High-Pressure Regulator Volume Segmentation for Leak Prevention
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Solution Overview
Problem
High-pressure regulators in hydrogen fuel cell electric vehicles experience internal leaks due to pressure differences between the front and rear end portions, leading to gas leakage and safety risks when the gas storage tank is shut off, as existing pressure regulation methods fail to effectively manage pressure differences and prevent leaks.
Innovation Solution
A pressure control method involving a pressure sensor and control unit to measure and regulate pressure differences by adjusting the volume ratio between the front and rear end portions of the high-pressure regulator, using a high-pressure shut-off valve with a bobbin and plunger mechanism to maintain airtightness and prevent excessive pressure buildup.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the gas storage tank is shut off, then the high-pressure fuel line retains high-pressure gas, but this causes excessive pressure to be applied to the high-pressure sealing portion inside the high-pressure regulator, leading to micro leaks
Solution Approach 1:
The high-pressure regulator is divided into front end portion and rear end portion with separate volume control. The front end volume is reduced to 1/3 or less of the rear end volume, segmenting the pressure management zones to prevent excessive pressure buildup at the sealing portion while maintaining necessary pressure for regulator operation.
Solution Approach 2:
The volume ratio between front end portion and rear end portion is changed as a key parameter. By controlling the front end volume to be 1/3 or less of the rear end volume, the pressure distribution parameters are optimized to reduce the pressure difference across the sealing portion, preventing micro leaks while maintaining reliable sealing.
2Reliability
If the front end volume is reduced to 1/3 or less of the rear end volume, then the pressure difference is minimized and micro leaks are prevented, but the device complexity increases due to volume regulation mechanism
Solution Approach 1:
The high-pressure shut-off valve automatically regulates the front end volume to be 1/3 or less of the rear end volume based on pressure conditions. This self-service mechanism maintains the optimal volume ratio without requiring external control systems, achieving reliable internal airtightness while avoiding excessive device complexity.
3Device complexity
If conventional high-pressure regulator design is used, then the structure is simple, but high-pressure gas remains excessively in the high-pressure fuel line causing pressure to increase toward the outlet port, leading to gas leakage and safety risks
Solution Approach 1:
The regulator structure is segmented into front end portion and rear end portion with distinct volume characteristics. The front end portion volume is controlled to be 1/3 or less of the rear end volume, creating separate pressure management zones that prevent excessive pressure buildup and gas leakage while maintaining a relatively simple overall structure.
Solution Approach 2:
The volume ratio parameter between front end and rear end portions is changed to 1:3 or less. This parameter change optimizes pressure distribution to prevent gas leakage and safety risks while avoiding excessive structural complexity in the regulator design.
Data Source
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AI summary
The present invention provides a pressure control method for a high-pressure regulator to prevent internal leak, and the high-pressure shut-off valve so as to minimize an internal leak, due to high-pressure gas remaining in a high-pressure fuel line when a valve of a gas storage tank is shut off, caused by a pressure difference between a front end portion and a rear end portion of the high-pressure regulator introducing or discharging high-pressure gas. Accordingly, the convenience for connecting work is provided, the high safety is ensured, and the high-pressure regulator is used with the high reliability.