Air Flow Control Housing

Abstract

An apparatus having at least two thermal zones of different temperatures, each thermally isolated from the other. Ambient air flow is used to isolate the two zones. The housing may have a double wall construction above, below, and / or around the sides, defining an air conduit between the two walls. A heat generating device may be mounted within the housing. In operation, a blower within the housing draws air into the air conduit at the rear of the housing. The intake air flows around the housing and then into the heat generating device. A cool zone may be located within the housing upstream of the blower and may be kept cool by the ambient air flow. A hot zone may be located downstream from the blower. A third zone of intermediate temperature may be located downstream from the blower and upstream from the device. The heat generating device may be physically isolated from the cool zone by a blower and an insulated wall to which the blower may be attached. Ambient air sent to the hot zone may provide an oxygen source for the heat generating device.

Description

[Technical field]

[0001] The present invention relates to a housing, and more particularly to a structure of a housing that houses a heat generating mechanism such as a fuel cell, a net exothermic device, or a fuel reformer. [Background technology]

[0002] Heat generating mechanisms, such as catalytic oxidation devices, combustion devices, or reforming devices, are often controlled by various electronic systems. It can be important to protect electronic devices from the heat generated by these mechanisms. It can also be important to isolate the heat generated by these mechanisms so that they can be more conveniently integrated into their surroundings. For example, internal combustion engines, fuel cells, and fuel reformers generate significant amounts of heat. This can create challenges when attempting to place these mechanisms in close proximity to individuals or within homes and other structures. This can also create challenges when attempting to provide compact housings for compact devices, where parts of the mechanism, such as electronic devices, must be in close proximity but thermally isolated from one another.

[0003] The design of conventional heat generating mechanisms, such as internal combustion engines, fuel cells, and fuel reformers, creates additional challenges that make these mechanisms difficult to integrate into inhabited environments.

[0004] It would therefore be desirable to provide an improved structure for a heat generating mechanism that overcomes the shortcomings of the prior art. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] U.S. Patent No. 17267095 [Patent Document 2] U.S. Patent No. 9,627,700 [Patent Document 3] U.S. Patent No. 9,627,701 Summary of the Invention

[0006] Generally speaking, according to the invention, the device has at least two thermal zones of different temperatures, each thermally isolated from the other. Each zone can have a subzone of intermediate temperature between the hot and cold zones. An airflow of ambient air from an inlet of the device can be used to isolate the zones. In one embodiment of the invention, the airflow passes through the outside of the device, thermally isolating the outer surface of the device from the interior. In another embodiment of the invention, the airflow at the inlet is used to thermally isolate at least two interior zones of the device. In yet another embodiment of the invention, both the outer surface and the interior zones are thermally isolated by airflow within and / or around the device.

[0007] In one embodiment of the invention, the device includes a heat generating mechanism, such as an internal combustion engine, a fuel reformer, or a fuel cell. An inlet airflow for the oxygen source of the heat generating mechanism is used to help keep the thermal zones thermally isolated from each other. For example, a flow of ambient air can be blown or drawn over various components of the mechanism, such as electronic components, to keep these components cool. The inlet airflow can also thermally isolate the exterior surface of the device from the heat generated inside. This can be accomplished by drawing the inlet air into the exterior surface of the device, surrounding the outside of the heat generating elements. This airflow can be blown or drawn over any electronics or other elements that need to be kept cool. This air can then flow into the heat generating elements and act as an oxygen source for any chemical reactions inside.

[0008] In one embodiment of the invention, the heat generating mechanism can be housed within a double or multi-walled enclosure of a housing for the mechanism. The interior space between the outer and inner walls can act as an intake conduit that can function as a barrel-within-a-barrel structure. An array of fins can extend across the gap between the outer and inner walls to transform this structure into an intake barrel assembly that surrounds the entire length of the heat generating mechanism. This intake airflow can be drawn or blown from one or more internal cold compartments of the mechanism and then sent to the heat generating compartments of the mechanism as an air / oxygen source. All hot exhaust air can be sent directly to the exterior of the housing and piped to a convenient exhaust location. Thus, if the intake is at the rear end of the device, cool ambient air can be drawn into and around the entire top and / or bottom and / or sides of the device, including the internal cold portions of the device. The intake air can then be sent to the hot compartments that generate heat, and the exhaust can be discharged from the rear end. The intake and exhaust can be side-by-side or concentric. For example, the intake may surround the exhaust.

