Patent ID: 12261339

DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

Hereinafter, exemplary embodiments of the present disclosure will be described in detail with reference to the accompanying drawings. In the drawings, the same reference numerals will be used throughout to designate the same or equivalent elements. In addition, a detailed description of well-known techniques associated with embodiments of the present disclosure will be omitted in order not to unnecessarily obscure the gist of the present disclosure.

Terms such as first, second, A, B, (a), and (b) may be used to describe the elements in exemplary embodiments of the present disclosure. These terms are only used to distinguish one element from another element, and the intrinsic features, sequence or order, and the like of the corresponding elements are not limited by the terms. Unless otherwise defined, all terms used herein, including technical or scientific terms, have the same meanings as those generally understood by those with ordinary knowledge in the field of art to which the present disclosure belongs. Such terms as those defined in a generally used dictionary are to be interpreted as having meanings equal to the contextual meanings in the relevant field of art, and are not to be interpreted as having ideal or excessively formal meanings unless clearly defined as having such in the present application.

Referring toFIG.1, a fuel cell system according to an exemplary embodiment of the present disclosure may include a fuel cell stack11(seeFIG.7), a fuel cell stack enclosure12accommodating the fuel cell stack11, a fuel process system13supplying and processing a fuel (hydrogen) used in the fuel cell stack11, an air process system14supplying and processing oxygen in the air, which is an oxidizing agent used in the fuel cell stack11, a thermal management system15removing reaction heat from the fuel cell stack11and controlling an operating temperature of the fuel cell stack11, and a support frame16supporting the fuel cell stack enclosure12.

Referring toFIG.7, the fuel cell stack11may be disposed in the fuel cell stack enclosure12, and the fuel cell stack11may be protected by the fuel cell stack enclosure12. The fuel cell stack enclosure12may have a low profile, flat structure, whereby the fuel cell system may be easily flattened.

Referring toFIG.1, the fuel process system13may be directly mounted on a front end of the fuel cell stack enclosure12, and the air process system14may be directly mounted on the support frame16. The thermal management system15may be directly mounted on a rear end of the fuel cell stack enclosure12. The arrangement of the fuel process system13, the air process system14, and the thermal management system15is not limited to that illustrated inFIG.1, and may be varied.

The fuel process system13, the air process system14, and the thermal management system15may be disposed between the periphery of the fuel cell stack enclosure12and the support frame16. In particular, the fuel process system13, the air process system14, and the thermal management system15may be on the same level as that of the fuel cell stack enclosure12in a height direction of the fuel cell stack enclosure12. Since the fuel process system13, the air process system14, and the thermal management system15do not protrude above or below the fuel cell stack enclosure12, the fuel cell system may have a low profile, full flat structure.

According to an exemplary embodiment, as illustrated inFIGS.1and2, a high voltage junction box17may be attached to one side edge of the fuel cell stack enclosure12.

According to another exemplary embodiment, as illustrated inFIG.3, the high voltage junction box may not be attached to an edge of the fuel cell stack enclosure12, but may be disposed inside the fuel cell stack enclosure12or be in a different location.

According to the exemplary embodiment illustrated inFIG.1, the support frame16may surround the fuel cell stack enclosure12, the fuel process system13, the air process system14, and the thermal management system15. The support frame16may include a plurality of horizontal members16aand a plurality of vertical members16b, and the plurality of horizontal members16aand the plurality of vertical members16bmay be at least partially connected to each other.

Referring toFIG.3, both opposing edges of the fuel cell stack enclosure12may be elastically connected to the support frame16by a plurality of connection systems20.

The plurality of connection systems20may be symmetrically disposed on both side edges of the fuel cell stack enclosure12. Referring toFIGS.2and3, two connection systems20may be connected to one side edge of the fuel cell stack enclosure12, and the other two connection systems20may be connected to the other side edge of the fuel cell stack enclosure12.

Each connection system20may cause the fuel cell stack enclosure12to be elastically biased to a reference position. Thus, the fuel cell stack enclosure12may be maintained in the reference position by the plurality of connection systems20.

Referring toFIGS.4to6, the fuel cell stack enclosure12may have a first flexible flange31and a second flexible flange32extending from the side edge of the fuel cell stack enclosure12toward the support frame16. The first flexible flange31may be spaced apart from the second flexible flange32in the height direction of the fuel cell stack enclosure12. The first flexible flange31may be located above the second flexible flange32.

