Integrated Pressure Regulator Relief Valve Design
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Solution Overview
Problem
Conventional gas regulators for hydrogen fueling systems lack effective overpressure relief mechanisms, which can lead to equipment damage and leaks, particularly critical in vehicles transporting people.
Innovation Solution
A gas regulator with an integrated relief valve that directs overpressure to a leak circuit, featuring a piston and valve stem design with return members to automatically open communication between pressure chambers and a leakage circuit when downstream pressure exceeds a threshold, ensuring safety and compactness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional gas regulator is used without an integrated relief valve, then the device complexity is reduced and manufacturing is easier, but the reliability decreases due to lack of overpressure protection
Solution Approach 1:
The relief valve is integrated into the regulator body, merging two previously separate functions (pressure regulation and overpressure relief) into a single unified device. This eliminates the need for separate relief valve components and reduces overall system complexity while improving reliability through built-in protection.
Solution Approach 2:
The regulator body is designed to perform multiple functions: primary pressure regulation through the main valve mechanism and secondary overpressure relief through the integrated relief valve. This multi-functionality approach allows a single component to provide both regulation and safety protection, resolving the contradiction between simplicity and reliability.
2Reliability
If a separate relief valve system is added to the regulator, then overpressure protection is improved, but the device becomes bulkier and more complex
Solution Approach 1:
The relief valve mechanism is merged with the regulator body structure, utilizing existing internal chambers and passages. The relief valve shares the same housing and internal geometry as the main regulation mechanism, eliminating the need for additional external components and reducing overall device volume while maintaining safety functionality.
Solution Approach 2:
The relief valve components are nested within the existing regulator structure. The relief valve seat and valve element are positioned within the regulator body's internal geometry, utilizing available space efficiently. This nesting approach allows the relief function to be accommodated without increasing the external dimensions of the regulator.
3Reliability
If the relief valve opens at lower pressure thresholds, then safety is improved by preventing seal damage, but gas loss increases through the leak circuit
Solution Approach 1:
The leak circuit serves as an intermediary pathway that safely directs excess gas away from sensitive components. Rather than allowing uncontrolled leakage that could damage seals, the intermedi ary leak circuit provides a controlled escape route for overpressure gas, protecting seals while managing gas loss in a predictable manner.
Solution Approach 2:
The relief valve is calibrated to open at specific pressure thresholds before damage can occur to seals and other components. This beforehand activation prevents the harmful buildup of excessive pressure, cushioning the system against potential damage while managing gas loss through controlled early release.
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 reliable pressure regulation and safety by preventing overpressure damage, ensuring reliable operation between high and low pressure ranges, and includes a safety system for manual reset in case of pressure drops, enhancing the safety and reliability of gas filling and withdrawal devices.
Implementation Method 1
a first return member compressed between the piston and the upstream body by biasing the piston in the direction of the downstream body
Implementation Method 2
a second return member compressed between the piston and a plate integral with the valve stem biasing the stem valve, relative to the piston, in the direction of pressing the relief valve against the relief seat
Implementation Method 3
on the gas from the low-pressure chamber presses on one side
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
Pressure regulator (6) comprising: – a downstream body (61) delimiting a low-pressure chamber (613); – an upstream body (63) delimiting a high-pressure chamber (66) and bearing a relief-valve seat (652); – a mobile piston (62) having an internal passage (620) having an upper end forming a relief-valve seat (621) and a lower end opening onto an intermediate chamber (624) connected to a leakage circuit; – a tubular valve stem (67) passing through the internal passage of the piston and an internal passage of the upstream body, having an upper end forming a pressure-relief valve shutter (671) and a lower end forming a regulating valve shutter (672) able to come to bear against the relief-valve seat; – a first return member (68) compressed between the piston and the upstream body and urging the piston towards the downstream body; – a second return member (69) compressed between the piston and a plateau (673) attached to the valve stem, urging this stem in the direction of pressing the pressure-relief valve shutter firmly against the relief-valve seat.