Blower filter assembly

Abstract

An apparatus having an air consuming mechanism therein. The apparatus has a housing with an air consuming mechanism, such as a fuel cell mounted therein. At least one blower assembly is in fluid communication with the air inlet and supplies air to the air consuming mechanism. The blower inlet has a filter, such as an N95 filter. The blower and the filter have attachment structures adapted to releasably engage each other.

Description

Technical Field

[0001] The present invention relates to a filter assembly, and more particularly, to a filter assembly for a blower, particularly a blower for use in a fuel processing device requiring a flow of air or other oxygen-containing gas, such as a fuel reformer, a fuel cell system, a fuel burner, etc. As used herein, the term air shall include ambient air which may be enriched with oxygen or diluted with nitrogen or otherwise diluted. Background Art

[0002] Heat release mechanisms, such as catalytic oxidation, combustion, fuel reforming or fuel cell devices, are usually controlled by various electronic systems. Generally, it is necessary to control gas flow valves and blower speeds to properly regulate chemical reactions. It may be important to shield electronic devices from the heat emitted by these mechanisms. It is also important to isolate the heat emitted from these mechanisms so that they can be more conveniently integrated into their surroundings. For example, internal combustion engines, fuel cells and fuel reformers generate considerable amounts of heat. When trying to locate these mechanisms near individuals or in habitats, residences, offices or other living structures, this may be difficult. When trying to provide a compact device with a compact housing, excessive heat may also be difficult, where parts of the mechanism (such as electronic devices) must be tight, close but thermally isolated.

[0003] Fuel consuming devices may also require precise airflow to ensure that oxidation of the fuel occurs in a well-controlled manner. For example, blowers used to supply air to these devices are often controlled by electronics that receive information from sensors, monitoring devices, etc. Some of these electronics and other BOP components need to be protected from the heat emitted by the equipment they are controlling.

[0004] The construction of conventional heat-generating mechanisms such as internal combustion engines, fuel cells, and fuel reformers presents additional difficulties that make it difficult to integrate these mechanisms into a living environment. Furthermore, the need to protect the electronics and other components from the heat generated by the device can complicate efforts to construct the device in a compact manner if the physical separation of the components and electronics from the heat-generating elements takes up too much space.

[0005] Blowers can be used to provide air as a source of oxygen to fuel consuming devices. Some blowers are provided with air filters. However, these filters are often bulky and interfere with compact construction. Replacing these filters may also be inconvenient, and some filters are insufficient to filter dust and other impurities in the inhaled air. Many fuel cell assemblies and reformers utilize ambient air as a source of oxygen for the chemical and electrochemical reactions that occur therein, as well as for temperature control within the unit. Ambient air typically includes particles (e.g., dirt / dust), pollutants (e.g., sulfur, hydrocarbons), and / or moisture, each of which may damage the highly sensitive catalytic surfaces within the fuel cell and reformer unit. Existing filtration systems have proven insufficient to protect these systems.

[0006] It would therefore be desirable to provide an improved structure for a heat generating mechanism that overcomes the shortcomings of the prior art. Summary of the invention

[0007] Generally speaking, according to the present invention, the device has at least two regions, at least three or more thermal zones, each thermally isolated from each other and each thermal zone at a different temperature range. The airflow of ambient air from the air inlet of the device can be used to maintain these zones at different temperatures, such as a cooling zone and a hot zone at a temperature higher than the cooling zone; and an intermediate zone at a temperature between the two. Preferably, the cooling zone is at a temperature suitable for the electronic components.

[0008] In one embodiment of the present invention, the airflow passes over the exterior of the device to thermally isolate the exterior of the device from the interior where heat is generated. In another embodiment of the present invention, the airflow from the air inlet is used to cool the temperature of one, two or more cooling zones of the device so that heat-sensitive components (e.g., electronic devices) are not damaged by the heat generated by the heat release device.

[0009] In one embodiment of the present invention, the device includes a heat generating mechanism, such as a fuel burner, a fuel reformer, a fuel cell or a fuel cell stack. As used herein, the term fuel cell stack may include a plurality of assembled fuel cells. Each fuel cell can generate electricity in the form of direct current from the electrochemical reaction occurring therein. The fuel cell system according to the present invention may include a fuel reforming part integrated with a power generation part, which is integrated into a single fuel cell structure. Individual fuel cells may be combined into a stack, and auxiliary factory equipment (BOP) components may include various systems and structures for generating electricity, including fuel reformers, chemical reactors, gaskets, pumps, sensors, evaporators, heat exchangers, blowers, switches, relays, thermistors, thermocouples, conduits, control electronics, catalytic oxidizers, burners, etc.

[0010] The airflow (including oxygen-enriched airflow) from the air inlet can be used as an oxygen source for the heat generating mechanism. The airflow can be used to help keep the area and sub-area thermally cooled, although it may be very close to the heat from the heat releasing mechanism. For example, ambient air flow can be blown or sucked on various components of the mechanism (such as electronic components) to keep these components cool. The suction air flow can also thermally isolate the outer surface of the device from the heat generated therein. This can be achieved by external suction intake around the heat releasing element. The airflow can also be blown or sucked on any electronic device or other component that needs to be kept cool. Excess intake air not required for the exothermic reaction can be directly supplied to the outside of the housing.

