Reformer container and fuel cell system

Abstract

A fuel cell system with an airflow system includes a first thermal region, a second thermal region, and a blower disposed between the first and second thermal regions. The first thermal region is connected to an inlet port of the fuel cell system. The second thermal region is connected to an outlet port of the fuel cell system. The blower is configured to draw air from the first thermal region and provide air to the second thermal region.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This patent application claims the benefit of U.S. Provisional Application No. 62 / 724,983, filed on August 30, 2018, the entire disclosure of which is incorporated herein by reference. Technical Field

[0003] The present invention relates to a fuel cell system having different thermal zones optimized for different types of components, and more particularly, to a forced air flow system or method for providing temperature cooling air or dilution air for a fuel cell system. Background Art

[0004] Forced air flow systems have been developed for temperature cooling or fuel dilution in fuel consuming equipment, such as fuel cell reformers or fuel cell systems, to prevent equipment malfunction or damage due to high temperatures, or to maintain a desired thermal environment suitable for its intended operation.

[0005] Typically, a blower is used to generate a forced airflow. In many cases, the blower is located on the outer wall of its housing, causing unwanted noise or reducing airflow efficiency, or is arranged locally on or around a specific component within the equipment. However, there is a lack of consideration for the design (or design rules) of the size, shape or configuration of the airflow channel therein, the position of the blower in the air channel, and / or the configuration of the components according to its thermal requirements, so the cooling or dilution efficiency cannot be maximized.

[0006] Therefore, a new airflow system or method is needed for providing airflow to a device to meet the given thermal or dilution requirements of various types of components of the device. Summary of the invention

[0007] The foregoing and other features and advantages of the present invention will be more fully understood from the following drawings, description, detailed exemplary embodiments, and claims.

[0008] According to one aspect of the present invention, a containment box for enclosing a device is provided. The containment box includes a first thermal region, a second thermal region, and a blower. The first thermal region is connected to an inlet port disposed on a first outer wall of the containment box. The second thermal region is connected to an outlet port disposed on a second outer wall of the containment box. The blower is disposed between the first and second thermal regions and is configured to draw air from the first thermal region and provide air to the second thermal region.

[0009] In one embodiment, the second thermal zone is airflow-isolated from the first thermal zone except by the blower.

[0010] In one embodiment, when the blower is operating, the temperature level of the second thermal zone is higher than the temperature level of the first thermal zone.

[0011] In one embodiment, when the blower is operating, the pressure level of the second thermal zone is higher than the pressure level of the first thermal zone.

[0012] In one embodiment, the inlet port is configured to draw air from outside the device into the first thermal region. The outlet port is configured to exhaust air from the second thermal region.

[0013] In one embodiment, the containment tank further includes one or more power electronic components disposed in the first thermal region and one or more fuel processing components for power generation disposed in the second thermal region.

[0014] In one embodiment, the apparatus includes a fuel cell system having one or more fuel processing components. The one or more fuel processing components include one or more BOP components configured to supply reformate to a fuel cell stack, and the fuel cell stack is configured to generate electricity based on the reformate provided from the one or more BOP components.

[0015] In one embodiment, the one or more BOP components include at least one of a fuel reformer, a chemical reactor, a gasket, a pump, a sensor, a humidifier, a heat exchanger, and a combustor.

[0016] In one embodiment, the containing box further comprises a flow switch unit, which is configured to be closed when the air flow measured by the flow switch unit does not meet the preset requirements to shut down the operation of the device, and to be turned on when the air flow meets the preset requirements to keep the operation of the device.

[0017] In one embodiment, the flow switch unit comprises at least one of a valve or a differential pressure switch.

[0018] In one embodiment, the containment box further includes a partition wall formed of a thermally insulating material between the first and second thermal regions.

[0019] In one embodiment, the second thermal region includes a first sub-region and a second sub-region, the temperature level to be controlled in the second sub-region being different from that in the first sub-region. The first sub-region and the second sub-region are separated by another partition wall formed of a thermal insulation material.

[0020] In one embodiment, the apparatus includes a fuel cell system having one or more fuel processing components. The one or more fuel processing components include one or more BOP components configured to supply reformate to a fuel cell stack, and the fuel cell stack is configured to generate electricity based on the reformate provided from the one or more BOP components. The fuel cell stack is disposed in a first sub-area and the BOP components are disposed in a second sub-area.

[0021] In one embodiment, the first thermal zone extends from the inlet port to the blower in an L-shape and the second thermal zone extends from the blower to the outlet port in a straight line.

[0022] In one embodiment, the inlet port is connected to an inlet duct extending to an outdoor space through which ambient air is introduced into the first thermal region.

[0023] In one embodiment, the outlet port is connected to an outlet duct extending to an outdoor space, through which air from the second thermal zone is exhausted.

[0024] According to another aspect of the present invention, a method for providing airflow to an apparatus is provided. The method includes: disposing a first thermal region and a second thermal region within a containment box of the apparatus; disposing a blower between the first and second thermal regions; disposing one or more power electronic components in the first thermal region; and disposing one or more fuel processing components in the second thermal region.

[0025] In one embodiment, the first thermal zone is connected to an inlet port disposed on a first outer wall of the containment box, and the second thermal zone is connected to an outlet port disposed on a second outer wall of the containment box.

[0026] In one embodiment, when the blower is operating, the temperature level of the second thermal zone is higher than the temperature level of the first thermal zone.

[0027] In one embodiment, when the blower is operating, the pressure level of the second thermal zone is higher than the pressure level of the first thermal zone.

[0028] In one embodiment, the method further includes: setting a flow switch unit in the device; shutting down the operation of the device when the air flow measured by the flow switch unit does not meet the preset requirements; and keeping the device running when the air flow meets the preset requirements.

[0029] In one embodiment, the flow switch unit comprises at least one of a valve or a differential pressure switch.

[0030] In one embodiment, the method further comprises providing a dividing wall formed of a thermally insulating material between the first and second thermal regions.

[0031] In one embodiment, the method further comprises dividing the second thermal region into at least a first sub-region and a second sub-region using another partition wall formed of a thermally insulating material. The temperature level to be controlled in the second sub-region is different from that in the first sub-region.

[0032] In one embodiment, the method further includes: disposing a fuel cell stack of one or more fuel processing components in the first sub-region; and disposing one or more BOP components of the one or more fuel processing components in the second sub-region.

