Fuel Cell Blower Geodesic Cover for Ice Bridge Prevention
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Solution Overview
Problem
In fuel cell systems of motor vehicles, existing fans face challenges in preventing ice bridge formation between the impeller and housing components, especially at low temperatures, which can lead to motor blockage and delayed startup, requiring additional components or increased assembly effort to manage water drainage.
Innovation Solution
A fan design featuring a geodetically positioned flow housing cover with an inclined impeller surface and a water reservoir that collects and directs water away from rotating parts, eliminating the need for additional components or lines, ensuring water does not contact the impeller or shaft, thus preventing ice bridge formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If water drainage is implemented using additional pipes or flushing gases, then ice bridge formation is prevented, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines the water drainage function with the existing flow housing structure by integrating a water reservoir directly into the housing cover. This merging eliminates the need for separate drainage pipes or flushing gas systems, as the housing itself serves dual purposes: conveying hydrogen and collecting water. The water reservoir is formed by the housing cover's geometry, merging structural and functional elements into a single integrated component.
Solution Approach 2:
The fan housing automatically collects and stores water that condenses during operation through its own structural design. The water reservoir, formed as an integral part of the housing cover, passively accumulates water without requiring active pumping or flushing mechanisms. The system serves itself by using the housing's own volume to contain and manage water, eliminating dependency on external drainage infrastructure.
2Volume of moving object
If the impeller is positioned closer to the housing cover to reduce size, then compactness is improved, but water accumulation on the impeller surface increases ice bridge risk
Solution Approach 1:
The patent resolves the spatial conflict by utilizing the vertical dimension between the impeller and housing cover. Instead of increasing horizontal spacing, the design creates a water reservoir in the vertical space below the impeller, formed by the housing cover's downward inclination. This allows the impeller to remain compact while the water collection function is achieved in the unused vertical volume, preventing water accumulation on the impeller surface.
Solution Approach 2:
The housing cover is designed with a predetermined downward inclination that directs water flow away from the impeller surface before water can accumulate. This preliminary geometric configuration ensures that condensing water is automatically channeled into the reservoir area, preventing ice bridge formation on the impeller. The water management function is built into the structure's geometry from the outset, requiring no additional active components.
3Loss of substance
If drainage lines are added to remove water from the housing, then water management is improved, but assembly effort and manufacturing complexity increase
Solution Approach 1:
The patent extracts the water from the hydrogen flow path and isolates it in a dedicated water reservoir formed as part of the housing cover. By separating the water collection function from the hydrogen conveyance function, the design eliminates the need for complex drainage lines that would require connections, seals, and additional assembly steps. Water is taken out of the main system flow and contained in the integrated reservoir, simplifying the overall structure.
Solution Approach 2:
The housing cover serves multiple functions simultaneously: it forms the enclosure for the fan, provides the downward inclination for water drainage, and creates the water reservoir for water storage. This multi-functionality eliminates the need for separate drainage components, reducing the number of parts and assembly operations required. The single housing cover structure performs what would traditionally require multiple specialized components.
4Loss of substance
If flushing gas is used to remove water, then water drainage is achieved, but additional gas consumption and system complexity increase
Solution Approach 1:
The patent converts the harmful effect of water condensation into a beneficial function by designing the housing cover to automatically collect and store the condensing water. Instead of viewing water as a problem requiring active removal through energy-consuming flushing gas, the design embraces water accumulation as a natural function, using the housing's own geometry to manage water passively. The condensing water is redirected into the reservoir, transforming a potential harm into a self-managed system feature.
Solution Approach 2:
The patent uses gravity-driven hydraulic principles instead of pneumatic flushing. The downward inclination of the housing cover creates a gravity-based water flow path that naturally directs condensed water into the reservoir. This passive hydraulic approach replaces active pneumatic flushing systems, eliminating gas consumption while achieving effective water management through gravitational force and geometric design.
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 allows for immediate startup of the fuel cell system without additional components or lines, ensuring the fan operates without ice bridges forming, even when the vehicle is inclined, by effectively managing water drainage and preventing contact with rotating parts.
Implementation Method 1
the inclined second impeller surface being fluidically connected to the intermediate space via at least one through opening. Thus, the water, which is located on the top of the impeller or between the impeller and the second flow housing part attached to the cover after the fuel cell system has been switched off, can flow over the inclined surface to the passage opening and from there through the passage opening to the intermediate space
Data Source
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AI summary
Blowers for conveying hydrogen in a fuel cell system of a motor vehicle are known, comprising a flow housing (10) which has a flow housing cover (16), an inlet (30) and an outlet (44) which are formed on the flow housing (10), a conveying channel (36, 38) arranged in the flow housing (10) which fluidically connects the inlet (30) with the outlet (44), an impeller (48) rotatably mounted in the flow housing (10) and a drive shaft (14) on which the impeller (48) is arranged.To prevent the blower from freezing due to ice bridge formation, it is proposed according to the invention that the flow housing cover (16) is arranged geodesically below the impeller (48) and that a cover surface (64) of the flow housing cover (16) facing the impeller (48) is formed closed, wherein an intermediate space (62) is formed between the cover surface (64) and a first impeller surface (56) facing the cover surface (64).