[0009] In one embodiment of the invention, the housing for the device has a double wall construction with both the inlet and outlet at the rear end. The heat generating mechanism can be mounted on a platform and slid in and out of the front end of the housing. Thus, when the device is used to generate electricity, it can remain plugged in alone to the installation site, such as a home, R / V, or workplace, and the core stack / BOP and electronics can be slid out of the housing to be serviced or replaced. A blower can be located at the front end. The blower can draw cooling air into the rear end of the housing, through the double walled air passages around the length of the device, and out the front end of the housing. The front interior area at the front end of the housing can act as a cold area where electronics and other elements that need to be kept cool can be mounted. After passing through the cold area over the exterior of the heat generating device, the intake air flow can be blown into the heat generating element and then exhausted to the exterior of the device. An additional cold area can be provided above, or preferably below, the main blower to house a flow control blower that controls the precise air flow to the heat generating element and helps control the exothermic reaction therein. In a preferred embodiment of the invention, such a further electronically controlled blower is located within this flow controlled cold zone, and the flow of air into this zone keeps this flow controlled zone cool.

[0010] By adjusting the dimensions of the double wall air conduit, the air flow through the intake conduit can be high velocity, providing a highly efficient cooling system to insulate the heat generating elements from the outside of the device. In this way, the velocity of the incoming air through the housing conduit can be kept high enough to help ensure that the pre-heating of the intake air is low enough to maximize cooling of the exterior surface. Thus, the device can be placed in close proximity to individuals near the device. The exterior surface of the device does not need to get very hot. Also, the device can be relatively compact. Any electronics or other elements for the device can be kept cool in the cold zone without requiring significant physical separation.

[0011] Other advantages and objects of the present invention will become apparent from the following drawings and description. [Brief description of the drawings]

[0012] The following drawings are presented for illustrative purposes only and should not be considered as limiting the scope of the invention. Although the drawings are to scale, other scales may be used within the spirit and scope of the invention. [Figure 1] 1 is a perspective view of a fuel cell according to a preferred embodiment of the present invention; [Diagram 2] FIG. 2 is a side cross-sectional view of the fuel cell of FIG. [Diagram 3] FIG. 2 is an exploded cross-sectional view of the fuel cell of FIG. [Figure 4] 2 is a cross-sectional end view of the front of the fuel cell of FIG. 1. [Diagram 5] 2 is a cross-sectional end view of the rear of the fuel cell of FIG. 1. [Figure 6] 1 is a schematic cross-sectional view of a fuel cell according to a preferred embodiment of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0013] The present disclosure may be understood more readily by reference to the following detailed description of the disclosure in conjunction with the accompanying drawings, which form a part hereof: It is to be understood that the disclosure is not limited to the specific devices, methods, conditions, or parameters described and / or illustrated herein, and that the terminology used herein is for the purpose of describing particular embodiments by way of example only, and is not intended to be limiting of the disclosure as claimed.

[0014] Also, as used in this specification, including the appended claims, the singular forms "a," "an," and "the" include plurals and, when referring to a particular numerical value, include at least that particular value unless the context clearly dictates otherwise. Ranges may be expressed herein as from "about" or "approximately" one particular value and / or to "about" or "approximately" another particular value. When such a range is expressed, another embodiment includes from the one particular value and / or to the other particular value. Similarly, when values ​​are expressed as approximations, by use of the antecedent "about," it will be understood that the particular value forms another embodiment.

[0015] The present invention relates to a heat generating mechanism. Examples include fuel consuming devices, fuel processors, heat generating devices, or other heat generating devices. These terms can encompass any heat generating device based on any type of fuel, including devices described in U.S. Patent No. 17267095, filed February 9, 2021, and U.S. Patent Nos. 9,627,700 and 9,627,701, the contents of which are incorporated herein by reference. Heat generating and / or heat generating devices include generators, fuel reformers, fuel cell stacks and systems, and the like. The term fuel shall be understood to include both liquid and gaseous fuels, including vaporized liquid fuels.

[0016] As used herein, the term fuel cell stack may include a plurality of assembled fuel cells. Each fuel cell may generate electricity in the form of direct current from electrochemical reactions occurring therein. Individual fuel cells may be combined into a stack, and balance-of-plant (BOP) components may include various systems and structures for the generation of electrical power, including fuel reformers, chemical reactors, gaskets, pumps, sensors, carburetors, heat exchangers, blowers, switches, relays, thermistors, thermocouplers, conduits, control electronics, catalytic oxidizers, combustors, etc.

