Water separator for separating water from a fluid flow

Abstract

The invention relates to a water separator (100) for separating water from a fluid flow, in particular from a gas flow of a fuel cell system, comprising at least one first separation stage (10) with a first flow-guiding region (18) which is connected to a fluid line (17). A coarse water separator (20) is arranged in the fluid line (17). A separation region (22) is connected to a water outlet (24). The water separator (100) comprises at least one second separation stage (30) with a second flow-guiding region (38), wherein the second separation stage (30) is arranged downstream of the first separation stage (10). The second flow-guiding region (38) has at least one separation element (50, 60) which is exposed to the fluid flow.

Description

Technical area

[0001] The invention relates to a water separator for separating water from a fluid flow, in particular from a gas flow of a fuel cell system. State of the art

[0002] EP 1167743 B1 discloses a water separator designed as a swirl separator. The water separator comprises an inner tube and an outer tube arranged one after the other in the axial direction, with the inner tube extending into the outer tube with an axial portion, and the outer tube having a water outlet arranged tangentially in the swirl direction. Disclosure of the invention

[0003] An object of the invention is to provide an improved water separator for separating water from a fluid flow, in particular a gas flow of a fuel cell system.

[0004] The aforementioned problem is solved according to one aspect of the invention by a water separator for separating water from a fluid flow, in particular from a gas flow of a fuel cell system, comprising at least a first separation stage with a first flow-guiding region which is connected to a fluid line, wherein the first flow-guiding region has at least one inner tube and at least one outer tube which are arranged in an axial direction to each other, wherein the inner tube connects to the outer tube and is arranged downstream of the outer tube in the flow direction, wherein a coarse water separator is arranged in the fluid line, wherein a separation region is arranged on a radial outside of the inner tube and the outer tube and is connected to a water outlet, comprising at least a second separation stage with a second flow-guiding region,wherein the second separation stage is arranged downstream of the first separation stage, wherein the inner tube of the first flow-guiding region is fluidically coupled to an inlet opening of the second flow-guiding region, wherein the second flow-guiding region has at least one separation element against which the fluid flow flows.

[0005] Advantageous embodiments and advantages of the invention emerge from the further claims, the description and the drawing.

[0006] According to one aspect of the invention, a water separator for separating water from a fluid flow, in particular from a gas flow of a fuel cell system, is proposed, comprising at least a first separation stage with a first flow-guiding region connected to a fluid line. The first flow-guiding region has at least one inner tube and at least one outer tube, which are arranged in an axial direction relative to one another. The inner tube adjoins the outer tube and is arranged downstream of the outer tube in the flow direction. A coarse water separator is arranged in the fluid line. A separation region is arranged on a radial outer side of the inner tube and the outer tube and is connected to a water outlet.The water separator further comprises at least a second separation stage with a second flow-conducting region, wherein the second separation stage is arranged downstream of the first separation stage. The inner tube of the first flow-conducting region is fluidically coupled to an inlet opening of the second flow-conducting region. The second flow-conducting region has at least one separation element against which the fluid flow flows.

[0007] The gas flow in the fuel cell system can be, for example, air, hydrogen, or nitrogen.

[0008] The proposed water separator can be used, for example, on the cathode side and / or on the anode side of a fuel cell system, on the anode side preferably in the recirculation circuit upstream of a feed pump.

[0009] Water from the reaction of hydrogen with oxygen in a fuel cell system is present as product water and is removed from the anode circuit by means of a water separator. The separated water is usually released into the environment of the fuel cell system, but can also be reused for other components that require liquid water, such as humidifiers for the process gases. Depending on the type and flow rate of the fuel cell, very high separation efficiencies may be required at the water separator, which can only be achieved with a multi-stage process.

[0010] The proposed multi-stage water separator advantageously exhibits a high water separation efficiency. A first separation stage serves to remove large quantities of water from the fluid flow at the airflow inlet. Here, for example, up to 90% of the water can be separated. A second separation stage can incorporate an impactor with downstream separation components. These components are used either all or partially, according to a modular system, to separate the remaining liquid water from the fluid flow. This allows for the advantageous combination of separation components for low flow velocities with those for high flow velocities, all of which can be arranged in a compact design within the housing of the second separation stage.

[0011] The water separator can be adapted to different requirements, making it particularly advantageous to achieve long service lives for the fuel cell system.

[0012] Advantageously, the first separation stage of the water separator can be designed as an axial cyclone. In this design, centrifugal forces create a film of liquid water from the air, which then flows down the inner wall of the first separation stage to the drainage system.

[0013] The water droplets remaining in the airflow are guided through the inner pipe of the first separation stage, which acts as a connecting pipe, into the second separation stage, where the flow is forced to change direction several times. The second separation stage serves as a fine water separator for the remaining water in the fluid flow. Advantageously, the housing of the water separator can contain at least one element against which the fluid flow impinges and is thereby deflected. Due to the inertial force of the flow change, the water droplets cannot follow it and can thus be separated. Depending on the housing design, several flow deflections can occur in the second separation stage, with a corresponding number of separation elements such as a separating fleece, a separating impactor, a lamellar separator, or the like.

[0014] The proposed water separator advantageously allows a swirling flow to be generated in the inlet area of ​​the water separator using an axial cyclone, with subsequent water separation in several separation stages by centrifugal force, inertia, and / or gravity. The water separator thus differs favorably from the state of the art by offering improved overall separation performance with comparable pressure loss.

[0015] The water separator can advantageously be operated in a horizontal installation or a vertical installation, for example in a fuel cell system.

[0016] For the modular design principle, the water separator can consist of several, especially interchangeable, individual parts, or be manufactured as a single component, for example from plastic using conventional injection molding processes.

[0017] The first separation stage can be equipped, for example, with a swirl generator as a coarse water separator, which can either be integrated with the fluid line or arranged in an interchangeable manner.

[0018] The first and second separation stages of the water separator, as well as individual elements of the second separation stage, can be manufactured cost-effectively as separate components. In a multi-stage water separator, these components can be assembled modularly into a complete system using a building block principle. The components and housings of the individual separation stages can be welded or bonded together, for example.

