Embedded Power Connector in Fuel Cell End Plate

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Mechanical connections in fuel cell devices lead to potential voltage loss, heat buildup, increased labor time, and assembly errors, as well as the risk of corrosion with metal current collectors.

Innovation Solution

An electrically conductive end plate with an embedded electrical connector eliminates the need for separate current collectors, providing a reliable and corrosion-free connection by integrating the connector within the plate, made from materials like graphite, which reduces component handling and assembly time.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a mechanical connection using a fastener is used to attach a connector to the end plate, then an electrically conductive connection is established, but voltage loss occurs across the connection and heat buildup occurs at the mechanical connections

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidvoltage loss and heat buildup

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The connector is merged with the end plate by embedding it directly into the plate structure. This eliminates the separate mechanical fastener connection and creates an integrated electrical pathway, thereby eliminating voltage loss and heat buildup at connection points while maintaining reliable electrical conductivity.

Inventive Principle:

Principle #5Merging (Combining)

2Reliability

If a mechanical connection using a fastener is used to attach a connector to the end plate, then an electrically conductive connection is established, but additional labor time is required and assembly errors are possible

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidassembly time and labor

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The connector and end plate are combined into a single integrated component where the connector is embedded within the plate. This eliminates the need for separate assembly steps involving fasteners and reduces the risk of assembly errors, thereby reducing labor time and improving assembly reliability.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The connector is pre-positioned and embedded within the end plate during manufacturing, rather than being attached separately during assembly. This preliminary action eliminates the need for on-site mechanical connection steps, reducing assembly time and minimizing the risk of assembly errors.

Inventive Principle:

Principle #10Preliminary action

3Reliability

If a separate current collector and connector assembly is used, then electrical connection is achieved, but corrosion risk increases with metal components

Engineering Contradiction:

Improveelectrical connectionVSAvoidcorrosion risk

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The end plate is constructed from composite materials, specifically a polymer matrix with embedded conductive elements or carbon fiber reinforcement. This composite structure provides both the mechanical properties needed for the end plate and the electrical conductivity required for current collection, while being inherently corrosion-resistant compared to traditional metal components.

Inventive Principle:

Principle #40Composite materials

Data Source

PatentUS10038201B2Fuel cell component with embedded power connector

Publication Date: 2018.07.31 AUDI AG

AI summary

An exemplary fuel cell component includes a plate comprising an electrically conductive material. An electrical connector includes a first portion embedded in the plate. A second portion of the electrical connector extends from the plate. The second portion is configured to make an electrically conductive connection with another device.