 190 includes at least two connectors 191 arranged sequentially along the stacking direction, such as... Figure 6 As shown. To reduce the size of the connector 191 in the stacking direction, in this embodiment, the connection positions 192 of the connector 191 are arranged in at least two rows, and each row of connection positions 192 contains more than two connection positions 192. When arranging the rows, the number of connection positions 192 should be equally divided. For example, if the connector 191 has 10 connection positions 192, and the 10 connection positions 192 are arranged in two rows, then each row contains 5 connection positions 192.

[0060] Furthermore, to facilitate wiring, the connection positions 192 in at least two rows of connection positions 192 are staggered, and the spacing between connection positions 192 in the same row is the same. That is, the connection positions 192 in each row are staggered. If the connection positions 192 in the same row are numbered, the first connection position 192 in each row is staggered, the second connection position 192 in each row is staggered, and so on. By adopting a row-by-row and staggered arrangement, the spacing between two adjacent connection positions 192 in the same row is at least twice the inter-plate spacing d of the bipolar plates 141 of two adjacent single cells.

[0061] In this embodiment, both odd-numbered and even-numbered single cells in the core 140 are provided with tabs 142. The tabs 142 of the odd-numbered single cells form a first tab row 1441, and the tabs 142 of the even-numbered single cells form a second tab row 1442. Correspondingly, in this embodiment, the connector assembly 190 includes at least two connectors 191 arranged sequentially along the stacking direction; the connectors 191 include two rows of connection positions 192, with each row containing four or more connection positions 192, and the connection positions 192 in the two rows are staggered. The spacing D between the connection positions 192 in the same row is 4d. Compared to the existing technology where only one row of tabs 144 is provided and only one row of connection positions 192 is provided on the connector 191, the spacing D of each connection position 192 of the connector 191 provided in this embodiment can be four times that of the spacing of each connection position 192 of the connector 191 in the existing technology, ensuring that the connector 191 has sufficient wall thickness, thereby improving its structural strength.

[0062] To facilitate the arrangement of the connector 191, in this embodiment, the first end of the connector 191 along the stacking direction is provided with a recess, and the second end is provided with a protrusion that mates with the recess. During assembly, the protrusion of the preceding connector 191 fits precisely into the recess of the following connector 191, providing a certain limiting effect. Connection positions 192 are provided on both the protrusion and the recess, thereby ensuring the continuity of voltage monitoring.

[0063] Please see Figure 6 Since the first tab row 1441 and the second tab row 1442 in this embodiment are both connected to the connector assembly 190, the first connector A and the second connector C in the second row can detect the voltage of the first bipolar plate a and the third bipolar plate c, respectively, and the first connector B in the first row can detect the voltage of the second bipolar plate b (located between the last inspection connection position 192 of the first connector A and the first inspection connection position 192 of the second connector B). Thus, the voltage of the two outermost bipolar plates 141 of the adjacent connectors 191 can be detected simultaneously, ensuring the continuity of voltage inspection.

[0064] Fuel cells exhibit end-side effects during operation, meaning the voltage stability and output voltage of the individual cells at the ends of the core 140 are poor. The reasons for this are: 1. The end cells dissipate heat faster, making it difficult to maintain optimal reaction temperatures compared to the cells in the middle; 2. The clamping force of the core 140 decreases from the ends to the middle, with the middle cells experiencing a relatively uniform clamping force, while the end cells experience the greatest clamping force.

[0065] To mitigate end-side effects, in some embodiments, the core 140 has a sealing structure at at least one end along the stacking direction. This sealing structure includes at least one dummy membrane electrode and at least one electrode plate unit alternately stacked along the stacking direction. The dummy membrane electrode has a structure similar to the membrane electrode structure of a single cell in the core 140, but differs in that it cannot undergo electrochemical reactions. A sealing ring is provided on the dummy membrane electrode, and this sealing ring has the same structure as the sealing ring inside the core 140. Therefore, the sealing ring for end-side sealing can be interchangeable with the sealing ring inside the core 140. This reduces the variety of sealing ring designs, lowers mold costs, and simplifies the assembly process. Furthermore, because the sealing rings are identical, under the compression of the stack fastening assembly 180, the deformation of each sealing ring and the sealing area are essentially the same, minimizing leakage of fluid media, especially hydrogen, in the stack.

