Water separator for separating water from a fluid flow

Abstract

The present invention relates to a water separator (100) for separating water from a fluid flow, particularly from a gas flow in a fuel cell system, comprising at least a first separation stage (10) having a first flow area (18) connected to a fluid conduit (17). A crude water separator (20) is located within the fluid conduit (17). A separation area (22) is connected to a water outlet (24). The water separator (100) comprises at least a second separation stage (30) having a second flow area (38), the second separation stage (30) being located downstream of the first separation stage (10). In this context, the second flow area (38) includes at least one separation element (50, 60) exposed to the approaching fluid flow.

Description

Technical Field

[0001] The present invention relates to a water separator for separating water from a fluid flow, particularly from the gas flow of a fuel cell system.

Background Art

[0002] European Patent No. 1167743 discloses a water separator configured as a swirl separator. This water separator includes an inner tube and an outer tube arranged continuously in the axial direction. The axial part of the inner tube protrudes into the outer tube, and the outer tube has a water discharge port arranged tangentially in the direction of the swirling flow.

Summary of the Invention

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

[0004] According to one aspect of the present invention, the above object is achieved by a water separator for separating water from a fluid flow, particularly from the gas flow of a fuel cell system, the water separator comprising at least a first separation stage having a first flow region connected to a fluid conduit, the first flow region including at least one inner tube and at least one outer tube arranged axially with respect to each other, the inner tube being arranged downstream of the outer tube in the flow direction adjacent to the outer tube, a coarse water separator being arranged in the fluid conduit, the separation region being arranged radially outside the inner tube and the outer tube and connected to a water outlet, the water separator further comprising at least a second separation stage having a second flow region, the second separation stage being arranged downstream of the first separation stage, the inner tube of the first flow region being coupled to fluidly communicate with an inlet opening of the second flow region, the second flow region including at least one separation element exposed to an approaching fluid flow.

[0005] Advantageous configurations and advantages of the present invention can be obtained from the further claims, the specification, and the drawings.

[0006] According to one aspect of the present invention, a water separator is proposed for separating water from a fluid flow, particularly from a gas flow in a fuel cell system, the water separator comprising at least a first separation stage having a first flow region connected to a fluid conduit. The first flow region includes at least one inner tube and at least one outer tube arranged axially with respect to each other. The inner tube is adjacent to the outer tube and located downstream of the outer tube in the flow direction. A crude water separator is located within the fluid conduit. The separation region is located radially outward of the inner and outer tubes and connected to a water outlet. Furthermore, the water separator comprises at least a second separation stage having a second flow region, the second separation stage being located downstream of the first separation stage. The inner tube of the first flow region is coupled to fluid communication with an inlet opening of the second flow region. In this regard, the second flow region includes at least one separation element exposed to an approaching fluid flow.

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

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

[0009] The water produced by the reaction of hydrogen and oxygen exists within the fuel cell system as product water and is removed from the anode circuit by a water separator. The separated water is typically discharged into the fuel cell system environment, but can be reused, if necessary, for other components requiring liquid water, such as humidifiers for process gases. Depending on the type of fuel cell and volumetric flow rate, very high separation efficiency of the water separator may be required, which is only achievable through a multi-stage process.

[0010] The proposed multi-stage water separator has the advantage of high water separation efficiency. Therefore, the first separation stage plays the role of separating a large amount of water from the fluid flow at the air inlet. Here, for example, up to 90% of the water can be separated. In the second separation stage, an impactor with downstream separation components may be arranged. According to the modular system, all or some of the separation components are employed to separate the remaining liquid water from the fluid flow. This allows for the advantageous combination of low-flow separation components with high-flow separation components, which can be arranged in a compact configuration within the housing of the second separation stage.

[0011] Water separators can be advantageously adapted to different requirements. Therefore, they can particularly advantageously achieve a long service life for fuel cell systems.

[0012] Advantageously, the first separation stage of the water separator is configured as an axial flow cyclone. Here, centrifugal force generates a wall film from the liquid water in the air, which is then discharged to the drain section at the inner wall of the first separation stage.

[0013] Water droplets remaining in the airflow are guided to a second separation stage through an inner tube of a first separation stage, which is configured as a connecting conduit, where the direction of the flow is changed multiple times. The second separation stage functions as a fine water separator for the residual water in the fluid flow. Advantageously, the housing of the water separator is provided with at least one element into which the fluid flow collides and is thereby deflected. The water droplets cannot follow the flow changes due to the mass force effect and are therefore separated. Depending on the embodiment of the housing, the flow can be deflected multiple times in the second separation stage by a number of appropriately provided separation elements, such as separation nonwoven fabrics, separation impactors, and lamellar separators.

[0014] Advantageously, in the proposed water separator, a swirling flow can be generated by an axial flow cyclone in the inlet region of the water separator, and subsequently, the water can be separated in multiple separation stages by centrifugal force, inertia, and / or gravity effects. Thus, the water separator is beneficially different from the prior art in that it has improved overall separation performance while having comparable pressure loss.

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

[0016] In the case of a modular system, the water separator can consist of several interchangeable individual parts, or it can be manufactured as a single integrated component of plastic material, for example, by conventional injection molding.

[0017] The first separation stage may include, for example, a swirling flow generator as a crude water separator, which may be arranged integrally with the fluid conduit or may be arranged in a replaceable manner.

[0018] The first and second separation stages of the water separator, as well as the individual elements of the second separation stage, can be manufactured as separate components, and in the case of a multi-stage water separator, they can be modularly joined into the whole system according to a modular system. In this regard, the components and housings of the individual separation stages can be welded or bonded, for example.

[0019] According to a beneficial embodiment of the water separator, the separation element includes a structured surface and / or nonwoven fabric facing the direction of the fluid flow, the structured surface including a plurality of ridges, particularly a plurality of parallel-arranged truncated pyramidal structures. Other shapes of the ridges are also possible, such as cylindrical, rectangular, spherical, or conical. The separation element alters the direction of the fluid flow. Due to the abrupt deflection of the fluid flow within the separation element and the tendency of water droplets to move linearly, the water droplets remain in contact with the separation element for a longer period. In this regard, water droplets in the fluid flow remain deep within the structured surface or nonwoven fabric, grow larger, and are then discharged downward in the direction of gravity into the water recovery chamber.