[0019] According to a favorable embodiment of the water separator, the separation element can have a surface structured counter to the direction of fluid flow and / or a fleece, wherein the structured surface comprises a plurality of elevations, in particular a plurality of parallel truncated pyramids. Other shapes of elevations are also possible, such as cylinders, cuboids, spheres, cones, etc. The fluid flow can be forced to change direction by the separation element. Due to the sharp flow deflection of the fluid flow at the separation element and the tendency of the water droplets to move in a straight line, these remain in contact with the separation element for a longer period. The water droplets in the fluid flow remain in the depth of the structured surface or in the fleece, grow in size, and can then flow downwards in the direction of gravity into a water collection chamber.

[0020] According to a favorable design of the water separator, the separating element can be configured as an impactor plate without an interior or with an interior open downwards in the direction of gravity. The separating element can be positioned opposite an inlet opening of the second flow-carrying area. By positioning the separating element opposite the inflow direction, the flow directly impacts the separating element, thus forcing the fluid flow to redirect its direction. The impactor plate can be flat, curved, stepped, or otherwise uneven. Separated water can flow from the separating element, which may have a closed surface or openings, through the interior and / or at the front into the water collection chamber.

[0021] In a favorable design of the water separator, the front surface of the impactor plate, exposed to the fluid flow, can be structured. Water droplets can advantageously settle or separate on the elements of the structured surface and flow downwards by gravity into a water collection chamber.

[0022] According to a favorable embodiment of the water separator, at least one passage opening for the passage of the fluid flow into the interior of the impactor plate can be arranged in the front side of the impactor plate. The at least one passage opening can have any shape and size. In particular, holes of a plurality of passage openings can have any shape and size. Holes of a plurality of passage openings can be designed in the form of a perforation of the impactor plate. This allows at least a portion of the fluid flow to pass through the front side into the interior of the impactor plate. Liquid water in the fluid flow can thus advantageously settle on the wall of the flow-calmed interior and thus be separated from the fluid flow.

[0023] In a favorable design of the water separator, drainage channels can be formed on the front of the impactor plate to allow the separated water to flow away by gravity. This allows the water separated at the separator element to flow downwards more easily and then be directed into the water collection chamber.

[0024] According to a favorable design of the water separator, the fleece can be arranged inside and / or on the front of the impactor plate. The fleece can thus contribute to the separation of water at various points on the separation element and absorb at least some of the separated water.

[0025] According to a favorable embodiment of the water separator, a first flow-calmed region, in particular a flow-calmed region of a drainage chamber, can be formed on a side of the separation element facing away from the fluid flow. The flow-calmed region can advantageously contribute to the additional separation of water from the fluid flow and guide separated wall films to the drainage point.

[0026] According to a favorable design of the water separator, the inlet opening can open into an impactor nozzle arranged inside the second flow-guiding area, which is designed to direct the fluid flow toward the separation element. This allows the fluid to be directed toward the separation element in a targeted manner, thus favorably increasing the separation efficiency.

[0027] According to a favorable embodiment of the water separator, a lamella separator can be arranged in the second separation stage. The lamella separator can be arranged transversely to the flow direction of the fluid flow in the second flow-guiding region of the second separation stage. In particular, the lamella separator can have a cross-section that corresponds to a cross-section of the second flow-guiding region. The lamella separator can be arranged such that the entire fluid flow between the inlet opening and outlet opening of the second separation stage of the water separator is guided through the lamella separator. This advantageously increases the surface area for water separation and thus improves the efficiency of water separation.

[0028] According to a favorable embodiment of the water separator, an outlet pipe of the second separation stage can be arranged in a region of the second flow-carrying area opposite the direction of gravity. In particular, the outlet pipe in the second flow-carrying area can be arranged diagonally opposite the inlet opening. This advantageously forces the fluid flow to reverse its direction, thus increasing water separation within the housing.

[0029] In a favorable design of the water separator, the outlet pipe can have a collar at its inlet opening that is angled away from the inlet opening. The fluid flow can advantageously encounter a kind of flow-calmed zone behind the collar, which can contribute to improved water separation.

[0030] According to a favorable embodiment of the water separator, a fleece can be arranged between the collar and a downstream side wall of the second flow-guiding area, at least partially surrounding the outlet pipe. The fleece can also contribute to improved water separation and absorption of separated liquid from the fluid flow.

[0031] According to a favorable design of the water separator, the fleece can be formed, at least in part, as part of a truncated cone, with a tip of the cone oriented toward the inlet opening of the outlet pipe. This shape, together with the flow-calmed zone, can further contribute to improved water separation and the absorption of separated liquid from the fluid flow.

[0032] According to a favorable embodiment of the water separator, a baffle plate can be arranged opposite the inlet opening of the outlet pipe, transverse to the flow direction and spaced from an upper side of the second flow-guiding region. The baffle plate can provide an additional option for redirecting the flow direction in the second separation stage, which can contribute to improved water separation from the fluid flow.

[0033] According to a favorable embodiment of the water separator, an inner wall of the second flow-guiding region can be arranged at a distance from an upstream side wall. The additional inner wall creates a region separated from the fluid flow, which is shielded from the air flow in the second flow-guiding region and can thus guide separated wall films to the drainage point.

[0034] According to a favorable design of the water separator, a second flow-reducing area can be formed between the inner wall and the upstream side wall. This second flow-reducing area can ensure that the already separated water droplets are not re-entrained by the fluid flow, thus advantageously offering another opportunity for improved water separation.

[0035] According to a favorable design of the water separator, a water collection chamber can be arranged in a part of the second flow-conducting area located at the bottom in the direction of gravity. In particular, the water collection chamber can have a water outlet, particularly at its lowest point. Separating water can thus be efficiently collected and drained away without the already separated liquid water components being resuspension and entrained by the fluid flow.

[0036] In a favorable design of the water separator, a water extraction system can be provided in the water collection chamber, which is fluidically connected to the flow-calmed area of ​​the separator element's drainage chamber. Optionally, the water can not only flow freely, but, depending particularly on the water volume and position of the water collection chamber, as well as the installation position of the water separator, it can also be actively extracted. Advantageously, the water extraction system can be arranged in conjunction with an impactor plate that has an internal chamber.

