Fuel Cell Stack Sensing Terminal Assembly With Self-Engaging Separators
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Solution Overview
Problem
The existing fuel cell module mounting process is complicated due to the need to check if the distal portions of the connector projections are holding the mounting portion of the first separator, making it difficult to mount the connector correctly.
Innovation Solution
A fuel cell stack with metal sensing terminals that include a base portion, an arm portion, and second engagement portions, which are inserted between the first and second separators, and engage with first engagement portions on the separators via a recess-and-projection relationship to secure the terminal in place, simplifying the mounting process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the connector uses two projections to hold the mounting portion, then the connector can be mounted to the cell, but the operator needs to check whether the distal portions of the two projections are holding the mounting portion, which complicates the mounting operation
Solution Approach 1:
The sensing terminal is designed with an L-shaped arm portion that automatically engages with the engagement portion on the first separator during insertion. The arm portion's distal end fits into the engagement portion without requiring manual verification, allowing the terminal to self-align and self-secure during the mounting process.
Solution Approach 2:
The L-shaped arm portion acts as an intermediary element between the sensing terminal body and the first separator. It provides a mechanical interface through the engagement portion that ensures proper positioning and connection, eliminating the need for operators to manually verify the connection status.
2Productivity
If the sensing terminal is inserted between the first and second separators, then the terminal can be mounted to the stack main body, but additional engagement mechanisms are needed to prevent the terminal from coming off
Solution Approach 1:
The sensing terminal is divided into functional segments: a base portion for insertion, an L-shaped arm portion for engagement, and a sensing portion for measurement. The arm portion is further segmented with a specific engagement portion that interfaces with the first separator, allowing each segment to perform its specific function independently.
Solution Approach 2:
Instead of using a complex locking mechanism to secure the sensing terminal, the design inverts the approach by using the arm portion's geometry to passively engage with the engagement portion on the first separator. The engagement is achieved through the arm portion fitting into the engagement portion, preventing removal without requiring active locking components.
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
The solution facilitates easier and more secure mounting of the sensing terminals by allowing them to be inserted and engaged with the separators, preventing them from coming off the stack main body, thus streamlining the assembly process and ensuring proper alignment without additional complexity.
Implementation Method 1
The arm portion is in contact with the second facing surface while being elastically deformed toward the first facing surface
Data Source
AI summary
A fuel cell stack includes a stack main body including stacked single cells, and sensing terminals made of metal. Two surfaces facing each other in any adjacent two of the single cells are respectively defined as a first facing surface and a second facing surface. The first facing surface is a surface of the first separator of one of the two single cells. The second facing surface is a surface of the second separator of the other single cell. The first facing surface is provided with at least one first engagement portion. Each sensing terminal includes a base portion, an arm portion, and at least one second engagement portion that is engaged with the at least one first engagement portion of the first facing surface. The arm portion is in contact with the second facing surface while being elastically deformed toward the first facing surface.