According to an exemplary embodiment, referring toFIGS.3and5-7, a first band33may surround an upper portion of the fuel cell stack enclosure12, and a second band34may surround a lower portion of the fuel cell stack enclosure12. The first flexible flange31may extend from each end portion of the first band33toward the support frame16. The second flexible flange32may extend from each end portion of the second band34toward the support frame16. Referring toFIG.2, the first band33may surround the upper portion of the fuel cell stack enclosure12and an upper portion of the high voltage junction box17, and the second band34may surround the lower portion of the fuel cell stack enclosure12and a lower portion of the high voltage junction box17.

According to another exemplary embodiment, the first flexible flange31and the second flexible flange32may extend from each side edge of the fuel cell stack enclosure12. That is, the first flexible flange31and the second flexible flange32may be directly connected to the side edge of the fuel cell stack enclosure12, so the first band33and the second band34may be omitted.

A connection bar35may be interposed between the first flexible flange31and the second flexible flange32, and the connection bar35may keep a distance between the first flexible flange31and the second flexible flange32. The connection bar35may be connected to the first flexible flange31and the second flexible flange32by fasteners. The connection bar35may extend along each side edge of the fuel cell stack enclosure12. The connection bar35may connect the plurality of connection systems20mounted on the side edge of the fuel cell stack enclosure12. In the connection bar35, an upper bar35aand a lower bar35bmay be joined by welding and/or the like.

The first flexible flange31and the second flexible flange32may be formed of a material that may be flexibly deformed. The first flexible flange31and the second flexible flange32may be deformed in response to a movement of the fuel cell stack enclosure12(seeFIGS.8to11).

Referring toFIG.4, each connection system20may include a shaft25. The shaft25may have a pair of mounting projections25aand25bprovided on both ends thereof, and a pair of mounting flanges25cand25dadjacent to the pair of mounting projections25aand25b, respectively. The mounting projections25aand25bof the shaft25may be fixed to the support frame16so that the shaft25may be mounted on the support frame16.

Each connection system20may include a first connection member21connecting the shaft25and the first flexible flange31, and a second connection member22connecting the shaft25and the second flexible flange32. The first connection member21and the second connection member22may be arranged in a row in a longitudinal direction of the fuel cell stack enclosure12.

A portion of the first connection member21may be rotatable around the shaft25, and the other portion of the first connection member21may be connected to the first flexible flange31. Referring toFIG.5, the first connection member21may include a first body21ahaving a circular cavity in which the shaft25is received, and a first extension portion21bextending from the first body21atoward the fuel cell stack enclosure12. The first extension portion21bmay be attached to a top surface of the first flexible flange31. The first extension portion21bmay be connected to the first flexible flange31and the second flexible flange32through first fasteners26aand26b. The first fasteners26aand26bmay be a first bolt26aand a first nut26b. The first bolt26amay pass through the first extension portion21bof the first connection member21, the first flexible flange31, the connection bar35, and the second flexible flange32, and the first bolt26amay be screwed into the first nut26bon a bottom surface of the second flexible flange32, and accordingly, the first extension portion21bof the first connection member21, the first flexible flange31, the connection bar35, and the second flexible flange32may be fastened together by the first bolt26aand the first nut26b.

A portion of the second connection member22may be rotatable around the shaft25, and the other portion of the second connection member22may be connected to the second flexible flange32. Referring toFIG.6, the second connection member22may include a second body22ahaving a circular cavity in which the shaft25is received, and a second extension portion22bextending from the second body22atoward the fuel cell stack enclosure12. The second extension portion22bmay be attached to the bottom surface of the second flexible flange32. The second extension portion22bmay be connected to the first flexible flange31and the second flexible flange32through second fasteners27aand27b. The second fasteners27aand27bmay be a second bolt27aand a second nut27b. The second bolt27amay pass through the second extension portion22bof the second connection member22, the second flexible flange32, the connection bar35, and the first flexible flange31, and the second bolt27amay be screwed into the second nut27bon the top surface of the first flexible flange31, and accordingly, the second extension portion22bof the second connection member22, the second flexible flange32, the connection bar35, and the first flexible flange31may be fastened together by the second bolt27aand the second nut27b.

The first extension portion21bof the first connection member21and the second extension portion22bof the second connection member22may be spaced apart from each other in the height direction of the fuel cell stack enclosure12. The first extension portion21bof the first connection member21may be located above the second extension portion22bof the second connection member22.

Referring toFIG.4, each connection system20may include a first biasing member23causing the first connection member21to be elastically biased toward the reference position, and a second biasing member24causing the second connection member22to be elastically biased toward the reference position.

