Fuel cell power system performing AC inversion, method of distributing AC power, and method of operating a fuel cell power system

• US 6,630,259 B2
• Filed: 05/23/2001
• Issued: 10/07/2003
• Est. Priority Date: 05/23/2001
• Status: Expired due to Fees

• Current Assignee: Emergent Power Inc. (Plug Power Inc.)
• Original Assignee: Avista Laboratories Inc. (Plug Power Inc.)
• Inventors: Fuglevand, William A.
• Primary Examiner(s): Gulakowski, Randy
• Assistant Examiner(s): Scaltrito, Donald V.
• Application Number:
  US09/864,409
• Publication Number:
  US 20020177015A1
• Time in Patent Office: 867 Days
• Field of Search: 429/12, 429/13, 429/17, 429/22, 429/23
• US Class Current: 429/432
• CPC Class Codes: H01M 16/003 of fuel cells with other electrochemical devices, e.g. capacitors, electrolysers
• CPC Class Codes: H01M 8/04298 Processes for controlling fuel cells or fuel cell systems
• CPC Class Codes: H01M 8/04567 of auxiliary devices, e.g. batteries, capacitors
• CPC Class Codes: H01M 8/04947 of auxiliary devices, e.g. batteries, capacitors
• CPC Class Codes: H01M 8/0612 from carbon-containing material
• CPC Class Codes: H01M 8/241 with solid or matrix-supported electrolytes
• CPC Class Codes: H01M 8/249 comprising two or more groupings of fuel cells, e.g. modular assemblies
• CPC Class Codes: Y02E 60/50 Fuel cells
• CPC Class Codes: Y10S 429/90 Fuel cell including means for power conditioning, e.g. Conversion to ac

Abstract

A fuel cell power system, comprising a fuel cell which generates DC voltage; a plurality of energy storage devices selectively electrically coupled with the fuel cell; and circuitry for sequentially selectively electrically coupling and decoupling the respective energy storage devices to a load in a manner which approximates a voltage sine wave.

Claims

1. A fuel cell power system, comprising:

a fuel cell which generates DC voltage;

a plurality of energy storage devices selectively electrically coupled with the fuel cell; and

circuitry for sequentially selectively electrically coupling and decoupling the respective energy storage devices to a load having an AC voltage demand in a manner which approximates an AC voltage sine wave to supply at least a portion of the AC voltage demand of the load.

2. A fuel cell power system as claimed in claim 1, wherein the fuel cell comprises multiple fuel cells.

3. A fuel cell power system as claimed in claim 2, wherein the energy storage devices are ultracapacitors which each have a variable DC voltage condition.

4. A fuel cell power system as claimed in claim 3, and further comprising:

second circuitry which electrically couples and decouples the respective fuel cells to an ultracapacitor based on the voltage condition of the ultracapacitor.

5. A fuel cell power system as claimed in claim 1, wherein the fuel cell is defined by a plurality of fuel cell subsystems, each fuel cell subsystem comprising an ion exchange membrane.

6. A fuel cell power system as claimed in claim 5, wherein each fuel cell has an associated group including one or more energy storage devices, and wherein the second circuitry electrically couples the fuel cell to its associated group when the voltage of the group is less than a first predetermined DC voltage, and electrically decouples the fuel cell from its associated group when the voltage of the group is greater than a second predetermined DC voltage.

7. A fuel cell power system as claimed in claim 6 wherein the energy storage devices comprise ultracapacitors.

8. A fuel cell power system as claimed in claim 7, wherein each of the ultracapacitors have a maximum voltage rating, and wherein each fuel cell is defined by a number of fuel cell subsystems which are electrically coupled together in series, and wherein the combined DC voltage of the fuel cell subsystems is not greater than the maximum voltage rating of the associated group, in operation.

9. A fuel cell power system as claimed in claim 8, wherein at least one of the ultracapacitors has an operating voltage of about 1.8 to about 2.2 volts DC, and wherein the associated fuel cell subsystems electrically coupled to same produces a DC voltage of about 0.6 volts.

10. A fuel cell power system as claimed in claim 9, and further comprising:

a battery electrically coupled in parallel with each ultracapacitor and which has a maximum voltage, and wherein the combined voltage of the fuel cell subsystems electrically coupled with same is not greater than maximum voltage of the battery which is electrically coupled in parallel with each ultracapacitor.