[0011] This air can then flow into the device to serve as a source of oxygen for any chemical reactions therein. However, it may be important to filter impurities from the air to help ensure that this intake air does not damage sensitive internal components, such as catalytic surfaces and the like.

[0012] In one embodiment of the present invention, the heat release mechanism can be encapsulated in a double-walled shell of a housing for the mechanism. The internal space between the outer wall and the inner wall can be used as an air intake duct, which can be used as a tube-in-tube structure. The fin array can extend through the gap between the outer wall and the inner wall to transform the structure into an assembly of an air intake pipe around the entire length of the heat release mechanism. The intake air flow can also be sucked or blown through one or more internal cooling zones of the device and then fed into the heat release portion of the mechanism as an air / oxygen source. Any hot exhaust can be directly supplied to the outside of the housing and can be piped to a convenient exhaust position. Therefore, if the air inlet is located at the rear end of the device, cold ambient air can be sucked in and surround the entire top and / or bottom and / or side of the device including the relatively cold part inside it. The intake air can then be fed into the heat release hot part, and the exhaust can be discharged from the rear end. The air inlet and the exhaust port can be side by side or concentric. For example, the air inlet can surround the exhaust port.

[0013] In one embodiment of the invention, the housing for the device has a double-walled construction with an inlet and an outlet at the rear end. The heat generating mechanism can be mounted on a platform and slide in and out of the front end of the housing. The blower can be positioned toward the front end. The blower can draw cooling air into the rear end of the housing, around the length of the device through the double-walled air channel, and into the front end of the housing. The interior area in the front end of the housing can be used as a cooling zone, in which at least some electronic devices and other components that need to be kept cool can be installed. After passing outside the device housing and through the cooling zone, the intake air flow can be blown into the heat releasing element by one or more blowers and then discharged to the outside of the device.

[0014] According to the present invention, a centrifugal blower device is also provided, which includes a blower unit having a blower housing having an axial inlet and a radial outlet. An impeller is arranged in the housing for sucking a gaseous medium (e.g., air) at a first pressure into the axial inlet and discharging the gaseous medium at a second higher pressure through the radial outlet. A motor is provided for driving the impeller. The blower also includes an air intake assembly. The housing has an air inlet and an air outlet. The air outlet is connected to the axial inlet of the blower housing of the blower unit. A check valve can be installed in the housing, positioned to allow air flow to flow from the air inlet to the air outlet, and prevent air flow from flowing back to the air inlet from the air outlet.

[0015] It may be advantageous to filter the ambient air before it enters the equipment. Conventional mechanical filters can be used to remove relatively large impurities. It is also advantageous to filter the air immediately before it is sent to the fuel consumption or power generation device to help remove particles, volatile compounds, sulfur compounds, etc. It can help reduce moisture. The filter can be some kind of reticulated foam (low pressure drop) and may be doped with specific materials to perform the tasks listed above. In a preferred embodiment of the present invention, the filter can be formed of N95 certified materials, including off-the-shelf N95 certified filters.

[0016] It is advantageous to include a check valve in the blower. The check valve helps prevent zero flow conditions from causing backflow of the fan and other process air. This backflow can damage the solid oxide fuel cell (SOFC) and the catalyst through oxidation. The present invention can prevent this from happening. The check valve can be a soft elastomer that causes very little pressure drop to open, and uses the slight inherent stiffness and spring constant of the material to close and seal.

[0017] The blower that delivers air to the heat release device is advantageously configured as a two-stage blower assembled in series. A system utilizing multiple blowers linked according to the present invention can be used to achieve the airflow requirements of a fuel cell or other sensitive heat release mechanism. The dual blowers help enable the system to benefit from a low inertia impeller for control and low drive motor rpm and power consumption to provide the required gas flow and pressure.

[0018] Thus, the arrangement of a single multi-stage centrifugal blower can provide improved response time and control over a wide range of gas pressure and gas flow requirements. Fuel cell blower assemblies featuring such an arrangement of multi-stage centrifugal blowers are described, for example, in U.S. Patent Nos. 9,017,893; 9,593,686 and 9,512,846, the entire contents of each of which are incorporated herein by reference. Additional fuel cell blower assemblies featuring such a multi-stage centrifugal blower arrangement are described, for example, in International Application No. PCT / US2012 / 020707 filed on March 16, 2015 and International Publication No. WO / 2016 / 148681 published on September 22, 2016, the entire contents of each of which are incorporated herein by reference.

[0019] It may be particularly advantageous to filter the air entering the exothermic fuel consumption device (e.g., a fuel reformer or a fuel cell) discussed herein. In a preferred embodiment of the present invention, the blower is in fluid communication with the intake air and filters the air before it is sent to the exothermic device. The preferred blower includes a blower housing having an axial inlet and a radial outlet. The inlet may include a filter attachment mechanism. A filter having an attachment portion designed to cooperate and engage with the attachment mechanism of the housing may provide a releasable attachment mechanism for mounting the filter on the air inlet of the blower to filter the air before the air is about to enter the exothermic device.

