Hydrogen fuel cell voltage monitoring interface

Abstract

Aspects of the present disclosure include hydrogen fuel cell voltage monitor interfaces utilizing spring loaded contacts and methods of using the same. An example vehicle includes an electric motor and a fuel cell stack electrically connected to the electric motor. The fuel cell stack includes a plurality of bipolar plates. Each bipolar plate includes one or more battery voltage measurement tabs. The first set of bipolar plates includes a first location of the battery voltage measurement tabs, and the second set of bipolar plates includes a second location of the battery voltage measurement tabs offset relative to the first location of the battery voltage measurement tabs. The fuel cell stack includes a plurality of insulator washer layers alternating with a plurality of bipolar plates. The edge of each battery voltage measurement tab is molded to define a hemispherical pocket for placing a spring loaded contactor of a measurement device.

Description

TECHNICAL FIELD

[0001] The present disclosure relates to hydrogen fuel cell and fuel cell voltage monitoring, and in particular to hydrogen fuel cell voltage monitoring interfaces utilizing spring loaded contacts. BACKGROUND

[0002] Hydrogen fuel cells and related technology have emerged as a promising clean energy solution, providing high efficiency and zero emissions for a variety of applications, from transportation (e.g., personal and commercial vehicles, ships, airplanes, etc.) to stationary power generation. In a hydrogen fuel cell, hydrogen enters through an anode, where it is split into protons and electrons. The protons pass through an electrolyte membrane, while the electrons flow through an external circuit, generating electricity. At the cathode, the protons, electrons, and oxygen combine to produce water. Hydrogen fuel cells are typically implemented in a fuel cell stack (an assembly of multiple individual hydrogen fuel cells connected in series) to increase the total voltage and power output.

[0003] As research in this field progresses, understanding and optimizing fuel cell stack performance has become critical for widespread adoption and commercialization. One key aspect of fuel cell stack operation is the monitoring and control of cell voltage, known as cell voltage monitoring (CVM), as cell voltage directly impacts overall system performance and durability. CVM allows researchers and engineers to assess the health and efficiency of individual cell units within the stack. Another important measurement technique is hydrogen adsorption / desorption (HAD) measurement, as HAD measurement provides a direct measurement of the available surface area for electrochemical reactions critical to fuel cell performance, as well as diagnostic measurements of cross current and short circuit values for individual cell units. SUMMARY

[0004] In one example embodiment, a vehicle includes an electric motor and a fuel cell stack electrically connected to the electric motor. The fuel cell stack includes a plurality of bipolar plates. Each bipolar plate includes one or more cell voltage measurement tabs. A first set of bipolar plates includes a first positioning of the cell voltage measurement tabs, and a second set of bipolar plates includes a second positioning of the cell voltage measurement tabs offset relative to the first positioning of the cell voltage measurement tabs. The fuel cell stack includes a plurality of insulating subgasket layers alternating with the plurality of bipolar plates. An edge of each cell voltage measurement tab is molded to define a hemispherical pocket for placement of a spring loaded contact of a measurement device.

[0005] In addition to one or more features described herein, in some embodiments, each bipolar plate of the plurality of bipolar plates is formed by joining an anode half-plate and a cathode half-plate.

[0006] In some embodiments, the edge of each cell voltage measurement tab is molded to define the hemispherical pocket by molding the anode half-plate on a first end of a forming tool and molding the cathode half-plate on a second end of the forming tool.

[0007] In some embodiments, the insulator spacer block has one or more through-holes sized to accommodate spring-loaded contacts of a measurement device.

[0008] In some embodiments, each of the plurality of insulator grommet layers includes a corrugated edge.

[0009] In some embodiments, the insulator spacer block includes one or more alignment teeth positioned to align with respective corrugated edges of the plurality of insulator grommet layers.

[0010] In some embodiments, the through-holes are offset to position the spring-loaded contacts against a first positioning of the battery voltage measurement tabs, and a second positioning of the battery voltage measurement tabs is offset relative to the first positioning of the battery voltage measurement tabs.

[0011] In another example embodiment, a fuel cell stack includes a plurality of bipolar plates. Each bipolar plate includes one or more battery voltage measurement tabs. A first set of bipolar plates includes a first positioning of the battery voltage measurement tabs, and a second set of bipolar plates includes a second positioning of the battery voltage measurement tabs offset relative to the first positioning of the battery voltage measurement tabs. The fuel cell stack includes a plurality of insulator grommet layers alternating with the plurality of bipolar plates. An insulator spacer block having one or more alignment holes is positioned to accommodate one or more respective alignment tabs of the bipolar plates.

[0012] In some embodiments, each of the plurality of bipolar plates is formed by joining an anode half-plate and a cathode half-plate.

[0013] In some embodiments, the insulator spacer block further includes one or more measurement tab slots positioned to accommodate one or more respective battery voltage measurement tabs of the bipolar plates.

[0014] In some embodiments, the insulator spacer block further includes one or more through-holes sized to accommodate spring-loaded contacts of a measurement device.

[0015] In some embodiments, the through-holes are offset to position the spring-loaded contacts against a first positioning of the battery voltage measurement tabs, and a second positioning of the battery voltage measurement tabs is offset relative to the first positioning of the battery voltage measurement tabs.

[0016] In some embodiments, each of the one or more measurement tab slots includes one or more channels.

[0017] In some embodiments, the one or more channels are positioned and sized to accommodate a tip of a spring-loaded contact of a measurement device.

[0018] In yet another example embodiment, a method can include forming a plurality of bipolar plates. Each bipolar plate includes one or more cell voltage measurement tabs. A first set of bipolar plates includes a first positioning of cell voltage measurement tabs, and a second set of bipolar plates includes a second positioning of cell voltage measurement tabs offset relative to the first positioning of cell voltage measurement tabs. The method includes forming a plurality of insulator spacer gasket layers alternating with the plurality of bipolar plates. The method includes molding an edge of each cell voltage measurement tab to define a hemispherical pocket for placement of a spring-loaded contact of a measurement device.

[0019] In some embodiments, each bipolar plate of the plurality of bipolar plates is formed by joining an anode half-plate and a cathode half-plate.

