FUEL EJECTOR FOR A FUEL CELL

Abstract

A fuel ejector for providing gaseous fuel to a fuel cell is disclosed. The fuel ejector includes an ejector body having first and second fluid inlets and a mixing volume. A nozzle is removably engaged with the ejector body in axial alignment with the first fluid inlet. The nozzle is axially adjustable in position with shims to position the nozzle inlet at a desired location within the mixing volume. A sleeve can also be selected and positioned within the first inlet to establish a throat diameter.

Description

CROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims priority to and the benefit of the filing date of Indian Provisional Application No. 202441015323 filed on March 1, 2024, which is incorporated herein by reference. AREA OF REVELATION

[0002] The present disclosure relates generally to fuel ejectors and, more particularly, to a fuel ejector for a fuel cell. GENERAL STATE OF THE ART

[0003] Fuel cells can use hydrogen gas as a fuel source to mix with air to form water and electricity via electrolysis in a fuel cell membrane. The electricity is then used as the main power source to rotate an output shaft, for example, to propel a vehicle. Unused hydrogen gas, as well as water vapor and nitrogen from the electrolysis process, can be recycled to the fuel cell for reuse. Such recirculation systems typically employ a venturi device, such as a fuel ejector, to inject the recycled gases into the main gaseous hydrogen fuel supply. However, such venturi devices must be configured with dimensional parameters specific to the application in which the fuel cell is to be used in order to generate the required flow rates and recirculation ratios.Therefore, there is still a need for the unique facilities, systems, and techniques disclosed in this document. DISCLOSURE OF ILLUSTRATIVE EMBODIMENTS

[0004] In order to clearly, concisely, and accurately describe illustrative embodiments of the present disclosure, the manner and process of making and using them, and to enable the practice, manufacture, and use thereof, reference will now be made to certain exemplary embodiments, including those illustrated in the figures, and specific language will be used to describe them. It should be understood, however, that no limitation upon the scope of the invention is thereby created, and that the invention includes and protects such variations, modifications, and other applications of the exemplary embodiments as would occur to one skilled in the art. SUMMARY

[0005] The present disclosure includes a fuel ejector for providing gaseous fuel to a fuel cell system. The fuel cell system uses hydrogen gas as a fuel source along with air and includes a fuel cell that uses electrolysis to generate electricity. The electrolysis process results in residues of nitrogen gas, water vapor, and hydrogen gas. To preserve the unused hydrogen gas, these residues are returned to the fuel ejector for entrainment and recirculation with incoming hydrogen gas fuel and then provided to the fuel cell for further electrolysis and electricity generation.

[0006] In one embodiment, the fuel ejector includes an elongated ejector body extending along a longitudinal axis from a first inlet to an outlet end of the ejector body. The ejector body includes a second inlet downstream of the first inlet and a longitudinally extending fuel channel defining a mixing volume and fluidly connecting the first inlet and the second inlet upstream of the outlet end. The fuel ejector also includes a nozzle removably engaged with the outlet end of the ejector body. The nozzle includes a nozzle inlet positioned within the mixing volume for receiving gaseous fuel mixed in the mixing volume. The nozzle further includes a nozzle outlet for discharging the mixed gaseous fuel to the fuel cell.The nozzle is adjustable relative to the ejector body along the longitudinal axis to position the nozzle inlet at a selected location within the mixing volume.

[0007] In one embodiment, the fuel ejector includes the elongated ejector body extending along the longitudinal axis from the first inlet to the outlet end of the ejector body. The ejector body includes the second inlet downstream of the first inlet and the longitudinally extending fuel channel defining the mixing volume and fluidly connecting the first inlet and the second inlet upstream of the outlet end. The fuel ejector includes the nozzle engaged with the outlet end of the ejector body. The nozzle includes the nozzle inlet positioned within the mixing volume to receive gaseous fuel mixed in the mixing volume. The nozzle further includes the nozzle outlet for discharging the mixed gaseous fuel to the fuel cell. The fuel ejector also includes a sleeve removably positioned in the fuel channel upstream of the mixing volume.The sleeve defines a throat diameter of the fuel channel in the ejector body.

