Component for a vehicle, vehicle per se and method for producing the component

Abstract

A component for a vehicle that can be operated with a combustible operating gas has a first component element which has or forms an at least partially open or free cavity, and a second component element which is designed as a displacement component and at least partially fills the cavity of the first component element.

Claims

1. A vehicle component of a hydrogen vehicle or a natural gas vehicle that is operated with a combustible operating gas, comprising: a first component element which has or forms an at least partially open or free cavity, wherein the combustible operating gas in a surrounding of the first component element is enterable and collectable in the cavity; and a second component element which is formed as a displacement element and which at least partially fills the cavity of the first component element such that no free residual volume in the cavity results or such that combustible operating gas collected in a free residual volume in the cavity is no longer combustible.

2. The vehicle component according to claim 1, wherein the free residual volume: (i) amounts to less than 10% of a volume of the cavity of the first component element, and/or (ii) encompasses less than 2000 cm.sup.3.

3. The vehicle component according to claim 1, wherein the free residual volume: (i) amounts to less than 1% of a volume of the cavity of the first component element, and/or (ii) encompasses less than 500 cm.sup.3.

4. The vehicle component according to claim 1, wherein the second component element is formed with or from at least one of: a foam material, a plastics material, a polyurethane material, a polystyrene material, a mechanically and/or acoustically damping material, a material which absorbs mechanical work and/or mechanically supports the first component element, a material with low flammability or a non-flammable material, a material which is inert with respect to the operating gas and/or an atmosphere of the operating environment, a material which is dimensionally stable during installation, a material which is not dimensionally stable during installation, or a material which is liquid and which cures in air or in a process gas.

5. The vehicle component according to claim 1, wherein the second component element is designed to be reversibly installable.

6. The vehicle component according to claim 1, wherein the second component element is releasably fastened in the cavity of the first component.

7. A hydrogen vehicle or a natural gas vehicle, comprising: an assembly which can be driven with a combustible operating gas or with an element containing the combustible operating gas gas; and a component according to claim 1.

8. The vehicle according to claim 7, wherein the component is formed at least as part of a body, as part of a space of the assembly which is operable with the combustible operating gas, as part of an engine compartment or in a vicinity of an engine, and/or as part of a tank or in a vicinity of the tank of the combustible operating gas.

9. A method for producing a component of a hydrogen vehicle or a natural gas vehicle that is operated with a combustible operating gas, the method comprising the steps of: providing a first component element, which has or forms an at least partially open or free cavity, wherein the combustible operating gas in a surrounding of the first component element is enterable and collectable in the cavity; providing a second component element or a preform thereof; attaching the second component element or the preform on and/or in the first component element such that the second component element or the preform functions so as to be configured as a displacement element and at least partially fills the cavity of the first component element such that no free residual volume in the cavity results or such that combustible operating gas collected in a free residual volume in the cavity is no longer combustible.

10. The method according to claim 9, wherein a conventional vehicle component is provided as the first component element.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 shows, in a partially sectional side view, a conventional component in conjunction with a conventional vehicle, which can function as a starting point for the concept according to the invention.

(2) FIGS. 2 and 3 show, in partially sectional side views, two embodiments of the component according to the invention.

(3) FIG. 4 shows, in a partially sectional side view, a conventional component in an operating state in which a certain quantity of an operating gas or operating gas mixture has collected in a cavity.

DETAILED DESCRIPTION OF THE DRAWINGS

(4) Below, exemplary embodiments and the technical background of the invention will be described in detail with reference to FIGS. 1 to 4. Identical and equivalent parts and elements, and parts and elements of identical or equivalent action, will be denoted by the same reference designations. The detailed description of the denoted parts and elements will not be given at every case of their occurrence.

(5) The illustrated features and further characteristics may be isolated from one another in any form and combined with one another as desired without departing from the core of the invention.

(6) FIG. 1 shows, in a partially sectional side view, a conventional component 10′ in conjunction with a conventional vehicle 1′, which can function as a starting point for the concept according to the invention.

(7) Here, the conventional component 10′ of the conventional vehicle 1′ comprises exclusively a first component element 11 which, in a particular region, forms a cavity 15 which is at least partially open and/or opened to the surroundings, such that operating gas 20 released from the surroundings can enter and collect in the cavity, as illustrated in conjunction with FIG. 4.

(8) FIG. 4 thus shows, in a partially sectional side view, a conventional component 10′ in an operating state in which a certain quantity of an operating gas 20 has collected in the cavity 15, wherein the collected quantity of operating gas 20 may, owing to the absolute quantity or owing to the concentration, be critical with regard to risks associated with a combustion, deflagration or explosion.

(9) In order to reduce or eliminate the risks associated therewith, the present invention as illustrated by way of example in conjunction with FIGS. 2 and 3 was devised.