[0066] The electrode unit is either a bipolar plate 141 or a pseudo-bipolar plate. A pseudo-bipolar plate is an electrode structure that prevents fluid medium from flowing into the flow field. A pseudo-bipolar plate can have one or both single plates as pseudo-single plates. Specifically, it may be that there is no corresponding flow guiding structure ("layered" or "straight-through" structure) between the fluid inlet and the fluid transition zone of the pseudo-single plate, or the pseudo-bipolar plates are welded together, blocking the inlet and outlet of the flow channel. As a result, the fluid inlet of the pseudo-single plate is not connected to the fluid field, and the fluid medium cannot enter the fluid field. The electrode unit is provided with tabs 142. Specifically, the tabs 142 of the electrode unit are set in the same way as the tabs 142 of the dual electrode plates 141 of the single cell in the core 140. For example, if the sealed structure includes two or more electrode units, there are also odd-numbered electrode units and even-numbered electrode units. The positions of the tabs 142 of the odd-numbered electrode units are different from those of the even-numbered electrode units.

[0067] From its external appearance, this sealed structure is identical to the single cell of core 140. Therefore, this sealed structure can be considered a single cell that cannot undergo electrochemical reactions or generate electricity; thus, from its external structure alone, it can be seen as a continuation of the single cell of core 140. To ensure functional integrity, the side of the sealed structure furthest from core 140 is a dummy membrane electrode; the side of the sealed structure closest to core 140 is an electrode unit, and this electrode unit contacts the membrane electrode at the end of core 140. The corresponding electrode unit on the side of the sealed structure closest to core 140 includes both dummy single plates and true single plates, with the true single plates closer to core 140 used to provide a hydrogen or air field.

[0068] The connector assembly 190 is electrically connected to both the tabs 142 of the core 140 and the tabs 142 of the sealing structure. Therefore, when designing the connection positions 192 of the connector assembly 190, the number of tabs 142 of the sealing structure needs to be considered. Furthermore, the connection positions 192 electrically connected to the tabs 142 of the sealing structure do not require low-voltage wiring harnesses. Since the sealing structure is located at the end of the core 140, it effectively transfers the end effect of the core 140 to the sealing structure. Firstly, this prevents the single cells (membrane electrode + bipolar plate 141) at the end of the core 140 from dissipating heat too quickly, resulting in a low output voltage and improving the consistency of the output voltage of each single cell in the core 140. Secondly, the sealing structure provides a certain degree of thermal insulation, keeping the end side of the core 140 warm during cold starts at low temperatures, allowing the core 140 to reach its optimal operating state as quickly as possible. Thirdly, the sealing structure withstands significant fastening force, forming a transition zone for the fastening force, ensuring that the fastening force borne by each single cell in the entire core 140 is essentially the same. This reduces the end effect of core 140 and improves the output performance of core 140.

[0069] The fuel cell stack 100 also includes an inlet end plate 110, an inlet end insulation plate 120, an inlet end current collector 130, a blind end current collector 150, a blind end insulation plate 160, a blind end end plate assembly 170, and a fastening assembly 180. The fastening assembly 180 connects the inlet end plate 110 and the blind end end plate assembly 170 to provide a fastening force. In this embodiment, the structure of the blind end plate assembly 170 is not specifically limited. In some embodiments, the blind end plate assembly 170 may include a blind end plate 171, a disc spring support plate 172, and a disc spring assembly (not shown in the figure) disposed between the blind end plate 171 and the disc spring support plate 172 for adaptive adjustment. Other undescribed structures of the fuel cell stack 100 can be referred to in relevant prior art disclosures, and will not be elaborated here.

[0070] Example 2:

[0071] See Figure 8 and Figure 9Based on the same inventive concept, this application provides another fuel cell stack 100, which also includes a low-voltage wiring harness, a stack core 140 with tabs 144, and a connector assembly 190 electrically connected to the tabs 144. The stack core 140 includes a plurality of stacked single cells, each single cell including a membrane electrode assembly and a bipolar plate 141. Odd-numbered and / or even-numbered single cells in the stack core 140 are provided with tabs 142, and each tab 142 constitutes a tab assembly 144. The connector assembly 190 is connected to the tabs 142 of the odd-numbered and / or even-numbered single cells in the stack core 140, and at least one connector assembly 190 is electrically connected to the low-voltage wiring harness.

