Fuel Cell Stack Weight Reduction via Integrated Resin Frame Positioning

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

The existing manufacturing method for fuel cell stacks increases the weight and number of components due to the use of holding pins and retaining rings, making it difficult to separate the resin frame equipped membrane electrode assembly and the separator member.

Innovation Solution

A manufacturing method and apparatus that positions and welds a resin frame equipped membrane electrode assembly and a separator member using a positioning device with a lifting mechanism, eliminating the need for holding pins and retaining rings by integrating the components during the welding process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If holding pins and retaining rings are used to connect the MEA and separator, then the components are securely connected and difficult to separate, but the weight of the fuel cell stack increases and the number of components increases

Engineering Contradiction:

Improveconnection reliabilityVSAvoidfuel cell stack weight

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The invention extracts and eliminates the holding pins and retaining rings from the fuel cell stack structure. By using the resin frame member's own structure to provide positioning and retention functions, the separate holding components are removed, thereby reducing weight and component count while maintaining connection reliability.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The invention merges the functions of the resin frame member with the positioning and retention functions previously performed by separate holding pins and retaining rings. The resin frame member is designed to integrate these multiple functions into a single component, eliminating the need for additional fastening elements.

Inventive Principle:

Principle #5Merging (Combining)

2Reliability

If holding pins are used for each power generation cell, then the components are securely connected, but the number of components increases

Engineering Contradiction:

Improveconnection reliabilityVSAvoidnumber of components

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The resin frame member is designed to perform multiple functions simultaneously: structural support, positioning of the MEA, and retention of the separator. This multi-functional design eliminates the need for separate holding pins and retaining rings, thereby reducing the total number of components while maintaining secure connections.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The invention combines the positioning and retention functions into the resin frame member itself, merging what were previously separate components (frame, holding pins, retaining rings) into an integrated structure. This reduces device complexity by eliminating redundant components.

Inventive Principle:

Principle #5Merging (Combining)

3Stability of the object's composition

If the resin frame equipped MEA and separator member are joined together, then they remain connected during stacking, but separation of the components becomes difficult

Engineering Contradiction:

Improveassembly stabilityVSAvoidease of separation

Core Design Contradiction:

Stability of the object's compositionVSEase of manufacture

Solution Approach 1:

The resin frame member is designed with dynamic characteristics that allow it to maintain a secure connection during stacking operations while enabling easy separation when needed. The flexible or elastically deformable nature of the resin frame allows it to adapt during assembly and then release cleanly for disassembly, providing both stability and ease of manufacture.

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 approach reduces the weight of the fuel cell stack by eliminating unnecessary components and ensures the resin frame equipped membrane electrode assembly and the separator member can be removed as a single unit without separation, improving manufacturing efficiency.

Implementation Method 1

positioning the resin frame equipped membrane electrode assembly and the separator member by inserting a positioning pin provided in a base of a positioning device into positioning holes formed in the resin frame equipped membrane electrode assembly and the separator member

Methodology Applied

Scientific EffectMechanical positioning: Mechanical Force

Implementation Method 2

welding and joining the resin frame equipped membrane electrode assembly and the separator member to thereby obtain the fuel cell member

Methodology Applied

Scientific EffectWelding: Welding

Implementation Method 3

lifting the fuel cell member in a direction away from the positioning pin by lifting the lifting member

Methodology Applied

Scientific EffectMechanical lifting: Mechanical Force

Data Source

PatentUS11508972B2Manufacturing method and manufacturing apparatus for fuel cell member

Publication Date: 2022.11.22 HONDA MOTOR CO LTD

AI summary

A manufacturing apparatus for a fuel cell member includes a positioning device for positioning a resin frame equipped membrane electrode assembly and a separator member. This positioning device includes a base and positioning pins which are inserted into positioning holes formed in the resin frame equipped membrane electrode assembly and the separator member. Lifting members are provided around the positioning pins. The lifting member is lifted and lowered by a lifting mechanism.