Angled Conductive Rubber Voltage Tapping for Fuel Cell Edge Contacts
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Solution Overview
Problem
Existing fuel cell voltage tapping systems face challenges when the contact area between conductive rubber elements and bipolar plates is significantly smaller, such as when contacting solely via a narrow edge area, which can lead to reduced robustness against vibration and shock, and increased risk of short circuits.
Innovation Solution
The use of a conductive rubber element with alternating electrically conductive and insulating regions, arranged at an angle α to the bipolar plates, where the angle and dimensions of the conductive and insulating regions are optimized to ensure effective electrical contact and prevent short circuits, even in constrained contact areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If spring contacts are used to measure cell voltages, then electrical contact can be established, but the system is vulnerable to degradation mechanisms and external vibration and shock loads
Solution Approach 1:
The patent replaces expensive, fragile metal and precious metal contact pairings with a conductive rubber element that is more tolerant of degradation. The rubber element can withstand external vibration and shock loads better than traditional metal contacts, effectively using a more durable material to replace the vulnerable contact pairing system.
Solution Approach 2:
The invention uses a composite conductive rubber element that combines conductive and insulating properties in a single component. This composite material approach allows the element to provide electrical contact while simultaneously preventing short circuits, replacing multiple separate components with one integrated solution that is more robust against mechanical stresses.
2Ease of operation
If conductive rubber element is used for voltage tapping, then geometric adjustment is easier and contact pairing degradation is reduced, but the contact area may be insufficient in constrained applications
Solution Approach 1:
The patent addresses the limited contact area problem by arranging the conductive rubber element at an angle α between 0° and 45° relative to the bipolar plate surface. This angular orientation allows the element to span across the narrow edge area contact zone, effectively utilizing the available space in a different geometric dimension to achieve adequate electrical contact despite the constrained contact area.
Solution Approach 2:
The invention optimizes the geometric parameters of the conductive rubber element, including its width, length, and angular orientation, to adapt to constrained contact areas. By adjusting these parameters, the element can maintain effective electrical contact even when the available contact area on the bipolar plate is significantly reduced.
3Volume of moving object
If conductive rubber element contacts bipolar plate at narrow edge area, then space is utilized better, but robustness against vibration and shock is reduced
Solution Approach 1:
By orienting the conductive rubber element at an angle to the bipolar plate, the invention maximizes the utilization of the narrow edge area contact space while distributing the mechanical stress across a more favorable geometric configuration. This angular arrangement helps maintain robustness against vibration and shock by reducing stress concentration at the contact point.
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 configuration enhances the robustness of electrical contacting against vibration and shock, while maintaining effective voltage tapping and preventing short circuits, even as the bipolar plates undergo geometric changes over their life cycle.
Implementation Method 1
The electrically conductive regions of the conductive rubber element provide electrical contact with the bipolar plates
Implementation Method 2
The electrically insulating regions prevent a short circuit between the bipolar plates
Data Source
AI summary
A fuel cell includes a plurality of bipolar plates having a plurality of contacting surfaces and a conductive rubber element having a plurality of electrically conductive regions alternating successively with a plurality of electrically insulating regions. The conductive rubber element is arranged at an angle α to an orthogonal of the contacting surfaces of the bipolar plates, wherein B≥3.5·p·cos(α)−b·sin(α) is satisfied. B is a width of one of the contacting surfaces on one of the bipolar plates, b is a width of the electrically conductive regions and electrically insulating regions of the conductive rubber element, and p is a grid pitch of the conductive rubber element.