Fuel cell mechanical components

• US 8,440,362 B2
• Filed: 09/23/2011
• Issued: 05/14/2013
• Est. Priority Date: 09/24/2010
• Status: Active Grant

• Current Assignee: Bloom Energy Corporation
• Original Assignee: Bloom Energy Corporation
• Inventors: Richards, Gilbert, Trevisan, David, Mahler, Jessica, Parker, Ross, Clarabut, Alex, Pearson, Chad, Ballantine, Arne, Weingaertner, David, Hixson, Jason, Mitlitsky, Fred, Lee, Michael L
• Primary Examiner(s): Ryan, Patrick
• Assistant Examiner(s): Quraishi, Kiran
• Application Number:
  US13/242,194
• Publication Number:
  US 20120189940A1
• Time in Patent Office: 599 Days
• Field of Search: 180/68.5, 180/65.21, 180/65.1, 221/282, 206/703, 429408-427, 429429-471, 429163-187, 429507-516, 554/83, 553/00, 952/58, 952/86, 95/78, 294/263, 298/973, 414/800
• US Class Current: 429/471
• CPC Class Codes: H01M 2250/10 Fuel cells in stationary systems, e.g. emergency power source in plant
• CPC Class Codes: H01M 8/06 Combination of fuel cells with means for production of reactants or for treatment of residues regenerative fuel cells H01M8/18
• CPC Class Codes: H01M 8/0662 Treatment of gaseous reactants or gaseous residues, e.g. cleaning
• CPC Class Codes: H01M 8/0675 Removal of sulfur
• CPC Class Codes: H01M 8/24 Grouping of fuel cells, e.g. stacking of fuel cells
• CPC Class Codes: H01M 8/249 comprising two or more groupings of fuel cells, e.g. modular assemblies
• CPC Class Codes: Y02B 90/10 Applications of fuel cells in buildings
• CPC Class Codes: Y02E 60/50 Fuel cells
• CPC Class Codes: Y10T 29/49623 Static structure, e.g., a building component
• CPC Class Codes: Y10T 29/49819 with conveying of work or disassembled work part

Abstract

A modular fuel cell system includes a base, at least four power modules arranged in a row on the base, and a fuel processing module and power conditioning module arranged on at least one end of the row on the base. Each power module includes a separate cabinet which contains at least one fuel cell stack located in a hot box. The power modules are electrically and fluidly connected to the at least one fuel processing and power conditioning modules through the base.

Claims

1. A modular fuel cell system, comprising:

a base;

at least one power modules arranged in a row on the base; and

a fuel processing module and a power conditioning module arranged on at least one end of the row on the base;

wherein;

each power module comprises a separate cabinet comprising at least one fuel cell stack located in a hot box; and

the at least four power modules are electrically and fluidly connected to the fuel processing and the power conditioning modules through the base,

wherein the hot box is supported, moved or installed by air rollers, wherein the air rollers comprise pneumatic devices that include one or more air bladders operatively connected to retracted wheels or rollers.

2. The system of claim 1, wherein the fuel processing and power conditioning modules are located in a common input/output cabinet.

3. The system of claim 1, wherein the fuel processing module is located in a first cabinet and the power conditioning module is located in a second cabinet which is separate from the first cabinet.

4. The system of claim 3, wherein the first cabinet, the second cabinet and each power module cabinet have doors facing perpendicular to an axis of the row.

5. The system of claim 1, wherein the fuel processing module comprises at least one adsorption bed and the power conditioning module comprises a DC/AC converter, electrical connectors for AC power output and a system controller.

6. The system of claim 1, wherein each power, fuel processing and power conditioning module may be serviced, repaired or removed from the system without opening the remaining module cabinets in the system and without taking off line, servicing, repairing or removing the other modules in the system.

7. The system of claim 1, wherein the base comprises a pre-cast concrete, geopolymer or steel base comprising channels which contain electrical bus bar conduits, input and output fuel conduits and at least one water conduit which extend to the system, from the system, or between the modules.

8. The system of claim 1, wherein the cabinet comprises:

a cabinet housing; and

a door in the housing;

wherein;

the door comprises one or more inner portions and one or more outer portions; and

the outer portions may be opened while the inner portions remain closed or the outer portions comprises a different material than the inner portions.

9. The system of claim 8, wherein:

the inner portion forms a framework for the door and couples the door to the cabinet housing; and

the outer portion is coupled to the inner portion and provides an outer fascia for the door.

10. The system of claim 9, wherein the outer portion is formed of non-fire resistant polymer material and the inner portion is formed of a fire resistant material selected from metal and fire resistant polymer material.

11. The system of claim 9, wherein the entire door is injection molded as a single structure made of different materials or is made by vacuum thermoforming, such that the inner portion is made from a heat and flame resistant plastic sheet, and the outer portion is made from a plastic that is weather resistant and has a lower heat and flame resistance than the inner portion.

12. The system of claim 8, further comprising at least one air filter located in a space between the inner and outer portions of the door, such that the outer portion may be opened while the inner portion remains closed.

13. The system of claim 12, wherein:

the at least one filter comprises a plurality of the filters which are located over each other in the space between the inner and the outer door portions;

the filters are supported on the inner surface of the outer portion;

an edge of the door between the inner and outer portions comprises an air inlet opening to the space between the inner and outer door portions; and

the inner door portion includes an air outlet opening into an interior of the cabinet.