[0020] In some embodiments, the edge of each cell voltage measurement tab is molded to define a hemispherical pocket by molding an anode half-plate on a first end of a forming tool and molding a cathode half-plate on a second end of the forming tool.

[0021] In some embodiments, the insulator spacer block having one or more alignment holes is positioned to receive one or more corresponding alignment tabs of the bipolar plate.

[0022] In some embodiments, the method includes forming an insulator spacer block having one or more through-holes sized to receive a spring-loaded contact of a measurement device.

[0023] In some embodiments, each insulator spacer gasket layer of the plurality of insulator spacer gasket layers includes a corrugated edge.

[0024] In some embodiments, the insulator spacer block includes one or more alignment teeth positioned to align with a corresponding corrugated edge of the plurality of insulator spacer gasket layers.

[0025] The above features and advantages of the present disclosure, and other features and advantages, are readily apparent from the following detailed description, when taken in connection with the accompanying drawings. BRIEF DESCRIPTION OF DRAWINGS

[0026] Other features, aspects, and details are described below with reference to the drawings.

[0027] Figure 1 a vehicle configured in accordance with one or more embodiments;

[0028] Figure 2A An example portion of a fuel cell stack is shown in accordance with one or more embodiments;

[0029] Figure 2B An example portion of a fuel cell stack is shown in accordance with one or more embodiments; Figure 2Aan exemplary cross-sectional view of a fuel cell stack of

[0030] Figure 2C shows an exemplary detailed cross-sectional view of a portion of a fuel cell stack in accordance with one or more embodiments Figure 2B an exemplary detailed cross-sectional view of a portion of a fuel cell stack of

[0031] Figure 3A shows an exemplary view of a bipolar plate in accordance with one or more embodiments, prior to installation of an insulator spacer block Figure 2A an exemplary view of a bipolar plate of

[0032] Figure 3B shows an exemplary view of a bipolar plate in accordance with one or more embodiments, after installation of an insulator spacer block Figure 3A an exemplary view of a bipolar plate of

[0033] Figure 3C shows an exemplary view of a bipolar plate in accordance with one or more embodiments, along line A-A of Figure 3B an exemplary view of a bipolar plate in accordance with one or more embodiments, along line B-B of

[0034] Figure 3D shows an exemplary view of a bipolar plate in accordance with one or more embodiments, along line B-B of Figure 3B an exemplary view of a bipolar plate in accordance with one or more embodiments, along line B-B of

[0035] Figure 4A shows an exemplary schematic view of an insulator spacer block in accordance with one or more embodiments

[0036] Figure 4B shows an exemplary rear view of an insulator spacer block of Figure 4A

[0037] shows an exemplary front view of an insulator spacer block of Figure 4C Figure 4A shows an exemplary side view of an insulator spacer block of

[0038] Figure 4D Figure 4A shows an exemplary side view of an insulator spacer block of

[0039] Figure 5A shows an exemplary view of a spring-loaded contact that is pressed against the edge of a cell voltage measurement tab in accordance with one or more embodiments

[0040] Figure 5B shows an exemplary view of a pocket of a cell voltage measurement tab in accordance with one or more embodiments during engagement with a spring-loaded contact

[0041] Figure 5C and 5D shows an exemplary view of a pocket of a cell voltage measurement tab in accordance with one or more embodiments during engagement with a spring-loaded contact

[0042] ​​Figure 6A An exemplary view of a bipolar plate after the formation of a recess is shown according to one or more embodiments;

[0043] Figure 6B An exemplary view of a bipolar plate after the formation of a recess is shown according to one or more embodiments;

[0044] Figure 6C An exemplary view of a bipolar plate during hydrogen adsorption / desorption (HAD) measurement operation is shown according to one or more embodiments;

[0045] Figure 7A An exemplary view of a fuel cell stack during battery voltage monitoring (CVM) measurement operation is shown according to one or more embodiments;

[0046] Figure 7B An exemplary view of a fuel cell stack during HAD measurement operation is shown according to one or more embodiments;

[0047] Figure 7C An exemplary view of a fuel cell stack during CVM measurement operation is shown according to one or more embodiments;

[0048] Figure 8 A computer system according to one or more embodiments; and

[0049] Figure 9 It is a flowchart according to one or more embodiments. Detailed Implementation

[0050] The following description is exemplary in nature only and is not intended to limit this disclosure, its application, or use. It should be understood that throughout the drawings, corresponding reference numerals denote the same or corresponding parts and features.

[0051] Understanding and optimizing fuel cell stack performance has become crucial for the widespread adoption and commercialization of hydrogen fuel cell technology. Two of the most important techniques for evaluating fuel cell quality and performance are cell voltage monitoring (CVM) and hydrogen adsorption / desorption (HAD) measurements. CVM allows researchers and engineers to assess the health and efficiency of individual cells within a hydrogen fuel cell stack, while HAD measurements are used to evaluate the hydrogen storage capacity and surface properties of fuel cell materials.

[0052] Bipolar plates (BPPs) play a crucial role in fuel cell stacks, serving multiple functions such as distributing reactant gases, removing reaction products, conducting current between cells, and providing mechanical support. Specifically, BPPs are useful in the context of CVM and HAD measurements because, during CVM, the bipolar plates act as conductive interfaces between adjacent cells, allowing for the measurement of voltage across individual cells. This enables researchers to identify underperforming cells, detect potential problems such as membrane degradation or catalyst poisoning, and optimize stack performance. The conductive properties of BPPs ensure accurate voltage readings while maintaining electrical connectivity throughout the stack. For HAD measurements, including improved hydrogen adsorption / desorption (MHAD) techniques, BPPs play a key role in gas distribution and current harvesting. HAD and MHAD measurements are used to assess the electrochemically active surface area (ECSA) of the catalyst layer, a critical parameter for evaluating fuel cell performance. The flow field design incorporated into BPPs ensures uniform gas distribution throughout the effective region, allowing for accurate HAD and MHAD measurements.