[0037] According to a favorable embodiment of the water separator, a receiving tube with an outlet pipe located inside the receiving tube can be arranged at the inlet opening of the second flow-carrying section. The separating element can be located on the inside of the receiving tube and at least partially surround the outlet pipe. The outlet pipe can be at least partially closed at its downstream end and have a plurality of fluid passage openings opposite the separating element. The fluid flow can thus be forced by the outlet pipe to redirect its flow direction and be directed onto the separating element, which is arranged, for example, in a ring around the outlet pipe. This allows for the effective additional separation of liquid water from the fluid flow immediately after it exits the outlet pipe.

[0038] According to a favorable design of the water separator, the intake pipe can be arranged in the second flow-conducting area. In a simplified embodiment, the second separation stage of the water separator can thus comprise the intake pipe and the separation element arranged around the outlet pipe. This allows for a particularly compact design of the water separator. Short description of the drawings

[0039] Further advantages will become apparent from the following description of the drawings. The drawings illustrate exemplary embodiments of the invention. The drawings, the description, and the claims contain numerous features in combination. Those skilled in the art will conveniently consider the features individually and combine them into useful further combinations. The following schematic representations are shown as examples: Fig. 1 a sectional view of a water separator for separating water from a fluid flow, in particular from an air flow of a fuel cell system, according to an embodiment of the invention; Fig. 2 a sectional view of a water separator according to a further embodiment of the invention; Fig. 3 a sectional view of a water separator according to a further embodiment of the invention; Fig. 4 a sectional view of a water separator according to a further embodiment of the invention; Fig. 5 a sectional view of a water separator according to a further embodiment of the invention; Fig. 6 a sectional view of a water separator according to a further embodiment of the invention; Fig. 7 a sectional view of a water separator according to a further embodiment of the invention; Fig. 8 a sectional view of a water separator with a simplified second separation stage according to a further embodiment of the invention; Fig. 9 a sectional view of a water separator with a simplified second separation stage according to a further embodiment of the invention; Fig. 10 a sectional view of a water separator according to a further embodiment of the invention; Fig. 11 is a sectional view of a second separation stage according to a further embodiment of the invention with an alternative arrangement of impactor plate and separation collar, which is arranged downstream of a first separation stage 10; Fig. 12 a cross-sectional view through the second separation stage along the section line BB according to Fig. 11; Fig. 13 a cross-sectional view through the second separation stage along the section line CC according to Fig. 11; Fig. 14 is a plan view of a separation element of a water separator according to an embodiment of the invention; Fig. 15 a sectional view through the separating element along the section line AA according to Fig. 14; Fig. 16 an enlarged view of detail C of the sectional view according to Fig. 15; Fig. 17 an enlarged view of detail B of the plan view according to Fig. 14; Fig. 18 is a plan view of a separation element according to a further embodiment of the invention; Fig. 19 a sectional view through the separating element along the section line AA according to Fig. 18; Fig. 20 is a plan view of a separation element according to a further embodiment of the invention; Fig. 21 a sectional view through the separating element along the section line AA according to Fig. 20; Fig. 22 a top view of a separation element according to a further embodiment of the invention; Fig. 23 a sectional view through the separation element along the section line AA according to Fig. 22; Fig. 24 an enlarged representation of a detail of the cross-sectional image according to Fig. 23; Fig. 25 an enlarged representation of a detail of the top view Fig. 22; Fig. 26 a top view of a separation element according to a further embodiment of the invention; Fig. 27 a sectional view through the separation element along the section line AA according to Fig. 26; Fig. 28 an enlarged representation of detail B of the cross-sectional image according to Fig. 27; Fig. 29 an enlarged view of detail C from the top view Fig. 26. Embodiments of the invention

[0040] In the figures, identical or similar components are numbered with the same reference numerals. The figures show only examples and are not to be understood as limiting.

[0041] Fig. Figure 1 shows a schematic sectional view of a water separator 100 for separating water from a fluid flow, in particular from a gas flow of a fuel cell system, especially from air, hydrogen, or nitrogen, according to an embodiment of the invention.

[0042] The water separator 100 comprises a first separation stage 10 with a first flow-carrying area 18, which is connected to a fluid line 17.

[0043] The first separation stage 10 serves as the main separator for larger quantities of water at the fluid flow inlet.

[0044] The first flow-carrying section 18 has an inner tube 14 and an outer tube 16, which are arranged in an axial direction 82 relative to each other. The inner tube 14 connects to the outer tube 16 and is arranged downstream of the outer tube 16 in the flow direction 80. The flow direction 80 is indicated by arrows. The first separation stage 10 is arranged here in a housing 12.

[0045] A coarse water separator 20 is arranged in the fluid line 17. The coarse water separator 20 can, for example, be a swirl generator in the form of an axial cyclone. A separation area 22 is arranged in the housing 12 on a radial outer surface of the inner tube 14 and the outer tube 16. The separation area 22 is connected to a water outlet 24 located at the bottom of the housing 12 in the direction of gravity 84.

[0046] In the first separation stage 10, the air entering via the fluid line 17 is directed to the coarse water separator 20. The air is set in rotation and exits through the funnel-shaped outer tube 16 into the separation area 22 of the housing 12. Centrifugal forces move the water droplets present in the air radially outward relative to the flow, creating a wall film on the inner wall of the water separation area 22 of the first separation stage 10, which moves toward the drainage area. The separated water can flow to the water outlet 24.

[0047] The water separator 100 further comprises a second separation stage 30 with a second flow-guiding region 38. The second separation stage 30 is arranged downstream of the first separation stage 10 and combines various separation elements according to a modular principle. The second separation stage 30 is arranged in a housing 32.

[0048] The second separation stage 30 serves as a fine water separator for the remaining amount of water in the fluid flow.

[0049] The inner tube 14 of the first separation stage 10 is fluidically coupled to an inlet opening 34 of the second flow-guiding region 38. In a further embodiment, the inner tube 14 can also extend into the housing 32 for this purpose.

[0050] The second flow-guiding region 38 has a separating element 50 designed as an impactor plate 54, which is exposed to the fluid flow entering the housing 32 of the second separation stage 30 via the inner tube 14 and being directed there via the impactor nozzle 144. The impactor plate 54 has a structured surface 51 with pyramid-shaped protrusions 57 on its front face 56, which faces away from the fluid flow. Behind the separating element 50, on a side of the separating element 50 facing away from the fluid flow, a first flow-stabilized region 36 is formed.

