Fuel cell power system

Abstract

Disclosed is a fuel cell power system comprising: a container; a fuel cell stack; power electronics and a cell electrically connected to the fuel cell stack. Heat exchangers are mounted on the wall of the container, each heat exchanger drawing outside air into the container. The coolant line is connected to the plurality of heat exchangers. A fan assembly is mounted on the top of the container, the fan assembly configured to draw outside air through the heat exchanger and exhaust the exhaust.

Description

Technical Field

[0001] The present invention relates generally to hydrogen power units and more particularly to a thermal management system for a hydrogen fuel cell power container. Background Art

[0002] Hydrogen ("H2") power units such as fuel cells, hydrogen fueled internal combustion engines and their associated fuel storage systems play an important role in the pursuit of clean and efficient energy solutions. Fuel cells have gained considerable traction as an alternative power source, and they are frequently used in applications ranging from transportation to stationary power generation.

[0003] A hydrogen fuel cell is an electrochemical device that converts the chemical energy stored in hydrogen fuel into electricity, with water as a byproduct. Fuel cells operate through a redox reaction between hydrogen and oxygen, typically using a proton exchange membrane (PEM) or an alkaline electrolyte, which typically uses hydrogen as a fuel and oxygen from the air as an oxidant. In these cells, hydrogen gas is fed into the anode, where it is oxidized to produce protons and electrons. The protons move through the membrane to the cathode, while the electrons flow through an external circuit to produce electricity. At the cathode, oxygen molecules react with the incoming protons and electrons to form water. A hydrogen internal combustion engine, on the other hand, operates similarly to a conventional internal combustion engine, but uses hydrogen as a fuel instead of gasoline or diesel.

[0004] Fuel cell power systems are typically complex and include various auxiliary systems for cooling, air intake, and power conditioning. These systems require a robust cooling system to manage the heat generated during the electrochemical reactions in the fuel cell stack. Heat dissipation is critical because the stack coolant accounts for more than 50% of the total chemical energy. For optimal fuel cell performance, the operating temperature range of the stack coolant is typically 60 to 65°C. In addition, the use of power conversion electronics and auxiliary devices such as motors to drive fans and pumps increases the complexity of the system, requires additional space, and increases the overall cost. Despite the absence of a traditional combustion process, the fuel cell stack still generates a considerable amount of heat due to the exothermic nature of the chemical reactions involved. This heat must be effectively managed to maintain optimal operating conditions for the fuel cell stack.

[0005] Others have attempted to develop systems for cooling fuel cell stacks, but have not fully addressed issues such as space limitations, cooling efficiency, and ambient temperature control in containers. For example, CN215266399U (hereinafter referred to as the "CN reference") discloses a fuel cell power system belonging to the field of fuel cell technology. However, despite the lack of a comprehensive approach to managing space limitations, optimizing cooling efficiency, and maintaining ambient temperature within a container, the CN reference still needs to be improved in these areas.

[0006] It can therefore be seen that a need exists for a compact electrical energy system with efficient thermal energy system management. Summary of the invention

[0007] According to one aspect of the present invention, a fuel cell power system is disclosed. The fuel cell power system includes: a container having a single compartment; a fuel cell stack; a group of power electronic devices and a battery electrically connected to the fuel cell stack; a plurality of heat exchangers mounted on a plurality of walls on the container, each heat exchanger having an inlet louver for drawing outside air into the container; a common manifold connecting a plurality of coolant lines to the plurality of heat exchangers, at least one of the plurality of coolant lines circulates hot coolant from the fuel cell power system to the plurality of heat exchangers, and at least one of the plurality of coolant lines circulates cold coolant to the fuel cell power system; a pump for conveying coolant through the plurality of coolant lines; and a plurality of fan assemblies mounted on the top of the container, the plurality of fan assemblies being configured to draw outside air through the plurality of heat exchangers and exhaust air out of the container.

[0008] According to another aspect of the present invention, a thermal management system for a container fuel cell power system is disclosed. The thermal management system includes: a plurality of heat exchangers integrated into a plurality of walls of a container, each heat exchanger being configured to draw external air into the container, the container having a fuel cell, a power electronic device, and a battery; a common manifold connecting a plurality of coolant lines to the plurality of heat exchangers; a pump configured to deliver coolant through the plurality of coolant lines, at least one of the plurality of coolant lines being configured to circulate the coolant from the fuel cell to the plurality of heat exchangers, and at least one of the plurality of coolant lines being configured to circulate the coolant to the A container-type fuel cell power system; a plurality of fan assemblies mounted on the container, which are configured to draw the outside air into the container through the plurality of heat exchangers and are further configured to exhaust exhaust from the container; a thermostat and a plurality of thermocouples in communication with the thermostat, the plurality of thermocouples being disposed throughout the container-type fuel cell power system; and a control unit in communication with the thermostat, the pump, and the plurality of fan assemblies, the control unit being configured to regulate the operation of the pump and the plurality of fan assemblies based on temperature readings received from the thermostat.

