Fuel Cell Stack Case Cover Recess for Tab Bus Bar Placement

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Solution Overview

Problem

In fuel cell systems, the protrusion of tabs on separators leads to increased stack case size, inefficiently utilizing space outside the cover, as the bus bar and tab placement is not optimized between the cell stack body and the cover.

Innovation Solution

The fuel cell system design includes a stack case with a cover that has a recessed structure, allowing the tab and bus bar to be efficiently positioned between the cover and the cell stack body, utilizing space effectively by positioning the second outer surface more towards the cell stack body than the first outer surface, and using an outer surface coupling part to integrate these components.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If a tab protruding outward is provided on the outer marginal portion of a separator and a bus bar is disposed below the cover in the protruding direction, then electrical power can be supplied to the outside, but the stack case size increases in the height direction and space outside the cover cannot be effectively utilized

Engineering Contradiction:

Improveelectrical power supplyVSAvoidstack case size

Core Design Contradiction:

Ease of manufactureVSVolume of stationary object

Solution Approach 1:

The patent changes the arrangement dimension from the height direction (protruding direction) to the width direction by providing tabs at both outer marginal portions of the separator. This allows bus bars to be disposed at both sides of the stack case in the width direction, effectively utilizing space outside the cover without increasing the stack case height.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The patent employs asymmetric arrangement by providing tabs at both outer marginal portions of the separator rather than a single centralized tab. This asymmetric distribution enables the bus bars to be positioned at both sides of the stack case, optimizing space utilization and maintaining a compact stack case size.

Inventive Principle:

Principle #4Asymmetry

2Volume of stationary object

If the second outer surface is positioned more toward the cell stack body than the first outer surface, then space outside the cover can be effectively utilized, but the cover structure becomes more complex

Engineering Contradiction:

Improvespace utilizationVSAvoidcover structure

Core Design Contradiction:

Volume of stationary objectVSDevice complexity

Solution Approach 1:

The cover is segmented into multiple outer surfaces (first outer surface and second outer surface) positioned at different locations in the width direction. This segmentation allows the cover to effectively utilize space outside the stack case while maintaining a manageable structural complexity through modular design.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different portions of the cover have different spatial positions and functions. The first outer surface is positioned on one end side while the second outer surface is positioned on the other end side more toward the cell stack body. This local quality differentiation enables effective space utilization without requiring complex overall restructuring of the cover.

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS11316186B2Fuel cell system and fuel cell vehicle

Publication Date: 2022.04.26 HONDA MOTOR CO LTD

AI summary

An outer surface of an upper wall of a stack case of a fuel cell system provided in a fuel cell vehicle includes a first outer surface, a second outer surface which is positioned closer than the first outer surface to a cell stack body, and an outer surface coupling part. Space is formed between a first upper wall of the upper wall and the cell stack body. Tabs and bus bars are disposed in the space.