Blower and filter assembly

Abstract

A device having an air consumer therein. The device has a housing with an air consumer, such as a fuel cell, mounted therein. At least one blower assembly is in fluid communication with the air intake and supplies air to the air consumer. The blower intake has a filter, such as an N95 filter. The blower and filter have mounting structure adapted to removably engage one another.

Description

[Technical field]

[0001] The present invention relates to a filter assembly, and more particularly to an air blower, particularly a filter assembly for an air blower, for use in fuel processing systems such as fuel reformers, fuel cell systems, fuel combustors, etc., which require a flow of air or other oxygen-containing gas. As used herein, the term air includes ambient air, which may be enriched with oxygen, or ambient air, which may be diluted with nitrogen or another substance. [Background technology]

[0002] Heat generating mechanisms such as catalytic oxidation devices, combustion devices, fuel reforming devices, or fuel cell devices are often controlled by various electronic systems. Often, gas flow valves and blower speeds need to be controlled to properly regulate chemical reactions. It can be important to shield electronic devices from the heat these mechanisms give off. It can also be important to isolate the heat these mechanisms give off so that they can be more conveniently integrated into the surrounding environment. For example, internal combustion engines, fuel cells, and fuel reformers generate significant amounts of heat. This can create challenges when attempting to install these mechanisms in close proximity to individuals or in residential environments, homes, offices, or other inhabited structures. Excessive heat can also create challenges when attempting to provide compact housing for compact devices, and parts of the mechanisms, such as electronic devices, must be thermally isolated while still in close proximity.

[0003] Fuel consuming devices may also require precise airflow to ensure that oxidation of the fuel proceeds in a well-controlled manner. For example, the blowers that supply air to these devices are often controlled by electronics that receive information from sensors, monitoring devices, etc. These electronics and some of the other balance of plant (BOP) components need to be protected from the heat generated by the devices they control.

[0004] The construction of conventional heat-generating mechanisms, such as internal combustion engines, fuel cells, and fuel reformers, creates additional challenges that make it difficult to integrate these mechanisms into inhabited environments, and the need to protect electronics and other components from the heat generated by the device can complicate efforts to construct compact equipment when too much space is taken up by the physical separation of components and electronics from the heat-generating elements.

[0005] Air blowers can be useful for providing air as an oxygen source to fuel consuming devices. Some blowers are equipped with air filters. However, these filters tend to be bulky and prevent compact configurations. Also, these filters can be inconvenient to replace, and some are insufficient to filter the intake air from dust and other impurities. Many fuel cell assemblies and reformers utilize ambient air as an oxygen source for the chemical and electrochemical reactions occurring therein and for temperature control within the units. Ambient air typically contains particulate matter (e.g., soil / dust), contaminants (e.g., sulfur, hydrocarbons), and / or moisture, which can damage the very sensitive catalyst surfaces within the fuel cell and reformer units, respectively. Existing filtration systems have proven insufficient to protect these systems.

[0006] It would therefore be desirable to provide an improved structure for a heat generating mechanism that overcomes the shortcomings of the prior art. [Prior art documents] [Patent documents]

[0007] [Patent Document 1] U.S. Patent No. 9,017,893 [Patent Document 2] U.S. Pat. No. 9,593,686 [Patent Document 3] U.S. Patent No. 9,512,846 [Patent Document 4] International Application No. PCT / US2012 / 020707 [Patent Document 5] International Publication No. 2016 / 148681 [Patent Document 6] U.S. Patent No. 17267095 [Patent Document 7] U.S. Patent No. 9,627,700 [Patent Document 8] U.S. Patent No. 9,627,701 Summary of the Invention

[0008] Generally speaking, in accordance with the present invention, an apparatus has at least two zones, at least three, or four or more thermal zones, each thermally isolated from the others and each within a different temperature range. Using an airflow of ambient air from an air intake of the apparatus, the zones can be kept at different temperatures, such as a cold zone and a hot zone at a temperature above the cold zone, and an intermediate zone at a temperature between the cold zone and the hot zone. Preferably, the cold zone(s) is at a temperature suitable for the electronic components.

[0009] In one embodiment of the invention, the airflow passes over the exterior of the device to thermally isolate it from the interior where heat is generated. In another embodiment of the invention, the airflow in the air intake is used to cool the temperature of one, two, or more cold zones of the device so that heat sensitive components, such as electronics, are not damaged by the heat generated by heat generating devices.

[0010] In one embodiment of the invention, the device includes a heat generating mechanism such as a fuel combustor, a fuel reformer, a fuel cell, or a fuel cell stack. As used herein, the term fuel cell stack may include a plurality of assembled fuel cells. Each fuel cell may generate electricity in the form of direct current from electrochemical reactions occurring therein. A fuel cell system according to the invention may include a fuel reformer integrated with an electricity generating section integrated into a single fuel cell structure. Individual fuel cells may be combined into a stack, and balance of plant (BOP) components may include various systems and structures for the generation of electrical power, including fuel reformers, chemical reactors, gaskets, pumps, sensors, carburetors, heat exchangers, blowers, switches, relays, thermistors, thermocouplers, conduits, control electronics, catalytic oxidizers, combustors, etc.

