Vehicle-mounted hydrogen module and assembling method thereof

Abstract

The invention provides a vehicle-mounted hydrogen module and an assembling method thereof, the vehicle-mounted hydrogen module comprises a shell and a control panel arranged in the shell, two independent cavities and an air inlet leading to the two independent cavities are formed in the shell, a breathable grating is arranged in the air inlet, and waterproof breathable films are arranged between the breathable grating and the independent cavities. The two independent cavities are designed for the hydrogen detection element and correspondingly contain the detection element and the compensation element of the catalytic hydrogen sensor, the product performance stability is improved, the gas exchange efficiency is improved, and therefore the response time and desorption time of the device are shortened; one cavity is divided into two small independent cavities which share one gas inlet, so that the cavity volume and the gas inlet diameter of the cavity are optimized, and the path of hydrogen diffused to the hydrogen detection element is greatly shortened; compared with a traditional large cavity design, the structure enables the response time to be remarkably shortened, and the safety requirement of a vehicle-mounted scene for quick leakage response is met.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of sensors, in particular to a hydrogen module. BACKGROUND

[0002] Hydrogen energy, as a zero-carbon clean energy, is favored due to its advantages of only generating water during combustion, easy-to-obtain raw materials (hydrogen produced by electrolysis of water), and high energy density, and is becoming an important direction of energy transformation. Hydrogen is widely used in the fields of petroleum, chemical industry, electric power, metallurgy, etc., and is more closely related to daily life with the development of new energy vehicles.

[0003] Hydrogen fuel cell vehicles take advantage of the clean characteristics of hydrogen to exhibit high efficiency and environmental protection. Given the flammable and explosive nature of hydrogen and its colorless and odorless characteristics, the industry chain relies on on-board hydrogen modules to monitor hydrogen leaks to ensure the safety of hydrogen refueling stations and vehicles.

[0004] The safety of new energy vehicle power batteries is crucial. Real-time monitoring of hydrogen leaks can effectively reduce the risk of spontaneous combustion, and the immediate initiation of emergency measures upon detection of a leak adds an extra layer of protection for the safety of passengers' lives and property.

[0005] The on-board hydrogen module is composed of an upper and lower shell and an internal control board. The control board has integrated hydrogen detection elements for detecting hydrogen. The shell is carefully manufactured through injection molding. The catalytic combustion type hydrogen concentration sensor is widely used on hydrogen fuel cell vehicles. Although the existing on-board hydrogen module for hydrogen energy vehicles has been widely used, the current on-board hydrogen module for hydrogen energy vehicles has the disadvantages of poor vibration resistance and weak waterproof effect. The existing on-board hydrogen module has a large sensitive element chamber, which affects the response speed of the sensor to some extent.

[0006] The utility model patent with publication date 2025.05.13 and publication number CN222866595U discloses a waterproof and breathable hydrogen sensor device, which comprises a shell, a waterproof and breathable membrane for waterproof and breathable, a gas pressure buffer cover for gas shunting, a PCB board carrying a hydrogen chip, and a bottom cover. The utility model patent has a thin waterproof and breathable membrane attached to the inner wall of the air inlet grille of the shell, which can block water molecules from entering the chamber inside the shell while maintaining ventilation, achieving the waterproof and breathable function of the hydrogen sensor device. The waterproof and breathable membrane at the inner wall of the air inlet grille is tightly pressed by the gas pressure buffer cover, preventing water molecules from entering the chamber inside the shell due to loose fitting of the waterproof and breathable membrane and the inner wall of the air inlet grille, and preventing the waterproof and breathable membrane from falling off due to the impact of high-pressure gas. The gas pressure buffer cover can shunt high-speed flowing gas, thereby reducing the flow rate of high-speed flowing gas and allowing it to diffuse gently into the chamber inside the shell. However, the shell of the utility model patent has a single chamber, which has slow response speed, poor stability, and weak anti-interference ability. SUMMARY

[0007] In order to solve the above technical problems, the present application provides a vehicle-mounted hydrogen module and an assembling method thereof.