[0020] The filter according to the present invention can advantageously meet the N95 standard. For example, an off-the-shelf commercially available N95 filter can be used. In order to improve the surface area and thus improve filtration and airflow, the filter should be a double-layer filter with an internal structure that maintains the layer separation during inhalation filtration so that the entire outer surface is available for air filtration and airflow to maximize airflow per filter area.

[0021] In a preferred embodiment of the invention, the housing of the entire device has a double wall structure with an inlet and outlet at the rear end. By adjusting the size of the double wall air duct, the air flow rate can be adjusted and the cooling by the air flow is maximized. The heat generating mechanism can be mounted on a platform and can slide in and out of the front end of the housing. If the device is used for power generation, the device can remain independently connected to the facility, such as a home, R / V, office, etc., and the core stack / BOP and electronics can slide out of the housing for maintenance, repair or component replacement.

[0022] The fuel cell system according to the present invention can be wired to supply power to a home, RV or other residence. The overall dimensions can be relatively small, 6-24 inches x 6-24 inches x 12-36 inches, preferably less than 4 feet in total length, and preferably greater than 6 inches in total length. A fuel line for providing reformable fuel should also be included. If liquid fuel is to be used, a vaporizer for vaporizing the liquid fuel is useful.

[0023] The main blower can be positioned at the front end. The blower can draw cooling air into the rear end of the housing, around the length of the device through the double-walled air channel, and into the front end of the housing. The front inner area in the front end of the housing can be used as a cooling zone, where electronic devices and other components that need to be kept cool can be installed. After passing through the outside of the exothermic device and through the cooling zone, a portion of the incoming air flow can be blown into the hot zone where the exothermic element is located, and then discharged to the outside of the device. This helps to balance the air flow and helps to reduce the temperature of the hot zone. Additional cooling zones can be set upstream of the main blower or preferably downstream of the main blower. The flow control cooling zone can accommodate a flow control blower, which electronically controls the precise airflow entering the exothermic element and helps control the exothermic reaction therein. In a preferred embodiment of the present invention, this additional electronically controlled blower is located in the flow control cooling zone, and the air flow entering the zone keeps the flow control zone cool. According to the present invention, filters on these flow control blowers help protect the exothermic element receiving the air.

[0024] The flow control electronics preferably measures the air flow resistance through the blower to determine whether the filter on these blowers needs to be changed. In a preferred embodiment of the invention, the filter can be screwed on and off the air inlet of these blowers for easy replacement and firm, well-sealed connection.

[0025] Other advantages and objects of the present invention will be apparent from the following drawings and description. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] The following drawings are for illustration only and should not be considered to limit the scope of the present invention. The drawings are to scale, but other scales are also acceptable within the spirit and scope of the present invention.

[0027] FIG1 is a schematic side cross-sectional view of a heat release device according to a preferred embodiment of the present invention;

[0028] 2 is a side cross-sectional view of an integrated fuel reformer and fuel cell device (fuel cell) according to a preferred embodiment of the present invention;

[0029] 3 is a bottom perspective view of a blower and filter assembly according to a preferred embodiment of the present invention;

[0030] 4 is a bottom perspective view of the blower and filter of FIG. 3 with the filter removed from the filter housing;

[0031] 5 is a partial top perspective view of a housing for the blower and filter assembly of FIG. 3 ;

[0032] FIG6 is a top plan view of a portion of the housing of FIG5 ;

[0033] FIG7 is a partial side view of the housing of FIG5;

[0034] FIG8 is a bottom perspective view of the filter of the housing and filter assembly of FIG5;

[0035] FIG9 is a bottom view of the filter of FIG8;

[0036] FIG10 is an inverted side view of the filter of FIG8;

[0037] 11 is a bottom perspective view of a filtered flow control blower assembly according to a preferred embodiment of the present invention;

[0038] FIG12 is an exploded perspective view of the filtered flow control blower assembly of FIG11; and

[0039] 13 is a partially exploded view of the filtered flow control blower assembly of FIG. 11 . DETAILED DESCRIPTION

[0040] The present disclosure may be more readily understood by reference to the following detailed description of the present disclosure in conjunction with the accompanying drawings, which form a part of the present disclosure. It should be understood that the present disclosure is not limited to the specific apparatus, methods, conditions or parameters described and / or shown herein, and that the terminology used herein is only for the purpose of describing specific embodiments by way of example and is not intended to limit the disclosure claimed.

[0041] In addition, as used in the specification and including the appended claims, the singular forms "a", "an", and "the" include plural, and references to a particular 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 a particular value and / or to another particular value. Similarly, when a value is expressed as an approximation by using the antecedent "about", it is understood that the particular value forms another embodiment.

[0042] The present invention relates to heat release mechanisms. Examples include catalytic fuel oxidizers or reformers, fuel consumption devices, fuel processing devices, and other heat generating devices. These terms may include any heat release device based on any kind of fuel, including the devices described in Serial No. 17 / 267,095 filed on February 9, 2021 and U.S. Patent Nos. 9,627,700 and 9,627,701. The contents of this application and these patents are incorporated herein by reference. Heat generation and / or heat release devices include generators, fuel reformers, fuel cell systems, etc. The expression fuel should be understood to include both liquid fuels and gaseous fuels, including vaporized liquid fuels. The term fuel cell will include an integrated device that reforms the fuel and generates electricity.

