MODULAR CELLULAR SOLID GAS STORAGE PLATFORM SYSTEM

Abstract

Onboard hydrogen storage of 5-13 kg of H.sub.2 is required to enable a vehicle driving range greater than 500 Kms, using pot fuel cell or internal combustion engines. Current storage systems face many challenges related to cost, durability/operability, charge/discharge rates and safety, which may limit widespread commercialization of vehicles powered by hydrogen. The present invention aims to overcome these challenges and is based on a modular cellular solid product platform system that stores gases such as hydrogen in interconnected unit cells at pressures up to or exceeding 100 MPa. The system provides a more efficient and safer way of storing gases for mobility applications and other, with greater performance, allowing a wider spread of hydrogen as the fuel of the future.

Claims

1. A modular cellular solid gas storage platform system comprising: a modular cellular solid storage platform that comprises one or more modules, wherein each module has a plurality of unit cells suitable for storing a gaseous fuel, the unit cells are interconnected among them forming spaces among them; the interconnected unit cells are suitable to allow the flow of the gaseous fuel from one or more modules simultaneously according to operation demand; a plurality of collectors located in the storage platform suitable to act as pressure stabilizers of the fuel; wherein the interconnected unit cells are linked to the collectors; pressure relief valves suitable for avoiding pressure piling in the system; pressure regulating unit; temperature sensors; and anchoring points suitable for assembly purposes.

2. The modular cellular solid gas storage platform system according to claim 1, further comprising a vacuum insulation chamber and/or a conformal cooling.

3. The modular cellular solid gas storage platform system according to claim 1, wherein the spaces are filled with a lattice structure suitable to decrease weight of the platform and increase its stiffness and/or crashworthiness.

4. The modular cellular solid gas storage platform system according to claim 1, wherein the unit cells have different shapes and sizes.

5. The modular cellular solid gas storage platform system according to claim 1, wherein the system material is ferrous metals or non-ferrous metals or composites material or any combination thereof.

6. The modular cellular solid gas storage platform system according to claim 5, wherein the system material further comprises a plastic material.

7. The modular cellular solid gas storage platform system according to claim 5, wherein the system material further comprises a reinforcing material.

8. The modular cellular solid gas storage platform system according to claim 7, wherein the reinforcing material is selected from the group consisting of carbon fibres, nylon fibres, kevlar fibres, aramid fibres and mixtures thereof.

9. The modular cellular solid gas storage platform system according to claim 1, wherein the gaseous fuel stored is hydrogen or any other gas.

10. The modular cellular solid gas storage platform system according to claim 9, wherein the hydrogen is in the form of a compressed gas, cold and cryo-compressed or liquid.

11. The modular cellular solid gas storage platform system according to claim 1, wherein the system further comprises a vacuum insulation chamber when the hydrogen is in cold and cryo-compressed or liquid form.

12. Modular cellular solid gas storage platform system according to claim 1, wherein the system further comprises a conformal cooling when the hydrogen is in compressed gaseous form.

13. The modular cellular solid gas storage platform system according to claim 1, wherein the structure of unit cells interconnection and packaging is adapted to fit vacuum insulation chamber and/or the conformal cooling.

14. Use of the modular cellular solid gas storage platform system described in claim 1 in land transportation vehicles, in marine transportation vehicles, in aerospace transportation vehicles, in stationary stations, in buildings or portable applications.

Description

BRIEF DESCRIPTION OF FIGURES

[0034] FIG. 1 is a perspective of a unit spherical cell according to the present invention.

[0035] FIG. 2 represents arrays of interconnected cells, stacked to form a platform.

[0036] FIG. 3 shows a cross section of the platform, showing the periodic arrangement of the cells.

[0037] FIG. 4 shows the general geometric layout of the architecture of a storage platform system for a vehicle application: 1Hydrogen storage platform; 2Vacuum insulation chamber; 3Conformal cooling; 4Collector accumulator chamber; 5Primary pressure regulating unit; 6Fuel Cell/ICE; 7Refueling chamber; 8Refueling interface (temperature sensor, pressure relief valve, etc.); 9Refueling station; AFeed line; BRefueling line.

[0038] FIG. 5 Shows arrangements of cells and voids among them.

