Fluid separator with fluid recirculation passage and multiple outlet passages

Abstract

A fluid separator device includes an outer wall member defining an interior, an inlet end with an inlet, and an outlet end with a first outlet and a second outlet. Additionally, the fluid separator includes a fluid flow path system defined within the interior. The fluid flow path system includes a first flow path extending from the inlet through the inner flow member in a first downstream direction toward at least one of the first outlet and the second outlet. The fluid flow path system also includes a second flow path, at least partially defined between the outer wall member and the inner flow member. The second flow path extends from the outlet end toward the inlet end in a second downstream direction, and the second flow path is configured to receive flow from the first flow path.

Description

[0001] Cross-reference to related applications

[0002] This application claims priority to Indian Provisional Patent Application No. 202411009872, filed on February 13, 2024, the entire contents of which are incorporated herein by reference. Technical Field

[0003] This technical field generally relates to fluid separators, and more specifically, to a fluid separator having a fluid recirculation path and multiple outlet paths. Background Technology

[0004] It is known to install fluid separators in some fluid systems. During operation, the separator can receive fluids containing multiple components, and the separator can influence the flow of one component relative to another, thereby providing a degree of component separation.

[0005] For example, in some systems, the turbine stage (i.e., the expander) of a turbine may receive an exhaust stream containing air, water vapor, and liquid droplets. These droplets can negatively impact the operation of the turbine stage, reducing efficiency, causing premature wear, or leading to other problems. Therefore, it is preferable to include a device in the system to remove droplets before they enter the turbine stage.

[0006] However, existing fluid separation devices have certain drawbacks. They may fail to separate components effectively under certain operating conditions. In some cases, fluid separation devices may interfere with flow to downstream devices (such as turbine / expander stages of turbines). Fluid separation devices may also be difficult to manufacture or otherwise inefficiently manufactured. Furthermore, some fluid separation devices may be large, heavy, and / or contain a large number of parts, which may be detrimental to larger systems.

[0007] Therefore, it is desirable to provide a fluid separator that effectively separates one component of a fluid flow from other components (e.g., separating liquid water droplets from an exhaust stream) under a wide range of operating conditions without significantly affecting the flow to downstream devices. It is also desirable to provide a fluid separator that can be manufactured efficiently. Furthermore, it is desirable to provide a relatively lightweight, compact fluid separator and / or one manufactured with a relatively few parts. Other desirable features and characteristics will become apparent from the following detailed description and the appended claims, taken in conjunction with the accompanying drawings and this background art. Summary of the Invention

[0008] A fluid separator device is disclosed, configured to separate a portion of a fluid mixture from another portion of a fluid mixture. The fluid separator device includes an outer wall member defining an interior of the fluid separator device. This interior defines a longitudinal axis of the fluid separator device. The separator device includes an inlet end defining a fluid inlet connected to the interior and configured to receive a fluid mixture. The separator device also includes an outlet end spaced apart from the inlet end along the longitudinal axis. The outlet end defines a first fluid outlet from the interior. The longitudinal axis extends through the first fluid outlet. Furthermore, the separator device includes an outlet pipe supported within the interior and the first fluid outlet. The outlet pipe defines a second fluid outlet from the interior. Additionally, the separator device includes an inner flow member supported within the interior. Further, the fluid separator includes a fluid flow path system defined within the interior. The fluid flow path system includes a first flow path extending from the fluid inlet in a first downstream direction through the inner flow member toward at least one of the first and second fluid outlets. The fluid flow path system also includes a second flow path at least partially defined between the outer wall member and the inner flow member. The second flow path extends from the outlet end toward the inlet end in a second downstream direction. The second flow path is configured to receive flow from the first flow path.

[0009] In another example embodiment, a method of manufacturing a fluid separator device is disclosed, the fluid separator device being configured to separate a portion of a fluid mixture from another portion of a fluid mixture. The method includes providing an outer wall member defining an interior of the fluid separator device. The interior defines a longitudinal axis of the fluid separator device. The method also includes providing an inlet end defining a fluid inlet fluidly connected to the interior and configured to receive a fluid mixture. Additionally, the method includes providing an outlet end spaced apart from the inlet end along the longitudinal axis. The outlet end defines a first fluid outlet from the interior. The longitudinal axis extends through the first fluid outlet. Furthermore, the method includes supporting an outlet pipe within the interior and the first fluid outlet. The outlet pipe defines a second fluid outlet from the interior. The method also includes supporting an inner flow member within the interior. Additionally, the method includes defining a fluid flow path system within the interior. The fluid flow path system includes a first flow path extending from the fluid inlet in a first downstream direction through the inner flow member toward at least one of the first and second fluid outlets. The fluid flow path system also includes a second flow path at least partially defined between the outer wall member and the inner flow member. The second flow path extends from the outlet end toward the inlet end in a second downstream direction. The second flow path is configured to receive flow from the first flow path.

