Water Separator Throttle Insert for Low Gas Loss Drainage
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Solution Overview
Problem
Existing water separators in fuel cell systems face challenges in efficiently separating water while minimizing gas flow loss and requiring additional seals or fastening means, which increases costs and complexity.
Innovation Solution
A water separator with a flow-conducting throttle element embedded as an insert part in the water outlet, eliminating the need for additional seals or fastening means, and allowing for efficient gas flow limitation by controlling fluid exit through a constricted region, thereby reducing gas loss and enhancing operational stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional seals or fastening means are used to connect the throttle element to the water outlet, then the connection reliability is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The throttle element is integrated directly into the water outlet structure, merging two previously separate components (throttle element and water outlet) into a single unified structure. This eliminates the need for additional seals or fastening means, thereby reducing device complexity while maintaining connection reliability through the integrated design.
Solution Approach 2:
The water outlet is designed to serve multiple functions: it acts as both the outlet for water drainage and as the mounting structure for the throttle element. This multi-functionality eliminates the need for separate fastening mechanisms, reducing overall device complexity while ensuring reliable connection through the combined structural design.
2Reliability
If additional seals or fastening means are used to connect the throttle element to the water outlet, then the connection reliability is improved, but the manufacturing cost increases
Solution Approach 1:
The throttle element and water outlet are merged into a single integrated structure, eliminating the need for separate seals and fastening components. This reduction in part count directly lowers manufacturing costs while maintaining connection reliability through the unified design that eliminates potential failure points at connection interfaces.
Solution Approach 2:
The patent extracts and eliminates the unnecessary intermediate components (seals and fastening means) from the assembly, keeping only the essential functional elements. This simplification reduces manufacturing costs by reducing material requirements, assembly steps, and quality control points while maintaining sufficient connection reliability for the application.
3Device complexity
If the throttle element is embedded with form fit and/or friction fit in the water outlet, then the assembly is simplified and manufacturing cost is reduced, but the connection durability may be compromised
Solution Approach 1:
The throttle element and water outlet are merged into an integrated structure where the throttle element becomes an inherent part of the water outlet geometry. This merging eliminates the need for separate fastening mechanisms, simplifying assembly while ensuring long-term durability through the monolithic design that prevents relative movement and wear between components.
Solution Approach 2:
The patent employs composite construction where the throttle element and water outlet are made from compatible materials that can be permanently bonded or integrated through processes such as injection molding or adhesive bonding. This composite approach ensures both simplified assembly and enhanced durability by creating a unified structure that withstands operational stresses without the need for mechanical fasteners.
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 simplifies assembly, reduces costs, and ensures long-term durability by permanently fixing the throttle element, while effectively limiting gas flow loss and maintaining high operational efficiency even under high loads, particularly in fuel cell systems where fluid speeds approach the speed of sound.
Implementation Method 1
a flow-conducting throttle element which is embodied as an insert part and embedded with form fit and/or friction fit in the water outlet... allowing for efficient gas flow limitation by controlling fluid exit through a constricted region
Implementation Method 2
In the heated insert method, also referred to as heat-set insert method, the insert part is heated and is pressed into a hollow space of the water outlet. The temperature of the insert part melts locally the plastic material of the water outlet. After solidification, the insert part is fixedly connected, in particular with form fit, to the material of the water outlet.
Data Source
AI summary
A water separator including a flow-conducting interior, and a water outlet connected to the flow-conducting interior, the water outlet including a throttle element that is inserted in the water outlet and configured to conduct water flow into the throttle element. The throttle element includes a first channel section including a conical section tapering in a direction of the water flow into the first channel section, a constriction directly connected to an output of the first channel section, the constriction including a cylindrical section, and a cylindrical channel section directly connected to an output of the constriction, the cylindrical channel section having a cross-section that is larger than a cross-section of the constriction.