Mechanical Check Valve for Gas Tank Refueling
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Solution Overview
Problem
Existing refueling systems for gaseous media face challenges in automatically terminating the refueling process when the tank is full, especially when infrared interfaces are dirty, damaged, or not functioning correctly, and there is a risk of igniting explosive gases with electromagnetically actuated valves.
Innovation Solution
A purely mechanical check valve design that includes a piston and end pieces with a sealing seat, a flow guide device, and an elastic element to ensure the valve closes at a defined pressure, ignoring pressure fluctuations and preventing further refueling by narrowing the flow channel as pressure increases, ensuring optimal filling and safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If electromagnetically actuated valves are used to automatically terminate refueling, then refueling can be automatically controlled, but there is a risk of igniting explosive gaseous medium due to sparking
Solution Approach 1:
The patent replaces electromagnetic actuation with a purely mechanical valve mechanism. The valve uses a piston that responds to pressure differential across the valve body - when the tank pressure exceeds the supply pressure by a certain margin, the piston automatically closes the valve opening, terminating refueling without any electrical components that could cause sparks.
Solution Approach 2:
The valve system is self-regulating through the piston mechanism. The piston automatically positions itself based on the pressure difference between supply and tank sides, closing the valve when the tank is sufficiently filled (when tank pressure exceeds supply pressure by the spring force equivalent). This eliminates the need for external control systems, sensors, or power sources.
2Reliability
If mechanically actuated valves are designed to close automatically at defined pressure, then refueling termination is achieved, but pressure fluctuations on the supply side may cause premature or delayed closure
Solution Approach 1:
The spring element is pre-compressed during valve manufacturing or initial setup, establishing a predetermined force that corresponds to the desired pressure differential for valve closure. This pre-set spring force creates a hysteresis effect where the valve closes only when tank pressure exceeds supply pressure by a specific margin, ignoring smaller pressure fluctuations that would otherwise cause premature closure.
Solution Approach 2:
The spring element acts as a cushioning mechanism that absorbs pressure fluctuations. By designing the spring with appropriate stiffness and pre-compression, the system tolerates normal pressure variations without triggering valve closure, while still responding reliably when the tank reaches its maximum fill level and tank pressure significantly exceeds supply pressure.
3Productivity
If the flow channel is kept open for fast refueling, then refueling speed is improved, but the valve cannot effectively narrow the flow channel to signal full tank condition
Solution Approach 1:
The valve transition from open to closed state is dynamic rather than static. The piston moves continuously in response to changing pressure differential, and the spring force provides a progressive resistance. This dynamic response allows the valve to maintain an open state with high flow capacity during normal refueling, then smoothly transition to closed state when the pressure differential exceeds the spring force, providing a clear and reliable closure signal.
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 mechanical check valve effectively and safely terminates refueling by closing at a set pressure, ensuring faster refueling and optimal tank filling without electrical components, suitable for gases like hydrogen, methane, and their mixtures, while maintaining safety from pressure variations.
Implementation Method 1
The piston (12) is designed in such a way that, viewed from the supply side, the front side of the piston and the front side of the second end piece (14) form a sealing seat (14.7) when seen from the tank side upon contact with one another. This sealing seat (14.7) closes a passage opening (14.3) set blocking pressure and ignores and closes a further increase in pressure, pressure decrease or any pressure fluctuations on the inlet side of the second end piece (14), e.g. pressure fluctuations caused by the refueling system.
Data Source
Figure 1
Figure 2~3
AI summary
A shut-off valve (1) for filling a tank with a gaseous medium, comprising a valve housing (11) wherein a piston (12) is arranged to be axially displaceable in the valve housing (11), wherein the piston (12) has an axially through bore (12.2), a first end piece (13) of the valve housing (11) wherein the first end piece (13) has an outlet opening (13.1) flow-connected to the axially through bore (12.2) of the piston (12), a second end piece (14) of the valve housing (11) wherein the second end piece (14) has an inlet opening (14.3) flow-connected to the axially through bore (12.2) of the piston (12), wherein a first end face (12.5) of the piston (12) and a first end face (14.7) of the second end piece (14) of the valve housing (11), upon contact form a sealing seat, wherein a flow guide device (S) is located downstream of the inlet opening (14.3) of the second end piece (14), wherein the flow guide device (S) comprises at least one radially outwardly leading bore (14.4) of the second end piece (14) flow-connected to the inlet opening (14.3) of the second end piece (14) and a chamber (K), wherein the chamber (K) is formed between the piston (12) and the second end piece (14), wherein a flow guide device (S) is formed downstream of the inlet opening (14.3) of the second end piece (14), wherein the flow guide device (S) comprises at least one radially outwardly leading bore (14.4) of the second end piece (14) flow-connected to the inlet opening (14.3) of the second end piece (14) and a chamber (K), wherein the chamber (K) is formed between the piston (12) and the second end piece (14), so that the gaseous medium from the inlet opening (14.3) via at least one radially outwardly arranged bore (14.4) of the second end piece (14) can flow into the chamber and the gaseous medium in the chamber (K) is directed from the outside to the inside in the direction of the first end face (14.7) of the second end piece (14) and a deflection of the gaseous medium in the direction of the axially through bore of the piston (12) is caused.