[0020] According to a beneficial embodiment of the water separator, the separation element is configured as an impactor plate having no interior or an interior that opens downward in the direction of gravity. In this regard, the separation element may be positioned opposite the inlet opening of the second flow region. By positioning the separation element opposite the inflow direction, the separation element is directly exposed to the approaching flow, thereby deflecting the direction of the fluid flow. The impactor plate can be formed in a planar, curved, stepped, or otherwise non-planar shape. In a separation element whose surface may be closed or have an opening, the separated water is discharged into a water recovery chamber through the interior and / or at the front.

[0021] According to a beneficial embodiment of the water separator, the front surface of the impactor plate exposed to the approaching fluid flow is configured as a structured surface. Water droplets are advantageously deposited or separated onto elements of the structured surface and discharged downward in the direction of gravity into the water recovery chamber.

[0022] According to a beneficial embodiment of the water separator, at least one through opening is provided on the front surface of the impactor plate to allow the fluid flow to pass into the interior of the impactor plate. In this regard, the at least one through opening can have any shape and size. In particular, the holes of the multiple through openings can have any shape and size. The holes of the multiple through openings can be configured in the form of perforations in the impactor plate. This allows at least a portion of the fluid flow to pass through the front surface into the interior of the impactor plate. Thus, the liquid water of the fluid flow can be advantageously deposited on the walls inside the quiescent flow and thus separated from the fluid flow.

[0023] According to a beneficial embodiment of the water separator, a drainage channel for the outflow of separated water in the direction of gravity is provided on the front of the impactor plate. This allows the water separated by the separation element to flow more easily downward and then be discharged into the water recovery chamber in the desired manner.

[0024] According to a beneficial embodiment of the water separator, a nonwoven fabric is placed inside and / or in front of the impactor plate. This allows the nonwoven fabric to contribute to the separation of water at different locations on the separation element and to absorb the separated water at least partially.

[0025] According to a beneficial embodiment of the water separator, a first quiescent flow region, particularly a quiescent flow region in the drainage chamber, is formed on the surface of the separation element opposite to the fluid flow. The quiescent flow region not only contributes favorably to further separation of water from the fluid flow, but can also guide the separated wall membrane to the drainage point.

[0026] According to a beneficial embodiment of the water separator, the inlet opening opens into an impactor nozzle located inside a second flow area and configured to guide the fluid flow toward the separation element. This allows the separation element to be exposed to the approaching flow in a desired manner, thus beneficially increasing the separation efficiency.

[0027] According to an advantageous embodiment of the water separator, a lamella separator is arranged in the second separation stage. In this regard, the lamella separator can be arranged transversely to the flow direction of the fluid flow in the second flow region of the second separation stage. In particular, in this regard, the lamella separator can have a cross-section corresponding to the cross-section of the second flow region. The lamella separator can be arranged such that the entire fluid flow between the inlet opening and the outlet opening of the second separation stage of the water separator passes through the lamella separator. Thereby, the surface area for water separation can be advantageously enlarged, and thus the efficiency of water separation can be improved.

[0028] According to an advantageous configuration of the water separator, the outlet pipe of the second separation stage is arranged in the region of the second flow region opposite to the direction of gravity. In particular, in this regard, the outlet pipe can be arranged on the opposite side of the diagonal of the inlet opening in the second flow region. Thereby, the flow direction of the fluid flow can be deflected, and thus the water separation within the housing can be increased.

[0029] According to an advantageous embodiment of the water separator, the outlet pipe has, at its inlet opening, a collar crimped outward from the inlet opening. Behind the collar, the fluid flow advantageously flows into a kind of calm flow region, which can contribute to the improvement of water separation.

[0030] According to an advantageous embodiment of the water separator, a non-woven fabric that at least partially surrounds the outlet pipe is arranged between the collar and the outflow-side side wall of the second flow region. The non-woven fabric can further contribute to the improvement of water separation and the absorption of the liquid separated from the fluid flow.

[0031] According to an advantageous embodiment of the water separator, the non-woven fabric is at least partially configured as part of a truncated cone, and the tip of the cone is oriented towards the inlet opening side of the outlet pipe. This shape, together with the calm flow zone, can further contribute to the improvement of water separation and the absorption of the liquid separated from the fluid flow.

[0032] According to a beneficial embodiment of the water separator, a baffle plate is positioned opposite the inlet opening of the outlet pipe, across the flow direction, and spaced relative to the upper surface of the second flow region. The baffle plate may serve as an additional means for deflecting the flow direction in the second separation stage, which may contribute to improved water separation from the fluid flow.

[0033] According to the beneficial configuration of the water separator, the inner wall of the second flow region is positioned spaced apart from the inlet side wall. The additional inner wall creates a region separated from the fluid flow and shielded from the airflow within the second flow region, thus guiding the separated wall membrane to the drain point.

[0034] According to the beneficial configuration of the water separator, a second quiescent flow region is formed between the inner wall and the inlet side wall. The second quiescent flow region ensures that already separated water droplets are not re-encompassed by the fluid flow, thereby advantageously providing further opportunities for improved water separation.

[0035] According to a beneficial embodiment of the water separator, a water recovery chamber is located in a portion of the bottom of the second flow area in the direction of gravity. In this regard, the water recovery chamber may have a water outlet, particularly at its lowest point. This allows the separated water to be recovered and discharged beneficially without the already separated liquid water being stirred up again and carried along by the fluid flow.

[0036] According to a beneficial embodiment of the water separator, a water siphon device is provided in the water recovery chamber, connected to the quiescent flow region of the drainage chamber of the separation element to communicate with the fluid. Optionally, the water can not only be freely discharged but can also be actively siphoned, particularly depending on the water volume, the location of the water recovery chamber, and the installation location of the water separator. Advantageously, the water siphon device can be arranged in combination with an impactor plate, including an internal structure.

