Fuel Cell Module Layout With Surface-Mounted Converters
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Solution Overview
Problem
Fuel cell units, particularly those used in fuel cell electric vehicles, face challenges with poor mountability and installability when multiple fuel cell stacks are required for high output demands.
Innovation Solution
The fuel cell unit is designed with a configuration that includes two fuel cell modules, each with a power converter, where the power converters can be housed separately or in a common case, and terminal connections are arranged to avoid overlap and interference, allowing for improved mountability and connection efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If multiple fuel cell stacks are mounted to achieve high output, then power output is improved, but mountability and installability deteriorate
Solution Approach 1:
The fuel cell unit is divided into multiple independent fuel cell modules, each with its own power converter. This segmentation allows each module to be independently installed and connected, improving mountability while achieving high total output through parallel configuration of multiple modules.
Solution Approach 2:
The patent arranges fuel cell modules and power converters in a three-dimensional configuration where power converters are positioned on surfaces of fuel cell modules rather than stacking them vertically. This spatial arrangement in multiple dimensions improves installability while maintaining high power output capability.
2Productivity
If power converters are integrated with fuel cell stacks to convert power, then power conversion efficiency is improved, but device complexity increases
Solution Approach 1:
The power converters are designed as multi-functional units that can serve multiple fuel cell modules simultaneously. A single power converter can convert power from multiple fuel cell stacks, reducing the total number of power converters needed and simplifying the overall system while maintaining efficient power conversion.
Solution Approach 2:
The patent combines power converters with fuel cell modules in an integrated configuration where the power converter is positioned on the surface of the fuel cell module. This merging reduces the number of separate components and simplifies installation while maintaining efficient power conversion capability.
3Ease of operation
If terminal plates are arranged to facilitate electrical connections, then ease of connection is improved, but risk of terminal overlap and connection errors increases
Solution Approach 1:
The terminal plates are designed with asymmetric arrangements where positive and negative terminals are positioned at different locations and orientations. This asymmetric design prevents overlap between terminals from adjacent modules and reduces the risk of connection errors while maintaining ease of connection through clear terminal identification and accessibility.
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 design enhances the mountability and installability of the fuel cell unit, facilitating easier integration and connection of modules while reducing the size of the power converter and improving collision safety.
Implementation Method 1
A fuel cell is a cell that generates electrical energy through a chemical reaction between an oxidant gas containing oxygen and a fuel gas containing hydrogen
Implementation Method 2
a power converter configured to convert power of the fuel cell module
Data Source
AI summary
A fuel cell unit includes: a fuel cell module; and a power converter. The fuel cell module includes a first fuel cell module including a first fuel cell stack that is a stack of first single cells, and a second fuel cell module including a second fuel cell stack that is a stack of second single cells. The power converter includes a first power converter, and a second power converter. The first power converter is located on a first surface of the first fuel cell module. The second power converter is located on a first surface of the second fuel cell module. The first surfaces face each other. A first normal direction to the first surfaces is orthogonal to a stacking direction of the first single cells and the second single cells.