[0008] This summary is neither intended to identify central or essential features of the claimed subject matter, nor is it intended to be used as a means of limiting the scope of the claimed subject matter. Other embodiments, forms, objects, features, advantages, aspects, and benefits will become apparent from the following description and drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] The description in this document refers to the accompanying drawings, where like numbers refer to like parts in the several views and where the following applies: Fig. Figure 1 is a simplified schematic diagram of a fuel cell system. Fig. 2 is a perspective view of an exemplary fuel ejector for the fuel cell system of Fig. 1. Fig. 3 is a longitudinal sectional view showing the exemplary fuel ejector of Fig. 2 illustrates. Fig. 4 an exploded sectional view of the fuel ejector from Fig. 2. Fig. 5 is a longitudinal sectional view showing various dimensional parameters of the fuel ejector of Fig. 2 illustrates. Fig. 6 is an enlarged detail view of a portion of the fuel ejector of Fig. 5. DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

[0010] With reference to Fig. 1 illustrates a simplified fuel cell system 10 that includes a fuel ejector 20 and a fuel cell 12. The fuel cell 12 generates power by using air and hydrogen for electrolysis in one or more membranes to generate electricity. Residual hydrogen gas, as well as nitrogen and water vapor, from the fuel cell 12 are recycled in a recirculation loop 14 connected to the fuel ejector 20. The fuel cell system 10 also includes a hydrogen source 16 connected to the fuel ejector 20 to provide pressurized hydrogen gas. The fuel ejector 20 takes the two incoming gaseous streams and provides the mixture to a fuel supply 18 connecting the fuel ejector 20 and the fuel cell 12. Further details of the fuel ejector 20 will be described with reference to Fig. 2-6 provided.

[0011] In one embodiment, the fuel ejector 20 provides gaseous fuel to the fuel cell 12. The fuel ejector 20 includes an elongated ejector body 22 extending along a longitudinal axis L from a first inlet 24 to an outlet end 28 of the ejector body 22. The ejector body 22 includes a second inlet 26 downstream of the first inlet 24 and a longitudinally extending fuel channel 30 defining a mixing volume 32 and fluidly connecting the first inlet 24 and the second inlet 26 upstream of the outlet end 28. The fuel ejector 20 also includes a nozzle 60 removably engaged with the outlet end 28 of the ejector body 22. The nozzle 60 includes a nozzle inlet 62 positioned within the mixing volume 32 to receive gaseous fuel mixed in the mixing volume 32.The nozzle 60 further includes a nozzle outlet 64 for discharging the mixed gaseous fuel to the fuel cell 12. The nozzle 60 is adjustable relative to the ejector body 22 along the longitudinal axis L to position the nozzle inlet 62 at a selected location within the mixing volume 32.

[0012] In one embodiment, the fuel ejector 20 includes the elongated ejector body 22 extending along the longitudinal axis L from the first inlet 24 to the outlet end 28 of the ejector body 22. The ejector body 22 includes the second inlet 26 downstream of the first inlet 24 and the longitudinally extending fuel channel 30 defining the mixing volume 32 and fluidly connecting the first inlet 24 and the second inlet 26 upstream of the outlet end 28. The fuel ejector 20 includes the nozzle 60 engaged with the outlet end 28 of the ejector body 22. The nozzle 60 includes the nozzle inlet 62 positioned within the mixing volume 32 to receive gaseous fuel mixed in the mixing volume 32. The nozzle 60 further includes the nozzle outlet 64 for discharging the mixed gaseous fuel to the fuel cell 12.The fuel ejector 20 also includes a sleeve 90 removably positioned in the fuel channel 30 upstream of the mixing volume 32. The sleeve 90 defines a throat diameter Dt of the fuel channel 30 in the ejector body 22.

[0013] With reference to Fig. 2, the ejector 20 includes the ejector body 22 having the first inlet 24, the second inlet 26, and the outlet end 28. The first inlet 24 and the outlet end 28 are aligned along the longitudinal axis L, the body 22 is elongated along the longitudinal axis L, and the second inlet 26 is transverse to the longitudinal axis L. In one embodiment, the second inlet 26 is perpendicular to the longitudinal axis L, but non-orthogonal orientations are also contemplated and are not excluded.