[0008] In order to achieve the above-mentioned purpose, the technical scheme of the present application is as follows: The vehicle-mounted hydrogen module comprises a shell and a control board arranged in the shell, wherein the shell is provided with two independent chambers and an air inlet leading to the two independent chambers, the air inlet is provided with a gas-permeable grille, and a waterproof gas-permeable film is arranged between the gas-permeable grille and the independent chambers.

[0009] Further, the shell comprises a detachable outer shell and a lower cover, and the two independent chambers are arranged on the outer shell; a sensor sealing gasket is arranged between the control board and the outer shell and cooperates with the two independent chambers.

[0010] Further, the sensor sealing gasket has an "8" shape, and the inner side of the outer shell and the edges of the two independent chambers are provided with an "8" shaped sensor sealing groove cooperating with the sensor sealing gasket.

[0011] Further, the gas-permeable grille and the waterproof gas-permeable film are welded integrally with the outer shell.

[0012] Further, the outer side of the outer shell is provided with a cylindrical body for accommodating the gas-permeable grille.

[0013] Further, the gas-permeable grille is provided with a foolproof protrusion, and the inner side of the cylindrical body is provided with a corresponding foolproof groove.

[0014] Further, the middle part of the lower cover is provided with a groove, at least two limiting columns abutting against the control board are arranged in the middle part of the groove; at least two limiting blocks are arranged on the lower cover near the periphery of the groove; and the at least two limiting blocks are located outside the groove.

[0015] Further, the outer shell is provided with an accommodating cavity for accommodating the control board, screw hole bosses are arranged around the accommodating cavity, and the control board is provided with screw holes aligned with the screw hole bosses.

[0016] Further, the control board is provided with a through-hole pad, and the shell is provided with a pin that is plugged into the through-hole pad.

[0017] The vehicle-mounted system comprises the vehicle-mounted hydrogen module of any one of the preceding aspects, and further comprises a hydrogen sensor, wherein the detection element and the compensation element of the hydrogen sensor are respectively placed in two independent chambers.

[0018] The assembling method of the vehicle-mounted hydrogen module of any one of the preceding aspects comprises the following steps. S1, the shell, the waterproof and breathable film and the breathable grid are welded into one by ultrasonic welding process; S2, the sensor sealing gasket is sleeved on the detection element and the compensation element of the hydrogen sensor on the control board, then the control board is installed at the corresponding position of the accommodating cavity of the shell, and the detection element and the compensation element of the hydrogen sensor are respectively placed in two independent chambers. S3, a screw is placed into a corresponding screw hole for locking, and then the through-hole pad on the control board and the pin on the shell are respectively welded by using an electric soldering iron. S4, the shell sealing ring is placed in the sealing groove of the shell, and the lower cover is buckled with the shell, and the assembly is completed.

[0019] The beneficial effects of the present application are as follows: 1, the control board and the shell are rigidly fixed by screws, replacing the traditional buckle or adhesive method, effectively suppressing the resonance of the control board or the hydrogen detection element caused by high-frequency vibration during vehicle driving; the screw pre-tightening force can be quantitatively controlled to ensure that the circuit board and the shell form a mechanical integrity, avoiding signal noise or solder fatigue fracture caused by vibration; 2, the present application designs two independent chambers for the hydrogen sensor, which correspond to the detection element and the compensation element of the catalytic hydrogen sensor, improves the product performance stability and the gas exchange efficiency, thereby speeding up the response time and the desorption time of the device; 3, the present application optimizes the cavity volume and the inlet diameter of the independent chamber, greatly shortens the path of hydrogen diffusion to the hydrogen detection element; compared with the traditional large chamber design, this structure makes the response time (T90) improve by more than 50%, meeting the safety requirements of rapid response to leakage in vehicle-mounted scenarios; 4, the present application places the waterproof and breathable film at the middle breathable hole of the outer surface of the shell, then installs the breathable grid, and then performs ultrasonic welding process on the waterproof and breathable film, the breathable grid and the shell to fuse them into one, which not only improves the waterproof performance, but also improves the stability and durability; 5. The hydrogen sensor is sealed by the sensor sealing gasket, the PCB carrying the hydrogen sensor is fixed with the shell by screws, the detection element and the compensation element of the hydrogen sensor are respectively in the independent chambers, the sensor sealing gasket is designed with a pressing amount at the plane of the two independent chambers, the sealing performance of the hydrogen sensor in the independent chamber is ensured, the catalytic combustion reaction efficiency is improved, and the rapid response and desorption effects are achieved; 6. The hydrogen sensor is sealed by the sensor sealing gasket, the PCB carrying the hydrogen sensor is fixed with the shell by screws, the detection element and the compensation element of the hydrogen sensor are respectively in the independent chambers, the sensor sealing gasket is designed with a pressing amount at the plane of the two independent chambers, the sealing performance of the hydrogen sensor in the independent chamber is ensured, the catalytic combustion reaction efficiency is improved, and the rapid response and desorption effects are achieved; BRIEF DESCRIPTION OF DRAWINGS

