Fuel Cell Pressure Regulator Piston Design for Leakage Prevention
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Solution Overview
Problem
Existing pressure regulators for fuel cell systems suffer from complex configurations, high costs, poor operational stability, and durability issues due to internal leaks and abrasion in sliding airtight structures, which can lead to safety hazards and system damage.
Innovation Solution
A pressure regulator design featuring a housing with an inlet and outlet port, a piston moving within the housing, and a spring for elastic support, which minimizes the influence of outlet pressure on inlet pressure, eliminating the need for a balance hole and reducing the risk of hydrogen leakage by positioning the spring outside the housing, thus simplifying the structure and enhancing durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a balance hole is added to equalize pressure, then pressure regulation stability is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent removes the balance hole from the housing and relocates its pressure equalization function to the piston structure itself. The piston includes a pressure equalization chamber that communicates with both the inlet and outlet sides, achieving pressure balance without adding complex external structures. This extraction principle simplifies the overall device while maintaining pressure regulation stability.
Solution Approach 2:
The patent combines the pressure equalization function with the piston structure by integrating a pressure equalization chamber into the piston body. This merging of functions eliminates the need for separate balance holes in the housing and reduces the number of components, thereby simplifying the device structure while maintaining reliable pressure regulation.
2Reliability
If sliding airtight structures are used to seal the piston, then sealing effectiveness is improved, but durability deteriorates due to abrasion
Solution Approach 1:
The patent replaces rigid sliding airtight structures with flexible sealing elements including O-rings and elastic sealing rings. These flexible seals conform to the mating surfaces and maintain sealing effectiveness through elastic deformation, significantly reducing wear and improving durability compared to rigid sliding seals.
Solution Approach 2:
The patent changes the material parameters of the sealing elements by using elastic materials with appropriate hardness and compressibility. The sealing rings are made from materials that can deform elastically to maintain contact pressure, adapting to surface irregularities and maintaining sealing effectiveness over extended operational periods without excessive wear.
3Volume of moving object
If the spring is positioned inside the housing, then compactness is improved, but hydrogen leakage risk increases
Solution Approach 1:
The patent extracts the spring from the housing interior and positions it externally on the outlet side of the piston. This relocation eliminates the spring's exposure to high-pressure hydrogen environments, removing the leakage risk pathway while maintaining the compact overall design through optimized external spring mounting.
4Measurement precision
If a complex pressure regulation mechanism is used to achieve precise control, then pressure control precision is improved, but manufacturing cost and complexity increase
Solution Approach 1:
The patent employs a self-regulating pressure control mechanism where the piston automatically balances pressures between inlet and outlet sides through its movable position. The elastic sealing elements self-adjust to maintain sealing contact, and the spring provides automatic force compensation. This self-service approach achieves precise pressure control without complex external regulation systems, significantly reducing manufacturing cost and complexity.
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
The solution provides a stable, high-flow hydrogen supply with improved durability and operational stability, reducing manufacturing costs and complexity, while preventing gas leakage and maintaining precise pressure regulation.
Implementation Method 1
a spring provided in the housing to elastically support the pressure acting portion of the piston
Data Source
AI summary
A pressure regulator for a fuel cell system may include: a housing having an inlet port into which gas is introduced, an outlet port through which gas is discharged, and an regulated pressure chamber connected to an outside through the outlet port; a piston moving up and down in the housing, having a main flow path penetrating through an inside of the housing and a pressure acting portion applying a pressure of gas in the regulated pressure chamber of the housing, and selectively communicating between the inlet port and the regulated pressure chamber of the housing through the main flow path as the piston moves up and down; and a spring provided in the housing to elastically support the pressure acting portion of the piston on an opposite side of the regulated pressure chamber.