A fuel cell system is provided which includes a compression retention enclosure with upper and lower compression shells and side sheet components coupled by interlocking hem joints. Methods for manufacturing compression retention enclosures with hem joints such that the enclosure remains sealed upon
A fuel cell system is provided which includes a compression retention enclosure with upper and lower compression shells and side sheet components coupled by interlocking hem joints. Methods for manufacturing compression retention enclosures with hem joints such that the enclosure remains sealed upon operational swelling of the fuel stack are also provided. A compression shell may be formed from a light weight composite structure having a polymeric layer interposed between steel skins, and an extension of the top steel skin may form a hemmed edge or may form a side sheet having a hemmed edge. Side sheet panels may be coupled to the end plates by interlocking two opposing hemmed edges to form the hem joint, or by sliding an opposing C-linking element between two hemmed edges held under compression force in an interlocking position.
대표청구항▼
1. A fuel cell system comprising: a fuel cell stack assembly having a plurality of fuel cells disposed between a first end plate and a second end plate; anda compression retention enclosure comprising an upper compression shell disposed in contact adjacent the first end plate, a lower compression sh
1. A fuel cell system comprising: a fuel cell stack assembly having a plurality of fuel cells disposed between a first end plate and a second end plate; anda compression retention enclosure comprising an upper compression shell disposed in contact adjacent the first end plate, a lower compression shell disposed in contact adjacent the second end plate, the upper compression shell having a descending extension substantially orthogonal to the first endplate, the lower compression shell having an ascending extension substantially orthogonal to the second end plate, said descending extension extending toward and substantially coplanar with said ascending extension, and each extension having an outwardly hemmed edge coplanar with the outwardly hemmed edge of the other extension, and at least one side sheet, each side sheet having a first hemmed edge coupled to the upper compression shell by an interlocking hem joint and a second hemmed edge coupled to the lower compression shell by an interlocking hem joint. 2. The fuel cell system according to claim 1 comprising a sustained compression force on the fuel cell stack assembly substantially equal to a total tensive force of the compression retention enclosure. 3. The fuel cell system according to claim 2, wherein the compression retention enclosure possesses sufficient strength to remain substantially sealed even upon operational swelling of the fuel cell stack. 4. The fuel cell system according to claim 1, wherein the at least one side sheet is match-fit to a predetermined fuel cell stack height. 5. The fuel cell system according to claim 1, further comprising first and second end caps and a side panel edge adjacent an end cap edge is disposed to form a contact area between the side panel and end cap, wherein the first and second end caps are coupled to the side sheets via clinching, welding or self-piercing rivets at the contact area. 6. The fuel cell system according to claim 5, wherein the first and second end caps are welded to the side sheets by a projection weld. 7. The fuel cell system according claim 5, wherein the first and second end caps are clinched to the side sheets by an interlocking clinch. 8. The fuel cell system according to claim 5, wherein a cure-in-place or form-in-place sealant forms a sealing contact between the compression shells, side sheets and end caps to seal the compression retention enclosure. 9. The fuel cell system according to claim 1 wherein the upper compression shell is generally dome-shaped. 10. The fuel cell system according to claim 1 wherein at least one of the upper and lower compression shells is fabricated from a composite material comprising a polymeric layer and at least one metallic layer. 11. The fuel cell system according to claim 10 wherein the at least one metallic layer comprises steel and/or aluminum. 12. The fuel cell system according to claim 11 wherein the steel comprises an advanced high strength steel (AHSS) selected from DP and TRIP steels. 13. The fuel cell system according to claim 12 wherein DP steel is selected from DP 350 and DP 600, and TRIP steel is selected from TRIP 350 and TRIP 600. 14. The fuel cell system according to claim 10, wherein the polymeric layer is a polymeric core and the composite material comprises a polymeric core interposed between a bottom steel skin layer and a top steel skin layer. 15. The fuel cell system according to claim 14, wherein a hemmed edge of the upper compression shell is an extension of the top steel skin layer and a hemmed edge of the lower compression shell is an extension of the bottom steel skin layer. 