[0033] In one embodiment, providing the first thermal zone includes extending the first thermal zone from the inlet port to the blower in an L-shape. Providing the second thermal zone includes extending the second thermal zone from the blower to the outlet port along a straight line. BRIEF DESCRIPTION OF THE DRAWINGS

[0034] It should be understood that the drawings described below are for illustrative purposes only. The drawings are not necessarily drawn to scale, and emphasis is generally placed on illustrating the principles of the present invention. The drawings are not intended to limit the scope of the present invention in any way. Like numbers generally refer to like parts.

[0035] Figure 1 is a perspective view of an exemplary fuel cell system according to an exemplary embodiment of the present invention;

[0036] Figure 2A yes Figure 1 A top view of a fuel cell system;

[0037] Figure 2B yes Figure 2A A simplified arrangement of a top view of FIG. 1 showing the cold and hot zones and the blowers and air flow passages therethrough;

[0038] Figure 2C is a simplified arrangement of a top view of a fuel cell system according to an exemplary embodiment of the present invention;

[0039] Figure 2D yes Figure 2C A rear view of the arrangement;

[0040] Figure 2E is a simplified arrangement of a top view of a fuel cell system according to an exemplary embodiment of the present invention;

[0041] Figure 2F yes Figure 2E A rear view of the arrangement;

[0042] Figure 2G is a simplified arrangement of a top view of a fuel cell system according to an exemplary embodiment of the present invention;

[0043] Figure 2H yes Figure 2G A rear view of the arrangement;

[0044] Figure 3A is a block diagram of an exemplary flow switch unit implemented using a valve according to an exemplary embodiment of the present invention;

[0045] Figure 3B is a block diagram of an exemplary flow switch unit implemented using a differential pressure switch according to an exemplary embodiment of the present invention;

[0046] Figure 4 yes Figure 1 A perspective view of a fuel cell system of FIG. 1 as viewed from a front wall thereof, showing the cold zone in more detail;

[0047] Figure 5A yes Figure 1 A perspective view of a fuel cell system of FIG. 1 when viewed from its rear wall, showing in more detail the thermal region including two sub-thermal regions;

[0048] Figure 5B When along Figure 5B A vertical cross-sectional view of the fuel cell system when the plane BB' is taken;

[0049] Fig. 6A yes Figure 1 An example top view layout of a fuel cell system showing the dimensions of the cold and thermal regions and the blower according to an exemplary embodiment of the present invention;

[0050] Figure 6B yes Figure 1 An example top view layout of a fuel cell system showing sub-thermal regions of a thermal region and dimensions of a blower according to an exemplary embodiment of the present invention; and

[0051] Figure 7 is a flow chart illustrating a method for providing forced air flow within a fuel cell system according to an exemplary embodiment of the present invention. DETAILED DESCRIPTION

[0052] It has now been found that the advantage of an apparatus (e.g., a fuel consumption apparatus) according to the present invention is that a forced air flow system has separate thermal zones so as to adaptively meet the different thermal control levels required for various types of components or parts within the apparatus. According to an embodiment of the present invention, the thermal zones can be separated by a blower.

[0053] The term "fuel-consuming device" as used herein refers to any device that operates on any type of fuel, as described in U.S. Provisional Application No. 62 / 724,993 filed by the applicant on August 30, 2018, the entire contents of which are incorporated herein by reference.

[0054] By way of example only, fuel consuming equipment may include, but is not limited to: an internal combustion engine, or all kinds of equipment including an internal combustion engine, such as a vehicle, a generator, etc.; and a fuel cell reformer or a fuel cell system.

[0055] The expression "fuel" is to be understood as comprising any kind of liquid fuel and gaseous fuel.

[0056] For descriptive purposes, the present invention will be described with reference to a fuel consuming device (more specifically, a fuel cell system) as an example of a device that requires a forced air flow system, however the scope of the present invention or exemplary embodiments are not limited thereto. For example, the scope of the present invention may be extended to any device that contains heat generating components with different thermal cooling requirements or a containment box that encapsulates the device, such that components with relatively high cooling requirements (e.g., a CPU) may be placed behind a blower (e.g., Figure 2A 120) of the thermal region (e.g., Figure 2A 210A), while other components with relatively lower cooling requirements (e.g., I / O, network interface) can be placed in another thermal area located before the blower (e.g., Figure 2A 110a).

[0057] For example, a fuel cell system may include one or more fuel processing subsystems for power generation, such as one or more fuel cell stacks, balance-of-plant (BOP) components, and other electronic (or electrical) components for power conditioning, communications, and the like.

[0058] A fuel cell stack includes a plurality of fuel cells. Each fuel cell can generate electricity in the form of direct current (DC) through an electrochemical reaction occurring therein. Individual fuel cells are typically combined in series to form a fuel cell stack. As used herein, "power plant auxiliary equipment" may refer to all supporting components and auxiliary systems of a fuel cell system so that the fuel cell stack generates electricity. For example, BOP components may include, but are not limited to: fuel reformers, chemical reactors, gaskets, pumps, sensors, humidifiers, heat exchangers, burners, blowers, fans, switches, relays, thermistors, thermocouples, reactant piping, control electronics, and / or the like.

[0059] For example, as described in U.S. Pat. Nos. 9,627,700 and 9,627,701 (the entire disclosure of which is incorporated herein by reference), a fuel reformer can be configured to supply reformate (e.g., hydrogen-rich reformate) to a fuel cell stack, which needs to operate in a relatively high heat environment to maximize power generation. In addition, a sufficient amount of air flow needs to be supplied to the fuel cell stack and / or BOP components so that the air flow can be used to mix with the fuel to provide, for example, a fuel-air mixture and hydrogen-rich reformate, or to dilute the fuel to meet the safety requirements of the system. In addition, other electronic components of the fuel cell system can be used as heat sources that need to be cooled.

[0060] That is, depending on the type or function of the various components that make up the fuel cell system, there may be different desired thermal environments. With these requirements in mind, a new and improved forced air flow system is provided for a fuel cell system.

[0061] The use of the terms "comprising", "having", "including", including their grammatical equivalents, should generally be construed as open and non-limiting, e.g., not excluding additional uncited elements or steps, unless specifically stated or understood otherwise from the context.

