Fuel Cell Stack Power Outlet Assembly for Vibration-Resistant Isolation
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Solution Overview
Problem
Existing fuel cell stacks face issues with secure and adaptable power outlet connections that can withstand vibrations and prevent damage to insulation, while maintaining electrical isolation and preventing contamination.
Innovation Solution
A power outlet connection system using a first nut with a tightening stop and a threaded element, such as a threaded bolt, secured by a second nut, with optional vibration prevention features like lock nuts and self-lock threads, and insulated by molded plastic housings, ensuring a stable connection adaptable to various connector sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a screw is used to fasten the external connector to the power output terminal, then a stable electric conductive connection is achieved, but the plastic cover or housing may be damaged if the connector thickness is too small
Solution Approach 1:
The invention divides the fastening function into two separate components: a first nut that provides a tightening stop to prevent over-tightening and damage to the plastic housing, and a second nut that secures the threaded element to maintain the electric connection. This segmentation allows each component to specialize in one function, resolving the contradiction between connection reliability and housing integrity.
Solution Approach 2:
The first nut acts as an intermediary element between the threaded element (screw) and the plastic housing. It provides a controlled interface that limits the tightening force transmitted to the housing through the tightening stop, while still allowing the threaded element to secure the connector. This intermediary protects the housing from damage while maintaining connection stability.
2Strength
If the external connector thickness is increased to prevent housing damage, then housing integrity is maintained, but the screw connection may not be tightened enough and may come loose under vibrations
Solution Approach 1:
The fastening system is segmented into two nuts with distinct functions: the first nut (with tightening stop) controls the tightening limit to protect the housing, while the second nut provides additional securing force to prevent loosening under vibration. This segmentation allows the system to maintain both housing integrity and connection stability simultaneously.
Solution Approach 2:
The dual-nut system creates a dynamic fastening mechanism where the first nut establishes a fixed tightening stop position, and the second nut can be tightened further to compensate for vibrations. This dynamic arrangement allows the connection to adapt to vibrational forces while maintaining a safe distance from the housing damage threshold.
3Reliability
If a plastic housing is used to cover the power output terminal, then electrical isolation and contamination prevention are achieved, but accessibility to the power output terminal is reduced
Solution Approach 1:
The power output terminal is nested within the plastic housing, with the terminal positioned inside the housing cavity. This nesting arrangement provides electrical isolation and contamination protection while maintaining accessibility, as the terminal can be reached through the housing opening for connector attachment and detachment operations.
Data Source
AI summary
An electric cell stack assembly includes at least an electric energy generating cell stack body with a plurality of stacked unit cells. Each unit cell is a unit fuel cell includes a bipolar plate and a membrane electrode assembly, a first and second terminal plate sandwiching the cell stack body, which are adapted to collect the electric energy generated by the cell stack body. Each terminal plate includes a power output terminal, which is connectable to an external connector, and a tightening arrangement adapted to tighten the external connector to the power output terminal, for providing an electric connection between the external connector and the power output terminal. The tightening arrangement includes at least a first nut and a threaded element wherein the threaded element is adapted to be screwed into the first nut with a first end, and wherein the first nut is adapted to provide a tightening stop for the threaded element.