[0011] Airflow from the air intake (including oxygen-enriched airflow) can be used as an oxygen source for the heat-generating mechanism. This airflow can be used to help keep zones and subzones thermally cool even in close proximity to heat from the heat-generating mechanism. For example, ambient airflow can be blown or drawn over various components of the mechanism, such as electronic components, to keep these components cool. The intake airflow can also thermally isolate the exterior surfaces of the device from the heat generated inside. This can be accomplished by drawing the intake air around the outside of the heat-generating elements. This airflow can also be blown or drawn over any electronics or other elements that need to be kept cool. Excess intake air not required for the exothermic reaction can be directed to the exterior of the housing.

[0012] This air can then flow into the device and act as a source of oxygen for any chemical reactions therein. However, it may be important to filter impurities from the air, thereby helping to ensure that sensitive internal components, such as catalytic surfaces, are not damaged by such inlet air.

[0013] In one embodiment of the invention, the heat generating mechanism can be housed within a double-walled enclosure of a housing for the mechanism. The interior space between the outer and inner walls can act as an intake conduit that can function as a barrel-within-a-barrel structure. An array of fins can extend across the gap between the outer and inner walls to transform this structure into an intake barrel assembly that surrounds the entire length of the heat generating mechanism. This intake airflow can be drawn or blown from one or more internal cooler zones of the device and then sent to the heat generating section of the mechanism as a source of air and / or oxygen. Any hot exhaust air can be sent directly to the exterior of the housing or piped to a convenient exhaust location. Thus, if the air intake is at the rear end of the device, cool ambient air can be drawn all over and around the top and / or bottom and / or sides of the device, including the relatively cooler parts of the interior of the device. The intake air can then be sent to the heat generating hot section and the exhaust can be discharged from the rear end. The intake and exhaust can be side-by-side or concentric. For example, the intake may surround the exhaust.

[0014] In one embodiment of the present invention, the housing for the device has a double-walled construction, with both the inlet and outlet at the rear end. The heat-generating mechanism is mounted on a platform and can be slid in and out of the front end of the housing. A blower can be located towards the front end. The blower can draw cooling air into the rear end of the housing, through the double-walled air passage around the length of the device, and into the front end of the housing. The interior area at the front end of the housing can serve as a cold area where at least some of the electronics and other elements that need to be kept cool can be mounted. After passing over the exterior of the device housing and through the cold area(s), the intake airflow can be blown by the blower(s) over the heat-generating elements and then exhausted to the exterior of the device.

[0015] According to the present invention there is also provided a centrifugal blower apparatus comprising a blower unit having a blower casing having an axial inlet and a radial outlet. An impeller is disposed within the casing for drawing in a gaseous medium (e.g. air) at a first pressure into the axial inlet and discharging the gaseous medium at a second, higher pressure out of the radial outlet. A motor is provided for driving the impeller. The blower also includes an air intake assembly. The casing has an air inlet and an air outlet. The air outlet is connected to the axial inlet of the blower casing of the blower unit. A check valve is mounted within the casing and may be arranged to permit air flow from the air inlet through the check valve to the air outlet and to prevent air flow from the air outlet from passing through the check valve back to the air inlet.

[0016] It may be advantageous to filter the ambient air before it enters the device. Conventional mechanical filters may be used to remove larger impurities. It may also be advantageous to filter the air just before sending it to the fuel consuming or electricity generating device to help remove particulate matter, volatile compounds, sulfur compounds, etc. Reducing moisture may be helpful. The filter may be some type of reticulated foam (low pressure drop) and may be doped with certain materials to perform the tasks listed above. In a preferred embodiment of the invention, the filter may be formed from N95 certified materials, including off-the-shelf N95 certified filters.

[0017] It is advantageous to include a check valve in the blower. The check valve can help prevent a zero flow condition from causing backflow from the fan or other process air. This backflow can damage the Solid Oxide Fuel Cell (SOFC) and catalyst through oxidation. The present invention can prevent this from happening. The check valve can be a soft elastomer that opens without inducing much pressure loss and closes to seal using the slight inherent stiffness and spring constant of the material.

[0018] The blower that delivers air to the heat generating device is advantageously configured as a two-stage blower assembled in series. Utilizing a system of linked blowers according to the present invention may be useful in achieving the airflow requirements of a fuel cell or other sensitive heat generating mechanism. Dual blowers can help enable the system to benefit from both a controlled low inertia impeller and low drive motor rpm and power consumption to provide the necessary airflow and pressure.

[0019] Thus, a single multiple centrifugal blower arrangement can improve response time and control over a wide range of gas pressures and airflow requirements. Fuel cell and blower assemblies featuring this multiple centrifugal blower arrangement are described, for example, in U.S. Patent Nos. 9,017,893, 9,593,686, and 9,512,846, the contents of each of which are incorporated herein by reference in their entirety. Additional fuel cell and blower assemblies featuring multiple centrifugal blower arrangements are described, for example, in International Application No. PCT / US2012 / 020707, filed March 16, 2015, and International Publication No. WO 2016 / 148681, published September 22, 2016, the contents of each of which are incorporated herein by reference in their entirety.

[0020] It may be particularly advantageous to filter air entering a heat generating, fuel consuming device of interest herein, such as a fuel reformer or fuel cell. In a preferred embodiment of the present invention, an air blower is in fluid communication with the intake air and filters the air before it is delivered to the heat generating device. A preferred blower comprises a blower housing having an axial intake and a radial exhaust. The intake may include a filter mounting mechanism. A filter having a mounting portion designed to mate and engage with the mounting mechanism of the housing may provide a removable mounting mechanism for placing the filter over the air intake of the blower to filter the air just before it enters the heat generating device.