[0009] According to another aspect of the present invention, a method for generating electricity in a container fuel cell power system is disclosed. The method includes: providing a fuel cell stack, power electronics, a battery, and a control unit within a container; integrating a plurality of heat exchangers into the wall of the container; mounting a plurality of fan assemblies on the container for thermal management; activating the container fuel cell power system for power generation; activating the container fuel cell power system for power generation; and starting power generation in the fuel cell stack by converting hydrogen and oxygen into electricity and water.

[0010] These and other aspects and features of the present invention will be better understood when the following detailed description is read in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] Figure 1 is a perspective view of a fuel cell power system according to an embodiment of the present invention.

[0012] Figure 2 is in an open configuration according to an embodiment of the present invention Figure 1 A perspective view of a fuel cell power system.

[0013] Figure 3 According to an embodiment of the present invention Figure 2 A perspective flow diagram of a door assembly of a fuel cell cooling system.

[0014] Figure 4 According to an embodiment of the present invention Figure 1 Schematic diagram of a fuel cell power system.

[0015] Figure 5 There is no frame according to an embodiment of the present invention Figure 1 A perspective view of a fuel cell power system.

[0016] Figure 6 According to an embodiment of the present invention Figure 2 A close-up perspective view of the door on a fuel cell power system.

[0017] Figure 7 According to another embodiment of the present invention, there is no frame Figure 2 A perspective view of a fuel cell power system.

[0018] Figure 8 According to an embodiment of the present invention Figure 2 Close-up of the fan system on a fuel cell power system.

[0019] Fig. 9 According to an embodiment of the present invention, Figure 1 Schematic diagram of the cooling system of a fuel cell power system.

[0020] Fig.10 According to an embodiment of the present invention, Figure 1 Block diagram of the thermal management system of a fuel cell power system.

[0021] Fig.11 According to an embodiment of the present invention Figure 1 Flow chart of a method for storing hydrogen in an H2 fuel system of an operating machine.

[0022] The accompanying drawings depict one embodiment of the disclosed content presented for the purpose of illustration only. Those skilled in the art will readily recognize from the following discussion that alternative embodiments of the structures and methods shown herein may be employed without departing from the principles described herein. DETAILED DESCRIPTION

[0023] Referring now to the drawings, and with particular reference to the described examples, a fuel cell power system 100 is shown, which is illustrated as a containerized fuel cell power system. Although the following detailed description describes exemplary aspects related to a containerized energy system powered by a fuel cell, it should be understood that the description is equally applicable to using the present invention in other energy storage containers powered by power including, but not limited to, generators, hydrogen energy systems, renewable energy, backup power systems, industrial applications, and mobile power solutions requiring thermal management systems.

[0024] Reference Figure 1 , a fuel cell power system 100 is shown according to one embodiment of the present invention. The fuel cell power system 100 includes a container 102 having walls 104, a top 106, and a bottom (not shown). The container 102 can be designed as a single compartment to accommodate various components, as well as designed to fit within the constraints of a shipping container, such as an ISO container, and is referred to as a containerized fuel cell power system, as is known in the art. The container 102 is made of a high-strength metal alloy, or of an alternative material such as a reinforced composite material. The wall 104 is made of reinforced steel or a high-strength composite material to serve as a structural frame for the container 102. The wall 104 may include insulation or other thermal management materials to maintain the internal temperature.

[0025] The fuel cell power system 100 also includes a plurality of fan assemblies 108, each having a duct assembly 110 for directing airflow. The duct assembly 110 includes a fan louver 112 for controlled passage of air. The fuel cell power system 100 also includes a container end 114 and a plurality of doors 116 to facilitate access to the internal components of the fuel cell power system 100. The container end 114 and the door 116 facilitate maintenance or component replacement. The door 116 can be sealed with a gasket to maintain an environmentally controlled internal atmosphere.

[0026] Reference Figure 2According to one embodiment of the present invention, the fuel cell power system 100 is shown with a pair of doors 116 open. Figure 2 As shown, multiple heat exchangers 200 are integrated with the wall 104 and / or door 116 of the container 102. Multiple heat exchangers 200 can include various types, such as radiators, plate heat exchangers, shell and tube heat exchangers, or fin tube heat exchangers, each designed to facilitate effective heat transfer. Multiple heat exchangers 200 can be made of materials such as aluminum, copper, stainless steel or other thermally conductive materials to ensure effective heat dissipation. Multiple fan assemblies 108 can include centrifugal fans 202.