[0053] In short, the integration of bipolar plates in a fuel cell stack is fundamental for accurate and reliable cell voltage monitoring and hydrogen adsorption / desorption measurements. As research in hydrogen fuel cell technology advances, optimizing BPP design will continue to be a key driver for improving overall stack performance and durability. Unfortunately, current BPP designs are somewhat limited. One of the current challenges in fuel cell stack design, particularly BPP design, is improving the electrical coupling with the CVM and HAD contact points. For example, ensuring the alignment of pogo-pins and / or pogo-pin boards with the CVM / HAD contact points in the stacking direction (with and without cell repeatability tolerances) is difficult, partly due to alignment issues inherited from upstream blade-type tab / insulator designs. Another somewhat related challenge involves finding solutions for stack configurations with non-uniform plate / plate distributions (e.g., the plate-to-plate spacing in a fuel cell stack may be inconsistent throughout a given stack). Packaging presents another challenge because sufficiently high CVM / HAD contact points can cause interference in the stacked BPP package. In short, shipping the BPP may require special packaging and / or isolators to prevent CVM / HAD damage, as the BPP contact points may be higher than the uncompressed metal strip seal height (e.g., in an exemplary configuration, the socket feature could be ~1.8 mm, while the uncompressed metal strip seal height could be ~1.3 mm). Furthermore, even disregarding contact point issues, the small cell repeat distance or board spacing between cells (e.g., 0.9 to 1.2 mm), coupled with limited space for electrical contact (e.g., commercially available 2 mm diameter spring pins), presents packaging challenges for the application.

[0054] This disclosure describes a hydrogen fuel cell voltage monitor interface utilizing spring-loaded contacts. For CVM and / or HAD measurements, an insulating spacer is provided to guide the spring-loaded contacts directly against the flat edge of the measuring tabs of the fuel cell bipolar plate, instead of relying on conventional plate contactors (also known as clamping clamps) for battery voltage measurements on the top surface of alternating plate / spacer tabs. Advantageously, the insulating spacer electrically insulates the tabs from creepage and gap issues and limits the deflection of the relatively thin plate tab features when a force is applied perpendicular to the plate edge. In some embodiments, the bipolar plate described herein is modified to include hemispherical contact recesses to maximize the contact area with the geometry of the ball-end spring-loaded contacts (spring pins).

[0055] It is worth noting that the combined electrode assembly (UEA) sub-gaskets can be positioned to overlap with the BPP edge, thus creating a corrugated edge during assembly as the BPP contents recesses are pushed against the sub-gasket surface at the repetitive distance of the stacked cells. One advantage of this configuration is that the corrugated effect from the displacement of the semi-rigid plates provides additional strength along the corrugated axis. Another advantage is that the repetitive height of the stacked BPP sockets is inherently less prone to misalignment due to the curved BPP material—in short, this configuration results in self-correcting and more repeatable positioning of the BPP contact area for connecting components or tooling engagement, as the height of the stacked sockets with the sub-gaskets positioned therebetween limits the permissible amount of displacement. Other advantages are achieved and will be discussed in more detail below.

[0056] According to an exemplary embodiment, the vehicle is Figure 1The vehicle 100 is generally designated as 100. The vehicle 100 is shown in the form of an automobile having a body 102. The body 102 includes a passenger compartment 104, within which a steering wheel, front seats, and rear passenger seats (not shown separately) are arranged. Multiple components are arranged within the body 102, including, for example, a fuel cell stack 106, a hydrogen fuel storage tank 108, an intake manifold 110, a battery 112, and an electric motor 114 configured to provide output torque to an output component 116 using electrical energy (each component is shown by projection near the front hood). The fuel cell stack 106 receives a flow of hydrogen or other fuel gases from the hydrogen fuel storage tank 108 and a flow of air including oxygen from the intake manifold 110. The fuel cell stack 106 may include an air compressor unit (not shown separately) for pressurizing the air to a desired pressure. The fuel cell stack 106 may directly supply electrical energy to the electric motor 114 and / or the fuel cell stack 106 may supply electrical energy to the battery 112 for storage and later use. Output component 116 can provide output torque for, for example, powering vehicle 100. For ease of illustration and discussion only, fuel cell stack 106, hydrogen fuel storage tank 108, intake manifold 110, battery 112, and electric motor 114 are shown. It should be understood that the configuration, location, size, arrangement, etc., of these components are not intended to be particularly limited, and all such configurations (including multi-motor configurations) are within the scope of this disclosure. Furthermore, although this disclosure is discussed primarily in the context of fuel cell stack 106 configured for use in vehicle 100, the aspects described herein can be similarly incorporated into any system (vehicle, building, or otherwise) having a hydrogen fuel cell-based electrical and / or energy storage system, and all such configurations and applications are within the scope of this disclosure. As will be described in detail herein, fuel cell stack 106 includes bipolar plates designed to abut against insulating spacers configured to guide spring-loaded contacts directly against the flat edges of the measuring tabs of the respective bipolar plates for CVM and / or HAD measurements.

[0057] Figure 2A An exemplary portion of a fuel cell stack 106 according to one or more embodiments is shown. The number of individual fuel cells (not individually indicated) and their configuration in the fuel cell stack 106 are not intended to be particularly limited, and any number of fuel cells can be combined in the fuel cell stack 106 to produce a desired power output. For example, for vehicles (e.g., Figure 1 The fuel cell stack 106 of the vehicle 100 may have two hundred or more stacked fuel cells. The fuel cell stack 106 receives cathode input gas, typically forced through the airflow of the fuel cell stack 106 by a compressor (see [link to relevant documentation]). Figure 1(Discussion to be continued). Not all oxygen is consumed by the fuel cell stack 106, and some air may be output as cathode exhaust gas, which may include water as a stack byproduct. The fuel cell stack 106 also receives anode hydrogen input gas flowing into the anode side of the fuel cell stack 106. In each fuel cell in the fuel cell stack 106, the anode and cathode typically include finely divided catalyst particles, such as platinum (Pt), which are supported on carbon particles and mixed with ionomers. The catalyst mixture is deposited on opposite sides of a membrane. The combination of the anode catalyst mixture, the cathode catalyst mixture, and the membrane defines the membrane electrode assembly (MEA) of the respective fuel cell.

