Blower and Air Filter Assembly

Abstract

The outlet of the blower extends through a hole in the circuit board to which the blower is attached. Electronic devices on the board control the operation of the blower. The blower can be configured as two consecutive blowers to provide more accurate control of the air flow. An air filter, such as an N95 filter, is removably attached to the air inlet of the blower on the front side of the circuit board. The front side of the board can be attached to the support panel with a gap between them and with the air filter facing and in fluid communication with the gap. An air filter gasket is disposed around the perimeter of the front edge of the circuit board such that air drawn through the air filter covering the air inlet of the blower first passes through the air filter gasket between the circuit board and the support panel. The air filter gasket can have a coarser mesh than the air filter. The blower is suitable for use in a fuel cell device to supply an electronically controlled air flow to a fuel cell.

Description

[Technical Field]

[0001] The present invention relates to an assembly of a blower with an air filter and a circuit board, and more particularly to an assembly for a filtered air blower and a circuit board with electronics for controlling the blower for use in fuel processing systems such as fuel reformers, fuel cell assemblies, fuel combustors, etc., which require a well-controlled flow of filtered air or other oxygen-containing gas. As used herein, the term air will include oxygen-enriched air or air diluted with nitrogen or other oxygen. [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. In these situations, precisely controlled airflow is required to regulate the oxygen level of a chemical or electrochemical reaction to ensure proper reaction control. Gas flow valves and blower speeds often need to be electronically controlled to properly regulate the chemical reaction. Shielding the electronics from the heat generated by these mechanisms can be important. It can also be important to filter the air being delivered to the reactor.

[0003] Internal combustion engines, fuel cells, and fuel reformers generate significant amounts of heat, which can create challenges when attempting to install these systems in close proximity to individuals or within homes, offices, or other occupied structures. This can also create challenges when attempting to provide compact devices in compact housings, as parts of the system, such as electronic controls containing electronics for controlling airflow, must be thermally isolated from the exothermic reactions while still being in close proximity to them.

[0004] Fuel-consuming devices may require precise airflow to ensure that fuel oxidation 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 other balance-of-plant (BOP) components need to be protected from the heat generated by the exothermic reactions they control and / or monitor.

[0005] The construction of conventional heat-generating mechanisms, such as internal combustion engines, fuel cells, and fuel reformers, presents additional challenges that make it difficult to integrate these mechanisms into inhabited environments and / or to install these mechanisms in compact housings. The need to protect electronics and other components from the heat generated by the device can complicate efforts to construct a compact apparatus when too much space is taken up by physically separating the components and electronics from the heat-generating elements.

[0006] Air blowers can be useful for supplying 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. Additionally, these filters can be inconvenient to replace, and some are insufficient to protect the internal electronics from dust, moisture, impurity droplets, and the like. Many fuel cell assemblies and reformers utilize ambient air as an oxygen source for the electrical and chemical reactions occurring therein and for temperature control within the unit. Ambient air often contains particulate matter (e.g., dirt / dust), contaminants (e.g., sulfur, hydrocarbons), and / or moisture, which can damage fuel cell and reformer units, respectively. Unfortunately, existing filtration systems have proven inadequate for use with these systems.

[0007] 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]

[0008] [Patent Document 1] U.S. Patent No. 9,017,893 [Patent Document 2] U.S. Patent 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

[0009] Generally speaking, in accordance with the present invention, an apparatus has at least two zones, each thermally isolated from the other. Using a flow of ambient air from an air intake of the apparatus, the zones can be maintained at different temperatures, such as one or more cold zones and one or more hot zones at temperatures above the temperature of the cold zones. Preferably, the cold zones are suitable for electronic components. In one embodiment of the present invention, the air flow passes around the exterior of an exothermic reactor or other heat-generating device to thermally isolate the exterior surface of the outer apparatus housing from the heat-generating device contained therein. In another embodiment of the present invention, the air flow from the air intake is used to cool the temperature of one, two, or more cold zones of the apparatus so that heat-sensitive components, such as electronic equipment, are not damaged by the heat generated by the heat-generating device.