[0021] The filter of the present invention can advantageously meet the N95 standard. For example, it can adopt the N95 filter that is a ready-made commercial product. To improve surface area and therefore improve filtration and airflow, the filter should be a two-layer filter with an internal structure that keeps layers apart during intake filtration, so that the entire outer surface is available for air filtration and airflow to maximize the airflow per area of ​​the filter.

[0022] In a preferred embodiment of the invention, the outer housing of the entire device has a double wall construction with both an inlet and an outlet at the rear end. By adjusting the dimensions of the air conduits in the double wall, the speed of the airflow can be adjusted to maximize the cooling provided by this airflow. The heat generating mechanism can be mounted on a platform and can be slid in and out of the front end of the housing. If the device is used to generate electricity, the device can remain independently connected to a facility such as a home, R / V, office, etc., and the core stack / BOP and electronics can be slid in and out of the housing for maintenance, servicing, or part replacement.

[0023] A fuel cell system according to the present invention can be hardwired to power a home, R / V or other residence. The overall dimensions can be relatively small, 6-24 inches by 6-24 inches by 12-36 inches, with an overall length preferably less than 4 feet, and similarly greater than 6 inches. A fuel line should also be included to provide reformable fuel. If liquid fuel is to be used, a vaporizer to vaporize the liquid fuel is useful.

[0024] A main blower can be located at the front end. The blower can draw cooling air into the rear end of the housing, through a double-walled air passage around the length of the device, and into the front end of the housing. The front interior area of ​​the front end of the housing can serve as a cold area where electronic equipment and other elements that need to be kept cool can be mounted. After passing over the exterior of the heat generating device and through the cold area, a portion of the intake airflow can be blown into the hot area where the heat generating elements are located, and then exhausted to the exterior of the device. This helps balance the airflow and helps lower the temperature of the hot area. An additional cold area can be provided upstream, or preferably downstream, from the main blower. This flow-controlled cold area can house a flow-controlled blower that electronically controls the precise airflow to the heat generating elements and helps control the internal exothermic reaction. In a preferred embodiment of the invention, such additional electronically controlled blower is located in this flow-controlled cold area, and the airflow to this area keeps this flow-controlled area cool. Filters on these flow-controlled blowers, according to the invention, help protect the heat generating elements that receive this air.

[0025] Flow control electronics preferably measure the resistance of airflow through the blowers to determine if the filters on these blowers need to be changed. In a preferred embodiment of the invention, the filters can be screwed on and off the intakes of these blowers for convenient replacement and a reliable, tightly sealed installation.

[0026] Other advantages and objects of the present invention will become apparent from the following drawings and description. [Brief description of the drawings]

[0027] The following drawings are presented for illustrative purposes only and should not be considered as limiting the scope of the invention. Although the drawings are to scale, other scales may be used within the spirit and scope of the invention. [Figure 1] 1 is a schematic cross-sectional side view of a heat generating device according to a preferred embodiment of the present invention; [Diagram 2] 1 is a side cross-sectional view of a device (fuel cell) in which a fuel reformer and a fuel cell are integrated according to a preferred embodiment of the present invention. [Diagram 3] FIG. 2 is a bottom perspective view of an air blower and filter assembly according to a preferred embodiment of the present invention; [Figure 4] FIG. 4 is a bottom perspective view of the air blower and filter of FIG. 3 with the filter removed from the filter housing. [Diagram 5] FIG. 4 is a partial top perspective view of a housing for the air blower and filter assembly of FIG. [Figure 6] FIG. 6 is a top view of the partial housing of FIG. 5. [Figure 7] FIG. 6 is a partial side view of the housing of FIG. 5. [Figure 8] FIG. 6 is a bottom perspective view of the filter of the housing and filter assembly of FIG. 5. [Figure 9] FIG. 9 is a bottom view of the filter of FIG. 8. [Figure 10] FIG. 9 is an upside-down side view of the filter of FIG. 8. [Figure 11] FIG. 2 is a bottom perspective view of a filtered flow control blower assembly according to a preferred embodiment of the present invention. [Figure 12] FIG. 12 is an exploded perspective view of the filtered flow control blower assembly of FIG. [Figure 13] FIG. 12 is a partial exploded view of the filtered flow control blower assembly of FIG. [Figure 14] FIG. 12 is a partial side view of the circuit board, filter and air blower assembly of FIG. 11. [Figure 15] 13 is a partial cross-sectional view of the circuit board, filter and air blower assembly of FIG. 11 taken along line XV of FIG. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0028] The present disclosure may be understood more readily by reference to the following detailed description of the disclosure in conjunction with the accompanying drawings, which form a part hereof: It is to be understood that the present disclosure is not limited to the specific devices, methods, conditions, or parameters described and / or illustrated herein, and that the terminology used herein is for the purpose of describing particular embodiments by way of example only, and is not intended to be limiting on the scope of the claims.

