Resin Block Module Integrates Flow Paths in Fuel Cell Systems
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Solution Overview
Problem
Current fuel-cell power generation systems face challenges in manufacturability and size reduction, particularly in household and stationary applications, where the use of metal piping and complex assembly processes increase costs and reduce efficiency.
Innovation Solution
The implementation of a resin block module with integrally molded flow paths made of resin, which includes devices such as cutoff valves and flow meters, allows for a compact and lightweight design by using the same material for both the module and fixing screws, and employs vibration welding for assembly, reducing the need for metal components and simplifying the assembly process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metal piping and complex assembly processes are used in fuel-cell power generation systems, then connection reliability and durability are improved, but system size increases, manufacturing complexity increases, and production costs increase
Solution Approach 1:
The patent merges multiple separate components (piping, flow paths, device housings, and structural elements) into a single integrally molded resin block module. This consolidation eliminates the need for complex metal piping and multiple assembly steps, reducing manufacturing complexity while maintaining connection reliability through integral construction that eliminates joint interfaces.
Solution Approach 2:
The resin block module serves multiple functions simultaneously: it provides structural support, contains fluid flow paths, houses devices, and enables connections. This multi-functionality replaces the traditional separate metal piping system, reducing both assembly complexity and the number of components required while maintaining system reliability.
2Reliability
If metal piping is used in fuel-cell power generation systems, then chemical durability and temperature resistance are improved, but system weight increases and manufacturing costs increase
Solution Approach 1:
The patent changes the material parameter from metal to resin, selecting resin materials with specific properties (high melting point, chemical resistance) that match or exceed metal performance requirements. This parameter change enables weight reduction while maintaining chemical durability and temperature resistance through carefully selected resin compositions.
Solution Approach 2:
The patent employs resin materials that, while potentially having shorter service life than metal, provide sufficient durability for the application and enable significant cost reduction and weight reduction. The resin block module is designed as a replaceable unit, optimizing the balance between durability, weight, and manufacturing cost.
3Ease of repair
If multiple separate components are used in fuel-cell power generation systems, then ease of repair and maintenance are improved, but system size increases and assembly complexity increases
Solution Approach 1:
The patent segments the system into modular resin block modules that can be manufactured separately and assembled into the complete fuel cell system. Each module is self-contained with integral flow paths and device housings, reducing overall system size while maintaining ease of repair through modular replacement rather than component-level disassembly.
Solution Approach 2:
The resin block module employs a nested structure where devices are housed within the molded resin body, and flow paths are integrated within the same structure. This nesting reduces system size by eliminating external piping and mounting structures, while the modular nature maintains ease of repair through module replacement.
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 enhances manufacturability, reduces system size by approximately 20%, improves reliability, and lowers production costs by eliminating the need for extensive metal piping and complex assembly, while maintaining high temperature resistance and chemical durability.
Implementation Method 1
employs vibration welding for assembly
Implementation Method 2
a fuel cell that generates electricity by electrochemical reaction using fuel and an oxidizer
Implementation Method 3
employs vibration welding for assembly
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
According to one embodiment, a fuel-cell power generation system includes a fuel cell that generates electricity by electrochemical reaction using fuel and an oxidizer and a resin module (140) that includes a flow path through which fuel, air, or water flows, inner walls defining the flow path being made of resin.