Conformable Fuel Tank Thermal Recirculation for Faster Filling

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Solution Overview

Problem

Conformable fuel tanks for alternative fuels like hydrogen and natural gas face challenges in reducing fill-up time due to high fuel temperatures, which are not adequately addressed by existing systems that rely on fuel recirculation or alternating fuel flow methods.

Innovation Solution

A system with a multi-flow inlet and recirculation passages equipped with pumps to actively manage fuel temperature, using a coolant passage to dissipate heat and recirculate fuel from hotter portions to the inlet, thereby maintaining or increasing fill-up rates while keeping fuel temperatures below a threshold.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If fuel is recirculated from the end of the tank to mix with incoming fuel, then fuel temperature is reduced, but fill-up rate decreases

Engineering Contradiction:

Improvefuel temperatureVSAvoidfill-up rate

Core Design Contradiction:

TemperatureVSProductivity

Solution Approach 1:

The fuel tank is divided into multiple zones with separate recirculation passages for different regions. The system segments the recirculation flow paths to allow simultaneous cooling of different tank regions without compromising overall fill-up rate, as each segment operates independently with its own pump and coolant passage configuration.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system pre-cools fuel before it enters the storage vessels by routing it through coolant passages in the inlet region. This preliminary cooling action reduces the thermal load on recirculated fuel, allowing faster fill-up rates while maintaining temperature control.

Inventive Principle:

Principle #10Preliminary action

2Productivity

If fuel fill-up rate is increased, then time is saved, but fuel temperature increases beyond threshold

Engineering Contradiction:

Improvefill-up rateVSAvoidfuel temperature

Core Design Contradiction:

ProductivityVSTemperature

Solution Approach 1:

A coolant fluid is introduced as an intermediary substance to transfer heat away from the fuel during high-rate filling. The coolant passages in the inlet region and recirculation system act as a thermal mediator, allowing rapid fuel filling while maintaining temperature through active heat exchange with the coolant.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The system dynamically adjusts recirculation flow rates and coolant flow rates as parameters to maintain fuel temperature within thresholds during high-speed filling. By changing these operational parameters in real-time, the system achieves both high fill-up rates and temperature control.

Inventive Principle:

Principle #35Parameter changes

3Loss of time

If alternating fuel flow through multiple ports is used, then fill-up time is reduced, but thermal management becomes insufficient

Engineering Contradiction:

Improvefill-up timeVSAvoidfuel temperature

Core Design Contradiction:

Loss of timeVSTemperature

Solution Approach 1:

The system merges multiple functions into the recirculation system: it combines the alternating flow capability with active recirculation pumping and integrated coolant cooling. This unified approach allows simultaneous achievement of reduced fill-up time and adequate thermal management through coordinated operation of multiple subsystems.

Inventive Principle:

Principle #5Merging (Combining)

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 approach effectively reduces fuel temperatures and increases fill-up rates, saving time for vehicle operators by actively managing thermal loads within the fuel tank.

Implementation Method 1

a first recirculation passage having a first pump and a second recirculation passage having a second pump, wherein each of the first and second recirculation passages are fluidly coupled to a conduit upstream of the multi-flow inlet

Methodology Applied

Scientific EffectFluid recirculation:

Implementation Method 2

The coolant passage may be in thermal contact with hotter portions of the conformable fuel tank, such as portions distal to an inlet port where the fuel is hotter due to a heat of compression

Methodology Applied

Scientific EffectHeat dissipation:

Implementation Method 3

recirculating fuel from an end of the fuel tank, distal to an inlet of the fuel tank, as the fuel tank fill-up occurs. In this way, hot fuel in the end of the fuel tank may mix with cool fuel entering through the inlet of the fuel tank

Methodology Applied

Scientific EffectFuel mixing:

Data Source

PatentUS11738636B2Methods and systems for conformable fuel tank

Publication Date: 2023.08.29 FORD GLOBAL TECH LLC

AI summary

Filling methods and systems are provided for a conformable fuel tank. In one example, a system comprises an active thermal management arrangement for the conformable fuel tank. The active thermal management arrangement comprises one or more recirculation passage for mixing hot fuel distal to an inlet port of the conformable fuel tank with cool incoming fuel flowing to the inlet port.