[0029] Also, as used in this specification, including the appended claims, the singular forms "a," "an," and "the" include plurals, and when a particular numerical value is referenced, the particular value is included, unless the context clearly dictates otherwise. Ranges may be expressed herein as from "about" or "approximately" one particular value and / or to "about" or "approximately" another particular value. When such a range is expressed, another embodiment includes from the one particular value and / or to the other particular value. Similarly, when values ​​are expressed as approximations, by use of the antecedent "about," it will be understood that the particular value forms another embodiment.

[0030] The present invention relates to a heat generating mechanism. Examples include catalytic fuel oxidizers or reformers, fuel consumption devices, fuel processors, and other heat generating devices. These terms can encompass any heat generating device based on any type of fuel, including the devices described in US Patent No. 17267095, filed February 9, 2021, and US Patent No. 9627700 and US Patent No. 9627701, the contents of which are incorporated herein by reference. Heat generating devices and / or heat generating devices include generators, fuel reformers, fuel cell systems, and the like. The term fuel shall be understood to include both liquid and gaseous fuels, including vaporized liquid fuels. The term fuel cell includes an integrated device that reforms fuel and generates electricity.

[0031] As used herein, the term fuel cell stack may include a plurality of assembled fuel cell units. Each fuel cell may generate electricity in the form of direct current from electrochemical reactions occurring therein. Individual fuel cells may be combined into a stack, and balance-of-plant (BOP) components may include various systems and structures for the generation of electrical power, including fuel lines, fuel vaporizers, fuel reformers, chemical reactors, gaskets, pumps, sensors, heat exchangers, blowers, switches, relays, thermistors, thermocouplers, conduits, control electronics, and the like.

[0032] Examples of heat generating devices according to the present invention include those described in U.S. Pat. No. 9,627,700 and U.S. Pat. No. 9,627,701, the contents of which are incorporated herein by reference in their entirety. The fuel reformer according to the present invention may be configured to provide a reformed fuel, such as a hydrogen-rich reformed fuel, to the fuel cell stack. The fuel cell stack may operate at a relatively high temperature to maximize power production. Additionally, a sufficient amount of airflow may be required for the fuel cell and reformer and / or BOP components. Some or all of the airflow may be mixed with the fuel to provide, for example, a fuel-air mixture and a hydrogen-rich reformed fuel. The airflow may also be used to dilute the fuel or reformed fuel to control the intensity of the chemical reaction. Additionally, other electronic components of the fuel cell system may act as heat generating sources that need to be cooled for proper operation.

[0033] Thus, there may be various thermal zones and thermal sub-zones of those thermal zones that need to be maintained at different temperatures depending on the types and functions of the individual components therein.

[0034] As used herein, the terms hot zone and cold or low temperature zone are relative in nature. For example, a cold or low temperature zone may be significantly above room temperature, but below the temperature of the hot zone and below the temperature at which electrical components are destroyed. Furthermore, the hot zone and the cold zone may include various sub-zones of different relative temperatures.

[0035] A heat generating device according to a preferred embodiment of the present invention may include a low temperature heat zone and a high temperature heat zone. An insulating wall may be provided at the interface between the two zones. The low temperature (low temperature) heat zone may be in fluid communication with an air inlet through which a flow of ambient air is drawn into the device, for example by a main blower. The high temperature (high temperature) heat zone contains a heat generating device, such as a fuel reformer, a fuel cell, an internal combustion engine, etc. The two zones may be separated by an insulating wall. At the interface between the two zones, preferably in the low temperature zone or low temperature subzone, there may be an air blower. The air blower may draw ambient air into the low temperature zone and maintain the low temperature of the low temperature zone by a constant flow of ambient air. The blower may then blow this air into the high temperature zone, the low temperature subzone, or both, as needed for the proper operation of the exothermic reaction therein.

[0036] The ambient air may contain undesirable particulate matter, contaminants, and / or moisture that may affect the proper operation of the fuel cell assembly and / or reformer. These particulate matter or contaminants may include sulfur or hydrocarbons and / or moisture that may damage the fuel cell and reformer units. This damage may take the form of oxidation to internal components, catalyst fouling, hot spots from accumulated particulate matter, or rapid cooling, among other things, that may cause structural failure in the components.

[0037] The components of the fuel cell assembly of the present invention are designed to maintain their mechanical, chemical, and / or electrical integrity during start-up and normal operating modes, where they are exposed to high operating temperatures. During cool-down periods, such as during transition to low power modes or shutdown procedures, problems may arise. For example, as the system cools down, air inside the fuel cell assembly may condense, creating a vacuum within the fuel cell assembly that may continue to draw in outside air from the air inlet and / or exhaust. Exposure of the fuel cell assembly to this additional outside air may result in oxidation or damage to the structural integrity of the fuel cell stack. Thus, the air intake check valve and filter, as described herein, can help prevent these problems.

[0038] The apparatus according to the invention may comprise a heat generating device mounted on a platform and a housing surrounding the platform. The housing may have a double wall with two layers with an air intake conduit between them. The inner and outer layers of the double wall may be divided by a number of fins running the length of the wall to create a tubular structure with multiple air passages along the length of the double wall to increase the efficiency of the air flow.

