Blind-Bore H2 Manifold Layout for Compact High-Pressure Distribution
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Solution Overview
Problem
Existing high-pressure hydrogen system distributors face issues with excessive space usage due to unused interfaces and inadequate design for sensor units, particularly in tight workspaces, and require careful material selection to handle high pressures.
Innovation Solution
A distributor design with a blind bore main body and interchangeable radial and axial interfaces, optimized for minimized space usage and enhanced fatigue resistance, incorporating a sensor bore for efficient hydrogen distribution and reduced material requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If unused interfaces are sealed with screw plugs, then the distributor can maintain pressure integrity, but excessive space is occupied in tight workspaces
Solution Approach 1:
The invention extracts the sealing function from traditional screw plugs and integrates it directly into the distributor body through a recess design. The recess accommodates a sealing element that closes the blind bore without requiring external plugs, thereby maintaining pressure integrity while eliminating the space-consuming protruding plugs.
Solution Approach 2:
The sealing function is merged with the distributor body structure itself. The recess and sealing element form an integrated closing mechanism that combines the structural housing with the sealing function, eliminating the need for separate screw plug components and reducing overall space occupation.
2Ease of operation
If standard interfaces are used for sensor unit installation, then sufficient space is provided, but more space than required is wasted in tight workspaces
Solution Approach 1:
The invention applies local quality by providing a specifically sized recess at the exact location where sensor unit installation is needed. Rather than using oversized standard interfaces throughout, the recess is precisely dimensioned to accommodate only the required sensor unit, optimizing space utilization while maintaining ease of installation for the specific application.
3Productivity
If a through bore is used for hydrogen distribution, then hydrogen flow is simplified, but fatigue resistance is reduced due to sharp edges
Solution Approach 1:
The invention replaces the sharp edges of a through bore with a rounded blind bore geometry. The curved transition at the end of the blind bore eliminates stress concentration points that would lead to fatigue failure, while still maintaining efficient hydrogen flow distribution to the radial interfaces.
4Adaptability or versatility
If multiple axial interfaces are provided, then versatility is increased, but device complexity and material usage increase
Solution Approach 1:
The invention makes the radial interfaces universal by designing them to accept both input and output functions. Rather than requiring separate axial interfaces for different functions, the radial interfaces can be configured to handle various flow directions and connections, reducing the total number of interfaces needed while maintaining system versatility.
Data Source
Figure 1
Figure 2~3
AI summary
The present invention relates to a distributor (110) for a high-pressure H2 system (100), wherein the distributor (110) comprises a main body (120) with a number of radial and/or axial interfaces (124) for connecting the distributor (110) to a refueling infrastructure (150) and/or the high-pressure H2 system (100), wherein the number of interfaces (124) are interconnected to distribute fluid via a main bore (122) along the main body (120), wherein the main bore (122) in the main body (120) is designed as a blind bore (126). Furthermore, the invention relates to a high-pressure H2 system (100) comprising at least one distributor (110).