[0014] In the illustrated embodiment, the ejector body 22 includes a tapered portion 34 connecting a block-shaped inlet portion 36 and a block-shaped mixing portion 38. The inlet portion 36 and the mixing portion 38 may include holes or other features to facilitate assembly of the fuel ejector 20 into the fuel cell system 10. The inlet portion 36 and the mixing portion 38 may also include other shapes and configurations, such as cylindrical shapes, spherical shapes, conical shapes, irregular shapes, etc.

[0015] With further reference to Fig. 3-4, a longitudinal sectional view and an exploded sectional view of the fuel ejector 20 are provided. Various dimensional parameters of the ejector body 22, the nozzle 60 and the sleeve 90 are shown on a fuel ejector template 120 in Fig. 5-6 shown for better overview.

[0016] The fuel channel 30 has a first inlet diameter D1 at or near the first inlet 24. The fuel channel 30 also includes a tapered diffuser portion 41 having a diffuser length Lb. The tapered diffuser portion 41 extends from the first inlet diameter D1 and tapers at an inlet angle A1 toward a throat region 40 of the fuel channel 30. The throat region 40 extends from the diffuser portion 40 to the mixing volume 32. The throat region 40 provides a constant throat diameter Dm along a throat length Lm upstream of the mixing volume 32. The fuel channel 30 widens into the mixing volume 32 at a throat outlet angle A2.

[0017] The sleeve 90 is positionable in the neck region 40 and includes an inner diameter 98 that provides a desired neck diameter Dm when the sleeve 90 is positioned in the fuel channel 30 along the neck region 40. The sleeve 90 includes a sleeve length 92 between opposing sleeve ends 94, 96. In one embodiment, the sleeve length 92 corresponds to the neck length Lm. In one embodiment, the sleeve 90 is selected from a plurality of sleeves 90 having different inner diameters to individually adjust the neck diameter Dm of the fuel ejector 20. In other embodiments, the sleeve 90 is omitted because the neck region 40 of the fuel channel 30 provides the desired neck diameter Dm.

[0018] The second inlet 26 includes a tubular configuration defining a second inlet channel 42. The second inlet channel 42 includes a second inlet diameter D2 configured to admit the recirculated hydrogen gas, recirculated nitrogen, and recirculated water vapor from the fuel cell 12. The second inlet channel 42 opens into the mixing volume 32 such that the recirculated hydrogen, nitrogen, and water vapor from the fuel cell 12 mix with hydrogen fuel provided through the fuel channel 30 from the fuel source 16 connected to the first inlet 24.

[0019] The nozzle 60 includes a nozzle body 66 that extends from the nozzle inlet 62 to the nozzle outlet 64. The nozzle body 66 defines a nozzle channel 68 that extends from the nozzle inlet 62 to the nozzle outlet 64. The nozzle body 66 includes a sealing portion 70 with circumferential grooves 72. The circumferential grooves 72 each receive a seal 74. In one embodiment, the seals 74 are annular elastomeric seals that fit into corresponding ones of the grooves 72. The seals 74 contact an inner wall surface 46 of the ejector body 22 to prevent flow of gaseous fuel between an outer surface of the nozzle body 66 and the ejector body 22. In the illustrated embodiment, two seals 74 are provided. Other embodiments contemplate a single seal 74 or three or more seals 74.

[0020] The nozzle body 66 also includes a threaded portion 76 between the sealing portion 70 and an outer, radially extending flange 78. The threaded portion 76 is threadably engageable with internal threads along the ejector body 22 adjacent the outlet end 28. The threaded portion 76 forms an axially facing lip 80 adjacent and downstream of the sealing portion 70. The outer flange 78 is located outside the ejector body 22 and is positioned adjacent or in axial engagement with the outlet end 28 of the ejector body 22.

[0021] The ejector body 22 includes an internal, radially extending surface 48 facing the outlet end 28. A washer 82 is positioned between the radially extending surface 48 and the axially facing lip 80 to adjust or fix a longitudinal position of the nozzle inlet 62 within the mixing volume 32. In particular, the axial location of the nozzle inlet 62 can be controlled to provide the desired performance characteristic by using one or more washers 82 between the nozzle 60 and the ejector body 22. Thus, fine-tuning and axial adjustment of the nozzle 60 along the longitudinal axis L is possible with the washers 82, while leakage is prevented with the seals 74.