[0039] There can be an ambient air inlet at the rear end of the housing, and an air blower inside the front end of the housing. Thus, air can be drawn into the inlet and flow through the housing, around the outside of the entire device, and into its front region. This can create a cool zone around the exterior surface of the device. The rear end can also contain a cool zone into which ambient air is drawn. The front end can also contain a cool zone as ambient air flows from the air passages into the open front end of the housing. As a result, the cool zone can be air-separated from the hot zone across the air blower. Thus, components that need to be cool, such as electronic components, can be mounted in the cool zone (front, rear, or bottom) and the exterior surface of the device can be kept relatively cool.

[0040] In one embodiment of the present invention, the device includes a fuel cell system having one or more fuel processing components. The one or more fuel processing components can include one or more balance of plant (BOP) components configured to provide reformed fuel mixed with air to a fuel reformer section of the fuel cell stack. The fuel cell stack can be configured to generate power based on the reformed fuel provided from the reformer section. Electronically controlled blowers can be installed in the air flow control section. These blowers control the precise flow of air to the fuel cell components. These blowers can be installed in the flow control section that is kept cool by the internal ambient air flow. Any excess air blown into the flow control section can be exhausted through an exhaust port of the device.

[0041] In one embodiment of the present invention, the BOP component can include a flow switch unit configured to regulate the speed of the blower and be stopped when the airflow does not meet the pre-set requirements. The airflow can be measured by the flow switch unit. When the amount of airflow meets the pre-set requirements, the airflow in one or more of the blowers can also be adjusted to maintain proper performance of the device. In one embodiment of the present invention, the airflow switch unit can include a flat top or a differential pressure switch. Blowers, preferably dual blowers that can be electronically controlled to operate at different speeds, can be employed to adjust the airflow to the heat generating device as needed. These flow control blowers of the BOP component can be installed in the cold zone for flow control, and the airflow through and around the flow control blower keeps the zone at a lower temperature than the hot zone to help protect any electronic components of the flow control system.

[0042] The housing for the device may include a thermal isolation wall formed of insulating material to separate the hot and cold zones and sub-zones. Further, the cold zone(s) or the hot zone(s) may be divided into different sub-zones maintained at different temperatures.

[0043] In one embodiment of the present invention, the fuel cell system and one or more fuel processing components can include one or more BOP components configured to provide reformed fuel to a fuel cell stack. The fuel cell stack can be configured to generate electrical power based on the reformed fuel provided by the one or more BOP components. The fuel cell stack can be located in a first high temperature sub-zone, and the BOP components can be located in a second high temperature sub-zone that is cooler than the first high temperature sub-zone.

[0044] In one embodiment of the invention, the air inlet port is located at the rear end of the housing and can be configured to draw ambient air into the cold zone. The hot zone can include a hot zone exhaust port that exhausts hot gases produced by an exothermic reaction therein. The hot zone exhaust port can also be located at the rear of the housing. In one embodiment of the invention, the exhaust port and the inlet port are concentric. In one embodiment of the invention, the exhaust port is surrounded by the air inlet port. The exhaust port and the inlet port can also be side-by-side at the rear of the device.

[0045] In operation, the main blower can draw air from the inlet into the interior of the rear end of the housing, around the exterior of the housing, and into the interior space of the open front end of the housing. The blower can then blow air into a hot zone or into a hot or cold sub-zone, such as a flow control zone with an electronically controlled blower for blowing air into an oxygen-consuming heat generating device such as a fuel reformer, fuel processor, or fuel burner. The blower can also blow intake air into a cold zone for flow control to control the precise air flow to the fuel consuming / combustion / reforming device. The hot exhaust exits through an outlet port in the hot zone. Electronic components can be located in the cold zone and fuel processing components can be located in the hot zone of the device, with the cold zone being upstream from the hot zone(s) and in fluid communication with the ambient intake air inlet. The hot zone can be downstream from the air blower and in fluid communication with the outlet port. In one embodiment of the invention, the hot zone may be completely surrounded by at least one of the cold zones at the front, sides, and / or rear, except for the exhaust port.

[0046] One preferred embodiment of a heat generating fuel consuming device constructed in accordance with the present invention is generally shown in FIG. 1 as a fuel cell 100. The fuel cell 100 includes a rear end 110, a central section 150, and a front end at a front end cap 180. The central section 150 extends from a central section front portion 150f to a central section rear portion 150r. The central section rear portion 150r of the central section 150 is located at the rear end 110 of the reformer 100. The central section front portion 150f of the central section 150 is located at the front cap 180 of the reformer 100. The rear end 110 of the reformer includes an inlet 111 concentric with an outlet 112 formed through the rear cap 113. The central section 150 includes a housing cover 160 around a fuel cell 171 mounted within a high temperature zone 170 that is kept at a high temperature from heat generated by the fuel cell 171. The fuel cell 171 includes at its anode end an arrangement of fuel reformer reactors which produce a hydrogen-rich reformed fuel, and at its cathode end where electricity is produced a blower 172 for drawing air into the inlet 111, and an electronics assembly 183 mounted in a cold section 182 within a front cap 180. The front cap 180 may be removably secured to the midsection rear 150r by bolts.

[0047] The flow control blowers and electronic systems for regulating the precise flow of air to the fuel cell 171 by controlling the speed of these flow control blowers can be mounted in a low temperature flow control section 200. The fuel cell 171, blower 172, electronics 183, and systems (described below) of the flow control section 200 can all be mounted together on a mounting platform as a unit that can be slid in and out of the housing front end cap 180 for maintenance, servicing, or part replacement. The fuel cell system 100 can remain electrically connected to a recipient of the electricity generated by the fuel cell system 100.

