In-situ hydrogen production module suitable for mobile power carrier and preparation process thereof

Abstract

The application discloses a kind of in-situ hydrogen production module suitable for mobile power carrier and preparation process thereof, including raw material storage module, waste heat recovery reforming hydrogen production module, palladium membrane hydrogen purification module, low-pressure hydrogen storage buffer tank, waste heat coupling heat exchange component, multi-working condition intelligent control unit, hydrogen leakage safety linkage unit, wireless communication scheduling unit.The application discloses a kind of in-situ hydrogen production module suitable for mobile power carrier and preparation process thereof, including raw material storage module, waste heat recovery reforming hydrogen production module, palladium membrane hydrogen purification module, low-pressure hydrogen storage buffer tank, waste heat coupling heat exchange component, multi-working condition intelligent control unit, hydrogen leakage safety linkage unit, wireless communication scheduling unit.The application discloses a kind of in-situ hydrogen production module suitable for mobile power carrier and preparation process thereof, including raw material storage module, waste heat recovery reforming hydrogen production module, palladium membrane hydrogen purification module, low-pressure hydrogen storage buffer tank, waste heat coupling heat exchange component, multi-working condition intelligent control unit, hydrogen leakage safety linkage unit, wireless communication scheduling unit.

Description

[0001] manual Technical Field

[0002] This invention belongs to the field of mobile carrier hydrogen production technology, and particularly relates to an in-situ hydrogen production module and its preparation process that are compatible with various mobile power carriers. It can be adapted to fuel cell vehicles, two-wheeled fuel cell motorcycles, three-wheeled cargo fuel cell motorcycles, warehouse / park inspection mobile robots, and long-endurance heavy-duty industrial drones. Background Technology

[0003] Fuel cell power equipment relies on a high-purity hydrogen supply, and existing technologies fall into two categories: high-pressure hydrogen storage tank refueling and on-board methanol reforming hydrogen production. High-pressure hydrogen storage tanks are bulky, pose an explosion safety hazard due to high pressure storage, and have extremely high construction costs for hydrogen refueling stations. Traditional on-board reforming hydrogen production equipment lacks a carrier waste heat recovery structure, relying entirely on electric heating to maintain the reaction temperature, resulting in a significant increase in overall energy consumption. Furthermore, the hydrogen produced mixture contains many impurities, the purification equipment has a complex structure, and the entire device is too large, only suitable for fuel cell vehicle chassis, and cannot be adapted to small, lightweight mobile vehicles such as motorcycles, robots, and drones.

[0004] Existing hydrogen production devices employ a single-layer catalyst arrangement, resulting in low catalytic efficiency and susceptibility to high-temperature failure. The separate welding of components leads to numerous pipeline joints and a high risk of hydrogen leakage. Furthermore, the inability to couple the waste heat generated by the carrier operation results in low energy utilization. Developing dedicated equipment for automobiles, motorcycles, robots, and drones requires multiple patents, incurring high application and maintenance costs, and limiting the scope of intellectual property protection, thus hindering the commercialization of in-situ hydrogen production technology across various scenarios. Summary of the Invention

[0005] Purpose of the invention To address the shortcomings of existing technologies, this paper provides an in-situ hydrogen production module and its preparation process that are compatible with various mobile power carriers. This solves the technical problems of existing equipment, which are only compatible with automobiles, are large in size, have high energy consumption, insufficient purification, cannot recover waste heat, are prone to pipeline leakage, and have high patent costs for multi-scenario deployment. Technical solution