[0027] Reference Figure 3 , illustrates an assembly of one of the doors 116 integrated with one of the plurality of heat exchangers 200 according to an embodiment of the present invention. Each of the plurality of heat exchangers 200 may include an air inlet louver 300 designed to filter all outside air drawn into the container 102. The air inlet louvers 300 are strategically positioned to draw in outside air, which then flows through the plurality of heat exchangers 200 for cooling purposes. The air inlet louvers 300 may be constructed of a variety of materials, such as aluminum, stainless steel, or coated steel, and designed with angled slats to reduce the ingress of water and debris into the system. Optionally, the air inlet louvers 300 may include a mesh or screen for additional filtration, which is designed to prevent the ingress of water and debris. The air inlet louvers 300 may be adjustable to adjust the airflow and may be coated with a waterproof material for enhanced protection.

[0028] Depending on the specific thermal management requirements, the multiple heat exchangers 200 within the door 116 can be of different types, such as plate-fin, shell-and-tube, or microchannel. This design allows for a more streamlined cooling process, utilizing the walls 104 of the container 102 and the door 116 as multifunctional components that help maintain an optimal temperature range within the container. By integrating the multiple heat exchangers 200 into the door 116, the system provides a compact and efficient way to manage heat while maximizing space utilization within the container 102.

[0029] Reference Figure 4, showing a schematic top view of a fuel cell power system 100 according to one embodiment of the present invention. The container 102 is designed to have a single compartment to accommodate a fuel cell stack 400, power electronics 402, and a battery 404 for the fuel cell power system 100. The fuel cell power system 100 may also include a control unit 406 mounted on one of the doors 116 or inside the container 102. The control unit 406 can be designed to manage the flow of hydrogen to the fuel cell stack, control power output, monitor overall system health, and ensure that safety measures are taken. The control unit 406 facilitates system monitoring and operation, and may also be digitally interfaced with a microcontroller, which in turn is connected to the battery 404. The battery 404 can be used as a backup power source and can be of various types, including but not limited to lithium-ion batteries, nickel-metal hydride batteries, or lead-acid batteries.

[0030] The control unit 406 may feature a touch screen interface and various input / output ports for real-time monitoring and system adjustments, as well as connectivity capabilities including WIFI, 5G, LTE or other mobile cellular services to communicate with logistics systems or off-site teams, as is known in the art. The control unit 406 is configured to seamlessly interact with the fuel cell stack 400, power electronics 402, and battery 404 to optimize system performance while maintaining safety protocols, thereby achieving efficient and safe operation of the fuel cell power system 100.

[0031] like Figure 4 As shown, a plurality of fan assemblies 108 are located on top of the top cover 106 to draw hot air out of the container 102, thereby cooling the interior compartment of the container 102 to further cool the fuel cell stack 400, power electronics 402, and battery 404, thereby preventing overheating and promoting efficient operation. The fan assembly 108 is configured to draw air through the plurality of heat exchangers 200 and then exhaust the exhaust gas out of the container 102. The plurality of heat exchangers 200 are integrated with the wall 104 and / or the door 116 of the container 102, such as Figure 3 shown.

[0032] Alternatively, the fan in the fan assembly 108 can be centrifugal, axial or bladeless. Expand the type of fan that can be used in the fan assembly 108, various fan configurations can be adopted to achieve optimal cooling performance. For example, a centrifugal fan utilizes a rotating impeller to move air radially, usually providing a higher pressure capacity than other types of fans. An axial fan is another option, which moves air along the axis of the fan, providing a high flow rate but generally lower pressure. These are useful for quickly discharging hot air from the container 102. A bladeless fan uses a brushless motor to inhale air and push it out through a circular or annular hole, thereby providing less turbulent airflow and quieter operation. Each type of fan provides specific advantages, such as energy efficiency, noise reduction or easy maintenance, and selection can depend on the specific cooling requirements of the fuel cell power system 100.

[0033] Reference Figure 5 , shows a perspective view of a fuel cell power system 100 without a container 102 according to one embodiment of the present invention. In one embodiment, the fuel cell power system 100 includes a fuel cell stack 400, a DC choke stack 502, and a common manifold 500 connected to a plurality of cold coolant lines 504 and a plurality of hot coolant lines 506 (collectively referred to as "coolant lines 504, 506"). The common manifold 500 serves as a hub to standardize the coolant flow. There may also be an air filter 508 for filtering the air used for hydrogen combustion in the fuel cell stack 400.

