Fuel Cell Terminal Friction Stir Welding for Contact Resistance
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Solution Overview
Problem
Existing fuel cell stacks face issues with variable contact states and reduced current collection performance due to complex assembly processes and numerous components in the terminal connections, making them laborious and costly to produce.
Innovation Solution
The integration of electrically conductive plate members and rod terminals through friction stir welding, which improves joint flatness and reliability, reducing contact resistance and the number of components needed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the electrode pole is inserted into the insulating sleeve and fixed through the nut, then the terminal structure is assembled, but the assembling operation becomes laborious and a large number of components are required
Solution Approach 1:
The patent merges the insulating sleeve and the fixing nut into a single integrated component. The insulating sleeve is designed with an integrated nut structure, eliminating the need for separate components and simplifying the assembly process while maintaining the electrical insulation and mechanical fixing functions.
Solution Approach 2:
The insulating sleeve is designed to perform multiple functions simultaneously: providing electrical insulation, mechanical support, and integrated fastening through the built-in nut structure. This multi-functional design reduces the total number of components needed in the terminal assembly.
2Reliability
If the electrode pole is simply connected to the terminal plate, then the structure is simple, but the contact state varies and current collection performance is lowered
Solution Approach 1:
The terminal plate is pre-formed with a recessed portion that precisely accommodates the electrode pole before final assembly. This preliminary structural preparation ensures proper alignment and contact state, preventing variability in the contact interface and maintaining reliable current collection performance.
Solution Approach 2:
The terminal plate features a localized recessed portion with specific geometric characteristics designed to optimize the contact interface with the electrode pole. This local structural modification ensures consistent and reliable electrical contact without requiring complex overall terminal结构设计.
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 method enhances current collection performance, simplifies the assembly process, and reduces production costs by minimizing component damage and heat distortion, while maintaining stable product quality.
Implementation Method 1
a joint portion joining the electrically conductive plate member and the electrically conductive rod terminal is formed by friction stir welding
Implementation Method 2
the friction stir welding (FSW: Friction Stir Welding) is a technique of joining two workpieces in the solid state together by utilizing friction heat generated at the time of inserting a rotating probe into a workpiece (object)
Data Source
AI summary
A fuel cell stack includes a stack body formed by stacking a plurality of power generation cells. A terminal, an insulating plate, and an end plate are provided at one end of the stack body, and a terminal, an insulating plate, and an end plate are provided at the other end of the stack body. Each of the terminals includes an electrically conductive plate member, and an electrically conductive rod terminal joined integrally with the electrically conductive plate member. A joint portion joining the electrically conductive plate member and the electrically conductive rod terminal is formed by friction stir welding.