[0010] In an additional embodiment, a fuel cell system is disclosed, comprising a fuel cell stack, a turbine having a turbine section, and a fluid separator device fluidly connected to the fuel cell stack and configured to receive a fluid mixture from the fuel cell stack. The fluid separator device is fluidly connected upstream to the turbine section. The fluid separator device is configured to separate a portion of the fluid mixture from another portion of the fluid mixture to provide a separated exhaust flow from the fuel cell stack to the turbine section. The fluid separator device includes an outer wall member defining an interior of the fluid separator device. This interior defines a longitudinal axis of the fluid separator device. The fluid separator device includes an inlet end defining a fluid inlet fluidly connected to the interior and configured to receive a fluid mixture. Additionally, the fluid separator device includes an outlet end spaced apart from the inlet end along the longitudinal axis. The outlet end defines a first fluid outlet from the interior. The longitudinal axis extends through the first fluid outlet. Furthermore, the fluid separator device includes an outlet pipe supported within the interior and the first fluid outlet. The outlet pipe defines a second fluid outlet from the interior. The fluid separator device includes an inner flow member supported within the interior. Additionally, the fluid separator device includes a fluid flow path system defined within the interior. The fluid flow path system includes a first flow path extending from a fluid inlet in a first downstream direction through an inner flow member and toward at least one of a first fluid outlet and a second fluid outlet. Additionally, the fluid flow path system includes a second flow path at least partially defined between an outer wall member and an inner flow member. The second flow path extends from an outlet end in a second downstream direction toward an inlet end. The second flow path is configured to receive flow from the first flow path. Attached Figure Description

[0011] Various embodiments will be described below with reference to the accompanying drawings, wherein the same reference numerals denote the same elements, and in the drawings: Figure 1 This is a schematic diagram of a fuel cell system according to an exemplary embodiment of the present disclosure, the fuel cell system including a fluid separator device; Figure 2 This is an example embodiment based on the present disclosure. Figure 1 The longitudinal sectional view of the fluid separator device shown; Figure 3 yes Figure 1 and Figure 2 An exploded, three-dimensional, and partial cross-sectional view of several first features of the fluid separator device shown is presented to illustrate a method of manufacturing the fluid separator device according to an exemplary embodiment. Figure 4 yes Figure 1 and Figure 2 An exploded perspective view of several second features of the fluid separator device is shown to further illustrate a method of manufacturing the fluid separator device according to an example embodiment. Figure 5 yes Figure 1 and Figure 2 An exploded, three-dimensional, and partial cross-sectional view of several first and second features of the fluid separator device shown is presented to further illustrate a method of manufacturing the fluid separator device according to an exemplary embodiment. Figure 6 According to the example embodiment Figures 1-5 A perspective view of the swirling element of the fluid separator device shown; and Figure 7 This is according to another exemplary embodiment of the present disclosure. Figures 1-5 A perspective view of the swirling element of the fluid separator device shown. Detailed Implementation

[0012] The following detailed embodiments are merely exemplary in nature and are not intended to limit the various embodiments or their applications and uses. Furthermore, they are not intended to be construed as being bound by any theories presented in the foregoing background or the following detailed embodiments.

[0013] In a broader sense, the exemplary embodiments disclosed herein include a fluid separator for separating one portion (e.g., liquid water droplets) of a fluid mixture from another portion (e.g., water vapor / air). The fluid separator of this disclosure may include an inlet end with an inlet and an outlet end with multiple outlets. The inlet end and the outlet end may be spaced apart along a longitudinal axis. The fluid separator may also include a first flow path extending along the longitudinal axis. Furthermore, the fluid separator may include a second flow path. Fluid entering the first flow path may flow partially from the inlet along the first flow path to one or more outlets. Liquid water droplets may flow with air and branch off from the first flow path into the second flow path for discharge therefrom, and the air in the second flow path may be recirculated back to the first flow path. The fluid separator may also include a swirling member within the first flow path that swirls the fluid within the first flow path, for example, guiding liquid water droplets toward the second flow path. Additionally, at least one outlet may be configured to define a low-pressure region for discharging water vapor from the separator.

[0014] Figure 1 This is a schematic diagram of a fuel cell system 100, which includes a fluid separator 101 (i.e., a demister, fluid separation device, etc.) that can be constructed according to embodiments of the present disclosure. The fluid separator 101 is fluidly connected to a fuel cell stack 104 of the fuel cell system 100. During operation, the fluid separator 101 receives an exhaust stream 109 from the fuel cell stack 104. The fluid separator 101 is operable / configurable to separate fluid droplets (e.g., water droplets) from the exhaust stream 109 and output a separated exhaust stream 111, which is supplied downstream to a turbine section 115 of a turbine 117.