[0062] The use of the singular herein, such as "a", "an" and "the", includes the plural (and vice versa) unless specifically stated otherwise.

[0063] It should be understood that the order of steps or the order in which certain actions are performed is immaterial as long as this section remains operable. For example, the methods described herein may be performed in any suitable order unless otherwise specified herein or clearly contradictory to the context. In addition, two or more steps or actions may be performed simultaneously.

[0064] The use of any and all examples, or exemplary language, such as "such as", provided herein, is intended only to better illustrate the present invention and is not intended to limit the scope of the present invention unless otherwise specified. No language in the specification should be construed as indicating any non-claimed element is essential to the practice of the present invention.

[0065] The phrases "at least one," "one or more," and "and / or" are open-ended expressions that are both conjunctive and disjunctive in operation. For example, the expressions "at least one of A, B, and C," "at least one of A, B, or C," "one or more of A, B, and C," "one or more of A, B, or C," and "A, B, and / or C" each mean A alone, B alone, C alone, A and B together, A and C together, B and C together, or A, B, and C together.

[0066] The term "switched on" used herein may refer to an operation in which a switching system, a switching unit, a switch, etc. is "closed" to activate an electrical connection between its two end nodes so that power can flow through the electrical connection. In addition, the term "switched off" used herein may refer to an operation in which a switching system, a switching unit, a switch, etc. is "disconnected" to invalidate an electrical connection between its two end nodes so that power cannot flow through the electrical connection. Therefore, throughout the present invention, the terms "on" and "closed" may be used interchangeably, and the terms "disconnected" and "open" may be used interchangeably.

[0067] Throughout this description, the terms "hot zone" and "cold zone" are used. These terms are relative in nature and may refer to areas that require different temperature requirements. Thus, a "hot zone" may refer to an area that contains heat-generating components and requires a greater amount of cooling than other system components. However, a "cold zone" may refer to an area in which components may or may not generate heat and may or may not require cooling, but may require less cooling than components in the "hot zone."

[0068] Figure 1 is a perspective view of an exemplary fuel cell system 1 showing an outer wall of a housing box 10 according to an exemplary embodiment of the present invention. Figure 2A yes Figure 1 Top view of a fuel cell system. Figure 2B yes Figure 1 1 is a simplified arrangement of a top view of a block diagram illustrating cold and hot zones along with a blower 120 and airflow passages 150 therethrough according to an exemplary embodiment of the present invention. Figure 2C is a simplified arrangement of a top view of a fuel cell system according to an exemplary embodiment of the present invention. Figure 2D yes Figure 2C Rear view of the arrangement. Figure 2E is a simplified arrangement of a top view of a fuel cell system according to an exemplary embodiment of the present invention. Figure 2F yes Figure 2E Rear view of the arrangement.

[0069] Reference now Figure 1, the fuel cell system 1 is surrounded by six outer walls of the containment box 10. The containment box 10 may be configured such that all outer walls are sealed relative to the outside in terms of pressure, temperature, etc., except for the inlet port 100 and the outlet port 200. The inlet port 100 may be provided on one outer wall (e.g., the front wall) and configured to have one or more openings, through which fresh and / or cold air (e.g., ambient air) may be introduced into the containment box 10 of the fuel cell system 1. Similarly, the outlet port 200 may be provided to have one or more openings, through which hot air or gas generated in the hot zone 210 may be discharged to the outside of the fuel cell system 1.

[0070] Reference now Figure 2A and 2B , the fuel cell system 1 can be configured to include a blower 120 and two thermal zones; a cold zone 110 and a hot zone 210, which are separated by the blower 120. For example, the blower 120 can be disposed between the cold zone 110 and the hot zone 210, separating these zones 110 and 210. In one embodiment, the blower 120 can be implemented using an electric fan (e.g., EBM PABS T RER 160). With particular reference to Figure 2B When the blower 120 is driven to operate, an airflow channel 150 may be formed along a path from the inlet port 100 to the outlet port 200 through the cold zone 110, the blower 120, and the hot zone 210. The inlet port 100 and the outlet port 200 may be disposed at both ends of the airflow channel 150.

[0071] Reference now Figure 2A , the cold zone 110 may correspond to the upstream portion of the airflow channel 150, where the electronic components that need to be cooled are placed. The electronic components may include, but are not limited to: power conversion or regulation components 111, electronic circuits for communication 112, etc. In the cold zone 110, fresh or cold air (flow) may be drawn through the inlet port 100 to generate effective forced convection on the electronic components 111 and 112, thereby reducing their temperature. Figure 2B As shown, in one embodiment, the cold zone 110 may extend in directions D1 and D2 to form an L-shaped path starting from the inlet port 100 to the blower 120 .

[0072] The hot zone 210 may correspond to a downstream portion of the air flow channel 150, where the fuel cell stack 211 and the BOP component 212 are placed, so the temperature of the hot zone 210 is relatively high compared to the cold zone 110, so the hot air or gas will be discharged through the outlet port 200 of the fuel cell system 1. In one embodiment, the hot zone 210 may extend straight from the blower 120 to the outlet port 200 in the opposite direction to D1 and D2. In the drawings of the present invention, the directions D1, D2, and D3 are perpendicular to each other.

[0073] Therefore, the entire path of the airflow channel 150 may be U-shaped, such as Figure 2B As shown, it allows all required components of the fuel cell system (e.g., 1) to be deployed in the confined space (e.g., 10) of the housing box, providing greater design flexibility. However, exemplary embodiments of the present invention are not limited thereto, and the air flow channel can be adaptively designed to meet design requirements, such as the size or shape of the entire box, etc. And the positions and structures of the corresponding inlet ports and outlet ports can be changed accordingly.

[0074] In one embodiment, now refer to Figure 2C and 2D , the inlet port 100a and the outlet port 200a may be disposed at the same rear end of the fuel cell system. Figure 2D As shown, the inlet port 100a can be arranged next to the outlet port 200a, so that air will be sucked into the fuel cell system through the inlet port 100a and flow out through the outlet port 200a via the blower 120 to form the air flow channel 150a. For example, when the blower 120 is driven to operate, the air flow channel 150a can be formed along the path from the inlet port 100a to the outlet port 200a, sequentially through the cold zone 110a, the blower 120 and the hot zone 210. The entire path of the air flow channel 150a can be U-shaped, such as Figure 2C shown.