[0010] In one embodiment of the present invention, the device includes a heat-generating mechanism, such as a fuel combustor, a fuel reformer, a fuel cell, or a fuel cell stack. A fuel cell system according to the present invention can include a fuel reformer integrated with an electricity generating unit integrated into a single fuel cell structure. The airflow from the air intake can be used as an oxygen source for the heat-generating mechanism. This airflow can be used to help keep areas thermally cool from the heat of the heat-generating mechanism, even in close proximity to the heat-generating mechanism. For example, a flow of ambient air can be blown or drawn over various components of the device, such as electronic components, to keep these components cool. The intake airflow can also thermally insulate the exterior surfaces of the device from heat generated internally. This can be accomplished by drawing the intake air around the outside of the heat-generating elements. This airflow can be blown or drawn over any electronics or other components that need to be kept cool. This air can then flow into the device and serve as an oxygen source for any chemical reactions therein.

[0011] In a preferred embodiment of the present invention, the heat-generating mechanism can be housed within a double-walled enclosure of a housing for the entire device. The interior space between the outer and inner walls of the housing can act as an intake conduit, functioning as a barrel-within-a-barrel structure. An array of fins can extend across the gap between the outer and inner walls, transforming 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 cold compartments or subcompartments of the device and then routed to the heat-generating compartment of the mechanism as a source of air and / or oxygen. Hot exhaust air and any excess intake air not required for the exothermic reaction can be routed directly outside the housing and piped to a convenient exhaust location. Thus, if the air intake is at the rear end of the device, cold ambient air can be drawn throughout and around the top, bottom, and / or sides of the device, including the cold open space inside the device. At least a portion of the intake air can then be routed to the hot compartment where it generates heat, and the exhaust air can be discharged from the rear end. The intake and exhaust can be side-by-side or concentric, for example, the intake can surround the exhaust.

[0012] In one embodiment of the present invention, the housing for the device has a double-walled structure, with both the inlet and outlet located at the rear end. The heat-generating mechanism is mounted on a platform that can slide in and out of the front end of the housing. A blower can be located at the front end. The blower can draw cooling air into the rear end of the housing, through an air passage in the double wall, around the length of the device, and into an internal cold zone at the front of the housing. The internal zone at the front end of the housing can serve as a cold zone in which at least some of the electronics and other elements that need to be kept cool can be mounted. After passing around the exterior of the heat-generating device and through the cold zone, at least a portion of the intake airflow can be received by the heat-generating mechanism, while the hot exhaust air and excess intake air not needed by the heat-generating device can be exhausted to the outside of the device.

[0013] According to the present invention, there is provided a blower apparatus comprising a blower unit having a blower casing with an axial inlet and a radial outlet. An impeller is disposed within the casing for drawing a gaseous medium (e.g., air) into the axial inlet at a first pressure and discharging the gaseous medium through the radial outlet at a second, higher pressure. 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 may be mounted within the casing and positioned 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.

[0014] It may be advantageous to filter the incoming air to filter out particulate matter, volatile compounds, sulfur compounds, hydrocarbons, impurities, etc. from the environment and / or reduce moisture before the air enters the blower intake. A check valve prevents zero-flow conditions from causing backflow or other processing air from the fan. The filter may be some type of reticulated foam (low pressure drop) and may be doped with specific materials to perform the tasks listed above. In preferred embodiments of the present invention, the filter meets N95 certification standards. In preferred embodiments of the present invention, standard off-the-shelf N95 respirator filters may be employed, eliminating the need for custom manufacturing. In other embodiments, custom N95-compatible filters are used. The filter may have two layers and may be designed to keep the inner surfaces of the two layers spaced apart to increase the filter surface area and therefore the filtered airflow. The check valve may be a soft elastomer that opens with little pressure drop and closes and seals using the material's slight inherent stiffness and spring constant.

[0015] 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.

[0016] Fuel cell and blower assemblies and fuel reformer and blower assemblies 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.

[0017] A centrifugal blower according to the present invention may comprise a blower unit having a blower casing with an axial inlet and a radial outlet. An impeller is disposed within the casing for drawing in a gaseous medium at a first pressure into the axial inlet and discharging the gaseous medium at a second, higher pressure through the radial outlet. A motor is disposed within the housing for driving the impeller. The blower intake assembly comprises an intake casing having an air inlet and an air outlet. The air outlet is coupled to the axial inlet of the blower casing of the blower unit. Advantageously, a check valve is mounted within the casing and positioned to permit air flow from the air inlet to the air outlet and to prevent air flow from the air outlet to the air inlet.

[0018] A preferred blower system includes a series of blower units, each of which includes a blower unit casing having an axial inlet and a radial outlet, an impeller, and a motor for driving the impeller. A duct connects the radial outlet of a first blower unit in the series with the axial inlet of at least a second blower unit. An intake assembly of the blower assembly includes an intake assembly casing having an air inlet and an air outlet. The air outlet is connectable to the axial inlet of the blower unit casing of a first blower unit in the series. A check valve is mounted within the intake assembly casing and should be adapted and arranged to allow air flow from the air inlet to the outlet but prevent air flow from the air outlet to the air inlet.

