Fuel Cell Case Anodization via Through-Hole Contacts
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Solution Overview
Problem
The existing methods for manufacturing aluminum-based fuel cell cases with anodized surfaces to prevent corrosion are costly due to the need for a separate part to be formed for contact during anodization.
Innovation Solution
A method where through-holes in the fuel cell case, used for mounting on a vehicle, serve as the contact for anodization, reducing manufacturing costs and allowing for sufficient flatness and visibility for pin insertion, while alumite is formed on the surface excluding the inner through-holes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate part is formed for contact during anodization, then the anodization process can be performed effectively, but the manufacturing cost increases
Solution Approach 1:
The through-hole serves dual functions: (1) as a mounting feature for positioning the fuel cell case on the vehicle using pins, and (2) as a contact for anodization to form alumite on the surface. By making the through-hole perform both functions simultaneously, the patent eliminates the need for a separate contact part, thereby reducing manufacturing cost while ensuring effective corrosion prevention through anodization
Solution Approach 2:
The patent merges the mounting function and anodization contact function into a single through-hole structure. Instead of having separate features for mounting and anodization contact, the through-hole combines both functions, reducing the number of parts and manufacturing steps while achieving both positioning accuracy and corrosion protection
2Device complexity
If through-holes are formed at one side position in lateral directions, then the structure is simplified, but positional offset between through-holes and pins increases
Solution Approach 1:
The patent employs asymmetric positioning of through-holes relative to the fuel cell case dimensions. By placing through-holes at specific positions considering the longer lateral dimension, the design creates an asymmetric configuration that optimizes alignment with pins during mounting, reducing positional offset while maintaining structural simplicity
3Manufacturing precision
If through-holes are formed by cutting, then a surface with sufficient flatness is achieved for anodization contact, but additional manufacturing steps are required
Solution Approach 1:
The cutting process to form through-holes is performed as a preliminary action that simultaneously achieves both the mounting feature and the anodization contact surface. By cutting the through-holes before anodization, the flat surface is prepared in advance, ensuring adequate contact for the anodization process while integrating this preparation into the overall manufacturing sequence
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces manufacturing costs, minimizes positional offset issues, and facilitates easy pin insertion by forming through-holes at strategic positions, ensuring effective corrosion prevention without increasing costs.
Implementation Method 1
forming alumite on a surface of the fuel cell case by anodizing the surface using the through-hole as a contact
Data Source
AI summary
To reduce a manufacturing cost on anodization in an aluminum-type fuel cell case, a method of manufacturing a fuel cell case made of one of aluminum and aluminum alloy and for accommodating a fuel cell is provided, which includes forming, in a fuel cell case, through-holes for receiving pins when the fuel cell case is mounted on a vehicle, and forming alumite on a surface of the fuel cell case by anodizing the surface using the through-hole as a contact.