Fuel Cell Stack Collision Safety Mounting
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Solution Overview
Problem
Fuel cell stacks in electrically driven vehicles are prone to entering the passenger compartment during collisions due to their weight and positioning, posing a risk of damage and hydrogen gas leakage.
Innovation Solution
A support frame system is implemented, where the fuel cell stack is mounted externally within a holding compartment, with a shelter space created between the passenger compartment and the road surface, allowing the stack to move downward and into the shelter space during collisions, preventing it from entering the passenger compartment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the fuel cell stack is held in a holding compartment at the front or rear side of the passenger compartment, then the electrically driven vehicle can generate electric power efficiently, but the fuel cell stack is liable to enter the inside of the passenger compartment during collision
Solution Approach 1:
The support frame is divided into a first support frame and a second support frame positioned at different locations. The fuel cell stack is supported by both frames through multiple mounts, distributing the support function across separate structural elements. This segmentation allows the system to maintain power generation efficiency while improving collision safety through redundant support structures.
Solution Approach 2:
The patent introduces a vertical dimension to the collision safety problem by allowing the fuel cell stack to move downward into a predetermined safe zone below the passenger compartment during collision. The support frames are positioned and configured to guide this vertical movement, transforming the collision response from horizontal intrusion into vertical displacement into a protected area.
2Reliability
If the fuel cell stack is positioned externally in a holding compartment, then collision safety is improved, but the structural complexity increases due to additional support frames and fastening structures
Solution Approach 1:
The support frames serve multiple functions: they provide structural support for the fuel cell stack during normal operation, guide the stack's movement during collision, and define the safe zone boundaries. The fastening structures perform both attachment and positioning functions. This multi-functionality reduces the need for separate dedicated components for each function.
Solution Approach 2:
The fuel cell stack is positioned within the holding compartment formed by the support frames and fastening structures, creating a nested configuration where the stack is contained within a protective structural envelope. This nesting arrangement provides protection while maintaining a compact overall structure.
3Stability of the object's composition
If multiple mounts are used to support the fuel cell stack on the support frame, then the stack stability is improved, but the manufacturing complexity increases
Solution Approach 1:
Different mounts are positioned at specific locations on the support frames to provide targeted support at critical points. The first and second support frames have mounts arranged to address specific stability requirements at different positions, optimizing stability while avoiding unnecessary mounts in less critical areas.
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 design effectively prevents the fuel cell stack from entering the passenger compartment during serious collisions, reducing the risk of damage and hydrogen gas leakage, and enhances safety by directing the stack into a sheltered area.
Implementation Method 1
a fuel cell stack generating electric power by an electrochemical reaction between a fuel gas and oxidant gas
Data Source
AI summary
An electrically driven vehicle comprises: a body frame arranged in a holding compartment formed in front of a passenger compartment; a suspension member fastened to the body frame in the holding compartment through a rear side fastening structure; and a fuel cell stack supported on the suspension member through a rear side mount at a position in front of the rear side fastening structure. When a serious collision occurs, the fuel cell stack moves rearward and strikes the fastening structure whereby the fastening structure breaks and thereby suspension member separates from the body frame and the fuel cell stack moves downward and heads toward the inside of the shelter space between the holding compartment and a road surface.