[0037] According to a useful embodiment of the water separator, a receiving pipe is positioned at the inlet opening of a second flow area, and an outlet pipe is positioned inside the receiving pipe. In this regard, a separation element may be positioned inside the receiving pipe and at least partially surrounding the outlet pipe. The outlet pipe may be at least partially closed at its downstream end and have a plurality of fluid passage openings positioned opposite the separation element. This deflects the flow direction of the fluid flow by the outlet pipe and guides it, for example, in an annular manner, to the separation element arranged around the outlet pipe. This effectively allows for further separation of liquid water from the fluid flow immediately after exiting the outlet pipe.

[0038] According to a beneficial embodiment of the water separator, the receiving pipe is located within a second flow area. In a simplified embodiment, the second separation stage of the water separator thus comprises separation elements arranged around the receiving and outlet pipes. This allows for a particularly compact configuration of the water separator.

[0039] Further advantages can be derived from the description of the drawings below. The drawings illustrate embodiments of the present invention. Numerous features are included in combination in the drawings, specification, and claims. Those skilled in the art can appropriately consider and combine these features, both individually and individually, to provide further combinations. These are illustrated below in schematic diagrams. [Brief explanation of the drawing]

[0040] [Figure 1] This is a cross-sectional view of a water separator according to one embodiment of the present invention, for separating water from a fluid flow, particularly from the airflow of a fuel cell system. [Figure 2] This is a cross-sectional view of a water separator according to a further embodiment of the present invention. [Figure 3] This is a cross-sectional view of a water separator according to a further embodiment of the present invention. [Figure 4] This is a cross-sectional view of a water separator according to a further embodiment of the present invention. [Figure 5] This is a cross-sectional view of a water separator according to a further embodiment of the present invention. [Figure 6]This is a cross-sectional view of a water separator according to a further embodiment of the present invention. [Figure 7] This is a cross-sectional view of a water separator according to a further embodiment of the present invention. [Figure 8] This is a cross-sectional view of a water separator comprising a simplified second separation stage according to a further embodiment of the present invention. [Figure 9] This is a cross-sectional view of a water separator comprising a simplified second separation stage according to a further embodiment of the present invention. [Figure 10] This is a cross-sectional view of a water separator according to a further embodiment of the present invention. [Figure 11] This is a cross-sectional view of a second separation stage having an impactor plate and separation collar in an alternative arrangement, located downstream of the first separation stage, according to a further embodiment of the present invention. [Figure 12] This is a cross-sectional view of the second separation stage along line BB in Figure 11. [Figure 13] This is a cross-sectional view of the second separation stage along line CC in Figure 11. [Figure 14] This is a plan view of the separation element of a water separator according to one embodiment of the present invention. [Figure 15] This is a cross-sectional view of the separating element along line AA in Figure 14. [Figure 16] This is an enlarged view of detail C in the cross-sectional view shown in Figure 15. [Figure 17] This is an enlarged view of detail B in the plan view of Figure 14. [Figure 18] This is a plan view of a separation element according to a further embodiment of the present invention. [Figure 19] This is a cross-sectional view of the separating element along line AA in Figure 18. [Figure 20] This is a plan view of a separation element according to a further embodiment of the present invention. [Figure 21] This is a cross-sectional view of the separating element along line AA in Figure 20. [Figure 22] This is a plan view of a separation element according to a further embodiment of the present invention. [Figure 23] This is a cross-sectional view of the separation element along line AA in Figure 22. [Figure 24]This is an enlarged view of the detailed cross-sectional view shown in Figure 23. [Figure 25] This is an enlarged view of the detailed part of the plan view shown in Figure 22. [Figure 26] This is a plan view of a separation element according to a further embodiment of the present invention. [Figure 27] This is a cross-sectional view of the separating element along line AA in Figure 26. [Figure 28] This is an enlarged view of detail B in the cross-sectional view shown in Figure 27. [Figure 29] This is an enlarged view of detail C in the plan view shown in Figure 26. [Modes for carrying out the invention]

[0041] In the diagrams, identical or similar components are indicated by the same reference symbol. These diagrams are for illustrative purposes only and should not be understood as limiting.

[0042] Figure 1 is a schematic cross-sectional view of a water separator 100 according to one embodiment of the present invention, for separating water from a fluid flow, particularly from a gas flow in a fuel cell system, and especially from air, hydrogen, or nitrogen.

[0043] The water separator 100 includes a first separation stage 10 having a first flow area 18 connected to a fluid conduit 17.

[0044] The first separation stage 10 functions as a main separator for a larger volume of water at the fluid inlet.

[0045] The first flow region 18 includes an inner tube 14 and an outer tube 16 arranged axially 82 to each other. The inner tube 14 is adjacent to the outer tube 16 and is located downstream of the outer tube 16 in the flow direction 80. The flow direction 80 is indicated by an arrow. The first separation stage 10 is located here within the housing 12.

[0046] A crude water separator 20 is located inside the fluid conduit 17. The crude water separator 20 is a swirling flow generator in the form of, for example, an axial flow cyclone. Within the housing 12, a separation region 22 is located radially outward of the inner pipe 14 and the outer pipe 16. The separation region 22 is connected to a water outlet 24 located at the bottom of the housing 12 in the direction of gravity 84.

[0047] In the first separation stage 10, the air flowing in via the fluid conduit 17 is guided to the crude water separator 20. The air is rotated and exits through the funnel-shaped outer tube 16 into the separation region 22 of the housing 12. Due to centrifugal force, water droplets in the air move radially outward relative to the flow, forming a wall film on the inner wall of the water separation region 22 of the first separation stage 10, which moves towards the drainage region. The separated water is discharged towards the water outlet 24.

[0048] The water separator 100 further comprises a second separation stage 30 having a second flow area 38. The second separation stage 30 is located downstream of the first separation stage 10 and combines different separation elements with each other according to a modular system. The second separation stage 30 is located within a housing 32.

[0049] The second separation stage 30 functions as a fine water separator for the amount of residual water in the fluid flow.

[0050] The inner tube 14 of the first separation stage 10 is coupled to the inlet opening 34 of the second flow region 38 to communicate with the fluid. In a further embodiment, the inner tube 14 may protrude into the housing 32 for this purpose.

