Miniature Fuel Cell Package With Integrated Conductive Crossbars
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Solution Overview
Problem
There is a lack of a simple package design for miniature fuel cells that can replace traditional batteries in portable devices, such as microcomputers and phones, which effectively integrates multiple fuel cell elements for efficient power supply.
Innovation Solution
A package design featuring an upper plate with openings for receiving fuel cell elements, connected by conductive tracks and a lower plate forming a closed space with an access port for fuel, enhancing mechanical strength and tightness through gluing and spacers, allowing series connection of cell elements without the need for intermediary wires.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If multiple fuel cell elements are assembled in a package, then the power output and energy supply capability are improved, but the device complexity and packaging difficulty increase
Solution Approach 1:
The patent merges multiple fuel cell elements into a single integrated package with unified structure. The upper plate, lower plate, and side walls form a single packaging unit that accommodates multiple cell elements, their holders, and interconnection components, reducing the number of separate assemblies and simplifying the overall device complexity while maintaining enhanced power output capability.
Solution Approach 2:
The upper plate serves multiple functions: it provides structural support, forms the packaging enclosure, and incorporates conductive tracks for electrical interconnection between cell elements. The lower plate similarly serves as both structural base and fuel distribution manifold. This multi-functionality reduces the number of separate components needed, simplifying the package design while enabling multiple cell elements to work together for increased power output.
2Reliability
If cell elements are connected using traditional wiring methods, then electrical connection is achieved, but the device complexity and assembly difficulty increase
Solution Approach 1:
The patent extracts the electrical interconnection function from separate wiring assemblies and integrates it directly into the package structure through conductive tracks formed on the upper and lower plates. This eliminates the need for additional wires, connectors, and associated assembly steps, reducing device complexity and assembly difficulty while maintaining reliable electrical connections between series-connected cell elements.
Solution Approach 2:
The conductive tracks are merged with the package plates themselves, combining the electrical interconnection function with the structural packaging function. The upper plate's conductive tracks and the lower plate's conductive tracks work together to electrically connect multiple cell elements in series, eliminating the need for separate wiring harnesses and reducing overall device complexity.
3Strength
If the package structure is made more robust for mechanical strength, then the mechanical integrity is improved, but the manufacturing complexity and assembly difficulty increase
Solution Approach 1:
The package merges the upper plate, lower plate, and side walls into a single integrated structural unit with unified manufacturing. The plates are formed with integrated features (conductive tracks, fuel channels, mounting structures) that provide both mechanical strength and functional capabilities, reducing the need for multiple separate components and complex assembly operations while maintaining robust mechanical integrity.
Solution Approach 2:
The plates are pre-formed with integrated conductive tracks, fuel distribution channels, and mounting structures before final assembly. This preliminary action incorporates multiple functions into the base structures, reducing the complexity of subsequent assembly steps while ensuring the package has the necessary mechanical strength to protect and support the fuel cell elements.
4Reliability
If cell elements are tightly sealed in the package, then the tightness and leakage prevention are improved, but the assembly difficulty and manufacturing precision requirements increase
Solution Approach 1:
The patent uses gaskets or sealing films between the upper plate, lower plate, and side walls to create tight seals around the fuel cell elements and fuel channels. These flexible sealing elements accommodate minor dimensional variations and assembly tolerances, achieving reliable tightness and leakage prevention without requiring extremely high manufacturing precision or complex assembly procedures.
Solution Approach 2:
Sealing features such as gasket grooves, sealing surfaces, and alignment structures are pre-formed in the upper and lower plates during manufacturing. This preliminary preparation of sealing interfaces simplifies the final assembly process and reduces the precision requirements during assembly, while still achieving the necessary tightness to prevent fuel and gas leakage from the package.
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
The package provides a compact, efficient, and secure integration of multiple fuel cell elements, ensuring reliable power supply and mechanical integrity, while eliminating the need for additional wiring and enhancing the tightness and mechanical strength of the assembly.
Implementation Method 1
this crossbar having at least a conductive track portion having a first end connected to a pad of a first cell element and having a second end connected to a pad of a neighboring cell element
Implementation Method 2
each cell element is glued under the corresponding opening
Data Source
AI summary
A package for a fuel cell having an upper plate having a plurality of openings, the front surface of a cell element being intended to be received under each opening to close it, each cell element having a first pad and a second connection pad, each opening being provided with at least one crossbar connecting two sides of the opening, this crossbar having at least a conductive track portion having a first end connected to a pad of a first cell element and having a second end connected to a pad of a neighboring cell element.