[0019] The intake assembly for the centrifugal blower system herein offers several advantages over single-stage blowers. The blower includes a filter for the incoming air prior to the check valve to filter, for example, particulate matter, volatile compounds, sulfur compounds, and other impurities that may be present in the ambient air. The filter may also include a desiccant to reduce moisture.

[0020] The check valve of the present invention can prevent a zero-flow condition from allowing backflow of air pushed close to the blower from the intake fan and other air processes. High-temperature backflow can damage solid oxide fuel cells (SOFCs) and catalysts through oxidation. The present invention can prevent this from occurring.

[0021] By utilizing the multiple blower system of the present invention to meet the airflow requirements of a fuel cell or other heat-generating device, the system can benefit from both a low-inertia impeller for control and low drive motor rpm and power consumption to provide the necessary airflow and pressure. Therefore, because this integrated / interconnected arrangement of multiple centrifugal blowers inherently has lower inertia than a single, larger centrifugal blower of comparable airflow capacity, the centrifugal blower system herein provides improved response time and control over a wide range of gas pressure and airflow requirements compared to a single centrifugal blower unit. Fuel cell and blower assemblies featuring this arrangement of multiple centrifugal blowers are described, for example, in U.S. Patent Nos. 9,017,893, 9,593,686, and 9,512,846, the entire contents of each of which are incorporated herein by reference. Additional fuel cell and blower assemblies featuring this arrangement of multiple centrifugal blowers 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 entire contents of each of which are incorporated herein by reference.

[0022] It may be particularly advantageous to filter air entering a fuel-consuming device such as a fuel reformer or fuel cell. In a preferred embodiment of the present invention, an air blower is in fluid communication with intake air. The blower includes a housing having an axial intake and a radial outlet. The intake can include a mounting mechanism, and a filter having a mounting portion designed to mate and engage with the mounting mechanism on the housing can provide a removable mounting mechanism for placing the filter over the air intake of the blower.

[0023] A filter according to the present invention can advantageously meet N95 standards. To improve surface area, and therefore filtration and airflow, the filter should be a two-layer filter with an internal structure that keeps the layers apart, making the entire outer surface available for air filtration.

[0024] The flow control electronics preferably measures the resistance of airflow through the blower to determine if the filter needs to be changed. In a preferred embodiment of the invention, the filter can be screwed on and off the blower intake for convenient replacement and a secure, tightly sealed installation.

[0025] In a preferred embodiment of the present invention, the blower (including a dual impeller blower) is mounted on the same circuit board that controls the operation of the blower. For example, the circuit board may have a hole, i.e., a nominal outside diameter, for the air intake. The blower may be mounted on the front side of the circuit board, and the intake may extend through the hole to the rear side of the board. The front side may have most or all of the circuitry and chips. A filter may be mounted on the intake on the rear side, e.g., the top side, of the board.

[0026] The rear (bottom) side of the board, along with the exposed filter, can be mounted on a support panel in a cold compartment of the device or in a hot subcompartment where the temperature is low enough for the control electronics. A gasket, such as a gasket made of air filter material, can be sandwiched between the outer edge of the rear side of the circuit board and the support panel to provide airflow separation between the board and the panel. When the blower operates, it draws air into the gap between the circuit board and the support panel, through the air filter gasket, through the filter, and then over the heat-generating device, helping to keep the board cool. The filter gasket can trap impurities and help prevent the blower's filter from clogging.

[0027] By adjusting the dimensions of the double-walled air conduit and / or the clearance around the circuit board on which the intake blower is mounted, airflow through the intake conduit of the outer housing and over the circuit board attached to the blower can be high velocity, providing a highly efficient cooling system and isolating heat-generating elements from outside the device and / or heat-sensitive components in the cold zone(s). Thus, the device can be installed in close proximity to individuals near the device, while protecting the internal electronics. Additionally, the device can be relatively compact. Any electronics or other elements for the device can be kept cool in the cold zone without significant physical separation.

[0028] A fuel cell system according to the present invention can be connected to power a home, recreational vehicle (R / V), or other dwelling. The overall dimensions can be relatively small, 6-24 inches by 6-24 inches by 12-36 inches, with a total length preferably less than 4 feet, and similarly preferably 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.

