Katerina Swanson
Fuel cell gas tanks in cars are made of stainless steel, aluminum, or plastic and are generally located behind the driver, not under the vehicle. They are usually boxy and mounted inside the car, often in the bed of trucks and off-road vehicles. The size of the tank varies, with some holding over 10 gallons, and they are reinforced with baffles and bladders to protect against damage. The longevity of fuel cells depends on the type of fuel used and the quality of the safety foam baffling, which should be checked regularly and replaced if found to be brittle.
Fuel Cell Gas Tanks in Cars
| Characteristics | Values |
|---|---|
| Materials | Stainless steel, aluminum, plastic, carbon fiber, fiberglass |
| Location | Behind the driver, not under the vehicle |
| Mounting | Inside the vehicle, in the bed for trucks and off-road vehicles |
| Shape | Boxy |
| Add-ons | Collectors, sumps, reserve tanks, surge tanks, baffles, pumps, dry-breaks, quick-fill valves, level senders, filters |
| Safety | Protected from damage, reduced risk of fuel spills |
| Maintenance | Fuel cell foam requires regular checks and replacement |
| Cost | Cheaper options available but may lack safety features |
| Fuel Type | Gasoline/diesel, hydrogen |
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What You'll Learn
Fuel cell types: gasoline/diesel or hydrogen
Fuel cells are electrochemical cells that convert the chemical energy of a fuel, typically hydrogen, and an oxidizing agent, usually oxygen, into electricity. This electricity is produced through a pair of redox reactions. Fuel cells differ from batteries in that they require a constant source of fuel and oxygen to sustain the chemical reaction, while batteries contain the chemical energy required for the reaction.
There are several types of fuel cells, classified by the kind of electrolyte they employ. The most common fuel types are gasoline/diesel or hydrogen. Gasoline fuel cells are reinforced tanks with baffles and sometimes a bladder. They are usually made of stainless steel, aluminium or plastic and are located behind the driver. Hydrogen fuel cells, on the other hand, take hydrogen gas and combine it with atmospheric oxygen to produce water and electricity directly. They are very lightweight and efficient, but hydrogen storage is a challenge.
Polymer electrolyte membrane (PEM) fuel cells, also known as proton exchange membrane fuel cells, are a type of hydrogen fuel cell that delivers high power density and have the advantages of low weight and volume. They use a solid polymer as an electrolyte and porous carbon electrodes containing platinum or platinum alloy catalysts. PEM fuel cells only need hydrogen, oxygen from the air, and water to operate. They are typically fuelled by pure hydrogen supplied from storage tanks or reformers and operate at low temperatures of around 80°C, allowing for quick start-ups and better durability. However, they require expensive noble-metal catalysts.
Direct methanol fuel cells (DMFCs) are another type of fuel cell that uses methanol as a fuel. Methanol has a higher energy density than hydrogen, although less than gasoline or diesel, and is easier to transport and supply using existing infrastructure. It is a liquid, like gasoline, and is often used to power portable devices such as cell phones or laptops.
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Materials used for the container/shell
The materials used for the container/shell of a fuel cell gas tank in a car depend on the type of vehicle and fuel. For liquid fuels, a fuel cell is generally a boxy, reinforced gas tank, usually mounted inside the vehicle. These fuel cells are typically made from stainless steel, aluminium, or plastic.
Aluminium is a popular choice for fuel cell containers, providing a lightweight yet strong shell. Steel is also used, offering a robust and durable solution, albeit with a slight weight penalty.
In some cases, more exotic materials are employed, such as carbon fibre or fibreglass. These materials offer high strength-to-weight ratios and excellent corrosion resistance. However, they tend to be more expensive and are often reserved for specialised racing vehicles or high-performance cars.
For hydrogen fuel cells, the storage of hydrogen gas poses unique challenges. Hydrogen is highly volatile, and as such, the container/shell materials must be carefully selected to ensure safety. While some hydrogen fuel cell tanks utilise similar materials to their liquid fuel counterparts, the design and engineering requirements are far more stringent.
In terms of shape, fuel cell gas tanks can vary. While they are usually boxy, this is not always the case, and they can be designed to fit specific vehicle cavities or spaces.
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Mounting locations
The mounting location of a fuel cell in a car depends on the type of vehicle and the intended use. In general, fuel cells are located inside the vehicle, either behind the driver or in the truck bed, rather than under the vehicle. This is for safety reasons, as it protects the fuel cell from impacts and reduces the risk of damage.
For example, in race cars, fuel cells are typically mounted in the truck bed, where they are protected from impacts. This mounting location provides the advantage of added safety but comes with the trade-off of losing storage space.
In off-road vehicles, fuel cells are often mounted directly behind the driver or passenger seat. This location offers easier access for servicing and replacing the in-tank fuel pump. It is also safer than mounting the fuel cell under the vehicle.
