Grid Cell Voltage Pickup With Loop Contacts for Low-Force Insertion
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Solution Overview
Problem
Existing cell voltage pickups for fuel cell stacks have complex structures, require high insertion forces, and are prone to damage during insertion, with contacts that may accidentally disengage during operation.
Innovation Solution
A resilient loop-shaped contact part that laterally compresses upon insertion, ensuring secure and reliable contact with bipolar plates using a low insertion force, and is secured by a latching mechanism to prevent disengagement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a traditional multi-channel potential tap with needle-shaped terminals and springs is used, then voltage measurement capability is achieved, but the structure becomes complex and insertion force becomes excessively high
Solution Approach 1:
The contact device is divided into modular components: a housing with multiple contact sockets arranged in rows and columns, individual spring contact elements for each socket, and integrated guiding ribs. This segmentation allows each component to be optimized independently while simplifying the overall structure compared to traditional multi-channel taps.
Solution Approach 2:
The spring mechanism is extracted from the contact element itself and integrated into the housing structure through the resilient bottom surface and guiding ribs. This separation allows the contact element to be a simple conductive probe while the housing provides the mechanical resilience and guidance functions.
2Reliability
If traditional contact terminals are used, then electrical contact is achieved, but contact damage occurs during insertion
Solution Approach 1:
The housing bottom surface is designed with resilient properties that provide cushioning during insertion. The guiding ribs with rounded profiles and the elastic bottom surface absorb insertion shocks before they reach the contact sockets, protecting the contact terminals from damage.
Solution Approach 2:
The contact element geometry is changed from traditional needle-shaped terminals to spring contact elements with a specific resilient profile. This geometric parameter change allows the contact element to deform elastically during insertion, reducing peak forces and preventing damage to both the contact element and the bipolar plate contact surfaces.
3Reliability
If high insertion force is applied, then contact establishment is achieved, but contact force becomes excessive and may cause damage
Solution Approach 1:
The spring contact elements provide dynamic compliance during insertion. As the contact element enters the socket, the resilient housing bottom surface and spring mechanism progressively engage, allowing the insertion force to be distributed over time and distance rather than applied as a single high-peak force.
Solution Approach 2:
The contact element cross-sectional area and material properties are optimized to provide appropriate spring constant. This allows the contact element to deflect by a controlled amount during insertion, transforming the insertion process into a controlled elastic deformation that establishes contact at lower forces.
4Ease of manufacture
If simple contact elements are used, then manufacturing is simplified, but accidental disengagement occurs during operation
Solution Approach 1:
The spring contact elements are designed with a flexible, elongated geometry that allows them to be formed from bent wire or rod stock. This flexible design enables simple manufacturing through bending and forming operations while providing retention through elastic friction and geometric interference within the contact sockets.
Solution Approach 2:
The contact element length, diameter, and elastic modulus are optimized to provide appropriate spring force for retention. The element is long enough to engage deeply in the socket, has sufficient diameter for structural integrity, and is made of material with elastic modulus that provides retention force without excessive insertion force.
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
Enables secure, quick, and automated electrical contact with bipolar plates without damage, maintaining consistent contact force and preventing accidental disengagement.
Implementation Method 1
The spring contact elements (11) form a needle-ear-shaped wire loop (12) at their plug-in end that is resiliently compressed when the spring contact elements (11) are inserted into the contact sockets (21). Thus, two wire loop sections of the wire loop (12) of the spring contact elements (11) are pressed transversely to the plug-in direction (S) against the contact sockets (21) under a spring force.
Data Source
AI summary
A fuel cell voltage pickup (100) for electrically contacting a contact device of a fuel cell stack (20) of the fuel cell has electrical contact sockets (21) arranged in one or more rows and/or columns. The contact device has a housing (15). The cell voltage pickup (100) has spring contact elements (11) at corresponding positions. The spring contact elements are formed by a wire loop and extend away from the cell voltage pickup (100) in the plug-in direction (S). The spring contact elements (11) form a needle-ear-shaped wire loop (12) that is resiliently compressed when the spring contact 10 elements are inserted into the contact sockets (21). Thus, two wire loop sections (12a, 12b) of the wire loop (12) of the spring contact elements (11) are pressed transversely to the plug-in direction (S), against the contact sockets (21), under a spring force. The contact sockets (21) have a latching (23) that secure the wire loops (12) in the plugged-in state.