An air-cooled fuel cell system integration structure

Abstract

The utility model discloses an air cooling fuel cell system integrated structure belongs to fuel cell technical field. The integrated structure is to set up fuel cell stack and its auxiliary components on the air deflector cover, and the side plate of air deflector cover and the cathode bottom plate, anode bottom plate of electric pile are connected to form the side surrounding casing structure of fuel cell stack, and the opposite side of fuel cell stack and fan is without side plate and opens to the environment, the fan in air management subassembly provides fresh air to the cooling and cathode flow channel on the polar plate in fuel cell stack, in hydrogen circulation subassembly, hydrogen passes control valve and enters hydrogen into the stack mouth on the cathode bottom plate, supplies to the anode manifold entrance of fuel cell stack through hydrogen flow channel in the cathode bottom plate, and the hydrogen that is not consumed is led out again by hydrogen out of the stack mouth on the cathode bottom plate and enters hydrogen circulation pipeline, and it is controlled by circulating pump to return to hydrogen into the stack mouth on the cathode bottom plate again. The utility model optimizes and reduces the overall size of fuel cell, guarantees the heat dissipation performance and improves the space utilization of fuel cell.

Description

Technical Field

[0001] This utility model belongs to the field of fuel cell technology, specifically relating to an integrated structure for an air-cooled fuel cell system. Background Technology

[0002] Auxiliary components of a fuel cell system include temperature and pressure sensors, controllers, pressure reducing valves, flushing valves, air filters, low-voltage power supplies, and circulation pumps. These components play a crucial role in optimizing system performance and ensuring the power generation performance of the fuel cell. Air-cooled fuel cell systems offer advantages in simplicity and cost-effectiveness. However, auxiliary plant (BOP) components (including fans, sensors, solenoid valves, water management modules, and electrical control equipment) and their interconnecting electrical and gas piping occupy significant space, limiting the overall system compactness and hindering system integration and maintenance on space-constrained two-wheeled vehicles. Current system designs typically involve separate BOP installation structures, leading to increased volume, weight, and integration complexity. An innovative approach is needed to integrate BOP components more efficiently and compactly, reducing production costs and simplifying the assembly process. Utility Model Content

[0003] Purpose of the utility model: This utility model aims to provide an integrated structure for an air-cooled fuel cell system, in which the fan frame and air guide shroud, typically used to support the cooling fan, are redesigned as mounting platforms for various BOP (Balance of Plant) components. This integration significantly reduces system size, simplifies assembly, and improves overall system efficiency.

[0004] To achieve the above objectives, the technical solution provided by this utility model is as follows:

[0005] An integrated structure for an air-cooled fuel cell system is disclosed, wherein the fuel cell stack and its auxiliary components are integrated onto an air guide shroud. The air guide shroud includes two side plates, which, together with a cathode base plate and an anode base plate, form a side-enclosing shell structure for the fuel cell stack. The fuel cell stack has no side plates on the opposite side from the fan. The auxiliary components include:

[0006] An air management component includes a fan, which is located behind the air guide shroud and is capable of directly supplying air to the cooling and cathode flow channels on the plates of the fuel cell stack.

[0007] The hydrogen circulation assembly includes a hydrogen supply port, a circulation pump, a control valve, and connecting pipelines. The hydrogen supply port is used to connect to a hydrogen source. Hydrogen enters the hydrogen inlet on the cathode base plate through the control valve. The hydrogen inlet supplies hydrogen to the first gas collection port of the fuel cell stack through the hydrogen flow channel in the cathode base plate. The second gas collection port of the fuel cell stack serves as the hydrogen outlet. Hydrogen that is not consumed by the fuel cell reaction is collected at the second gas collection port and enters the cathode base plate. It is then led out through the hydrogen outlet on the cathode base plate into the hydrogen circulation pipeline, and the circulation pump controls it to return to the hydrogen inlet on the cathode base plate.

[0008] Furthermore, the cathode base plate and the anode base plate are located on the cathode side and the anode side of the fuel cell stack, respectively, and the bipolar plate and the membrane electrode are fixed between the cathode base plate and the anode base plate by bolts.

[0009] The cathode base plate and the anode base plate are provided with a set of relatively opposite process positioning holes. The process positioning holes penetrate the fuel cell stack and are used for clamping and fixing during the current collector assembly process, and also include the adjustment of clamping pressure.