[0015] It should be understood that the fluid separator 101 of this disclosure may be included in other fuel cell systems 100 (and other fluid systems) without departing from the scope of this disclosure. In some embodiments, the fuel cell system 100 may be included in a vehicle, such as a car, truck, SUV, van, motorcycle, etc. However, it should be understood that the fuel cell system 100 may be configured for different uses without departing from the scope of this disclosure.

[0016] Fuel cell stack 104 may include multiple fuel cells. Hydrogen may be supplied to fuel cell stack 104 from storage tank 106, and air may be supplied to fuel cell stack 104 to generate electricity through known chemical reactions. Fuel cell stack 104 may generate electricity for electrical devices such as electric motor 105. As previously mentioned, fuel cell system 100 may be included in a vehicle; therefore, in some embodiments, electric motor 105 may convert electrical power into mechanical power to drive and rotate the vehicle's axles (thereby driving one or more wheels).

[0017] Compressed air may be supplied to the fuel cell stack 104 at least in part by the compressor section 116 of the turbine 117. The compressor section 116 may compress the inlet airflow 127 into a compressed airflow 129, which is directed to the fuel cell stack 104 to improve the operating efficiency of the fuel cell system 100.

[0018] In some embodiments, turbine 117 may also include a motor, such as electric motor 131. A common shaft may extend between compressor section 116, motor 131, and turbine section 115. Thus, the shaft may be driven to rotate by turbine section 115 and / or motor 131, thereby rotatably driving the compressor impeller within compressor section 116.

[0019] Various components of the fuel cell system 100 can be controlled by a control system 134. The control system 134 may be a computerized system having a processor, various sensors, and other components for electrically controlling the operation of the fuel cell stack 104, the motor 131, and / or other features of the system 100. In some embodiments, the control system 134 may define or be part of an electronic control unit (ECU) of a vehicle.

[0020] Figure 2 A fluid separator 1101 according to an exemplary embodiment of the present disclosure is shown in detail. The fluid separator 1101 may correspond to... Figure 1 The separator 101, and in some embodiments may be incorporated into the fuel cell system 100.

[0021] Fluid separator 1101 may define a straight longitudinal axis 1102 extending between an inlet end 1104 and an outlet end 1106 of separator 1101. In some embodiments, fluid separator 1101 may be generally frustoconical, and a large portion of fluid separator 1101 may comprise a plurality of walls 1112 having a substantially uniform wall thickness. The walls 1112 may be arcuate, profiled, and circular about axis 1102 in the circumferential direction. Furthermore, the walls 1112 may be generally centered on axis 1102. The flow through fluid separator 1101 will be discussed in detail below; however, the flow through fluid separator 1101 may generally be downstream of inlet end 1104 toward outlet end 1106 along axis 1102.

[0022] In some embodiments, the fluid separator 1101 may include an inlet member, such as an inlet pipe 1114, which defines a fluid inlet 1116 (i.e., a fluid inlet passage) passing through it. The fluid inlet 1116 may have a circular cross-section orthogonal to axis 1102. The fluid inlet 1116 may be the only fluid inlet into the fluid separator 1101. The fluid inlet 1116 may be centered on axis 1102 at an inlet end 1104. The inlet pipe 1114 may include an inlet lip 1120 and a downstream terminal 1122, spaced apart along axis 1102. The inlet lip 1120 may be attached to a corresponding pipe, line, conduit, passage, etc., for fluid connection to the fuel cell stack 104 (…). Figure 1 This allows fluid inlet 1116 to receive fluid mixture 1124 therefrom. Mixture 1124 may comprise fluid from fuel cell stack 104 ( Figure 1 The combination of water vapor, liquid water droplets, and gaseous air provided.

[0023] The fluid separator 1101 may also include an outlet component, such as a first outlet pipe 1136 defining a first fluid outlet 1138 (i.e., a first fluid outlet passage) therethrough. The first fluid outlet 1138 may have a circular cross-section orthogonal to axis 1102. The first fluid outlet 1138 may be centered on axis 1102 at an outlet end 1106. The first outlet pipe 1136 may include an upstream end 1140 and a downstream terminal lip 1142, spaced apart along axis 1102. The downstream terminal lip 1142 may be attached to a corresponding pipe, line, conduit, passage, etc., for fluid connection to turbine section 115 (…). Figure 1 Additionally, as will be discussed, the fluid separator 1101 may be configured to separate and substantially remove liquid water droplets from the fluid mixture 1124, allowing air and, in some cases, water vapor to exit from the separator 1101.

