Three-Stage Pressure Regulator Layout for Compact Hydrogen Supply
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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 regulation stages and components are used to achieve required pressure range and flow capacity, then pressure regulation performance is improved, but device weight and complexity increase
Solution Approach 1:
The patent combines three separate pressure regulation stages into a single integrated regulator body, merging multiple functions (pressure reduction, flow control, relief valve, gauges) into one unified device. This integration eliminates the need for multiple separate components and their associated mounting hardware, reducing overall weight while maintaining the required pressure regulation performance across the 50-6000 psi range.
Solution Approach 2:
The regulator body serves multiple functions simultaneously: it houses three pressure regulation stages, incorporates relief valves, includes pressure gauges, and provides flow control mechanisms. This multi-functionality eliminates the need for separate dedicated components for each function, significantly reducing the total weight and complexity of the system while achieving reliable pressure regulation.
2Reliability
If traditional spring designs are used in regulator stages, then pressure control function is achieved, but regulator height and overall size increase
Solution Approach 1:
The patent employs crested-to-crested wave springs with a curved, wave-like geometry instead of traditional linear coil springs. This curved configuration allows the springs to provide the necessary pressure control function while occupying significantly less axial space, reducing the regulator height by 50% and enabling a more compact overall design.
3Weight of moving object
If aluminum construction is used to reduce mass, then weight is reduced, but manufacturing precision requirements increase
Solution Approach 1:
The regulator utilizes an aluminum alloy construction that combines lightweight properties with enhanced strength and machinability. The specific alloy composition and heat treatment processes enable the aluminum to meet the tight manufacturing precision requirements for internal passages, sealing surfaces, and threaded features while maintaining reduced mass compared to traditional steel constructions.
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 potential leak sites by 46%, enhances safety, and supports high-flow rates up to 3 kW, suitable for hydrogen fuel-cell applications, with improved reliability and reduced assembly time.
Implementation Method 1
Crest-to-crest wave-springs in regulator stages one and two reduce the spring height by 50%
Implementation Method 2
The two dynamic seals in each of the first and second stages are multi-lobed seals, which reduces friction, enhances sealing and extends life
Implementation Method 3
All stages use balls for their flow seals
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.