Fuel Cell Stack Mount Structure with Constricted Breakaway Bracket
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Solution Overview
Problem
The existing fuel cell stack structures are complex, heavy, and prone to damage from external loads due to the use of resin fluid manifold members and weak end plates, requiring dedicated protection and mount structures, which increases size and weight, and are not economical.
Innovation Solution
A fuel cell stack with a mount member attached to the end plates that covers the fluid manifold and acts as a reinforcement, using separate bracket members with a constricted portion that breaks under external load, allowing the stack to be fixed to installation members while protecting the manifold and reducing weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a resin fluid manifold member is used in the fuel cell stack, then the manufacturing cost is reduced and ease of manufacture is improved, but the strength and reliability deteriorate causing the manifold member to be damaged easily by external loads
Solution Approach 1:
The patent applies composite materials by combining resin with metal reinforcement structures. The end plates are made as composite structures where metal plates provide structural strength and rigidity to resist external loads, while resin components maintain manufacturing advantages. This composite approach allows the fluid manifold member to achieve both ease of manufacture and sufficient strength against vibrations and impacts during vehicle operation.
2Strength
If the thickness of the end plate is increased to suppress deformation and improve strength, then the strength and reliability are improved, but the weight and size increase
Solution Approach 1:
The end plates are constructed as composite structures combining metal and resin materials. The metal plate component provides the necessary strength and rigidity to suppress deformation under external loads, while the optimized thickness and composite design prevent excessive weight increase. This allows achieving sufficient strength without proportionally increasing the overall weight of the fuel cell stack.
Solution Approach 2:
The patent applies local quality by providing reinforcement only where needed. The metal plate portions of the end plates are strategically positioned and dimensioned to provide local reinforcement at critical areas that experience higher stresses, rather than uniformly increasing the thickness of the entire end plate. This localized reinforcement approach improves strength while minimizing weight increase.
3Reliability
If a dedicated protection structure is added to protect the fluid manifold member, then the reliability is improved, but the device complexity and size increase
Solution Approach 1:
The patent merges the protection function with existing structural components. The metal plate portions of the end plates serve dual purposes: they provide structural strength for the end plates themselves and simultaneously act as protection structures for the fluid manifold members. By combining these functions into a single integrated component, the patent improves reliability without adding separate protection structures that would increase device complexity.
Solution Approach 2:
The end plate structure is designed with multi-functionality. The metal plate components perform multiple functions including: providing structural support for the end plate, serving as reinforcement against external loads, and acting as protective shielding for the resin fluid manifold members. This universal design approach allows a single structure to fulfill multiple roles, improving reliability while avoiding the need for additional dedicated protection components.
4Reliability
If separate dedicated mount structure and protection structure are used, then the reliability and protection are improved, but the device complexity, size, and weight increase
Solution Approach 1:
The patent merges the mount structure and protection structure functions into the end plate assembly. The metal plate portions of the end plates are configured to serve both as mounting interfaces for securing the fuel cell stack to the vehicle and as protection structures for the fluid manifold members. By combining these previously separate functions into a single integrated end plate structure, the patent reduces device complexity, size, and weight while maintaining improved reliability.
Solution Approach 2:
The end plate structure is designed with multi-functionality to simultaneously perform mounting and protection functions. The metal plate components are positioned and dimensioned to provide both structural reinforcement for protecting the resin manifold members and mounting surfaces for securing the fuel cell stack to the vehicle frame. This universal design eliminates the need for separate dedicated mount and protection structures, thereby reducing overall device complexity, size, and weight while maintaining reliability.
Data Source
AI summary
A second end plate constituting a fuel cell stack is provided with a cooling medium supply manifold member and a cooling medium discharge manifold member. The second end plate is also provided with a mount member that affixes the fuel cell stack to an automobile body frame and covers the cooling medium discharge manifold member.