[0051] In a part of the housing 32 located at the bottom in the direction of gravity 84, a water collection chamber 76 is arranged for the separated water. The water collection chamber 76 has a water outlet 44 at its lowest point for draining the separated water.

[0052] The flow-calmed region 36 is fluidically connected to the water collection chamber 76. On the side of the separation element 50 facing away from the fluid flow, another flow-calmed region of the drainage chamber 143 is formed, which is fluidically connected to a water suction device 78.

[0053] The air, which has encountered the separating element 50 and undergone a deflection of its flow direction, then encounters a lamellar separator 40. The lamellar separator 40 is arranged transversely to the flow direction 80 of the fluid flow in the second flow-guiding region 38. The lamellar separator 40 has a cross-section that corresponds to a cross-section of the second flow-guiding region 38, so that the fluid flow must pass completely through the lamellar separator 40.

[0054] An outlet pipe 42 of the second separation stage 30 is arranged in a region of the second flow-guiding region 38 opposite to the direction of gravity 84. In particular, the outlet pipe 42 is arranged diagonally opposite the inlet opening 34 of the second flow-guiding region 38 in order to achieve favorable flow guidance through the second flow-guiding region 38.

[0055] The outlet pipe 42 has a collar 48 at its inlet opening 46, which is bent away from the inlet opening 46. A nonwoven fabric 43 is arranged between the collar 48 and a downstream side wall 33 of the housing 32, surrounding the outlet pipe 42 at least partially, in particular in an annular form. The nonwoven fabric 43 is flush with the downstream side wall 33 and is spaced apart from the upper surface 37 of the second flow-conducting area 38. The nonwoven fabric 43 can have various cross-sections and contours. With a sufficient material thickness, the upper surface 37 is at least partially contacted.

[0056] Opposite the inlet opening 46 of the outlet pipe 42, a baffle plate 70 is arranged transversely to the flow direction 80 and spaced from an upper side 37 of the second flow-guiding region 38.

[0057] Furthermore, an inner wall 72 is arranged at a distance from a side wall 35 on the upstream side. Between the inner wall 72 and the side wall 35 on the upstream side, a further flow-calmed area 74 is formed. This further flow-calmed area 74 is also fluidically connected to the water collection chamber 76.

[0058] The water droplets remaining in the airflow after the pre-separation of water in the first separation stage 10 are thus guided via the inner pipe 14 of the first separation stage 10, which is designed as a connecting line, into the second separation stage 30, in which the flow is forced to change direction several times.

[0059] Advantageously, at least one element can be located at the point of flow deflection, against which the fluid flow impinges and which captures the water droplets that cannot follow the change in flow due to inertia. Depending on the design of the housing 32, several deflections can take place in the second separation stage 30, with a corresponding number of separation elements, such as a separation element 50 designed as an impactor plate 54, a lamellar separator 40, a separation collar 48, a separation fleece 43, or the like.

[0060] In the Fig. In the embodiment shown in Figure 1, the fluid flow from the impactor nozzle 144 directly impinges on the separation element 50. At the separation element 50, the fluid flow is first slowed down and deflected, so that a further portion of the water carried along with the fluid flow can settle or be separated. The space behind the separation element 50 forms a drainage chamber 143 with a flow-calmed area, which is fluidically connected to the water collection chamber 76. Alternatively, the drainage chamber 143 with the flow-calmed area can be fluidically connected to the water suction unit 78.

[0061] The redirected fluid flow then passes through the lamellar separator 40. This serves to separate a further portion of liquid water in an area of ​​low flow velocity.

[0062] The fluid flow then fills the upper region of the second flow-conducting area 38, where the outlet pipe 42, with its cranked collar 48 and the surrounding fleece 43, further reduces the liquid water content. Water droplets can be separated at the baffle plate 70 located opposite the inlet opening 46 of the outlet pipe 42. The inner wall 72, with the flow-calmed area 74 behind it, provides an additional flow-calmed zone 74, thus facilitating drainage from this part of the second flow-conducting area 38. The flow-calmed zone 74 can advantageously be fluidically connected to the water collection chamber 76.

[0063] The separating element 50 in which Fig. The embodiment shown in Figure 1 has a structured surface 51. The structured surface 51, which is shown only schematically, can, for example, comprise a plurality of protrusions 57 oriented against the direction of fluid flow, in the illustrated embodiment, parallel truncated pyramids. When the fluid flow impacts the truncated pyramids 57, it can be significantly slowed down and deflected, allowing liquid water to condense on the truncated pyramids 57 and flow downwards.

[0064] In Fig. Figure 2 shows a sectional view of a water separator 100 according to a further embodiment of the invention. In this embodiment, the fleece 43 arranged around the outlet pipe 42 is spaced apart from the side wall 33 of the housing 32 and directly adjoins the bent collar 48 of the outlet pipe 42. The fleece 43 can have different dimensions and shapes. The free space between the side wall 33 and the collar 48 can be equipped with fleece 43 of different sizes and shapes. This additionally creates a flow-calmed zone with defined properties.

[0065] In this embodiment, the separation element 50 is also designed as an impactor plate 54 with pyramid-shaped elevations 57 of the structured surface 51.

[0066] Fig. Figure 3 shows a cross-sectional view of a water separator 100 according to a further embodiment of the invention, in which the nonwoven fabric 43 is conical, with one apex of the cone oriented towards the inlet opening 46. Advantageous separation of liquid water from the fluid flow can also be achieved with this configuration of the nonwoven fabric 43.

[0067] In Fig. Figure 4 shows a sectional view of a water separator 100 according to a further embodiment of the invention, in which the fleece 43 around the outlet pipe 42 has the same shape as in the one described in Fig. 3. However, here the separation element 50, designed as an impactor plate 54, does not have a structured surface 51, but rather a fleece 52. Water droplets directly impacting the fleece 52 penetrate into the depth of the fleece 52 and are thereby separated from the redirected fluid flow. Thus, a large amount of liquid water can be absorbed in the fleece 52 without being swept away by the fluid flow. The absorbed water can then advantageously flow out of the fleece 52 into the water collection chamber 76.

[0068] Fig. 5 shows a sectional view of a water separator 100 according to another embodiment of the invention.