11. A fuel cell power system as claimed in claim 10, wherein the battery is a single cell battery.

12. A fuel cell power system, comprising:

means for electrochemically converting hydrogen to DC voltage;

a plurality of means defining capacitances selectively electrically coupled with the means for electrochemically converting hydrogen;

electrochemical energy storage means coupled in parallel to each capacitance defining means and

means for sequentially selectively electrically coupling and decoupling the respective energy storage devices to a load having an AC voltage demand in a manner which approximates an AC voltage sine wave to substantially meet the AC voltage demand of the load.

13. A fuel cell power system as claimed in claim 12, wherein the means for electrochemically converting hydrogen comprises a fuel cell of a type selected from the group consisting of:

proton exchange membrane, solid oxide, phosphoric acid, alkaline, and molten carbonate.

14. A fuel cell power system as claimed in claim 13, wherein the respective means defining capacitances comprise ultracapacitors which each have a variable voltage condition.

15. A fuel cell power system as claimed in claim 14, and further comprising:

second circuitry which electrically couples and decouples the respective means for electrochemically converting hydrogen to one ultracapacitor when the ultracapacitor has a predetermined voltage.

16. A fuel cell power system as claimed in claim 12, wherein each means for electrochemically converting hydrogen has associated capacitance defining means, the fuel cell power system further comprising second circuitry which electrically couples the means for electrochemically converting hydrogen to its associated capacitance means when the voltage of the capacitance means is less than a first predetermined DC voltage, and electrically decouples the fuel cell from its associated capacitance means when the voltage of the capacitance means is greater than a second predetermined DC voltage.

17. A fuel cell power system as claimed in claim 12, wherein each capacitance defining means has a maximum DC voltage rating, and wherein each means for electrochemically converting hydrogen is defined by a number of fuel cell subsystems which are electrically coupled together in series, and wherein the combined DC voltage of the fuel cell subsystems is not greater than the maximum DC voltage rating of the associated capacitance defining means, in operation.

18. A fuel cell power system as claimed in claim 12, wherein the capacitance means are respectively defined by one or more ultracapacitors and which are capable of operating in a voltage range of about 1.8 to about 2.2 volts DC, and wherein the associated means for electrochemically converting hydrogen electrically coupled to same produces a voltage of about 0.6 volts DC.

19. A fuel cell power system as claimed in claim 12, wherein the electrochemical energy storage means comprise respective batteries each having a maximum voltage, and wherein the voltage of the means for electrochemically converting hydrogen is not greater than maximum voltage of any battery to which the means for electrochemically converting hydrogen is selectively coupled.

20. A fuel cell power system as claimed in claim 19, wherein the batteries are single cell batteries.

21. A fuel cell power system, comprising:

a plurality of fuel cells which respectively generate DC voltage while operating;

a plurality of ultracapacitors, each ultracapacitor having a DC voltage condition;

circuitry which, when operating, electrically couples a fuel cell to an ultracapacitor in response to the voltage of that ultracapacitor being less than a first predetermined DC voltage, and electrically de-couples the fuel cell from the ultracapacitor in response to the voltage of that ultracapacitor being greater than a second predetermined DC voltage; and

circuitry which, when operating, selectively electrically couples and de-couples ultracapacitors to and from a load having an AC voltage demand at different times, the times and number of ultracapacitors electrically coupled to the load at any of those times being selected by the circuitry so as to approximate an AC voltage sine wave, whereby the fuel cell power system performs AC inversion to substantially meet the AC voltage demand of the load.

22. A fuel cell power system in accordance with claim 21 wherein the ultracapacitors each have a maximum DC voltage rating, and wherein each fuel cell is defined by a number of fuel cell subsystems which are electrically coupled together in series, and wherein the combined DC voltage of the numbered fuel cell subsystems for a fuel cell is no greater than the maximum DC voltage rating of the ultracapacitor to which it is coupled or decoupled.

23. A fuel cell power system in accordance with claim 22, and further comprising a single cell battery which is electrically coupled in parallel with each ultracapacitor and which has a maximum voltage, and wherein the combined DC voltage of the numbered fuel cell subsystems of each fuel cell is not greater than the maximum voltage of the battery which is electrically coupled in parallel with the ultracapacitor and which is coupled and de-coupled with that fuel cell.

24. A fuel cell power system in accordance with claim 21, wherein each ultracapacitor has an operating voltage range, and wherein at least one of the fuel cells is defined by a plurality of fuel cell subsystems which are electrically coupled together in series and which, when coupled to an ultracapacitor, produces a cumulative DC voltage within the operating range of the ultracapacitor.