[0075] In one embodiment, reference Figure 2E and 2F , the two inlet ports 100b1 and 100b2 and the outlet port 200b may be disposed at the same rear end of the fuel cell system. Figure 2E As shown, two inlet ports 100b1 and 100b2 may be provided on both sides of the outlet port 200b, so that air will be drawn into the fuel cell system through the two inlet ports 100b1 and 100b2, and flow out through the outlet port 200b via the blower 120, respectively, to form two air flow channels 150b1 and 150b2, respectively. For example, when the blower 120 is driven to operate, the air flow channel 150b1 may be formed along the path from the inlet port 100b1 to the outlet port 200b, sequentially via the cold zone 110b1, the blower 120, and the hot zone 210, and further, the air flow channel 150b2 may be formed along the path from the inlet port 110b2 to the outlet port 200b, sequentially via the cold zone 110b2, the blower 120, and the hot zone 210. The entire path of each air flow channel 150b1 or 150b2 may be U-shaped, such as Figure 2E shown.

[0076] In one embodiment, reference Figure 2G and 2H , the two inlet ports 100b1 and 100b2 and the outlet port 200b may be disposed at the same rear end of the fuel cell system. More specifically, as Figure 2E As shown, two inlet ports 100b1 and 100b2 may be provided on both sides of the outlet port 200b, so that air will be drawn into the fuel cell system through the two inlet ports 100b1 and 100b2, and flow out through the outlet port 200b via the blower 120, respectively, to form two air flow channels 150b1 and 150b2, respectively. For example, when the blower 120 is driven to operate, the air flow channel 150b1 may be formed along the path from the inlet port 100b1 to the outlet port 200b, sequentially via the cold zone 110b1, the blower 120, and the hot zone 210, and further, the air flow channel 150b2 may be formed along the path from the inlet port 110b2 to the outlet port 200b, sequentially via the cold zone 110b2, the blower 120, and the hot zone 210. The entire path of each air flow channel 150b1 or 150b2 may be U-shaped, as shown in FIG. Figure 2G This configuration will also provide cooling to the exhaust gas exiting through outlet port 200b as the cooler inlet air entering through inlet ports 100b1 and 100b2 surrounds outlet port 200b.

[0077] Despite Figure 2D and 2F , the overall shape of each inlet port 100a, 100b1, or 100b2 is shown as a quadrilateral centered in the vertical direction D3, but the exemplary embodiments of the present invention are not limited thereto. For example, the overall shape of each inlet port may be a circle or any kind of polygon, and / or the inlet port 100a, 100b1, or 100b2 may extend to cover the entire area of ​​the cold zone 110a, 110b1, or 110b2 to ensure a more efficient suction operation; for example, see Figure 2H .

[0078] Reference now Figures 2A to 2H In one embodiment, the inlet port 100, 100a, 100b1 or 100b2 and the outlet port 200, 200a or 200b can be configured to be connected to another ventilation component (such as a duct, such as Figure 1However, in some environments, in which the fuel cell system is installed in an indoor space or enclosure with limited ventilation conditions, the inlet port 100, 100a, 100b1 or 100b2 and / or the outlet port 200, 200a or 200b may be further connected to a corresponding duct (not shown) to enhance air ventilation through the air flow channel. For example, the inlet port 100, 100a, 100b1 or 100b2 may be further connected to an inlet duct (not shown) extending to an outdoor space or any other space, so that fresh or cold air can be introduced from the outdoor space. Although in Figure 1 In the figure, it is shown that the inlet port (e.g., 100) has a plurality of small openings arranged on the front wall of the fuel cell system 1 without any supporting components being connected to the inlet duct, but the size, shape, position and / or configuration of the inlet port according to the present invention are not limited thereto. In addition, the outlet port 200, 200a or 200b can be further connected to an outlet duct (not shown) extending to the outdoor space for more effectively discharging hot air or gas passing therethrough. All ventilation-related components including the inlet port 100, 100a, 100b1 or 100b2, the inlet duct, the outlet port 200, 200a or 200b and the outlet duct can be completely sealed to prevent exhaust / effluent from returning to the indoor / surrounding or containing box of the fuel cell system.

[0079] As described above, the cold zone 110, 110a, 110b1, or 110b2 may be a place where electronic (or electrical) components are placed so as to be cooled due to the cold air or fresh air drawn through the inlet port 100, 100a, 100b1, or 100b2. The electronic (or electrical) components may include: power electronics 111 for processing power conditioning and power conversion of electricity generated, for example, from the fuel cell stack 211; and other communication electronics 212. For example, the power electronics 111 may include a power inverter, a power converter, a battery, etc.

[0080] In addition, the hot zone 210 may be where the fuel cell stack 211 and the BOP component 212 are placed. The blower 120 may be located between the cold zone 110, 110a, 110b1, or 110b2 and the hot zone 210, separating the cold zone 110, 110a, 110b1, or 110b2 from the hot zone 210. The blower 120 is configured to suck in the air flow passing through the cold zone 110, 110a, 110b1, or 110b2 and blow the air toward the hot zone 210.

[0081] In reference Figures 2A to 2FIn an exemplary embodiment, the cold zone 110, 110a, 110b1 or 110b2 and the hot zone 210 are separated by a blower 120 and a partition wall 310, 310a, 310b1 or 310b2, so that the hot zone 210 is isolated from the gas (or air) flow of the cold zone 110, 110a, 110b1 or 110b2 except through the blower 120; for example, there is no gas or air communication between the cold zone 110, 110a, 110b1 or 110b2 and the hot zone 210 except through the blower 120.

[0082] In addition, the housing box (e.g., 10) of the fuel cell system can be designed to be isolated from external gas (or air) except through the inlet port 100, 100a, 100b1 or 100b2 and the outlet port 200, 200a or 200b. The partition wall 310, 310a, 310b1 or 310b2 can extend from the left side wall forming the outlet port 200, 200a or 200b along the direction D1 to the blower 120. The partition wall 310, 310a, 310b1 or 310b2 can be formed of an insulating material to prevent heat transfer between the hot zone 210 and the cold zone 110, 110a, 110b1 or 110b2. Therefore, still referring to Figures 2A to 2F The separation formed by the blower 120 and the partition wall 310, 310a, 310b1 or 310b2 can create a pressure difference between the two areas 110, 110a, 110b1 or 110b2 and 210 to enhance the thermal separation therebetween, thereby allowing independent thermal control of each thermal area.