[0051] The second flow region 38 includes a separation element 50 configured as an impactor plate 54, which is exposed to an approaching fluid flow that flows through the inner tube 14 into the housing 32 of the second separation stage 30 and is then guided further through the impactor nozzle 144. On the front surface 56 facing the fluid flow, the impactor plate 54 has a structured surface 51 having pyramidal ridges 57. A first quiescent flow region 36 is formed on the rear surface of the separation element 50, opposite to the fluid flow.

[0052] A water recovery chamber 76 for separated water is located in a part of the housing 32 at the bottom in the direction of gravity 84. The water recovery chamber 76 has a water outlet 44 at its lowest point for discharging the separated water.

[0053] The quiescent flow region 36 is connected to the water recovery chamber 76 for fluid communication. On the side of the separation element 50 opposite to the fluid flow, a further quiescent flow region of the drainage chamber 143 is formed, which is connected to the water siphon device 78 for fluid communication.

[0054] The air, which collides with the separation element 50 and has its flow direction deflected there, then collides with the lamellar separator 40. The lamellar separator 40 is positioned across the flow direction 80 of the fluid flow in the second flow region 38. In this regard, the lamellar separator 40 has a cross-section corresponding to the cross-section of the second flow region 38, and therefore the fluid flow must pass through the lamellar separator 40 completely in any case.

[0055] The outlet pipe 42 of the second separation stage 30 is located in the region of the second flow region 38 opposite to the direction of gravity 84. In this regard, the outlet pipe 42 is located diagonally opposite the inlet opening 34 of the second flow region 38, in particular to achieve the conduction of beneficial flow through the second flow region 38.

[0056] The outlet pipe 42 is equipped with a collar 48 at its inlet opening 46, which is crimped outward from the inlet opening 46. A nonwoven fabric 43 is positioned between the collar 48 and the outlet-side wall 33 of the housing 32, which surrounds the outlet pipe 42 at least partially, particularly in an annular manner. The nonwoven fabric 43 abuts against the outlet-side wall 33 and is spaced apart from the upper surface 37 of the second flow area 38. The nonwoven fabric 43 can have a variety of cross-sections and contours. Where there is a corresponding thickness of material, the upper surface 37 is at least partially in contact.

[0057] Opposite the inlet opening 46 of the outlet pipe 42, the baffle plate 70 is positioned across the flow direction 80 and at a distance from the upper surface 37 of the second flow region 38.

[0058] Furthermore, the inner wall 72 is positioned at a distance from the inlet-side side wall 35. A further quiescent flow region 74 is formed between the inner wall 72 and the inlet-side side wall 35. This further quiescent flow region 74 is also connected to the water recovery chamber 76 for fluid communication.

[0059] After the preliminary separation of water in the first separation stage 10, the water droplets remaining in the airflow are guided to the second separation stage 30 through the inner tube 14 of the first separation stage 10, which is formed as a connecting conduit, where the direction of the flow is changed multiple times.

[0060] At the flow deflection position, advantageously, at least one element may be provided to absorb water droplets that collide with the fluid flow and cannot follow the flow change due to the inertial effect. Depending on the embodiment of the housing 32, the second separation stage 30 can perform multiple deflections using a number of appropriately provided separation elements, such as separation element 50 configured as an impactor plate 54, lamellar separator 40, separation collar 48, separation nonwoven fabric 43, etc.

[0061] In the embodiment shown in Figure 1, the fluid flow from the impactor nozzle 144 directly impacts the separation element 50. In the separation element 50, the fluid flow is first decelerated and deflected, resulting in the deposition or separation of any further portion of the water entrained in the fluid flow. The space behind the separation element 50 forms a drainage chamber 143 having a quiescent flow region connected to a water recovery chamber 76. Alternatively, the drainage chamber 143 having a quiescent flow region may be connected to a water siphon device 78.

[0062] The deflected fluid flow then passes through the lamellar separator 40, which serves to separate further portions of the liquid water in the low flow rate region.

[0063] Next, the fluid flow fills the upper region of the second flow area 38, where the liquid water content is further reduced by the outlet pipe 42, which has an outwardly crimped collar 48, and the nonwoven fabric 43 arranged around it. The water droplets can be separated by a baffle plate 70 positioned opposite the inlet opening 46 of the outlet pipe 42. The inner wall 72 and the quiescent flow region 74 behind it provide an additional quiescent flow region 74, thereby facilitating drainage from this portion of the second flow area 38. The quiescent flow region 74 may be connected to a water recovery chamber 76 to facilitate fluid communication for this purpose.

[0064] In the embodiment shown in Figure 1, the separation element 50 has a structured surface 51. The structured surface 51, shown only schematically, may include, for example, a plurality of ridges 57 oriented opposite to the direction of fluid flow, and in the illustrated embodiment, parallel-arranged frustums. As the fluid flow collides with the frustums 57, the fluid flow is significantly slowed and deflected, resulting in the liquid water accumulating on the frustums 57 and being discharged downward.

[0065] Figure 2 shows a cross-sectional view of a water separator 100 according to a further embodiment of the present invention. In this embodiment, the nonwoven fabric 43 arranged around the outlet pipe 42 is separated from the side wall 33 of the housing 32 and directly adjacent to a collar 48 crimped to the outside of the outlet pipe 42. The nonwoven fabric 43 can have different dimensions and shapes. Nonwoven fabrics of different sizes and shapes can be provided in the free space between the side wall 33 and the collar 48. This allows for the additional provision of a quiescent flow region having defined characteristics.

[0066] In this embodiment as well, the separation element 50 is formed as an impactor plate 54 having a pyramidal raised portion 57 on the structured surface 51.

[0067] Figure 3 is a cross-sectional view of a water separator 100 according to a further embodiment of the present invention, in which the nonwoven fabric 43 is formed in a conical shape and the tip of the cone is oriented toward the inlet opening 46. This embodiment of the nonwoven fabric 43 also allows for advantageous separation of liquid water from a fluid flow.