[0017] Examples of heat generating devices according to the present invention include those described in U.S. Patent Nos. 9,627,700 and 9,627,701, the entire contents of which are incorporated herein by reference. A fuel reformer according to the present invention may be configured to supply a reformed fuel, such as a hydrogen-rich reformed fuel, to a fuel cell stack. The fuel cell stack may operate at a relatively high temperature to maximize power generation. Additionally, a sufficient amount of airflow may be required for the fuel cell stack and / or BOP components. Some or all of the airflow may be mixed with the fuel to provide a suitable fuel-air mixture for, for example, generating a hydrogen-rich reformed fuel. The airflow may also be used to dilute the fuel to control the intensity of a chemical reaction or to maintain operation below a particular explosion limit for a flammable fuel. Additionally, other electronic components of the fuel cell system may act as heat generating sources that need to be cooled for proper operation.

[0018] Thus, there may be various thermal zones and thermal sub-zones of those thermal zones that need to be maintained at different temperatures depending on the types and functions of the individual components therein.

[0019] As used herein, the terms hot zone or cold or low temperature zone are relative in nature. For example, a cold or low temperature zone may be significantly above room temperature, but below the temperature of the hot zone. Furthermore, the hot and cold zones may include various sub-zones of different relative temperatures.

[0020] A heat generating device according to a preferred embodiment of the present invention may include a lower temperature heat zone and a higher temperature heat zone. An insulating wall and / or an air blower may be provided at the interface between the two zones. The lower temperature (low temperature) heat zone may be in fluid communication with an air inlet through which a flow of ambient air is drawn into the device. The higher temperature (high temperature) heat zone may include a heat generating device such as a fuel reformer, a fuel cell, a catalytic oxidizer, a combustor, an internal combustion engine, etc. The two zones may be separated by an insulating wall. At the interface between the two zones there may be an air blower. The air blower may draw ambient air into the lower temperature zone and maintain the lower temperature of the lower temperature zone with a constant flow of ambient air. The blower may then blow this air into the higher temperature zone as needed for the proper operation of the exothermic reaction therein.

[0021] The heat generating apparatus may be configured such that the heat generating device is mounted on a platform and a housing surrounds the platform. The housing may have two double (or multi-layer) walls with an air passage therebetween. The inner and outer layers of the double or multi-layer walls may be divided by a number of fins running the length of the walls to create a multiple air passage tube structure along the length of the double wall to enhance airflow efficiency.

[0022] There can be an ambient air inlet at the rear end of the housing, and an air blower at the front end of the housing. Thus, air can be drawn into the inlet, flow through the housing, flow around the outside of the entire device, and flow to its front region. This can create a cold zone around the outside of the device. The rear end can also contain a cold zone into which ambient air is drawn. The front end can also contain a cold zone as ambient air flows from the air passage to the front end of the housing. As a result, the cold zone can be isolated by airflow from the hot zone across the air blower. Thus, components that need to be cool, such as electronic components, can be mounted in one of the cold zones (front, side, or rear) and the exterior surface of the device can be kept at a relatively cool temperature.

[0023] In one embodiment of the invention, an apparatus includes a fuel cell system having one or more fuel processing components. The one or more fuel processing components can include one or more balance of plant (BOP) components configured to provide reformed fuel to a fuel cell stack. The fuel cell stack can be configured to generate power based on the reformed fuel provided by the one or more BOP components. The heat generating components can be located in the hot zone, and any components that need to be kept cool, such as an electronically controlled blower that controls air to the heat generating components, can be located in the cold zone and draw air from there.

[0024] In one embodiment of the invention, the housing / blower assembly can include a flow switch unit configured to shut off the airflow when the airflow does not meet a preset requirement. The airflow can be measured by the flow switch unit. When the amount of airflow meets the preset requirement, the airflow in the blower(s) can be adjusted to maintain device performance. In one embodiment of the invention, the airflow switch unit can include a flat upper or differential pressure switch. Blowers operating at different speeds can be employed to adjust the airflow as needed.

[0025] The housing for the device may include a thermal isolation wall formed of insulating material to separate the hot and cold zones. Further, the cold or hot zones may be divided into different sub-zones maintained at different temperatures.