[0043] As used herein, the term fuel cell stack may include a plurality of assembled fuel cell units. Each fuel cell can generate electricity in the form of direct current from the electrochemical reaction occurring therein. Individual fuel cells can be combined into stacks, and auxiliary plant equipment (BOP) components may include various systems and structures for generating electricity, including fuel lines, fuel evaporators, fuel reformers, chemical reactors, gaskets, pumps, sensors, heat exchangers, blowers, switches, relays, thermistors, thermocouples, conduits, control electronics, etc.

[0044] Examples of heating 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 these patents are incorporated herein by reference. The fuel reformer according to the present invention can be configured to supply reformate, such as hydrogen-rich reformate, to the fuel cell stack. The fuel cell stack can be operated at a relatively high temperature to maximize power generation. In addition, the fuel cell and the reformer and / or BOP components may require a sufficient amount of airflow. A portion or all of the air flow can be mixed with the fuel to provide, for example, a fuel-air mixture and a hydrogen-rich reformate. The air flow can also be used for the purpose of diluting the fuel or reforming the fuel to control the intensity of the chemical reaction. In addition, other electronic components of the fuel cell system can be used as a heat source and need to be cooled for normal operation.

[0045] Thus, there may be various thermal zones and thermal sub-zones of those zones that need to be maintained at different temperatures, depending on the type and function of the various components therein.

[0046] As used herein, the terms hot zone and cold or cooling zone are relative in nature. For example, a cold or cooling zone may be well above room temperature, but below the temperature of the hot zone and below the temperature at which electronic components are damaged. In addition, the hot zone and the cold zone may include various sub-zones of different relative temperatures.

[0047] The heating device according to a preferred embodiment of the present invention may include a low temperature hot zone and a high temperature hot zone. The heat-insulating wall may be located at the interface of the two zones. The low temperature (cold) hot zone may be in fluid communication with the air inlet, wherein the ambient air flow is sucked into the device such as by the main blower. The high temperature (high heat) hot zone comprises a heating device, such as a fuel reformer, a fuel cell, an internal combustion engine, etc. The two zones may be separated by a heat-insulating wall. The blower may be present at the interface of the two zones, preferably in a cooling zone or a cooling sub-zone. The blower may suck ambient air into the cold zone, and the low temperature of the cold zone is maintained by the constant flow of ambient air. Then, the blower may blow the air into the hot zone, the cold sub-zone or both according to the needs of the appropriate operation of the exothermic reaction.

[0048] Ambient air may include undesirable particles, contaminants, and / or moisture that may affect the normal operation of the fuel cell assembly and / or reformer. These particles or contaminants may include sulfur or hydrocarbons, and / or moisture, which may damage the fuel cell and reformer units. Such damage may be in the form of oxidation of internal components, contamination of catalysts, hot spots from accumulated particles, or rapid cooling that may cause structural defects in the components.

[0049] The components of the fuel cell assembly according to the present invention are designed to maintain their mechanical, chemical and / or electrical integrity during startup and normal operating modes when exposed to high operating temperatures. During the cooling period, for example, switching to a low power mode or a power-off process, problems may occur. For example, when the system cools, the air in the fuel cell assembly can condense and create a vacuum in the fuel cell assembly, which can continue to inhale external air through the air inlet and / or exhaust port. Exposure of the fuel cell assembly to this additional external air may cause damage to the oxidation or structural integrity of the fuel cell stack. Therefore, as described herein, the check valve and filter in the air inlet can help prevent these problems.

[0050] The apparatus according to the invention may be configured to have a heat generating device mounted on a platform and having a housing surrounding the platform. The housing may have two layers of double walls with an air intake duct therebetween. The inner and outer layers of the double wall may be segmented by a plurality of fins extending along the length of the wall to form a plurality of air channel tube structures along the length of the double wall and improve the efficiency of the air flow.

[0051] An ambient air inlet may be present at the rear end of the housing, and a blower may be present in the front end of the housing. Thus, air may be drawn into the inlet and flow through the housing, around the outside of the entire device to its front area. This may create a cooling zone around the outer surface of the device. The rear end may also include a cooling zone, into which ambient air is drawn. The front end may also include a cooling zone, as ambient air flows from the air passage to the open front end of the housing. Thus, a cooling zone may be an airflow that is isolated from a hot zone across the blower. Thus, components that require cooling (such as electronic components) may be mounted in a cooling zone (front, rear, or bottom), and the outer surface of the device may be maintained at a relatively cool temperature.

[0052] In one embodiment of the invention, the device includes a fuel cell system having one or more fuel processing components. These one or more fuel processing components may include one or more auxiliary factory equipment (BOP) components, which are configured to supply reformate fuel mixed with air to the fuel reforming part of the fuel cell stack. The fuel cell stack can be configured to generate electricity based on the reformate provided from the reforming section. An electronically controlled blower can be located in an airflow control area. These blowers control the precise flow of air to the fuel cell assembly. These blowers can be located in a flow control area, and are kept cool by the ambient air flow therein. Any excess air blown into the flow control area can be discharged from the device exhaust port.

