Integrated Natural Gas Regulator with Thermal Homogenization
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Solution Overview
Problem
Current natural gas vehicle (NGV) systems have complex, large envelope designs with numerous leak points due to non-integrated fuel conditioning equipment, leading to inefficient fuel temperature and pressure management, resulting in suboptimal engine performance and increased emissions.
Innovation Solution
An integrated fuel management system that combines filtration, heating, flow shut-off, pressure regulation, pressure sensing, temperature sensing, and over-pressurization protection within a single module, utilizing a manifold block with a high pressure coalescing filter, heated fuel management module, and isolated engine coolant fluid flow paths for optimized temperature control and reduced leak points.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If non-integrated fuel conditioning equipment is used with fittings and hoses, then the system can be assembled from standard components, but the system becomes complex with large envelope and numerous leak points
Solution Approach 1:
The patent integrates pressure regulation, temperature control, filtration, and flow management functions into a single compact regulator body. This merging of previously separate components (pressure regulator, heater, filters, sensors) eliminates numerous fittings and hoses, thereby reducing leak points and system complexity while maintaining manufacturability through integrated design
2Temperature
If fuel heating is performed only downstream of pressure regulation, then downstream equipment temperature constraints are met, but fuel density range becomes uncontrolled
Solution Approach 1:
The patent implements pre-heating of fuel upstream of the pressure regulator, before pressure reduction occurs. This preliminary heating action ensures that fuel enters the regulator at an elevated temperature, allowing precise control of fuel density after pressure regulation while still meeting downstream temperature requirements. The heated fuel maintains consistent density through the injection system
3Device complexity
If pressure regulation is performed without upstream temperature control, then the system is simpler, but fuel density varies intermittently leading to poor engine performance
Solution Approach 1:
The patent applies preliminary heating upstream of the pressure regulator to control fuel temperature before pressure reduction. This ensures consistent fuel density at the regulator inlet, which maintains stable fuel/air ratios during engine operation. The pre-heating action prevents intermittent density variations that would otherwise degrade engine performance
4Device complexity
If temperature sensing response time is slow, then the system is simpler, but fuel/air ratio accuracy deteriorates during transient fuel demands
Solution Approach 1:
The patent implements upstream temperature control and pre-heating that acts before fuel enters the injection system. By controlling temperature upstream where fuel is stationary or moving slowly, the system establishes proper fuel density before transient demands occur. This preliminary temperature management compensates for slow sensor response during transient operations, maintaining accurate fuel/air ratios
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 integrated system ensures tighter temperature control of natural gas, improving engine performance and reducing emissions by providing consistent fuel/air ratios and minimizing leak points, thus enhancing the durability and reliability of the fuel management system.
Implementation Method 1
for heating of the metal manifold with an externally supplied heat exchange media, a heat exchange media inlet, heat exchange media outlet and a heat exchange media flow path between the heat exchange media inlet and the heat exchange media outlet
Implementation Method 2
The filter housing is in thermally conductive relationship with the manifold such that heat can flow from the manifold to the filter housing
Implementation Method 3
a pressure regulator assembled to the metal manifold and disposed along the fluid flow path for regulating the pressure of the fluid exiting the module
Implementation Method 4
a filter assembly upstream of the pressure regulator, the filter assembly including a metal filter housing and a filter element contained within the metal filter housing
Data Source
AI summary
A fluid pressure regulation and conditioning module comprises a metal manifold including a fluid flow path between fluid inlet outlets, a pressure regulator assembled to the metal manifold and disposed along the fluid flow path for regulating the pressure of the fluid exiting the module, and a filter assembly. The metal manifold further includes, for heating of the metal manifold with an externally supplied heat exchange media, a heat exchange media flow path extending between heat exchange media inlet and outlet. The filter assembly includes a metal filter housing and a filter element contained within the metal filter housing, the metal filter housing being in direct thermal contact with the metal manifold whereby heat from the metal manifold can flow to the metal filter housing for heating of the fluid not only in the metal manifold but also within the metal filter housing.