[0022] The nozzle 60, the ejector body 22, the sleeve 90, and / or the washers 82 may form a modular assembly or subassembly of the fuel ejector 20. For example, the final components of the fuel ejector 20 may be selected from a plurality of nozzles 60, a plurality of ejector bodies 22, a plurality of sleeves 90, and / or a plurality of washers 82 having different dimensional parameters. The selected nozzle 60, ejector body 22, sleeve 90, and / or washer(s) 82 are assembled to provide the fuel ejector 20 with the desired fuel flow and mixing characteristics for a specific fuel cell application.For example, a fuel cell 12 with a first kilowatt output requires a fuel ejector 20 with different configuration and / or dimensional parameters than a fuel ejector 20 for a fuel cell with a second, higher kilowatt output due to different flow rate and / or recirculation ratio requirements.

[0023] For example, an ejector body 22 may be selected that provides a desired throat length Lm, a tapered diffuser length Lb, and / or a mixing chamber length 32. The throat length Lm and / or the tapered diffuser length Lb provide different suction, entrainment, and / or recirculation ratio capabilities. Different mixing chamber lengths may provide different mixing volumes and interfaces with the nozzle 60.

[0024] If the neck diameter Dm of the selected ejector body 22 is too large, a sleeve 90 having the desired neck diameter Dm may be selected and placed in the fuel channel 30 along the neck region 40. The sleeve 90 may or may not have a length 92 corresponding to the neck length Lm of the selected ejector body 22.

[0025] Additionally or alternatively, a nozzle 60 and / or washer(s) 82 may be selected to provide the desired nozzle performance characteristics. The length of the nozzle 60 from the lip 80 to the nozzle inlet 62 and / or the washer(s) 82 may be used to control the distance S1 of the nozzle inlet 62 from the downstream end 33 of the mixing chamber 32.

[0026] Additionally, the nozzle 60 includes an orifice 84 adjacent the nozzle inlet 62. The nozzle inlet 62 defines an inlet opening 86 into the orifice 84 that tapers in a downstream direction at an angle A3 toward the orifice 84. The orifice 84 has a constant orifice diameter Do along an orifice length Lt. The nozzle 60 then expands at an angle A4 along an extension length Ln toward an outlet region 88 of the nozzle channel 68. The outlet region 88 has a constant diameter D3 up to the outer flange 78.

[0027] The nozzle 60 can be selected from a variety of nozzles 60 having different dimensions for these parameters. Different sizes / configurations for the orifice 84 provide different flow rates, which affect the suction and entrainment capabilities. The selected nozzle 60 can then be engaged with the selected ejector body 22. A sleeve 90 and / or one or more washers 82 can also be used to provide the final desired dimensional parameters for the assembled fuel ejector 20.

[0028] The modularity and interchangeability of the various components of the fuel ejector 20 also allows for different materials to be readily used for different components of the fuel ejector 20, such as the ejector body 22, the nozzle 60, and / or the sleeve 90. Exemplary materials that may be used for any one or more or all of the components in an assembled fuel ejector 20 include, for example, stainless steel, aluminum, and / or plastic. Other materials are also contemplated and are not precluded.

[0029] Various aspects of the present disclosure are contemplated. According to one aspect, a fuel ejector for providing gaseous fuel to a fuel cell is provided. The fuel ejector includes an elongated ejector body extending along a longitudinal axis from a first inlet to an outlet end of the ejector body. The ejector body includes a second inlet downstream of the first inlet and a longitudinally extending fuel channel defining a mixing volume fluidly connecting the first inlet and the second inlet upstream of the outlet end. The fuel ejector also includes a nozzle removably engaged with the outlet end of the ejector body. The nozzle includes a nozzle inlet positioned within the mixing volume to receive gaseous fuel mixed in the mixing volume.The nozzle further includes a nozzle outlet for discharging the mixed gaseous fuel to the fuel cell. The nozzle is adjustable relative to the ejector body along its longitudinal axis to position the nozzle inlet at a selected location within the mixing volume.