[0053] In one embodiment of the present invention, the BOP component may include an airflow switch unit configured to adjust the blower speed and be closed when the airflow does not meet the preset requirements. The airflow can be measured by the airflow switch unit. When the air flow meets the preset requirements, the airflow at one or more blowers can also be adjusted to maintain the proper performance of the equipment. In one embodiment of the present invention, the airflow switch unit may include a flat upper portion or a differential pressure switch. Blowers, preferably dual blowers, can be used, which can be electronically controlled to operate at different speeds to adjust the flow of air entering the heat release device as needed. These flow control blowers of the BOP components can be installed in an airflow control cooling zone, where the air flow entering and around the flow control blower keeps the area at a cooler temperature than the hot zone to help protect any electronic components of the airflow control system.

[0054] The housing for the device may include a thermal separation wall formed of a thermally insulating material to separate hot and cold zones and sub-zones. In addition, the cold zone or hot zone may be divided into different sub-zones, maintained at different temperatures relative to each other.

[0055] In one embodiment of the invention, the fuel cell system and the one or more fuel processing components may include one or more BOP components configured to supply reformate to the fuel cell stack. The fuel cell stack may be configured to generate electricity based on the reformate provided from the one or more BOP components. The fuel cell stack may be located in a first thermal sub-region, and the BOP components may be disposed in a second thermal sub-region having a lower temperature than the first thermal sub-region.

[0056] In one embodiment of the invention, the air inlet port may be positioned at the rear end of the housing and configured to draw ambient air into the cooling zone. The hot zone may include a hot zone exhaust port to exhaust hot gases generated by the 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 port is surrounded by the air inlet port. The exhaust port and the air inlet port may also be side by side at the rear of the device.

[0057] In operation, the main blower may draw air through the inlet, into the interior of the rear end of the housing, around the exterior of the housing and into the interior of the open front end of the housing. The blower may then blow air into the hot zone, or into a hot or cold sub-zone, such as a flow control zone with an electronically controlled blower, for delivering air to an oxygen consuming exothermic device, such as a fuel reforming, processing or combustion device. The blower may also blow the intake air into a flow control cooling zone to control the precise air flow to the fuel consuming / combusting / reforming device. The hot exhaust gas is discharged through the hot zone exhaust port. Electronic components may be located in the cold zone, and fuel processing components may be located in the hot zone of the device, the cold zone being in fluid communication with the ambient air inlet upstream of the hot zone. The hot zone may be downstream of the blower, in fluid communication with the exhaust port. In one embodiment of the present invention, the hot zone may be completely enclosed at the front, side and / or rear by at least one cold zone, except for the exhaust port.

[0058] A preferred embodiment of an exothermic fuel consumption device constructed in accordance with the present invention is generally shown in FIG. 1 as a fuel cell 100. The fuel cell 100 includes a rear end 110, a middle section 150, and a front end at a front cover 180. The middle section 150 extends from a middle section front portion 150f to a middle section rear portion 150r. The middle section rear portion 150r of the middle section 150 is located at the rear end 110 of the reformer 100. The middle section front portion 150f of the middle section 150 is located at the front cover 180 of the reformer 100. The reformer rear end 110 includes an inlet 111 concentric with an outlet 112 formed through a rear cover 113. The middle section 150 includes a housing cover 160 surrounding a fuel cell 171, which is mounted in a hot zone 170 to maintain heat by heat emitted by the fuel cell 171. The fuel cell 171 includes an array of fuel reforming reactors at its anode end producing a hydrogen-rich reformate and at its cathode end producing electricity, a blower 172 for drawing air into the inlet 111, and electronic components 183 mounted in a cooling zone 182 within a front cover 183. The front cover 183 may be removably and securely held to the mid-section rear portion 150r with bolts.

[0059] Flow control blowers and electronic systems for regulating the precise flow of air entering the fuel cell 171 by controlling the speed of these flow control blowers can be mounted in the cooling temperature flow control area 200. The fuel cell 171, blowers 172, electronic devices 183 and the system of flow control area 200 (discussed below) can all be mounted together as a unit on a mounting platform that can slide in and out of the housing front end cover 180 for maintenance, repair or component replacement. The fuel cell system 100 can remain electrically connected to a receiver of the electricity generated thereby.

[0060] The housing cover 160 is formed with an outer wall 161 and an inner wall 162. A housing duct 165 for intake air flow is formed between the outer wall 161 and the inner wall 162. An array of fins 166 extends from the inner surface of the outer wall 161 into the housing duct 165, reaches the inner wall 162, and forms an array of tubular ducts along the inner surface of the outer wall 161.

[0061] The inner wall 162 is shorter than the outer wall 161. Therefore, the housing conduit 165 is exposed at the rear end 150r and the rear end 150r of the middle section 150. The gasket 115 exists around the outer edge of the inner surface of the rear cover 113. The rear end 150r of the middle section 150 is pressed into the gasket 115. Because the inner wall 162 of the middle section 150 is shorter than the outer wall 161 and the fin 166, the internal conduit 165 can be approached at the rear end 150r of the middle section 150. Similarly, the gasket 181 exists around the outer edge of the inner surface of the front cover 180. Therefore, the internal conduit 165 can also be approached at the front end 150f. Therefore, internal spaces are formed inside the rear cover 113 and the front cover 180. These internal spaces are in fluid communication with the housing conduit 165.