For street cars, fuel cell mounting locations can vary. Some street-driven cars have fuel cells mounted on the rear shelf or in the stock fuel tank location, typically under the trunk floor. In some cases, a mid-mounted fuel cell may be considered safer than a trunk-mounted one. However, the specific mounting location depends on the vehicle's design and available space.
The choice of mounting location also depends on the type of fuel cell. For liquid fuels, a fuel cell is typically a boxy, reinforced gas tank. These fuel cells are usually mounted inside the vehicle, either in the cabin or the truck bed, to provide protection and safety.
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Add-ons and components
Fuel cells are generally made from stainless steel, aluminium, or plastic, and they can be mounted either inside the vehicle or in the bed of a truck or off-road vehicle. The mounting location can vary, but it is often placed behind the driver for safety and easier servicing.
The container or can is a crucial component of a fuel cell, as it houses the bladder and provides a mounting solution for the fuel cell in the car. These containers are designed to closely fit the bladder and maximise capacity. They can be made from aluminium, steel, carbon fibre, or even fiberglass.
There are numerous add-ons and components that can be included with a fuel cell to tailor it to specific needs. Here are some examples:
- Collectors/Surge Tanks: These are optional components that act as a catch inside the bladder. They are usually plastic boxes with pickup pumps and check balls or trap doors to collect fuel for the pump.
- Baffles: These are structures within the fuel cell that help control the movement of liquid.
- Pumps: In-tank fuel pumps can be included and are easier to service when the fuel cell is mounted behind the driver.
- Dry-breaks: These are components that can be added to the fuel cell system.
- Quick-fill Valves: These valves can be added to the fuel cell system to facilitate faster refuelling.
- Level Senders: These components provide information about the fuel level in the tank.
- HydraMat: This is a sponge-like mat that continuously soaks up fuel, ensuring a constant supply to the intake. It can be rectangular or cross-shaped, depending on the shape of the fuel cell.
- Filters: These can be added to the fuel cell system to maintain fuel quality.
- Reserve Tanks: These provide additional fuel storage.
- Sumps: These are used to address fuel starvation issues, particularly during braking.
Additionally, fuel cells can be certified with the FIA-FT3 standard, which is required for certain racing classes. This certification ensures the safety and durability of the fuel cell.
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Maintenance and longevity
Maintenance Practices:
- Regular Inspections: It is crucial to inspect the fuel cell components periodically. This includes checking the condition of the safety foam baffling, which should be done at least annually for the first three years, then twice a year for the subsequent two years, and more frequently thereafter.
- Foam Replacement: The longevity of safety foam baffling depends on the type of fuel used. Typically, fuel cell foam should be replaced every five years if maintained properly. To determine if replacement is necessary, perform a pinch-pull test. If the foam breaks off in large portions, it indicates that it is brittle and needs to be replaced.
- Evaporative Emissions System: It is important to ensure that the evaporative emissions system is functional. Without it, fuel can stale quickly and even disappear when the car is parked, resulting in monetary losses.
- Hologram Sticker: To verify the certification of your fuel cell, you may need to remove the can lid or pull out the bladder. Certified fuel cells will have a hologram sticker indicating a validity period of five years from the original manufacture date.
- Add-on Components: Consider incorporating add-on components such as collectors, sumps, reserve tanks, surge tanks, and quick-fill valves to enhance the functionality and longevity of your fuel cell.
Longevity Enhancers:
- Container Material: The choice of container material can impact the longevity of the fuel cell. Containers are typically made from materials like aluminum, steel, carbon fiber, or fiberglass. Steel and aluminum offer durability and protection to the bladder.
- Mounting Location: The mounting location of the fuel cell can affect its longevity. In race cars, mounting the fuel cell in a protected area, such as the truck, can shield it from potential damage during impacts or crashes.
- Fuel Type: The type of fuel used influences the longevity of certain components, such as the safety foam baffling. Different fuels have varying levels of compatibility with the materials used in the fuel cell, affecting their durability.
- FIA Certification: When considering longevity, it is worth noting that fuel cells with FIA-FT3 certification, such as the Enduro line, may offer enhanced durability and safety compared to non-certified options.
By adhering to these maintenance practices and considering the factors that impact longevity, you can maximize the lifespan and performance of your fuel cell gas tank in your car.
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Frequently asked questions
In general terms, a fuel cell gas tank is a stainless, aluminum, or plastic gas tank that's usually located behind the driver and not under the vehicle. There are two main types: a gasoline/diesel fuel cell and a hydrogen fuel cell.
Fuel cell gas tanks are generally safer than stock tanks as they are usually located in a protected area of the vehicle. They also provide a way to mount the fuel cell in the car.
The cheaper fuel cell gas tanks are likely to be less safe than stock tanks as they are just plastic shells with easy-to-break-off fittings. They also don't have a working evaporative emissions system, which means fuel can go stale quickly.