[0034] At least one of the hot coolant lines 506 delivers hot coolant from the fuel cell stack 400 to the heat exchanger 200. At least one cold coolant line 504 pumps cold coolant back to the fuel cell stack 400. The coolant lines 504, 506 may be made of reinforced rubber or metal tubing capable of handling the elevated temperatures and pressures within the system. There may be a coolant reservoir (not shown) in fluid communication with the coolant lines 504, 506, and a set of valves integrated within the coolant lines 504, 506, allowing for selective control of coolant flow through each line for effective temperature regulation.

[0035] The system also includes a DC choke stack 502 located near the top of the container 102, allowing the DC choke exhaust to be exhausted through the plurality of fan assemblies 108. The DC choke may be implemented as a laminated core inductor or a toroidal inductor and is connected to the power electronics 402 and the fuel cell stack 400 via high conductivity cables.

[0036] Reference Figure 6, shows a close-up perspective view of one of the heat exchangers 200 in the fuel cell power system 100 according to one embodiment of the present invention. Each of the plurality of heat exchangers 200 includes a radiator outlet line 600 and a radiator inlet line 602 for conveying coolant via a plurality of cold coolant lines 504 and hot coolant lines 506.

[0037] Reference Figure 7 , shows a perspective view of a fuel cell power system 100 without a container 102 according to another embodiment of the present invention. In one embodiment, the fuel cell power system 100 includes a power distribution unit 700 connected to the fuel cell stack 400 and the DC choke stack 502. The fuel cell power system 100 also includes a common manifold 500 connected to a plurality of cold coolant lines 504 and a plurality of hot coolant lines 506. The common manifold 500 also serves as a hub for standardizing the coolant flow. Air filter 508 The air filter 508 is used to filter the air used for hydrogen combustion in the fuel cell stack 400.

[0038] In general, the fuel cell power system 100 operates as an integrated unit. The fuel cell stack 204 generates electricity and heat. Heat is managed by transferring hot coolant to the heat exchanger 200 through the hot coolant line 506. The cold coolant from the heat exchanger 200 is then returned to the fuel cell stack 400 via the cold coolant line 504. The fan assembly 108 draws air through the heat exchanger 200 and exhausts it from the container 102, maintaining the internal atmosphere in the container 102 at a controlled temperature.

[0039] Reference Figure 8 , shows a close-up perspective view of one of the fan assemblies 108 in a fuel cell power system 100 according to one embodiment of the present invention. Each fan assembly 108 may include a duct assembly 110 to draw and direct exhaust gas out of the container 102 using a centrifugal fan 202. The fan assemblies 108 are positioned and designed to ensure effective ventilation and cooling within the fuel cell power system 100. The duct assembly 110 directs air from the interior of the container 102 to the external environment. Figure 8 , the duct assembly 110 is shown without a top cover. The duct assembly 110 may be made of materials such as galvanized steel, aluminum, or high-grade plastic to ensure durability and corrosion resistance.

[0040] Within each fan assembly 108, a centrifugal fan 202 is used to efficiently move air. The centrifugal fan 202 operates by using the centrifugal force generated by the high-speed rotation of its blades to accelerate air radially outward. The centrifugal design allows for high-pressure air flow, providing appropriate air movement to cool the fuel cell stack 400, power electronics 402, batteries 404, DC choke stack 502, and power distribution unit 700.

[0041] In addition, the fan assembly 108 may include fan shutters 112 that can be opened or closed to adjust the discharge of warm air from the container 102. The fan shutters 112 can be manually adjustable or automatically controlled by a sensor or control unit 406 to adapt to changing thermal conditions within the container 102. Other types of fans, such as axial fans or bladeless fans, may also be used depending on specific system requirements. Due to the modular design of the fan assembly 108, these alternative fan types can be easily swapped out or integrated. In summary, the fan assembly 108, together with the duct assembly 110 and the centrifugal fan 202, provides effective thermal management of the fuel cell power system 100.

[0042] Reference Fig. 9 , shows a schematic flow chart of air flow in a fuel cell power system 100 according to one embodiment of the present invention. The inlet louvers 300 are strategically positioned to draw in external air 900, which then flows through the plurality of heat exchangers 200 for cooling purposes. The plurality of heat exchangers 200 each have an air inlet louver 300 designed to filter the external air 900 as it enters the container 102. The air inlet louvers 300 filter contaminants from the incoming air and direct the external air flow 900 through the heat exchangers 200, which also helps to cool the coolant in the hot coolant line 506.

[0043] Within the container 102, a container air stream 902 circulates to promote internal cooling. The container air stream 902 is drawn from the internal environment of the container 102 and passes through the heat exchanger 200 to absorb heat generated by the components of the system. A plurality of fan assemblies 108 located at the top of the top 106 are responsible for pulling the container air stream 902 upward and out of the container 102, exhausting it as exhaust 904.