[0062] The air inlet 111 is in fluid communication with the interior defined by the rear cover 113 / front end 110. However, the outlet 112 is sealed and isolated from the interior of the front cover 113. Therefore, any air entering the inlet 111 enters the interior of the front cover 113, which is in fluid communication with the housing duct 165 at the rear end 150r of the middle section 150. The housing duct 165 is in fluid communication with the front interior 182 closed by the front cover 180 at the front end 150f of the middle section 150. The inlet end 173 of the blower 172 is in fluid communication with the interior 182 of the front cover 180. The radial outlet 174 of the blower 172 is in fluid communication with the fuel cell 171. Therefore, when the blower 172 is operated, it draws air into the inlet 111 in the direction of arrow A, along the housing duct 165 in the direction of arrow B, and then enters the rear interior 182 in the direction of arrow C. The electronic assembly 183 is mounted in the rear interior 182. Therefore, the intake air is blown over the electronic devices 183 before entering the fuel cell 171 to keep the electronic devices 183 cool in the electronic device cooling zone.

[0063] Due to the intake air flowing along the outside of the fuel cell 100 and entering the interior 182 of the front cover 180, a cooling zone is formed on the outside of the fuel cell 100 and at the front interior 182. Therefore, the outer surface of the fuel cell 100 and the front interior 182, which contains the electronic device 183 and other elements that need to be kept cool, can be provided. The insulating wall 167 is set at the rear end of the electronic device cooling zone 182. The blower 172 is installed on the insulating wall. The wall 167 and the blower 172 and the intake air flowing through the conduit 165 together help to isolate the heat release portion of the fuel cell 100.

[0064] The blower 172 can direct the intake air into the flow control area 200 in the direction of arrow D. The air from the flow control area 200 flows to the hot zone 170, and some of the air is blown directly into the fuel cell 171, where it participates in the exothermic reaction, producing a hot exhaust gas flow, traveling in the direction of arrow E. The exhaust gas flow and the hot air heated by the exothermic heat of the fuel cell 171 then leave the exhaust port 112 of the fuel cell 100 in the direction of arrow F. The exhaust port 112 can be elongated to convey the hot exhaust gas to an appropriate chimney, flue or other structure. However, because the exhaust port 112 is concentric within the intake port 111, the intake air helps to isolate this heat.

[0065] The cold flow control zone 200 is in fluid communication with ambient air drawn in by the blower 172. The controlled blower in the flow control zone 200 regulates the precise amount of air entering the fuel cell 171. Excess air can flow around the fuel cell 171.

[0066] A fuel cell device having a combined fuel reformer and fuel cell stack is generally shown in FIG. 2 as an exothermic device 201. A stream of ambient temperature intake air 216 enters the device 201 through an intake port 211. The intake air 216 flows along a conduit 265 formed by a double-walled outer shell 250, which is similar to the housing of the reformer 100. The intake air 216 is sucked into the device 201 by a main blower 273. An open rear recess 282 is located at the rear end of the device 201. A front cover 280 is securely held against the conduit 265 by bolts. An assembly of electronic devices 283 is mounted in the rear recess 282. The intake air 216 can be directed below above the rear end of the electronic devices 283, through the front side of the electronic devices 283, or both.

[0067] The device 201 includes an integrated fuel reformer and fuel cell 271. The fuel reformer portion receives a fuel flow from a fuel line and receives an air flow through a reformer air intake hose 276. The fuel cell portion, which generates electricity from the reformed products, receives an air flow from a fuel cell hose 275. The air flow from hoses 275 and 276 is controlled by an assembly of flow control electronics 290. The flow control electronics 290 controls the air flow from a fuel cell blower assembly 350. The flow control electronics 290 and the blower 300 are located in a flow control area 202, which is located below a hot zone 270 that houses the fuel cell 271.

[0068] The flow control region 202 is in fluid communication with the ambient intake 216. Thus, a flow of flow control air 217 flows from the blower 272 into the flow control region 202 and maintains the flow control region 202 as a relatively cool region within the heat release device 201. The air supply 217 provides an intake air supply to the fuel cell 271, as controlled by the flow control electronics 290.

[0069] The dual fan blower 300 of the blower assembly 350 is generally shown in Figures 3 and 4. The blower 300 includes a housing 301 having an axial inlet 310 and a radial outlet 320. In Figure 3, a filter 400 is shown attached to the inlet 310. In Figure 4, the filter 400 is shown separated from the inlet 310. The filter 400 cooperates with the inlet 310 in the direction of arrow A. Therefore, any air supplied to the fuel cell 271 can be filtered. The preferred filter meets the requirements of the N95 certification.

[0070] A top perspective view of a portion of a blower housing 500 of the blower 300 is shown in Figure 5. A top plan view of the housing 500 is shown in Figure 6, and a side view of the housing 500 is shown in Figure 7. The housing 500 includes a fan area 510 for accommodating an electronically controlled fan (not shown) to draw air into the inlet 310 and blow air out of the outlet 320.

