Fuel Cell Connector with Alternating Projections for Compact Stacking
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Solution Overview
Problem
The existing fuel cell connectors face challenges with thinner single cells due to spatial interference and insufficient structural strength, leading to manufacturing inefficiencies and potential damage during installation, while also failing to meet the demand for a lower profile and smallest possible size for fuel cells.
Innovation Solution
A connector design featuring a housing with alternating projections on upper and lower halves, allowing for closer terminal spacing without reducing the thickness of the housing, and utilizing a resin construction with a lever-like lock member for secure engagement, ensuring mechanical strength and efficient electrical connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the housing thickness is reduced to avoid spatial interference between adjacent connectors, then the profile size is reduced, but the structural strength becomes insufficient leading to manufacturing inefficiency and damage during installation
Solution Approach 1:
The patent transitions from a conventional single-plane terminal arrangement to a three-dimensional arrangement where detection terminals are mounted in both the upper half and lower half of the housing. This spatial redistribution allows terminals to be positioned at different heights, reducing horizontal interference between adjacent connectors while maintaining adequate housing thickness for structural strength.
Solution Approach 2:
The detection terminals are segmented into two groups: those mounted in the upper half of the housing and those mounted in the lower half. This segmentation enables the housing to maintain sufficient thickness for strength while accommodating all necessary terminals without spatial interference, as terminals are distributed across different vertical zones rather than competing for the same horizontal space.
2Length of stationary object
If detection terminals are arranged in a single plane, then the housing can be made thinner, but spatial interference occurs between adjacent connectors preventing proper mounting
Solution Approach 1:
The patent adds a vertical dimension to the terminal arrangement by mounting detection terminals in both the upper half and lower half of the housing. This three-dimensional configuration eliminates spatial interference between adjacent connectors while maintaining a compact overall profile, as terminals are distributed vertically rather than extending horizontally.
3Device complexity
If a conventional single-plane terminal arrangement is used, then the structure is simple, but the connector cannot accommodate all single cells without spatial interference
Solution Approach 1:
The detection terminals are divided into two segments: upper-half terminals and lower-half terminals. This segmentation allows the connector to accommodate detection terminals for all single cells in the stack without spatial interference, as terminals are distributed across different vertical levels rather than crowded in a single plane.
Data Source
AI summary
A connecter comprises a housing having a first projection formed on an upper half of a first lateral surface over the entire width thereof between the front surface and the rear surface, and a second projection formed on a lower half of a second lateral surface opposed to the first lateral surface; a single detection terminal mounted inside the first projection, capable of connection to an electrode of a single cell contained in a fuel cell; and a detection terminal mounted in the lower half of the housing, capable of connection to the electrode of the single cell contained in the fuel cell. The detection terminals are all arranged at equal intervals.