[0039] FIG. 6 Representation of conformal cooling and/or vacuum insulation chambers of storage platform: 2Vacuum insulation chamber: 3conformal cooling.

DESCRIPTION OF EMBODIMENTS

[0040] Hydrogen has the highest energy per mass of any fuel; however, its low ambient temperature density results in a low energy per unit volume, requiring the development of advanced storage methods with higher energy density, which poses a considerable challenge for its widespread safe application, since, as described previously there are still many technical barriers and problems that have to be solved, requiring extensive research. The main challenges are related to safe storage of hydrogen at higher pressures, at adequate cost, higher gravimetric and volumetric capacity and smooth refueling and release flow during operation. The present invention aims to solve most of the challenges and research gaps summarized in Table 4.

[0041] The present invention is based on a modular cellular solid product platform system that stores the hydrogen (or any other gas) in interconnected unit cells at pressures exceeding 100 MPa. The shape of the cell will be spherical since the sphere is the geometrical shape that allows the largest volume to surface area ratio, however, any polyhedral shape cell could be used. The spherical cell shape also minimizes the membrane stresses when subjected to internal pressure and minimizes heat transfer due to high-volume-to-surface ratio. The cellular solid platform will be fabricated by additive and subtractive manufacturing, but other manufacturing processes could be envisaged such casting processes, injection moulding and others.

[0042] The basic element of the invention concept is a Unit Spherical Cell (or polyheadral shape) that can perform various functions: storage of hydrogen, cooling and insulation.

[0043] The storage product platform system (flat or other configuration) will be generated as a periodic cellular structure of Unit Spherical Cells or other shapes, as showed in FIG. 1, which are arranged/stacked and interconnected in such a manner as to create a fuel storage apparatus with a configuration able to meet the target specifications of the product platform, and fit the packaging requirements of the intended use, as illustrated in FIG. 2 and FIG. 3.

[0044] The interconnected cells will be linked to collectors/accumulators, located at the top of the platform or other, that will act as pressure stabilizer of the gas/liquid, facilitating the flow both during refueling and operation (feeding the fuel cell or internal combustion engine). The platform can be composed of a single module/block or various modules supplying the hydrogen to the collector simultaneously or partially according to operation demand. The number, dimensions and shape of the cells will be defined through a topological optimization analysis, taking into account in particular, but not exclusively: [0045] Design for additive/subtractive manufacturing framework [0046] Total volume of hydrogen to be stored [0047] Strength of the cells for the system design pressure, in accordance with applicable standards [0048] Optimal flow rates of the gas during refilling and release during operation [0049] Architecture that optimizes the packaging of the storage platform into the body in white chassis of the vehicle or the other applications [0050] Number of modules or physical blocks forming the platform [0051] Integrated Conformal Cooling system in the case of compressed hydrogen to limit the temperature increase during refilling and operation of the system and during parking in the case of liquid/cryo-compressed hydrogen (improving dormancy period) [0052] Integration in the platform chambers for vacuum or other insulation systems when using liquid, cold and cryo-compressed hydrogen [0053] Integration of hydrogen pressure accumulators/stabilizing collectors for refueling and feeding the powertrain (fuel cell or combustion engine) [0054] Built in secondary safety functions (such as valves, flow meters, piping, and pressure regulating unit, temperature sensors) that control the flow of the hydrogen during the system operation and also any leakage due to malfunction of the system [0055] Flexural strength and/or crashworthiness of the storage platform and possible contribution for the structural integrity of the body in white of the vehicle

[0056] The embodiment of this invention concept can have an integral architecture to maximize performance, materialized and made possible by the use of additive/subtractive manufacturing processes, with many built in functions. However, some components can be fitted to the main platform as individual modules/physical blocks, such as the pressure regulating unit and other secondary safety devices required according to applicable standards. FIG. 4 illustrates the general geometric layout of storage platform architecture, with schematic representation of pressure stabilizer collector.

