Solid-oxide fuel cell system having an integrated air supply system

• US 6,608,463 B1
• Filed: 06/24/2002
• Issued: 08/19/2003
• Est. Priority Date: 06/24/2002
• Status: Expired due to Fees

• Current Assignee: Delphi Technologies, Inc. (BorgWarner Incorporated)
• Original Assignee: Delphi Technologies, Inc. (BorgWarner Incorporated)
• Inventors: Kelly, Sean M., Grover, Trevor T.
• Primary Examiner(s): Tso, Edward H.
• Assistant Examiner(s): TIBBITS, PIA FLORENCE
• Application Number:
  US10/178,823
• Time in Patent Office: 421 Days
• Field of Search: 320/101, 429/20, 429/12, 429/13, 429/22, 429/17, 429/23, 361/600, 361/622, 361/676, 361/678, 361/679, 62/37, 624/01, 123/696
• US Class Current: 320/101
• CPC Class Codes: H01M 2250/20 Fuel cells in motive systems, e.g. vehicle, ship, plane
• CPC Class Codes: H01M 8/04089 of gaseous reactants
• CPC Class Codes: H01M 8/0612 from carbon-containing material
• CPC Class Codes: Y02E 60/50 Fuel cells
• CPC Class Codes: Y02T 90/40 Application of hydrogen technology to transportation, e.g. using fuel cells

Abstract

A solid-oxide fuel cell system having an integrated air supply system, including a central air pump, distribution manifold, air control valves, mass air flow sensors, and supply ducts, for controllably supplying oxygen for the fuel cell reaction, both through and controllably bypassing cathode air heat exchangers; combustion air for a combustor of tail gas from the anodes; cooling air for electronic controls; and reforming air to a liquid fuel vaporizer integral with a hydrocarbon fuel reformer.

Claims

1. A fuel cell system for generating electric power by combination of oxygen with hydrogen-containing fuel, comprising:

a) a plurality of individual fuel cells organized into at least one fuel cell stack assembly including a plurality of cathodes and anodes;

b) manifold means having passageways for conveying said fuel and said oxygen in the form of air to said stack assembly and passageways for returning spent cathode air and tail gas from said stack assembly;

c) an integrated reformer and tail gas combustor connected to said manifold means for reforming hydrocarbons to provide said fuel to said stack assembly and for combusting tail gas returned from said stack assembly; and

d) an integrated air supply system for controllably supplying air to said stack assembly, said reformer and said combustor via said manifold means.

2. A fuel cell system in accordance with claim 1 wherein said air supply system comprises:

a) at least one air pump for pressurizing intake air into an output air stream;

b) a distribution manifold for receiving said output air stream and distributing said air stream among said passagways; and

c) a plurality of control valves disposed in said manifold for regulating flows through said passageways to said stack assembly, said reformer, and said combustor.

3. A fuel cell system in accordance with claim 2 further comprising a control system, wherein the action of said control valves is controlled by said control system.

4. A fuel cell system in accordance with claim 3 wherein said air supply system further includes an enclosure for housing and cooling said control system.

5. A fuel cell system in accordance with claim 1 wherein said air supply system further includes at least one mass air flow sensor for measuring at least a portion of the air mass flowing through said air supply system.

6. A fuel cell system in accordance with claim 1 wherein said system is configured for being mounted on a vehicle.

7. A fuel cell system in accordance with claim 1, wherein said fuel cell system is configured for being mounted on at least one of a car, truck, boat, and airplane.

8. A fuel cell system in accordance with claim 6, wherein said system is an auxiliary power unit for said vehicle.

9. An automotive vehicle, comprising a fuel cell system for generating auxiliary power for said vehicle, said system including

a plurality of individual fuel cells organized into at least one fuel cell stack assembly including a plurality of cathodes and anodes,

manifold means having passageways for conveying said fuel and said oxygen in the form of air to said stack assembly and passageways for returning spent cathode air and tail gas from said stack assembly;

an integrated reformer and tail gas combustor unit connected to corresponding passageways of said manifold means for reforming hydrocarbons to provide said fuel to said stack assembly and for combusting tail gas returned from said stack assembly; and

an integrated air supply system for controllably supplying air to said stack assembly, said reformer and said combustor via said manifold means.

10. A fuel cell system for generating electric power by combination of oxygen with hydrogen-containing fuel, comprising:

a stack housing, at least one fuel cell stack assembly disposed within said stack housing, a plurality of stack housing inlets and stack housing outlets defined by said stack housing;

manifold means having passageways in fluid communication with corresponding stack housing inlets for conveying said fuel and said oxygen to said stack assembly, and passageways in fluid communication with corresponding stack housing outlets for conveying spent cathode air and tail gas from said stack assembly;

an integrated reformer and tail gas combustor unit connected to said manifold means for reforming hydrocarbons to provide said fuel to said stack assembly and for combusting tail gas returned from said stack assembly; and

an integrated air supply system for controllably supplying air to said stack assembly, said reformer and said combustor via said manifold means.

11. The fuel cell system of claim 10, wherein said manifold means comprises at least one manifold housing, said at least one manifold housing defining at least in part said passageways, said at least one manifold housing being attached to said stack housing.