[0020] In order to more clearly illustrate the technical solutions in the embodiments of the present application or the prior art, the following will briefly introduce the drawings needed to be used in the embodiments or the prior art description. Obviously, the drawings in the following description are only some embodiments of the present application, and other drawings can also be obtained by those skilled in the art without creative labor.

[0021] Figure 1 The structural schematic diagram of the present application is shown in the figure; Figure 2 The explosive structural schematic diagram of the present application is shown in the figure; Figure 3 The inside structure schematic diagram of the shell of the present application is shown in the figure; Figure 4 The top structure schematic diagram of the shell of the present application is shown in the figure; Figure 5 The structure schematic diagram of the lower cover of the present application is shown in the figure.

[0022] In the figure: 10, air grille, 101, foolproof convex, 20, waterproof air permeable film, 30, shell, 301, containing cavity, 302, independent chamber, 303, sensor sealing groove, 306, screw hole boss, 307, sealing groove, 308, plug-in part, 309, boss reinforcing rib, 310, air inlet, 311, clamping convex, 312, cylindrical boss, 313, fixing foot, 314, fixing hole, 315, metal insert, 316, clamping block, 317, plug-in port, 318, plug pin, 40, sensor sealing gasket, 50, control board, 518, welding hole, 519, hydrogen sensor, 60, screw, 70, shell sealing ring, 80, lower cover, 801, buckle, 802, groove, 803, limiting block, 804, limiting column, 805, edge plane. DETAILED DESCRIPTION

[0023] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0024] like Figure 1 As shown, the vehicle-mounted hydrogen module of Embodiment 1 of the present invention includes a housing and a control board 50 disposed within the housing, as follows: Figure 2 As shown, the control board 50, or PCBA, is used to house the hydrogen sensor 519. The hydrogen sensor 519 includes a detection element and a compensation element. The housing has two independent chambers 302 for housing the detection element and compensation element of the hydrogen sensor 519, respectively, and a ventilated grille 10 is provided on the outer side of each of the two independent chambers 302. In this embodiment, the outer side of the two independent chambers 302 shares a single ventilated grille 10, and a waterproof and breathable membrane 20 is provided between the ventilated grille 10 and the two independent chambers 302.

[0025] Furthermore, such as Figure 2 As shown, the housing includes a detachably connected outer shell 30 and a lower cover 80. In this embodiment, the outer shell 30 and the lower cover 80 are fastened together. That is, a boss is provided on one of the outer shell 30 and the lower cover 80, and an elastic latching arm is provided on the other. The elastic latching arm has a latching hole for latching onto the boss, thereby realizing the fastening connection between the outer shell 30 and the lower cover 80.

[0026] Furthermore, such as Figure 2 As shown, a housing sealing ring 70 is provided between the outer shell 30 and the lower cover 80. In a preferred embodiment, the outer shell 30 is provided with a sealing groove 307 for inserting the housing sealing ring 70, and the housing sealing ring 70 protrudes out of the sealing groove 307, so that the housing sealing ring 70 can be pressed tightly by the lower cover 80 connected to the outer shell 30.

[0027] In a preferred embodiment, the two independent chambers are cylindrical chambers, with a diameter of less than 8 mm and a volume of less than 100 mm³ for each chamber.