[0048] The housing cover 160 is formed by an outer wall 161 and an inner wall 162. An intake airflow housing conduit 165 is formed between the outer wall 161 and the inner wall 162. An array of fins 166 extend from the inner surface of the outer wall 161 into the housing conduit 165 and to the inner wall 162 to form an array of tubular conduits along the inner surface of the outer wall 161.

[0049] The inner wall 162 is shorter than the outer wall 161. Thus, the housing conduit 165 is exposed at the rear end 150r and the rear end 150r of the central section 150. A gasket 115 is present around the outer periphery of the inner surface of the rear cap 113. The rear end 150r of the central section 150 is pressed into the gasket 115. Since the inner wall 162 of the central section 150 is shorter than the outer wall 161 and the fins 166, the inner conduit 165 is accessible at the rear end 150r of the central section 150. Similarly, a gasket 181 is present around the outer periphery of the inner surface of the front cap 180. Thus, the inner conduit 165 is accessible at the front end 150f. As a result, there are internal spaces within the rear cap 113 and the front cap 180. The housing conduit 165 is in fluid communication with these internal spaces.

[0050] The air inlet 111 is in fluid communication with the interior defined by the rear cap 113 / front end 110. However, the outlet 112 is sealed from the interior of the rear cap 113. Thus, all air entering the inlet 111 enters the interior of the rear cap 113 which is in fluid communication with a housing conduit 165 at the rear end 150r of the central section 150. The housing conduit 165 is in fluid communication with a front interior 182 enclosed by the front cap 180 at the front end 150f of the central section 150. The inlet end 173 of the blower 172 is in fluid communication with the interior 182 of the front cap 180. The radial outlet 174 of the blower 172 is in fluid communication with the fuel cell 171. Thus, when the blower 172 is operated, the blower 172 draws air into the inlet 111 in the direction of arrow A, along the housing conduit 165 in the direction of arrow B, and then into the rear interior 182 in the direction of arrow C. The rear interior 182 has mounted therein an electronics assembly 183. Thus, intake air is blown over the electronics 183 before entering the fuel cell 171, keeping the electronics 183 cool in the electronics cool zone.

[0051] Intake air flows along the outside of the fuel cell 100 and into the interior 182 of the front end cap 180, creating a cold zone on the outside of the fuel cell 100 and the front interior 182. Thus, there may be an exterior surface of the fuel cell 100 and a front interior 182 that contains electronics 183 and other elements that need to be kept cool. An insulated wall 167 is provided at the rear end of the cold zone 182 for the electronics. A blower 172 is attached to this insulated wall. The wall 167 and blower 172, as well as the intake air flowing through conduit 165, together help to isolate the heat generating parts of the fuel cell 100.

[0052] Blower 172 may direct intake air into flow control area 200 in the direction of arrow D. Air from flow control area 200 flows into high temperature area 170, with a portion of the air being blown directly into fuel cell 171 where it participates in an exothermic reaction, producing a hot exhaust stream traveling in the direction of arrow E. The warmed exhaust stream and hot air from the heat of the fuel cell 171 exothermic process then exits fuel cell 100 through exhaust 112 in the direction of arrow F. Exhaust 112 may be elongated to transport the hot exhaust to a suitable chimney, stack, or other structure. However, because exhaust 112 is concentric within intake 111, the intake air helps isolate this heat.

[0053] The cold flow control section 200 is in fluid communication with the ambient air drawn in by the blower 172. The blower, controlled in the flow control section 200, regulates the precise amount of air entering the fuel cell 171. Excess air is allowed to flow around the fuel cell 171.

[0054] A combined fuel reformer and fuel cell stack fuel cell device is generally shown in FIG. 2 as heat generating device 201. A flow of intake air 216 at ambient temperature enters device 201 at intake 211. The intake air 216 flows along a conduit 265 formed by a double-walled outer housing 250 similar to the housing of reformer 100. The intake air 216 is drawn into device 201 by a main blower 273. An open front recess 282 is located at the front end of device 201. A front cap 280 is held in place by bolts against conduit 265. An assembly of electronics 283 is attached to front recess 282. The intake air 216 can be directed to blow over the rear end of electronics 283, or past the front of electronics 283, or both.

[0055] The apparatus 201 includes an integrated fuel reformer and fuel cell 271. The fuel reformer section receives a flow of fuel from a fuel line and an air flow from a reformer intake hose 276. The fuel cell section, which generates electricity from the reformed fuel, receives an air flow from a fuel cell hose 275. The air flow from hoses 275 and 276 is controlled by a flow control electronics 290 assembly. The flow control electronics 290 controls the air flow from a fuel cell blower assembly 350. The flow control electronics 290 and blower 300 are located in a flow control section 202 that is located below the high temperature section 270 that houses the fuel cell 271.

[0056] Flow control area 202 is in fluid communication with ambient inlet air 216. Thus, flow control air flow 217 flows from blower 272 into flow control area 202, keeping flow control area 202 a relatively cool area within heat generating device 201. Air supply 217, as controlled by flow control electronics 290, provides inlet air to fuel cell 271.

