Flexible, multi-cartridge, reconfigurable/selectable air contaminant control system and method for fuel cells

• US 8,882,874 B1
• Filed: 10/13/2005
• Issued: 11/11/2014
• Est. Priority Date: 10/13/2005
• Status: Active Grant

• Current Assignee: Jonathan Cross
• Original Assignee: Jonathan Cross
• Inventors: Cross, Jonathan
• Primary Examiner(s): CLEMENTE, ROBERT ARTHUR
• Application Number:
  US11/248,619
• Time in Patent Office: 3,316 Days
• Field of Search: 55481-482, 55485-487, 555/29, 553/501, 554/80, 555/06, 555/02, 95/90, 95286-287, 96131-132, 96134-135, 961/21, 961/38, 964/17
• US Class Current: 55/482
• CPC Class Codes: B01D 2253/102 Carbon
• CPC Class Codes: B01D 2253/104 Alumina
• CPC Class Codes: B01D 2253/106 Silica or silicates
• CPC Class Codes: B01D 2253/108 Zeolites
• CPC Class Codes: B01D 2253/11 Clays
• CPC Class Codes: B01D 2253/206 Ion exchange resins
• CPC Class Codes: B01D 2257/302 Sulfur oxides
• CPC Class Codes: B01D 2257/304 Hydrogen sulfide
• CPC Class Codes: B01D 2257/404 Nitrogen oxides other than dinitrogen oxide
• CPC Class Codes: B01D 2257/408 Cyanides, e.g. hydrogen cyanide (HCH)
• CPC Class Codes: B01D 2257/502 Carbon monoxide
• CPC Class Codes: B01D 2257/504 Carbon dioxide
• CPC Class Codes: B01D 2257/702 Hydrocarbons
• CPC Class Codes: B01D 2257/7022 Aliphatic hydrocarbons
• CPC Class Codes: B01D 2257/7025 Methane
• CPC Class Codes: B01D 2257/7027 Aromatic hydrocarbons
• CPC Class Codes: B01D 2257/708 Volatile organic compounds V.O.C.'s
• CPC Class Codes: B01D 2259/4148 Multiple layers positioned apart from each other
• CPC Class Codes: B01D 2259/4583 for removing chemical, biological and nuclear warfare agents
• CPC Class Codes: B01D 2267/40 Different types of filters
• CPC Class Codes: B01D 2275/206 : Special forms, e.g. adapted to a certain housing
• CPC Class Codes: B01D 53/04 : with stationary adsorbents B01D53/025 takes precedence
• CPC Class Codes: B01D 53/0407 : Constructional details of adsorbing systems
• CPC Class Codes: H01M 8/0662 : Treatment of gaseous reactants or gaseous residues, e.g. cleaning
• CPC Class Codes: Y02A 50/2351 : Atmospheric particulate matter [PM], e.g. carbon smoke microparticles, smog, aerosol particles, dust
• CPC Class Codes: Y02C 20/20 : of methane
• CPC Class Codes: Y02C 20/40 : of CO2
• CPC Class Codes: Y02E 60/50 : Fuel cells

Abstract

A unique, multi-cartridge, easily re-configurable ambient air filter assembly (air contaminant control system) that removes particulate and gaseous chemical/biological contaminants from the incoming cathode air stream on a fuel cell or similar devices is described. The filter assembly is composed of individual filter cartridges (sub-assemblies) of various filtration media that are targeted at removing specific airborne contaminants. Combining specific sets of cartridges enables the filter assembly to be readily/rapidly configured (and re-configured) for specific applications—such as urban, rural, industrial, or military battlefield environments. Selection of correct media ensures complete removal of potential contaminants, enables rapid re-configuration to different environments, quick replacement of spent cartridges without disposal of non-spent media (reducing waste and cost). The invention concept is highly configurable to various sizes and shape fuel cells or other applications requiring clean ambient air by simply scaling the filter assembly size and air flow rates.