[0026] In one embodiment of the present invention, the fuel cell system and one or more fuel processing components can include one or more BOP components configured to provide reformed fuel to a fuel cell stack. The fuel cell stack can be configured to generate electrical power based on the reformed fuel provided by the one or more BOP components. The fuel cell stack can be located in a first high temperature sub-zone, and the BOP components can be located in a second high temperature sub-zone that is cooler than the first high temperature sub-zone.

[0027] In one embodiment of the invention, the air inlet port may be located at the rear end of the housing and configured to draw ambient air into the cold zone. The hot zone may include a hot zone exhaust port to exhaust hot gases produced by an exothermic reaction therein. The hot zone exhaust port may also be located at the rear of the housing. In one embodiment of the invention, the exhaust port and the inlet port are concentric. In one embodiment of the invention, the exhaust port is surrounded by the air inlet port.

[0028] In operation, the blower draws air from the inlet into the rear end interior space enclosed by the housing, around the outside of the housing, and into the front end interior area of ​​the housing. The blower can then blow the air first through the cold area and then directly into a hot area, such as in a fuel reformer or combustion device, or indirectly into the hot area. The hot exhaust gas exits through the hot area outlet port. Electronic components can be located in the cold area and fuel processing components can be located in the hot area of ​​the device, with the cold area in fluid communication with the ambient intake air inlet and the hot area in fluid communication with the outlet port. In one embodiment of the invention, the hot area can be completely surrounded by the cold area at the front, sides, and / or rear, except for the outlet port.

[0029] A preferred embodiment of a fuel cell device constructed in accordance with a preferred embodiment of the present invention is shown generally in Figure 1 as fuel cell system 100. A simplified schematic diagram of a fuel cell system similar to fuel cell system 100 is shown generally in Figure 6 as fuel cell system 600.

[0030] The fuel cell system 600 includes an aft end 610, a central section 650, and a front end 680. The central section 650 extends from a central section rear portion 650r to a central section front portion 650f. The central section rear portion 650r of the central section 650 is located at the aft end 610 of the fuel cell 600. The central section front portion 650f of the central section 650 is located at the front end 680 of the fuel cell 600. The fuel cell aft end 610 includes an inlet 611 concentric with an outlet 612 formed through a rear cap 613. The central section 650 includes a housing cover 660 around a hot section 670, in which a heat generating fuel cell stack 671 is mounted. The fuel cell stack 671 includes a fuel reformer portion for converting fuel to electricity, an anode portion, and a cathode portion.

[0031] A blower 672 is mounted to the front of the hot zone 670 and draws air into the fuel cell system 600. An electronics control assembly 683 is mounted in a cold zone 682 at the front end of the housing cover 660. Further electronic controls can be installed downstream, or optionally upstream, from the blower 672 in a flow control zone 200 that can receive a portion of the intake air. The flow control zones can be considered cold or hot sub-zones because they are warmer than the cold zone 682 but cooler than the hot zone 670. The fuel cell 671, blower 672, and electronics 683 (and optional flow control zone 200) can all be mounted together as a unit that can slide in and out of the front end 680 of the housing cover 660.

[0032] Housing cover 660 is formed having an outer wall 661 and an inner wall 662. An internal conduit 665 is formed between outer wall 661 and inner wall 662. An array of fins 666 extends from the inner surface of outer wall 661, through internal conduit 665, to inner wall 662, forming an array of tubular conduits along the inner surface of outer wall 661.

[0033] The inner wall 662 is shorter than the outer wall 661. Thus, the internal conduit 665 is exposed at the rear end 650r and the front end 650f of the central section 650. A gasket 615 is present around the outer periphery of the inner surface of the rear cap 613. The rear end 650r of the central section 650 is pressed into the gasket 615. Since the inner wall 662 of the central section 650 is shorter than the outer wall 661 and the fins 666, the internal conduit 665 is accessible at the rear end 650r of the central section 650. Similarly, a gasket 681 is present around the outer periphery of the inner surface of the front end 680. Thus, the internal conduit 665 is accessible at the front end 650f. As a result, there are internal spaces inside the rear cap 613 and the front end 680. These internal spaces are in fluid communication with the internal conduit 665.