[0024] In addition, the fluid separator 1101 may include an outer wall member 1130. The outer wall member 1130 may be hollow and generally cylindrical, having a substantially constant wall thickness. The outer wall member 1130 may define a large portion of the interior 1146 of the separator 1101. The outer wall member 1130 typically includes an inlet end wall 1132 disposed at the inlet end 1104. The inlet end wall 1132 may be attached to and may extend laterally from the inlet pipe 1114, and the inlet pipe 1114 may extend through the inlet end wall 1132 to fluidly connect the fluid inlet 1116 to the interior 1146. The outer wall member 1130 may also include an outlet end wall 1134 disposed near the outlet end 1106. The outlet end wall 1134 may be attached to and may extend laterally from the first outlet pipe 1136, and a first fluid outlet 1138 may be fluidly connected to the interior 1146. In addition, the outer wall member 1130 may include an outer longitudinal wall 1144 that extends substantially along the longitudinal axis between the inlet end wall 1132 and the outlet end wall 1134.

[0025] The inlet end wall 1132 may include an inlet end wall surface 1150 located in a plane that may be inclined relative to axis 1102. The outer longitudinal wall 1144 may include a longitudinal wall surface 1152 facing axis 1102, extending circumferentially about axis 1102, and generally extending along axis 1102. The longitudinal wall surface 1152 may gradually increase radially outward relative to the longitudinal axis 1102 as it extends along the longitudinal axis 1102 from inlet end 1104 toward outlet end 1106. In other words, the radius of the longitudinal wall surface 1152 may gradually increase as it extends along the longitudinal axis 1102 from inlet end 1104 toward outlet end 1106 (i.e., from inlet end wall 1132 to outlet end wall 1134). The outlet end wall 1134 may include an outlet end wall surface 1156. The outlet end wall surface 1156 may face substantially upstream along axis 1102 (i.e., toward inlet end 1104). The outlet end wall 1156 may extend transversely to the axis 1102 from the first outlet pipe 1136 to the longitudinal wall 1152 of the outer longitudinal wall 1144. The end wall 1156 may be tapered as it extends between the first outlet pipe 1136 and the outer longitudinal wall 1144. The end wall 1156 may radially expand outward relative to the axis 1102 as it extends along the longitudinal axis 1102 away from the inlet end 1104 and toward the outlet end 1106. Therefore, as... Figure 2 As shown, the inlet end wall 1150, the longitudinal wall 1152, and the outlet end wall 1156 can be fitted together to define the interior 1146 of the fluid separator 1101.

[0026] Furthermore, the fluid separator 1101 may include an inner flow member 1160. The inner flow member 1160 may be frustoconical and may include an upstream end 1162, a downstream end 1164, an outer surface 1166 facing away from the axis 1102, and an inner surface 1168 facing the axis 1102. The upstream end 1162 and the downstream end 1164 may have circular cross-sections perpendicular to the axis 1102. Furthermore, the outer surface 1166 and the inner surface 1168 may be tapered. For example, along a significant portion of the axial length (along the axis 1102) of the inner flow member 1160, the outer surface 1166 and the inner surface 1168 may gradually expand radially outward as the inner flow member 1160 extends along the axis 1102 from the inlet end 1104 toward the outlet end 1106. The inner flow member 1160 may be supported (e.g., fixed) within an interior 1146 defined by an outer wall member 1130. For example, the fluid separator 1101 may include a plurality of strut members 1170 extending from the downstream end 1164 of the inner flow member 1160 to the outlet end wall 1134 to support the inner flow member 1160. The upstream end 1162 may be attached (e.g., received in and attached to) the downstream terminal 1122 of the inlet pipe 1114 to further support the inner flow member 1160 within the interior 1146.

[0027] The fluid separator 1101 may also include a swirl member 1172. For example... Figure 6 As shown, the swirl member 1172 may include a hub (or swirl plate) 1174 and a plurality of blades 1176, the blades 1176 radiating radially outward from the hub 1174 along the axis 1102. In some embodiments, the hub 1174 may be tapered or truncated cone-shaped, having an upstream end 1178 spaced apart along the axis 1102. Figure 2 The upstream end 1178 may be pointed, and the hub 1174 may be radially flared outward toward the downstream end 1180. The downstream end 1180 may be circular and orthogonal to the axis 1102. The blades 1176 may each include an inner radial end 1182 fixed to the hub 1174. The blades 1176 may extend radially outward from the inner radial end 1182 and may terminate at the outer radial end 1184. Figure 6 ).like Figure 2 As shown, the outer radial end 1184 of the blade 1176 can be fixed to the inner diameter surface opposite the end 1122 of the inlet pipe 1114. Therefore, the fluid mixture 1124 via the inlet pipe 1114 can flow through the swirling member 1172.

[0028] The swirling member 1172 is configured to at least partially guide the flow of the mixture 1124 radially outward away from the axis 1102 as it flows downstream along the axis 1102. As will be discussed, the swirling member 1172 causes the mixture 1124 to swirl as it flows downstream. Therefore, as the mixture 1124 flows downstream through the separator 1101, centrifugal force causes droplets in the mixture 1124 to move radially outward. The droplets can be separated to some extent from water vapor and air in the flow of the mixture 1124. Thus, the swirling member 1172 imparts at least some separation to the various portions of the mixture 1124 during operation.

