Fuel Cell Bus Plate Unit with Bent Ends and Insulation

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Solution Overview

Problem

Conventional bus bars in fuel cell systems have a large volume, leading to increased separation cavities and restricted mounting space, which hinders the output density of unit stacks.

Innovation Solution

A bus plate unit utilizing thin plates with bent end portions and an insulating layer to increase contact area with unit stacks, reducing separation cavities and improving output density by minimizing thickness and size through an inclined component between terminals.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If conventional bus bars with square cross-section are used, then substantial electrical energy can be transmitted and mechanical strength is substantial, but the volume of the unit stack increases and separation cavity is formed

Engineering Contradiction:

Improveelectrical energy transmissionVSAvoidunit stack volume

Core Design Contradiction:

PowerVSVolume of stationary object

Solution Approach 1:

The patent replaces conventional thick square bus bars with thin flexible bus plates. The bus plates have a thickness of 0.5-2mm compared to conventional bus bars that are 10-20mm thick. These thin plates maintain electrical conductivity while dramatically reducing volume, allowing them to conform to the unit stack surface and eliminate separation cavities.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The invention transitions from a three-dimensional square cross-section bus bar to a two-dimensional thin plate configuration. This dimensional change allows the bus plate to cover a larger surface area with minimal thickness, increasing contact area while reducing volume occupied in the stacking direction.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Strength

If conventional bus bars with square cross-section are used, then substantial mechanical strength is achieved, but mounting space is restricted and separation cavity is formed

Engineering Contradiction:

Improvemechanical strengthVSAvoidmounting space

Core Design Contradiction:

StrengthVSArea of stationary object

Solution Approach 1:

The thin bus plates are designed with sufficient mechanical strength despite their reduced thickness. The flexibility allows them to conform to the unit stack surface contours, maximizing mounting space utilization while maintaining structural integrity for electrical connection.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The bus plate design integrates the electrical connection function with the mounting structure. By making the bus plate thin and flexible, it can be directly mounted onto the unit stack surface, merging the electrical conductor with the mounting substrate and eliminating the need for separate mounting components that would consume space.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS10411270B2Bus plate unit

Publication Date: 2019.09.10 HYUNDAI MOTOR CO LTD

AI summary

A bus plate unit is provided. The bus plate unit electrically connects a unit stack for a fuel cell having a (+) and a (−) stack terminal at both sides. The unit includes a (+) bus plate having a first end portion bent toward a first side surface of the unit stack and electrically coupled to a (+) stack terminal of the unit stack. A second end portion has a (+) bus terminal and abuts an upper first side of the unit stack. A (−) bus plate has a first end portion bent toward a second side surface of the unit stack and electrically coupled to the (−) stack terminal of the unit stack. A second end portion provides a (−) bus terminal and is proximate to the upper second side of the unit stack. An insulating layer encloses a surface of the (+) bus plate and the (−) bus plate.