(10) FIGS. 2 and 3 show two embodiments of the component 10 according to the invention in partially sectional side views.

(11) By contrast to the conventional component 10′ and state illustrated in FIG. 1, in which the cavity 15, which can also be referred to as the interior of the first component element 11, is completely free and unfilled, such that, in the hazardous case, the state illustrated in FIG. 4 with complete filling with the operating gas 20 can occur, it is the case in FIGS. 2 and 3 that the cavity 15 of the first component element 11 is, in FIG. 2, filled partially, specifically apart from a residual volume 16, by the second component element 12 composed of the displacement material 13. In the embodiment as per FIG. 3, the filling is even complete or substantially complete, such that a free residual volume 16 is no longer present or is at least immeasurable.

(12) The structure according to the invention, specifically the creation of a component 10 composed of a first component element 11 with cavity 15 and the partial or complete filling of the cavity 15 with a second component element 12, may also be used as a retrofit kit, for example in the form of a transition from the conventional state as per FIG. 1 by partial or complete filling of the cavity 15 with a displacement material 13, specifically in order to attain the final states according to the invention shown in FIG. 2 or 3.

(13) These and further features and characteristics of the present invention will be discussed in more detail on the basis of the following explanations.

(14) In the context of the present invention, consideration has been given to so-called gas vehicles. A gas vehicle is to be understood to mean a vehicle 1 in which at least one assembly is operated with a gas 20, for example hydrogen or natural gas or the like. The assembly need not be a part of the vehicle drive, although this may be a possible main use. In this context, the vehicle may then also be referred to as a hydrogen vehicle or natural gas vehicle depending on the driving gas or operating gas 20.

(15) During the operation of gas vehicles, gas leakages are particularly critical if the operating gas 20, for example in the context of a fuel, that is to say for example H.sub.2 or NG, collects in cavities of the vehicle 1 and in particular mixes with the ambient gas, for example air, because a fire may develop, or even an explosion may occur, if a critical concentration and/or quantity forms.

(16) In order to identify critical fuel concentrations and/or fuel quantities, use is often made of sensors which can measure the volumetric fuel concentration in a cavity 15.

(17) Cavities 15, in particular those with a large volume, are thus safety-critical structural spaces in vehicles 1 with a gaseous operating medium, in particular with gaseous fuel.

(18) However, even if a critical fuel concentration is measured, there is conventionally no suitable protective measure because, for this purpose, it would for example be necessary to additionally install a separate active ventilation means in order, for example, to dilute a critical mixture which is present.

(19) According to the invention, safety-relevant cavities 15 on and/or in a vehicle 1 are, during the course of the manufacture of the vehicle, reduced in terms of their free volume to a non-critical dimension for example by means of very lightweight volume components and/or by means of a foam 12, 13.

(20) Here, volume components 12 and/or foams 13 provided according to the invention—in particular in the context of so-called second component elements 12—preferably have one or more of the characteristics listed below: impermeability to the gas in question, for example to a gaseous fuel, a low weight, low material, manufacturing and/or installation costs, possibility of simple and/or fast installation, possibility of simple and/or fast uninstallation, and inert characteristics with respect to the materials situated in the surroundings.

(21) If the volume components 12 are composed of foam 13, said foam may for example be composed of large and/or gas-impermeable pores.

(22) Furthermore, a foam 13 can also be particularly easily removed again in order for repair work to be carried out or in the event of maintenance.

(23) A removal of a foam material 13 may be performed for example by dissolution—for example by means of irradiation, for example with light, and/or by application of a gas as solvent.

(24) It would also be conceivable for the foam to be warmed by external electromagnetic stimulation such that said foam decomposes. This could be achieved for example by incorporation of a molecule which can be stimulated at its resonance frequency by external means.

(25) According to the invention, the free volume of critical vehicle cavities 15 is reduced to a non-critical dimension. The collection of fuel gases 20 is reliably reduced or even prevented.

(26) According to the invention, no sensor arrangement or other protective measure is required in order to control a critical combustion gas mixture in a cavity 15. In this way, according to the invention, the susceptibility of sensor-based systems to faults is avoided. Also, according to the invention, costs that are incurred in the case of sensor-based systems in order to achieve the required integrity are avoided.

(27) By means of this avoidance measure, the collection of critical gas mixtures in cavities 15 is prevented.

LIST OF REFERENCE DESIGNATIONS

(28) 1 Vehicle according to the invention 1′ Conventional vehicle 10 Component according to the invention 10′ Conventional component 11 (First) component element 12 (Second) component element, displacement element 13 Foam material, displacement material 15 Cavity, interior 16 Residual volume 20 Operating gas/critical gas mixture