[0069] The water separator 100 is largely designed like the one in Fig. 4. However, here, a receiving tube 62 with an outlet tube 145 arranged inside the receiving tube 62 is arranged at the inlet opening 34 of the second flow-guiding region 38. A further separation element 60 is arranged on an inner side of the receiving tube 62. The separation element 60 surrounds the outlet tube 145 at least in some areas. The outlet tube 145 is at least partially closed at its downstream end 28. Furthermore, the outlet tube 145 has a plurality of fluid passage openings 26 opposite the separation element 60.

[0070] The fluid flow through the inner tube 14 can flow into the outlet tube 145, exit the outlet tube 145 through the fluid passage openings 26, and is thus redirected in the flow direction 80. As the fluid flow exits the outlet tube 145, it directly impacts the separation element 60, which in this embodiment is also formed with a fleece 52. Further water separation can thus advantageously take place at the additional separation element 60. For this purpose, the receiving tube 62 has an additional drainage 61, through which the separated water can reach the water collection chamber 76 of the housing 32.

[0071] The Fig. The embodiment shown in Figure 5 thus represents a water separator 100 which, according to the modular principle, has a further optional separation stage within the second separation stage 30, namely the separation element 60 inside the receiving pipe 62. This allows for a further improved separation performance.

[0072] The Fig. The sectional view of a water separator 100 shown in Figure 6 shows a further embodiment, similar to that shown in Fig. 5, with a separating element 60 arranged within the receiving tube 62, which, however, in contrast to the embodiment shown in Fig. The embodiment shown in Figure 5 is equipped with a structured surface 51. This also advantageously improves the overall separation efficiency of the water separator 100.

[0073] Fig. Figure 7 shows a sectional view of a water separator 100 according to a further embodiment of the invention.

[0074] The main difference to the Fig. The difference in the embodiments shown in Figures 1 to 6 is that the two separation stages 10, 30 are not arranged in separate housings 12, 32 which can be conveniently joined to form the water separator 100, but rather that the two separation stages 10, 30 are arranged in a single housing 12. The inner tube 14 of the first separation stage 10 is formed integrally with the impactor nozzle 144 of the second separation stage 30.

[0075] In the Fig. In the embodiment shown in Figure 7, the separating element 50 is designed with pyramid-shaped protrusions 57 on the structured surface 51. The nonwoven fabric 43 is arranged as in the embodiment shown in Figure 7. Fig. 1 is shown. Alternatively, the others are also shown in the Fig. The embodiments shown in 1 to 6 are possible for separating element 50 and fleece 43.

[0076] Fig. Figure 8 shows a sectional view of a water separator 100 with a simplified second separation stage 30 according to a further embodiment of the invention.

[0077] This embodiment is derived from the one in Fig. 5. The housing 32 of the second separation stage 30 is designed as a receiving tube 62 with an outlet tube 145 arranged inside the receiving tube 62 at the inlet opening 34 of the second flow-guiding region 38. A separation element 60 is arranged on an inner side of the receiving tube 62 and surrounds the outlet tube 145 at least in part. The outlet tube 145 is at least partially closed at its downstream end 28 and has a plurality of fluid passage openings 26 opposite the separation element 60.

[0078] The inner tube 14 of the first separation stage 10 is fluidically coupled directly to the inlet opening 34 so that the fluid flow can flow through the inner tube 14 into the outlet tube 145.

[0079] The fluid flow through the inner tube 14 can thus enter the outlet tube 145, exit the outlet tube 145 through the fluid passage openings 26, and is thereby deflected in the flow direction 80. As the fluid flow exits the outlet tube 145, it directly encounters the separating element 60, which in this embodiment is also formed with a fleece 52. Further water separation can thus advantageously take place at the additional separating element 60. For this purpose, the receiving tube 62 has a water outlet 44 through which the separated water can exit the water collection chamber 76 of the housing 32.

[0080] In this way, a particularly compact water separator 100 can be represented, which nevertheless has an effective water separation capability.

[0081] The water separator 100 shown here represents another example of an inexpensive water separator 100 built in a modular design from individual modular components.

[0082] Fig. Figure 9 shows a further embodiment of a water separator 100 constructed in this manner, in which, according to the embodiment in Fig. 6 the separation element 60 is designed as a structured surface 51. In this way, water can also be separated from the fluid flow in a very compact and effective manner.

[0083] Fig. Figure 10 shows a sectional view of a water separator 100 according to a further embodiment of the invention.

[0084] In this embodiment, the first separation stage 10 corresponds to the first separation stage 10 of the Fig. 1 to 6. However, the second separation stage 30 is designed differently.

[0085] The second separation stage 30 is arranged in a housing 32 and serves as a fine water separator for the remaining amount of water in the fluid flow.

[0086] The inner tube 14 of the first separation stage 10 is fluidically coupled to the inlet opening 34 of the second flow-guiding region 38.

[0087] The second flow-guiding region 38 has a separation element 50 designed as an impactor plate 54, which is subjected to the fluid flow entering the housing 32 of the second separation stage 30 via the inner tube 14 and forwarded there via the impactor nozzle 144. The impactor plate 54 has a structured surface 51 on the front side 56 directed against the fluid flow, in particular with pyramid-shaped elevations 57. Behind the separation element 50, on a side of the separation element 50 facing away from the fluid flow, a first flow-calmed region 36 is formed.

[0088] In a part of the housing 32 located at the bottom in the direction of gravity 84, a water collection chamber 76 is arranged for the separated water. The water collection chamber 76 has two water outlets 44 on its bottom surface for draining the separated water.

[0089] The flow-calmed area 36 is fluidly connected to the water collection chamber 76.

[0090] An outlet pipe 42 is arranged in the axial direction 82 opposite the inlet opening 34 of the second flow-guiding region 38 in order to achieve a favorable flow guidance through the second flow-guiding region 38.

[0091] The outlet pipe 42 has a collar 48 at its inlet opening 46 which is bent away from the inlet opening 46.

[0092] The water droplets remaining in the air stream after the pre-separation of water in the first separation stage 10 are thus guided via the inner pipe 14 of the first separation stage 10, which is designed as a connecting line, into the second separation stage 30, in which the flow is forced to change direction.