[0010] Furthermore, a sealing ring is provided at the junction of the first gas collecting port and the second gas collecting port with the hydrogen supply port on the cathode base plate;

[0011] The first and second gas collection ports are both formed by stacking and sealing the gas collection ports on the manifold plate.

[0012] Furthermore, the connecting pipes in the hydrogen circulation assembly include pressure sensors to monitor hydrogen pressure.

[0013] The power output terminal of the fuel cell stack is connected to a DC-DC voltage regulator, and the current passing through the DC-DC voltage regulator supplies power to the load; the fan is controlled by the on-board controller FCU and connected to a power source, which may be the fuel cell or an independent power source, including combining it with the DC-DC voltage regulator to achieve voltage regulation.

[0014] The connecting pipelines in the hydrogen circulation assembly include a water vapor separator.

[0015] In the above-mentioned configuration, the hydrogen circulation component is deployed around the fan, which can use the hot airflow from the fuel cell stack blown by the fan to heat the circulating hydrogen pipeline.

[0016] Furthermore, the heat dissipation methods for this fuel cell stack include either air supply or exhaust heating.

[0017] The aforementioned air-blowing type refers to the use of a fan to blow air onto the fuel cell stack for heat dissipation, with the air passing through the fuel cell stack and flowing out from its opposite side;

[0018] The aforementioned heat extraction type refers to a negative pressure formed by a fan on the side of the fuel cell stack, with the fuel cell stack receiving air from its opposite side, passing through the fuel cell stack, and outputting from the side where the fan is located.

[0019] Furthermore, a pipeline is led out from the hydrogen outlet for anode flushing, and this pipeline includes a flushing valve and a gas source connection port.

[0020] Furthermore, the integrated structure includes an air filter for the air entering the fuel cell stack. This air filter can be located at the air inlet of the bipolar plate without side plates or at the air supply side of the fan to the bipolar plate, i.e., it can be located at the corresponding air inlet position.

[0021] The integrated structure provided by this utility model includes a control circuit based on the air guide shroud, and the air guide shroud has a mounting groove for wiring harness deployment on the outer side of the fuel cell stack.

[0022] Beneficial Effects: Compared with existing technologies, this invention directly mounts the BOP (Body-Operated Plant) components (including but not limited to auxiliary equipment such as air management, thermal management, and control) onto the fan frame structure or integrates them within the fan frame structure. Furthermore, it employs injection molding to form the fan frame containing the BOP cavity, thereby reducing the overall system space footprint and facilitating mass production and integration. This invention features high space utilization, efficient assembly according to preset mounting positions (set on the air guide shroud), and a modular design that ensures high integration of system functional units during manufacturing and assembly. The assembled overall structure is compact and robust, further improving system reliability and lifespan. Based on the air guide shroud's adjustable heat dissipation control, superior heat dissipation performance is achieved, ensuring uniform and smooth airflow within the fuel cell stack, improving system heat exchange efficiency, and enhancing the stability of the fuel cell under high load and long-term operation. Attached Figure Description

[0023] Figure 1 This is a schematic diagram of the integrated structure described in this utility model;

[0024] Figure 2 This is a schematic diagram of the open side structure of a fuel cell stack;

[0025] Figure 3 This is a structural diagram of the electrode plates in a fuel cell stack;

[0026] Figure 4 It is the anode surface structure of a bipolar plate;

[0027] Figure 5 It is the cathode surface structure of a bipolar plate;

[0028] Figure 6 It is the structure on the cathode side of the fuel cell stack;

[0029] Figure 7 This is a schematic diagram of the cathode base plate;

[0030] Figure 8 It is the structure on the anode base plate side;

[0031] Figure 9 It is the structure on the fan side;

[0032] Figure 10 This is a structural diagram of a fuel cell control system. Detailed Implementation

[0033] The following description, in conjunction with the accompanying drawings, describes an integrated structure for an air-cooled fuel cell system provided by this utility model.