[0068] Figure 4 shows a cross-sectional view of a water separator 100 according to a further embodiment of the present invention, in which the nonwoven fabric 43 around the outlet pipe 42 has the same configuration as in the embodiment shown in Figure 3. However, the separation element 50, configured as an impactor plate 54, has a nonwoven fabric 52 instead of a structured surface 51. Water droplets that directly impact the nonwoven fabric 52 penetrate deep into the nonwoven fabric 52, thereby being separated from the deflected fluid flow. Thus, the nonwoven fabric 52 can absorb a large amount of liquid water without being re-encompassed by the fluid flow. The absorbed water can then be beneficially discharged from the nonwoven fabric 52 into the water recovery chamber 76.

[0069] Figure 5 is a cross-sectional view of a water separator 100 according to a further embodiment of the present invention.

[0070] The water separator 100 is configured substantially the same as the embodiment shown in Figure 4. However, here the receiving pipe 62 is located at the inlet opening 34 of the second flow area 38, and the outlet pipe 145 is inserted inside the receiving pipe 62. In this regard, an additional separation element 60 is located inside the receiving pipe 62. The separation element 60 at least partially surrounds the outlet pipe 145. The outlet pipe 145 has at least partially closed downstream end 28. Furthermore, the outlet pipe 145 has a plurality of fluid passage openings 26 located opposite the separation element 60.

[0071] The fluid flow through the inner pipe 14 flows into the outlet pipe 145 and flows out again from the outlet pipe 145 through the fluid passage opening 26, thereby deflecting the flow direction 80. In this regard, as the fluid flow flows out from the outlet pipe 145, it directly collides with the separation element 60, which is also made of nonwoven fabric 52 in this embodiment. Advantageously, this allows for further water separation in the additional separation element 60. For this purpose, the receiving pipe 62 is equipped with an additional drain section 61 through which the separated water can reach the water recovery chamber 76 of the housing 32.

[0072] Therefore, the embodiment shown in Figure 5 represents a water separator 100 having further arbitrary separation stages within the second separation stage 30, in the form of a separation element 60 inside the receiving pipe 62 according to a modular system. This makes it possible to achieve even more improved separation performance.

[0073] The cross-sectional view of the water separator 100 shown in Figure 6 shows a further embodiment similar to the embodiment shown in Figure 5, in which the separation element 60 is arranged within the receiving pipe 62, but in contrast to the embodiment shown in Figure 5, it has a structured surface 51. This also allows for an advantageous improvement in the overall separation performance of the water separator 100.

[0074] Figure 7 is a cross-sectional view of a water separator 100 according to a further embodiment of the present invention.

[0075] A key difference from the embodiments shown in Figures 1 to 6 is that the two separation stages 10 and 30 are housed in a single housing 12, rather than in separate housings 12 and 32 that can be beneficially joined to the water separator 100. In this regard, the inner tube 14 of the first separation stage 10 is integrally formed with the impactor nozzle 144 of the second separation stage 30.

[0076] In the embodiment shown in Figure 7, the separation element 50 is formed by pyramidal protrusions 57 on the structured surface 51. The nonwoven fabric 43 is configured in the arrangement shown in the embodiment of Figure 1. Alternatively, other embodiments relating to the separation element 50 and nonwoven fabric 43 shown in Figures 1 to 6 are also possible.

[0077] Figure 8 is a cross-sectional view of a water separator 100 comprising a simplified second separation stage 30 according to a further embodiment of the present invention.

[0078] This embodiment is derived from the embodiment shown in Figure 5. The housing 32 of the second separation stage 30 is configured as a receiving pipe 62 at the inlet opening 34 of the second flow region 38, and the outlet pipe 145 is located inside the receiving pipe 62. In this regard, the separation element 60 is located inside the receiving pipe 62 and at least partially surrounds the outlet pipe 145. The outlet pipe 145 is at least partially closed at its downstream end 28 and has a plurality of fluid passage openings 26 located opposite the separation element 60.

[0079] The inner tube 14 of the first separation stage 10 is directly connected to the inlet opening 34 to communicate with the fluid, thereby allowing the fluid flow to pass through the inner tube 14 and into the outlet tube 145.

[0080] Therefore, the fluid flow through the inner pipe 14 is deflected with respect to the flow direction 80 by flowing into the outlet pipe 145 and flowing out again from the outlet pipe 145 through the fluid passage opening 26. In this regard, as the fluid flow flows out from the outlet pipe 145, it directly collides with the separation element 60, which is also formed of nonwoven fabric 52 in this embodiment. Advantageously, this allows for further water separation in the additional separation element 60. For this purpose, the receiving pipe 62 is equipped with a water outlet 44 through which the separated water can flow out from the water recovery chamber 76 of the housing 32.

[0081] This makes it possible to realize a water separator 100 that exhibits effective water separation capabilities despite having a particularly compact structure.

[0082] The water separator 100 realized in this way represents another example of a useful water separator 100, constructed with a modular structure of individually modularly attachable components.

[0083] Figure 9 shows a further embodiment of the water separator 100 designed in this way, in which the separation element 60 is configured as a structured surface 51 according to the embodiment of Figure 6. This also allows for the effective separation of water from a fluid flow in a very compact manner.

[0084] Figure 10 is a cross-sectional view of a water separator 100 according to a further embodiment of the present invention.

[0085] In this embodiment, the first separation stage 10 corresponds to the first separation stage 10 in the embodiments shown in Figures 1 to 6. However, the second separation stage 30 has a different configuration.

[0086] The second separation stage 30 is located within the housing 32 and functions as a fine water separator for residual water in the fluid flow.

[0087] The inner tube 14 of the first separation stage 10 is connected to the inlet opening 34 of the second flow region 38 so as to be in fluid communication with it.

[0088] The second flow region 38 includes a separation element 50 formed as an impactor plate 54, which is exposed to an approaching fluid flow that flows through the inner tube 14 into the housing 32 of the second separation stage 30 and from there is guided further through the impactor nozzle 144. The impactor plate 54 has a structured surface 51, particularly a pyramidal ridge 57, on the front surface 56 facing the fluid flow. A first quiescent flow region 36 is formed on the rear of the separation element 50, on the surface of the separation element 50 opposite to the fluid flow.

[0089] A water recovery chamber 76 for separated water is located in a part of the housing 32 at the bottom in the direction of gravity 84. The water recovery chamber 76 has two water outlets 44 at its bottom for discharging the separated water.

[0090] The quiescent flow region 36 is connected to the water recovery chamber 76 to establish fluid communication.

