Active Fuel Cooling System for Hydrogen Refueling
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Fuel cell vehicles face challenges in managing temperature rises during hydrogen refueling, as hydrogen gas expansion heats up the fuel tank, requiring significant pre-cooling energy, and different tank materials have varying temperature thresholds, necessitating customized cooling approaches.
Innovation Solution
An active fuel cooling system with a fuel tank, pipes for refrigerant delivery, and an electronic control unit that adjusts compressor speed based on temperature and mass flow rate to maintain optimal tank temperature, reducing the need for pre-cooling and allowing for the use of lighter materials like plastics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If hydrogen gas is pre-cooled at the fueling station to prevent temperature rise during expansion, then the fuel tank temperature remains within safe thresholds, but significant energy is consumed for cooling
Solution Approach 1:
The cooling action is performed preliminarily by pre-cooling the hydrogen gas at the fueling station before delivery to the vehicle. This advance cooling ensures that when the gas expands during refueling, the temperature rise remains within safe thresholds for the fuel tank materials, while allowing the vehicle to use lighter materials like plastic liners
Solution Approach 2:
The system changes the temperature parameter of the hydrogen gas by actively cooling it to lower temperatures before refueling. This parameter modification allows the gas to withstand the temperature rise during expansion without exceeding the lower temperature thresholds of lighter tank materials, thereby reducing the need for heavy-duty cooling systems at the vehicle
2Weight of moving object
If lighter materials like plastic are used for the fuel tank liner, then vehicle weight is reduced, but the temperature threshold for damage is lower
Solution Approach 1:
The hydrogen gas is pre-cooled at the fueling station before being delivered to the vehicle. This preliminary cooling action ensures that even though the lighter plastic liner has a lower temperature threshold, the gas temperature remains within safe limits during refueling and operation, allowing the use of weight-reducing plastic materials
Solution Approach 2:
The temperature parameter of the hydrogen gas is modified through active cooling to match the lower temperature thresholds of plastic tank liners. This parameter adjustment enables the system to use lighter materials while maintaining safety, as the cooled gas does not exceed the reduced thermal tolerance of plastic components
3Use of energy by moving object
If active cooling system is implemented in the vehicle, then pre-cooling energy requirements are reduced, but device complexity increases
Solution Approach 1:
The cooling function is extracted from the vehicle and relocated to the fueling station infrastructure. By implementing active cooling at the station rather than in the vehicle, the system reduces pre-cooling energy requirements for the vehicle while avoiding the addition of complex cooling equipment to the vehicle itself
Solution Approach 2:
The fueling station acts as an intermediary system that performs the cooling function. This intermediary approach allows the vehicle to benefit from pre-cooled gas without needing its own complex cooling system, as the station infrastructure serves as the mediating cooling source
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 system reduces energy consumption, allows for faster refueling, and extends fuel tank lifespan by actively managing temperature, enabling the use of lighter materials and minimizing thermal cycling, while preventing nozzle freeze and reducing costs.
Implementation Method 1
heat exchange between gaseous fuel tank and heat transfer medium
Implementation Method 2
one or more pipes positioned adjacent to, in contact with, or within the fuel tank
Implementation Method 3
compressor for pumping the refrigerant through the one or more pipes
Implementation Method 4
refrigerant that cools the fuel tank
Implementation Method 5
the hydrogen gas exhibits a negative Joule-Thomson effect. That is, the hydrogen gas increases in temperature or 'heats up' when the hydrogen gas expands
Data Source
AI summary
Methods, systems, and apparatus for an active fuel cooling system (“fuel cooling system”). The fuel cooling system includes a fuel tank configured to store fuel. The fuel cooling system includes one or more pipes positioned adjacent to, in contact with, or within the fuel tank that are configured to deliver refrigerant that cools the fuel tank. The fuel cooling system includes a compressor for pumping the refrigerant through the one or more pipes to cool the fuel stored within the fuel tank. The fuel cooling system includes an electronic control unit connected to the compressor and configured to operate the compressor to pump the refrigerant through the one or more pipes to cool the fuel stored in the fuel tank.