[0058] like Figure 2A As shown, the fuel cell stack 106 includes a series of bipolar plates 202. In some embodiments, each cell in the fuel cell stack 106 is defined by a pair of bipolar plates 202 (one anode-side bipolar plate and one cathode-side bipolar plate) sandwiching an MEA (not shown separately). In some embodiments, the bipolar plates 202 and MEAs are located between two end plates (not shown separately). In some embodiments, each fuel cell has two bipolar plates 202 on its sides, one on the anode side and one on the cathode side, and the bipolar plates 202 conduct electricity between adjacent cells in the fuel cell stack 106, allowing the fuel cell stack 106 to generate higher voltages. While not intended to be particularly limiting, in some embodiments, the bipolar plates 202 serve as both separators and connectors. The bipolar plates 202 separate the anode of one cell from the cathode of an adjacent cell, preventing the mixing of reactant gases (hydrogen and oxygen). In this configuration, the bipolar plates 202 conduct current from one cell to the next, allowing the cells to be connected in series to achieve a desired voltage and / or power output. In some embodiments, the bipolar plate 202 includes flow channels that uniformly distribute hydrogen to the anode and oxygen to the cathode across the active region of each cell, thereby ensuring efficient electrochemical reactions. The bipolar plate 202 also helps manage heat generated during fuel cell operation and can provide structural integrity and mechanical support to the fuel cell stack 106 (ensuring, for example, that the cells are properly compressed and aligned). In some embodiments, the bipolar plate 202 is made of a composite material (e.g., graphite), wherein two plate halves are separately molded and then glued together such that an anode flow channel is disposed on one side of one plate half, a cathode flow channel is disposed on the opposite side of the other plate half, and optionally, a cooling fluid flow channel is disposed between the plate halves. In some embodiments, two separate half-plates are stamped and then welded together such that an anode flow channel is disposed on one side of one half-plate, a cathode flow channel is disposed on the opposite side of the other half-plate, and a cooling fluid flow channel is disposed between the half-plates.

[0059] like Figure 2AAs further shown, in some embodiments, the fuel cell stack 106 includes an insulator gasket layer 204 (also referred to as a UEA sub-gasket). In some embodiments, the insulator gasket layer 204 is used to seal the edges of the MEA to prevent gas leakage and to provide electrical insulation between adjacent bipolar plates 202. The insulator gasket layer 204 can be made of a range of suitable semi-rigid polymers and / or plastic films, such as various rubbers (e.g., silicone rubber, fluorocarbon rubber, etc.) and elastomers (e.g., polyolefin elastomers, fluoropolymers, etc.).

[0060] In some embodiments, the bipolar plate 202 includes a cell voltage measurement tab 206. The cell voltage measurement tab 206 is a conductive protrusion and / or contact point disposed on (or integrated with) the bipolar plate 202 within the fuel cell stack 106 to provide access for measuring the voltage of each individual cell in the fuel cell stack 106. In some embodiments, the cell voltage measurement tab 206 is designed to provide electrical contact with an active component (not individually indicated) of each cell.

[0061] like Figure 2A As further shown, in some embodiments, the bipolar plate 202 includes two alternating configurations for the battery voltage measurement tab 206. Specifically, the bipolar plate 202 may include an A-type plate 208 alternating with the B-type plate 210. In some embodiments, the positioning of the battery voltage measurement tab 206 in the A-type plate 208 is offset relative to the positioning of the battery voltage measurement tab 206 in the B-type plate 210 to allow for electrical creepage and clearance (arc) requirements. It is observed that in this configuration, the bipolar plate 202 and the battery voltage measurement tab 206 are positioned such that a plurality of spring-loaded contactors 212 can be axially applied to the respective edges 214 of the battery voltage measurement tab 206 via spring-loaded contactor forces.

[0062] Figure 2B The following are illustrated according to one or more implementation schemes. Figure 2A An exemplary cross-sectional view of the fuel cell stack 106. Figure 2C An illustration is provided according to one or more embodiments. Figure 2B An exemplary detailed cross-sectional view of a portion 216 of the fuel cell stack 106. (See attached image.) Figure 2B and 2C As shown, an electrical contact point 218 is formed between the edge 214 of the battery voltage measuring tab 206 and the tip portion 220 of the spring-loaded contactor 212.

[0063] Figure 3A A bipolar plate 202 is shown prior to the installation of an insulator spacer block 302, according to one or more embodiments. Figure 2A An exemplary view of the bipolar plate 202. Regarding Figures 4A-4DThe insulator spacer 302 will be discussed in more detail. Figure 3B The following is illustrated after the installation of the insulating spacer block 302, according to one or more embodiments. Figure 3A An exemplary view of the bipolar plate 202. Figure 3C The figure shows the traverse according to one or more embodiments. Figure 3B An exemplary view of the bipolar plate 202 of line AA. Figure 3D The figure shows the traverse according to one or more embodiments. Figure 3B An exemplary view of the bipolar plate 202 of line BB.

[0064] like Figures 3A-3D As shown, the insulator spacer 302 may include one or more alignment openings (or slots) 304 positioned to fit onto one or more corresponding alignment tabs 306 (also referred to as retaining features or metal retaining features) of the bipolar plate 202 and / or otherwise accommodate one or more corresponding alignment tabs 306 of the bipolar plate 202. The number of alignment openings 304 is not particularly limited. For example, as shown, 12 alignment openings 304 are arranged in two rows of six holes each (six along the top of the insulator spacer 302 and six along the bottom of the insulator spacer 302). Other configurations (e.g., with different numbers of alignment openings 304) are possible, and all such configurations are within the scope of this disclosure.

[0065] In some embodiments, the insulator spacer block 302 may include one or more measuring tab grooves 402 (see...). Figure 4B It is positioned to be mounted on one or more corresponding battery voltage measuring tabs 206 of the bipolar plate 202 and / or otherwise accommodate one or more corresponding battery voltage measuring tabs 206 of the bipolar plate 202.