[0034] The air inlet 611 is in fluid communication with the interior defined by the rear cap 613 / rear end 610. However, the outlet 612 is sealed from the interior of the rear end 610. Thus, all air entering the inlet 611 enters the interior of the rear end 610 which is in fluid communication with an internal conduit 665 at the rear end 650r of the central section 650. The internal conduit 665 is in fluid communication with a front interior 682 of the front end 680 at the front end 650f of the central section 650. An inlet end 673 of the blower 672 is in fluid communication with the interior 682 of the front end 680, and an outlet end 674 of the blower 672 is in direct or indirect fluid communication with the hot zone 670 and the fuel cell 671. Thus, as blower 672 operates, it draws air into inlet 611 in the direction of arrow A, along interior conduit 665 in the direction of arrow B, and then into front interior 682 in the direction of arrow C. Front interior 682 has electronics assembly 683 mounted therein. Thus, cool intake air is blown over electronics 683 before entering hot section 670 and / or fuel cell 671 directly or indirectly.

[0035] Intake air flows along the outside of the fuel cell system 600 and into an interior 682 at the front end 680, creating a cold zone on the outside of the fuel cell 600 and on the front interior 682. Thus, an exterior surface of the fuel cell 600 and a front interior 682 containing electronics 683 and other elements that need to be kept cool can be provided. An insulated wall 667 is provided at the rear end of the cold zone 682. A blower 672 is attached to the insulated wall 667. The wall 667 and blower 672, together with the intake air flowing through conduit 665, help isolate the heat generating parts of the fuel cell 600.

[0036] Intake air flows to and around the fuel cell 671 in the direction of arrow D. In a preferred embodiment of the invention, at least a portion of the air from the blower 672 is exhausted to the cold zone 200 and from there to the fuel cell 671. The air enters the fuel cell 671 and participates in an exothermic reaction, generating usable electricity that can be exhausted from the system 600 and a hot exhaust gas stream traveling in the direction of arrow E. The exhaust stream then exits the fuel cell system 600 through an exhaust port 612 in the direction of arrow F. The exhaust port 612 may be elongated to transport the hot exhaust gas to a suitable chimney, stack, or other structure. However, because the exhaust port 612 is concentric within the intake port 611, the intake air assists in isolating this heat.

[0037] Referring again to FIG. 1, the fuel cell system 100 is shown in FIG. 2 in cross section along line II-II. FIG. 3 shows the fuel cell system 100 in its two main parts, the housing section 101 and the mechanism section 102. To assemble the fuel cell 100, the mechanism rear end 102r of the mechanism section 102 is inserted into an opening in the housing front section 101f of the housing 101. The mechanism rear section 102r includes four threaded tubular sections 103. When the mechanism section 102 is inserted into the housing 101, the threaded tubular sections 103 are received in corresponding bolt-receiving openings 104. Four bolts 105 are inserted into the tubular sections 103, drawing the mechanism rear section 102r tightly against the housing rear section 101r of the housing 101. The mechanism front section 102f is also drawn tightly against the housing front section 101f. A rear gasket 115 seals the mechanism rear 102r to the housing rear 101r. A front gasket 181 in a front cap 183 seals the front 102f to the gasket 181 at the housing front 101f.

[0038] Fuel cell system 100 includes a rear end 110, a central section 150, and a front end 180. Central section 150 extends from a central section rear 150r to a central section front 150f. Central section rear 150r is located at the rear end 110 of fuel cell system 100. Central section front 150f is located at the front end 180. Fuel cell rear section 110 includes an inlet 111 concentric about an outlet 112. Rear end 110 also includes a rear cap 113. Front end 180 includes a front cap 183.

[0039] The central compartment 150 includes a housing cover 160 around a fuel cell 170 in the machinery compartment 102. The fuel cell 170 includes a fuel reformer section that receives a mixture of fuel and oxygen-containing gas, an anode section, and a cathode section, and has wiring to draw externally usable electricity from the fuel cell 170. A blower 172 is attached to the insulating wall 167. The fuel cell 170 is located in the hot zone behind the insulating wall 167. An electronic control assembly 173 is located in front of the insulating wall 167. Additional electronic controls can be installed in a separate flow control cold compartment 201.

[0040] The housing cover 160 has a double wall construction having an outer wall 161 around an inner wall 162. An air conduit 165 is formed between the outer wall 161 and the inner wall 162. An array of fins 166 extends across the conduit 165 between the inner surfaces of the outer wall 161 and the inner wall 162. The fins 166 form an array of cylindrical conduits that extend from the front end to the rear end of the air conduit 165.

