Fuel Cell Connector Locking Boss and Groove Design
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Solution Overview
Problem
The existing cell voltage measuring connectors for fuel cell stacks are prone to detachment due to vibrations and impacts, leading to inaccurate voltage measurements and reduced reliability, especially when used in vehicles with ultra-slim separating plates.
Innovation Solution
The connector features locking bosses that insert into lock grooves of the separating plates, along with spaced connecting pieces to prevent contact line interference, ensuring secure attachment even with thin plates, and a lock releasing aperture for easy detachment without disassembling the panel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the connector is formed integrally with a length that corresponds to the whole stack, then all terminals of separating plates can be connected, but alignment accuracy becomes critical and terminals may be deflected or damaged during assembly
Solution Approach 1:
The connector is divided into multiple separate connector bodies, each corresponding to a specific separating plate. Each connector body has its own terminal connecting portion that interfaces with terminals of a specific separating plate. This segmentation eliminates the need for precise alignment across the entire stack, as each segment independently connects to its corresponding separating plate without interfering with others.
2Reliability
If the connector is used in a vehicle environment, then voltage measurement is enabled, but vibrations and impacts cause detachment and measurement inaccuracy
Solution Approach 1:
The connector body includes a locking boss that is preliminarily positioned to engage with a locking groove on the separating plate before final assembly completion. This preliminary locking action secures the connector to the separating plate in advance, preventing detachment due to subsequent vibrations and impacts during vehicle operation. The locking mechanism is activated during the assembly process itself, ensuring stability before the connector begins its measurement function.
3Length of moving object
If the separating plates are made ultra-slim with thickness of about 0.1 mm or less, then stack density is improved, but contact force becomes vulnerable and connecting terminals may separate
Solution Approach 1:
The locking boss is preliminarily positioned to engage with the locking groove on the ultra-slim separating plate before the terminal connecting portion applies full contact force. This preliminary locking provides mechanical support and positioning, allowing the terminal connecting portion to make contact with the thin terminal without causing deflection or separation. The locking mechanism compensates for the reduced structural strength of ultra-slim separating plates.
4Reliability
If the connector is securely locked to prevent detachment, then reliability under vibrations is improved, but detachment for component replacement becomes difficult
Solution Approach 1:
The locking mechanism transitions from a static locked state during operation to a dynamically releasable state during maintenance. The locking boss engages with the locking groove to provide stable locking during vehicle operation, preventing detachment under vibrations. However, the locking groove includes a lock releasing aperture that allows a separating tool to engage and lift the locking boss, dynamically changing the locked state to an unlocked state for easy removal and component replacement.
Data Source
AI summary
A connector that may be prevented from detaching from separating plates of a stack even when vibrations or an external impact of a vehicle occurs by maintaining a locking state in which locking bosses of a CPA are inserted into lock grooves of terminals of separating plates. In addition, connecting points of connecting pieces of connecting terminals are spaced apart to not contact each other with respect to a contact line. The connecting terminals are not detached from the separating plates even when the separating plates is a ultra-slim film having a thickness of about 0.1 mm or less, making it possible to increase a reliability of a product.