[0083] Preferably, the cold zone 110, 110a, 110b1 or 110b2 and the hot zone 210 are pressure-sealed from each other so that when the blower 120 is running, the pressure of the hot zone 210 can be higher than the pressure of the cold zone 110, 110a, 110b1 or 110b2. For example, as the blower 120 is running, the pressure of the hot zone 210 may become higher (e.g., positive differential pressure +ΔP), and the pressure of the cold zone 110, 110a, 110b1 or 110b2 may become lower (e.g., negative differential pressure -ΔP). By way of example only, the desired pressure difference between the cold zone 110, 110a, 110b1 or 110b2 and the hot zone 210 may be 0.22 to 0.3 inWC. More specifically, such a relatively high pressure of the hot zone 210 may facilitate the hot air or gas generated in the hot zone 210 to be discharged to the outside through the outlet port 200, 200a or 200b.

[0084] Similar to what is described in U.S. Pat. Nos. 9,627,700 and 9,627,701, the blower 120 according to the present invention can introduce air or oxygen-containing gas into the pipeline of the fuel reformer (not shown) or any other similar functional component or element by using various heaters, vaporizers, igniters, reaction units, etc. of the fuel reformer, and the fuel reformer or any other similar functional component or element requires air supply to mix with the fuel to provide a fuel-air mixture and a hydrogen-rich reformate. The air or oxygen-containing gas can be used to dilute the fuel to meet the safety requirements of the system.

[0085] The blower 120 can help move the hydrogen-rich reformate to the fuel cell stack 211. The fuel cell stack 211 includes a plurality of fuel cells. The amount of electrical power or energy efficiency of the fuel cell stack depends on several factors, such as the type of fuel cell, the size of the cell, its operating temperature (e.g., operating temperature), and the pressure of the gas supplied to the cell. For example, it is well known that the energy efficiency of fuel cells is typically between 40%-60%, however, if waste heat is captured in a cogeneration scheme, the efficiency can be as high as 85% in an operating temperature range of 800°C to 1200°C.

[0086] Reference now Figures 2A to 2H , deploying the blower 120 between the cold zone 110, 110a, 110b1 or 110b2 and the hot zone 210 provides several technical advantages as follows. First, since the blower 120 is located upstream of the hot zone 210 (where high temperature air or gas is generated from the BOP component 212 and / or the fuel cell stack 212), no hot air or gas will flow back from the hot zone 210 to the blower 120, thereby preventing the blower 120 from being damaged by such hot air or gas from the hot zone 210, which may otherwise result in a reduction in motor life or premature failure of its function. In addition, since the blower 120 located between the cold zone 110, 110a, 110b1 or 110b2 and the hot zone 210 can prevent the hot air or gas of the hot zone 210 from flowing back to the cold zone 110, 110a, 110b1 or 110b2, the temperature of the cold zone 110, 110a, 110b1 or 110b2 will not be affected by the high temperature of the hot zone 210, so that the temperature of the cold zone is cooled more easily. In addition, since the blower 120 is located inside the containing box (e.g., 10), the noise level generated by the blower 120 can be reduced accordingly.

[0087] In one embodiment, one or more safety sensors and / or switches may be disposed in the airflow passage 150, 150a, 150b1, or 150b2, preferably near the blower 120 of the cold zone 110, 110a, 110b1, or 110b2, the hot zone 210, and / or both. By way of example only, Figure 2AAs shown, the flow switch unit 113 can be arranged near the blower 120 in the cold zone 110. The applicant's U.S. Provisional Application No. 62 / 724,993 filed on August 30, 2018 describes a safety control switch assembly connected between a power node and a fuel safety shut-off valve. In one embodiment of the present invention, the safety control switch assembly includes switch units connected in series, each of which is turned on or off based on a corresponding safety-related environmental condition. For example, in at least one switch unit (e.g., Figure 2A 113) is cut off, the safety control switch assembly can be cut off to shut off the power supply entering the fuel safety shut-off valve, thereby blocking the fuel supply entering the fuel consuming equipment for safe operation. Figure 2A The flow switch unit 113 exemplarily shown in FIG. 1 may be used as one of the switch units in the safety control switch assembly. The flow switch unit 113 may be turned on or off based on whether a sufficient amount of air flows into the hot zone 210. For example, when it is detected that the amount of air is less than a preset level, the flow switch unit 113 may be turned off to shut off the fuel safety shutoff valve (e.g., Figure 5A and 5B 217) or any other safety-related components of the fuel cell system 1 to ensure safe operation. If the air volume is equal to or greater than a preset level, the flow switch unit 113 can be turned on to allow the fuel cell system 1 to operate without interruption, maintaining the fuel supply to the fuel cell system 1.

[0088] Reference now Figure 3A , which shows a block diagram of an exemplary flow switch unit 113a, which can be implemented using a valve-type flow meter 411 (referred to as a "flapper") that can measure the amount of air (or air flow rate) flowing into the blower 120.

[0089] As an example only, the valve 412 may be provided between the relay coil 413 and the normally open switch 414. The relay coil 413 has one terminal node connected directly or indirectly to the power source 411, and another terminal node connected to the ground GND through the valve 412. The normally open switch 414 is a mechanical switch that remains normally open, and turns on (e.g., closes) when current flows through the relay coil 413, so as to engage the connection between the terminal nodes N1 and N2 to power the fuel safety shutoff valve 217.

[0090] If the air flow rate at the position where the valve 412 is located is equal to or greater than a preset air flow rate threshold, the valve 412 is configured to snap one terminal node to another terminal node, thereby connecting the electrical connection between the two terminal nodes. In addition, if the air flow rate is less than the preset air flow rate threshold, the valve 412 is configured to cut off the electrical connection between the terminal nodes.

[0091] For example, when the valve 412 is turned on, current flows through the two terminal nodes of the relay coil 413 to generate a magnetic field around it and force the normally open switch 414 to close, so that the entire flow switch unit 113a will be turned on. If the valve 412 is open, no current flows through the relay coil 413, so the normally open switch 414 will remain open.