[0029] The swirl member 1172 may include any suitable number of blades 1176. The blades 1176 may have any suitable type of blade profile. In some embodiments, the blades 1176 may be twisted, helically extended about axis 1102, bent about an axis orthogonal to axis 1102, and / or exhibit other blade profile features. Furthermore, the hub 1174 may have various sizes, surface profiles, and / or other features without departing from the scope of this disclosure. For example, additional embodiments of the swirl member 2172 include… Figure 7 As shown in the diagram. The swirl member 2172 may have a different number of blades, and the blades may have the same... Figure 6 The swirl member 1172 has different blade profiles (i.e., different blade shapes, different blade profiles, different sizes, etc.). In some embodiments, the blade profile can be selected based on the flow characteristics of the mixture 1124 within the system. Figure 6 Swirl member 1172 or swirl member 2172 is used in fluid separator 1101. For example, if the operation of fuel cell system 100 results in exhaust flow 109 flowing at a lower velocity, lower mass flow rate, and lower inlet pressure, then [the following option] can be selected. Figure 6 The swirl member 1172 is used in the separator 1101. Conversely, if the exhaust flow 109 flows at a higher velocity, higher mass flow rate, higher inlet pressure, etc., then... Figure 7 The swirl member 2172 is used in the separator 1101.

[0030] Back Figure 2The fluid separator 1101 may further include an internal outlet pipe 1186. The internal outlet pipe 1186 may be hollow and cylindrical, having a circular cross-section perpendicular to axis 1102. The internal outlet pipe 1186 may have a straight axis and may be centered on axis 1102. The internal outlet pipe 1186 may include an upstream end 1188, a downstream end 1190, an inner radial surface 1192 facing inward toward axis 1102, and an outer radial surface 1194 facing outward away from axis 1102. The radius of the internal outlet pipe 1186 may remain substantially constant along axis 1102. The wall thickness of the internal outlet pipe 1186 may remain substantially constant along most of its axial length. The upstream end 1188 may flare slightly radially outward from axis 1102. The internal outlet pipe 1186 may be fixedly attached to the first outlet pipe 1136. For example, one or more bridging supports 1193 may extend between the inner radial region of the first outlet pipe 1136 and the outer radial region of the inner outlet pipe 1186. Therefore, the inner outlet pipe 1186 may be coaxial and centered within the first outlet pipe 1136. Furthermore, the fluid inlet 1116, the first fluid outlet 1138, the second fluid outlet 1199, and the inner flow member 1160 may be coaxial and centered relative to the longitudinal axis 1102. The downstream end 1190 of the inner outlet pipe 1186 may be received in the first fluid outlet 1138 of the first outlet pipe 1136. Furthermore, the upstream end 1188 may be disposed within the interior 1146 defined by the outer wall member 1130. More specifically, the upstream end 1188 may partially extend into the inner flow member 1160. In other words, the upstream end 1188 of the inner outlet pipe 1186 may be disposed upstream of the downstream end 1164 of the inner flow member 1160 along the axis 1102 at a distance 1198. Therefore, the internal outlet pipe 1186 may define a second fluid outlet 1199 extending from the interior 1146 of the fluid separator 1101. It should be understood that the second fluid outlet 1199 may provide a lower pressure outlet for one or more components of the mixture 1124. For example, the second fluid outlet 1199 may provide an effective outlet for water vapor that has been separated from other parts of the flow, as will be discussed.

[0031] The fluid separator 1101 may additionally include a discharge member 1171, which projects outward at a positive angle 1175 from the axis 1102 and from the outer wall member 1130 near the inlet end 1104. A discharge orifice 1173 may extend through the discharge member 1171 and through the outer wall member 1130 to fluidly communicate with the interior 1146. The discharge orifice 1173 may be fluidly connected at the transition between the inlet end wall 1132 and the outer longitudinal wall 1144. The inlet end wall 1132 may be inclined toward the discharge member 1171 to guide liquid to the discharge member. As will be discussed, the discharge member 1171 may be configured to discharge liquid that has been separated from the fluid mixture 1124 and collected within the interior 1146.

[0032] In addition, the fluid separator 1101 may include one or more recirculation orifices 1148. Multiple recirculation orifices 1148 may be present, defined by a gap, hole, or other passage defined between the upstream end 1162 of the inner flow member 1160 and the downstream end 1122 of the inlet pipe 1114. Multiple recirculation orifices 1148 spaced apart about the axis 1102 may be present.

[0033] Therefore, fluid separator 1101 may be defined within interior 1146 and include a fluid flow path system 1126 extending through fluid separator 1101. Fluid mixture 1124 may enter inlet end 1104 as exhaust flow 109, and fluid mixture 1124 may contain air, gaseous water vapor, and liquid water droplets. Fluid separator 1101 may separate droplets from air and gaseous water vapor. This separation may occur passively. Droplets may be collected and discharged from separator 1101 via discharge member 1171.