[0093] At the point of flow redirection, at least one element can advantageously be located, onto which the fluid flow impinges and which collects the water droplets that cannot follow the flow change due to inertia. Depending on the design of the housing 32, a separation element 50, for example, designed as an impactor plate 54, can be arranged in the second separation stage 30 for redirection.

[0094] In the Fig. In the embodiment shown in Figure 10, the fluid flow from the impactor nozzle 144 directly hits the separation element 50. At the separation element 50, the fluid flow is first slowed down and deflected, so that a further part of the water carried along with the fluid flow can settle or be separated.

[0095] Thereafter, the fluid flow fills the area of ​​the second flow-guiding area 38, in which the outlet pipe 42 with its bent collar 48 ensures a further reduction of the liquid water content.

[0096] The separating element 50 in which Fig. The embodiment shown in Figure 10 has a structured surface 51. The structured surface 51, which is shown only schematically, can, for example, comprise a plurality of protrusions 57 oriented against the direction of fluid flow, in the illustrated embodiment, parallel truncated pyramids. When the fluid flow impacts the truncated pyramids 57, it can be significantly slowed down and deflected, allowing liquid water to condense on the truncated pyramids 57 and flow downwards.

[0097] Impactor plate 54 corresponds to the one in Fig. 2 illustrated embodiment.

[0098] The impactor plate 54 of the separation element 50 can be inclined relative to the axial direction 82. Preferably, the impactor plate 54 can be arranged perpendicular to the axial direction 82, as shown in the exemplary embodiment. Alternatively, however, it is also possible for the impactor plate to be inclined at an angle 64 away from the perpendicular to the axial direction 82 or at an angle 66 towards the axial direction 82 in order to favorably modify the separation effect of the separation element 50.

[0099] Fig. Figure 11 shows a sectional view of a second separation stage 30 according to a further embodiment of the invention with an alternative arrangement of impactor plate 54 and separation collar 48, which is downstream of a first separation stage 10.

[0100] The Fig. The embodiment shown in Figure 11 can, for example, be an implementation of the second separation stage 30 of the [system / device]. Fig. The water separator shown in the illustration represents 100 units.

[0101] The second separation stage 30 with the second flow-guiding region 38 is constructed in a simplified manner in a cylindrical housing 32. The impactor nozzle 144 and the separation element 50 are arranged at a defined distance.

[0102] The separation element 50 is designed as an impactor plate 54 with pyramid-shaped elevations 51 and has an interior 55 designed as a drainage chamber 143 with a flow-calmed area. In this arrangement, a further flow-calmed area 36 is created behind the separation element 50.

[0103] The outlet pipe 42 has a separating collar 48. A conveniently arranged water outlet 44 is fluidically connected to the water collection chamber 76.

[0104] In the Fig. In the embodiment of a second separation stage 30 shown in Figure 11, the impactor nozzle 144, separation element 50, separation collar 48 and outlet pipe 42 are formed in a housing 32 in a coaxial arrangement and have defined distances to each other.

[0105] The separated water collected in the water collection chamber 76 can flow out via the water outlets 44.

[0106] Fig. Figure 12 shows a cross-sectional view through the second separation stage 30 along the section line BB according to Fig. 11. A top view of the separating element 50, designed as an impactor plate 54, is shown. The impactor plate 54 has a structured surface 51 with pyramid-shaped protrusions 57. The impactor plate 54 can have any shape, for example, a round or angular contour. The inner wall of the housing 12 and the outer contour of the impactor plate 54 can be unevenly spaced. The water outlet 24 is visible in cross-section.

[0107] In Fig. Figure 13 is a cross-sectional view through the second separation stage 30 along the section line CC according to Fig. Figure 11 shows a cross-section through the outlet pipe 42. The impactor plate 54 and the separating collar 48 have different outer contours. The housing 12 can have any shape, for example, round or square.

[0108] Fig. 14 shows a plan view of a separation element 50 of a water separator 100 according to an embodiment of the invention. In Fig. 15 is a sectional view through the separating element 50 along the section line AA according to Fig. 14 shown, while Fig. 16 an enlarged view of detail C of the sectional view according to Fig. 15 and Fig. 17 an enlarged view of detail B of the plan view according to Fig. 14 shows.

[0109] The separation element 50 designed as an impactor plate 54 has a structured surface 51, thus representing an embodiment as it is in the Fig. The water separators 100 shown in Figures 1 to 3 are used. The structured surface 51 has, as elevations 57, parallel rows of truncated pyramids 57 oriented against the direction of fluid flow. The truncated pyramids 57 in immediately adjacent rows are each offset from one another. By impacting the truncated pyramids 57, the fluid flow can be significantly slowed down and deflected, so that liquid water can settle on the truncated pyramids 57 and / or be separated there.

[0110] As particularly in Fig. As can be seen in Figure 15, the separating element 50 is designed as an impactor plate 54 with an interior 55 which is open downwards in the direction of gravity 84. Alternatively, the separating element 50 can also have a curved shape or be designed as a bent plate. The separating element 50 is arranged in the second separation stage 30 of the water separator 100 opposite the inlet opening 34 of the housing 32, as shown in the figures. Fig. 1 to 3 are recognizable and are directly exposed to the fluid flow. The separating element 50 can, for example, be fixed to a base of the housing 32.

[0111] In the Fig. In the embodiment of a separation element 50 shown in Figures 14 to 17, the front side 56 of the impactor plate 54, which is exposed to the fluid flow, is designed as a structured surface 51.

[0112] In the detailed descriptions in the Fig. 16 and Fig. Figure 17 shows the truncated pyramids 57 of the structured surface 51 enlarged. This allows favorable dimensions for the truncated pyramids 57 to be defined.

[0113] The height 110 of the truncated pyramids 57 can advantageously be between 4 mm and 40 mm, and for example be 8 mm. The edge length 111, 112 of a base face of the truncated pyramid 57 can advantageously be between 1 mm and 20 mm, and for example be 4 mm. The base face can advantageously be square, as in the illustrated embodiments, so that the two edge lengths 111, 112 are equal. The edge length 113, 114 of an end face of the truncated pyramid 57 can advantageously be between 0.25 mm and 5 mm, and for example be 1 mm. If the base face is square, the end face can also advantageously be square, so that the two edge lengths 113, 114 are equal. With these dimensions, an angle between the lateral faces of the truncated pyramid 57 is, for example, 21°.

