Cryogenic Hydrogen Tank and Fuel Cell Thermal Integration
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Solution Overview
Problem
The challenge of using hydrogen as a fuel in aviation applications is hindered by the need for heavy tanks to store hydrogen in gaseous or liquid form and the weight and drag penalties associated with thermal management systems in fuel cell electric propulsion systems, leading to low energy density and high costs.
Innovation Solution
A system utilizing cryogenic and non-cryogenic tanks, heat exchangers, and fuel cells to efficiently store and manage hydrogen, including the use of single-wall tanks and thermal compression to minimize weight and maximize energy density, while also employing a control system to optimize hydrogen usage and reduce mechanical compression needs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If hydrogen is stored in gaseous or liquified form, then adequate fuel storage is achieved, but tank weight increases significantly
Solution Approach 1:
The patent utilizes the phase transition of hydrogen between liquid and gaseous states to resolve the weight-capacity contradiction. Liquid hydrogen storage tanks are designed to allow controlled boil-off and phase change to gaseous hydrogen, which then feeds the fuel cells. This phase transition enables adequate fuel storage capacity while using lighter single-wall tanks compared to high-pressure gaseous storage requirements.
Solution Approach 2:
The system changes the temperature parameter of hydrogen storage from ambient (gaseous) to cryogenic (liquid at -253°C). This parameter change allows hydrogen to be stored in a denser liquid state, reducing tank volume and weight, while the single-wall tank design accepts the thermal challenges of cryogenic storage.
2Reliability
If thermal management systems are added to dissipate fuel cell heat, then fuel cell operation is enabled, but system weight and drag increase
Solution Approach 1:
The patent implements a self-service thermal management approach where the fuel cell cooling system is integrated with the hydrogen boil-off management. The same thermal pathways that manage hydrogen phase changes also provide cooling for the fuel cells, eliminating the need for separate heavy thermal management equipment. The system serves multiple functions through shared infrastructure.
Solution Approach 2:
The thermal management system merges the fuel cell cooling function with the hydrogen liquid-to-gas phase change process. Heat exchangers and thermal pathways are combined to simultaneously cool fuel cells and manage hydrogen boil-off, reducing overall system weight and component count compared to separate systems.
3Weight of moving object
If single-wall tanks are used instead of double-wall vacuum tanks, then tank weight is reduced, but hydrogen boil-off rate increases
Solution Approach 1:
The patent converts the harmful effect of increased boil-off in single-wall tanks into a beneficial resource. The boil-off hydrogen gas is captured and directed to the fuel cells as feedstock, transforming what would be a loss into a useful fuel source. This approach enables the use of lighter single-wall tanks while maintaining overall hydrogen utilization efficiency.
4Use of energy by moving object
If hydrogen is transported as liquid at cryogenic temperatures, then energy density is improved, but thermal management complexity increases
Solution Approach 1:
The thermal management system is designed with multi-functionality to handle both cryogenic liquid hydrogen storage and fuel cell cooling through integrated heat exchangers and thermal pathways. The same infrastructure manages phase changes and temperature control for multiple system components, reducing overall complexity despite the cryogenic requirements.
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 significantly reduces the weight and drag of hydrogen storage and thermal management systems, enhancing the energy efficiency and cost-effectiveness of hydrogen use in aviation, allowing for more viable hydrogen fuel applications by improving mass fraction and energy density.
Implementation Method 1
a heat exchanger, and a gaseous hydrogen reservoir in communication with the heat exchanger
Implementation Method 2
a hydrogen fuel cell in communication with the gaseous hydrogen reservoir and adapted to power the aircraft
Implementation Method 3
a plurality of liquid hydrogen tanks adapted to store liquid hydrogen and a header tank in communication with the liquid hydrogen tanks and adapted to receive the liquid hydrogen from the liquid hydrogen tanks
Data Source
AI summary
A system, method and apparatus are disclosed for enabling the efficient utilization of hydrogen as an emissions-free fuel for airships and other aircraft, including in one embodiment for transporting cryogenic hydrogen as the airship's payload. A system, method and apparatus are disclosed to provide substantially higher net energy density for the propulsion system, optimizing the weight of the cryogenic tanks, utilizing boiloff directly or indirectly for propulsion power, and employing a novel thermal management system both to cool the fuel cells and help regulate the conversion of liquid hydrogen into gas. A system, method and apparatus are also disclosed for ground-based facilities including strategically located depots, optionally supplied by such hydrogen transport vehicles, and utilizing a novel thermal compression system to store, pressurize and distribute hydrogen, including but not limited to gaseous hydrogen pipelines, transport trailers, and dispensing systems.