[0091] In order to achieve a beneficial flow guidance function through the second flow region 38, the outlet pipe 42 is positioned in the axial direction 82 opposite the inlet opening 34 of the second flow region 38.

[0092] The outlet pipe 42 is equipped with a collar 48 at its inlet opening 46, which is crimped outward from the inlet opening 46.

[0093] After the preliminary separation of water in the first separation stage 10, the water droplets remaining in the airflow are guided to the second separation stage 30 through the inner tube 14 of the first separation stage 10, which is formed as a connecting conduit, where the direction of the flow is changed multiple times.

[0094] At the flow deflection position, advantageously, at least one element may be provided to absorb water droplets that collide with the fluid flow and cannot follow the flow changes due to inertial effects. Depending on the embodiment of the housing 32, for example, a separation element 50 formed as an impactor plate 54 for deflection can be placed in the second separation stage 30.

[0095] In the embodiment shown in Figure 10, the fluid flow from the impactor nozzle 144 directly impacts the separation element 50. In the separation element 50, the fluid flow is first decelerated and deflected, resulting in the deposition or separation of any further portion of the water entrained in the fluid flow.

[0096] Next, the fluid flow fills the second flow region 38, where the liquid water content is further reduced by the outlet pipe 42, which has an outwardly crimped collar 48.

[0097] The separation element 50 in the embodiment shown in Figure 10 has a structured surface 51. The structured surface 51, shown only schematically, may include, for example, a plurality of ridges 57 oriented opposite to the direction of fluid flow, and in the illustrated embodiment, parallel-arranged frustums. When the fluid flow collides with the frustums 57, the fluid flow is significantly slowed and deflected, as a result of the liquid water accumulating on the frustums 57 and being discharged downward.

[0098] In this regard, the impactor plate 54 corresponds to the embodiment shown in Figure 2.

[0099] The impactor plate 54 of the separation element 50 can be tilted with respect to the axial direction 82. Therefore, the impactor plate 54 can preferably be positioned perpendicular to the axial direction 82, as shown in the embodiment. Alternatively, to beneficially change the separation effect of the separation element 50, the impactor plate can also be tilted with respect to the vertical at an angle 64 away from the axial direction 82, or at an angle 66 toward the axial direction 82.

[0100] Figure 11 is a cross-sectional view of a second separation stage 30 having an impactor plate 54 and separation collar 48 in an alternative arrangement, located downstream of the first separation stage 10, according to a further embodiment of the present invention.

[0101] The embodiment shown in Figure 11 represents, for example, an example of the second separation stage 30 of the water separator 100 shown in Figure 10.

[0102] The second separation stage 30, which has a second flow area 38, is constructed in a simplified form within a cylindrical housing 32. The impactor nozzle 144 and the separation element 50 are arranged at predetermined intervals.

[0103] The separation element 50 is configured as an impactor plate 54 having a pyramidal protrusion 51 and has an interior 55 configured as a drainage chamber 143 having a quiescent flow region. In this configuration, an additional quiescent flow region 36 is generated behind the separation element 50.

[0104] The outlet pipe 42 is equipped with a separation collar 48. Beneficially, the water outlet 44 is connected to communicate with the water recovery chamber 76.

[0105] In the embodiment of the second separation stage 30 shown in Figure 11, the impactor nozzle 144, separation element 50, separation collar 48, and outlet pipe 42 are arranged coaxially within the housing 32 and are spaced apart from each other.

[0106] The separated water recovered in the water recovery chamber 76 can be discharged through the water outlet 44.

[0107] Figure 12 is a cross-sectional view of the second separation stage 30 along line BB in Figure 11. A plan view of the impactor plate 54 forming the separation element 50 is shown. The impactor plate 54 has a structured surface 51 having pyramidal ridges 57. The impactor plate 54 can have any shape, for example, a circular or angular contour. The inner wall of the housing 12 and the outer contour of the impactor plate 54 may be spaced unevenly apart. The water outlet 44 is shown in cross-section.

[0108] Figure 13 is a cross-sectional view of the second separation stage 30 along line CC in Figure 11. In this regard, a cross-section through the outlet pipe 42 is shown. The impactor plate 54 and separation collar 48 have different outer contours. The housing 12 can have any shape, for example, a round or angular shape.

[0109] Figure 14 is a plan view of the separation element 50 of a water separator 100 according to one embodiment of the present invention. Figure 15 is a cross-sectional view of the separation element 50 along line AA in Figure 14, Figure 16 is an enlarged view of detail C of the cross-sectional view in Figure 15, and Figure 17 is an enlarged view of detail B of the plan view in Figure 14.

[0110] The separation element 50, formed as an impactor plate 54, is provided with a structured surface 51, representing an embodiment such as that used in the water separators shown in Figures 1 to 3. The structured surface 51 includes a row of frustums 57 arranged in parallel and oriented opposite to the direction of fluid flow, as a raised section 57. The frustums 57 in directly adjacent rows are each offset from one another. As the fluid flow collides with the frustums 57, the fluid flow is significantly slowed and deflected, resulting in the liquid water accumulating on and / or separating there.

[0111] In particular, as can be seen in Figure 15, the separation element 50 is formed as an impactor plate 54 having an interior 55 that opens downward in the direction of gravity 84. Alternatively, the separation element 50 may have a curved shape and can be formed as a curved plate. In this regard, as can be seen in Figures 1 to 3, the separation element 50 is positioned in the second separation stage 30 of the water separator 100 opposite the inlet opening 34 of the housing 32, and the fluid flow flows directly toward it. The separation element 50 can be fixed, for example, to the bottom of the housing 32.

[0112] In the embodiment of the separation element 50 shown in Figures 14 to 17, the front surface 56 of the impactor plate 54 exposed to the approaching fluid flow is configured as a structured surface 51.

[0113] In the detailed views of Figures 16 and 17, the truncated pyramid 57 of the structured surface 51 is shown in magnified view. This allows us to define useful dimensions of the truncated pyramid 57.