[0041] The inner wall 162 is shorter than the outer wall 161. Thus, the array of tubular conduits of the internal conduits 165 is exposed at the central section front 150f and the central section rear 150r. The rear and front ends of the outer wall 161 are sealed against gaskets 115 and 181, respectively. Thus, the inlet 111 is in fluid communication with the conduits 165. As air enters the inlet 111, it travels along the conduits 165, along the outside of the central section 150 to the front end 180 of the fuel cell system 100.

[0042] The front end of the outer wall 161 presses against the front gasket 181. The inner wall 162 does not reach the front gasket 181. Thus, the front end of the air conduit 165 is in fluid communication with a front interior 182 defined by a front cap 183 at the front end 180.

[0043] The intake side of the blower 172 is exposed within the rear end of the front interior 182. When the blower 172 is operated, it blows air from the front interior 182 directly or indirectly into the fuel cell 170. In a preferred embodiment of the present invention, the blower 172 directs a flow of air into the flow controlled cold zone 201. The air from the flow controlled zone 201 flows to the fuel cell 170. The area surrounding the fuel cell 170 is the hot zone. When the blower 172 is operated, a lower pressure is created in the front interior 182. Because the front interior 182 is in fluid communication with the conduit 165, which is in fluid communication with the air inlet 111, when the blower 172 is operated, it draws air into the inlet 111 in the direction of arrow A'. This intake air then flows around the outside of the fuel cell system 100 in the direction of arrow B'. The intake air then flows in the direction of arrow C' through the electronics assembly 173 on the front cap 183 into the front interior 182. These air passages are insulated from the fuel cell 170. Thus, these air passages provide a cool zone that is significantly below the temperature of the hot zone area surrounding the fuel cell 170, protecting electronics that may be located in the cooler zones 182 and 201.

[0044] The blower 172 may direct at least a portion of the intake air in the direction of arrow D' into the flow control zone 201. From there, at least a portion of the air flows into the fuel cell 170 and at least a portion of the air flows around the fuel cell 170. Oxygen in the air entering the fuel cell 170 participates in an exothermic reaction in the fuel cell 170, generating a hot exhaust gas stream traveling in the direction of arrow E'. The exhaust stream then exits the exhaust port 112 of the fuel cell system 100 in the direction of arrow F'.

[0045] Ambient intake air flows along the outside of the housing 101 of the fuel cell 100 and into the front interior 182 of the front end 180, creating a cold zone around the outside of the fuel cell system 100 and within the front interior 182. Thus, the exterior surfaces of the fuel cell system 100 can be maintained at an acceptable temperature. Elements such as electronic controls can be mounted within the front interior 182 or in the flow control zone 201 if they need to be kept cool. A portion of the intake air flow can also be redirected to provide other cool zones of the system 100. The flow control zone 201 is typically warmer than the cool front interior 182, but cooler than the hot zone around the fuel cell 170.

[0046] The thickness and cross-sectional area of ​​conduit 165 will affect the velocity of the air flowing therethrough in the direction of arrow B'. One skilled in the art will know how to select a blower and size air conduit 165 to provide a sufficient amount of air to the fuel cell system to provide air flowing at an acceptable velocity for cooling purposes, without introducing so much air resistance as to affect the total airflow to the fuel cell.

[0047] The fuel cell system can be hardwired to a home, R / V, or other dwelling. The overall dimensions can be relatively small, 6-24 inches by 6-24 inches by 12-36 inches, with an overall length preferably less than 4 feet, and similarly greater than 6 inches. A fuel line should also be included to provide the reformable fuel. If liquid fuel is to be used, a vaporizer to vaporize the liquid fuel is useful.

[0048] 4 is a cross-sectional rear end view of the front cap 183 taken along line IV-IV of FIG. 3. As can be seen, the gasket 181 is disposed around the inner edge of the front cap 183. Referring to FIG. 3, the mechanism section 102 is slid into the housing section 101 and the front cap 183 is urged against the housing 101 to create a sealing engagement between the gasket 181 and the front end of the outer wall 161 of the air conduit 165, but not between the gasket 181 and the front end of the inner wall 162 of the air conduit 165. This seal at the outer wall 161 simply directs the airflow from the conduit 165 into the front interior 182 of the cold section. As mentioned above, the front interior 182 is defined by the space between the front cap 183 and the insulated wall 167 to which the blower 172 is attached. The circuit board with the electronic controller 173 is mounted to the rear surface of the front cap 183 and is therefore located within the cooler zone of the front interior 182 where cool intake air from the conduit 165 is drawn by the blower 172 over the circuit board 173.

