Fuel Cell Connector Slits for Tab Alignment

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Conventional electrical connectors face challenges with thin flow plates in fuel cell stacks, as they lack stiffness and structural integrity to resist compressive forces and often misalign due to manufacturing tolerances, making it difficult to form and connect cell voltage monitoring tabs effectively.

Innovation Solution

A connector device with a planar member featuring spaced-apart slits with a curved profile and tapered ends, designed for sliding engagement with tabs, providing a secure and aligned connection by using a printed circuit board with conductive tracks and retention members to prevent tab release.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Weight of stationary object

If flow plate thickness is reduced to decrease weight and increase power density, then weight reduction is achieved, but tab stiffness and structural integrity deteriorate

Engineering Contradiction:

Improveflow plate weightVSAvoidtab stiffness

Core Design Contradiction:

Weight of stationary objectVSStrength

Solution Approach 1:

The connector device divides the connection function into multiple slits arranged in arrays, with each slit independently receiving and securing a tab. This segmentation allows the connector to distribute mechanical loads across multiple contact points, compensating for the reduced stiffness of thin tabs while maintaining overall connection integrity

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The connector device acts as an intermediary component between the thin tabs and the external monitoring system. It provides mechanical support and structural reinforcement to the otherwise fragile thin tabs, enabling reliable electrical connections without requiring the tabs themselves to bear full mechanical loads

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If conventional push-fit spring-loaded connectors are used on thin tabs, then electrical connection is achieved, but tab collapse occurs due to insufficient stiffness

Engineering Contradiction:

Improveelectrical connectionVSAvoidtab structural integrity

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

Instead of applying compressive force from the end of the tab (conventional push-fit approach), the connector device engages with the tabs through a different mechanism where the slits receive and secure the tabs in a manner that distributes forces along the tab length, preventing localized compression and collapse

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The connector device incorporates flexible or resilient elements within the slit structure that can dynamically adapt to tab position variations and manufacturing tolerances. This dynamic capability allows the connector to maintain reliable electrical contact while accommodating the limited stiffness of thin tabs without causing collapse

Inventive Principle:

Principle #15Dynamics

3Productivity

If manufacturing tolerances are present in tab arrays, then mass production is feasible, but alignment precision deteriorates

Engineering Contradiction:

Improvemass production capabilityVSAvoidtab alignment

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The connector device is designed with adjustable or flexible geometric parameters, including slit width, spacing, and orientation, that can accommodate variations in tab position. This parameter flexibility allows the connector to maintain proper alignment and electrical contact despite manufacturing tolerances in the tab arrays

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The connector incorporates dynamic alignment capabilities through resilient mounting structures or adjustable slit positions that can adapt to tab array variations. This dynamic adjustment mechanism enables the connector to self-align with tabs within acceptable tolerance ranges, ensuring reliable connections without requiring precision manufacturing

Inventive Principle:

Principle #15Dynamics

Data Source

PatentUS10505321B2Connector device including planar member with slits to receive electrical tabs of fuel cell stack

Publication Date: 2019.12.10 INTELLIGENT ENERGY LTD

AI summary

An electrical connection system for cell voltage monitoring in a fuel cell stack. A fuel cell stack assembly comprises a plurality of fuel cells disposed in a stacked configuration, each cell substantially parallel to an x-y plane and including an electrical tab extending laterally from an edge of a plate in the cell in the x-direction to form an array of tabs extending along a side face of the fuel cell stack in a z-direction orthogonal to the x-y plane. A connector device comprises a planar member having a plurality of spaced-apart slits formed in an edge of the planar member, each slit having an electrically conductive material on an inside face of the slit. The slits are spaced along the edge of the planar member and configured to receive the tabs by sliding engagement in the y-direction. Alternatively, each tab may be crimped to create a distortion in the tab out of the x-y plane of the plate and a connector device comprises a planar member having a plurality of generally parallel slits formed in the body of the planar member, each slit having an electrically conductive material on an inside face of the slit, the slits being spaced within the planar member and configured to receive the tabs by sliding engagement in the x-direction so that each tab engages with at least a portion of the electrically conductive material on the inside face of a respective slit.