[0066] In some embodiments, the insulator spacer 302 may include one or more through holes 308, the through holes 308 being sized to accommodate a corresponding spring-loaded contactor 212 among a plurality of spring-loaded contactors 212. The number of through holes 308 is not particularly limited. In some embodiments, the through holes 308 are arranged to position the spring-loaded contactor 212 against the battery voltage measuring tab 206 of alternating type A plates 208 and type B plates 210 (see...). Figure 3C and Figure 3DIn other words, in some embodiments, some through holes 308 can be offset relative to each other in a manner similar to how the battery voltage measuring tabs 206 of the alternating A-type plates 208 and B-type plates 210 can be offset relative to each other. For example, as shown, 24 through holes 308 are arranged in four rows, with six through holes 308 in each row, where one pair of rows (12 through holes in total) is positioned for the cell voltage measuring tabs 206 of the A-type plate 208, and another pair of rows (12 through holes in total) is positioned for the cell voltage measuring tabs 206 of the B-type plate 210. Other configurations (different numbers of through holes 308, different numbers of rows, etc.) are possible, and all of these configurations are within the scope of this disclosure.

[0067] In some embodiments, the insulator spacer 302 is configured to engage with a tool plate 310 (e.g., a printed circuit board) having one or more through holes 312, the through holes 312 being sized and positioned to accommodate a corresponding one of a plurality of spring-loaded contactors 212 and align with one or more through holes 308 of the insulator spacer 302, thereby allowing the spring-loaded contactor 212 to be inserted through the tool plate 310 and through the underlying insulator spacer 302 to contact the battery voltage measuring tab 206. In some embodiments, the insulator spacer 302 includes one or more alignment holes 314, and the tool plate 310 includes one or more alignment holes 316 to aid in aligning the corresponding components during installation.

[0068] Now for reference Figure 3C and 3D Once installed, the insulator spacer 302 and tool plate 310 are used to guide the spring-loaded contactor 212 to the edge 214 of the battery voltage measuring tab 206 of the bipolar plate 202. Observed Figure 3C The bipolar plate 202 in the middle is a type A plate 208 and Figure 3D The bipolar plate 202 is a type B plate 210, and the positioning of the battery voltage measuring tab 206 in the type A plate 208 is offset relative to its positioning in the type B plate 210. In this configuration, the insulator spacer block 302 and the tool plate 310 work together to repeatedly position any number of edge contacts (i.e., the edges 214 of the battery voltage measuring tab 206) to corresponding multiple spring-loaded contactors 212 to electrically insulate the battery voltage measuring tab 206 from creepage and clearance issues, and to limit the deflection of the battery voltage measuring tab 206 when a force is applied perpendicular to the edge 214 during measurement operation.

[0069] Figure 4A An insulating spacer block 302 according to one or more embodiments is shown (e.g., Figures 3A-3D An exemplary schematic diagram of the insulating spacer block 302.Figure 4B It shows Figure 4A An exemplary rear view of the insulating spacer block 302. Figure 4C It shows Figure 4A An exemplary front view of the insulating spacer block 302. Figure 4D It shows Figure 4A An exemplary side view of the insulating spacer block 302.

[0070] like Figures 4A-4D As shown, the insulator spacer block 302 may include a plurality of through holes 308, a plurality of alignment holes 314, a plurality of alignment openings 304, and a plurality of measuring tab slots 402. In some embodiments, the measuring tab slots 402 are positioned to mate with one or more corresponding battery voltage measuring tabs 206 of the bipolar plate 202 and / or otherwise accommodate one or more corresponding battery voltage measuring tabs 206 of the bipolar plate 202 (see [link to documentation]). Figure 3A ).

[0071] like Figure 4B As shown, in some embodiments, the dimensions of the measuring tab slot 402 are designed to allow the battery voltage measuring tab 206, inserted into the corresponding measuring tab slot 402, to contact the spring-loaded contactor 212 (see [reference]). Figure 3B Two (as shown) or more (not shown individually) of the 402 measuring tab grooves. In some embodiments, each of the measuring tab grooves 402 includes one or more (such as Figure 4B As shown, there are two channels 404. In some embodiments, each of the channels 404 is positioned and sized to receive the tip 220 of one of the spring-loaded contactors 212 (see [reference]). Figure 2C In this way, each channel 404 allows a pair of spring-loaded contactors 212 to contact the edge 214 of the bipolar plate 202.

[0072] In some embodiments, the insulator spacer 302 may include an end portion 406, which includes an alignment opening 304 and extends toward a corresponding alignment tab 306 of the bipolar plate 202 (see [link]). Figure 3A , Figure 3C and Figure 3D In some embodiments, end 406 partially defines a recessed cavity feature 408, which can be used for CVM and / or HAD positioning and alignment.

[0073] Figure 5A An exemplary view of a spring-loaded contactor 212 pressing against the edge 214 of a battery voltage measuring tab 206 according to one or more embodiments is shown. Figure 5AAs observed, the contact interface 502 between the spring-loaded contactor 212 and the edge 214 is itself limited by the thickness D of the edge 214. The thickness D is not particularly limited, but can be less than 3 mm (e.g., 0.05 to 3 mm, 1 mm, etc.). This results in a relatively small contact surface for landing the spring-loaded contactor 212. To address this issue, in some embodiments, the edge 214 is molded to create a recess 504 (also known as a hemispherical CVM / HAD recess).

[0074] Figure 5B An exemplary view of a recess 504 in a battery voltage measuring tab 206 according to one or more embodiments is shown. In some embodiments, the recess 504 is a hemispherical recess. As previously described, in some embodiments, the bipolar plate 202 can be formed by connecting two halves 506 and 508 (e.g., via connecting an anode half to a cathode half). In some embodiments, the recess 504 is formed during engagement of the two halves 506 and 508. For example, in some embodiments, a forming tool (not shown separately) can be placed between the halves 506 and 508 having a shape and position corresponding to the desired recess 504. In this way, the recess 504 can be formed when the two halves 506 and 508 are pressed together.