[0029] The fuel cell, blower, circuit board, and filter can all be mounted on a platform that can be slid out of the housing, allowing the internal components on the platform to slide out for service while still maintaining electrical connections to the home or other facility.

[0030] Other advantages and objects of the present invention will become apparent from the following drawings and description. [Brief explanation of the drawings]

[0031] 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 proportions may be used within the spirit and scope of the invention. [Figure 1] 1 is a schematic side cross-sectional view of a heat generating device according to a preferred embodiment of the present invention; [Figure 2] 1 is a cross-sectional side view of an integrated fuel reformer and fuel cell device according to a preferred embodiment of the present invention; [Figure 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 disassembled. [Figure 5] FIG. 4 is a partial perspective top view of a housing for the air blower and filter assembly of FIG. 3; [Figure 6] FIG. 6 is a top view of the housing part of FIG. 5. [Figure 7] FIG. 6 is a side view of the housing portion of FIG. 5. [Figure 8] FIG. 6 is a bottom perspective view of the filter of FIG. 5. [Figure 9] FIG. 9 is a bottom view of the filter of FIG. 8. [Figure 10] FIG. 9 is a side view of the filter of FIG. 8. [Figure 11] FIG. 1 is a bottom perspective view of a circuit board, filter, and air blower assembly according to a preferred embodiment of the present invention. [Figure 12] FIG. 12 is an exploded perspective view of the assembly of FIG. [Figure 13] FIG. 12 is a partially exploded perspective top view of the assembly of FIG. 11. [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. 13. DETAILED DESCRIPTION OF THE INVENTION

[0032] 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 particular 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.

[0033] Also, as used in this specification, including the appended claims, the singular forms "a," "an," and "the" include plurals, and references to specific numerical values ​​include at least that particular value 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.

[0034] The present invention relates to a heat-generating mechanism. Examples include catalytic fuel oxidizers or reformers, fuel cell systems, fuel consumption devices, fuel processors, or other heat-generating devices. The terms heat-generating mechanism, heat-generating device, or heat-generating device can encompass any heat-generating device based on any type of fuel, including those described in U.S. Patent No. 17,267,095, filed February 9, 2021, and U.S. Patent Nos. 9,627,700 and 9,627,701, the contents of which are incorporated herein by reference. Heat-generating and / or heat-generating devices include generators, fuel reformers, internal combustion engines, 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 shall include an integrated device that reforms fuel and generates electricity in the integrated device.

[0035] 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. Individual fuel cells may be combined into stacks, and balance-of-plant (BOP) components may include various systems and structures for generating electrical power, including fuel reformers, chemical reactors, gaskets, pumps, sensors, vaporizers, heat exchangers, fuel lines, blowers, switches, relays, thermistors, thermocouplers, conduits, control electronics, etc.

[0036] Examples of heat-generating devices according to the present invention include those described in U.S. Patent Nos. 9,627,700 and 9,627,701, the entire contents of which are incorporated herein by reference. A fuel reformer according to the present invention can be configured to supply a reformed fuel, such as a hydrogen-rich reformed fuel, to a fuel cell stack. The fuel cell stack may operate at relatively high temperatures to maximize power generation. Therefore, a sufficient amount of airflow may be required for the fuel cell stack 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 to control the intensity of the chemical reaction. Additionally, other electronic components in the fuel cell system may act as heat-generating sources that must be cooled for proper operation.

[0037] Thus, there may be various thermal zones and thermal sub-zones within those thermal zones that need to be maintained at different temperatures depending on the type and function of the individual components therein.

[0038] As used herein, the terms hot zone or 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. Furthermore, the hot zone(s) and cold zone(s) may include various sub-zones of different relative temperatures.

[0039] 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 installed 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. The high-temperature (high-temperature) heat zone contains a heat-generating device, such as a fuel reformer, a fuel cell, or an internal combustion engine. The two zones may be separated by an insulating wall. A main air blower may be installed at the interface between the two zones. The main air blower may draw ambient air into the low-temperature zone, maintaining a low temperature in the low-temperature zone with a constant flow of ambient air. The blower may then blow this air directly or indirectly into the high-temperature zone as needed for the proper operation of the exothermic reaction therein. For example, a sub-zone may be installed between the main blower and the high-temperature zone, and air for the heat-generating device may be drawn from the sub-zone.

[0040] 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, hot spots from accumulated particulate matter, or rapid cooling, among other things, which may cause structural failure in the components.

