Fuel Cell Support Frame Segmentation for Strength and Scalability
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Solution Overview
Problem
The existing support frames for fuel cells in vehicles face challenges in manufacturing large sizes due to the difficulty in creating suitable manufacturing apparatuses and ensuring high strength, particularly with integrated metallic members manufactured by casting, which often lack toughness.
Innovation Solution
A support frame composed of interconnected members, where the first member is structurally connected to the second and third members through fitting and recessed portions, enhancing strength and allowing easy assembly and upscaling, while maintaining high toughness and reducing manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the support frame is manufactured as an integrated member by extrusion molding or casting, then the manufacturing process is simplified, but it becomes difficult to manufacture large-sized frames and the cost increases significantly
Solution Approach 1:
The support frame is divided into multiple separate members (first member, second member, third member, etc.) that can be manufactured independently using extrusion molding. These members are then connected through connecting portions with fitting structures, allowing the frame to be assembled into various sizes by selecting and combining different numbers and configurations of members, thus resolving the contradiction between manufacturing simplicity and size adaptability.
2Length of stationary object
If the integrated member is manufactured by casting, then large sizes can be achieved, but the toughness and strength are insufficient compared to other manufacturing methods
Solution Approach 1:
Instead of casting a single large integrated member with insufficient toughness, the frame is segmented into multiple smaller members that can be manufactured by extrusion molding, which produces members with high toughness and strength. The segmentation allows each member to maintain superior material properties while achieving the required large overall frame size through assembly.
Solution Approach 2:
The connecting portions are designed with fitting structures that create a composite assembly of multiple members. This composite structure, combined with the overlapping configuration of members in the connecting portions, achieves both large frame size and high overall strength, overcoming the limitations of casting.
3Area of stationary object
If the support frame is designed with a large size to accommodate large fuel cells, then the fuel cell can be supported, but the manufacturing cost and difficulty increase significantly
Solution Approach 1:
The large support frame is segmented into multiple standard-sized members that can be manufactured using conventional extrusion molding equipment. By assembling these pre-manufactured members through connecting portions with fitting structures, the frame achieves large overall area while avoiding the need for specialized manufacturing apparatus, thus reducing manufacturing cost and difficulty.
Solution Approach 2:
The members and connecting portions are designed with universal fitting structures that can be used across different frame configurations and sizes. This modular universality allows the same basic components to be reused in various assemblies, reducing the need for custom-manufactured parts and lowering overall manufacturing costs for large-sized frames.
Data Source
AI summary
A support frame includes a first member, a second member, and a third member each having a surface. The first member is connected to the second member by fitting, and the first member is connected to the third member by fitting. In each of connecting portions, one of members connected to each other is defined as a first connecting member and the other one of the members is defined as a second connecting member. A side end portion of the first connecting member on a side facing the second connecting member is provided with an extending portion. The extending portion has a flat shape, and the extending portion is provided with a fitted portion constituted by a recessed portion. A side end portion of the second connecting member on a side facing the first connecting member is provided with a fitting portion configured to fit in the fitted portion.