Fuel Cell Stack Connection Block With Scalable Integrated Humidifier
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Solution Overview
Problem
Existing fuel cell systems require significant redesign and engineering effort for each application, necessitating standardized, off-the-shelf components that can adapt to varying fuel cell stack sizes and humidification needs.
Innovation Solution
A stack connection block with an integrated humidifier cavity that accommodates humidifiers of varying sizes, allowing reuse across different fuel cell stacks by adjusting the humidifier dimensions and incorporating additional components like sensors and valves.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a fuel cell system is designed with standardized components for multiple applications, then development costs and engineering effort are reduced, but the ability to precisely match component specifications to specific application requirements deteriorates
Solution Approach 1:
The patent implements a universal stack connection block design that can be used across multiple fuel cell applications with different power outputs. The block incorporates standardized connection interfaces and a scalable humidifier cavity that accommodates various humidifier sizes, allowing a single component design to serve multiple applications from 100W to several kW without requiring complete redesign for each application.
Solution Approach 2:
The humidifier is designed to be nested within the stack connection block, with the humidifier cavity forming an integrated part of the block structure. This nesting allows the humidifier to be securely positioned while maintaining the compact overall design, and enables different sized humidifiers to be installed within the same block depending on the specific application requirements.
2Device complexity
If the humidifier is integrated into the stack connection block, then system integration and compactness are improved, but the complexity of adapting to different fuel cell stack sizes deteriorates
Solution Approach 1:
The patent addresses adaptability to different stack sizes by allowing parameter changes in the humidifier selection and configuration. While the stack connection block itself remains standardized, the humidifier parameters (size, capacity, dimensions) can be adjusted to match the specific requirements of different fuel cell stack power outputs, enabling the same block design to accommodate various stack configurations.
3Manufacturing precision
If a single stack connection block is used for multiple fuel cell stacks, then manufacturing precision and standardization are improved, but the ability to provide precise media preparation for specific performance classes deteriorates
Solution Approach 1:
The patent applies local quality by maintaining standardized manufacturing for the stack connection block while allowing localized customization of the humidifier parameters. The block itself is produced with consistent dimensions and connection interfaces for manufacturing precision, but the humidifier selected and installed within the block can be specifically sized and configured to provide the precise media preparation required for each performance class or application.
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
Enables the use of a single stack connection block in multiple fuel cell systems, reducing development costs and enabling efficient humidification and system integration without redesign, while maintaining performance across varying stack sizes.
Implementation Method 1
a humidifier (13) integrated into the stack connection block (5), said humidifier (13) being accommodated in a cavity (25) of the stack connection block (5)
Implementation Method 2
fuel cells are usually supplied with humid air. This humidity is generated by passing the humid exhaust gas (residual air containing product water) through a membrane humidifier
Implementation Method 3
This humidity is generated by passing the humid exhaust gas (residual air containing product water) through a membrane humidifier. Water is transported across the humidifier's membrane
Data Source
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AI summary
A stack connection block (5) for a fuel cell stack (3) has a stack connection (31, 37) for a fuel, such as hydrogen, a stack connection (33, 39) for a reaction partner, such as air, and a stack connection (35, 41) for a cooling medium. All three stack connections are designed for connection to the fuel cell stack (3). The stack connection block (5) is configured for a humidifier (13) which is integrated in the interior thereof, and which is adaptable in its performance depending on a resistance and/or performance of the fuel cell stack (3) being operated. At least one feed duct (45, 47) and at least one drain duct (49, 51) are guided in the stack connection block (5) to the humidifier (13). The feed duct (47) opens out into the stack connection (33) for the reaction partner (73). The invention also relates to a corresponding fuel cell system (1) having a stack connection block (5) and to a suitable method for multiple use of a stack connection block (5).