[0057] The dual fan blower 300 of the blower assembly 350 is generally shown in Figures 3 and 4. The blower 300 includes a housing 301 having an axial inlet 310 and a radial outlet 320. In Figure 3, a filter 400 is shown attached to the inlet 310. In Figure 4, the filter 400 is shown removed from the inlet 310. The filter 400 mates with the inlet 310 in the direction of arrow A. Thus, all the air supplied to the fuel cell 271 can be filtered. A suitable filter meets the requirements for N95 certification.

[0058] A top perspective view of a portion of blower housing 500 of blower 300 is shown in Figure 5. A top view of housing 500 is shown in Figure 6, and a side view of housing 500 is shown in Figure 7. Housing 500 includes a fan area 510 for housing an electronically controlled fan (not shown) that draws air into intake 310 and blows the air out outlet 320.

[0059] The inlet 310 is configured to removably secure the filter 400 to the inlet 310. The inlet 310 is circular and has a plurality (three) of prongs 315 extending outwardly from the inlet 310. Each prong 315 has a base 316 extending axially upward from the inlet 310, a smooth transition portion 317, and a hook portion 318 extending radially from the transition portion 317. Each prong 315 is offset toward the center of the inlet 310 at a shelf 319. Because the prongs 315 are offset toward the center of the inlet 310, the inlet 310 can provide an uninterrupted circular base 314 for an effective seal with the filter 400.

[0060] Filter 400 is shown in bottom perspective, bottom, and side views in Figures 8, 9, and 10, respectively. Filter 400 includes a central mounting portion 410 that extends axially from the bottom surface of filter 400. Mounting portion 410 includes a circular mating ledge 414 for engaging and sealing against base 314 of housing 500 of blower 300. Filter 400 also includes an engagement lip 411 that fits snugly inside the inner surface of base 314 to help seal filter 400 to air inlet 310.

[0061] The central mounting portion 410 of the filter 400 also includes a plurality (three) of engagement slots 415 for receiving respective (e.g., three) of the detents 315 of the blower housing 500. The mounting portion 400 also includes a plurality (three) of cam ribs 418. To mount the filter 400 to the blower 300, the mounting portion 410 is pressed upward in the direction of arrow A (FIG. 4) relative to the inlet 310. The filter 400 is then rotated radially until the hooks 318 of the detents 315 of the housing 500 pass downward through the slots 415 of the filter 400. The top surfaces 420 of the cam ribs 418 are sloped. The left end of each cam rib 418 is farther into the filter 400 from the surface of the engagement ledge 414 than the right end. Thus, the filter 400 is rotated after the detents 315 are inserted downward through the slots 415. This causes the upward facing surfaces of hooks 318 to engage the thinner / lower downward facing surfaces of cam ribs 418. Further rotation of filter 400 brings the downward facing surface of underside 420 into tighter engagement with the upward facing surfaces of hooks 318, tightening the engagement between engagement ledge 414 of filter 400 and base 314 of inlet 310 to provide an effective seal between filter 400 and inlet 310 of blower 300.

[0062] Filter 400 may be formed of any suitable filter material. Filter 400 is preferably a two-layer filter with spaces between the layers to provide a larger surface area and therefore a larger filter surface for filtering the airflow into inlet 310. Filter 400 is preferably N95 certified. Filter 400 is also preferably configured to space the top and bottom surfaces of filter 400 apart so that air can be filtered through both the top and bottom surfaces before entering inlet 310.

[0063] The flow control electronics 290 includes sensors to measure airflow. These sensors could detect if the filter 400 is too clogged for adequate airflow and / or proper filtration. In this case, the electronics 290 could activate a warning signal, such as a flashing light and / or an audible signal. At this time, the heat generating device 201 could be shut off and the filter 400 could be replaced. This could be done by rotating the filter 400 in the opposite direction and sliding the hook 318 towards the slot 415, which would allow the filter 400 to be removed from the inlet 310 in the opposite direction of arrow A.

[0064] The mounting of blower 300 on a printed circuit board (PCB) 375 is shown more clearly in Figure 13. Circuit board 375 includes a hole 376 for receiving axial intake 310 of blower 300. Blower 300 is mounted on board 375 in the direction of arrow Z with axial intake 310 inserted into hole 376. Filter 400 is then attached to the exposed axial intake 310 extending from hole 376 to provide a filtered air intake for air received by blower 300 to supply filtered air to fuel cell 271 as controlled by flow control circuitry 290.

[0065] 12 and 13, blower assembly 300 and control circuitry 290 are mounted on circuit board 375. PCB 375 is mounted in flow control area 202 of heat generating device 201 using BOP support panel 380. FIG. 11 shows a bottom perspective view of PCB 375 mounted on support panel 380, and FIG. 12 shows an exploded view. Air filter gasket 385 is sandwiched between the top surface of PCB 375 and support panel 380. Support panel 380 is secured within flow control area 202. Filter gasket 385 allows airflow in the direction of arrow X to reach filter 400. If filter 385 is coarser than filter 400, filter 385 will act as a primary filter and prevent filter 400 from clogging with larger particles that can be filtered by filter gasket 385. It is noted that certain embodiments of the present invention do not require that an N95 certified filter be used. In fact, certain embodiments of the present invention may omit filter 400 and simply use filter gasket 385 around the outer edge of the PCB-to-plate interface.