[0075] Figure 5C and 5D An exemplary view of the recess 504 of the battery voltage measuring tab 206 during engagement with the spring-loaded contactor 212, according to one or more embodiments, is shown. Figure 5C and 5D As shown, the contact interface 502 provided by the recess 504 is relative to Figure 5A The contact interface 502 is increased. In this way, the recess 504 increases electrical conduction and is more robust to tooling tolerances because the part is self-aligned, and the contact interface 502 is constrained by limiting the positional freedom between the battery voltage measuring tab 206 and the spring-loaded contactor 212.

[0076] Figure 6A The bipolar plate 202 after the formation of the recess 504 is shown according to one or more embodiments (e.g., Figure 2A An exemplary view of the bipolar plate 202. In some embodiments, the recess 504 includes a first plurality of recesses 504a and a second plurality of recesses 504b. In some embodiments, the first plurality of recesses 504a are aligned with the battery voltage measuring tab 206 of the type A plate 208. In some embodiments, the second plurality of recesses 504b are aligned with the battery voltage measuring tab 206 of the type B plate 210.

[0077] like Figure 6AAs further shown, type A plate 208 and type B plate 210 are stacked together, with insulator gasket layer 204 positioned between them. In some embodiments, type A plate 208, type B plate 210, and insulator gasket layer 204 are pressed together during the manufacturing process. Figure 6A It was observed that the insulator gasket layer 204 overlaps with the recess 504, and therefore, when the recess 504 is pushed into the insulator gasket layer 204, the insulator gasket layer 204 exhibits a corrugated edge 602 during manufacturing. In some embodiments, the insulator gasket layer 204 is provided as a flat sheet in a free state, which is forced into a corrugated shape (exhibiting a corrugated edge 602) by the alternating construction of the recesses 504. Furthermore, the insulator gasket layer 204 overlaps with the outer edge 604 of the bipolar plate 202, thereby defining a recess 606. While the exact contour of the corrugated edge 602 does not need to be particularly limited, in some embodiments, the recess 504 is recessed relative to the recess 606 for electrical insulation and to mitigate current creepage. In some embodiments, the recess 504 is positioned to provide a so-called 2X cell-to-cell repeating height, such that the corrugated edge 602 exhibits a sinusoidal corrugation. This type of construction allows for improved visual identification of the recessed socket position of recess 504 and robustness of the sub-washer folding or covering of the bipolar plate 202 along the socket axis. Alternatively, although recess 504 (BPP socket) and recess 606 (sine sub-washer recess) are in Figure 6A and 6B The features are shown as recessed from the adjacent edges (not shown separately) of the bipolar plate 202 or the insulator gasket layer 204, but these features can also be applied in line without recessing from the existing edges (although the bipolar plate 202 and the insulator gasket layer 204 still need to have a certain degree of overlap and / or offset for electrical insulation).

[0078] Figure 6B The bipolar plate 202 after the formation of the recess 504 is shown according to one or more embodiments (e.g., Figure 2AAn exemplary view of the bipolar plate 202 is shown. As illustrated, the recesses 504 are arranged in an alternating row of four recesses 504 (recesses A1, A2, A3, and A4 alternating with recesses B1, B2, B3, and B4), although the exact number of recesses 504 is merely illustrative and is not intended to be particularly limiting. In some embodiments, the insulator gasket layer 204 includes a plurality of insulator gasket layers 204a, 204b, 204c, 204d, and 204e configured and arranged as shown. Specifically, in some embodiments, the insulator gasket layers 204a, 204b, 204c, 204d, and 204e are configured such that two layers 608 of the gasket insulation material are positioned between each recess 504 having the same alignment (e.g., between recesses A1 and A2, between recesses B3 and B4, etc.). This configuration reduces the likelihood of short circuits (e.g., edge short circuits) forming between the bipolar plates 202. Multiple insulator washer layers 204a, 204b, 204c, 204d, and 204e were observed to further define recesses 606 relative to the outer plate edge 604 (see [link]). Figure 6A ).

[0079] Figure 6B One advantage of the configuration shown is the self-correcting positioning of the recesses 504 and the insulator gasket layers 204. For example, it can be observed that the height H of the recesses 504 with two sub-gasket insulation layers 608 inherently limits the magnitude of any permissible displacement between these components because each recess 504 provides resistance 610 towards the recess 504 both above and below each corresponding recess 504 (i.e., the recess 504 will resist collapse). As a result of this configuration, any initially misaligned recesses 504 will be forced back into alignment by adjacent recesses 504. Therefore, this configuration is less prone to disengagement from positional contact due to, for example, bending of the BPP material, thus allowing for more predictable and repeatable positioning of the BPP contact areas for interface components or tool engagement (e.g., for CVM and / or HAD measurements).

[0080] Figure 6C A bipolar plate 202 is shown during HAD measurement operation according to one or more embodiments (e.g., Figure 2A An exemplary view of the bipolar plate 202 is provided. Figure 6C To illustrate the multiple insulator gasket layers 204a, 204b, 204c, 204d and 204e (see...) Figure 6B How can the recess 606 defined by the spring be spring-loaded by the contactor plate (e.g., Figure 3A and 3BThe insulator spacer block 302 and tool plate 310 are used for alignment. For example, it is observed that the stacked insulator gasket layers 204a, 204b, 204c, 204d and 204e provide a planar stack of edges 612, resulting in recessed cavity features (e.g., cavity 606) that can be used for CVM and / or HAD positioning and alignment.

[0081] Figure 7A A fuel cell stack 106 is shown during CVM measurement operation according to one or more embodiments (reference). Figure 2A An example view. (e.g.) Figure 7A As shown, the CVM module 702 is mounted above the recess 504 of the battery voltage measurement tab 206. The CVM module 702 may include, for example, an insulator spacer 302 and a tool plate 310 (see [link to documentation]). Figure 3B ).exist Figure 7A In the configuration shown, the CVM module 702 positions the spring-loaded contactor 212 in an interleaved skip pattern, which places one spring-loaded contactor 212 against each bipolar plate 202 of the fuel cell stack 106 (note that only one contact is required per BPP for CVM measurement).