[0071] The inlet 310 is configured to releasably secure the filter 400 thereto. The inlet 310 is circular and has a plurality of (three) prongs 315 extending outwardly therefrom. Each prong 315 has a base 316 extending axially upward from the inlet 310, a smooth transition portion 317, and a hook portion 318 extending radially from the transition portion 317. Each prong 315 is offset to the center of the inlet 310 at a shelf 319. Because the prongs 315 are offset to the center of the inlet 310, the inlet 310 can present an uninterrupted circular base 314 for effective sealing with the filter 400.

[0072] In FIGS. 8 , 9 and 10 , the filter 400 is shown in a bottom perspective view, a bottom plan view and a side view, respectively. The filter 400 includes a central attachment portion 410 extending axially from a bottom surface of the filter 400. The attachment portion 410 includes a circular engagement ledge 414 for engaging with and sealing against a base 314 of a housing 500 of the blower 300. The filter 400 also includes an engagement lip 411 that nests within the inner surface of the base 314 to help seal the filter 400 against the inlet 310.

[0073] The central attachment portion 410 of the filter 400 also includes a plurality of (three) engagement slots 415 for receiving corresponding (e.g., 3) pins 315 of the blower housing 500. The attachment portion 400 also includes a plurality of (three) cam ribs 418. In order to attach the filter 400 to the blower 300, the attachment portion 410 is pressed against the inlet 315 in the direction of arrow A (FIG. 4). The filter 400 is then radially rotated until the hook 318 of the pin 315 of the housing 500 passes downward through the slot 415 of the filter 400. The upper surface 420 of the cam rib 418 is inclined. The left end of each cam rib 418 enters the interior of the filter 400 farther from the surface of the engagement frame 414 than the right end. Therefore, after the pin 315 is inserted downward through the slot 415, the filter 400 rotates. This places the upward facing surface of the hook 318 on the thin / low downward facing surface of the cam rib 418. As the filter 400 is further rotated, the engagement of the downwardly facing surface of the lower surface 420 with the upwardly facing surface of the hook 318 becomes more tightly engaged to tighten the engagement between the engagement frame 414 of the filter 400 and the base 314 of the inlet 310, thereby providing an effective seal between the filter 400 and the inlet 310 of the blower 300.

[0074] The filter 400 can be formed of any suitable filter material. It is preferably a two-layer filter with spaces between the layers for increasing the surface area, and therefore the filtering surface, for airflow filtering into the inlet 310. Preferably, the filter 400 meets the N95 certification standards. It is also preferred to construct the filter 400 to keep the top and bottom surfaces of the filter 400 separated so that air can be filtered through both the top and bottom surfaces before flowing into the inlet 310.

[0075] The flow control electronics 290 includes sensors for measuring air flow. These sensors will be able to detect if the filter 400 becomes too clogged to allow for adequate air flow and / or proper filtration. In this case, the electronics 290 can activate a warning signal, such as a flashing light and / or an audible signal. At this point, the heat release device 201 can be turned off and the filter 400 can be replaced. This can be achieved by rotating the filter 400 in the opposite direction to slide the hook 318 toward the slot 15, whereby the filter 400 can be removed from the inlet 310 in the direction opposite to the arrow A.

[0076] The attachment of the blower 300 to the printed circuit board (PCB) 375 is more clearly shown in FIG. 13. The circuit board 375 includes a hole 376 for receiving the axial inlet 310 of the blower 300. The blower 300 is mounted on the plate 375 in the direction of arrow Z, wherein the axial inlet 310 is inserted into the hole 376. The filter 400 is then attached to the exposed axial inlet 310 extending through the hole 376 to provide a filtered air intake for the air received by the blower 300 to supply the filtered air to the fuel cell 271, as controlled by the flow control circuit 290.

[0077] Referring to Figures 12 and 13, the components of the blower 300 and the control circuit 290 are mounted on a circuit board 375. The BOP support panel 380 is used to mount the PCB 375 within the flow control area 202 of the heat release device 201. Figure 11 is a bottom perspective view of the PCB 375 attached to the support panel 380, with the exploded view in Figure 12. The air filter gasket 385 is sandwiched between the top of the PCB 375 and the support panel 380. The support panel 380 is fixed within the flow control area 202. The filter gasket 385 allows airflow to reach the filter 400 in the direction of arrow X. If the filter 385 is coarser than the filter 400, it will act as a primary filter and prevent the filter 400 from being blocked by particles larger than the particles that can be filtered out by the available filter gasket 385. Note that in some embodiments of the present invention, it is not necessary to use an N95 certified filter. In fact, some embodiments of the present invention can omit the filter 400 and only use the filter gasket 385 around the outer edge of the PCB / board interface.