[0092] Alternatively, instead of having Figure 3A With the configuration of relay coil 413 and normally open switch 414 shown, valve 412 itself may be located between terminal nodes N1 and N2 to control the operation of fuel safety shutoff valve 217 .

[0093] Reference now Figure 3B , which shows a block diagram of an example flow switch unit 113b, which can be implemented using a differential pressure switch 415. The differential pressure switch 415 can optionally be set at a position substantially the same as the valve 412 or at a position near it. The differential pressure switch 415 can be implemented using one or more sensors that measure the pressure difference between the cold zone (e.g., 110, 110a, 110b1, or 110b2) and the hot zone (e.g., 210). As described above, when the blower 120 is running, a pressure difference occurs between the two zones (e.g., 110, 110a, 110b1, or 110b2 and 210). It should be understood that the better the air flows, the greater the pressure difference between the cold zone and the hot zone, and vice versa, so the pressure difference measured by the differential pressure switch 415 can be used as an indicator of how well the air flows along the air flow channel (e.g., 150, 150a, 150b1, or 150b2). Therefore, the pressure difference switch 415 can be configured to be cut off when the pressure difference between the cold zone and the hot zone is less than a preset pressure difference threshold, otherwise, the switch 415 is turned on. In one aspect, the pressure difference switch 415 can be incorporated into the switch unit 113b, such as Figure 3B As shown, its configuration and operation are basically the same as Figure 3A The configuration and operation of the valve 412 are the same or similar, except that a pressure difference switch 415 is used instead of the valve 412. Therefore, for the sake of simplicity, the repeated description thereof will be omitted.

[0094] In addition, instead of having Figure 3B With the configuration of the relay coil 413 and the normally open switch 414 shown in FIG. 4 , the differential pressure switch 415 itself may be located between the terminal nodes N1 and N2 to control the operation of the fuel safety shut-off valve 217 .

[0095] Still in one embodiment, one or more sensors (not shown) for measuring air flow (e.g., air velocity or air speed) may be additionally placed at a location of interest, or may be placed outside of valve 412 and / or pressure differential switch 415. In this case, the sensor may send the measurement results regarding the air flow to a controller (not shown) including one or more processors, and the controller may control the operation of the fuel safety shutoff valve based on the results provided by the sensor to indicate whether to shut off the fuel supply, as described in U.S. Pat. Nos. 9,627,700 and 9,627,701.

[0096] In one example scenario, any one of the valve 412, the pressure differential switch 415, or sensors in conjunction with the controller and / or a combination thereof may be used to identify whether there is a problem (e.g., a blockage in the inlet duct) that is impeding air flow through the inlet duct and / or airflow passage (e.g., 150).

[0097] Figure 4 yes Figure 1 1 is a perspective view of the fuel cell system 1 as viewed from its front panel, showing the cold zone (e.g., 110) in more detail. Figure 5A yes Figure 1 A perspective view of the fuel cell system 1 when viewed from its rear wall, which shows in more detail the hot zone 210 comprising two sub-hot zones. Figure 5B It is along Figure 5A A vertical cross-sectional view of the fuel cell system 1 taken along a plane BB'.

[0098] Reference now Figure 5A and 5B , the hot zone 210 may be further divided into at least two sub-hot zones 210a and 210b by at least one partition inner wall 510 for providing separate air supplies to the sub-hot zones 210a and 210b in consideration of different temperature requirements on the sub-hot zones 210a and 210b. For example, the air flow provided by the blower 120 may be divided into two air flows by the partition wall 510, so that one air flow may provide air for mixing with the fuel or for fuel dilution, while the other air flow may be used to maintain a cooler environment around the BOP components 212 near the fuel cell stack 211.

[0099] During operation of the fuel cell system 1, the temperature of the sub-thermal zone 210a can be maintained higher than that of the sub-thermal zone 210b. For example, the fuel cell stack 211 may require a relatively high operating temperature (e.g., about 800°C to 1200°C) for higher energy efficiency, while other BOP components (such as reactor units or any other heat radiating components) need to be maintained at a temperature lower than that of the sub-thermal zone 210a. Therefore, in one embodiment, the fuel cell stack 211 and some BOP components (e.g., thermistors, thermocouples, switches and / or the like) can be placed in the sub-thermal zone 210a, while other BOP components (e.g., CPOX or reactant blowers, fans, fuel control valves, fuel safety shut-off valves, sensors and / or the like) can be placed in the sub-thermal zone 210b. In some embodiments, control electronics and sensitive electrical components can be placed in the sub-thermal zone 210b. In one embodiment, the partition wall 510 can be formed of an insulating material, so that heat exchange between the sub-thermal zones 210a and 210b can be prevented or reduced.

[0100] Therefore, the containment box 10 encapsulating the fuel cell system 1 can have at least two (e.g., 110 and 210) or three separate thermal zones (e.g., 110, 210a, and 210b), and the temperature level of each zone can be independently controlled, making it easier to meet the different temperature requirements given to various types of components of the fuel cell system 1.

[0101] Despite Figure 5A and 5B The two sub-thermal zones 210a and 210b of the thermal zone 210 are shown to be separated along the vertical direction D3, but the exemplary embodiments of the present invention are not limited thereto. For example, the thermal zone 210 may have more than two sub-thermal zones, and / or the sub-thermal zones may be separated along other directions (e.g., direction D2).

[0102] Reference now Fig. 6A and 6B , showing exemplary sizes of the above-mentioned three thermal regions (eg, 110 , 210 a , and 210 b ) and the blower 120 of the fuel cell system 1 according to an exemplary embodiment of the present invention. Fig. 6A The dimensions of the top view arrangement are shown. As shown, the lengths of the box 10 in directions D2 and D1 are about 300 mm and about 450 mm; for example, the ratio of the length in direction D2 to the length in direction D1 is 1: about 1.5.

[0103] In a plane formed by directions D1 and D2, each of the hot zone 210 and the blower 120 is formed in a quadrilateral or a nearly quadrilateral, and the cold zone 110a is formed in an L-shape.

[0104] The rear wall of the box 10 (see Fig. 6AThe top of the box 10 can be divided into a cold zone 110 with a length of about 50 mm, a blower 120 with a length of about 50 mm, and a hot zone 210 with a length of about 350 mm along the direction D1. Fig. 6A The cold zone 110 extends to form an L-shape, and its inner surface has a length of about 400 mm and about 225 mm in the directions D1 and D2, respectively. The left side wall can be divided into a cold zone 110 with a length of about 75 mm and a hot zone 210 with a length of about 225 mm.