25. A fuel cell power system in accordance with claim 21, wherein at least one of the ultracapacitors is configured to operate in a voltage range of about 1.8 to about 2.2 Volts DC, and wherein a fuel cell is defined by a plurality of fuel cell subsystems which are electrically coupled together in series, and which each produce a voltage of about 0.6 Volts DC.

26. A fuel cell power system in accordance with claim 21, wherein respective fuel cells are defined by a plurality of fuel cell subsystems, each comprising an ion exchange membrane.

27. A fuel cell power system in accordance with claim 21, and further comprising:

one or more additional fuel cells electrically coupled in parallel with one of the fuel cells.

28. A fuel cell power system comprising:

a plurality of fuel cells, each fuel cell being defined by a plurality of fuel cell subsystems which are electrically coupled together in series, each fuel cell subsystem, in operation, producing direct current electrical energy;

a plurality of ultracapacitors, the ultracapacitors being associated with respective fuel cells, each ultracapacitor having a DC voltage condition;

a switch electrically coupled to each fuel cell to selectively electrically couple the fuel cell to its associated ultracapacitor; and

control circuitry to cause the switches, for each fuel cell, to electrically couple the fuel cell to the associated ultracapacitor in response to the DC voltage of that ultracapacitor being less than a first predetermined DC voltage, and to electrically de-couple the fuel cell from the associated ultracapacitor in response to the voltage of that ultracapacitor being greater than a second predetermined DC voltage, the control circuitry further causing the switches to couple and de-couple the ultracapacitors to and from a load having an AC voltage demand at different times, the times and number of ultracapacitors electrically coupled to the load at any of those times being selected by the control circuitry so as to approximate an AC voltage sine wave.

29. A fuel cell power system in accordance with claim 28, and further comprising a battery electrically coupled in parallel with each ultracapacitor, and wherein each battery has a maximum DC voltage, and wherein each ultracapacitor has an operating voltage range, and wherein, for each fuel cell, the cumulative voltage of the plurality of fuel cell subsystems electrically coupled together to define the fuel cell is within the operating DC voltage range of the associated ultracapacitor, and less than the maximum DC voltage of the battery electrically coupled in parallel with the associated ultracapacitor.

30. A fuel cell power system in accordance with claim 28, wherein the fuel cell subsystems of one of the fuel cells each produce about the same DC voltage, when operating.

31. A fuel cell power system in accordance with claim 28, wherein each ultracapacitor has an operating voltage range, and wherein the associated fuel cell produces a DC voltage within the operating voltage range of the ultracapacitor.

32. A fuel cell power system in accordance with claim 28, and further including, for at least one of the ultracapacitors, a second plurality of fuel cell subsystems which are electrically coupled together in series, and wherein the second plurality of fuel cell subsystems is in parallel with the first plurality of fuel cell subsystems associated with that ultracapacitor.

33. A fuel cell power system in accordance with claim 28, wherein at least one of the ultracapacitors has an operating voltage of 1.8 to 2.2 Volts DC, and wherein the associated fuel cell has exactly three fuel cell subsystems that produce a cumulative voltage of about 1.8 Volts DC, when operating.

34. A fuel cell power system in accordance with claim 28, wherein each fuel cell subsystem comprises an ion exchange membrane.

35. A fuel cell power system as claimed in claim 28, wherein the control circuitry comprises an embedded processor.

36. A method of operating a fuel cell power system, comprising:

providing a plurality of fuel cells which, in operation, respectively produce direct current electrical energy;

providing a plurality of ultracapacitors, each ultracapacitor having a DC voltage condition;

electrically coupling a fuel cell to an ultracapacitor when the voltage of that ultracapacitor is less than a first predetermined DC voltage, and electrically de-coupling the fuel cell from the ultracapacitor when the voltage of that ultracapacitor is greater than a second predetermined DC voltage; and

selectively coupling and de-coupling the individual ultracapacitors to and from a load having an AC voltage demand at different times, the times and number of ultracapacitors electrically coupled to the load at any of those times being selected so as to approximate an AC voltage sine wave.

37. A method in accordance with claim 36, and further comprising electrically coupling a battery in parallel with each ultracapacitor.

38. A method in accordance with claim 36, and further comprising electrically coupling a plurality of fuel cell subsystems together in series to define each of the fuel cells.