[0028] In another preferred embodiment, the two independent chambers are cylindrical chambers, with a diameter of less than 6 mm and a volume of less than 150 mm² for each individual microchamber. 3 .

[0029] Example 2, as Figure 3As shown, two independent chambers 302 are disposed on the housing 30; the two independent chambers 302 are aligned with the detection element and compensation element of the hydrogen sensor 519 on the control board 50. After the control board 50 is installed with the housing 30, the detection element and compensation element of the hydrogen sensor 519 extend into the two independent chambers 302. A sensor sealing gasket 40 is provided between the control board 50 and the housing 30 to seal the gap between the two independent chambers 302 and the hydrogen sensor 519.

[0030] The rest is the same as in Example 1.

[0031] Example 3, as Figure 2 As shown, the sensor sealing gasket 40 has an "8" shaped structure. (As...) Figure 3 As shown, an “8”-shaped sensor sealing groove 303 is provided on the inner side of the outer casing 30 and at the edge of the two independent chambers 302. The sensor sealing groove 303 cooperates with the sensor sealing gasket 40 to limit the installation of the sensor sealing gasket 40.

[0032] In a preferred embodiment, a raised truncated cone is provided in the middle of the inner side of the outer casing 30, and the inner ends of the two independent chambers 302, i.e., the ends located inside the casing, protrude from the truncated cone. The truncated cone increases the depth of the independent chambers 302. The figure-eight shaped sensor sealing groove 303 is disposed on the truncated cone. A groove extending along the thickness direction of the outer casing 30 is provided in the empty space outside the sensor sealing groove 303 on the truncated cone, which serves to reduce the thickness and weight.

[0033] In one embodiment, there is a groove on each of the empty spaces on both sides of the sensor sealing groove 303, and a small hole is provided at the bottom of one of the grooves. That is, a small hole is provided on the outer side of the housing 30 at the position corresponding to the groove, which plays the role of balancing the air pressure inside and outside the housing.

[0034] The rest is the same as in Example 2.

[0035] Example 4, as Figure 2 and Figure 4 As shown, a cylindrical body 312 is provided at the center of the outer side of the outer casing 30. The cylindrical body 312 is used to accommodate the ventilation grille 10. Figure 4 As shown, the cylindrical body 312 surrounds the outside of the two independent chambers 302, forming an air inlet 310 leading to the two independent chambers 302. That is, the two independent chambers 302 share a large air inlet 310. The ventilation grille 10 is installed inside the cylindrical body 312, that is, on the air inlet 310.

[0036] In this embodiment, the outer contour of the ventilation grille 10 is circular. For example... Figure 2As shown, the ventilation grille 10 has two large fan-shaped holes symmetrically arranged on it, which are aligned with the outer ports of the two independent chambers 302. The ventilation grille 10 also has two small fan-shaped holes symmetrically arranged on it, which are located in the empty space outside the two large fan-shaped holes and are aligned with the bottom of the groove, so that the small hole at the bottom of one of the grooves is directly connected to the outside.

[0037] The rest is the same as in Example 3.

[0038] Example 5, as Figure 4 As shown, the ventilation grille 10 has a horizontally extending anti-mistake protrusion 101 on one side, and the cylindrical body 312 has a corresponding anti-mistake groove on the inner side. Through the cooperation of the anti-mistake groove and the anti-mistake protrusion 101, the ventilation grille 10 is accurately placed into the cylindrical body 312, and the two large fan-shaped holes are aligned with the two independent chambers 302.

[0039] The rest is the same as in Example 4.

[0040] In Example 6, the breathable grille 10 and the waterproof and breathable membrane 20 are welded together with the outer shell 30. In this example, the outer shell adopts an IP68-level sealing design. The waterproof and breathable membrane (such as ePTFE material) allows gas phase permeation but blocks liquid water, supplemented by a three-dimensional breathable grille to mechanically block high-pressure water jets. The three components are ultrasonically welded to form a seamless integrated structure, completely solving the problem of water leakage due to aging of traditional sealing rings.

[0041] The rest is the same as in Example 5.