[0072] Unlike Embodiment 1 described above, in this embodiment, the fuel cell stack 100 has tabs 142 only on the odd-numbered or even-numbered individual cells in the core 140. For example, only the odd-numbered individual cells have tabs 142, such as... Figure 10 As shown; while the even-numbered single-cell tabless 142, as... Figure 11 As shown.

[0073] Therefore, in the fuel cell stack 100 of this embodiment, only one row of tabs 144 is provided in the entire stack core 140. A connector assembly 190 is connected to the tabs 144. The connector assembly 190 has a low-voltage wiring harness and can be electrically connected to the CVM. The specific structure of the connector assembly 190 is the same as that in Embodiment 1, or it adopts the connector 191 structure disclosed in the prior art. The specific details will not be repeated here.

[0074] In the fuel cell stack 100 of this embodiment, the bipolar plate 141 is also fabricated from the substrate 143. In some embodiments, the substrate 143 has two tabs 142, which are located on two opposite sides of the substrate 143. For ease of wiring, the two tabs 142 are located on two short sides of the substrate 143. The two tabs 142 are centrally symmetrically distributed, meaning that the position of one tab 142 completely overlaps with the position of the other tab 142 after rotating 180°. When fabricating the bipolar plate 141 from the substrate 143, at least one tab 142 on the substrate 143 can be selectively cut away: when only one tab 142 is cut away, bipolar plates 141 for odd-numbered single cells can be obtained, such as... Figure 10 As shown; when both tabs 142 are cut off, the bipolar plates 141 of the even-numbered single cell can be obtained, as shown. Figure 11 As shown. In other embodiments, the substrate 143 may be configured to have only one tab 142, in which case the substrate 143 can be directly used as the bipolar plate 141 of an odd-numbered single cell. When the tab 142 is cut off, the bipolar plate 141 of an even-numbered single cell can be obtained.

[0075] Since the fuel cell stack 100 of this embodiment only has one row of tabs 144 in the entire stack core 140, only a "two-plate-one-inspection" inspection scheme can be adopted. Since the bipolar plates 141 of even-numbered single cells do not have tabs 142, their weight is reduced compared to the current bipolar plates 141 with tabs 142. Furthermore, since the bipolar plates 141 of numbered single cells are not connected to the connector assembly 190, fewer connectors 191 are used, reducing the weight and cost of the stack.

[0076] The fuel cell stack 100 of this embodiment can also be provided with the sealing structure of Embodiment 1 above. Other undescribed structures of the fuel cell stack 100 of this embodiment can refer to the relevant content of Embodiment 1 above, or refer to the relevant disclosures of the prior art. The specific details will not be repeated here.

[0077] Example 3:

[0078] Based on the same inventive concept, this embodiment provides an assembly method for assembling the relevant structures of the fuel cell stack 100 of Embodiment 1 described above. Please refer to the attached diagram. Figures 1 to 7 The assembly method in this embodiment includes the following steps:

[0079] (1) Cut off one of the tabs 142 in the substrate 143 with two tabs 142 to obtain a bipolar plate 141.

[0080] Specifically, let's denote the two tabs 142 of substrate 143 as m and n, respectively. Let the positions of tabs m and n after rotating 180° be M and N, respectively. Then: cutting off tab m of substrate 143 yields bipolar plates 141 of odd-numbered single cells, as shown below. Figure 4 As shown; the tab n of the substrate 143 is cut off to obtain the bipolar plate 141 of the even-numbered single cell, as shown. Figure 5 As shown. The tabs 142 of the odd-numbered bipolar plates 141 and the tabs 142 of the even-numbered bipolar plates 141 are distributed on different sides of the bipolar plates 141.

[0081] (2) Assemble the battery stack; During the assembly of the battery stack, the bipolar plates 141 with odd or even numbers are rotated 180° and then stacked. The stacked bipolar plates 141 form the first tab row 1441 and the second tab row 1442.