[0044] The fan assemblies 108 are strategically positioned to maximize air flow, ensuring that hot air rises and is efficiently exhausted from the container 102 to help maintain the internal temperature of the container 102, thereby preventing overheating of key components such as the fuel cell stack 400, power electronics 402, and batteries 404. The fuel cell power system 100 achieves balanced and efficient air flow through the air inlet louvers 300, through the multiple heat exchangers 200, and through the air flow drawn by the multiple fan assemblies 108, optimizing cooling and overall operating efficiency. The fan assemblies 108 are configured to draw the container air flow 902 to be exhausted from the container 102 as exhaust gas 904. The multiple fan assemblies 108 may include at least two centrifugal fans, each centrifugal fan having a duct assembly 110 oriented or configured to direct and exhaust the exhaust gas 904 from the container 102 in opposite airflow directions for optimal airflow management.

[0045] refer to Fig.10 , a block diagram of a thermal management system 1000 in a fuel cell power system 100 according to one embodiment of the present invention is shown. The fuel cell power system 100 is equipped with a control unit 406, which is designed to maintain the temperature of the fuel cell stack 400 within a desired temperature range, for example, between 60-70 degrees Celsius. The control unit 406 is in communication with a thermostat 1002 and a plurality of thermocouples 1004, which are positioned near or adjacent to the fuel cell stack 400, the power electronics 402, the battery 404, the DC choke stack 502, the power distribution unit 700, the plurality of heat exchangers 200, the plurality of fan assemblies 108, and throughout the container 102. The control unit 406 is also in communication with a pump 1006, which delivers coolant through a cold coolant line 504 and a hot coolant line 506. The pump 1006 may be a variable speed pump configured for adjusting or changing the speed by the control unit 406, as is generally known in the art.

[0046] The control unit 406 continuously receives temperature data from a plurality of thermocouples 1004 for real-time monitoring of the temperature of the fuel cell stack 400. When the temperature data is received, the control unit 406 compares it with the target temperature range set by the thermostat 800. The thermostat 1002 is configured to set the target temperature range of the fuel cell stack 400 between 60 and 70 degrees Celsius. If the temperature is lower than or exceeds the range, the control unit 406 activates or deactivates a plurality of heat exchangers 200, a plurality of fan assemblies 108, a pump 1006, and any other components in the fuel cell power system 100 to return the temperature to the desired range. The control unit 406 also continuously receives temperature data from a plurality of thermocouples 1004 provided in the cold coolant line 504 and the hot coolant line 506 to monitor the temperature of the coolant.

[0047] Additionally, the control unit 406 may be programmed to remotely send an alert to a logistics system via wireless communications.The control unit 406 may be configured to initiate a shutdown of the fuel cell stack 400 if the temperature deviates from a set range for an extended period of time to ensure safety and longevity.

[0048] The control unit 406 can adjust power distribution and optimize energy storage during peak and off-peak time periods using a power management module in communication with the fuel cell stack 400, the power electronics 402, and the battery 404. A sensor assembly can interface with the power management module to continuously monitor the rate of energy consumption and adjust the operation of the fuel cell stack 400 and the power electronics 402 accordingly.

[0049] Integrating multiple heat exchangers 200 as heat sinks into the structure of the container 102 helps with efficient cooling and also helps maintain a compact form factor of the container 102. The integrated heat sinks are strategically positioned to maximize cooling efficiency, thereby reducing the need for larger and more complex cooling systems, achieving a more compact and optimized system, increasing ease of installation, and reducing overall costs. These heat sinks are made of highly conductive materials such as copper or aluminum, which helps to quickly dissipate heat and helps keep the temperature of the fuel cell stack 204 within a desired range.

[0050] The compact design facilitated by the integrated heat sink also improves space utilization, allowing more containers to be deployed in a given area, thereby increasing the total power generation capacity. The integrated heat sink and control unit 406 can be jointly connected to provide an efficient, compact and optimized fuel cell power system 100 to increase the total power generation capacity.

[0051] An external interface port may be provided on the container 102 to facilitate easy connection to an external power grid or other energy consuming system, allowing the fuel cell power system 100 to be used as a primary power source or a backup power source.

[0052] During the shutdown procedure, the control unit 406 initiates a cooling protocol to gradually reduce the temperature of the fuel cell stack 400 to a safe level for system shutdown. This ensures that no thermal stress is induced on the fuel cell stack 204, thereby preserving its life.