[0114] The height 110 of the frustum 57 can be usefully 4 mm to 40 mm, for example, 8 mm. The side lengths 111 and 112 of the base of the frustum 57 can be usefully 1 mm to 20 mm, for example, 4 mm. The base is usefully square, as in the illustrated embodiment, and therefore the two side lengths 111 and 112 are identical. The side lengths 113 and 114 of the end faces of the frustum 57 can be usefully 0.25 mm to 5 mm, for example, 1 mm. If the base is square, the end faces are also usefully square, and therefore the two side lengths 113 and 114 are identical. The angle between the sides of the frustum 57 is, for example, 21° in the case of these dimensions.

[0115] The column offset 115 between adjacent rows of frustums 57 is half the length of the base side 111, as can be seen in Figure 12, and is therefore 2 mm in the illustrated embodiment.

[0116] As can be seen in Figure 17, drainage channels 59 oriented in the direction of gravity 84 for draining separated water are formed on the front surface 56 of the impactor plate 54. The drainage channels 59 are located between rows of frustums 57. The width of the drainage channels 59 can be beneficially 0.25 mm to 5 mm.

[0117] Figure 18 is a plan view of the separation element 50 according to a further embodiment of the present invention, and Figure 19 is a cross-sectional view of the separation element 50 along line AA in Figure 18.

[0118] In this embodiment, the impactor plate 54 has a large through opening 58 on its front surface 56 through which a fluid flow can enter the interior 55. The interior 55 is filled with a nonwoven fabric 52, where water can be separated from the fluid flow. On the bottom side of the interior 55, which opens toward the housing 32 of the second separation stage 30, the separated water can be discharged into the water recovery chamber 76. As can be seen in Figure 19, the interior 55 may be completely filled with the nonwoven fabric. The depth 121 of the interior 55 and the thickness 120 of the nonwoven fabric 52 can be beneficially 0.1 mm to 50 mm, for example, 20 mm.

[0119] Figure 20 is a plan view of the separation element 50 according to a further embodiment of the present invention, and Figure 21 is a cross-sectional view of the separation element 50 along line AA in Figure 20.

[0120] In this embodiment, the front surface 56 of the impactor plate 54 has a plurality of small through openings 58 through which a fluid flow can pass into the interior 55 of the impactor plate 54. The plurality of small through openings 58 can be realized in the form of perforations. The holes of the plurality of small through openings 58 can have any shape and size. As in the previous embodiment, the interior 55 is filled with nonwoven fabric 52. As can be seen in Figure 21, an additional nonwoven fabric 53 is positioned on the front surface 56 of the impactor plate 54 on the upstream side of the flow direction of the through openings 58 and can function, for example, as a preliminary water separation stage.

[0121] The diameter 130 of the through opening 58 may be beneficially 1 mm to 20 mm, for example, 8 mm. The horizontal spacing 131 and vertical spacing 132 between the through openings 58 may be 1.5 mm to 30 mm, for example, 12 mm. However, the hole pattern may be asymmetrical, and therefore the spacing and angle of the center points of adjacent through openings 58 may be variable. The thickness 133 of the nonwoven fabric 52 inside 55 may be 0.1 mm to 50 mm, for example, 20 mm. The thickness 134 of the nonwoven fabric 53 on the front surface 56 may be 0.1 mm to 50 mm, for example, 4 mm.

[0122] Both nonwoven fabrics 52 and 53 may be present in the separation element 50. Alternatively, only one nonwoven fabric 52 may be present inside 55, or only one nonwoven fabric 53 may be present on the front surface 56 of the planar impactor plate 54.

[0123] Figure 22 is a plan view of the separation element 50 according to a further embodiment of the present invention, and Figure 23 is a cross-sectional view of the separation element 50 along line AA in Figure 22.

[0124] In this embodiment, a plurality of through openings 58 are arranged on the front surface 56 of the impactor plate 54, and the region between the through openings is covered with a structured surface 51 having raised portions 57 configured as truncated pyramidal pyramids 57. The interior 55 of the impactor plate 54 is empty, forming a quiescent flow region for collecting liquid water, and thus the fluid flow that enters the interior 55 can flow out downwards again.

[0125] Figure 24 is a magnified view of the cross-sectional view in Figure 23, and Figure 25 is a magnified view of the plan view in Figure 22. In Figures 24 and 25, the arrangement and dimensions of the separating element 50 can be seen more clearly.

[0126] The dimensions and spacing of the truncated pyramid 57 correspond to the dimensions and spacing of the embodiments shown in Figures 14 to 17. The diameter 130 of the through opening 58 can be 1 mm to 20 mm, and beneficially 8 mm, as in the previous embodiments. The horizontal spacing 141 and vertical spacing 142 of the through opening 58 can be 3 mm to 30 mm, for example 16 mm.

[0127] Figure 26 is a plan view of a separation element 50 according to a further embodiment of the present invention, and Figure 27 is a cross-sectional view of the separation element 50 along line AA in Figure 26. Figure 28 is an enlarged view of detail B in the cross-sectional view of Figure 27, and Figure 29 is an enlarged view of detail C in the plan view of Figure 26.

[0128] This embodiment corresponds to the embodiments shown in Figures 22 to 25, but the embodiments shown in Figures 26 to 29 differ in that the interior 55 of the impactor plate 54 is filled with nonwoven fabric 52.

[0129] In the nonwoven fabric 52, water from the fluid flow passing through the through opening 58 is advantageously separated and thereby further absorbed by the nonwoven fabric 52.

