Fuel Cell Stack Tension Elements for Secure Voltage Tap Assembly
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Solution Overview
Problem
Existing fuel cell stacks face challenges in maintaining reliable electrical connections under mechanical stress and vibrations due to limited space and complex cable connections, which complicate assembly and increase design complexity.
Innovation Solution
Integrate cell voltage taps mechanically secured by robust tension elements, allowing pre-assembly of plug connectors and incorporating pass-throughs for cables, simplifying assembly and reducing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If plug connectors are used for each fuel cell with locking plug connection, then electrical connection reliability under vibrations and mechanical shocks is improved, but device complexity and assembly effort increase due to limited space on bipolar plates and required cable connections
Solution Approach 1:
The patent combines the tension element (used for mechanical compression of fuel cells) with the electrical connection function by integrating plug connectors directly onto the tension element. This merging eliminates the need for separate cable connections and reduces the number of components, thereby maintaining electrical connection reliability while reducing device complexity
Solution Approach 2:
The tension element is given multiple functions: it serves both as a mechanical compression device (applying force to seal and compress fuel cell components) and as an electrical connection carrier (holding plug connectors for cell voltage monitoring). This multi-functionality reduces the overall number of components needed in the fuel cell stack
2Manufacturing precision
If plug connectors are used for each fuel cell, then electrical contact quality is improved, but assembly effort and design complexity increase due to limited space on bipolar plates
Solution Approach 1:
The patent merges the mechanical tensioning function and electrical connection function into a single integrated component (the tension element with integrated plug connectors). This eliminates the need for separate assembly steps for mounting connectors on bipolar plates, thereby improving ease of manufacture while maintaining electrical contact quality
Solution Approach 2:
The plug connectors are pre-mounted onto the tension elements before the fuel cells are assembled into the stack. This preliminary action simplifies the overall assembly process, as the electrical connections are already prepared and positioned correctly, reducing assembly effort and potential errors
Data Source
AI summary
A fuel cell stack includes a plurality of fuel cells arranged in the direction of the stack and tensioned by means of tension elements, of which at least one has a cell voltage tap for electrical connection to a cell monitoring unit, wherein the at least one cell voltage tap is mechanically secured by at least one of the tension elements as regards the connection to the fuel cells. A fuel cell device and a motor vehicle with a fuel cell device are also provided.