Fuel Cell Separator Plate Contact via Movable Connecting Element

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Solution Overview

Problem

Existing methods for connecting separator plates in fuel cell systems are time-consuming, costly, and prone to damage due to limited clamping force, leading to increased susceptibility to vibrations and contact resistance.

Innovation Solution

A method involving a connecting element with movable parts that can be inserted between adjacent separator plates, allowing for relative movement to increase contact pressure and achieve higher clamping forces without damaging the plates, using a design with sliding surfaces that can be wedged into place to improve electrical contact.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If terminals with greater clamping force are provided, then contact reliability is improved, but the terminals can no longer slide readily onto the separator plates and damage to the separator plates may occur

Engineering Contradiction:

Improvecontact reliabilityVSAvoiddamage to separator plates

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The connecting element incorporates movable connecting parts that can shift relative to each other during insertion. This dynamic mechanism allows the connecting element to initially slide onto the separator plate with low force, then progressively increase clamping force after insertion to ensure reliable electrical contact without damaging the separator plate during the insertion process.

Inventive Principle:

Principle #15Dynamics

2Reliability

If individual contact elements are crimped to electrical conductors, then electrical connection is achieved, but the process is time-consuming and costly

Engineering Contradiction:

Improveelectrical connectionVSAvoidconnection speed

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent combines multiple contact elements into a single integrated connecting element that can establish electrical contact with multiple separator plates simultaneously. This merging approach eliminates the need for individual crimping operations for each contact element, significantly reducing assembly time and cost while maintaining reliable electrical connections across all fuel cells.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The connecting element is designed as a multi-functional component that simultaneously performs electrical contact with multiple separator plates and provides mechanical connection. This universal design allows a single component to replace multiple individual connections, streamlining the assembly process and improving productivity without compromising connection reliability.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Ease of operation

If low clamping forces are used, then terminals can slide readily onto separator plates, but susceptibility to vibrations increases and contact resistances increase

Engineering Contradiction:

Improveease of insertionVSAvoidvibration resistance

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The connecting element uses a dynamic mechanism where movable connecting parts shift during insertion to progressively increase clamping force. This allows easy initial insertion with low force, then automatically increases clamping force after insertion to ensure vibration resistance and low contact resistance, resolving the contradiction between ease of operation and reliability.

Inventive Principle:

Principle #15Dynamics

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 method reduces the risk of damage and improves contact reliability by increasing clamping forces and reducing susceptibility to vibrations, while maintaining a cost-effective and space-efficient connection.

Implementation Method 1

Methodology Applied

Scientific EffectWedge: Wedge

Data Source

PatentUS11063278B2Method for making contact with a plurality of separator plates and fuel cell system

Publication Date: 2021.07.13 BAYERISCHE MOTOREN WERKE AG

AI summary

A method for making contact with a plurality of separator plates of a fuel cell system includes the steps of: inserting at least one connecting element of a cell voltage monitoring system between two directly adjacent separator plates so that two connecting parts of the connecting element that are able to move with respect to one another are arranged at least in certain regions between the directly adjacent separator plates; and relatively moving the two connecting parts that are able to move with respect to one another so that at least one first connecting part of the connecting parts moves at least in sections toward a separator plate of the directly adjacent separator plates.