[0082] Specifically, the intake end plate 110, intake end insulation plate 120, intake end current collector 130, core 140, blind end current collector 150, blind end insulation plate 160, and blind end plate assembly 170 are stacked sequentially, and then fastened by fastening assembly 180 to obtain the fuel cell stack. During the stacking assembly of the core 140, either odd-numbered bipolar plates 141 or even-numbered bipolar plates 141 are rotated 180° before stacking. For example, if odd-numbered bipolar plates 141 are placed first, then even-numbered bipolar plates 141 are rotated 180° and stacked on top of the odd-numbered bipolar plates 141. Since the position of tab m is on the same side of the core 140 as position N, and the position of tab n is on the same side of the core 140 as position M. This ensures that after the core 140 is loaded, two rows of tabs 144 can be formed on the same side: the first tab row 1441 and the second tab row 1442.

[0083] (3) Connect the connector assembly 190 with the low-voltage wiring harness and the connector assembly 190 without the low-voltage wiring harness to the first tab 1441 and the second tab 1442 respectively to obtain the fuel cell stack 100.

[0084] Specifically, connector assemblies 190 are connected to both the first tab row 1441 and the second tab row 1442, and a low-voltage wiring harness is connected to one of the connector assemblies 190, thus obtaining the fuel cell stack 100.

[0085] Other details regarding the assembly process of the fuel cell stack 100 that are not described in detail can be found in the relevant prior art disclosures, and will not be elaborated here.

[0086] Example 4:

[0087] Based on the same inventive concept, this embodiment provides another assembly method for assembling the relevant structures of the fuel cell stack 100 of Embodiment 2 described above. Please refer to the attached diagram. Figures 8 to 11 The assembly method in this embodiment includes the following steps:

[0088] (1) At least one tab 142 in the substrate 143 is cut off to obtain a bipolar plate 141, wherein: the bipolar plate 141 with odd number or the bipolar plate 141 with even number has a tab 142.

[0089] Specifically, the substrate 143 may be provided with two centrally symmetrical tabs 142. When processing the bipolar plate 141 from the substrate 143, at least one tab 142 on the substrate 143 can be selectively cut away. When only one tab 142 is cut away, bipolar plates 141 of odd-numbered single cells can be obtained, such as... Figure 10 As shown; when both tabs 142 are cut off, the bipolar plates 141 of the even-numbered single cell can be obtained, as shown. Figure 11As shown.

[0090] The substrate 143 can also have only one tab 142, in which case the substrate 143 can be directly used as the bipolar plate 141 of an odd-numbered single cell. When the tab 142 is cut off, the bipolar plate 141 of an even-numbered single cell can be obtained.

[0091] (2) Assemble the battery stack; During the assembly of the battery stack, the odd-numbered bipolar plates 141 or the even-numbered bipolar plates 141 are rotated 180° and then stacked, and the stacked bipolar plates 141 form a row of tabs 144.

[0092] Specifically, the intake end plate 110, intake end insulation plate 120, intake end current collector 130, core 140, blind end current collector 150, blind end insulation plate 160, and blind end plate assembly 170 are stacked sequentially, and then fastened by fastening assembly 180 to obtain the fuel cell stack. During the stacking assembly of the core 140, either odd-numbered bipolar plates 141 or even-numbered bipolar plates 141 are rotated 180° before stacking. For example, if odd-numbered bipolar plates 141 are placed first, then even-numbered bipolar plates 141 are rotated 180° and stacked on top of them. Since only odd-numbered bipolar plates 141 or only even-numbered bipolar plates 141 have tabs 142, the stacked bipolar plates 141 form a row of tabs 144.

[0093] (3) Connect the connector assembly 190 with the low-voltage wiring harness to the tab 144 to obtain the fuel cell stack 100.

[0094] Other details regarding the assembly process of the fuel cell stack 100 that are not described in detail can be found in the relevant prior art disclosures, and will not be elaborated here.

[0095] Example 5:

[0096] Please see Figure 10 Based on the same inventive concept, this application also provides a fuel cell module, including a low-pressure component and at least one fuel cell stack 100 of Embodiment 1 or Embodiment 2 described above. The low-pressure component includes a low-pressure inspection device, which is electrically connected to the low-pressure wiring harness of the fuel cell stack 100. That is to say, the fuel cell module can be a single-stack solution or a multi-stack integrated solution.

[0097] In some embodiments, to encapsulate the fuel cell stack 100, the fuel cell module includes a housing with a mounting cavity, within which the fuel cell stack 100 is encapsulated. In some embodiments, the fuel cell module also includes high-voltage components for outputting electrical energy, a hydrogen concentration sensor for detecting hydrogen concentration, and other components to output current and hydrogen leakage signals. For multi-stack integrated fuel cell modules, a manifold assembly for uniformly distributing gas among the individual stacks should also be included.