[0105] Figure 6B Shows that when following Figure 2A As shown in the figure, the upper sub-hot zone 210a and the lower sub-hot zone 210b are formed to have lengths of about 200 mm and about 70 mm in the vertical direction D3, respectively.

[0106] It should be understood that referring to Fig. 6A and 6B The described sizes of thermal zones 110, 210a and 210b and blower 120 are merely examples, and their absolute sizes or relative proportions of volume, area and / or length therebetween may be designed differently depending on the thermal requirements of the system to control each zone.

[0107] based on Fig. 6A and 6B , the volumes of the cold zone 110 and the hot zone 210 can be calculated to be, for example, approximately 12150 cm 3 and about 21625cm 3 , so the volume ratio of the cold zone 110 to the hot zone 210 is 1: about 1.78. In addition, in the hot zone 210, the volumes of the sub-hot zones 210a and 210b are, for example, 16018cm 3 and about 5606cm 3 , to give a volume ratio between the sub-hot zone 210b and the sub-hot zone 210a of 1: about 2.85.

[0108] Figure 7 is a flow chart illustrating a method of providing a forced air flow using a fuel cell system and driving the system according to an exemplary embodiment of the present invention.

[0109] Reference now Figure 1 , 2A 2E, 3A, 3B, 4, 5 and 7, as a step of providing an airflow system, the method may include placing a containment box (e.g., Figure 11) is divided into at least two thermal regions, such as a cold region (e.g., 110, 110a, 110b1, or 110b2) and a hot region (e.g., 210) (S710). In one embodiment, the hot region can be further divided into at least two sub-thermal regions (e.g., Figure 5A The method may further include placing a blower (e.g., Figure 2A 120) to provide airflow through the cold zone and the hot zone (S720); placing electronic (or electrical) components, such as power electronic components (e.g. Figure 2A 111) and / or any other control or communication related components (e.g., Figure 2A 112) into the cold zone (S730); and placing one or more fuel cell stacks (e.g., Figure 2A 211) and BOP components (e.g. Figure 2A In one embodiment, the fuel cell stack may be placed in a sub-thermal zone (e.g., 210a of FIG. 5 ), and the BOP components may be placed in a sub-thermal zone (e.g., 210b of FIG. 5 ). The method may also include placing one or more flow switches (e.g., Figure 2A , 3A and 113, 113a, 113b, 412 and / or 415 of 3B) or one or more air flow sensors (S750).

[0110] In addition, as a step for driving the fuel cell system, the method may further include: driving a blower (S810); measuring air flow (or air flow rate or flow speed) by a flow switch or sensor (S820); determining that the measured air flow meets a preset air flow requirement (S830); when the measured air flow meets the preset air flow requirement, maintaining the operation of the fuel cell system; yes (S840); when the measured air flow does not meet the preset requirement, shutting down the operation of the fuel cell system; no (S850). The preset air flow requirement may include the measured air flow being equal to or greater than a preset threshold. Shutting down the operation of the fuel cell system may include shutting off the fuel supply by controlling a fuel safety shut-off valve or disconnecting a power supply connection to the fuel safety shut-off valve.

[0111] The present invention includes other specific forms of embodiments without departing from its concept or essential characteristics. Therefore, the foregoing embodiments are to be considered in all respects as illustrative rather than limiting the invention described herein. Therefore, the scope of the present invention is indicated by the appended claims rather than by the foregoing description, and all changes within the meaning and range of equivalents of the claims are intended to be embraced therein.

Claims

1. A container for enclosing a heat release device, comprising: a first thermal region connected to an inlet port disposed on a first outer wall of the containment box; a second thermal region connected to the outlet port provided on the second outer wall of the containing box, the second thermal region including a heat release device and having a first sub-region and a second sub-region, and when the heat release device is operated, a temperature of the first sub-region is different from a temperature of the second sub-region, the first sub-region and the second sub-region being separated by a sub-region separation wall formed of a thermal insulation material; and A blower is disposed between the first and second thermal regions, the blower being configured to draw air from the first thermal region and provide air to the second thermal region.

2. The container according to claim 1, wherein: The second thermal zone is airflow isolated from the first thermal zone except by the blower. 3 . The containment box of claim 1 , wherein when the heat release device and the blower are operated, a temperature level of the second thermal zone is higher than a temperature level of the first thermal zone.

4. The containment box of claim 1, wherein when the blower is operating, a pressure level in the second thermal zone is higher than a pressure level in the first thermal zone.

5. The container according to claim 1, wherein: The inlet port is configured to draw air from outside the containment box into the first thermal region, and Wherein the outlet port is configured to exhaust air from the second thermal region.

6. The containing box according to claim 1, further comprising: one or more power electronic components disposed in the first thermal region; The heat release device includes one or more fuel processing components disposed in the second thermal region for generating electricity, Wherein when the blower and the heat release device are in operation, the temperature level of the second thermal region is higher than the temperature level of the first thermal region.

7. The containment box of claim 6, wherein the exothermic device comprises a fuel cell system having one or more fuel processing components, wherein the one or more fuel processing components include: One or more auxiliary plant equipment (BOP) components configured to supply reformate to the fuel cell stack; The fuel cell stack is configured to generate electricity based on reformate provided from one or more BOP components.

8. The containing box according to claim 7, wherein: The one or more BOP components include at least one of a fuel reformer, a chemical reactor, a gasket, a pump, a sensor, a humidifier, a heat exchanger, and a combustor.

9. The containing box according to claim 1, wherein: The first thermal region extends in an L-shape from the inlet port to the blower, and the second thermal region extends in a straight line from the blower to the outlet port.

10. The containing box according to claim 1, wherein: The first outer wall and the second outer wall are located in the same plane, and The first thermal region extends from the inlet port to the blower in an L-shape, and the second thermal region extends from the blower in a first direction to the outlet port.

