Integrated Three-Stage Pressure Regulator for Fewer Leak Sites
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Solution Overview
Problem
Current pressure regulators for hydrogen fuel-cell systems, particularly in drones and cell phone towers, are bulky, unreliable, and prone to leaks due to the need for multiple stages and components, which complicates integration and increases weight, making them unsuitable for high-demand environments.
Innovation Solution
A compact, three-stage pressure regulator with a rectangular body design that integrates all necessary functions, including a high-flow filling port, pressure sensing, and thermal protection, using crest-to-crest wave-springs to reduce size and weight, and featuring a tamper-resistant design to minimize potential leak sites and enhance reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple pressure regulator stages and components are ganged together to achieve required flow and input-pressure range, then the pressure regulation function is improved, but the device weight and complexity increase
Solution Approach 1:
The patent combines multiple pressure regulator stages (first stage, second stage, and third stage regulators) into a single integrated regulator body. This merging of previously separate components into one unified device reduces the overall weight and complexity while maintaining the required pressure regulation functionality across the full input pressure range of 50 to 6,000 psi.
2Reliability
If multiple pressure regulator stages and components are ganged together to achieve required flow and input-pressure range, then the pressure regulation function is improved, but the device complexity and number of leak sites increase
Solution Approach 1:
The patent integrates multiple regulator stages and peripheral functions (cylinder isolation, pressure readings, pressure relief) into a single regulator body with multiple ports. This consolidation reduces the total number of separate components and potential leak sites while achieving the required pressure regulation across 50-6,000 psi input range.
Solution Approach 2:
The regulator body serves multiple functions simultaneously: it acts as a cylinder isolation valve, a multi-stage pressure regulator, a pressure sensing point, and a pressure relief system. This multi-functionality eliminates the need for separate ganged components, reducing overall device complexity and potential leak sites.
3Reliability
If traditional spring designs are used in regulator stages, then the spring provides necessary pressure regulation, but the spring height and overall device size increase
Solution Approach 1:
The patent uses wave-springs (a type of flexible element) in the regulator stages instead of traditional coil springs. These wave-springs provide the necessary pressure regulation function while occupying significantly less axial space, reducing the spring height by at least 50% and thereby reducing the overall device size.
4Weight of moving object
If a compact design is implemented to reduce footprint and mass, then the regulator size is reduced, but the handling and installation difficulty increases due to small component sizes
Solution Approach 1:
The patent integrates all regulator stages and peripheral functions into a single compact regulator body, creating one unified component rather than multiple small separate parts. This integration maintains compact size (approximately half the size of a business card) while improving ease of installation by eliminating the need to assemble and align multiple small 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 provides a lightweight, reliable, and compact pressure regulation system that reduces the number of potential leaks, enhances safety, and supports high-flow rates suitable for applications up to 3 kW, while being tamper-resistant and efficient in size and mass reduction.
Implementation Method 1
Crest-to-crest wave-springs in regulator stages one and two reduce the spring height by ≥50%
Implementation Method 2
A ball seal isolates a valve body's inlet port from its outlet port
Implementation Method 3
A spring biases the ball seal toward the seat
Implementation Method 4
The two dynamic seals in each of the first and second stages are multi-lobed seals, which reduces friction, enhances sealing and extends life
Data Source
AI summary
An integrated pressure regulator is provided with three stages configured to reduce an extreme tank pressure down to a typical working pressure. The regulator is configured to supply a steady working pressure until the tank pressure is reduced to little more than the working pressure itself. Stages of the pressure regulator are integrated into a body and arranged to minimize regulator mass and volume. A thermally-triggered pressure relief device may be included with a triggering time adapted to enhance the safety of smaller cylinders that may be used, e.g., in aerial applications.