[0098] This embodiment does not modify the specific structure of the fuel cell module other than the fuel cell stack 100. Therefore, the structure of the fuel cell module in this embodiment that remains unchanged can refer to the existing technology, and the specific details will not be elaborated here.

[0099] Example 6:

[0100] Based on the same inventive concept, this embodiment provides a vehicle, such as... Figure 13 As shown, the vehicle includes at least one fuel cell stack 100 of Embodiment 1 or Embodiment 2 described above; or the vehicle includes a fuel cell module of Embodiment 5 described above. Specifically, the vehicle includes a fuel cell power system, which includes a fuel cell system, a DC / DC converter, a drive motor and its motor controller, and an on-board energy storage device. The fuel cell system includes a fuel cell module and a fuel cell auxiliary system, and the fuel cell system can operate normally under conditions of an external fuel supply source. The fuel cell module includes at least one fuel cell stack 100 of Embodiment 1 or Embodiment 2 described above; that is, the fuel cell module can be a single-stack solution or a multi-stack integrated solution.

[0101] The fuel cell auxiliary system of this fuel cell system includes an air supply subsystem, a fuel supply subsystem, a thermal management subsystem, and an automatic control system. The air supply subsystem supplies air to each stack of the fuel cell module and can selectively process the air through filtration, humidification, and pressure regulation. The air supply subsystem is connected to the air inlets and outlets of each stack of the fuel cell module. The fuel supply subsystem supplies fuel to each stack of the fuel cell module and can selectively process the fuel through humidification and pressure regulation to convert it into fuel gas suitable for operation within the fuel cell stack. Taking hydrogen as an example, the fuel supply subsystem is connected to the hydrogen inlets and outlets of each stack of the fuel cell module. The thermal management subsystem is connected to each stack of the fuel cell module to provide coolant for cooling and / or heating of the stacks, as well as to recycle water generated from the stacks.

[0102] The automatic control system is electrically connected to the fuel cell module, air supply subsystem, fuel supply subsystem, and thermal management subsystem, respectively. The automatic control system is an assembly including sensors, actuators, valves, switches, and control logic components, ensuring that the fuel cell system can operate normally without manual intervention. In other embodiments, the fuel cell auxiliary system may also include a ventilation system for mechanically venting gases from the fuel cell casing to the outside. In this embodiment, the fuel cell auxiliary system is not modified; therefore, more detailed information can be found in relevant prior art disclosures and will not be elaborated here.

[0103] In a fuel cell power system, the DC / DC converter is electrically connected to each fuel cell stack to convert voltage, regulating the voltage generated by each stack before outputting it to high-voltage devices such as the drive motor, the automotive air conditioning compressor, and energy storage devices such as batteries. The drive motor is electrically connected to the DC / DC converter to provide the torque required for vehicle operation. The motor controller is also electrically connected to the drive motor, controlling its start, stop, and torque output. The motor controller is connected to the vehicle control system, receiving driving signals from it, and can optionally be electrically connected to the fuel cell system's automatic control system. On-board energy storage devices, such as batteries, are used to store electrical energy to power other electronic devices within the vehicle and are electrically connected to the DC / DC converter.

[0104] In this embodiment, the DC / DC converter, drive motor and its motor controller, and on-board energy storage device in the fuel cell power system have not been modified. Therefore, more detailed information can be found in the relevant disclosures of the prior art, and will not be elaborated here.

[0105] In addition, the vehicle also needs to include a transmission system and a fuel storage device for storing fuel. The transmission system transmits the torque of the drive motor to drive the wheels to rotate. The fuel storage device functions similarly to the fuel tank in a gasoline vehicle. The fuel storage device is connected to the fuel supply subsystem of the fuel cell system through pipelines.

[0106] Therefore, the vehicle can be a hydrogen fuel cell vehicle or a hydrogen-powered hybrid electric vehicle, and can be a passenger car, bus, or truck. Since this embodiment does not modify the specific structure of the vehicle, the structural aspects of the vehicle that remain unchanged in this embodiment can refer to existing technologies, and specific details will not be elaborated here. Thus, the vehicle possesses all the features and advantages described above regarding the fuel cell power system, fuel cell system, fuel cell module, and fuel cell stack 100, which will not be repeated here.

