Fuel Cell Module Inductance Adjustment via Stacked Magnetic Sheets
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Solution Overview
Problem
The existing fuel cell systems require frequent design changes when motor specifications change, leading to increased trouble and costs due to the need for specific converter components matching the motor's power requirements.
Innovation Solution
A fuel cell module design that includes a first stacked body of unit cells and a second stacked body of magnetic sheets with embedded coils, where the sheets are electrically connected and configured to allow for adjustable inductance values by varying the number of reactor sheets, reducing the need for frequent design changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a converter with a coil of specific number of turns and diameter is used to match the maximum supply power required for the motor, then the power conversion performance is improved, but the device complexity increases and design changes are required each time motor specifications change
Solution Approach 1:
The coil is divided into multiple conductors that are embedded in separate magnetic body sheets. Each magnetic body sheet contains a conductor, and multiple sheets are stacked to form the complete coil structure. This segmentation allows the inductance to be adjusted by changing the number of stacked sheets rather than redesigning the entire coil geometry.
Solution Approach 2:
The inductance value of the reactor is made adjustable by varying the number of magnetic body sheets stacked in the stack. This dynamic configuration allows the converter to be adapted to different motor power requirements simply by changing the number of sheets, rather than requiring complete redesign of the coil dimensions and turns.
2Power
If a conventional coil structure with specific turns and diameter is used, then the inductance matches the motor power requirements, but the installation space for the step-up converter increases
Solution Approach 1:
The coil structure transitions from a traditional planar winding to a three-dimensional stacked configuration. Conductors are embedded in multiple magnetic body sheets stacked in the vertical dimension, allowing the inductance to be adjusted by stacking height rather than by increasing the horizontal footprint of the coil.
3Power
If frequent design changes are made to match motor specifications, then the power conversion performance is optimized, but the manufacturing cost and trouble increase
Solution Approach 1:
The magnetic body sheets are designed as standardized, interchangeable components that can be stacked in different quantities to achieve various inductance values. This universal design allows a single sheet type to serve multiple power rating requirements, reducing the need for specialized tooling and manufacturing processes for each motor specification.
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 allows for easy adjustment of inductance values and reduces the installation space required for the step-up converter, minimizing design changes and installation costs while maintaining efficient power generation.
Implementation Method 1
a second stacked body including a plurality of magnetic body sheets stacked on each other... the plurality of magnetic body sheets includes a coil... the first stacked body is superposed on the second stacked body so as to be electrically connected to the coil
Data Source
AI summary
A fuel cell module has: a first stacked body including a plurality of unit cells stacked on each other; and a second stacked body including a plurality of magnetic body sheets stacked on each other. The magnetic body sheets includes a coil. The first stacked body is superposed on the second stacked body so as to be electrically connected to the coil. A conductor serving as a part of the coil is embedded in each magnetic body sheet. The conductor has a first end portion and a second end portion exposed from surfaces of each magnetic body sheet on opposite sides from each other. The first end portion of the conductor of one of a set of magnetic body sheets adjacent to each other, among the magnetic body sheets, contacts the second end portion of the conductor of the other of the set of magnetic body sheets.