FUEL CELL POWER MODULE FRAME ASSEMBLY

• US 20090155655A1
• Filed: 12/05/2008
• Published: 06/18/2009
• Est. Priority Date: 12/07/2007
• Status: Active Grant

• Current Assignee: Hydrogenics Corporation (Cummins Incorporated)
• Original Assignee: Hydrogenics Corporation (Cummins Incorporated)
• Inventors: Kvachnine, Igor, Sabapathy, Anthony, Nunes, Vicente, Hill, Andrew
• Granted Patent: US 8,563,195 B2
• Time in Patent Office: Days
• US Class Current: 429/532
• CPC Class Codes: H01M 8/2475 Enclosures, casings or containers of fuel cell stacks
• CPC Class Codes: Y02E 60/50 Fuel cells

Abstract

A frame assembly for a fuel cell power module, particularly but not exclusively for use in lift trucks, has at least one frame element. The frame element is provided with an internal cavity that is filled with a fill material to provide a desired mass of the frame assembly. The frame assembly is configured to receive a fuel cell stack and other balance of plant components of a fuel cell power module and may also be configured to receive a fuel storage vessel. The frame assembly can be configured so that it can replace a battery pack of a lift truck and still provide adequate counterweight.

Claims

1. A frame assembly for use with a fuel cell power module, the frame assembly comprising:

at least one element including an internal cavity;

a fill material located in the cavity to provide a desired mass; and

a plurality of portions providing at least one mounting surface for receiving the fuel cell stack and balance of plant components of a fuel cell power module.

18. A fuel cell power module comprising a frame assembly as claimed in any preceding claim, further comprising:

a fuel cell stack mounted on the frame assembly;

a fuel storage device mounted on the frame assembly; and

balance of plant components mounted on the frame assembly.

19. A fuel cell power module as claimed in claim 18, wherein the balance of plant components comprise at least one electronics component, and the frame assembly is configured to dissipate heat from the electronics component.

20. A fuel cell power module as claimed in claim 18-19, wherein the balance of plant components comprise one or more components selected from:

a pump, a valve, a humidifier, a radiator for discharging excess heat, and a control unit.

21. A fuel cell power module as claimed in claim 18-20, in combination with a lift truck.

2. A frame assembly for use in a fuel cell power module, the frame assembly comprising a plurality of elements configured to receive a fuel cell stack, a fuel cell storage vessel and balance of plant components for a fuel cell power module, wherein at least one element of the frame assembly includes a cavity and a fill material in the cavity to provide a desired mass of the frame assembly.

3. A frame assembly as claimed in claim 2, wherein the fill material is a high density material to increase the mass of the frame assembly.

4. A frame assembly as claimed in claim 2-3, wherein the at least one element including a cavity is formed by casting.

5. A frame assembly as claimed in claim 4, wherein the at least one element formed by casting comprises cast iron and wherein the material for the cavity in the at least one element has been placed therein in molten form and then solidified.

6. A frame assembly as claimed in claim 5, wherein the material filling the cavity of the at least one element comprises lead.

7. A frame assembly as claimed in claim 2-6, including a closure panel for each cavity.

8. A frame assembly for a fuel cell power module, wherein the frame assembly is configured to receive a fuel cell stack, a fuel storage vessel and balance of plant components of the fuel cell power module, wherein at least one element of the frame assembly includes a cavity, with the cavity filled with a material of a higher density then the material of said element to increase the mass thereof, and wherein the frame assembly is configured to correspond to the dimensions of a battery pack for a lift truck.

9. A frame assembly for a fuel cell power module, the frame assembly comprising a bottom element and a top element, wherein the top and bottom elements together are configured to substantially enclose a fuel storage vessel, wherein the top and bottom elements are configured to receive a fuel cell stack and balance of plant components of a fuel cell power module, and wherein at least one of the top and bottom elements includes an internal cavity and the internal cavity is filled with a fill material to provide a desired mass of the frame assembly.

10. A frame assembly as claimed in claim 9, wherein the fill material is a high density material to increase the mass of the frame assembly.

11. A frame assembly as claimed in claim 9-10, wherein the top and bottom elements are configured to receive a fuel storage vessel that is generally cylindrical with hemispherical end portions.

12. A frame assembly as claimed in claim 9-11, wherein the top and bottom elements include complementary fuel cavities for receiving a fuel storage vessel, and recesses for securing straps for securing the fuel storage vessel to one of the top and bottom elements.

13. A frame assembly as claimed in claim 9-12, wherein both of the top and bottom elements include an internal cavity and wherein the top element is open at one side thereof to reveal the internal cavity thereof and the bottom element is open at the bottom to reveal the internal cavity thereof.

14. A frame assembly as claimed in claim 13, wherein each of the top and bottom elements is provided with a closure panel secured thereto, for closing off the internal cavities of the top and bottom elements.

15. A frame assembly as claimed in claim 9-14, wherein the top element includes an upper shelf for accommodating elements of the fuel cell power module.

16. A frame assembly as claimed in claim 9-15, wherein the bottom element includes an outer sidewall defining an elongate rectangular slot portion, for receiving elements of a fuel cell power module.

17. A frame assembly as claimed in claim 9-16, wherein one of the top and bottom elements includes threaded bores and the other of the top and bottom elements includes openings for receiving fasteners, for engaging the threaded bores to secure the top and bottom elements together.

22. A method of forming a frame component for use in a frame assembly for a fuel cell power module, the method for comprising the steps of:

configuring the frame element to receive at least one of a fuel storage vessel, at least one component of balance of plant components of a fuel cell power module and a fuel cell stack;

providing the frame element with at least one planar outer face;

providing the frame element with an internal cavity opening onto the outer face; and

filling the internal cavity of the frame element with a fill material having a desired density.

23. A method as claimed in claim 22, wherein the fill material has a higher density than the material of the frame element.

24. A method as claimed in claim 22-23, comprising forming the frame element by casting, and wherein the step of filling the internal cavity comprises pouring a material into a cavity in liquid form and permitting the material to solidify.

25. A method as claimed in claim 22-24, comprising forming the frame element by casting from iron and providing the fill material in the cavity in molten form at an elevated temperature, and permitting the fill material to cool and to solidify.