16. The fuel cell system according to claim 10, wherein the polymeric layer comprises a polymer selected from a plastic suitable for injection molding, or a syntactic foam. 17. The fuel cell system according to claim 1 further comprising an insulating layer interposed between the compression retention enclosure and the fuel cell stack. 18. A method of manufacturing a fuel cell system having a fuel cell stack under a substantially sustained compression force, the method comprising: enclosing a fuel cell stack having a plurality of fuel cells disposed between a first end cap and a second end cap in a compression retention enclosure, the compression retention enclosure comprising an upper compression shell disposed in contact adjacent the first end cap, a lower compression shell disposed in contact adjacent the second end cap, each compression shell having a hemmed edge extending substantially parallel to the end cap and coplanar with a hemmed edge of the other compression shell, and at least one side sheet, each side sheet having a first hemmed edge coupled to the upper compression shell by an upper interlocking hem joint and a second hemmed edge coupled to the lower compression shell by a lower interlocking hem joint, wherein the hemmed edges are positioned for coupling by applying an initial compressive force to the compression shells sufficient to overlap the hemmed edges of the compression shells with the corresponding hemmed edges of the side sheet such that when the compressive force is released, the hemmed edges interlock to form the upper and lower interlocking hem joints, resulting in a sustained compression force on the fuel cell stack substantially equal to the total tensive force of the compression retention enclosure, and wherein the difference between the initial compressive force and the total tensive force of the compression retention enclosure approximately accommodates operational membrane swell of the fuel cell stack. 19. A fuel cell system comprising: a fuel cell stack assembly having a plurality of fuel cells disposed between a first end plate and a second end plate;a compression retention enclosure comprising an upper compression shell disposed in contact adjacent the first end plate, a lower compression shell disposed in contact adjacent the second end plate, each compression shell having an extension toward and substantially coplanar with an extension of the other compression shell, the extension from the upper compression shell forming an upper side panel and the extension from the lower compression shell forming a lower side panel, each side panel having an outwardly hemmed edge;at least one C-link member opposing the outwardly hemmed edges and interlocking the hemmed edge of the upper side panel with the hemmed edge of the lower side panel to form an interlocked hem joint. 20. A method of manufacturing a fuel cell system according to claim 19, the method comprising: applying an initial compressive force to the compression shells sufficient to position the hemmed edge of the upper side panel relative to the hemmed edge of the lower side panel such that the C-link member slides into interlocking position; releasing the initial compressive force to engage the interlocking hem joint, resulting in a sustained compression force on the fuel cell stack substantially equal to a total tensive force of the compression retention enclosure, wherein the difference between the initial compressive force and the total tensive force of the compression retention enclosure approximately accommodates membrane swell of the fuel cell stack. 21. A fuel cell system according to claim 19, comprising a sustained compressive force on the fuel cell stack substantially equal to a total tensive force of the compression retention enclosure. 22. The fuel cell system according to claim 19, wherein the compression retention enclosure possesses sufficient strength to remain substantially sealed even upon operational swelling of the fuel cell stack. 23. The fuel cell system according to claim 19 wherein the upper and lower compression shells are fabricated from a composite material comprising a polymeric layer and a steel layer. 24. The fuel cell system according to claim 21, wherein the polymeric layer is a polymeric core and the composite material comprises a polymeric core interposed between a bottom steel skin layer and a top steel skin layer. 25. The fuel cell system according to claim 24, wherein the extensions forming the side panels are extensions of the bottom steel skin layer of the lower compression shell and the top steel skin layer of the upper compression shell.
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이 특허에 인용된 특허 (7)
Mease Kevin L. ; Brunner Adam K. ; Pitts Larry A. ; Winslow Alan F., Clamping apparatus and method for a fuel cell.
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