[0107] Although preferred embodiments of this application have been described, those skilled in the art, upon learning the basic inventive concept, can make other changes and modifications to these embodiments. Therefore, the appended claims are intended to be interpreted as including the preferred embodiments as well as all changes and modifications falling within the scope of this application.

[0108] Obviously, those skilled in the art can make various modifications and variations to this application without departing from the spirit and scope of this application. Therefore, if such modifications and variations fall within the scope of the claims of this application and their equivalents, this application also intends to include such modifications and variations.

Claims

1. A fuel cell stack, comprising a low-voltage wiring harness, a stack core with tabs, and a connector assembly electrically connected to the tabs, characterized in that: The core includes a plurality of stacked individual cells, each individual cell having tabs. Each tab forms a tab row, with the tabs of odd-numbered individual cells forming a first tab row and the tabs of even-numbered individual cells forming a second tab row. The first and second tab rows are located at different positions. A connector assembly connects to the tabs of both odd-numbered and even-numbered individual cells in the core, and each connector assembly connects only to either odd-numbered or even-numbered individual cells. Each connector assembly includes at least two connectors arranged sequentially along the stacking direction. Each connector includes at least two rows of connection positions, each row containing two or more connection positions. The connection positions in the at least two rows are staggered, and the spacing between connection positions in the same row is the same. At least one connector assembly is electrically connected to the low-voltage wiring harness, and the connectors not connected to the low-voltage wiring harness are used to achieve insulation between the tabs.

2. The fuel cell stack as described in claim 1, characterized in that: Both the first and second electrode groups are connected to the connector assembly, and at least one of the connector assemblies is electrically connected to the low-voltage wiring harness.

3. The fuel cell stack according to any one of claims 1-2, characterized in that: The reactor core has a sealing structure at at least one end along the stacking direction; the sealing structure includes at least one dummy membrane electrode and at least one electrode plate unit that are alternately stacked; the dummy membrane electrode is a membrane electrode structure with a sealing ring and unable to undergo electrochemical reactions, and the electrode plate unit has tabs; the connector assembly is electrically connected to both the tabs of the reactor core and the tabs of the sealing structure.

4. The fuel cell stack according to any one of claims 1-2, characterized in that: The connector includes two rows of connection positions; each row of connection positions contains four or more connection positions; the spacing D between each connection position in the same row is 4d, where d is the spacing between the bipolar plates of two adjacent single cells.

5. The fuel cell stack according to any one of claims 1-2, characterized in that: The connector has a recess at its first end along the stacking direction and a protrusion at its second end that mates with the recess.

6. The fuel cell stack according to any one of claims 1-2, characterized in that: The connector connected to the low-voltage wire harness is an integral part of the low-voltage wire harness.

7. The fuel cell stack according to any one of claims 1-2, characterized in that: The single cell includes stacked bipolar plates and membrane electrodes; the bipolar plates are processed from a substrate, and the substrate has two tabs, which are located on two opposite sides of the substrate.

8. The fuel cell stack as described in claim 7, characterized in that: The two electrodes are staggered or centrally symmetrically distributed; the two electrodes are located on the two short sides of the substrate respectively.

9. An assembly method for a fuel cell stack according to claim 1 or 2, characterized in that, Includes the following steps: One of the tabs in a substrate with two tabs is cut off to obtain a bipolar plate, wherein the tabs of the odd-numbered bipolar plates and the tabs of the even-numbered bipolar plates are distributed on different sides of the bipolar plate. Assemble the fuel cell stack; during the assembly process, the odd-numbered bipolar plates or the even-numbered bipolar plates are rotated 180° and then stacked, and the stacked bipolar plates form the first tab and the second tab. Connect the connector assembly with the low-voltage wiring harness and the connector assembly without the low-voltage wiring harness to the first electrode row and the second electrode row, respectively, to obtain the fuel cell stack.

10. A fuel cell module, characterized in that: It includes a low-voltage inspection device and at least one fuel cell stack according to any one of claims 1-8, wherein the low-voltage inspection device is electrically connected to the low-voltage wiring harness.

11. A vehicle, characterized in that: It includes at least one fuel cell stack according to any one of claims 1-8; or includes the fuel cell module according to claim 10.

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