[0034] Air-cooled hydrogen fuel cells refer to fuel cells that achieve heat dissipation through forced ventilation or natural air convection. Air-cooled hydrogen fuel cells possess advantages such as strong environmental adaptability, compact structure, low operating costs, and fast start-up speed, and have enormous application potential in many fields such as backup power, transportation, and off-grid power supply. Generally speaking, water-cooled fuel cell stack systems have high power output and are suitable for passenger cars and commercial vehicles; air-cooled systems have lower power output and are suitable for systems such as two-wheeled vehicles, three-wheeled vehicles, sightseeing vehicles, drones, and small-power unmanned boats.

[0035] refer to Figure 1 This invention presents an integrated structure for an air-cooled fuel cell system. The structure includes a fan 1, a fixed frame for the fan 1 fitted to a shroud 2, and a side plate located on both sides of the fuel cell stack. The side plates, along with a cathode base plate 3 and an anode base plate 10 positioned above and below the fuel cell stack, form a partial enclosure (semi-enclosure) of the stack. (Reference) Figure 2 The diagram shows the configuration of the opposite side of the fuel cell stack's fan side, which is open and has no side plate. Regarding the assembly of the fuel cell stack... Figure 1 The image shows that bolt holes are pre-drilled on the cathode base plate 3 and the anode base plate 10 for bolts 4 to assemble the fuel cell stack. The cathode base plate 3 and the anode base plate 10 also have relatively irregularly shaped process positioning holes, such as... Figure 1 The circular process positioning hole 5 and the square process positioning hole 6 shown, through their relatively irregular structure, enable rapid and precise bipolar plate positioning and stacking. (Reference) Figure 3 The provided structure illustrates the composition of the fuel cell stack. On the cathode side, the cathode copper electrode fiberglass insulating composite plate 25, cathode plate 21, bipolar plate 22, and membrane electrode 23 are arranged in overlapping layers, followed by an overlapping arrangement of bipolar plate 22 and membrane electrode 23. Similarly, on the anode side, an anode copper electrode fiberglass insulating composite plate 24 is provided. For details regarding the anode and cathode surfaces of the bipolar plate 22, please refer to [link / reference needed]. Figure 4 and Figure 5 As shown.

[0036] Based on the assembled fuel cell stack, the auxiliary components of the fuel cell system deployed according to this invention are described below. The auxiliary components shown and described in this embodiment are key operating components. Optimizations made by those skilled in the art based on this integrated structure and existing technology constitute other implementation methods and should not be construed as limitations or defects of the technical solutions provided by this invention.

[0037] It is worth noting that the fuel cell stack described in this invention adopts a semi-closed structure, which differs from the closed and open structures disclosed in existing technologies. In a semi-closed structure, the cooling air is split, with a portion becoming cathode reaction air and the majority serving as cooling air. In an open structure, there is no splitting, and the cooling and cathode air are combined, resulting in a large air volume that can easily cause membrane electrode assembly (MEA) drying failure. In a closed structure, cooling and cathode air are separated, with a dedicated cathode air blower and an additional cooling fan.

[0038] Further integration Figure 1 and Figure 6 This invention illustrates the BOP (Balance of Plant) assembly (AOP) of a fuel cell system deployed using a fan 1 mounting frame and a shroud 2. Typically, a BOP assembly (including a fan, sensors, solenoid valves, a water management module, and electrical control equipment) and its interconnected electrical and gas pipelines occupy a significant amount of space, limiting the overall system's compactness and making system integration and maintenance inconvenient on a space-constrained two-wheeled vehicle. Existing system designs usually involve separate BOP mounting structures, leading to increased volume, weight, and integration complexity. An innovative method is needed to integrate the BOP assembly more efficiently and compactly, reducing production costs and simplifying the assembly process. The specific structure is:

[0039] The fan 1 and its mounting frame are designed to provide structural support for the cooling fan, and this invention also functions as a BOP (Balance of Plant) assembly mount. Firstly, the fan frame is typically injection-molded from engineering plastics such as polyamide, polypropylene, ABS, or composite materials, possessing certain structural strength and electrical insulation capabilities. Secondly, the frame is chosen as the integrated platform due to its relatively low thermal conductivity and excellent shock absorption performance, which is particularly important for air-cooled fuel cells in automotive applications. The fan 1 delivers or draws air through the air inlet 14 located in the air guide shroud 2, forming a heat dissipation channel within the shroud 2 to enhance the system's thermal management capabilities. Finally, considering that the fan is an essential component of the air-cooled fuel cell stack, this invention already includes a frame; other BOP assemblies can be embedded into the existing fan frame. Utilizing the pre-reserved grooves or dedicated mounting cavities inside the fan frame and air guide shroud, the BOP module can be directly implanted into the fan frame. This not only makes efficient use of existing structural space but also makes the overall system layout more compact and effectively reduces the overall system volume.