[0130] The dimensions and spacing of the truncated pyramidal pyramid 57, the passage opening 58, and the nonwoven fabric 52 correspond to those of the previous embodiment. [Explanation of symbols]

[0131] 10 First separation stage 12 Housing 14 Inner tube 16 Outer tube 17 Fluid conduit 18. The first distribution area 20 Crude water separator 22 Separation area 24 Water outlet 26 Fluid passage opening 28 End 30 Second separation stage 32 Housing 33 Outlet side wall 34 Inlet opening 35 Inlet side wall 36. First quiescent flow region 37 Top 38. The second distribution area 40 Lamellar Separator 42 Outlet pipe 43 Nonwoven fabric 44 Water outlet 46 Inlet opening 48 Colors 50 separation elements 51 Structured Surface 52 Nonwoven fabric 53 Nonwoven fabric 54 Impact Plate 55 Inside 56 Front 57 Ridge, truncated pyramid 58 Passage opening 59 Drainage channel 60 separation elements 61 Drainage section 62 Receiving pipe 64 angle 66 angle 70 Baffle Plate 72 Inner wall 74. Second quiescent flow region 76 Water Recovery Room 78 Water siphon device 80 Flow direction 82 Axis 84 Gravity direction 100 water separator 110 Height 111 Side length of the base 112 Side length of the base 113 Side length of the end face 114 Side length of the end face 115-column offset 116 Angle between sides 120 Nonwoven fabric thickness 121 Internal depth 130 Diameter of the passage opening 131 horizontal spacing 132 vertical spacing 133 Thickness of the internal nonwoven fabric 134. Thickness of the nonwoven fabric on the front. 141 horizontal spacing 142 vertical spacing 143 Drain room 144 Impact Nozzles 145 Outlet pipe

Claims

1. A water separator (100) for separating water from a fluid flow, particularly from a gas flow in a fuel cell system, The water separator (100) comprises a first separation stage (10) including a fluid conduit (17), a first flow region (18) connected to the fluid conduit (17), a separation region (22), and a water outlet (24). The first flow region (18) includes at least one inner tube (14) and at least one outer tube (16) arranged axially (82) relative to each other, wherein the inner tube (14) is adjacent to the outer tube (16) and is located downstream of the outer tube (16) in the flow direction (80), The fluid conduit (17) includes a crude water separator (20) located inside the fluid conduit (17). The separation region (22) is located radially outside the inner pipe (14) and the outer pipe (16) and is connected to the water outlet (24). The water separator (100) further comprises a second separation stage (30) including a second flow area (38), the second separation stage (30) being located downstream of the first separation stage (10), The inner tube (14) of the first flow region (18) is connected to the inlet opening (34) of the second flow region (38) so as to be in fluid communication with it. Water separator (100), wherein the second flow region (38) includes at least one separation element (50, 60) configured to be exposed to an approaching fluid flow, the separation element (50) is configured as an impactor plate (54) having an interior (55) that opens downward in the direction of gravity (84), the separation element (50) is positioned opposite the inlet opening (34) of the second flow region (38), and the impactor plate (54) is positioned on the front surface (56) of the impactor plate (54) and has a plurality of through openings (58) for allowing the fluid flow to pass into the interior (55) of the impactor plate (54).

2. The water separator according to claim 1, wherein the separation elements (50, 60) include nonwoven fabrics (52, 53).

3. The water separator (100) according to claim 2, wherein the nonwoven fabrics (52, 53) are arranged inside (55) and on the front surface (56) of the impactor plate (54).

4. The water separator (100) according to any one of claims 1 to 3, wherein the second separation stage (30) further includes a first quiescent flow region (36) of the drainage chamber (143) of the separation element (50), the first quiescent flow region (36) being formed on the side of the separation element (50) opposite to the fluid flow.

5. The water separator (100) according to any one of claims 1 to 4, wherein the second separation stage (30) further includes an impactor nozzle (144) through which the inlet opening (34) opens, the impactor nozzle (144) being located inside the second flow region (38) and configured to guide the fluid flow toward the separation element (50).

6. The water separator (100) according to any one of claims 1 to 5, wherein the second separation stage (30) further includes a lamellar separator (40) positioned across the fluid flow direction (80) in the second flow region (38) of the second separation stage (30), the lamellar separator (40) having a cross section corresponding to the cross section of the second flow region (38).

7. The water separator (100) according to any one of claims 1 to 6, wherein the second separation stage (30) further includes an outlet pipe (42) located in the second flow region (38) opposite to the direction of gravity (84), and the outlet pipe (42) is located in the second flow region (38) on the diagonally opposite side of the inlet opening (34).

8. The water separator (100) according to claim 7, wherein the outlet pipe (42) has an inlet opening (46) and a collar (48) positioned in the inlet opening (46) and crimped outward from the inlet opening (46).

9. The water separator (100) according to claim 8, wherein the second flow area (38) further includes a nonwoven fabric (43) positioned between the collar (48) and the side wall (33) of the second flow area (38) and at least partially surrounding the outlet pipe (42).

10. The water separator (100) according to claim 9, wherein the nonwoven fabric (43) is formed at least partially as part of a frustocone, and the tip of the frustocone is oriented toward the inlet opening (46) of the outlet pipe (42).

11. The water separator (100) according to any one of claims 1 to 10, wherein the second flow region (38) further includes a baffle plate (70) positioned opposite the inlet opening (46) of the outlet pipe (42) and across the flow direction (80), the baffle plate (70) being positioned at a distance from the upper surface (37) of the second flow region (38).

12. The water separator (100) according to any one of claims 1 to 11, wherein the second flow area (38) further includes an inner wall (72) positioned spaced apart from the side wall (35) of the second separation stage (30).

13. The water separator (100) according to claim 12, wherein the second separation stage (30) further includes a second quiescent flow region (74) formed between the inner wall (72) and the side wall (35).

14. The water separator (100) according to any one of claims 1 to 13, wherein the second separation stage (30) further includes a water recovery chamber (76) located in a part of the bottom of the second flow area (38) in the direction of gravity (84), and the water recovery chamber (76) has a water outlet (44) at the lowest point of the water recovery chamber (76).

15. The water separator (100) according to claim 14, wherein the second separation stage (30) further includes a water siphon device (78) located within the water recovery chamber (76) and connected to communicate fluidly with a first quiescent flow region (36) of the drainage chamber (143) of the separation element (50).

16. The second separation stage (30) further includes a receiving pipe (62) positioned at the inlet opening (34) of the second flow region (38), and an outlet pipe (145) positioned inside the receiving pipe (62), The separation element (60) is positioned inside the receiving pipe (62) and surrounds the outlet pipe (145) at least partially. The downstream end (28) of the outlet pipe (145) is at least partially closed. The water separator (100) according to any one of claims 1 to 15, wherein the outlet pipe (145) has a plurality of fluid passage openings (26) located opposite the separation element (60).

17. The water separator (100) according to claim 16, wherein the receiving pipe (62) is located within the second flow area (38).

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