Hydrogen Tank Switching for Continuous Fuel Cell Refueling

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Solution Overview

Problem

Fuel cell systems in vehicles must be shut down during hydrogen refueling, leading to faster degradation and time-consuming startup, which is undesirable from both a longevity and customer convenience perspective.

Innovation Solution

Implement a continuous hydrogen delivery system with multiple primary and secondary hydrogen fuel tanks, utilizing valves and a controller to manage tank connections, allowing the secondary tank to maintain hydrogen availability to consumers during refueling of primary tanks.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the fuel cell system shuts down during refueling of hydrogen tanks, then the refueling process can be completed safely, but the fuel cell system experiences faster degradation and extended downtime

Engineering Contradiction:

Improvefuel cell system continuityVSAvoidfuel cell shutdown duration

Core Design Contradiction:

ReliabilityVSDuration of action of moving object

Solution Approach 1:

The hydrogen storage system is divided into multiple independent tanks (first plurality and second plurality). During refueling of the first plurality, the second plurality remains connected and operational, segmenting the refueling process so that the fuel cell system does not need to shut down completely, thus maintaining continuity while allowing safe refueling of individual tank groups

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A controller acts as an intermediary to manage the switching between different hydrogen tank groups. It coordinates the disconnection of one group for refueling while maintaining connection and hydrogen supply from the other group, enabling seamless transition without system shutdown

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If the fuel cell system shuts down during refueling, then refueling can proceed, but customer convenience deteriorates due to time-consuming startup

Engineering Contradiction:

Improverefueling safetyVSAvoidsystem startup time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The system maintains continuous hydrogen supply to the fuel cell by switching between multiple tank groups. While one group is being refueled, the other group continues to provide hydrogen, eliminating the need for complete system shutdown and subsequent restart, thus maintaining continuous useful action without time loss

Inventive Principle:

Principle #20Continuity of useful action

3Reliability

If multiple hydrogen tank groups are used to maintain continuous supply during refueling, then fuel cell availability is improved, but system complexity increases

Engineering Contradiction:

Improvehydrogen supply availabilityVSAvoidtank connection system complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The controller performs multiple functions: it manages the switching between tank groups, monitors hydrogen levels, controls valve operations, and coordinates refueling sequences. This multi-functionality consolidates the complexity into a single control unit rather than requiring separate control mechanisms for each function, making the increased system complexity manageable

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS20260009503A1A fuel cell system having a secondary hydrogen storage tank to avoid shutting down the fuel cell system during refueling

Publication Date: 2026.01.08 VOLVO TRUCK CORP

AI summary

A method in a continuous hydrogen delivery system having a plurality of primary hydrogen fuel tanks and at least one primary hydrogen fuel tank of the plurality of primary hydrogen fuel tanks acting as a secondary hydrogen fuel tank during refueling to maintain availability of hydrogen to fuel consumers during refueling of the primary hydrogen fuel tanks. The method further includes responsive to determining that the primary hydrogen fuel tanks is set up for refueling: before the refueling process begins: disconnecting the primary hydrogen fuel tanks from the primary fuel consumer while maintaining a connection of the secondary hydrogen fuel tank to at least one of the primary fuel consumer and the secondary fuel consumer. The method further includes after the tanks have been refueled: connecting the primary and the secondary hydrogen fuel tanks to at least one of the primary fuel consumer and the secondary fuel consumer.