[0040] The air management component extends the frame of fan 1 to match the transition air duct of the fuel cell cathode to form an air guide shroud 2. The air guide shroud 2 has a certain space between it and the fuel cell, optimizing the distribution of airflow relative to the cathode flow duct. The side of the bipolar plate 22 serves as the air inlet. The semi-enclosed air-cooled and side-enclosed shell structure described in this invention can be referenced. Figure 1-6 To determine this. The two side plates of the air guide shroud 2 are located on both sides of the fuel cell stack and are made of insulating material. The side plates are connected to the anode base plate 10 and the cathode base plate 3. Taking the cathode base plate 3 as an example, this structure is as follows: Figure 7 As shown, through Figure 7 It can be seen that the internal gas passage is provided. The cathode base plate 3 is provided with a hydrogen inlet 15 and a hydrogen outlet 16. The hydrogen inlet 15 is connected to the hydrogen injection port 20. The hydrogen injection port 20 is attached to the first gas collection port 17 and the second gas collection port 18 on the corresponding stack through the sealing ring 19. The first gas collection port 17 and the second gas collection port 18 are connected through the gas flow channel on the anode surface in the bipolar plate. The unconsumed hydrogen flows back through the second gas collection port 18, and is recycled again after being dried by gas-liquid separation and circulation pump 8, and then converges at the hydrogen inlet.

[0041] The integrated structure provided by this utility model can also be combined with Figure 8 and Figure 9 To learn more.

[0042] For the hydrogen circulation connection pipeline, the specific structure given in the embodiment is as follows: Hydrogen outlet 16 is pressurized by circulation pump 8 to allow it to exit the fuel cell stack. After drying (not specifically shown in the figure, but can be combined with a water vapor separator for drying and dehydration), a pipeline is led out from circulation pump 8 and equipped with a pressure sensor to monitor the hydrogen pressure in this pipeline. The pipeline connected to pressure sensor 12 is connected to the hydrogen supply pipeline via a three-way valve, and then enters the fuel cell stack. Hydrogen supply port 13 is connected to a hydrogen cylinder (hydrogen source). A control valve 9 is installed on the pipeline supplying hydrogen to the fuel cell stack. The control valve 9 can be a solenoid valve to control the adjustment of the hydrogen supply pressure, and a pressure sensor is also installed for detection. Furthermore, at hydrogen outlet 16, a pipeline is led out for anode flushing, controlled by flushing valve 11, to periodically release nitrogen and water vapor from the cathode.

[0043] The circuit structure of the fuel cell described in this embodiment can also be found in [reference needed]. Figure 10The provided power supply system structure diagram. Furthermore, it should be noted that for the deployment of control electronic equipment, this invention can also incorporate grooves on the outer surface of the air guide shroud 2 for installation and fixation. The injection mold design includes pre-reserved brackets and corresponding fixing holes for fixing the fuel cell controller, DC-DC regulator, valves, and pressure sensors. Simultaneously, the integrated frame and air shroud also contain channels for fixing wiring harnesses and cables, avoiding the snap-fit ​​fixing schemes of existing designs, providing a compact integrated design and improving the environmental protection level of the components.

[0044] This invention fixes the hydrogen circulation assembly, consisting of a hydrogen circulation pump, valves, pressure sensor 12, and pipelines, onto a fan frame, simplifying the fuel cell stack circulation loop design. Simultaneously, the hot airflow generated by the fuel cell stack and fan heats the circulating hydrogen pipeline, preventing water vapor condensation at the fuel cell stack inlet under low-temperature conditions. The circulating hydrogen loop is located near the fan exhaust outlet, saving space while ensuring the heat balance required for normal fuel cell operation. Regarding materials, this invention can utilize polymer materials suitable for injection molding and possessing good heat dissipation and weather resistance, such as engineering plastics (ABS, POM, PMMA, polyamide, polypropylene, polyethylene, etc.) or composite materials, to meet the mechanical strength and thermal stability requirements under long-term operating conditions.

