Fuel Cell Condensate Heating Using Residual Power
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
In fuel cell systems, particularly in industrial vehicles, condensate accumulation poses a risk of water accumulation on surrounding floors due to the lack of drainage facilities, leading to potential accidents when the vehicle is parked or stopped indoors, and existing solutions do not effectively manage condensate discharge efficiently.
Innovation Solution
An apparatus and method that utilize a first heater for the fuel cell stack's coolant and a second PTC heater for condensate, controlled by a controller using residual power from hydrogen and oxygen reactions, to dry and manage condensate, with operation modes adjusted based on temperature and battery state of charge to ensure efficient condensate discharge.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If condensate is discharged to outside using gravity drainage, then discharge simplicity is improved, but water accumulation risk increases in indoor parking spaces
Solution Approach 1:
The patent converts the harmful effect of condensate (water accumulation risk) into a beneficial drying function. The heater unit heats the condensate in the water trap to evaporate and dry the water, transforming the problematic liquid condensate into harmless vapor that can be safely discharged, thereby eliminating the water accumulation hazard while maintaining simple discharge operation
2Reliability
If heater is operated continuously to dry condensate, then condensate drying effectiveness is improved, but power consumption increases
Solution Approach 1:
The patent implements periodic heating cycles instead of continuous operation. The controller activates the heater in periodic intervals to provide sufficient heat for condensate evaporation, then shuts it off. This periodic action achieves effective condensate drying while significantly reducing overall power consumption compared to continuous heating
Solution Approach 2:
The system uses residual heat from the fuel cell stack to assist in condensate drying. The fuel cell's operational heat, which would otherwise be wasted, is utilized to warm the condensate, reducing the additional energy required from the heater and thereby lowering total power consumption while maintaining drying effectiveness
3Productivity
If water trap capacity is increased to reduce discharge frequency, then discharge operation frequency is reduced, but device volume increases
Solution Approach 1:
The patent replaces the purely mechanical gravity-based discharge system with a thermal processing system. By heating the condensate to evaporate and dry it in place, the system eliminates the need for large-capacity water traps designed to accommodate frequent discharge operations. The thermal drying process allows for smaller water trap volume while maintaining reduced discharge frequency
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
The solution effectively dries and discharges condensate, enhancing output stability and fuel cell life, improving driving stability by ensuring stable hydrogen supply and reducing the risk of water accumulation, while also managing battery state to prevent insulation breakdown and reduce unnecessary control power usage.
Implementation Method 1
a first heater for applying heat to a coolant of a fuel cell stack
Implementation Method 2
a second heater for applying heat to condensate produced in the fuel cell stack
Implementation Method 3
second heater for applying heat to condensate produced in the fuel cell stack
Implementation Method 4
the residual power includes power generated by residual hydrogen and oxygen, which are remained in the fuel cell stack, reacting with each other
Implementation Method 5
a portion of water flows from the air electrode back to a hydrogen electrode due to a back-diffusion phenomenon
Data Source
Figure 1
Figure 2
Figure 3
AI summary
Disclosed is an apparatus for managing condensate of a fuel cell. The apparatus includes a first heater for applying heat to coolant of a fuel cell stack, a second heater for applying heat to the condensate produced in the fuel cell stack, and a controller that controls an operation of the second heater using residual power based on whether at least some of functions of the first heater are activated.