[0078] The airflow through the blower 300 is more clearly shown in Figures 14 and 15. The air from the relatively cold flow control area 202 is sucked through the filter 385 by the blower 300 in the direction of the arrow X. The filter gasket 385 can be used as a primary filter and retain larger particles to prevent those particles from reaching and clogging the filter 400. This helps to extend the life of the filter 400. After passing through the filter 385, the air flows between the panel 380 and the plate 375. Due to the narrow size, the flow rate can be high. This improves heat transfer, and the improvement of heat transfer helps to keep the plate 375 cool. After passing between the plate 375 and the panel 380, the air is sucked through the filter 400. The size of the gap between the plate 375 and the panel 380 can be set to be wider than the height of the filter 400 to allow the air flow above and below the filter 400 so that the entirety of the filter 400 can be used for filtering. After passing through the blower 300, the air is guided through the outlet 320 and finally reaches the fuel cell 271.

[0079] Note that where the application has listed the steps of a method or procedure in a particular order, it is possible, or even advantageous in some cases, to change the order of performing some of the steps, and it is intended that the specific steps of the method or procedure claims set forth below are not to be construed as order-specific unless such order-specificity is explicitly stated in the claims.

[0080] Although preferred embodiments of the apparatus and method have been described with reference to the environment in which the apparatus and method are developed, they are merely illustrative of the principles of the invention. Modifications or combinations of the above-mentioned components, other embodiments, configurations, and methods for implementing the invention that are obvious to those skilled in the art, as well as changes in various aspects of the invention, are intended to fall within the scope of the claims.

Claims

1. A device having a heat generating and heat releasing mechanism, comprising: a housing having an outer surface and an inner surface defining a housing interior, the housing having a front and a rear and a length from the front to the rear, the heat release mechanism being mounted within the housing interior and having an air inlet port; an air intake conduit in fluid communication with a source of ambient air at an air inlet of the housing; a blower assembly having a blower having a blower inlet in fluid communication with the inlet conduit and a blower outlet in fluid communication with the inlet port of the heat release mechanism; The blower air inlet has a filter thereon adapted and positioned to filter air from the air inlet duct.

2. The device of claim 1, wherein the filter is an N95 certified filter.

3. The device according to claim 1 and 2, wherein: The blower assembly includes a second blower connected in series with the first blower, and each blower has a fan wheel operated by a motor.

4. The device according to claims 1 to 3, wherein: The blower has an annular shelf surrounding the blower air inlet, the annular shelf being configured and adapted to be releasably attached to the filter.

5. The device according to claims 1 to 4, wherein: The filter has an outer filter inlet surface in fluid communication with the filter interior and a filter outlet in fluid communication with the filter interior, the filter having an annular shelf surrounding an end of the filter outlet, the annular shelf being sized and configured to mate with the blower inlet.

6. The device according to claims 1 to 5, wherein: The blower air inlet includes at least one prong configured to engage a mating surface of the filter outlet.

7. The device according to claims 1 to 6, wherein: The blower air inlet includes three prongs configured to engage mating surfaces of the filter outlet.

8. The device according to claims 1 to 7, wherein: The filter outlet includes at least one cam surface adapted to engage the at least one prong of the filter inlet.

9. The device according to claims 1 to 8, wherein: The cam surface is inclined and adapted to cause rotating the filter relative to the blower inlet to tighten or loosen engagement between the filter outlet and the blower inlet.

10. The device according to claims 1 to 9, wherein: The prongs are offset into the interior of the blower inlet.

11. The device according to claims 1 to 10, wherein: The filter outlet includes at least one prong configured to engage a mating surface of the blower inlet.

12. The device according to claims 1 to 11, wherein: The blower inlet includes at least one cam surface adapted to engage the at least one prong of the filter outlet.

13. The device according to claims 1 to 12, wherein: An electronic control for the blower assembly is mounted proximate to the blower assembly.

14. The device according to claims 1 to 13, wherein: The filter has a first layer and a second layer, a gap is formed between the first layer and the second layer, and the filter includes the gap inside.

15. The device according to claims 1-14, wherein: The filter is disc-shaped.

16. The apparatus of claims 1-15, wherein the filter has a diameter of about 1-10 inches.

17. The apparatus of claims 1-16, wherein the filter has a diameter of about 3-7 inches.

18. An apparatus having an air consumption mechanism therein, comprising: a housing having an outer surface and an inner surface defining a housing interior, the housing having a front and a rear and a length from the front to the rear, the air consuming mechanism being mounted within the housing interior and having an air inlet port; an air intake conduit in fluid communication with a source of ambient air at an air inlet of the housing; at least one blower assembly having a blower having a blower inlet in fluid communication with the air intake conduit and a blower outlet in fluid communication with the air intake port of the air consuming mechanism; The blower air inlet has a filter, such as an N95 filter and / or a two-layer filter with gaps between the upper layers, adapted and positioned to filter air from the intake duct, the blower having an annular shelf surrounding the blower air inlet, the annular shelf being configured and adapted to be releasably attached to the filter outlet, the filter having an outer filter air inlet surface in fluid communication with the filter interior and a filter outlet in fluid communication with the filter interior, the filter having an annular shelf surrounding an end of the filter outlet, the annular shelf being sized and configured to mate with the blower air inlet; the blower air inlet including at least one prong configured to engage a mating surface of the filter outlet; The filter outlet includes at least one cam surface adapted to engage the at least one prong of the filter inlet, wherein the cam surface is inclined and adapted to cause rotation of the filter relative to the blower inlet to tighten or loosen engagement between the filter outlet and the blower inlet.

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