Additive Monolithic Fuel Cell Injection Unit
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Solution Overview
Problem
Modern hydrogen fuel cell injection units are bulky, prone to hydrogen leakage due to the use of elastomeric seals and complex forging techniques, leading to fuel loss and increased emissions.
Innovation Solution
An additively manufactured hydrogen fuel cell injection unit with a noise attenuation volume, integrated heat exchanger featuring a triply-periodic minimal surface lattice, and a venturi tube design that eliminates the need for elastomeric seals by forming a single, integral unit with curved surfaces, reducing hydrogen leakage and improving efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional forging techniques and elastomeric seals are used to connect components, then the injection unit can be assembled with standard manufacturing methods, but hydrogen leakage occurs through seals and connectors leading to fuel loss
Solution Approach 1:
The patent merges multiple separate components (heat exchanger, noise attenuator, injector, connectors) into a single monolithic body manufactured via additive manufacturing. This eliminates all elastomeric seals and mechanical connectors that previously caused hydrogen leakage, achieving complete sealing without traditional joining methods.
Solution Approach 2:
The noise attenuator is designed with an internal porous lattice structure that provides acoustic damping while maintaining hydrogen flow pathways. The porous design allows noise reduction functionality without creating seal interfaces that would leak hydrogen.
2Device complexity
If multiple separate components are used for heat exchange and noise attenuation, then each component can be optimized independently, but the overall unit becomes bulky and complex
Solution Approach 1:
The heat exchanger channels, noise attenuator lattice, injector pathways, and hydrogen flow channels are merged into a single integrated monolithic body. This consolidation eliminates the need for multiple separate components and their associated connectors, significantly reducing overall unit volume and complexity.
Solution Approach 2:
The heat exchanger channels are nested within the porous lattice structure of the noise attenuator. The injector pathways are integrated within the same monolithic structure, creating a nested arrangement where multiple functions occupy overlapping spatial volumes, reducing the overall footprint.
3Temperature
If hydrogen is heated using a separate heat exchanger, then the hydrogen temperature can be controlled, but the unit requires additional components and connection points for heating
Solution Approach 1:
The heat exchanger is merged into the monolithic body with channels directly integrated into the structure. Hydrogen flows through these embedded channels where it is heated by thermal conduction from the surrounding porous lattice, eliminating the need for separate heat exchanger components and their associated seals.
Solution Approach 2:
The mechanical connection system (seals, bolts, flanges) is replaced with a thermal field system where heating is achieved through thermal conduction through the monolithic structure itself. The porous lattice acts as both structural support and thermal transfer medium, eliminating mechanical interfaces.
4Loss of substance
If residual hydrogen is not recaptured, then the system operates simpler without recycle pathways, but hydrogen is lost through emissions
Solution Approach 1:
The recycle pathway is merged into the monolithic body as integrated flow channels. Residual hydrogen is recaptured through the same porous lattice structure that provides noise attenuation, and redirected through embedded channels back to the injector, eliminating the need for separate recycle system components.
Solution Approach 2:
The porous lattice structure serves multiple functions simultaneously: noise attenuation, structural support, thermal transfer, and hydrogen recapture pathways. The monolithic body acts as both the housing and the functional flow management system, eliminating dedicated recycle components.
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 results in a more compact, efficient fuel cell injection system with reduced hydrogen leakage, improved hydrogen distribution, and enhanced performance by recapturing residual hydrogen, thereby increasing the overall efficiency of hydrogen vehicles.
Implementation Method 1
a heat exchanger integrated within the noise attenuation volume and including a triply-periodic minimal surface (TPMS) lattice of unit cells arranged therein, the TPMS lattice being configured to heat hydrogen flowing therethrough
Implementation Method 2
the ejector nozzle surrounded by a gap, the gap leading to a recycle path inlet of the body for recapturing residual hydrogen proximate the recycle path inlet
Data Source
AI summary
Aspects of integrated hydrogen fuel cell injection units herein use additive manufacturing to form a single part. A space between a body and an ejector nozzle/venturi tube system forms an attenuation volume. The heat exchanger is integrated within the attenuation volume, saving space. The ejector nozzle/venturi tube, and the stack anode inlet to the fuel cell, are arranged through the heat exchanger and allow an injector at the base of the body to selectively emit hydrogen into the anode of the fuel cell. This architecture obviates the need for many O-rings and bolts used in present fuel injection systems using existing manufacturing techniques that may be unduly large and unwieldy and that may cause hydrogen leakage at different connection points.