The first biasing member23may be a torsion spring disposed between the first mounting flange25cof the shaft25and the first connection member21, and the first biasing member23may have a pair of support legs which are supported to the first mounting flange25cand the first connection member21, respectively. As illustrated inFIGS.8,10, and11, when the first connection member21is tilted upward by a predetermined angle (see a1and a2inFIG.8, a5inFIG.10, and a8inFIG.11) from the reference position due to an external impact, the first biasing member23may provide a biasing force in the opposite direction with respect to the tilting of the first connection member21so as to restore the first connection member21to the reference position. Specifically, the first biasing member23may provide the biasing force in a direction in which the first connection member21is tilted downward. Even if the first connection member21is moved by the external impact, the biasing force of the first biasing member23may cancel out the impact so that the first connection member21may be restored to the reference position, and thus the first flexible flange31and the second flexible flange32may be restored to the reference position.

The second biasing member24may be a torsion spring disposed between the second mounting flange25dof the shaft25and the second connection member22, and the second biasing member24may have a pair of support legs which are supported to the second mounting flange25dand the second connection member22, respectively. As illustrated inFIGS.9,10, and11, when the second connection member22is tilted downward by a predetermined angle (see a3and a4inFIG.9, a6inFIG.10, and a7inFIG.11) from the reference position due to an external impact, the second biasing member24may provide a biasing force in the opposite direction with respect to the tilting of the second connection member22so as to restore the second connection member22to the reference position. Specifically, the second biasing member24may provide the biasing force in a direction in which the second connection member22is tilted upward. Even if the second connection member22is moved by the external impact, the biasing force of the second biasing member24may cancel out the impact so that the second connection member22may be restored to the reference position, and thus the second flexible flange32and the first flexible flange31may be restored to the reference position.

As described above, the first biasing member23may provide the biasing force in a direction in which the first connection member21is tilted downward, and the second biasing member24may provide the biasing force in a direction in which the second connection member22is tilted upward. That is, the first biasing member23and the second biasing member24may provide the biasing force in the opposite directions.

Referring toFIG.7, when an external load is not applied to the fuel cell stack enclosure12, the fuel cell stack enclosure12may be in the reference position. Here, the reference position may refer to a position in which a central transverse axis of the fuel cell stack enclosure12is aligned with or parallel to a reference line P1. The reference line P1may be a virtual line (horizontal line) that virtually connects the center of the shaft25of the left connection system20and the center of the shaft25of the right connection system20. When the fuel cell stack enclosure12is in the reference position, the first extension portion21bof the first connection member21and the second extension portion22bof the second connection member22may be parallel to top and bottom surfaces of the fuel cell stack enclosure12. InFIGS.7to11, the reference position may be a horizontal position.

As illustrated inFIGS.8to11, when the fuel cell stack enclosure12is moved by external loads L1, L2, M1, and M2, the fuel cell stack enclosure12may be restored to the reference position by the connection systems20.

Referring toFIG.8, when a vertical load L1generated by an external impact acts on the fuel cell stack enclosure12from bottom to top, the fuel cell stack enclosure12may be moved upward, and accordingly, the first connection member21and the second connection member22of the left connection system20may be tilted upward by a predetermined angle a1from the reference line P1, and the first connecting member21and the second connecting member22of the right connecting system20may be tilted upward by a predetermined angle a2from the reference line P1. Here, the first biasing member23of the left connection system20may apply a biasing force in a direction in which the first connection member21of the left connection system20is tilted downward, and the first biasing member23of the right connection system20may apply a biasing force in a direction in which the first connection member21of the right connection system20is tilted downward, and accordingly, the vertical load L1applied to the fuel cell stack enclosure12may be cancelled out. Thus, the fuel cell stack enclosure12may be restored to the reference position.

Referring toFIG.9, when a vertical load L2generated by an external impact acts on the fuel cell stack enclosure12from top to bottom, the fuel cell stack enclosure12may be moved downward, and accordingly, the first connection member21and the second connection member22of the left connection system20may be tilted downward by a predetermined angle a3from the reference line P1, and the first connection member21and the second connection member22of the right connection system20may be tilted downward by a predetermined angle a4from the reference line P1. Here, the first biasing member23of the left connection system20may apply a biasing force in a direction in which the first connection member21of the left connection system20is tilted upward, and the first biasing member23of the right connection system20may apply a biasing force in a direction in which the first connection member21of the right connection system20is tilted upward, and accordingly, the vertical load L2applied to the fuel cell stack enclosure12may be cancelled out. Thus, the fuel cell stack enclosure12may be restored to the reference position.

Referring toFIG.10, when a moment load M1generated by an external impact acts on the fuel cell stack enclosure12in a counterclockwise direction, the fuel cell stack enclosure12may be twisted (tilted) to the left in response to the moment load M1. Accordingly, the first connection member21and the second connection member22of the left connection system20may be tilted upward by a predetermined angle a5from the reference line P1, and the first connection member21and the second connection member22of the right connection system20may be tilted downward by a predetermined angle a6from the reference line P1. Here, the first biasing member23of the left connection system20may apply a biasing force in a direction in which the first connection member21of the left connection system20is tilted downward, and the first biasing member23of the right connection system20may apply a biasing force in a direction in which the first connection member21of the right connection system20is tilted upward, and accordingly, the moment load M1applied to the fuel cell stack enclosure12may be cancelled out. Thus, the fuel cell stack enclosure12may be restored to the reference position.