[0034] More specifically, the fluid flow path system 1126 may include a first flow path 1128 (i.e., an axial flow path) that extends substantially along the longitudinal axis 1102 from the fluid inlet 1116 across the swirl member 1172 in a first downstream direction and through the inner flow member 1160 toward the first fluid outlet 1138 and the second fluid outlet 1199.

[0035] Additionally, the fluid flow path system 1126 may include one or more second flow paths, such as... Figure 2The second flow path 1129 is shown. As shown, the second flow path 1129 may be defined between the outer wall member 1130 and the inner flow member 1160. The second flow path 1129 may be defined radially between the outer wall member 1130 and the inner flow member 1160. The second flow path 1129 may also be defined axially (e.g., at one end) between the outer wall member 1130 and the inner flow member 1160. Furthermore, the second flow path 1129 may be partially defined by one or more recirculation orifices 1148. More specifically, the axial clearance between the downstream end 1164 and the outlet end wall 1156 may define the upstream portion of the second flow path 1129, wherein the fluid flow branches off from the first flow path, and the outlet end wall 1156 redirects the flow back in the axial direction opposite to the first flow path 1128. The longitudinal wall 1152 and outer surface 1166 may define a second flow path 1129 further downstream and guide flow longitudinally from the outlet end 1106 toward the inlet end 1104. The inlet end wall 1150 may further define the second flow path 1129 further downstream and redirect flow axially toward the recirculation orifice 1148. The recirculation orifice 1148 may fluidly connect the second flow path 1129 to the first flow path 1128. Thus, flow flowing through the recirculation orifice 1148 may re-enter the axial flow path 1128. In some embodiments, the recirculation orifice 1148 may fluidly connect to the axial flow path 1128 at an axial location at the end 1180 of the swirl member 1172, or at an axial location slightly downstream of the end 1180 of the swirl member 1172.

[0036] Furthermore, the discharge orifice 1173 can branch off from the recirculation flow path 1129. Therefore, the discharge member 1171 can define the liquid flow path, as will be described below.

[0037] In fuel cell system 100 ( Figure 1 During operation, fluid mixture 1124 may enter separator 1101 via inlet 1116. Fluid mixture 1124 may contain liquid water droplets (in... Figure 2 (represented by the symbol for droplets), gaseous water vapor (in) Figure 2 (represented by smaller points) and the accompanying gaseous air. The swirling member 1172 can swirl the flow, causing droplets to move radially outward away from the axis 1102 as the mixture 1124 flows further downstream along the first flow path 1128. Air and liquid water can be radially deflected outward from the first flow path 1128 and enter the second flow path 1129, as... Figure 2As shown. The liquid water can be discharged from the discharge port 1173, and the air in the second flow path 1129 can be re-entered into the first flow path 1128. Additionally, gaseous water vapor in the mixture 1124 entering the separator 1101 can flow through the swirl member 1172. The second fluid outlet 1199 can define a low-pressure region at the outlet end 1106, which efficiently extracts gaseous water vapor from the separator 1101. The first fluid outlet 1138 can also provide an outlet from the first flow path 1128. Therefore, the air in the mixture 1124 can flow directly from the inlet 1116 to the first fluid outlet 1138 and / or the second fluid outlet 1199, and the air in the mixture 1124 can also branch off from the first flow path 1128 and be recirculated back via the second flow path 1129.

[0038] Figures 3-5 A method of manufacturing a separator 1101 according to an example embodiment is illustrated. As will be discussed, the separator 1101 may include features that enhance modularity and / or allow the separator 1101 to be customized for a particular system 100. For example, the separator 1101 may be assembled from different parts / sections in an efficient and modifiable manner.

[0039] In some embodiments, one or more portions of separator 1101 may be made of or contain polymers or composite materials. For example, in some embodiments, separator 1101 may be made of glass fiber reinforced polyamide resin. Furthermore, in some embodiments, separator 1101 may be molded (e.g., formed via plastic injection molding). However, it should be understood that separator 1101 may be formed in other ways without departing from the scope of this disclosure.

[0040] like Figure 3 As shown, the inlet pipe 1114 and the outer wall component 1130 may be supplied together (e.g., plastic injection molded) as a one-piece, single-piece inlet component 3112. In some embodiments, a first outlet end lip 3102 may be included for use in further assembly, as will be discussed below. Furthermore, the swirl component may be selectively chosen, for example from components consisting of at least Figure 6 swirl component 1172 and Figure 7 The swirl element 2172 can be selected from group 3120. For example, it can be selected... Figure 6 The swirl member 1172 is attached to the inlet pipe 1114 to form the inlet terminal assembly 3100.

[0041] As described above, the swirl element 1172 may be selected instead of the swirl element 2172, for example, based on the expected flow rate, inlet pressure, mass flow rate, and / or other operating conditions during use. It should be understood that the dimensions of the inlet element 3112 can also be varied and selected in a similar manner for use.