[0114] A row offset 115 between the truncated pyramids 57 of adjacent rows of truncated pyramids 57 is, as in Fig. 12, half an edge length 111 of the base surface, i.e. 2 mm in the illustrated embodiment.

[0115] As in Fig. As can also be seen in Figure 17, 84 drainage channels 59 are formed on the front side 56 of the impactor plate 54 in the direction of gravity for the discharge of the separated water. The drainage channels 59 are located between the rows of truncated pyramids 57. The width of the drainage channels 59 can advantageously be between 0.25 mm and 5 mm.

[0116] Fig. 18 shows a plan view of a separating element 50 according to a further embodiment of the invention, while in Fig. 19 a sectional view through the separating element 50 along the section line AA according to Fig. 18 is shown.

[0117] In this embodiment, the impactor plate 54 has a large opening 58 on its front face 56, through which the fluid flow can enter the interior 55. The interior 55 is filled with a fleece 52, on which water can be separated from the fluid flow. The separated water can flow out into the water collection chamber 76 at the bottom of the interior 55, which is open to the housing 32 of the second separation stage 30. As in Fig. As can be seen in Figure 19, the fleece 52 can completely fill the interior space 55. The depth 121 of the interior space 55, as well as the thickness 120 of the fleece 52, can advantageously be between 0.1 mm and 50 mm, and, for example, be 20 mm.

[0118] In Fig. 20 is a plan view of a separating element 50 according to a further embodiment of the invention, while in Fig. 21 a sectional view through the separating element 50 along the section line AA according to Fig. 20 is shown.

[0119] In this embodiment, the front surface 56 of the impactor plate 54 has a plurality of small openings 58 through which the fluid flow can pass into the interior 55 of the impactor plate 54. The plurality of small openings 58 can be in the form of perforations. The holes of the plurality of small openings 58 can have any shape and size. The interior 55 is filled with the nonwoven fabric 52, as in the previous embodiment. Fig. As can be seen in section 21, a further fleece 53 is arranged on the front side 56 of the impactor plate 54 upstream of the through-openings 58 in the direction of flow, which can, for example, serve to pre-separate water.

[0120] The diameter 130 of the openings 58 can advantageously be between 1 mm and 20 mm, for example, 8 mm. The horizontal spacing 131 and the vertical spacing 132 between the openings 58 can be between 1.5 mm and 30 mm, for example, 12 mm. However, the hole pattern can also be asymmetrical, so that the distances and angles of adjacent centers of the openings 58 can vary. The thickness 133 of the nonwoven fabric 52 in the interior 55 can be between 0.1 mm and 50 mm, for example, 20 mm. The thickness 134 of the nonwoven fabric 53 on the front 56 can be between 0.1 mm and 50 mm, for example, 4 mm.

[0121] Both fleeces 52, 53 can be present at the separation element 50. Alternatively, it is also possible that only one fleece 52 is present in the interior 55 or only one fleece 53 is present on the front 56 of the flat impactor plate 54.

[0122] Fig. 22 shows a plan view of a separating element 50 according to a further embodiment of the invention, while in Fig. 23 a sectional view through the separating element 50 along the section line AA according to Fig. 22 is shown.

[0123] In this embodiment, a plurality of through-openings 58 are arranged on the front side 56 of the impactor plate 54, with the areas between the through-openings being covered with the structured surface 51 with elevations 57 formed as truncated pyramids 57. The interior 55 of the impactor plate 54 is empty and forms a flow-calmed zone for the accumulation of liquid water, so that the fluid flow entering the interior 55 can flow out again downwards.

[0124] Fig. 24 shows an enlarged view of a detail of the sectional view according to Fig. 23, while in Fig. 25 an enlarged view of a detail of the plan view according to Fig. 22. In the Fig. 24 and Fig. 25 the arrangement and dimensions of the separation element 50 can be seen more clearly.

[0125] The dimensions and distances of the pyramid truncated pieces 57 are the same as the dimensions and distances of the Fig. The embodiment shown in Figures 14 to 17. The diameter 130 of the passage openings 58 can, as in the previous embodiment, be between 1 mm and 20 mm and is advantageously 8 mm. A horizontal distance 141 and a vertical distance 142 of the passage openings 58 can be between 3 mm and 30 mm and, for example, be 16 mm.

[0126] Fig. 26 shows a plan view of a separating element 50 according to a further embodiment of the invention, while in Fig. 27 a sectional view through the separating element 50 along the section line AA according to Fig. 26 is shown. Fig. 28 is an enlarged view of detail B of the sectional view according to Fig. 27 and in Fig. 29 an enlarged view of detail C of the plan view according to Fig. 26 shown.

[0127] This embodiment corresponds to the one in the Fig. 22 to 25 with the difference that in the embodiment shown in the Fig. In the embodiment shown in Figures 26 to 29, the interior space 55 of the impactor plate 54 is filled with the fleece 52.

[0128] In this way, additional water from the fluid flow passing through the passage openings 58 can advantageously be separated and absorbed on the fleece 52.

[0129] The dimensions and distances of pyramid truncated members 57, through-openings 58 and fleece 52 are the same as in the previously illustrated embodiments. Reference symbol 10 first separation stage 12 housings 14 inner tube 16 Outer pipe 17 Fluid line 18 first flow-guiding area 20 coarse water separators 22 Separation area 24 Water outlet 26 Fluid passage opening 28 End 30 second separation stage 31 axial direction 32 cases 33 Side wall, outflow side 34 Entrance opening 35 Side wall, airflow side 36 first flow-calmed area 37 Top 38 second flow-carrying area 40 lamella separators 42 Outlet pipe 43 fleece 44 Water outlet 46 Entrance opening 48 collars 50 Separation element 51 structured surface 52 fleece 53 fleece 54 Impactor plate 55 Interior 56 Front 57 elevation, truncated pyramids 58 Passage opening 59 Drainage channel 60 Separation element 61 Drainage 62 receiving tube 64 angles 66 angles 70 impact plate 72 inner wall 74 second flow-calmed area 76 Water collection room 78 Water extraction 80 Flow direction 82 axial direction 84 Direction of gravity 100 water separators 110 height 111 Edge length base area 112 edge length base area 113 Edge length End surface 114 Edge length End surface 115 row offset 116 angles between side faces 120 mm thick fleece 121 Deep interior 130 diameter through-hole 131 Distance horizontal 132 vertical spacing 133 Thick fleece interior 134 Thick fleece front 141 horizontal spacing 142 vertical spacing 143 Drainage room 144 Impactor nozzle 145 Outlet pipe QUOTES CONTAINED IN THE DESCRIPTION