[0041] The components of the fuel cell assembly are designed to maintain their mechanical, chemical, and / or electrical integrity during start-up and normal operating modes, which expose them to high operating temperatures. Problems can arise during cool-down periods, such as during transitions to low-power modes or shutdown procedures. For example, as the system cools down, air inside the fuel cell assembly can condense, creating a vacuum that can continue to draw outside air into the fuel cell assembly through the air inlet and / or exhaust. Exposing the fuel cell assembly to this additional outside air can result in oxidation or damage to the structural integrity of the fuel cell stack. The check valves and filters described herein can help prevent these problems.

[0042] The apparatus according to the present 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 and an air intake conduit between them. The inner and outer layers of the double wall may be separated by a plurality of fins running the length of the wall to create a tubular structure with multiple air passages along the length of the double wall, enhancing airflow efficiency.

[0043] An ambient air inlet can be present at the rear end of the housing, and an air blower can be present inside the front end of the housing. Thus, air can be drawn into the inlet, flow through the housing, and flow 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 passage into the open front end of the housing. As a result, the cool zone can be isolated from the hot zone by the air flow 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.

[0044] 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 airflow control sections. These blowers control the precise flow of air to the fuel cell components. These blowers can be installed in flow control sections that are kept cool by the flow of ambient air inside. Any excess air blown into the flow control sections can be exhausted through an exhaust port of the device.

[0045] In one embodiment of the present invention, the BOP component can include a flow switch unit configured to regulate the speed of the blowers and shut them off when the airflow does not meet a preset requirement. The airflow can be measured by the flow switch unit. When the amount of airflow meets the preset requirement, the airflow in one or more of the blowers can 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 differential pressure switch. Blowers, preferably dual blowers that can be electronically controlled to operate at different speeds, can be employed to adjust the airflow as needed. These flow control blowers in the BOP component can be mounted in a cool flow control area, and the airflow to the flow control area keeps the area cool to help protect any electronic components in the flow control system.

[0046] The housing for the device may include a thermal isolation wall formed of insulating material to separate the hot and cold zones and subzones. Further, the cold zone(s) or hot zone(s) may be divided into different subzones maintained at different temperatures.

[0047] 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 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.

[0048] In one embodiment of the present invention, the air inlet port can be located at the front end of the housing and configured to draw ambient air into the cold zone. The hot zone can include a hot zone exhaust port for exhausting hot gases produced by an exothermic reaction therein. The hot zone exhaust port can also be located at the front of the housing. The exhaust port and the inlet can be concentric. In one embodiment of the present invention, the exhaust port is surrounded by the air inlet port. The exhaust port and the inlet can also be aligned at the rear of the device.

[0049] In operation, the main blower can draw air from the inlet into the open interior space at the rear end defined by the housing, through air conduits in the housing wall around the exterior of the housing, and into the interior space at the open front end of the housing. The blower can then blow air into a high-temperature zone or into a high-temperature or low-temperature subzone, such as a flow-controlled zone with an electronically controlled blower system for delivering electronically controlled amounts of air to an oxygen-consuming, heat-generating device, such as a fuel cell device, a fuel reformer, a fuel processor, or a fuel-combustion device. The blower can also blow intake air into a low-temperature zone for flow control to control the precise airflow to the fuel-consuming / combustion / reforming device. The high-temperature exhaust exits through an outlet port in the high-temperature zone. Electronic components can be located in the low-temperature zone, and heat-generating components can be located in the high-temperature zone of the device, with the low-temperature zone upstream from the high-temperature zone(s) and in fluid communication with the ambient intake air inlet. The high-temperature zone can be downstream from the air blower and in fluid communication with the outlet port. In one embodiment of the present invention, the hot zone may be completely surrounded at the front, sides, and / or rear by at least one of the cold zones, except for the exhaust port.

[0050] One preferred embodiment of a heat-generating fuel-consuming device constructed in accordance with the present invention is generally shown in FIG. 1 as fuel cell 100. Fuel cell 100 includes a rear end 110, a central section 150, and a front end at front end cap 180. 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 central section 150 is located at the rear end 110 of reformer 100. The central section front portion 150f of central section 150 is located at the front cap 180 of reformer 100. The reformer rear end 110 includes an inlet 111 concentric with an outlet 112 formed through rear cap 113. Central section 150 includes a housing cover 160 around fuel cell 171, which is mounted within a high temperature zone 170 that is maintained at a high temperature from the heat generated by the heat-generating fuel cell 171. The fuel cell 171 includes at its anode end an arrangement of fuel reforming reactors that produce a hydrogen-rich reformate, and at its cathode end, where electricity is generated from the reformate, 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 can be removably secured to the front of the central section 150f with bolts.