[0042] Additionally, such as Figure 4 As shown, the outlet end wall 1134, the first outlet pipe 1136, and the inner outlet pipe 1186 can be provided together (e.g., injection molded from plastic) as an integral, one-piece outlet component 3114. In some embodiments, a second outlet end lip 3103 may be included for use in subsequent assembly, as will be discussed later. Furthermore, the outlet component 3114 may include one or more tabs 3117 thereon. The inner flow member 1160 may also be formed (e.g., injection molded from plastic) to include a corresponding tab 3118 as shown. The pairs of tabs 3117, 3118 may be joined together (e.g., via fasteners, adhesives, etc.) to attach the inner flow member 1160 to the outlet component 3114 and define the aforementioned strut member 1170. Thus, the attached outlet component 3114 and the inner flow member 1160 can cooperate to define the outlet terminal assembly 3200.

[0043] Subsequently, as Figure 5 As shown, the inlet terminal assembly 3100 and the outlet terminal assembly 3200 can be combined to define the separator 1101. For example, the first outlet lip 3102 can be combined to the second outlet lip 3103 (e.g., via fasteners, adhesives, etc.).

[0044] Therefore, separator 1101 can draw air from exhaust flow 109 ( Figure 1 Liquid water is separated and removed from the separator 1101, and water vapor and air are supplied as a post-separation exhaust stream 111 to the turbine section 115 of the turbine 117. A relatively low pressure drop (i.e., a low pressure gradient) can exist across the separator 1101 from the inlet end 1104 to the outlet end 1106. Therefore, the separator 1101 can provide efficient fluid flow under a wide range of operating conditions, enabling the system 100 to operate at high efficiency. Furthermore, the separator 1101 can be compact and lightweight. The separator 1101 can also be manufactured efficiently with relatively few parts.

[0045] While at least one exemplary embodiment has been presented in the foregoing detailed descriptions of this disclosure, it should be understood that numerous variations exist. It should also be understood that one or more exemplary embodiments are merely examples and are not intended to limit the scope, applicability, or construction of this disclosure in any way. Rather, the foregoing detailed descriptions will provide those skilled in the art with a convenient roadmap for implementing exemplary embodiments of this disclosure. It should be understood that various changes can be made to the function and arrangement of the elements described in the exemplary embodiments without departing from the scope of this disclosure as set forth in the appended claims.

Claims

1. A fluid separator device configured to separate a portion of a fluid mixture from another portion of the fluid mixture, the fluid separator device comprising: An outer wall component defines the interior of the fluid separator device, and the interior defines the longitudinal axis of the fluid separator device; An inlet end, the inlet end defining a fluid inlet that is fluidly connected to the interior and configured to receive the fluid mixture; An outlet end, which is spaced a certain distance from the inlet end along the longitudinal axis, defines a first fluid outlet from the interior, and the longitudinal axis extends through the first fluid outlet; An outlet pipe, supported in the interior and the first fluid outlet, defines a second fluid outlet from the interior; An internal flow member supported within the interior; A fluid flow path system defined within the interior, the fluid flow path system comprising: A first flow path extends from the fluid inlet in a first downstream direction through the internal flow member toward at least one of the first fluid outlet and the second fluid outlet; as well as A second flow path, which is at least partially defined between the outer wall member and the inner flow member, extends from the outlet end toward the inlet end in a second downstream direction, and is configured to receive flow from the first flow path.

2. The fluid separator device according to claim 1, characterized in that, Also includes: A swirling member supported within the first flow path and configured to at least partially guide the first flow path radially outward from the longitudinal axis.

3. The fluid separator device according to claim 2, characterized in that, Also includes: A recirculation orifice extends through the inner flow member, the recirculation orifice connecting the second flow path fluid to the first flow path and configured to recirculate the flow from the second flow path to the first flow path.

4. The fluid separator device according to claim 3, characterized in that, The swirl component includes an upstream end, a downstream end, and multiple blades radiating around the longitudinal axis; and The recirculation orifice is fluidly connected to the first flow path at the downstream end of the swirl member.

5. The fluid separator device according to claim 4, characterized in that, Also includes: A discharge port extending through the outer wall member, the discharge port being fluidly connected to the second flow path and configured to discharge the liquid component of the fluid mixture from the fluid separator device.

6. The fluid separator according to any of the preceding claims, characterized in that, The outer wall member includes an inner surface that at least partially defines the interior, the inner surface expanding radially outward relative to the longitudinal axis as it extends along the longitudinal axis from the inlet end toward the outlet end.

7. The fluid separator according to claim 6, characterized in that, The internal flow member includes an outer surface that expands radially outward relative to the longitudinal axis as it extends along the longitudinal axis from the inlet end toward the outlet end.