11. A container for enclosing a heat release device, comprising: a first thermal region connected to an inlet port on a first outer wall of the containment box; a second thermal region connected to the outlet port on the second outer wall of the containing box, the second thermal region including a heat release device and having a first sub-region and a second sub-region, and when the heat release device is operated, a temperature of the first sub-region is different from a temperature of the second sub-region, the first sub-region and the second sub-region being separated by a sub-region separation wall formed of a thermal insulation material; a blower between the first and second thermal regions, the blower being configured and arranged to draw air from the first thermal region and to provide air to the second thermal region The containing box also includes a flow switch unit, which is configured to be turned off when the air flow measured by the flow switch unit does not meet the preset requirements to shut down the operation of the heat release device, and to be turned on when the air flow meets the preset requirements to maintain the operation of the heat release device.

12. The holding box of claim 11, wherein the flow switch unit comprises at least one of a valve or a differential pressure switch.

13. The containing box according to claim 11, further comprising a partition wall formed of a heat insulating material, which partitions the second thermal region into the first sub-region and the second sub-region.

14. The containing box according to claim 11, wherein the second thermal region includes a first sub-region and a second sub-region, the temperature level of the second sub-region needs to be controlled to be different from that of the first sub-region, The first sub-region and the second sub-region are separated by a further partition wall formed of a thermally insulating material.

15. The containment box of claim 14, wherein the exothermic device comprises a fuel cell system having one or more fuel processing components, wherein the one or more fuel processing components include: one or more BOP components configured to supply reformate to the fuel cell stack; and The fuel cell stack is configured to generate electricity based on reformate provided from the one or more BOP components, and The fuel cell stack is arranged in the first sub-area, and the BOP component is arranged in the second sub-area.

16. The containment tank of claim 15, wherein the BOP component comprises at least one of a blower, a fan, a fuel control valve, a fuel safety shutoff valve, and a sensor, wherein the one or more fuel processing components further comprises: One or more other BOP components, including at least one of a thermistor, a thermocouple, and a switch, are disposed in the first sub-region.

17. The containment box of claim 14, wherein the exothermic device comprises a fuel cell system having one or more fuel processing components, wherein the one or more fuel processing components include: a first set of BOP components including at least one of a thermistor, a thermocouple, and a switch; and a second set of BOP components including at least one of a blower, a fan, a fuel control valve, a fuel safety shutoff valve, and a sensor, The first group of BOP components is disposed in the first sub-region, and the second group of BOP components is located in the second sub-region.

18. A container for enclosing an exothermic device, comprising: a first thermal region connected to an inlet port disposed on a first outer wall of the containment box; a second thermal region connected to the outlet port provided on the second outer wall of the containing box, the second thermal region including a heat release device and having a first sub-region and a second sub-region, and when the heat release device is operated, a temperature of the first sub-region is different from a temperature of the second sub-region, the first sub-region and the second sub-region being separated by a sub-region separation wall formed of a thermal insulation material; a blower disposed between the first and second thermal regions, the blower configured to draw air from the first thermal region and provide air to the second thermal region; wherein the first outer wall and the second outer wall are located in the same plane, and the first thermal region extends from the inlet port to the blower in an L-shape, and the second thermal region extends from the blower to the outlet port along a first direction; and The third thermal zone is connected to the second inlet port on the first outer wall, and the third thermal zone extends in another L-shape from the second inlet port to the blower.

19. The containment box of claim 18, wherein the second thermal region is located between the first thermal region and the third thermal region.

20. A heat release device enclosed by the containment box of claim 1, wherein: The inlet port is connected to an inlet duct extending to an outdoor space, and ambient air is introduced into the first thermal region through the inlet duct.

21. A heat release device enclosed by the containment box of claim 1, wherein: The outlet port is connected to an outlet duct extending to an outdoor space, and air in the second thermal zone is exhausted through the outlet duct.

22. A method for providing airflow to a device, comprising: Disposing a first thermal region and a second thermal region within a containing box of the device; Disposing a blower between the first and second thermal regions; disposing one or more power electronic components in the first thermal region; One or more fuel processing components are disposed in the second thermal region, and are adapted to perform an exothermic treatment on the fuel in the second thermal region; The second thermal region is divided into at least a first sub-region and a second sub-region using a partition wall formed of a thermally insulating material, The second sub-zone is operated at a temperature level different from the temperature level of the first sub-zone.

23. The method of claim 22, wherein the first thermal zone is connected to an inlet port disposed on a first outer wall of the containment box, and the second thermal zone is connected to an outlet port disposed on a second outer wall of the containment box, and a blower draws air into the first thermal zone and blows it into the second thermal zone.

24. The method of claim 22, wherein when the blower is operating and the fuel is being processed, the temperature level of the second thermal zone is higher than the temperature level of the first thermal zone.

25. The method of claim 22, wherein when the blower is operating, the pressure level of the second thermal zone is higher than the pressure level of the first thermal zone.

26. The method of claim 22, further comprising providing a partition wall formed of a thermally insulating material between the first and second sub-regions.

27. The method of claim 22, further comprising: a fuel cell stack having one or more fuel processing components disposed in the first sub-region; and One or more BOP components of one or more fuel processing systems are disposed in the second sub-region.

28. The method of claim 23, wherein providing the first thermal zone comprises extending the first thermal zone in an L-shape from the inlet port to the blower, and wherein providing the second thermal zone comprises extending the second thermal zone in a straight line from the blower to the outlet port.

29. A method for providing airflow to a device, comprising: A first thermal region and a second thermal region are provided in a housing box of the device, the second thermal region includes a heat release device and has a first sub-region and a second sub-region, and when the heat release device is operated, a temperature of the first sub-region is different from a temperature of the second sub-region, the first sub-region and the second sub-region are separated by a sub-region separation wall formed of a thermal insulation material; Disposing a blower between the first and second thermal regions; disposing one or more power electronic components in the first thermal region; disposing one or more exothermic fuel processing components in the second thermal region; providing a flow switch unit in the device; When the air flow rate measured by the flow switch unit does not meet the preset requirements, the operation of the equipment is shut down; and When the air flow meets the preset requirements, keep the equipment running.

30. The method of claim 29, wherein the flow switch unit comprises at least one of a valve or a differential pressure switch.

31. The method of claim 29, further comprising dividing the second thermal region into at least a first sub-region and a second sub-region using another partition wall formed of a thermally insulating material, The temperature level that needs to be controlled in the second sub-zone is lower than that in the first sub-zone.

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