[0042] Example 7, as Figure 5 As shown, the lower cover 80 has a groove 802 in the middle, which is rectangular in this embodiment. At least two limiting posts 804 abut against the control plate 50 are provided in the middle of the groove 802; at least two limiting blocks 803 are provided on the lower cover 80 near the perimeter of the groove 802; and at least two limiting blocks 803 are located outside the groove 802. In this embodiment, four limiting posts 804 are provided inside the groove 802, and the four limiting posts 804 abut against the lower side of the rectangular control plate 50. A limiting block 803 is provided near each side of the groove 802, for a total of four limiting blocks 803, which provide a certain limiting effect on the control plate 50.

[0043] The rest is the same as in Example 6.

[0044] Example 8, as Figure 3 As shown, the outer shell 30 is provided with a receiving cavity 301 for accommodating the control board 50. The receiving cavity 301 is provided with four screw hole bosses 306 around its perimeter. The control board 50 is provided with screw holes aligned with the screw hole bosses 306.

[0045] The housing and control board 50 are rigidly fixed with screws, replacing traditional clips or adhesives, effectively suppressing control board resonance or hydrogen detection element breakage caused by high-frequency vibration during vehicle operation. The screw preload can be quantitatively controlled to ensure mechanical integration between the circuit board and the housing, avoiding signal noise or solder joint fatigue fracture caused by vibration.

[0046] Furthermore, the ultrasonic welding process for fixing screws to the breathable grille 10, waterproof and breathable membrane 20 and outer shell 30 is easy to automate and mass-produce, reducing manufacturing costs compared to traditional solutions.

[0047] The rest is the same as in Example 7.

[0048] Example 9, as Figure 2 As shown, the control board 50 has through-hole pads 518, and the housing 30 has pins 318 that engage with the through-hole pads 518. The pins 318 are soldered to the through-hole pads 518 on the control board 50. In this embodiment, the housing 30 has four pins; the through-hole pads 518 have four solder holes. The four pins of the housing are firmly soldered to the corresponding solder holes of the through-hole pads 518 on the control board using high-temperature solder.

[0049] The rest is the same as in Example 8.

[0050] Example 10: A vehicle-mounted system including the vehicle-mounted hydrogen module and hydrogen sensor 519 described in any of the above embodiments, wherein the detection element and compensation element of the hydrogen sensor 519 are respectively placed in two independent chambers 302.

[0051] The rest is the same as in Example 9.

[0052] Example 11, the assembly method of the vehicle-mounted hydrogen module according to any of the above-mentioned methods includes the following steps: S1. The outer shell 30, waterproof and breathable membrane 20, and breathable grille 10 are welded together using ultrasonic welding technology; S2. The sensor sealing gasket 40 is fitted onto the detection element and compensation element of the hydrogen sensor 519 on the control board 50. Then the control board 50 is installed in the corresponding position of the receiving cavity 301 of the housing 30, wherein the detection element and compensation element of the hydrogen sensor 519 are respectively placed in two independent chambers 302. S3. Use screw 60 to insert into the corresponding screw hole 520 and tighten it. Then use a soldering iron to solder the through hole pad 518 on the control board 50 to the four pins 318 on the outer casing 30 respectively. S4. Place the housing sealing ring 70 into the sealing groove 307 of the housing 30, and fasten the lower cover 80 to the housing 30 with the snap fastener to complete the assembly.

[0053] Working principle of the invention: The principle of catalytic combustion involves a Wheatstone bridge consisting of a detection element and a compensation element paired together. When the on-board hydrogen module is powered on, in clean air, the detection element and the compensation element have the same temperature and resistance, resulting in a balanced Wheatstone bridge and a zero output signal. When hydrogen gas reaches the surfaces of the detection element and the compensation element, the detection element's temperature rises due to the heat released during combustion, increasing its resistance, while the compensation element remains unresponsive, disrupting the bridge balance and generating a ΔV voltage signal.

[0054] The working process of this invention is as follows: The vehicle-mounted hydrogen module is powered on and preheats for 3 seconds to enter the working state. When there is a hydrogen leak, the hydrogen diffuses through the waterproof and breathable membrane into the hydrogen sensor chamber inside the outer shell. The hydrogen molecules reach the surface of the detection element and the compensation element. The temperature of the detection element increases due to the heat released by combustion, resulting in a larger resistance. The compensation element does not react and its resistance remains unchanged. The bridge is unbalanced and outputs a ΔV voltage signal. The signal is amplified by an operational amplifier, filtered, and then processed by a software algorithm through an MCU to output a signal that meets the customer's requirements.

