Fuel Cell Stack Case Inclined Side Wall Design
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Solution Overview
Problem
The existing fuel cell units face an increase in size when the side wall of the stack case is inclined with respect to the bottom wall, which complicates manufacturability and increases equipment costs.
Innovation Solution
A fuel cell unit design where the side wall of the stack case is inclined such that the distance between the side walls is greater at the flange than at the bottom wall, allowing the fuel cell stack to be housed efficiently without increasing the unit's size, using a flange with a flat surface and a power converter case with varying component distances to maintain compactness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the side wall of the stack case is inclined with respect to the bottom wall to improve manufacturability, then the ease of manufacture is improved, but the size of the fuel cell unit increases
Solution Approach 1:
The side wall is designed with different inclination angles at different locations: a first inclination angle at the first end and a second inclination angle at the second end. This local differentiation allows the side wall to provide draft angles for manufacturability while minimizing the overall increase in unit size by optimizing the inclination only where necessary for manufacturing access.
Solution Approach 2:
The bus bars are configured to extend in multiple directions: from the first terminal along the first side wall to the power converter, and from the second terminal along the second side wall to the power converter. This multi-dimensional routing allows electrical connections to be made without requiring the entire stack case to be enlarged, accommodating the inclined side walls while maintaining compact dimensions.
2Ease of manufacture
If the distance between side walls is greater at the flange than at the bottom wall to allow efficient housing of the fuel cell stack, then the ease of manufacture is improved, but the shape complexity increases
Solution Approach 1:
The stack case is designed with asymmetric side wall inclinations: the first side wall has a different inclination angle than the second side wall. This asymmetric configuration optimizes the internal space for housing the fuel cell stack and power converter while providing adequate clearance for manufacturing operations, accepting increased shape complexity as a necessary trade-off for manufacturability and efficient space utilization.
Data Source
AI summary
A fuel cell unit includes: a fuel cell stack including: a cell stack; a first terminal respectively disposed at a first end of the cell stack in the first direction; and a second terminal disposed at a second end of the cell stack in the first direction, an end plate disposed at a side opposite to the cell stack with respect to the first terminal; a power converter that converts output power of the fuel cell stack; a stack case that houses the fuel cell stack; a power converter case that houses the power converter and is fixed to the stack case; a first bus bar that electrically connects the first terminal and the power converter in the stack case and the power converter case; and a second bus bar that electrically connects the second terminal and the power converter in the stack case and the power converter case.