[0051] 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.

[0052] Housing cover 160 is formed by an outer wall 161 and an inner wall 162. An intake airflow housing conduit 165 is formed between outer wall 161 and inner wall 162. An array of fins 166 extends from the inner surface of outer wall 161 into housing conduit 165 and extends to inner wall 162, forming an array of cylindrical conduits along the inner surface of outer wall 161.

[0053] The inner wall 162 is shorter than the outer wall 161. Therefore, 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. Because the inner wall 162 of the central section 150 is shorter than the outer wall 161 and the fins 166, the internal 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. Therefore, the internal conduit 165 is also accessible at the front end 150f. As a result, internal spaces are formed within the rear cap 113 and the front cap 180. The housing conduit 165 is in fluid communication with these internal spaces.

[0054] Air inlet 111 is in fluid communication with the interior defined by rear cap 113 / front end 110. However, outlet 112 is sealed from the interior of rear cap 113. Thus, all air entering inlet 111 enters the interior of rear cap 113, which is in fluid communication with housing conduit 165 at rear end 150r of central section 150. Housing conduit 165 is in fluid communication with front interior 182 enclosed by front cap 180 at front end 150f of central section 150. An inlet end 173 of blower 172 is in fluid communication with interior 182 of front cap 180. A radial outlet 174 of blower 172 is in fluid communication with fuel cell 171. Thus, when blower 172 is operating, blower 172 draws air into inlet 111 in the direction of arrow A, along housing conduit 165 in the direction of arrow B, and then into front interior 182 in the direction of arrow C. Mounted within the front interior 182 is an electronics assembly 183. Thus, intake air is blown upstream of the fuel cell 171 and over the electronics 183 before entering the fuel cell 171, keeping the electronics 183 cool in the electronics cold zone.

[0055] Intake air flows along the outside of fuel cell 100 and into interior 182 of front end cap 180, creating a cold zone outside fuel cell 100 and front interior 182. Thus, there may be an outer surface of fuel cell 100 and front interior 182 containing electronics 183 and other elements that need to be kept cool. An insulated wall 167 is provided at the rear end of electronics cold zone 182. A blower 172 is attached to insulated wall 167. Wall 167 and blower 172, along with the intake air flowing through conduit 165, together help isolate heat-generating parts of fuel cell 100.

[0056] Blower 172 directs intake air into flow control area 200 in the direction of arrow D. At least a portion of the air from flow control area 200 flows into high temperature area 170, and a portion is 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's exothermic process then exits fuel cell 100 through exhaust port 112 in the direction of arrow F. Exhaust port 112 may be elongated to transport the hot exhaust to a suitable chimney, stack, or other structure. However, because exhaust port 112 is concentric within intake 111, the intake air helps isolate this heat.

[0057] The cold flow control section 200 is in fluid communication with 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.

[0058] A combined fuel cell device, combining a fuel reformer and a fuel cell stack, is generally shown in FIG. 2 as heat-generating device 201. A flow of intake air 216 at ambient temperature enters device 201 through 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 and is defined by a removable front cap 280. Front cap 280 is secured to conduit 265 with bolts. An assembly of electronics 283 is mounted in rear recess 282. The intake air 216 is directed to blow over the rear end of electronics 283, past the front of electronics 283, or both.

[0059] The device 201 includes an integrated fuel reformer and fuel cell 271. The fuel reformer section receives a flow of fuel from a fuel line and a flow of air from a reformer intake hose 276. The fuel cell section, which generates electricity from the reformed fuel, receives a flow of air 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 below a high temperature section 270 that houses the fuel cell 271. The high temperature section 270 can be surrounded by an insulated wall.

[0060] Flow control area 202 is in fluid communication with ambient intake air 216. Thus, flow control air flow 217 flows from blower 272 into flow control area 202, keeping it a relatively cool area within heat generation device 201. Air supply 217, as controlled by flow control electronics 290, provides intake air to fuel cell 271. Excess air blown into flow control area 202 flows into hot area 270 and around fuel cell 271. This air helps cool the outside of fuel cell 271 and hot area 270 so that they do not become too hot.

[0061] 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 intake 310 and a radial outlet 320. In Figure 3, a filter 400 is shown attached to the intake 310. In Figure 4, the filter 400 is shown removed from the intake 310. The filter 400 mates with the intake 310 in the direction of arrow A. Thus, all air supplied to the fuel cell 271 can be filtered. A suitable filter meets the requirements for N95 certification.