[0030] In one embodiment, a sleeve is removably positioned in the fuel channel upstream of the mixing volume. The sleeve defines a throat diameter of the fuel channel in the ejector body. In another embodiment, the sleeve is selected from a plurality of sleeves to provide the throat diameter based on a desired power output of the fuel cell.

[0031] In another embodiment, the ejector body defines a throat length along a portion of the fuel channel upstream of the mixing volume, and the sleeve defines a sleeve length corresponding to the throat length. In yet another embodiment, the fuel channel tapers toward the throat diameter upstream of the portion of the fuel channel that defines the throat length.

[0032] In one embodiment, at least one washer is positioned between the ejector body and the nozzle to adjust the position of the nozzle inlet along the longitudinal axis.

[0033] In another embodiment, the ejector body defines a radially extending surface facing the outlet end of the ejector body, the nozzle includes a radially extending lip, and the washer is positioned between the lip and the radially extending surface. In yet another embodiment, the nozzle includes an outer, radially extending flange portion adjacent to or in axial engagement with the outlet end of the ejector body.

[0034] In one embodiment, at least one seal is positioned between the nozzle and the ejector body. The at least one seal prevents the flow of gaseous fuel between the nozzle and the ejector body. In another embodiment, the at least one seal includes at least two seals.

[0035] In one embodiment, the nozzle is threadably engaged with the outlet end of the ejector body. In one embodiment, the mixing volume extends from a first location upstream of the second inlet to a second location downstream of the nozzle inlet.

[0036] According to another aspect of the present disclosure, a fuel ejector is provided for providing gaseous fuel to a fuel cell. The fuel ejector includes an elongated ejector body extending along a longitudinal axis from a first inlet to an outlet end of the ejector body. The ejector body includes a second inlet downstream of the first inlet and a longitudinally extending fuel channel defining a mixing volume fluidly connecting the first inlet and the second inlet upstream of the outlet end. The fuel ejector includes a nozzle engaged with the outlet end of the ejector body. The nozzle includes a nozzle inlet positioned within the mixing volume to receive gaseous fuel mixed in the mixing volume.The nozzle further includes a nozzle outlet for discharging the mixed gaseous fuel to the fuel cell. The fuel ejector includes a sleeve removably positioned in the fuel channel upstream of the mixing volume. The sleeve defines a throat diameter of the fuel channel in the ejector body.

[0037] In one embodiment, the nozzle is adjustable relative to the ejector body along the longitudinal axis to position the nozzle inlet at a desired location within the mixing volume. In another embodiment, at least one washer is positioned between the ejector body and the nozzle to adjust the position of the nozzle inlet along the longitudinal axis.

[0038] In yet another embodiment, the at least one washer is selected from a plurality of washers that provides a desired position of the nozzle inlet along the longitudinal axis. In yet another embodiment, at least one seal is positioned between the nozzle and the ejector body. The at least one seal prevents the flow of gaseous fuel between the nozzle and the ejector body.

[0039] In one embodiment, the sleeve is selected from a plurality of sleeves to provide the throat diameter based on a desired power output of the fuel cell. In one embodiment, the sleeve is located downstream of the first inlet and upstream of the second inlet. In one embodiment, the second inlet is perpendicular to the fuel channel.

[0040] While illustrative embodiments of the disclosure have been illustrated and described in detail in the drawings and the foregoing description, this is to be considered as illustrative and not restrictive, it being understood that only certain exemplary embodiments have been shown and described, and that all changes and modifications which come within the scope of the claimed inventions are intended to be protected. It is to be understood that the use of words such as preferred, preferably, or more preferred used in the above description, while indicating that the feature so described may be more desirable, it may not be necessary, and embodiments lacking it may be considered within the scope of the invention, which scope is defined by the following claims.When reading the claims, it should be noted that the use of words such as "a," "an," "at least one," or "at least a part" is not intended to limit the claim to only one subject matter, unless the claim expressly states otherwise. When the phrase "at least a part" and / or "a part" is used, the subject matter may include part and / or all of the subject matter, unless expressly stated otherwise.

