Fuel Cell Auxiliary Case Segmentation for Weight Reduction

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

The existing fuel cell systems face challenges in achieving weight reduction while maintaining the necessary strength and functionality for protecting fuel gas system devices from external loads and mounting to a vehicle body frame, as traditional auxiliary device cases become large and difficult to produce.

Innovation Solution

A fuel cell system with an auxiliary device case comprising a first case member made of high-rigidity material for protecting the fuel gas system device and a second case member made of lightweight material for covering the oxygen-containing gas system device, allowing for ventilating functions and mounting to the vehicle body frame, with the second case member being partially formed from materials like resin or rubber to achieve weight reduction.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If the entire auxiliary device case is formed by molding to satisfy the required strength for protection and mounting functions, then the strength and protection capability are improved, but the weight and size become large and production becomes difficult

Engineering Contradiction:

Improvestrength of auxiliary device caseVSAvoidweight of auxiliary device case

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The auxiliary device case is divided into two separate case members: a first case member made of high-rigidity material for protecting the fuel gas system device, and a second case member made of lightweight material for covering the oxygen-containing gas system device. This segmentation allows each part to be optimized independently for its specific function, achieving overall strength while reducing total weight.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the auxiliary device case are assigned different material properties according to their functional requirements. The first case member requires high rigidity for protection, while the second case member prioritizes lightweight characteristics. This local differentiation of material quality resolves the contradiction between strength and weight.

Inventive Principle:

Principle #3Local quality

2Strength

If the entire auxiliary device case is formed by molding to satisfy the required strength, then the protection function is improved, but the size becomes large and manufacturing complexity increases

Engineering Contradiction:

Improvestrength of auxiliary device caseVSAvoidmanufacturing ease of auxiliary device case

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

Dividing the auxiliary device case into two separate case members simplifies manufacturing by allowing each member to be produced independently using materials and processes optimized for their specific requirements, rather than attempting to mold a single large complex structure.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The auxiliary device case combines different materials (high-rigidity material and lightweight material) in a composite structure, allowing each material to be selected and processed according to its optimal manufacturing characteristics, improving overall ease of manufacture while maintaining required strength.

Inventive Principle:

Principle #40Composite materials

3Device complexity

If a single material is used for the entire auxiliary device case, then the structure is simple, but it cannot simultaneously achieve protection, ventilation, and weight reduction functions

Engineering Contradiction:

Improvestructural complexity of auxiliary device caseVSAvoidfunctional versatility of auxiliary device case

Core Design Contradiction:

Device complexityVSAdaptability or versatility

Solution Approach 1:

Different materials are assigned to different regions (first case member vs. second case member) according to their specific functional requirements for protection, ventilation, and weight reduction, allowing the structure to achieve multiple functions simultaneously.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The auxiliary device case uses a composite structure combining high-rigidity material and lightweight material, enabling the system to achieve protection function, ventilation function, and weight reduction function that cannot be achieved with a single material.

Inventive Principle:

Principle #40Composite materials

Data Source

PatentUS11456478B2Fuel cell system with auxiliary device case

Publication Date: 2022.09.27 HONDA MOTOR CO LTD

AI summary

A fuel cell system includes a stack case storing a fuel cell stack, and an auxiliary device case containing a fuel gas system device and an oxygen-containing gas system device. The auxiliary device case covers the fuel gas system device in a manner to protect the fuel gas system device against the external load, and includes a first case member provided with a mount fixed to a vehicle body frame, and a second case member made of material having specific gravity smaller than that of the first case member, and covers at least the oxygen-containing gas system device.