[0062] 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.

[0063] The inlet 310 is configured to removably secure the filter 400 thereto. 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 317, and a hook portion 318 extending radially from the transition 317. Each prong 315 is offset toward the center of the inlet 310 at a ledge 319. The offset of the prongs 315 toward the center of the inlet 310 allows the inlet 310 to provide a continuous circular base 314 for an effective seal with the filter 400.

[0064] 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 engaging lip 411 that fits snugly inside the inner surface of base 314 to help seal filter 400 to air inlet 310.

[0065] 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 attach the filter 400 to the blower 300, the mounting portion 410 is pressed upward in the direction of arrow A (FIG. 4) against 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 upper surfaces 420 of the cam ribs 418 are sloped. The left end of each cam rib 418 is located farther from the surface of the engagement ledge 414 within the filter 400 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 abut against the thin / low downward facing surfaces of cam ribs 418. Further rotation of filter 400 brings the downward facing surfaces of underside 420 into tighter engagement with the upward facing surfaces of hooks 318, tightening the engagement between engagement ledges 414 of filter 400 and base 314 of inlet 310, effectively sealing filter 400 with inlet 310 of blower 300.

[0066] Filter 400 can be formed of any suitable filter material. Filter 400 is preferably a two-layer filter with spaces between the layers to increase surface area and therefore filter surface for filtering airflow into inlet 310. Filter 400 preferably complies with N95 certification standards. 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.

[0067] The flow control electronics 290 includes sensors for measuring airflow. These sensors may detect whether the filter 400 is too clogged for adequate airflow and / or proper filtration. If so, the electronics 290 may activate a warning signal, such as a flashing light and / or an audible signal. At this time, the heat generating device 201 may be shut off and the filter 400 may be replaced. This may be done by rotating the filter 400 in the reverse direction and sliding the hook 318 toward the slot 415, which allows the filter 400 to be removed from the inlet 310 in the direction opposite arrow A.

[0068] The mounting of blower 300 on 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, which supplies filtered air to fuel cell 271 as controlled by flow control circuitry 290.

[0069] Referring to Figures 12 and 13, blower assembly 300 and control circuitry 290 are mounted on circuit board 375. PCB 375 is mounted within flow control area 202 of heat-generating device 201 using BOP support panel 380. Figure 11 shows a bottom perspective view of PCB 375 mounted on support panel 380, and Figure 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. Air flows through filter gasket 385 in the direction of arrow X. Filter gasket 385 allows airflow in the direction of arrow X to reach filter 400. If filter 385 is coarser than filter 400, it will prevent filter 400 from clogging with larger particles than those that can be filtered by filter gasket 385.

[0070] 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, blocking larger particles and preventing them from reaching and clogging filter 400, helping to extend the life of filter 400. After passing through filter 385, air flows between panel 380 and substrate 375. The narrow dimensions allow for high flow velocities, which helps keep substrate 375 cool. After passing between substrate 375 and panel 380, air is drawn through filter 400. The gap between substrate 375 and panel 380 can be 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 blower 300, the air is directed through outlet 320 and ultimately to fuel cell 271. Note that certain embodiments of the present invention do not require the use of an N95 certified filter. 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.

[0071] 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 it is not intended that the particular steps of the method or procedure claims below be construed as being in a specific order unless such a specific order is expressly recited in the claims.

[0072] 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 circuit board having a front side, a rear side, and a hole extending through the front side and the rear side; a blower unit mounted on the front side of the circuit board, the blower unit having an axial inlet and a radial outlet, the inlet extending through the hole to the rear side of the circuit board; a filter attached to the inlet at the rear side of the circuit board; the circuit board is mounted to a support panel with the rear side of the circuit board facing and parallel to the support panel, and a gasket is disposed around an outer edge of the circuit board between the circuit board and the support panel, the gasket being made of a filter material and adapted to allow airflow through the gasket to the filter attached to the intake.

2. 2. The blower assembly of claim 1, wherein the circuit board is a printed circuit board.

3. 3. A blower assembly as claimed in claim 1 or 2, wherein the filter mounted on the axial intake is an air filter.

4. 3. The blower assembly of claim 1, wherein a filter attached to the axial intake meets N95 certified filter standards.