Claims

[1] A fuel ejector for supplying gaseous fuel to a fuel cell, the fuel ejector comprising: an elongated ejector body extending along a longitudinal axis from a first inlet to an outlet end of the ejector body, the ejector body including a second inlet downstream of the first inlet and a longitudinally extending fuel channel defining a mixing volume fluidly connecting the first inlet and the second inlet upstream of the outlet end; and a nozzle removably engaged with the outlet end of the ejector body, the nozzle including a nozzle inlet positioned within the mixing volume for receiving gaseous fuel mixed in the mixing volume, the nozzle further including a nozzle outlet for discharging the mixed gaseous fuel to the fuel cell, the nozzle being adjustable relative to the ejector body along the longitudinal axis to position the nozzle inlet at a selected location within the mixing volume. [2] The fuel ejector of claim 1, comprising a sleeve removably positioned upstream of the mixing volume in the fuel channel, the sleeve defining a throat diameter of the fuel channel in the ejector body. [3] The fuel ejector of claim 2, wherein the sleeve is selected from a plurality of sleeves to provide the throat diameter based on a desired power output of the fuel cell. [4] Fuel ejector according to claim 2, wherein: the ejector body defines a throat length along a portion of the fuel channel upstream of the mixing volume; and the sleeve defines a sleeve length that corresponds to the neck length. [5] A fuel ejector according to claim 4, wherein the fuel channel tapers in the direction of the throat diameter upstream of the portion of the fuel channel defining the throat length. [6] A fuel ejector according to claim 1, comprising at least one washer between the ejector body and the nozzle to adjust the position of the nozzle inlet along the longitudinal axis. [7] Fuel ejector according to claim 6, wherein: the ejector body defines a radially extending surface facing the outlet end of the ejector body; the nozzle includes a radially extending lip; and the washer is positioned between the lip and the radially extending surface. [8] A fuel ejector according to claim 7, wherein the nozzle includes an outer, radially extending flange portion adjacent to or in axial engagement with the outlet end of the ejector body. [9] A fuel ejector according to claim 1, comprising at least one seal between the nozzle and the ejector body, wherein the at least one seal prevents a flow of gaseous fuel between the nozzle and the ejector body. [10] The fuel ejector of claim 9, wherein the at least one seal includes at least two seals. [11] A fuel ejector according to claim 1, wherein the nozzle is threadably engaged with the outlet end of the ejector body. [12] The fuel ejector of claim 1, wherein the mixing volume extends from a first location upstream of the second inlet to a second location downstream of the nozzle inlet. [13] A fuel ejector for supplying gaseous fuel to a fuel cell, the fuel ejector comprising: an elongated ejector body extending along a longitudinal axis from a first inlet to an outlet end of the ejector body, the ejector body including a second inlet downstream of the first inlet and a longitudinally extending fuel channel defining a mixing volume fluidly connecting the first inlet and the second inlet upstream of the outlet end; a nozzle engaged with the outlet end of the ejector body, the nozzle including a nozzle inlet positioned within the mixing volume for receiving gaseous fuel mixed in the mixing volume, the nozzle further including a nozzle outlet for discharging the mixed gaseous fuel to the fuel cell; and a sleeve removably positioned upstream of the mixing volume in the fuel channel, the sleeve defining a throat diameter of the fuel channel in the ejector body. [14] A fuel ejector according to claim 13, wherein the nozzle is adjustable relative to the ejector body along the longitudinal axis to position the nozzle inlet at a desired location within the mixing volume. [15] A fuel ejector according to claim 14, comprising at least one washer between the ejector body and the nozzle to adjust the position of the nozzle inlet along the longitudinal axis. [16] The fuel ejector of claim 15, wherein the at least one washer is selected from a plurality of washers that provides a desired position of the nozzle inlet along the longitudinal axis. [17] A fuel ejector according to claim 15, comprising at least one seal between the nozzle and the ejector body, wherein the at least one seal prevents a flow of gaseous fuel between the nozzle and the ejector body. [18] The fuel ejector of claim 13, wherein the sleeve is selected from a plurality of sleeves to provide the throat diameter based on a desired power output of the fuel cell. [19] A fuel ejector according to claim 13, wherein the sleeve is located downstream of the first inlet and upstream of the second inlet. [20] A fuel ejector according to claim 13, wherein the second inlet is perpendicular to the fuel channel.

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