Hydrogen Supply Manifold for Fuel Cell Systems
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Fuel cell vehicle systems face challenges with hydrogen leakages, increased costs, and complex assembly due to numerous connecting parts and sealing requirements in the hydrogen supply system, which complicates maintenance and air-tightness testing.
Innovation Solution
A compact hydrogen supply manifold system with a recirculation line and ejector unit that includes a first pressure manifold, nozzle, control valve, and second pressure manifold, which reduces the number of connecting parts and enhances assembly efficiency by using a metal and polymer material combination and insulation for heat management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple valves and regulators are used to decrease hydrogen pressure, then hydrogen supply control is improved, but the number of connecting parts increases leading to more hydrogen leak risks
Solution Approach 1:
The patent combines multiple pressure control functions (valves and regulators) into a single integrated pressure control device that directly connects to the hydrogen tank. This merging eliminates the need for multiple separate components and their associated connecting parts, thereby reducing hydrogen leak risks while maintaining effective pressure control.
Solution Approach 2:
The pressure control device performs multiple functions including pressure regulation, flow control, and safety valve operations within a single unified structure. This multi-functionality reduces the overall number of components needed in the hydrogen supply system while ensuring reliable pressure management.
2Reliability
If multiple pipes and manifolds are used to connect hydrogen components, then hydrogen supply distribution is improved, but the number of sealing members increases leading to higher costs and deteriorated productivity
Solution Approach 1:
The patent integrates multiple manifold functions into a single molded manifold structure that distributes hydrogen to multiple components. This unified manifold eliminates the need for multiple separate pipes and connection joints, reducing the number of sealing members required while maintaining effective hydrogen distribution to all necessary components.
Solution Approach 2:
The manifold is constructed using composite materials that combine structural integrity with integrated flow distribution channels. This allows the manifold to perform multiple distribution functions within a single component, reducing assembly complexity and sealing requirements.
3Ease of operation
If fitting and tubing are used to configure gas supply line, then flexibility in assembly is improved, but connecting portions increase making automatic assembly difficult
Solution Approach 1:
The patent uses integrated molded connections that combine the functions of fittings, tubing, and connection interfaces into unified structural elements. These integrated connections maintain the necessary flexibility for assembly while providing standardized interfaces that can be automatically assembled using robotic systems, thereby enabling automation.
4Adaptability or versatility
If more connecting portions are present in hydrogen supply system, then system adaptability is improved, but air-tightness test time and cost increase
Solution Approach 1:
The patent reduces the total number of connecting portions by integrating multiple functions into unified components. This reduction in connection points directly decreases the time required for air-tightness testing while maintaining the system's adaptability through intelligent design of the integrated components that can accommodate different configuration needs.
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 minimizes hydrogen leakages, reduces system complexity, and simplifies maintenance by creating a more compact structure that maintains hydrogen pressure and efficiency while preventing electrolyte film drying through recirculation of exhaust gases.
Implementation Method 1
a venturi and a diffuser in a direction that the fuel gas is injected from the nozzle, sucks exhaust gas of the stack, mixes the exhaust gas and the fuel that is injected from the nozzle
Implementation Method 2
a venturi and a diffuser in a direction that the fuel gas is injected from the nozzle, sucks exhaust gas of the stack, mixes the exhaust gas and the fuel that is injected from the nozzle, and emits the mixed gas through the venture and the diffuser
Data Source
AI summary
A fuel cell system having a hydrogen supply manifold is provided and includes a stack that uses supplied air and fuel gas to generate electricity. A recirculation line recirculates a fuel gas, to an inlet of the stack. An ejector unit is disposed on the recirculation line, supplies fresh fuel gas, and circulates the recirculated gas. The ejector unit includes a middle pressure manifold in which a nozzle mounting portion is formed and a supply passage to transmit fuel gas to the nozzle mounting portion. A control valve is disposed on the middle pressure manifold to adjust fuel supplied to the stack. A nozzle is engaged with an end portion of the nozzle mounting portion to inject fuel gas supplied through the supply passage. Additionally, a low pressure manifold is engaged with the middle pressure manifold to suction and mix exhaust gas of the stack.