39. A method in accordance with claim 38, and further comprising electrically coupling a single cell battery in parallel with each ultracapacitor, and which has a maximum DC voltage, the method further comprising selecting the number of fuel cell subsystems of each fuel cell such that the combined DC voltage of the fuel cell subsystems of each fuel cell is no greater than the maximum voltage of the battery which is electrically coupled in parallel with the ultracapacitor and to which that fuel cell is coupled and decoupled.

40. A method in accordance with claim 39, wherein each ultracapacitor has an operating voltage range, and wherein the fuel cell subsystems which are electrically coupled together in series for each fuel cell are selected so as to produce a cumulative DC voltage which lies within the operating voltage range of the ultracapacitor to which the fuel cell is coupled and decoupled.

41. A method in accordance with claim 40, wherein selectively coupling and de-coupling the respective ultracapacitors to and from the load at different times comprises electrically coupling ultracapacitors in series in a predetermined sequence and de-coupling ultracapacitors in a predetermined sequence.

42. A method in accordance with claim 36, wherein at least one of the ultracapacitors has an operating voltage of about 1.8 to about 2.2 Volts DC, and wherein the method further comprises:

defining a fuel cell using a plurality of fuel cell subsystems which are electrically coupled together in series, and wherein each of the fuel cell subsystems produces a voltage of about 0.6 Volts DC.

43. A method of distributing electrical AC power, which is generated by a fuel cell power system, to a load, comprising:

defining a plurality of fuel cells by electrically coupling a plurality of fuel cell subsystems together in series to define each fuel cell;

providing a plurality of ultracapacitors, the ultracapacitors being associated with respective fuel cells, and each ultracapacitor having a DC voltage condition;

providing a switch associated with each fuel cell, and which selectively electrically couples the fuel cell to its associated ultracapacitor; and

selectively controlling the switches to electrically couple a fuel cell to the associated ultracapacitor when the DC voltage of that ultracapacitor is less than a first predetermined DC voltage, and to electrically de-couple the fuel cell from the associated ultracapacitor when the DC voltage of that ultracapacitor is greater than a second predetermined voltage, and further causing the switches to couple and de-couple the respective ultracapacitors to and from a load having an AC voltage demand at different times, the times and number of ultracapacitors which are electrically coupled to the load at any of those times being selected by the control circuitry so as to approximate an AC voltage sine wave which provides at least a portion of the AC voltage demand of the load.

44. A method in accordance with claim 43, wherein the fuel cell subsystems of at least one of the fuel cells each produce about the same DC voltage.

45. A method in accordance with claim 43, and further comprising using a processor to selectively control the switches.

46. A method in accordance with claim 43, wherein each ultracapacitor has a maximum DC voltage, and the method further comprises, for each fuel cell, selecting the number of fuel cell subsystems to be electrically coupled together in series for that fuel cell such that the combined DC voltage produced by the fuel cell subsystems electrically coupled together in series is expected to be less than the maximum DC voltage of the associated ultracapacitor.

47. A method in accordance with claim 43, wherein at least one of the ultracapacitors has an operating voltage of about 1.8 to about 2.2 Volts DC.

48. A method in accordance with claim 43, wherein at least one of the ultracapacitors has an operating voltage of about 1.8 to about 2.2 Volts DC, and a maximum voltage which is greater than about 2.2 Volts DC, and wherein the method further comprises electrically coupling together in series, for the associated fuel cell, three fuel cell subsystems that together produce a voltage of about 1.8 Volts when operating.

49. A method in accordance with claim 43, wherein each fuel cell subsystem comprises an ion exchange membrane.

50. A method in accordance with claim 43, and further comprising electrically coupling a battery in parallel with each ultracapacitor, and wherein the battery is a single cell battery having a voltage of about 2 Volts DC.

51. A fuel cell power system, comprising:

a fuel cell which generates a D.C. voltage output while operating;

a load which has an A.C. voltage demand;

a plurality of energy storage devices each having a D.C. voltage condition and which, in operation, are selectively electrically coupled with the load having the A.C. voltage demand; and

circuitry which, in operation, substantially simultaneously and selectively electrically couples and decouples the D.C. voltage output of the fuel cell to the individual energy storage devices based upon the D.C. voltage condition of the respective energy storage devices, and further selectively electrically couples and decouples the respective energy storage devices to the load having the A.C. voltage demand in a manner which approximates an A.C. sine wave to meet the A.C. voltage demand of the load.