Claims

1. An integrated structure for an air-cooled fuel cell system, characterized in that, The integrated structure integrates the fuel cell stack and its auxiliary components onto the air guide shroud (2). The air guide shroud (2) includes two side plates, which are connected to the cathode base plate (3) and anode base plate (10) to form a side enclosure structure for the fuel cell stack. The fuel cell stack has no side plates opposite the fan (1). The auxiliary components include: An air management component includes a fan (1) located behind the air guide shroud (2) and capable of supplying air to the cooling and cathode flow channels (14) on the plates of the fuel cell stack. The hydrogen circulation assembly includes a hydrogen supply port (13), a circulation pump (8), a control valve (9), and connecting pipelines. The hydrogen supply port (13) is used to connect to a hydrogen source. Hydrogen enters the hydrogen inlet (15) on the cathode base plate (3) through the control valve (9). The hydrogen inlet (15) supplies the first gas collection port (17) of the fuel cell stack through the hydrogen flow channel in the cathode base plate (3). The second gas collection port (18) serves as the outlet of hydrogen. Hydrogen that is not consumed by the fuel cell reaction is collected at the second gas collection port (18) and enters the cathode base plate (3). Then, it is led out through the hydrogen outlet (16) on the cathode base plate (3) and enters the hydrogen circulation pipeline. The circulation pump (8) controls it to return to the hydrogen inlet (15) on the cathode base plate (3).

2. The integrated structure of the air-cooled fuel cell system according to claim 1, characterized in that, The cathode base plate (3) and anode base plate (10) are located on the cathode side and anode side of the fuel cell stack, respectively. The bipolar plate and membrane electrode are fixed between the cathode base plate (3) and anode base plate (10) by bolts (4). The cathode base plate (3) and the anode base plate (10) are provided with a set of relatively irregular process positioning holes. The process positioning holes penetrate the fuel cell stack and are used for clamping and fixing during the current collector assembly process, and also include the adjustment of clamping pressure.

3. The integrated structure of the air-cooled fuel cell system according to claim 1, characterized in that, A sealing ring (19) is provided at the junction of the first gas collecting port (17) and the second gas collecting port (18) with the hydrogen injection port (20) on the cathode base plate (3); The first gas collecting port (17) and the second gas collecting port (18) are both formed by stacking and sealing the gas collecting ports on the bipolar plate.

4. The integrated structure of the air-cooled fuel cell system according to claim 1, characterized in that, The connecting pipelines in the hydrogen circulation assembly include pressure sensors to monitor hydrogen pressure and control valves to control the on / off state or flow rate of hydrogen.

5. The integrated structure of the air-cooled fuel cell system according to claim 1, characterized in that, The power output terminal of the fuel cell stack is connected to a DC-DC voltage regulator, and the current passing through the DC-DC voltage regulator supplies power to the load. The fan (1) is controlled by the vehicle controller FCU and is connected to the power supply.

6. The integrated structure of the air-cooled fuel cell system according to claim 1 or 4, characterized in that, The connecting pipelines in the hydrogen circulation assembly include a water vapor separator.

7. The integrated structure of the air-cooled fuel cell system according to claim 1, characterized in that, The hydrogen circulation assembly is deployed around the fan and can use the hot airflow from the fuel cell stack blown by the fan to heat the circulating hydrogen pipeline.

8. The integrated structure of the air-cooled fuel cell system according to claim 1 or 7, characterized in that, The heat dissipation methods for the fuel cell stack include either air supply or exhaust heating. The aforementioned air supply type refers to the fan (1) blowing air to the fuel cell stack for heat dissipation, with the air passing through the fuel cell stack and flowing out from its opposite side; The aforementioned heat extraction type refers to the negative pressure formed by the fan (1) on the side of the fuel cell stack, the fuel cell stack taking in air from its opposite side, passing through the fuel cell stack and outputting from the side where the fan (1) is located.

9. The integrated structure of the air-cooled fuel cell system according to claim 1, characterized in that, A pipeline is led out from the hydrogen outlet (16) for anode flushing, and the pipeline includes a flushing valve and a gas source connection port.

10. The integrated structure of the air-cooled fuel cell system according to claim 1, characterized in that, The integrated structure includes an air filter for the air entering the fuel cell stack, which may be located at the bipolar plate air inlet without side plates or at the air supply side of the fan to the bipolar plate.

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