[0006] 1. Main structure of the device: The integrated heat-insulated shell integrates all core modules and utilizes the waste heat from the working motor of the mobile power carrier and the fuel cell for heating, which significantly reduces the energy consumption of electric heating; the layered composite catalyst improves the efficiency of the reforming reaction, the ultra-thin palladium membrane achieves deep purification of hydrogen, and the matching low-pressure buffer tank eliminates the safety risks of high-pressure hydrogen storage; the core structure is universal, and it can be adapted to various mobile power carriers such as automobiles, two-wheeled / three-wheeled motorcycles, mobile robots, and heavy-duty drones by only making minor adjustments to the size, shock-resistant sealing, high-altitude heat dissipation, and small explosion-proof structure. 2. Manufacturing process: The integrated vacuum die-cast shell reduces splicing gaps, the composite catalyst is prepared by layered high-temperature sintering, and the integrated pipeline is vacuum brazed to reduce leakage rate; the assembly process is matched with different carriers to make it lightweight, vibration-resistant and low-pressure compatible, and the multi-condition electronic control system is integrated and calibrated to ensure the consistency of mass production in multiple scenarios. Beneficial effects

[0007] 1. Improved energy efficiency: By coupling the waste heat of the mobile carrier as a heat source for hydrogen production, the energy consumption of electric heating is reduced by more than 35%, and the carrier's range is increased by 12%; 2. Versatile for multiple scenarios and reduced intellectual property costs: A single core structure is compatible with fuel cell vehicles, two-wheeled / three-wheeled motorcycles, mobile robots, and heavy-duty drones. One patent covers all applications, eliminating the need to file multiple divisional patents and significantly reducing patent application and annual maintenance costs. 3. Structural miniaturization: The module integration size can be adjusted according to the space of the carrier, adapting to the confined space of passenger cars and motorcycles, lightweight installation of robots, and the weight limit of drones; 4. High hydrogen purity: After purification by palladium membrane, the hydrogen purity is ≥99.97%, meeting the high-purity hydrogen standards for all types of fuel cells and extending the lifespan of the fuel cell stack; 5. Excellent safety performance: Only a low-pressure buffer tank is installed, with no high-pressure hydrogen storage components. The exhaust gas is recycled for secondary heating, and there is no direct discharge of waste gas for pollution. It is equipped with a graded explosion-proof and leakage interlock shutdown structure, which is suitable for various working conditions such as enclosed rooms, high altitudes, and bumpy roads. 6. Strong mass production stability: Vacuum die-cast shell and vacuum brazed pipeline reduce joint leakage, layered sintering catalyst life is increased by 2 times, preparation process steps are standardized, and various carriers can be adapted for large-scale production. Specific Implementation

[0008] Example 1: Hardware Implementation of Hydrogen Production Module for New Energy Fuel Cell Vehicles The integrated heat insulation shell is made of aluminum alloy vacuum die casting, with a 2mm aerogel heat insulation layer sprayed on the inner wall; the reforming catalyst has a bottom nickel-based support, a middle platinum-rhodium catalyst layer, and a top alumina protective layer; the vehicle waste heat exchange components are connected to the fuel cell heat dissipation circuit and the drive motor heat dissipation circuit respectively, and the electronic control unit collects the vehicle power and road conditions in real time to adjust the waste heat flow; the palladium membrane is 0.03mm thick, and purified hydrogen is introduced into a 0.3MPa low-pressure hydrogen storage buffer tank to directly supply the on-board fuel cell.

[0009] Example 2: Hardware Implementation of a Micro Hydrogen Production Module for a Two-Wheeled Fuel Cell Motorcycle Based on the core structure of Example 1, the overall integrated volume is reduced, anti-vibration sealing gaskets are added to the pipeline, and a small plate-type explosion-proof pressure relief window is provided; the waste heat coupling drive motor supplies waste heat to the reforming reaction, and the weight of the whole machine is controlled within 6kg, which is suitable for the narrow installation space under the footrest of a motorcycle; the electronic control program optimizes the logic of low-speed frequent start-stop operation, and the core structure of catalysis, palladium membrane purification, and waste heat exchange is completely consistent with that of Example 1.

