Hybrid Fuel Cell Burner Layout for Fast Stable Heating

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Solution Overview

Problem

Existing fuel cell burner devices face inefficiencies in heating speed and operational stability, with catalytic burners having low efficiency and flame burners requiring complex designs to prevent flame blowout, leading to high installation space and costs.

Innovation Solution

A hybrid burner device with a gas-permeable catalyst body and non-circular cross-sectional contour, combining catalytic and flame combustion, which enhances ignitability and heat output while reducing installation space and costs through parallel operation of catalytic and flame combustion.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Speed

If flame burners are used for heating up the fuel cell system, then heating speed is improved, but operational stability deteriorates due to flame blowout risk

Engineering Contradiction:
Improveheating speedVSAvoidoperational stability
Core Design Contradiction:
SpeedVSReliability

Solution Approach 1:

The patent combines flame combustion and catalytic combustion into a hybrid burner system. The flame burner provides high heating speed while the catalytic burner ensures operational stability by preventing flame blowout through catalytic reaction at lower temperatures. Both combustion modes operate in the same burner device with a common combustion chamber.

Inventive Principle:
Principle #5Merging (Combining)

Solution Approach 2:

The burner employs a hybrid combustion approach using both flame-based and catalytic-based combustion mechanisms. The catalytic coating material (such as platinum or palladium) is applied on the combustion chamber surface to enable catalytic combustion, creating a composite combustion system that leverages the advantages of both combustion types.

Inventive Principle:
Principle #40Composite materials

2Reliability

If complex design measures are implemented to protect flame from blowout, then operational stability is improved, but device complexity and installation space increase

Engineering Contradiction:
Improveflame protectionVSAvoiddesign complexity
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

Instead of adding complex protective structures to the flame burner, the patent integrates a catalytic combustion function directly into the burner's combustion chamber. The catalytic coating on the chamber surface provides inherent flame stabilization without requiring additional complex components, thereby maintaining operational stability while simplifying the overall design.

Inventive Principle:
Principle #5Merging (Combining)

3Reliability

If catalytic burners are used for heating, then operational stability is improved, but heating speed and efficiency deteriorate

Engineering Contradiction:
Improveoperational stabilityVSAvoidheating speed
Core Design Contradiction:
ReliabilityVSSpeed

Solution Approach 1:

The hybrid burner system combines the stable operation of catalytic combustion with the high heating speed of flame combustion. During startup or when high heating power is needed, the flame combustion mode dominates. During normal operation, the catalytic combustion mode ensures stable and efficient operation, thereby achieving both fast heating and operational stability.

Inventive Principle:
Principle #5Merging (Combining)

Solution Approach 2:

The burner can switch between flame combustion mode and catalytic combustion mode depending on operational requirements. During startup phase, flame combustion provides rapid heating. Once the fuel cell reaches operating temperature, the system transitions to catalytic combustion for stable and efficient operation, creating a periodic or conditional operation pattern.

Inventive Principle:
Principle #19Periodic action

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 hybrid combustion design significantly increases heat output and operational stability with reduced installation space and costs, achieving enhanced efficiency and simplified design.

Implementation Method 1

a fuel fluid flows through a catalyst body and catalytic combustion thereby takes place. This catalytic combustion generates heat

Methodology Applied
Scientific EffectCatalytic combustion: Catalysis

Implementation Method 2

burners which burn a fuel/air mixture, forming a flame, and in this way also generate heat

Methodology Applied
Scientific EffectCombustion: Combustion

Data Source

PatentUS20240097155A1Burner device for a fuel cell system
Publication Date: 2024.03.21 AVL LIST GMBH
  • US20240097155A1 patent drawing
  • US20240097155A1 patent drawing
  • US20240097155A1 patent drawing

AI summary

The present invention relates to a burner device (10) for a fuel cell system (100), having a burner housing (20) with a burner inlet (22) for admitting a fuel/air mixture (BL) and a burner outlet (24) for discharging a burner exhaust gas/air mixture (BAL), additionally having a catalyst body (30) within the burner housing (20) comprising a catalyst cavity (32) into which the burner inlet (22) opens, wherein the catalyst body (30) is gas-permeable and has a catalyst surface (34) with an at least partly catalytic coating (36), wherein a bypass volume (40) is formed between the catalyst surface (34) and the burner housing (20), said bypass volume opening into the burner outlet (24), wherein the catalyst body (30) additionally has a longitudinal axis (LA), and the catalyst surface (34) has a cross-sectional contour (QK) which deviates from a circular shape at least in some sections with respect to the longitudinal axis (LA).