[0053] Industrial Applicability

[0054] In operation, the present invention can be applied to many fields, including but not limited to renewable energy, backup power systems, industrial applications and mobile power solutions. Specifically, the thermal management and cooling systems and methods of the present invention can be used in hydrogen energy systems of various working machines, as well as fixed power systems, emergency backup power systems and grid balancing power systems. Although the foregoing detailed description is made with specific reference to fixed power systems, it should be understood that its teachings can also be applied to other hydrogen fuel cell applications.

[0055] Now refer to Fig.11 , a method 1100 for generating electricity in a fuel cell power system 100 according to one embodiment of the present invention is shown. In step 1102, the fuel cell power system 100 is provided with a fuel cell stack 400, power electronics 402, a battery 404, a control unit 406 in communication with a plurality of thermocouples 1004 in a container 102, a pump 1006, a plurality of heat exchangers 200 integrated into the wall 104 of the container 102, and a plurality of fan assemblies 108 mounted on the top 106 of the container, the plurality of fan assemblies 108 being configured to draw exhaust gas 904 out of the container 102.

[0056] The power electronics 402 may be placed near the fuel cell stack 400 to enable efficient energy conversion and management. The battery 404 may be placed near the fuel cell stack 400 for energy storage and backup. The DC choke stack 502 may be provided with the power electronics 402 and positioned near or adjacent to the top 106 inside the container 102 so that exhaust 904 from the DC choke stack 502 is quickly removed and sucked out by the plurality of fan assemblies 108. The plurality of fan assemblies 108 may be mounted directly above the DC choke stack 502. In step 1102, a plurality of heat exchangers 200 are aligned on the side of the container 102 to provide optimal thermal management by drawing outside air into the container 102 for cooling the coolant in the hot coolant line 506.

[0057] In step 1104, fuel cell power system 100 is activated to generate electricity via fuel cell stack 400. Upon system activation, plurality of heat exchangers 200, pump 1006, and fan assembly 108 are ready to activate when thermal management cooling is required to maintain container 102 within a temperature range or below a temperature threshold.

[0058] In step 1106 , the fuel cell stack 400 starts generating electricity through an electrochemical conversion process to convert hydrogen and oxygen into electricity and water within the fuel cell power system 100 .

[0059] In step 1108, the generated electricity is directed through power electronics 402 to condition the power to meet the specifications required by the intended load or external device. For example, power distribution unit 700 can distribute the conditioned power to external loads, which can range from the grid to a specific device or system.

[0060] In step 1114, the control unit 406 initiates continuous monitoring of the temperature of the fuel cell stack 400 via the plurality of thermocouples 1004. The control unit 406 receives the temperature signal from the thermometer sensor 802 and processes the collected data to determine if cooling action is required.

[0061] In step 1116, if the temperature in the container 102 deviates from a temperature range above / below a temperature threshold, such as a target range of 60-70 degrees Celsius, the control unit 406 activates at least one of the plurality of heat exchangers 200, the pump 1006, and the fan for cooling the fuel cell stack 400. The pump 1006 is activated to pump the coolant through the plurality of cold coolant lines 504 and the plurality of hot coolant lines 506.

[0062] In step 1118, the plurality of heat exchangers 200 begin cooling the hot coolant lines 506 by circulating coolant through the hot coolant lines 506, while the plurality of fan assemblies 108 begin drawing in outside air 900. The plurality of fan assemblies 108 draw in outside air 900 through the plurality of heat exchangers 200. The drawn in outside air 900 flows through the coolant lines 504, 506, internally through the plurality of heat exchangers 200 and in the container 102 to further cool the hot coolant lines 506, ensuring that the entirety of the container 102 remains within a desired thermal range.

[0063] In step 1120, the fan assembly 108 mounted on the top 106 of the container 102 begins to draw out the exhaust gas 904 that has been heated by the fuel cell stack 400, power electronics 402, and battery 404, thereby effectively removing excess heat from the container 102. This exhaust gas 904 is exhausted to the atmosphere, helping to maintain the overall thermal balance of the fuel cell power system 100.

[0064] In step 1122, the control unit 406 continues to dynamically manage thermal conditions based on ongoing feedback from the plurality of thermocouples 1004. If additional cooling is required, the control unit 406 may activate an auxiliary cooling mechanism or increase the speed of the fan assembly 108 or centrifugal fan 202, as well as the flow rate through the plurality of heat exchangers 200, to return the temperature of the container 102 and / or the fuel cell stack 400 to a desired range.

[0065] For safety, the thermal management system 1000 may also be configured to trigger an alarm via the control unit 406 when the temperature exceeds a safe temperature threshold of the fuel cell stack 400 and the fuel cell power system 100. As is known in the art, an audible alarm, a visual alarm, or a digital connection is activated to notify an operator or a logistics or remote team.