[0066] Airflow through blower 300 is more clearly shown in Figures 14 and 15. Air from flow control section 202, which is relatively cool, is drawn by blower 300 through filter 385 in the direction of arrow X. Filter gasket 385 acts as a primary filter and can intercept larger particles, preventing them from reaching and clogging filter 400, helping to extend the life of filter 400. After passing through filter 385, the air flows between panel 380 and substrate 375. The narrow dimensions allow for a high flow rate, which improves heat transfer and helps keep substrate 375 cool. After passing between substrate 375 and panel 380, the air is drawn through filter 400. The gap between substrate 375 and panel 380 can be sized wider than the height of filter 400 to allow airflow both above and below filter 400 so that all of filter 400 is available for filtration. After passing through the blower 300 , the air is directed through an outlet 320 and ultimately to the fuel cell 271 .

[0067] It should be noted that, where this application recites method or procedure steps in a particular order, the order in which some steps are performed may be varied or may be advantageous in particular circumstances, and the particular steps of the method or procedure claims below are not intended to be construed as being order specific, unless such order specificity is expressly recited in the claims.

[0068] While preferred embodiments of the devices and methods have been described with reference to the environments in which they are deployed, the preferred embodiments merely illustrate the principles of the invention. Modifications or combinations of the above assemblies, other embodiments, configurations, and methods for carrying out the invention, and variations of aspects of the invention that are obvious to those skilled in the art, are intended to be within the scope of the claims.

Claims

1. A device having a heat generating mechanism for generating heat therein, a housing having exterior and interior surfaces defining a housing interior, the housing having a front and a rear and a length from the front to the rear, the heat generating mechanism mounted within the housing interior, the housing having an air intake port; an air intake conduit in fluid communication with a source of ambient air at an air inlet of the housing; a blower assembly including a blower having a blower inlet in fluid communication with the air intake conduit and a blower outlet in fluid communication with the air intake port of the heat generating mechanism; The apparatus wherein the blower intake has a filter thereon adapted and positioned to filter air from the air inlet conduit.

2. 10. The device of claim 1, wherein the filter is an N95 certified filter.

3. 3. Apparatus according to claim 1 or 2, wherein the blower assembly comprises a second blower in series with the first blower, each blower having a fan impeller actuated by a motor.

4. 4. The apparatus of claim 1, wherein the blower has an annular shelf about the blower inlet that is configured and adapted to be removably attached to the filter.

5. 5. The apparatus of claim 1, wherein the filter has an outer filtered intake face in fluid communication with a filter interior, and a filter outlet in fluid communication with the filter interior, the filter having an annular ledge about an end of the filter outlet sized and configured to mate with the blower intake.

6. 6. The apparatus of claim 1, wherein the blower intake comprises at least one tab configured to engage a mating surface of the filter outlet.

7. 7. The apparatus of claim 1, wherein the blower intake comprises three prongs configured to engage a mating surface of the filter outlet.

8. 8. The device of claim 1, wherein the filter outlet comprises at least one cam surface adapted to engage the at least one tab of the filter inlet.

9. 9. The apparatus of claim 1, wherein a cam surface is inclined and adapted to tighten or loosen the engagement between the filter outlet and the blower inlet upon rotation of the filter relative to the blower inlet.

10. 10. The apparatus of claim 1, wherein the pawl is offset inwardly into the blower inlet.

11. 11. The apparatus of claim 1, wherein the filter outlet comprises at least one tab configured to engage a mating surface of the blower inlet.

12. 12. The apparatus of claim 1, wherein the blower inlet comprises at least one cam surface adapted to engage the at least one tab of the filter outlet.

13. 13. The apparatus of claim 1, wherein the blower assembly electronic controller is mounted adjacent to the blower assembly.

14. 14. The device of any one of claims 1 to 13, wherein the filter has a first layer and a second layer, a gap between the first layer and the second layer, and an interior of the filter includes the gap.

15. 15. The device of claim 1, wherein the filter is disc-shaped.

16. 16. The device of any one of claims 1 to 15, wherein the filter has a diameter of about 1 inch to about 10 inches.

17. 17. The apparatus of any one of claims 1 to 16, wherein the filter has a diameter of about 3 inches to about 7 inches.

18. An apparatus having an air consuming mechanism therein, a housing having exterior and interior surfaces defining a housing interior, the housing having a front and a rear and a length from the front to the rear, the air consuming mechanism mounted within the housing interior and having an air intake port; an air intake conduit in fluid communication with a source of ambient air at an air inlet of the housing; at least one blower assembly including a blower having a blower inlet in fluid communication with the air intake conduit and a blower outlet in fluid communication with the air intake port of the air consumer; the blower intake has a filter at an upper portion adapted and arranged to filter air from the air intake conduit, such as an N95 filter and / or a two-layer filter having a gap between the layers; the blower having an annular shelf around the blower inlet configured and adapted to be removably attached to the filter outlet, the filter having an outer filtered intake surface in fluid communication with a filter interior and a filter outlet in fluid communication with the filter interior, the filter having an annular shelf around an end of the filter outlet sized and configured to mate with the blower inlet; the blower inlet comprising at least one tab configured to engage a mating surface of the filter outlet; the filter outlet comprises at least one cam surface adapted to engage the at least one tab of the filter inlet, the cam surface being inclined and adapted to tighten or loosen the engagement between the filter outlet and the blower inlet upon rotation of the filter relative to the blower inlet.

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