[0000] This list of documents cited by the applicant was automatically generated and is included solely for the reader's convenience. The list is not part of the German patent or utility model application. The DPMA accepts no liability for any errors or omissions. Cited patent literature

[0000] EP 1167743 B1

[0002]

Claims

[1] Water separator (100) for separating water from a fluid flow, in particular from a gas flow of a fuel cell system, comprising at least one first separation stage (10) with a first flow-guiding region (18) which is connected to a fluid line (17), wherein the first flow-guiding region (18) has at least one inner tube (14) and at least one outer tube (16) which are arranged in an axial direction (82) relative to one another, wherein the inner tube (14) connects to the outer tube (16) and is arranged downstream of the outer tube (16) in the flow direction (80), wherein a coarse water separator (20) is arranged in the fluid line (17), wherein a separation area (22) is arranged on a radial outer side of the inner pipe (14) and the outer pipe (16) and is connected to a water outlet (24), comprising at least one second separation stage (30) with a second flow-guiding region (38), wherein the second separation stage (30) is arranged downstream of the first separation stage (10), wherein the inner tube (14) of the first flow-guiding region (18) is fluidically coupled to an inlet opening (34) of the second flow-guiding region (38), wherein the second flow-guiding region (38) has at least one separation element (50, 60) against which the fluid flow flows. [2] Water separator according to claim 1, wherein the separating element (50, 60) has a surface (51) structured counter to the fluid flow direction (80) and / or a fleece (52), wherein the structured surface (51) comprises a plurality of elevations (57), in particular wherein the structured surface (51) comprises a plurality of parallel truncated pyramids (57). [3] Water separator according to claim 1 or 2, wherein the separating element (50) is designed as an impactor plate (54) without an interior space or with an interior space (55) open downwards in the direction of gravity (84), wherein the separating element (50) is arranged opposite the inlet opening (34) of the second flow-guiding region (38). [4] Water separator according to claim 3, wherein a front side (56) of the impactor plate (54) against which the fluid flow flows is formed as a structured surface (51). [5] Water separator according to claim 3 or 4, wherein at least one passage opening (58) for the passage of the fluid flow into the interior space (55) of the impactor plate (54) is arranged in the front side (56). [6] Water separator according to one of claims 3 to 5, wherein drainage channels (59) are formed on the front side (56) of the impactor plate (54) for the separated water to flow away in the direction of gravity (84). [7] Water separator according to one of claims 3 to 6, wherein the fleece (52, 53) is arranged in the interior (55) and / or on the front side (56) of the impactor plate (54). [8] Water separator according to one of the preceding claims, wherein a first flow-calmed region (36), in particular a flow-calmed region of a drainage space (143), is formed on a side of the separating element (50) facing away from the fluid flow. [9] Water separator according to one of the preceding claims, wherein the inlet opening (34) opens into an impactor nozzle (144) arranged in the interior of the second flow-guiding region (38), which is designed to flow onto the separation element (50) with the fluid flow. [10] Water separator according to one of the preceding claims, wherein a lamella separator (40) is arranged in the second separation stage (30), wherein the lamella separator (40) is arranged transversely to the flow direction (80) of the fluid flow in the second flow-guiding region (38) of the second separation stage (30), in particular wherein the lamella separator (40) has a cross section which corresponds to a cross section of the second flow-guiding region (38). [11] Water separator according to one of the preceding claims, wherein an outlet pipe (42) of the second separation stage (30) is arranged in a region of the second flow-guiding region (38) opposite the direction of gravity (84), in particular wherein the outlet pipe (42) in the second flow-guiding region (38) is arranged diagonally opposite the inlet opening (34). [12] Water separator according to claim 11, wherein the outlet pipe (42) has at its inlet opening (46) a collar (48) bent away from the inlet opening (46). [13] Water separator according to claim 11 or 12, wherein a fleece (43) surrounding the outlet pipe (42) at least in regions is arranged between the collar (48) and a downstream side wall (33) of the second flow-guiding region (38). [14] Water separator according to claim 13, wherein the fleece (43) is formed at least in regions as part of a truncated cone, wherein a tip of the cone is directed in the direction of the inlet opening (46) of the outlet pipe (42). [15] Water separator according to one of the preceding claims, wherein a baffle plate (70) is arranged opposite the inlet opening (46) of the outlet pipe (42) transversely to the flow direction (80) and spaced from an upper side (37) of the second flow-guiding region (38). [16] Water separator according to one of the preceding claims, wherein an inner wall (72) of the second flow-guiding region (38) is arranged at a distance from an upstream side wall (35). [17] Water separator according to claim 16, wherein a second flow-calmed region (74) is formed between the inner wall (72) and the upstream side wall (35). [18] Water separator according to one of the preceding claims, wherein a water collecting chamber (76) is arranged in a part of the second flow-guiding region (38) lying at the bottom in the direction of gravity (84), in particular wherein the water collecting chamber (76) has a water outlet (44), in particular at its lowest point. [19] Water separator according to one of claims 8 to 18, wherein a water suction (78) is present in the water collection chamber (76), which is fluidically connected to the flow-calmed region of the drainage chamber (143) of the separation element (50). [20] Water separator according to one of the preceding claims, wherein a receiving tube (62) with an outlet tube (145) arranged in the interior of the receiving tube (62) is arranged at the inlet opening (34) of the second flow-guiding region (38), wherein the separation element (60) is arranged on an inner side of the receiving tube (62) and surrounds the outlet tube (145) at least in regions, wherein the outlet tube (145) is at least partially closed at its downstream end (28) and wherein the outlet tube (145) has a plurality of fluid passage openings (26) opposite the separation element (60). [21] Water separator according to claim 20, wherein the receiving tube (62) is arranged in the second flow-guiding region (38).

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