[0082] It was observed that some recesses 504 are skipped recesses 704, that is, only a portion of recesses 504 are used recesses 706. This staggered configuration increases the space available for mating components (e.g., approximately twice as much as a conventional straight configuration). Furthermore, the alternation of the alternating coverage areas between type A plates 208 and type B plates 210, and between predetermined subsets of the battery voltage measuring tabs 206 (e.g., between two of the four, as shown), results in a 4X battery repetition interval at the spring contact position.

[0083] Figure 7B A fuel cell stack 106 is shown during HAD measurement operation according to one or more embodiments (reference). Figure 2A An example view. (e.g.) Figure 7B As shown, the HAD module 708 is mounted above the recess 504 of the battery voltage measurement tab 206. The HAD module 708 may include, for example, an insulator spacer 302 and a tool plate 310 (see [link to documentation]). Figure 3B ).exist Figure 7B In the configuration shown, the HAD module 708 positions the spring-loaded contactors 212 in an interleaved skip pattern, which repeats once every four recesses 504, thereby placing two spring-loaded contactors 212 against each bipolar plate 202 of the fuel cell stack 106 (note that HAD measurements require two contacts per BPP). This configuration provides at least a four-fold improvement in spacing compared to a conventional straight configuration. It is observed that, with respect to... Figure 7AIn a similar manner to that discussed in CVM module 702, some recesses 504 are skipped from recess 704, and some recesses are used from recess 706.

[0084] Figure 7C A fuel cell stack 106 is shown during CVM measurement operation according to one or more embodiments (reference). Figure 2A An example view. (e.g.) Figure 7C As shown, the CVM module 702 is mounted above the recess 504 of the battery voltage measurement tab 206. The CVM module 702 may include, for example, an insulator spacer 302 and a tool plate 310 (see [link to documentation]). Figure 3B ).exist Figure 7C In the configuration shown, CVM module 702 includes alignment teeth 710 (also referred to as CVM / HAD spring pin plate teeth). Alignment teeth 710 can be incorporated into any underlying component of CVM module 702 (e.g., insulator spacer block 302 and / or tool plate 310). Furthermore, while CVM module 702 is shown, HAD module 708 (see reference...) Figure 7B It can similarly include alignment teeth 710.

[0085] from Figure 6A Recall that the insulator gasket layer 204 overlaps with the cavity 504, and thus, during manufacturing, it exhibits a corrugated edge 602 as the cavity 504 is pushed into the corresponding insulator gasket layer 204. In some embodiments, this configuration results in the insulator gasket layer 204 terminating at the bipolar plate 202 with an alternating pattern of stacked sub-gasket corrugated wide spaces 712 and stacked sub-gasket corrugated narrow spaces 714. In some embodiments, the CVM module 702 (or HAD module 708) is designed such that the alignment teeth 710 align with the stacked sub-gasket corrugated wide spaces 712. This configuration provides an intuitive, direct visual and tactile way to confirm the correct positioning of components of the fuel cell stack 106, such as the insulator gasket layer 204, the cavity 504, etc.

[0086] Figure 8 Various aspects of embodiments of a computer system 800 that can perform various aspects of the embodiments described herein are illustrated. In some embodiments, the computer system 800 may be implemented and / or otherwise incorporated into or combined with a bipolar plate measurement system (e.g., CVM module 702 or HAD module 708). For example, in some embodiments, the computer system 800 may apply or receive signals (e.g., voltage, current, etc.) to one (for CVM measurement) or two (for HAD measurement) spring-loaded contactors 212 and the underlying recesses 504.

[0087] Computer system 800 includes at least one processing device 802, which typically includes functions for performing various functions (e.g., regarding...).Figure 9 One or more processors or processing units (including any and / or all of the functions described). The components of computer system 800 also include system memory 804 and a bus 806 coupling various system components including system memory 804 to processing device 802. System memory 804 may include various computer system readable media. Such media may be any available media accessible by processing device 802, and include volatile and non-volatile media as well as removable and non-removable media. For example, system memory 804 includes non-volatile memory 808, such as a hard disk drive, and may also include volatile memory 810, such as random access memory (RAM) and / or cache memory. Computer system 800 may also include other removable / non-removable, volatile / non-volatile computer system storage media.

[0088] System memory 804 may include at least one program product having a set (e.g., at least one) of program modules configured to perform the functions of the embodiments described herein. For example, system memory 804 stores various program modules that typically perform the functions and / or methods of the embodiments described herein. One or more modules 812, 814 may be included to perform functions associated with any block diagram described herein. Computer system 800 is not limited thereto, as other modules may be included depending on the desired functionality of computer system 800. As used herein, the term "module" refers to processing circuitry that may include application-specific integrated circuits (ASICs), electronic circuitry, processors (shared, dedicated, or grouped) and memories executing one or more software or firmware programs, combinational logic circuitry, and / or other suitable components that provide the described functions.

[0089] The processing device 802 can also be configured to communicate with one or more external devices 816, such as, for example, a keyboard, pointing device, and / or any device that enables the processing device 802 to communicate with one or more other computing devices (e.g., a network interface card, a modem, etc.). Communication with various devices can occur via input / output (I / O) interfaces 818 and 820.

[0090] Processing device 802 can also communicate with one or more networks 822 (such as local area networks (LANs), general area networks (WANs), bus networks, and / or public networks (e.g., the Internet)) via network adapter 824. In some embodiments, network adapter 824 is or includes an optical network adapter for communication over an optical network. It should be understood that, although not shown, other hardware and / or software components may be used in conjunction with computer system 800. Examples include, but are not limited to, microcode, device drivers, redundant processing units, external disk drive arrays, RAID systems, and data archiving storage systems.

[0091] Now for reference Figure 9 According to one embodiment, a flowchart 900 of a hydrogen fuel cell voltage monitoring interface for monitoring a fuel cell stack using spring-loaded contacts is generally shown. (Reference) Figures 1-8 Flowchart 900 is described, and flowchart 900 may include Figure 9 Additional steps not shown. Although depicted in a specific order, Figure 9 The boxes depicted can be rearranged, subdivided, and / or combined.