[0066] The container 103 may include a humidity control system that is communicated with the control unit 406 to maintain an optimal humidity level in a single compartment of the container 102. The humidity control system may utilize a plurality of hybrid sensors that measure humidity and temperature. A plurality of thermocouples may include hybrid sensors that transmit humidity readings in the container 102 to the control unit 406, providing comprehensive environmental data. These sensors are strategically distributed throughout the container 102 to accurately monitor the internal atmosphere. Once they collect humidity and temperature data, the hybrid sensor relays this information to the control unit 406. The control unit 406 is programmed with specific humidity parameters that are ideal for the operation of the fuel cell, processes the data, and activates the necessary adjustments. These adjustments may include engaging a plurality of fan assemblies 108, a plurality of heat exchangers 106, or pumps 1006 for regulating the internal air circulation of the coolant flow and the container 102 to keep the environmental conditions within the optimal range. By doing so, the humidity control system plays a key role in maintaining the integrity and efficiency of the fuel cell power system contained in the container 102.

[0067] The fuel cell power system 100 can be designed for interoperability, allowing integration with external devices and systems. Standardized connectors and established protocols can be incorporated to facilitate connection to a larger grid so that the system can provide or draw power based on operating parameters. In addition, the control unit 406 within the system 100 can support multiple connectivity protocols, ensuring compatibility with various grid management systems and external devices.

[0068] The fuel cell power system 100 can be configured to be modular so that components including the fuel cell stack 400, power electronics 40, and battery 404 are configured to facilitate replacement or upgrade. The containerized design provides access to internal components, ensuring component replacement while reducing system downtime.

[0069] The thermal management system 1000 allows for increased power density from the containerized fuel cell power system 100. The increased power density is a direct result of the system's ability to maintain the optimal operating temperature of the fuel cell 400 and associated electronics. By effectively managing the heat generated during operation, the fuel cell power system can operate at a higher capacity without the risk of overheating, thereby generating more power per unit volume of the container. This aspect is particularly critical in applications where space and weight are at a premium, as it allows for a more powerful system to be deployed in a limited space.

[0070] In addition, thermal management system 1000 allows the use of high-performance fan assemblies to communicate cooling system elements, thereby eliminating the need for additional or other dedicated component fans for subsystems. Fan assembly 108 can be a high-performance centrifugal fan, which eliminates the need for excessive subsystem fans. The use of high-performance fan assemblies such as centrifugal fans 108 means that a single more effective cooling mechanism can replace multiple potentially less efficient subsystem-specific fans. The reduction in the number of fans not only reduces the complexity and potential failure points of the system, but also helps to reduce the total power consumption of cooling. Select high-performance centrifugal fans because they can move a large amount of air while overcoming system resistance, making them ideally maintain the air flow rate required for effectively cooling the entire system.

[0071] As can be seen from the foregoing, the technology disclosed herein has industrial applicability in a variety of settings that require reliable and efficient thermal management during power generation by hydrogen fuel cell systems, such as renewable energy facilities, backup power systems, and industrial power solutions.

Claims

1. A fuel cell power system, comprising: A container having a single compartment; Fuel cell stack; a set of power electronics electrically connected to the fuel cell stack; a plurality of heat exchangers mounted on a plurality of walls of the container and configured to draw outside air into the container; a common manifold connecting a plurality of coolant lines to the plurality of heat exchangers, at least one of the plurality of coolant lines circulating hot coolant from the fuel cell power system to the plurality of heat exchangers, and at least one of the plurality of coolant lines circulating cold coolant to the fuel cell stack; a pump for conveying coolant through the plurality of coolant lines; as well as A plurality of fan assemblies are mounted on a top of the container, the plurality of fan assemblies being configured to draw outside air through the plurality of heat exchangers and exhaust air out of the container.

2. The fuel cell power system according to claim 1, further comprising: a duct assembly for each of the plurality of fan assemblies, the duct assembly having an opening for discharging the exhaust gas; Power distribution unit; Battery; a DC choke bank positioned adjacent a top of the container and adjacent one of the plurality of fan assemblies; and Fuel cell air filter, which is used to clean the intake air of the fuel cell stack.

3. The fuel cell power system according to claim 1, further comprising: Thermostat; a plurality of thermocouples provided throughout the vessel and in communication with the thermostat; a control unit in communication with the thermostat, the fuel cell stack, the battery, the plurality of heat exchangers, the pump, the plurality of fan assemblies, and the set of power electronics, the control unit being configured to activate the pump, the plurality of heat exchangers, and the plurality of fan assemblies; a coolant reservoir in fluid communication with the plurality of coolant lines storing a reserve of the coolant for circulation; Humidity control systems in containers to maintain optimal humidity levels in containers; as well as An interface configured to connect to an external device and provide power from the fuel cell power system.