[0057] The following aspects of the embodiment of the invention are highlighted: [0058] The spaces among the unit spherical cells can be a void, as illustrated in FIG. 5 or can have a lattice structure (if a greater flexural strength is needed), to reduce its global weight and improve the gravimetric capacity of the storage system; [0059] The cells/spaces can be used to design and build into the platform the conformal cooling system and/or insulation chambers, as illustrated in FIG. 6; [0060] Since the additive manufacturing process allows many built in functions to be embedded into the system the number of parts will be decreased with a reduction of the Balance-of-Plant cost that can be of the order of 30%. Simultaneously the assembly cost will be reduced and reliability and durability increased; [0061] The platform can have a flat design which will make it easier to package into the body in white of the vehicle (contrary to current cylindrical tanks), especially if the body is designed around the storage platform as some OEMs are doing when fitting batteries packs in electric vehicles (Volskwagen, 2020).

[0062] In accordance with the present invention there is provided herein a gaseous fuel storage system in different forms comprising: [0063] a modular cellular solid storage platform that comprises one or more modules wherein each module having a plurality of unit cells for storing a gaseous fuel, the unit cells are interconnected among them forming spaces among them; the interconnected cells allowing the flow of the gaseous fuel from one or more modules simultaneously according to operation demand increasing the response of the system; [0064] a plurality of collectors located in the storage platform to act as pressure stabilizers of the fuel; wherein the interconnected unit cells are linked to the collectors to allow the stable flow of the gas during refueling and during operation; [0065] pressure relief valves for avoiding pressure piling in the system; [0066] pressure regulating unit; temperature sensors, [0067] anchoring points for assembly purposes [0068] optionally the system may comprise a vacuum insulation chamber and/or a conformal cooling.

[0069] The spaces are filled with a lattice structure, to decrease weight of the platform and increase its stiffness and/or crashworthiness.

[0070] The unit cells can have different shapes and sizes. The system material is ferrous metals or non-ferrous metals or composites material or any combination thereof. The system material further comprises a plastic material and optionally a reinforcing material, wherein the reinforcing material is selected from the group consisting of carbon fibres, nylon fibres, kevlar fibres, aramid fibres and mixtures thereof.

[0071] In one embodiment, the gaseous fuel stored in the system is hydrogen, wherein the hydrogen can be in different forms such compressed gas, cold and cryo-compressed or liquid.

[0072] The hydrogen storage system comprises a vacuum insulation chamber when the hydrogen is in cold and cryo-compressed or liquid form.

[0073] The hydrogen storage system comprises a conformal cooling when the hydrogen is in compressed gaseous form.

[0074] The structure of unit cells interconnection and packaging can be adapted to fit vacuum insulation chamber and/or the conformal cooling.

[0075] The hydrogen storage system stores hydrogen that can be at pressures higher than 100 MPa.

[0076] The hydrogen stored in the hydrogen system is used to feed fuel cells or internal combustion engines.

[0077] The configuration of the interconnection of the unit cells of the gaseous fuel storage system allows that the interconnecting cells can act as buffers to dissipate energy in cases of sudden pressure increase during an accident or explosion.

[0078] The gaseous fuel storage system is used primarily in land transportation vehicles, in marine transportation vehicles, in aerospace transportation vehicles, in stationary stations, in buildings or portable applications.

[0079] The platform of the gaseous fuel storage system will have a planar configuration or other, optimized for easy packaging and integration.

[0080] Even though hydrogen was disclosed herein as one embodiment of gas to be stored in the presently disclosed system, the present invention is not limited to hydrogen storage. Other gases are equally able to be stored in the modular cellular solid gas storage platform system of the present application.

[0081] The present invention has been described in terms of general concept embodiment, upon which this disclosure is based, but engineers, experts in the field, can used them as a basis for designing other structure systems with other architectures, with different degrees of modularity, adapted to different applications and purposes. It should also be understood that the terminology used for the purpose of description of the invention, should not be regarded as limiting. This means that the scope of the invention is not interpreted as being limited by the schematic embodiments illustrated in the figures above. Other variations are possible within the scope of the present invention, as defined in the listed claims. It should also be noted that the drawings in the figures, illustrating the apparatus of the present invention are not to scale and are not in proportion, for purposes of clarity. The blocks and the schematic geometric layout as well as other elements in the figures are intended to represent functional relationships among those elements/blocks, rather than any physical connections/relationships/interfaces is intended.

REFERENCES

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