[0092] At block 902, the method includes forming a plurality of bipolar plates. In some embodiments, each of the plurality of bipolar plates includes one or more battery cell voltage measuring tabs. In some embodiments, the plurality of bipolar plates includes a first set of bipolar plates and a second set of bipolar plates, the first set of bipolar plates having a first positioning of the battery voltage measuring tabs, and the second set of bipolar plates having a second positioning of the battery voltage measuring tabs offset relative to the first positioning of the battery voltage measuring tabs.

[0093] At frame 904, the method includes forming a plurality of insulator gasket layers alternating with a plurality of bipolar plates.

[0094] At frame 906, the method includes molding the edge of each battery voltage measuring tab to define a hemispherical recess for placing a spring-loaded contactor for the measuring device.

[0095] In some embodiments, each of the plurality of bipolar plates is formed by joining an anode half-plate and a cathode half-plate.

[0096] In some embodiments, the edges of each battery voltage measuring tab are molded to define a hemispherical recess by molding an anode half-plate on a first end of a forming tool and a cathode half-plate on a second end of a forming tool.

[0097] In some embodiments, the method includes forming an insulating spacer block having one or more through holes sized to accommodate a spring-loaded contactor of a measuring device.

[0098] In some embodiments, each of the plurality of insulator gasket layers includes a corrugated edge.

[0099] In some embodiments, the insulator spacer block includes one or more alignment teeth positioned to align with corresponding corrugated edges of a plurality of insulator gasket layers.

[0100] The terms “an” and “a” do not indicate a limitation of quantity, but rather that at least one of the referenced items is present. Unless the context clearly indicates otherwise, the term “or” means “and / or”. Throughout the specification, reference to “aspect” means that a particular element described in connection with that aspect (e.g., a feature, structure, step, or characteristic) is included in at least one aspect described herein and may or may not be present in other aspects. Furthermore, it should be understood that the described elements may be combined in any suitable manner in the aspects.

[0101] Furthermore, as used in this disclosure, phrases such as "at least one of A, B, or C" or "at least one of A, B, and C" should be interpreted as selecting at least one from the group including "A, B, and C". Unless explicitly stated otherwise in conjunction with specific examples in this disclosure, this phrasing does not imply "at least one of A, at least one of B, and at least one of C". As used in this disclosure, the example "at least one of A, B, or C" would cover any of the following selections: {A}, {B}, {C}, {A,B}, {A,C}, {B,C}, and {A,B,C}.

[0102] When an element, such as a layer, film, region, or substrate, is referred to as being “on” another element, it can be directly on the other element, or there may be intermediate elements present. Conversely, when an element is referred to as being “directly” on another element, there are no intermediate elements present.

[0103] Unless otherwise stated herein, all test standards are the most recent standards in effect as of the date of filing of this application, or, if priority is claimed, the date of filing of the earliest priority application in which a test standard appears.

[0104] Unless otherwise defined, the technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure pertains.

[0105] While the foregoing disclosure has been described with reference to exemplary embodiments, those skilled in the art will understand that various changes can be made and elements can be substituted with equivalents without departing from its scope. Furthermore, many modifications can be made to adapt particular situations or materials to the teachings of this disclosure without departing from the basic scope of this disclosure. Therefore, it is intended that this disclosure be limited to the specific embodiments disclosed, but will include all embodiments falling within its scope.

Claims

1. A vehicle comprising: Electric motor; as well as A fuel cell stack, electrically connected to the electric motor, the fuel cell stack comprising: A plurality of bipolar plates, each of the plurality of bipolar plates including one or more battery voltage measuring tabs, the plurality of bipolar plates including a first group of bipolar plates and a second group of bipolar plates, the first group of bipolar plates having a first positioning of the battery voltage measuring tabs, and the second group of bipolar plates having a second positioning of the battery voltage measuring tabs offset relative to the first positioning of the battery voltage measuring tabs; and Multiple layers of insulator gaskets alternating with the multiple bipolar plates; In this design, the edge of each battery voltage measuring tab is molded to define a hemispherical recess for housing the spring-loaded contactor of the measuring device.

2. The vehicle of claim 1, wherein each of the plurality of bipolar plates is formed by joining an anode half-plate and a cathode half-plate.

3. The vehicle according to claim 2, wherein, The edges of each battery voltage measuring tab are molded by molding the anode half-plate on the first end of the forming tool and the cathode half-plate on the second end of the forming tool, thereby defining the hemispherical recess.

4. The vehicle of claim 1, further comprising an insulator spacer having one or more through holes, the one or more through holes being sized to accommodate the spring-loaded contactor of the measuring device.

5. The vehicle according to claim 4, wherein, The through-hole offset positions the spring-loaded contactor against the first position of the battery voltage measuring tab, and the second position of the cell voltage measuring tab is offset relative to the first position of the battery voltage measuring tab.

6. The vehicle according to claim 4, wherein, Each of the plurality of insulator gasket layers includes a corrugated edge.

7. The vehicle according to claim 6, wherein, The insulator spacer includes one or more alignment teeth positioned to align with the corresponding corrugated edges of the plurality of insulator gasket layers.

8. A fuel cell stack, comprising: A plurality of bipolar plates, each of the plurality of bipolar plates including one or more battery voltage measuring tabs, the plurality of bipolar plates including a first set of bipolar plates and a second set of bipolar plates, the first set of bipolar plates having a first positioning of the battery voltage measuring tabs, and the second set of bipolar plates having a second positioning of the battery voltage measuring tabs offset relative to the first positioning of the battery voltage measuring tabs. Multiple layers of insulator gaskets alternating with the multiple bipolar plates; as well as An insulator spacer having one or more alignment holes positioned to receive one or more corresponding alignment tabs of the bipolar plate.

9. The fuel cell stack of claim 8, wherein each of the plurality of bipolar plates is formed by joining an anode half-plate and a cathode half-plate.

10. The fuel cell stack according to claim 8, wherein, The insulator spacer also includes one or more measuring tab slots, which are positioned to accommodate one or more corresponding battery voltage measuring tabs of the bipolar plate.

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