4. The fuel cell power system according to claim 2, wherein: the plurality of fan assemblies including at least two centrifugal fans each having the duct assembly oriented to direct the exhaust gas out of the container in opposite directions; The container includes an insulating layer on an interior of the plurality of walls; The pump is a variable speed pump that regulates coolant flow in the plurality of coolant lines based on heat load requirements; The plurality of heat exchangers are coated with an anti-corrosion material to ensure longevity under various environmental conditions, the plurality of heat exchangers each including an inlet louver to prevent ingress of water and debris; The plurality of fan assemblies are designed to dynamically adjust airflow based on thermal demand of the fuel cell power system; and The opening of the duct assembly includes an exhaust louver to prevent the ingress of water and debris.

5. A thermal management system for a containerized fuel cell power system, comprising: a plurality of heat exchangers integrated into a plurality of walls of a container, each heat exchanger configured to draw outside air into the container having a fuel cell and power electronics; a common manifold connecting a plurality of coolant lines to the plurality of heat exchangers; a pump configured to convey a coolant through the plurality of coolant lines, at least one of the plurality of coolant lines being configured to circulate the coolant from the fuel cell to the plurality of heat exchangers, and at least one of the plurality of coolant lines being configured to circulate the coolant to the fuel cell; a plurality of fan assemblies mounted on the container and configured to draw the outside air into the container through the plurality of heat exchangers and further configured to exhaust exhaust air from the container; a thermostat and a plurality of thermocouples in communication with the thermostat, the plurality of thermocouples being disposed throughout the containerized fuel cell power system; as well as A control unit is in communication with the thermostat, the pump, and the plurality of fan assemblies, the control unit being configured to regulate operation of the pump and the plurality of fan assemblies based on temperature readings received from the thermostat.

6. The thermal management system according to claim 5, further comprising: a duct assembly for each of the plurality of fan assemblies, the duct assembly having an opening for discharging the exhaust gas; The power electronics include a power distribution unit, a battery, and a DC choke pack positioned adjacent to a top of the container and adjacent to one of the plurality of fan assemblies; a humidity control system in the container to maintain an optimum humidity level within said container; and An air filter is used to filter the intake air into the fuel cell.

7. The thermal management system of claim 6, wherein: the control unit further being in communication with the fuel cell, the battery, the plurality of heat exchangers, the pump, the plurality of fan assemblies, and the power electronics; the control unit being configured to activate and deactivate the pump, the power electronics, the fuel cell, the plurality of heat exchangers, and the plurality of fan assemblies; as well as The plurality of fan assemblies are mounted on top of the container, the plurality of fan assemblies including at least two centrifugal fans, each centrifugal fan having the duct assembly oriented to direct exhaust air out of the container in opposite directions.

8. The thermal management system of claim 7, wherein: The container includes an insulating layer on an interior of the plurality of walls; The pump is a variable speed pump that adjusts the coolant flow according to the heat load requirements; The plurality of heat exchangers are coated with anti-corrosion materials to ensure life under various environmental conditions; the plurality of heat exchangers including first louvers to prevent ingress of water and debris as air is drawn into the container; The plurality of fan assemblies are designed to dynamically adjust airflow based on thermal requirements of the containerized fuel cell power system; and The opening of the duct assembly includes a second louver to prevent the ingress of water and debris.

9. A method for generating power in a containerized fuel cell power system, the method comprising: providing a fuel cell stack, power electronics, and a control unit within the container; integrating a plurality of heat exchangers into the wall of the vessel; mounting a plurality of fan assemblies on the container for thermal management; activating a containerized fuel cell power system for generating electricity; as well as Power generation is initiated in the fuel cell stack by converting hydrogen and oxygen into electricity and water.

10. The method according to claim 9, further comprising: providing a plurality of thermocouples in the container in communication with the control unit, wherein each of the plurality of thermocouples communicates a temperature signal to the control unit; continuously monitoring the temperature of the coolant and the container via the control unit and the plurality of thermocouples; circulating a coolant through a plurality of coolant lines disposed throughout the containerized fuel cell power system; drawing outside air through the plurality of heat exchangers to cool the plurality of coolant lines; exhausting exhaust gas out of the container via the plurality of fan assemblies mounted on a top portion of the container; as well as When the temperature deviates from a predetermined temperature range, circulation of the coolant, the plurality of heat exchangers, and the plurality of fan assemblies is adjusted by a control unit.

11. The method according to claim 10, further comprising: Provide interfaces for external devices; connecting an external device to the fuel cell power system via the interface; as well as Power is supplied from the containerized fuel cell power system to the external device.

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