[0010] Example 3: Hardware Implementation of Integrated Hydrogen Production Module for Three-Wheeled Freight Fuel Cell Motorcycle Based on the two-wheeled motorcycle micro-module, the raw material storage volume is increased, and the pipeline fixing support structure is strengthened under bumpy working conditions, making it suitable for heavy-duty three-wheeled long-term continuous driving conditions; the core structures of hydrogen leakage interlock, waste heat reforming, and palladium membrane purification remain unchanged.

[0011] Example 4: Implementation of Lightweight Hydrogen Production Module Hardware for Warehouse / Park Inspection Mobile Robot The entire machine is optimized for lightweight design, eliminating the large heat dissipation duct and equipping it with a silent micro cooling fan; it is equipped with an indoor high-sensitivity hydrogen sensor, which triggers forced ventilation and stops the robot in place upon leakage; the main structure for catalysis, hydrogen production, and hydrogen purification is the same as in Example 1, and the overall weight is controlled to ≤10kg.

[0012] Example 5: Hardware Implementation of a High-Altitude Dedicated Hydrogen Production Module for Long-Endurance Heavy-Duty Industrial UAVs A microchannel micro reforming reactor is adopted, equipped with a dedicated high-altitude low-pressure thermal management system to solve the heat dissipation defects of high-altitude low temperature and low pressure; the overall weight is reduced to adapt to the upper limit of drone payload, and the response speed of the emergency hydrogen cut-off mechanism is improved; the composite catalyst layer, palladium-silver thin film purification structure, and waste heat recovery architecture are completely universal with those of Example 1.

[0013] Example 6: Standardized preparation process of in-situ hydrogen production module S1 housing die casting: aluminum alloy vacuum die casting at 720℃, housing size matched according to carrier type, inner wall sprayed with 2mm~2.5mm aerogel heat insulation layer, cured at 90℃; S2 catalyst sintering: bottom nickel-based support held at 420℃ for 2 hours, middle platinum-rhodium catalyst layer held at 500℃ for 2.5 hours, top alumina protective layer held at 380℃ for 2 hours; S3 Vacuum Brazing: All pipelines and modules are brazed as a whole in a vacuum furnace at 850℃, without segmented joints; S4 graded integrated assembly: The automotive model uses a standard-sized housing; the motorcycle and robot models have smaller housings and are equipped with shock-resistant sealing components; the drone model replaces the microchannel reactor; all sizes use standardized sealing gaskets to secure the housing; S5 operating condition matching and debugging: vehicle gradient temperature rise 200-480℃, whole vehicle waste heat circuit calibration; small carrier matching and debugging corresponding to vibration, low temperature and high altitude operating conditions, hydrogen purity test ≥99.97%, qualified for factory delivery.

Claims

1. An in-situ hydrogen production module adapted to a mobile power vehicle, characterized in that, The system includes a raw material storage module, a waste heat recovery and reforming hydrogen production module, a palladium membrane hydrogen purification module, a low-pressure hydrogen storage buffer tank, a waste heat coupling heat exchange component, a multi-condition intelligent control unit, a hydrogen leakage safety linkage unit, and a wireless communication scheduling unit. The raw material storage module stores liquid hydrogen production raw materials. The waste heat recovery and reforming hydrogen production module utilizes the waste heat generated by the operation of the mobile power carrier to catalytically crack the liquid hydrogen production raw materials to generate crude hydrogen. The palladium membrane hydrogen purification module selectively purifies the crude hydrogen to output high-purity hydrogen. The low-pressure hydrogen storage buffer tank temporarily stores high-purity hydrogen and continuously supplies hydrogen to the fuel cell. The multi-condition intelligent control unit collects real-time operating conditions of the mobile power carrier and adaptively adjusts hydrogen production capacity, waste heat distribution ratio, and electric auxiliary heating output power. The hydrogen leakage safety linkage unit collects hydrogen concentration signals in real time and simultaneously triggers raw material cutoff, forced ventilation, and carrier shutdown safety interlock actions when the concentration exceeds the limit. The wireless communication scheduling unit collects raw material remaining quantity, carrier location, and mileage data, interacts with the cloud platform to match the nearest raw material replenishment station, and issues replenishment reminders.