5. 3. The blower assembly of claim 1, wherein the axial inlet and radial outlet are part of a blower casing, the blower unit comprising a centrifugal blower having an impeller disposed within the casing, the impeller and the casing configured and adapted to draw a gaseous medium into the axial inlet at a first pressure and discharge the gaseous medium out of the radial outlet at a second, higher pressure, and a motor mounted within the casing, the motor configured and adapted to drive the impeller.

6. 6. The blower assembly of claim 5, further comprising a check valve mounted within said casing positioned and adapted to permit airflow from said axial inlet to said radial outlet and to prevent airflow from said radial outlet to said axial inlet.

7. 7. The blower assembly of claim 6, wherein the check valve comprises a flexible diaphragm mounted in an axial inlet of the blower casing.

8. the blower unit comprises a series of blowers, each blower in the series comprising: a blower casing having an axial inlet and a radial outlet; an impeller disposed within the casing for drawing a gaseous medium into the axial inlet at a first pressure and discharging the gaseous medium from the radial outlet at a second, higher pressure; and a motor for driving the impeller; 3. A blower assembly as claimed in claim 1 or 2, wherein each blower casing comprises a duct connecting the radial outlet of at least a first blower in the series with the axial inlet of a second blower in the series.

9. 3. The blower assembly of claim 1, further comprising: a second blower unit mounted on the front side of the circuit board; a second air intake of the second blower unit extending to the rear side of the circuit board through a second hole extending through the circuit board; and a second filter mounted on the second air intake of the second blower unit on the rear side of the circuit board.

10. 3. The blower assembly of claim 1, wherein the gasket is a primary filter adapted to be a coarser filter than the filter mounted in the axial intake, whereby particles too small to be captured by the primary filter are captured by the filter mounted in the axial intake.

11. 3. The blower assembly of claim 1 or 2, wherein the radial outlet of the blower unit is coupled to and mounted within a fuel cell device for providing air to the fuel cell device.

12. 10. The blower assembly of claim 9, wherein the radial outlet of the blower unit is coupled to an anode of a fuel cell device and the radial outlet of the second blower unit is coupled to a cathode of the fuel cell device.

13. A blower assembly adapted to supply air to a fuel cell device, as described in claim 1 or 2, wherein the circuit board contains an electronic controller that controls the speed of air flowing from the one or more blower units to the fuel cell device.

14. 3. The blower assembly of claim 1, wherein the one or more blower units are mounted in a flow control chamber, into which ambient air is blown from a main fan, and the one or more blower units draw the air from the flow control chamber and blow the air into a fuel cell device.

15. The blower assembly of claim 14, wherein the support panel is attached to the flow control chamber.

16. 1. A method of operating a fuel cell, comprising: drawing ambient air into a flow control chamber; air is drawn from the flow control chamber through an air filter gasket as a primary filter disposed between an assembly of a support panel and a circuit board attached to the support panel with the air filter gasket sandwiched therebetween, to one or more blowers within the flow control chamber, the one or more blowers being attached to the assembly of the support panel and the circuit board; The air that has passed through the air filter gasket is passed through an air filter on the intake of the one or more blowers positioned between the circuit board and the support panel, and the filtered air that has passed through the air filter gasket and air filter is blown into the intake of the fuel cell.

17. 17. The method of claim 16, comprising electronically controlling operation of the one or more blowers with electronics on the circuit board.

18. 18. The method of claim 17, wherein the fuel cell generates heat relative to the circuit board, and the circuit board is cooled by the flow of ambient air in the flow control chamber.

19. A device having a heat generating mechanism that generates heat, a housing having an outer surface and an inner surface defining a housing interior, the housing having a front and a rear and a length from said front to said rear; the heat generating mechanism having a top, a bottom, a front, a rear, and sides, mounted within a high temperature zone within the housing; an air intake conduit in fluid communication with a source of ambient air at an air inlet of the housing, the air intake conduit in fluid communication with a cold zone within the housing, the cold zone being at a temperature below that of the hot zone; an air blower having an axial inlet and a radial outlet mounted to a front side of a circuit board mounted in the cold zone with the axial inlet extending through an aperture in the circuit board to a rear side of the circuit board; an air filter covering the axial intake at the rear side of the circuit board; the axial intake in fluid communication with the intake conduit; the heat generating mechanism having an air intake in fluid communication with a radial outlet of the air blower; the circuit board having a flow control electronics assembly adapted to control operation of the air blower to control the flow of air to the heat generating mechanism; a primary filter disposed on the circuit board upstream from the air filter, whereby air is first drawn through the primary filter before reaching the air filter covering the axial intake, the primary filter being coarser than the air filter.

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