Integrated Fuel Cell Air Filter Assembly for Multi-Stack Packaging
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Solution Overview
Problem
Multi-fuel cell vehicles require complex air intake systems with multiple air sources and filters for each fuel cell, increasing complexity and space usage under the hood.
Innovation Solution
A simplified air intake assembly with a single intake plenum, flexible seal, and multiple air boxes and ducts that correspond to the number of fuel cells, directing air from a single supply to each fuel cell with interchangeable filters and seals for compatibility with various OEM configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple separate air intake systems are used for each fuel cell, then each fuel cell receives adequate air supply, but the system complexity and space usage increase significantly
Solution Approach 1:
The patent combines multiple separate air intake systems into a single integrated air intake assembly that serves multiple fuel cells. The assembly includes a common air filter housing with multiple air filters, a single plenum chamber, and multiple output ducts that distribute air to each fuel cell. This merging approach maintains adequate air supply to each fuel cell while significantly reducing system complexity and space requirements compared to having separate intake systems for each fuel cell.
2Reliability
If multiple separate air intake systems are used for each fuel cell, then each fuel cell has dedicated air filtration, but the space available under the hood is insufficient
Solution Approach 1:
The patent merges multiple air filtration systems into a single integrated housing structure. The common air filter housing contains multiple air filters that can be arranged in a compact configuration, sharing common structural support and mounting mechanisms. This consolidation provides dedicated air filtration for each fuel cell while occupying significantly less space under the hood than multiple separate filtration systems would require.
Solution Approach 2:
The single plenum chamber serves multiple functions: it receives air from all air filters, distributes air to multiple fuel cells through output ducts, and provides a common mounting structure for the entire assembly. This multi-functional design maximizes the utility of the limited space available under the hood while maintaining proper air filtration for each fuel cell.
3Device complexity
If a single integrated air intake assembly is used for multiple fuel cells, then complexity and space usage are reduced, but air distribution to each fuel cell must be precisely controlled
Solution Approach 1:
The patent segments the air distribution system into distinct output ducts for each fuel cell, with each duct independently connected to the common plenum chamber. This segmentation allows for precise control of air distribution to each fuel cell while maintaining the benefits of the integrated assembly. The modular duct design enables easy adjustment and optimization of air flow to each fuel cell based on specific operational requirements.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design reduces complexity and saves space by using a single air intake system for multiple fuel cells, ensuring efficient air filtration and compatibility across different vehicle configurations.
Implementation Method 1
The intake assembly may further include a plurality of air filters disposed within their respective air boxes
Implementation Method 2
The flexible seal is sufficiently flexible to mate with an OEM plenum of the multi-fuel-cell vehicle
Data Source
AI summary
Systems and methods are provided for an integrated air filter assembly for a multiple fuel cell powertrain. The integrated air filter assembly can include a common inlet to pull air from a single plenum of the hood, where the intake path can be split into multiple ducts providing air flow into each respective fuel cell. Each duct can include a dedicated air filter to filter the incoming air. The assembly can also include flexible seal to adapt to the unique hood/plenum shape of different OEM plenums/intakes.