Referring toFIG.11, when a moment load M2generated by an external impact acts on the fuel cell stack enclosure12in a clockwise direction, the fuel cell stack enclosure12may be twisted (tilted) to the right in response to the moment load M2. Accordingly, the first connection member21and the second connection member22of the left connection system20may be tilted downward by a predetermined angle a7from the reference line P1, and the first connection member21and the second connection member22of the right connection system20may be tilted upward by a predetermined angle a8from the reference line P1. Here, the first biasing member23of the left connection system20may apply a biasing force in a direction in which the first connection member21of the left connection system20is tilted upward, and the first biasing member23of the right connection system20may apply a biasing force in a direction in which the first connection member21of the right connection system20is tilted downward, and accordingly, the moment load M2applied to the fuel cell stack enclosure12may be cancelled out. Thus, the fuel cell stack enclosure12may be restored to the reference position.

Referring toFIGS.1to3, two left connection systems20may be disposed on the left side of the fuel cell stack enclosure12, and two right connection systems20may be disposed on the right side of the fuel cell stack enclosure12. That is, a total of four connection systems20may be symmetrically arranged on both the left and right sides of the fuel cell stack enclosure12. This arrangement may allow the external impact to be cancelled out or absorbed when the external impact is applied to the fuel cell stack enclosure12in various directions, and thus the fuel cell stack enclosure12may be stably restored to the reference position.

Referring toFIG.12, when the fuel cell stack enclosure12is in the reference position, the bottom surface of the fuel cell stack enclosure12may be located higher than a bottom surface of the support frame16by a first distance h1. For example, the first distance h1may be 45 mm. The top surface of the fuel cell stack enclosure12may be located lower than a top surface of the support frame16by a second distance h2. For example, the second distance h2may be 45 mm. Accordingly, sufficient space may be provided under the bottom surface of the fuel cell stack enclosure12and above the top surface of the fuel cell stack enclosure12. Thus, even if the fuel cell stack enclosure12is moved by the external impact, the fuel cell stack enclosure12may be prevented from protruding from an upper end of the support frame16or contacting a bottom of the fuel cell system, therefore the fuel cell stack enclosure12may be prevented from interfering with an external component or having a secondary collision with an external component.

FIG.13illustrates a fuel cell system including a fuel cell mounting system according to another exemplary embodiment of the present disclosure. Referring toFIG.13, a support frame may include a pair of support structures56disposed on both sides of the fuel cell stack enclosure12, respectively. The pair of support structures56may surround both side edges of the fuel cell stack enclosure12. Each support structure56may include a longitudinal member56aextending in the longitudinal direction of the fuel cell stack enclosure12and a plurality of vertical members56bsupporting the longitudinal member56a. The shaft25of each connection system20may be mounted between two adjacent vertical members56b.

Since the other configurations of the fuel cell system are the same as or similar to those in the previous exemplary embodiments, a detailed description thereof will be omitted.

FIG.14illustrates a fuel cell system including a fuel cell mounting system according to another exemplary embodiment of the present disclosure. Referring toFIG.14, a support frame66may surround the fuel cell stack enclosure12, the fuel process system13, the air process system14, and the thermal management system15. The support frame66may include a plurality of horizontal members66a, a plurality of vertical members66b, and a plurality of closed walls66c. The plurality of horizontal members16aand the plurality of vertical members16bmay be at least partially connected to each other, and the plurality of closed walls66cmay face the front, rear, left side and right side of the fuel cell stack enclosure12.

As set forth above, according to exemplary embodiments of the present disclosure, as the fuel cell stack enclosure12is elastically restored to the reference position by the plurality of connection systems20, the fuel cell stack enclosure12may be a low profile, flat structure having a relatively low thickness (for example, 250 mm or less). Thus, the full flat structure of the fuel cell system may be achieved.

According to exemplary embodiments of the present disclosure, by reliably canceling out or absorbing the external impact even when the external impact is applied to the fuel cell stack enclosure in various directions, the fuel cell stack enclosure may be stably restored to the reference position.

Hereinabove, although the present disclosure has been described with reference to exemplary embodiments and the accompanying drawings, the present disclosure is not limited thereto, but may be variously modified and altered by those skilled in the art to which the present disclosure pertains without departing from the spirit and scope of the present disclosure claimed in the following claims.