Fuel Cell Stack Manifold Recess for Toe Board Collision Avoidance
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Solution Overview
Problem
In vehicles with fuel cell units positioned anterior to the dashboard, there is a risk of collision with the toe board during impacts due to insufficient space, and relocating the toe board would reduce driver footspace.
Innovation Solution
A recess portion is formed in the stack manifold to accommodate the air valve device, reducing its protrusion and allowing the fuel cell unit to be positioned closer to the toe board without narrowing the driver's footspace, achieved by integrating the air valve device within the recessed area of the stack manifold.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the fuel cell unit is positioned anterior to the dashboard, then the space utilization in the engine compartment is improved, but the gap between the fuel cell unit and toe board becomes small, creating collision risk during impacts
Solution Approach 1:
The air valve device is nested within a recess portion formed in the stack manifold, allowing the fuel cell unit to be positioned closer to the toe board while maintaining safety clearance. The recess portion accommodates the air valve device, effectively reducing the overall protrusion of the fuel cell unit and preventing collision during impacts.
Solution Approach 2:
Instead of increasing the gap between the fuel cell unit and toe board in the longitudinal direction, the invention creates a recess portion in the stack manifold that provides accommodation space in the lateral direction. This dimensional approach allows the fuel cell unit to be positioned anterior to the dashboard without compromising safety clearance.
2Reliability
If the toe board is relocated to a more rear side position, then the collision risk is reduced, but the space around the driver's feet becomes narrower
Solution Approach 1:
The air valve device is nested within the recess portion of the stack manifold, which reduces the longitudinal dimension of the fuel cell unit. This allows the fuel cell unit to be positioned closer to the toe board, maintaining adequate safety clearance without requiring the toe board to be relocated rearward, thereby preserving driver footspace.
Solution Approach 2:
The recess portion is pre-formed in the stack manifold during manufacturing, creating built-in accommodation space for the air valve device. This preliminary structural design enables compact positioning of the fuel cell unit without requiring subsequent modifications or relocation of the toe board.
3Power
If the air valve device is made larger to control high flow-rating pressure, then the valve control performance is improved, but the device size increases, requiring more space
Solution Approach 1:
The air valve device is nested within the recess portion of the stack manifold, which provides dedicated accommodation space for the valve and its actuating mechanism. This nesting arrangement allows a sufficiently large air valve device to be installed for controlling high flow-rating pressure, while the overall footprint is minimized by utilizing the recess space.
Solution Approach 2:
The recess portion provides additional volume in the lateral direction, allowing the air valve device to be positioned within the stack manifold structure rather than extending outward. This enables the installation of a larger-capacity air valve device without increasing the overall longitudinal dimension of the fuel cell unit.
Data Source
AI summary
Provided is a vehicle with a fuel cell unit, specifically, a vehicle with a configuration in which a fuel cell unit is arranged anterior to a dashboard as well as a toe board located below the dashboard, where the fuel cell unit is arranged to be prevented from colliding with the toe board upon occurrence of unforeseen impact on the fuel cell unit. The fuel cell unit includes at least a fuel cell group, a stack manifold provided on the fuel cell group on the vehicle rear side, and an air valve device fixed to the stack manifold. The stack manifold has a recess portion formed in a part thereof. The air valve device is fixed to the stack manifold with at least a part of the air valve device received within the recess portion.