[0049] 5 is a front end cross-sectional view of the rear cap 113 taken along line V-V of FIG. 3. As mentioned above, the rear cap 113 includes four bolt receiving holes 104 that engage with the bolt receiving sleeves 103. When the bolts 105 are pulled tight, this draws the mechanism section 102 into the gasket 115 (not shown in FIG. 5) within the rear cap 113, placing the interior of the rear cap 113 in fluid communication with the inlet 111 and the air conduit 165. Thus, air is drawn from the interior of the rear cap 113 through the blower 172, through the interior 182, through the conduit 165, after passing through the inlet 111. Exhaust gas from the fuel cell 170 is discharged through the exhaust port 112.

[0050] Although this application recites method or procedure steps in a particular order, the order in which some steps are performed may be varied or may be advantageous in particular circumstances, and it is not intended that the particular steps of the method or procedure claims described below be construed as being order specific, unless such order specificity is expressly recited in the claims.

[0051] While preferred embodiments of the devices and methods have been described with reference to the environments in which they are deployed, the preferred embodiments merely illustrate the principles of the invention. Modifications or combinations of the above assemblies, other embodiments, configurations, and methods for carrying out the invention, and variations of aspects of the invention that are obvious to those skilled in the art, are intended to be within the scope of the claims.

Claims

1. A device having a heat generating mechanism therein for generating heat, a housing having an outer surface and an inner surface, a front portion and a rear portion, and a length from said front portion to said rear portion; the heat generating mechanism having a top, a bottom, a front, a rear, and sides and mounted within the housing; an air intake conduit in fluid communication with a source of ambient air at an air inlet at an exterior rear of the housing, the air intake conduit in fluid communication with the heat generating mechanism, the air intake conduit constructed, arranged and adapted to provide the air from the air inlet to the heat generating mechanism, the air intake conduit positioned around the top, and / or the bottom, and / or the front, and / or the rear, and / or the sides of the heat generating mechanism; The apparatus, whereby the ambient air within the air inlet conduit insulates the exterior surface of the housing from the heat-generating mechanism.

2. 2. The apparatus of claim 1, wherein the housing has a double-walled construction having an outer wall, an inner wall, and a gap between the walls that defines an intra-walled conduit, and at least a portion of the air inlet conduit comprises the intra-walled conduit.

3. 3. The apparatus of claim 2, further comprising fins extending across the intra-wall conduit along a length of the intra-wall conduit from the outer wall to the inner wall and defining an array of airflow tunnels along the length of the intra-wall conduit.

4. 4. The apparatus of claim 1, wherein the rear of the housing includes an air inlet port in the outer surface, an inner surface of the housing defines a rear interior space, the rear interior space being in fluid communication with and downstream from the air inlet port, and the air inlet conduit includes the rear interior space.

5. 5. The apparatus of claim 1, wherein the rear of the housing includes a rear gasket, and a rear end of the air flow tube array is partially sealed against the rear gasket to seal the rear interior space in fluid communication with the air flow tube array.

6. 6. The apparatus of claim 1, wherein the front portion of the housing includes a front interior space, the air intake conduit includes the front interior space, and the front interior space is located upstream from the heat generating mechanism, whereby air from the front interior space flows to the heat generating mechanism.

7. 7. The apparatus of claim 1, further comprising an interface separating the front interior space from the heat generating mechanism, an air blower having an inlet and an outlet located at the interface downstream from the front interior space and upstream from the heat generating mechanism, and when the air blower is operating, an inlet of the air blower draws in air from the front interior space and blows the air from the front interior space downstream through an outlet of the air blower towards the heat generating mechanism.

8. 8. The apparatus of claim 1, wherein the blower directs the air downstream into an airflow control area, the airflow control area including an electronically controlled blower having an air flow inlet that draws air from the airflow control area and an air flow outlet in fluid communication with the heat-generating mechanism, the airflow control area being cooled by air from the air blower and being cooler than the heat-generating mechanism.