[0055] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that any modifications to the technical solutions described in the foregoing embodiments, or equivalent substitutions of some or all of the technical features thereof, within the spirit and principles of the present invention, do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention, and should all be included within the protection scope of the present invention.

Claims

1. A vehicle-mounted hydrogen module, characterized in that, Includes a housing and a control panel (50) disposed within the housing. The housing has two independent chambers (302) and an air inlet (310) leading to the two independent chambers (302). The air inlet (310) is provided with a breathable grille (10), and a waterproof and breathable membrane (20) is provided between the breathable grille (10) and the independent chambers (302).

2. The vehicle-mounted hydrogen module according to claim 1, characterized in that, The housing includes a detachably connected outer shell (30) and a lower cover (80), and two independent chambers (302) are disposed on the outer shell (30); a sensor sealing gasket (40) is provided between the control board (50) and the outer shell (30) to cooperate with the two independent chambers (302).

3. The vehicle-mounted hydrogen module according to claim 2, characterized in that, The sensor sealing gasket (40) has an "8" shaped structure. The inner side of the outer shell (30) and the edge of the two independent chambers (302) are provided with an "8" shaped sensor sealing groove (303) that cooperates with the sensor sealing gasket (40).

4. The vehicle-mounted hydrogen module according to claim 2 or 3, characterized in that, The breathable grille (10) and the waterproof breathable membrane (20) are welded together with the outer shell (30).

5. The vehicle-mounted hydrogen module according to claim 2 or 3, characterized in that, The outer side of the outer shell (30) is provided with a cylindrical body (312) for accommodating the ventilation grille (10). The ventilation grille (10) is provided with a foolproof protrusion (101), and the inner side of the cylindrical body (312) is provided with a corresponding foolproof groove.

6. The vehicle-mounted hydrogen module according to claim 2 or 3, characterized in that, The lower cover (80) has a groove (802) in the middle, and at least two limiting posts (804) that abut against the control plate (50) are provided in the middle of the groove (802); at least two limiting blocks (803) are provided on the lower cover (80) near the groove (802); and at least two limiting blocks (803) are located outside the groove (802).

7. The vehicle-mounted hydrogen module according to claim 2 or 3, characterized in that, The outer casing (30) is provided with a receiving cavity (301) for accommodating the control board (50). Screw hole bosses (306) are provided around the receiving cavity (301). The control board (50) is provided with screw holes aligned with the screw hole bosses (306).

8. The vehicle-mounted hydrogen module according to claim 2 or 3, characterized in that, The control board (50) is provided with through-hole pads (518), and the housing (30) is provided with pins (318) that are connected and mated with the through-hole pads (518).

9. A vehicle-mounted system, characterized in that, It includes the vehicle-mounted hydrogen module as described in any one of claims 1 to 8; it also includes a hydrogen sensor (519), wherein the detection element and the compensation element of the hydrogen sensor (519) are respectively placed in two independent chambers (302).

10. The assembly method of the vehicle-mounted hydrogen module as described in any one of claims 1 to 8, characterized in that, Includes the following steps: S1. The outer shell (30), waterproof and breathable membrane (20), and breathable grille (10) are welded together using ultrasonic welding process; S2. The sensor sealing gasket (40) is fitted onto the detection element and compensation element of the hydrogen sensor (519) on the control board (50). Then the control board (50) is installed in the corresponding position of the receiving cavity (301) of the housing (30). The detection element and compensation element of the hydrogen sensor (519) are placed in two independent chambers (302) respectively. S3. Use screws (60) to lock into the corresponding screw holes (520), and then use a soldering iron to solder the through hole pads (518) on the control board (50) to the pins (318) on the outer casing (30) respectively. S4. Place the housing sealing ring (70) into the sealing groove (307) of the housing (30), and fasten the lower cover (80) and the housing (30) together with the snap fastener to complete the assembly.

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