14. The system of claim 13, further comprising at least one perforated screen located in an air flow path between the air inlet opening and the at least one filter;

wherein;

a width of the space between the inner and outer door portions is larger than that of the air inlet opening; and

the space between the inner and outer door portions provides an air flow path comprising at least one turn of at least 90 degrees between the air inlet opening and the at least one filter such that debris in the air flow falls to a bottom of the space.

17. The system of claim 8, wherein the inner portion and the outer portion of the door are configured to open in tandem with a substantially vertical and then a substantially horizontal swing.

18. The system of claim 1, wherein the cabinet comprises:

a cabinet housing; and

a door on the housing, wherein the door is configured to open with a substantially vertical and then a substantially horizontal swing.

19. The system of claim 18, wherein:

the door opens by being moved up and then at least partially over the top of the cabinet in a substantially horizontal direction;

the door is mounted onto walls of the cabinet with plural independent mechanical arms;

the plural independent mechanical arms comprise two arms provided on a first side of the door and two arms provided on a second side of the door;

a first arm on the first side of the door comprises a first, generally straight end attached to an interior wall of the cabinet and a second, generally curved end attached to the door;

a second arm on the first side of the door comprises a first, generally curved end attached to the interior wall of the cabinet and a second, generally straight end attached to the door;

the second arm is longer than the first arm; and

in an open position, an upper portion of the door is located over a top surface of the cabinet and a lower portion of the door overhangs an opening to the cabinet.

20. The system of claim 18, further comprising a latch located inside the door between inner and outer portions of the door.

21. The system of claim 20, wherein the latch comprises:

a side handle;

at least one biasing member;

a wheeled latch actuating mechanism; and

a catch coupled to a frame of the cabinet;

wherein the side handle is hinged so that movement of the handle in a circular motion in a plane parallel to a front surface of the door causes the wheeled latch actuating mechanism to slide to a side to disengage or engage the catch.

22. The system of claim 1, further comprising an adsorption bed assembly, comprising:

a rotatable support; and

a plurality of vessels arranged on the rotatable support, each vessel containing an adsorption bed.

23. The assembly of claim 22, wherein:

the assembly comprises a desulfurizer assembly for the fuel cell system;

the adsorption bed comprises a bed of at least one of an impurity adsorption or desulfurization material; and

the plurality of vessels are connected in fluid series.

24. The assembly of claim 23, wherein each vessel comprises a canister having a generally rectangular prismatic body with a beveled edge and a plurality of separate internal channels and wherein all inputs and output connections for the plurality of vessels comprise swiveling leak-tight connections arranged on the same side of the assembly.

25. The assembly of claim 23, further comprising a species sensor or detector adapted to detect sulfur or other contaminant that has broken through a vessel in the fluid series.

15. A modular fuel cell system, comprising:

a base;

at least one power modules arranged in a row on the base; and

a fuel processing module and a power conditioning module arranged on at least one end of the row on the base;

wherein;

each power module comprises a separate cabinet comprising at least one fuel cell stack located in a hot box; and

the at least four power modules are electrically and fluidly connected to the fuel processing and the power conditioning modules through the base,

wherein the cabinet comprises;

a cabinet housing;

a door in the cabinet housing, wherein the door comprises one or more inner portions and one or more outer portions;

at least one filter located in a space between the inner and outer portions of the door, such that the outer portion may be opened while the inner portion remains closed;

a hinge on a bottom side of the door which allows the outer portion of the door to swing downward to open and expose the at least one filter without opening the inner portion of the door to the inside of the cabinet; and

at least one frame member holding the at least one filter, the at least one frame member is configured to pivot outward or to pivot the at least one filter outward when the outer door portion swings downward to expose the at least one filter, wherein;

the at least one filter comprises a plurality of the filters which are located over each other in the space between the inner and the outer door portions;

the filters are supported on the inner surface of the outer portion;

an edge of the door between the inner and outer portions comprises an air inlet opening to the space between the inner and outer door portions; and

the inner door portion includes an air outlet opening into an interior of the cabinet.

16. A modular fuel cell system, comprising:

a base;

at least one power modules arranged in a row on the base; and

a fuel processing module and a power conditioning module arranged on at least one end of the row on the base;

wherein;

each power module comprises a separate cabinet comprising least one fuel cell stack located in a hot box; and

the at least four power modules are electrically and fluidly connected to the fuel processing and the power conditioning modules through the base,

wherein the cabinet comprises;

a cabinet housing;

a door in the cabinet housing, wherein the door comprises one or more inner portions and one or more outer portions;

at least one air filter located in a space between the inner and outer portions of the door, such that the outer portion may be opened while the inner portion remains closed, wherein;

an edge of the door between the inner and outer portions comprises an air inlet opening to the space between the inner and outer door portions; and

the inner door portion includes an air outlet opening into an interior of the cabinet; and

a passive air intake louver located between the inner and the outer portions of the door, wherein the louver comprises a plurality of internal baffles which force an air intake stream provided from the at least one air inlet to change direction at least two times in the space between the inner and outer portions of the door before reaching the at least one air outlet,

wherein;

the at least one filter comprises a plurality of the filters which are located over each other in the space between the inner and the outer door portions;

the filters are supported on the inner surface of the outer portion.