Integrated Manifold Body for Backup Fuel Cell Generator
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Solution Overview
Problem
Existing fuel cell electric generators for backup power are bulky, costly, and require complex humidity and thermal control, leading to increased assembly time and maintenance complexity, with potential reliability issues due to uncontrolled coolant pressure and humidity fluctuations.
Innovation Solution
A fuel cell electric generator design featuring a manifold body with integrated coolant fluid expansion chambers and pressure reducing means, which improves thermal integration and reduces bulkiness by maintaining coolant fluid pressure below a safe value, while also optimizing reagent flow humidification and reducing the need for external humidification and cooling systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a plurality of fuel cells are piled into a stack with separate hydraulic circuits for coolant and reagents, then the fuel cell generator can achieve proper cooling and reagent supply, but the overall size, weight, and assembly complexity increase significantly
Solution Approach 1:
The patent combines the coolant hydraulic circuit and reagent hydraulic circuit into a single integrated manifold body. The manifold body contains both coolant channels and reagent distribution channels, allowing both functions to be performed by one component rather than separate circuits, thereby reducing overall system size and weight while maintaining proper cooling and reagent supply to all fuel cells in the stack
Solution Approach 2:
The manifold body serves multiple functions simultaneously: it acts as a coolant distribution system, a reagent distribution system, and a structural support element for the fuel cell stack. This multi-functionality eliminates the need for separate dedicated circuits for each function, reducing the number of components and overall system weight
2Reliability
If separate hydraulic circuits with pumps and piping are used for coolant and reagents, then proper fluid management is achieved, but the device complexity and assembly time increase
Solution Approach 1:
The patent merges the coolant circuit and reagent circuit into a single manifold body structure. The manifold body contains internally separated channels for coolant flow and reagent flow, eliminating the need for separate external piping systems and reducing the number of connections and components required
Solution Approach 2:
Within the unified manifold body, the patent uses segmentation to create distinct coolant channels and reagent channels that are physically separated but integrated within the same structure. This allows independent fluid management for each circuit while benefiting from the simplified overall architecture
3Reliability
If pressure reducing means are added to control coolant pressure, then coolant pressure can be maintained below safe values, but the manifold complexity and manufacturing difficulty increase
Solution Approach 1:
The pressure reducing means are integrated directly into the manifold body structure, combining the pressure control function with the existing coolant distribution channels. This integration eliminates the need for separate external pressure control devices and reduces the number of additional manufacturing steps required
Solution Approach 2:
The patent incorporates pressure reducing means that utilize the inherent flow characteristics and pressure differential across the fuel cell stack to automatically regulate coolant pressure. By designing the manifold channels with appropriate geometry and flow resistance, the system maintains coolant pressure below safe values through passive parameter control rather than active mechanical components
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 the overall size and weight of the generator, simplifies assembly and maintenance, enhances efficiency and reliability, and improves thermal integration, leading to cost savings and improved performance during start-up, shut-down, and regular operation.
Implementation Method 1
pressure reducing means of the first and second reagent flows
Implementation Method 2
a coolant fluid expansion chamber within which the pressure reducing means of the first and second reagent flows are positioned at least partially drowned by the coolant fluid
Implementation Method 3
a plurality of fuel cells are piled into a stack to generate electricity by being supplied with a combustible gas and an oxidising gas, on a fuel electrode (anode) and an oxidation electrode (cathode), respectively
Implementation Method 4
chambers for the mixing of said reagent flows with corresponding re-circulated product flows
Data Source
AI summary
A fuel cell electric generator designed for back-up in the absence of network electricity supply. The generator comprises a fuel cell stack, means for supplying the stack with a first and a second reagent flow comprising, in turn, pressure reducing means, and a manifold body to communicate with the stack said first and second reagent flows and at least a flow of coolant fluid via a respective coolant loop. The manifold body comprises inside chambers for the mixing of said reagent flows with corresponding re-circulated product flows and a coolant fluid expansion chamber within which said pressure reducing means of said first and second reagent flows are positioned at least partially drowned by said coolant. Method for the start-up and shutdown of the generator, and a method for detecting the flooding of a fuel cell and a method for detecting the presence of gas leakages in the generator are also disclosed.