2. The in-situ hydrogen production module adapted to a mobile power carrier according to claim 1, characterized in that, The mobile power carrier is a new energy fuel cell vehicle; the waste heat coupling heat exchange component couples the waste heat of the vehicle motor and fuel cell stack, and the entire module is arranged in layers on the double-layer chassis support platform of the vehicle.

3. The in-situ hydrogen production module adapted to a mobile power carrier according to claim 1, characterized in that, The mobile power carrier is a two-wheeled fuel cell motorcycle or a three-wheeled fuel cell freight motorcycle; the in-situ hydrogen production module adopts a micro-integrated structure, equipped with anti-vibration sealed pipelines and a small explosion-proof pressure relief structure, which is suitable for the narrow installation space of two-wheeled and three-wheeled vehicles.

4. The in-situ hydrogen production module adapted to a mobile power carrier according to claim 1, characterized in that, The mobile power carrier is a mobile robot for warehouse or park inspection; the in-situ hydrogen production module has a lightweight integrated design, with the whole machine weighing no more than 10kg, and is equipped with a low-noise heat dissipation structure and a forced exhaust system to enhance leakage under indoor working conditions.

5. The in-situ hydrogen production module adapted to a mobile power carrier according to claim 1, characterized in that, The mobile power carrier is a long-endurance, heavy-load industrial drone; the in-situ hydrogen production module is equipped with a high-altitude, low-pressure dedicated thermal management system and uses a microchannel micro reforming reactor inside, making it lightweight and adaptable to the drone's load limits.

6. The in-situ hydrogen production module adapted to a mobile power carrier according to claim 1, characterized in that, The waste heat recovery and reforming hydrogen production module has a built-in composite catalytic carrier; the composite catalytic carrier is formed from top to bottom by a bottom nickel-based porous carrier layer, a middle platinum-rhodium composite catalytic reaction layer, and a top alumina dense protective layer.

7. The in-situ hydrogen production module adapted to a mobile power carrier according to claim 1, characterized in that, The palladium membrane hydrogen purification module is provided with a pre-filter layer, a porous ceramic support substrate, an ultra-thin palladium-silver alloy film, and a metal gas collection and sealing frame arranged sequentially from the outside to the inside along the direction of gas flow.

8. The in-situ hydrogen production module adapted to a mobile power carrier according to claim 1, characterized in that, The multi-condition intelligent control unit includes a condition identification module and four mode switching units. The condition identification module collects vehicle speed, slope, ambient temperature, and load data. The four mode switching units automatically switch between four operating modes—urban congestion, highway cruising, mountain road climbing, and low temperature / high altitude—based on the collected parameters, and differentiate the hydrogen production capacity, waste heat distribution, and braking energy recovery strategies.

9. The in-situ hydrogen production module adapted to a mobile power carrier according to claim 1, characterized in that, The hydrogen leakage safety linkage unit includes a hydrogen concentration sensor array, a linkage control unit, a hydrogen cut-off actuator, and an explosion-proof ventilation actuator. When the hydrogen concentration in the detected space exceeds the safety threshold, the linkage control unit simultaneously controls the hydrogen cut-off actuator to cut off the raw material pipeline, the explosion-proof ventilation actuator to start forced ventilation, and issues a shutdown command to the mobile power carrier power control system.

10. The in-situ hydrogen production module adapted to a mobile power carrier according to claim 1, characterized in that, The wireless communication scheduling unit interacts bidirectionally with the cloud scheduling and analysis module. The cloud scheduling and analysis module combines the remaining mileage of the carrier, the remaining raw materials, the inventory of the supply stations, and the location information to generate the optimal supply route and send audio-visual reminders and navigation guidance to the carrier terminal.