Integrated Fuel Pressure Sensor Eliminates Leak Paths

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Solution Overview

Problem

Existing methods for determining the remaining fuel level in pressurized containers for fuel cells are either expensive or inaccurate, and previous solutions that use pressure sensors increase the risk of fuel leaks due to additional fluid interconnects.

Innovation Solution

A fuel supply system with a pressure sensing unit integrated within the container, which measures internal pressure to accurately estimate the remaining fuel level, reducing the likelihood of leaks by eliminating the need for additional fluid interconnects.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If multiple fluid interconnects are routed to the fuel supply container for pressure sensing, then fuel level measurement capability is improved, but the risk of fuel leaks and system complexity increases

Engineering Contradiction:

Improvefuel level measurementVSAvoidfuel leak risk

Core Design Contradiction:

Measurement precisionVSReliability

Solution Approach 1:

The pressure sensing unit is integrated directly into the fuel supply container structure, combining the fuel storage function with the pressure measurement function. This eliminates the need for separate fluid interconnects to route pressure signals to external sensors, thereby maintaining measurement capability while reducing leak risk points.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The pressure sensing unit is disposed within the interior chamber of the fuel supply container, nesting the sensing mechanism inside the fuel storage space. This allows the sensor to directly monitor fuel pressure without requiring external fluid pathways, reducing the number of potential leak points while maintaining accurate fuel level measurement.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Measurement precision

If multiple fluid interconnects are routed to the fuel supply container for pressure sensing, then fuel level measurement capability is improved, but manufacturing cost increases

Engineering Contradiction:

Improvefuel level measurementVSAvoidfuel supply container cost

Core Design Contradiction:

Measurement precisionVSEase of manufacture

Solution Approach 1:

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The fuel supply container is designed to serve multiple functions: fuel storage and integrated pressure sensing. By incorporating the pressure sensing unit within the container itself, the system eliminates the need for separate sensing components and fluid interconnects, simplifying manufacturing and reducing overall system cost.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Ease of operation

If estimated fuel consumption is subtracted from container capacity to determine remaining fuel, then fuel level information can be obtained, but measurement accuracy is insufficient for precise requirements

Engineering Contradiction:

Improvefuel level information availabilityVSAvoidfuel level accuracy

Core Design Contradiction:

Ease of operationVSMeasurement precision

Solution Approach 1:

The patent replaces the mechanical estimation method (tracking fuel consumption and subtracting from capacity) with a direct pressure-based sensing system. The pressure sensing unit directly measures the pressure of remaining fuel vapor, providing accurate real-time fuel level information without relying on consumption estimates or mathematical calculations.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The pressure sensing unit directly measures the fuel level through pressure detection within the container, making the system self-measuring rather than requiring external calculation based on consumption data. The sensor autonomously provides accurate fuel level information by detecting the pressure state of the remaining fuel vapor.

Inventive Principle:

Principle #25Self-service

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 system provides accurate fuel level estimation while maintaining system integrity, reducing the risk of leaks and operational costs associated with previous methods.

Implementation Method 1

a pressure sensing unit disposed within the interior chamber of the fuel container. The pressure sensing unit is configured to provide an output signal indicative of an amount of fuel remaining in the fuel container

Methodology Applied

Scientific EffectPressure sensing:

Data Source

PatentUS7788048B2Apparatus and method for integrating a fuel supply and a fuel level sensing pressure sensor

Publication Date: 2010.08.31 INTELLIGENT ENERGY LTD

AI summary

A fuel supply includes a fuel container having an interior chamber for containing fuel, and a pressure sensing unit disposed within the interior chamber of the fuel container. The pressure sensing unit is configured to provide an output signal indicative of an amount of fuel remaining in the fuel container.