8. The fluid separator according to any of the preceding claims, characterized in that, The internal flow member includes an inner surface that expands radially outward relative to the longitudinal axis as the inner surface extends along the longitudinal axis from the inlet end toward the outlet end.

9. The fluid separator according to claim 8, characterized in that, The outlet pipe extends partially into the internal flow member.

10. The fluid separator according to any of the preceding claims, characterized in that, The outer wall component includes an inlet end wall surface adjacent to the inlet end and extending transversely to the longitudinal axis, an outlet end wall surface adjacent to the outlet end and extending transversely to the longitudinal axis, and a longitudinal wall surface extending along the longitudinal axis between the inlet end wall surface and the outlet end wall surface; and The interior is defined by the cooperation of the inlet end wall, the outlet end wall, and the longitudinal wall.

11. The fluid separator according to claim 10, characterized in that, The outlet end wall expands radially outward relative to the longitudinal axis as it extends away from the inlet end and toward the outlet end along the longitudinal axis.

12. The fluid separator according to any of the preceding claims, characterized in that, The first fluid outlet and the second fluid outlet are coaxial with respect to the longitudinal axis and are centered.

13. The fluid separator according to claim 12, characterized in that, The longitudinal axis is straight, and the fluid inlet, the first fluid outlet, and the second fluid outlet are coaxial with respect to the longitudinal axis and centered.

14. The fluid separator according to claim 13, characterized in that, The fluid inlet, the first fluid outlet, the second fluid outlet, the internal flow member, and the outer wall member are coaxial with respect to the longitudinal axis and are centered.

15. A method of manufacturing a fluid separator device, the fluid separator device being configured to separate a portion of a fluid mixture from another portion of the fluid mixture, the method comprising: An outer wall member is provided to define the interior of the fluid separator device, the interior defining the longitudinal axis of the fluid separator device; An inlet is provided, the inlet defining a fluid inlet that is fluidly connected to the interior and configured to receive the fluid mixture; An outlet end is provided that is spaced at a distance from the inlet end along the longitudinal axis, the outlet end defining a first fluid outlet from the interior, the longitudinal axis extending through the first fluid outlet; An outlet pipe is supported in the interior and the first fluid outlet, the outlet pipe defining a second fluid outlet from the interior; The internal flow component is supported within the interior. A fluid flow path system is defined within the interior, the fluid flow path system comprising: A first flow path extends from the fluid inlet through the internal flow member in a first downstream direction and toward at least one of the first fluid outlet and the second fluid outlet; as well as A second flow path, which is at least partially defined between the outer wall member and the inner flow member, extends from the outlet end toward the inlet end in a second downstream direction, and is configured to receive flow from the first flow path.

16. The method according to claim 15, characterized in that, Also includes: A swirling member is supported within the first flow path, the swirling member being configured to at least partially guide the first flow path radially outward from the longitudinal axis.

17. The method according to claim 16, characterized in that, Also includes: The swirl member is selected from the group consisting of a first swirl member and a second swirl member, wherein the second swirl member has a different blade profile than the first swirl member.

18. The method according to claim 16 or 17, characterized in that, Also includes: The outer wall component and the inlet end are provided as an integral, single-piece part, and the swirling component is attached to the integral, single-piece part to form the first sub-assembly of the fluid separator device.

19. The method according to claim 18, characterized in that, Also includes: The outlet end and the outlet pipe are provided together as another integral, one-piece component, and the internal flow member is attached to this other integral, one-piece component to form a second sub-assembly of the fluid separator device; and It also includes attaching the first subcomponent to the second subcomponent.

20. A fuel cell system, comprising: Fuel cell stack; A turbine with a turbine section; as well as A fluid separator device fluidly connected to the fuel cell stack and configured to receive a fluid mixture from the fuel cell stack, the fluid separator device being fluidly connected upstream to the turbine section, the fluid separator device being configured to separate a portion of the fluid mixture from another portion of the fluid mixture to provide a separated exhaust stream from the fuel cell stack to the turbine section, the fluid separator device comprising: An outer wall component defines the interior of the fluid separator device, and the interior defines the longitudinal axis of the fluid separator device; An inlet end, the inlet end defining a fluid inlet that is fluidly connected to the interior and configured to receive the fluid mixture; An outlet end, which is spaced a certain distance from the inlet end along the longitudinal axis, defines a first fluid outlet from the interior, and the longitudinal axis extends through the first fluid outlet; An outlet pipe, supported in the interior and the first fluid outlet, defines a second fluid outlet from the interior; The internal flow member supported within the interior; and A fluid flow path system defined within the interior, the fluid flow path system comprising: A first flow path extends from the fluid inlet in a first downstream direction through the internal flow member toward at least one of the first fluid outlet and the second fluid outlet; and A second flow path, which is at least partially defined between the outer wall member and the inner flow member, extends from the outlet end toward the inlet end in a second downstream direction, and is configured to receive flow from the first flow path.

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