9. 9. The apparatus of claim 1, wherein the front interior space includes a front gasket, and a front end of the array of air flow tubes is partially sealed against the front gasket to seal the front interior space in fluid communication with the array of air flow tubes.

10. 10. Apparatus according to any one of claims 1 to 9, comprising an assembly of electronics, said electronics being located in the front interior space upstream from the blower.

11. 11. The apparatus of claim 1, wherein the boundary surface comprises an insulated wall, and the blower is mounted to the insulated wall.

12. 12. The apparatus of claim 1, wherein the housing interior includes a cold zone and a hot zone, the cold zone being kept cool by air from the air intake conduit and the hot zone being heated from heat from the heat generating mechanism.

13. 13. Apparatus according to any one of claims 1 to 12, wherein electronic components are mounted within the cold zone.

14. 14. The apparatus of any one of claims 1 to 13, wherein the heat generating mechanism is a fuel reformer, a fuel cell, a catalytic oxidizer, a fuel combustor, or an internal combustion engine.

15. 14. The apparatus of claim 1, wherein an outlet of the heat generating mechanism is located at the rear of the exterior surface of the housing.

16. 16. The apparatus of claim 1, wherein the outlet of the heat generating mechanism is concentric with the air inlet.

17. 1. An apparatus having a heat generating device constructed and arranged to conduct an exothermic chemical reaction through the oxidation of a liquid or gaseous fuel, comprising: a housing having an exterior open space and an interior open space, the housing having a front end, a rear end, a length between the front end and the rear end, a front interior space at the front end, and a rear interior space at the rear end; an air inlet at the rear end in fluid communication with the rear interior space such that ambient air enters the rear interior space through the air inlet; a housing, said exterior of said housing having at least two walls extending along a length of said housing, said exterior of said housing comprising a multi-walled conduit, an outer surface of said conduit being on said exterior of said housing and an inner surface of said conduit defining an interior space of said housing, said multi-walled conduit being downstream from and in fluid communication with said rear interior space and upstream from and in fluid communication with said front interior space; a partition wall at an upstream rear end of said front interior space; and an air blower on said partition wall, said air blower constructed, arranged and adapted to draw air into said air inlet, through said multi-walled conduit into said front interior space, and out an air blower outlet; an electronic component mounted in the interior open space of the housing; the heat generating device mounted within a high temperature zone of an interior space of the housing that is thermally sealed from the front interior space by the partition wall and the blower, downstream from the blower, and adapted to receive air directly or indirectly from the blower; the electronic component is located upstream from the heat-generating device, and the electronic component can be kept cooler than the heat-generating device by an airflow upstream of the heat-generating device; an exhaust outlet positioned and adapted to discharge exhaust air from the heat generating device to the exterior of the housing; whereby, when the blower is operated, it draws air from the air inlet into the front interior space, downstream into the multi-walled conduit, downstream into the front interior space, into the blower, and then upstream from the blower to the heat generating device.

18. 1. A method of operating a heat generating device mounted within a housing having a multi-walled structure, an outer wall spaced apart from an inner wall, and an air conduit in a space between the outer wall and the inner wall, comprising: operating a blower within said housing to draw ambient air into a rear end of said housing, then downstream and forward through said air conduit between said exterior and interior walls of said housing, then downstream into a front interior volume of said housing, and then downstream into said blower, said blower being mounted at a downstream rear end of said front interior volume; blowing the air directly or indirectly from the front interior space into a hot zone of the interior of the housing, the hot zone being insulated from the front interior space, and downstream to the heat generating device; and expelling exhaust air from the heat generating device through an outlet in the housing.

19. 20. The method of claim 18, wherein an electronic component assembly is mounted inside the housing in a component area that is separate and upstream from the heat generating device and where the blower keeps the electronic components cool by drawing the ambient air over the electronic components.

20. 20. The method of any one of claims 18 to 19, comprising: directing intake air from the front interior space into a flow control section having an electronically controlled blower therein, and blowing the air into the heat generating device with the electronically controlled blower while electronically controlling the electronically controlled blower.

21. 21. The method of any one of claims 18 to 20, wherein the exterior of the housing is insulated from the heat generating device by the flow of ambient air through the air conduit.

22. 22. The method of any one of claims 18 to 21, comprising electrically connecting the heat generating device to a residence, generating electricity with the heat generating device, and maintaining the electrical connection to the residence while an electricity generating component of the device is slid out of the interior of the housing for servicing or replacement.

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