Claims

1. A fuel cell cathode air filter assembly or air contaminant control system comprising:

an intake port that collects ambient air and directs it into the filter assembly;

a filter housing comprising a plurality of retainers and a removable panel that permits access to the filter housing;

a filter assembly comprising a plurality of individually configurable and separately removable filter cartridges arranged within the filter housing, wherein each filter cartridge fits within one of the retainers of the filter housing, and wherein each filter cartridge is surrounded by a compressible material; and

an outlet port assembly that connects to the oxidant intake port of the fuel cell or other device that requires clean ambient air.

2. The fuel cell cathode air filter assembly according to claim 1, wherein the filter assembly is constructed and configured for the fuel cell so that gaseous oxidant stream enters the intake port, passes through the filter assembly, passes through the individual cartridges sequentially within the filter assembly, and exits at outlet port.

3. The fuel cell cathode air filter assembly according to claim 2, wherein the gaseous oxidant stream is ambient air.

4. The fuel cell cathode air filter assembly according to claim 1, wherein the filter assembly is constructed and configured such that no external air ingress is permitted and where no gases are permitted to escape around the cartridges without passing through the filtration cartridges.

5. The fuel cell cathode air filter assembly according to claim 1, wherein the filter assembly further comprises:

one or more chemical adsorbent filter cartridges selected for removal of specific contaminants and one or more filter cartridges comprising a water management system.

6. The fuel cell cathode air filter assembly according to claim 5, wherein the one or more chemical adsorption filter cartridges comprise at least one of the following materials:

molecular sieves, activated carbon, activated alumina, ion exchange resins, silica gel, diatomaceous earths, clays, and zeolites.

7. The fuel cell cathode air filter assembly according to claim 6, wherein, when the one or more chemical adsorption filter cartridges comprise a plurality of chemical adsorption filters, each chemical adsorption filtration cartridge has different origin materials, particle size, particle shapes, effective pore sizes in order to be optimized to remove specific chemicals.

8. The fuel cell cathode air filter assembly according to claim 7, wherein an absorption amount associated with each of the chemical adsorption filtration cartridges varies to provide different adsorbent capabilities based on the contaminants in the ambient air to allow individual cartridges containing different amounts of media material to be inserted.

9. The fuel cell cathode air filter assembly according to claim 7, wherein at least one of the plurality of chemical adsorbent filtration cartridges is coated or impregnated with various chemicals to optimize selective adsorption or elimination of specific chemicals.

10. The fuel cell cathode air filter assembly according to claim 5, wherein each of the plurality of configurable and separately removable filter cartridges contain a useful service life indicator that indicates an extent to which a filter cartridge'"'"'s adsorption capabilities have been depleted.

11. The fuel cell cathode air filter assembly according to claim 1, wherein each filter cartridge comprises at least one of the following materials:

metallic mesh, cellulosic fibers, cloth fibers, polymeric materials, and high efficiency particulate arrestance (HEPA) media, and wherein each material is selected based on particulate sizes to be removed and desired air flow rates.

12. The fuel cell cathode air filter assembly according to claim 11, wherein each filter cartridge'"'"'s shape and size is determined by the amounts of filtration media necessary to remove target contaminants to acceptable levels and the volume of ambient air to be purified.

13. The fuel cell cathode air filter assembly according to claim 12, where the filter cartridges'"'"' shapes are selected from the group comprising:

square, rectangular, oval, circular, and tubular, and the sizes are selected from the group comprising;

width, length, diameter, and depth.

14. The fuel cell cathode air filter assembly according to claim 1, wherein the filter assembly is constructed and configured for the fuel cell so that gaseous oxidant stream enters the intake port, passes through the filter assembly, passes through the plurality of individually configurable and separately removable cartridges sequentially within the filter assembly, and exits at outlet port.

15. The fuel cell cathode air filter assembly according to claim 14, wherein the filter assembly is constructed and configured such that no external air ingress is permitted and where no gases are permitted to escape around the cartridges without passing through the filtration cartridges.

16. An air contaminant control system comprising:

intake port means for collecting ambient air and directing it into a filter assembly, wherein the filter assembly comprises a plurality of individually configurable and separately removable cartridges attached directly;

filter housing means, comprising a plurality of retainers wherein each of the plurality of cartridges fits within one of the plurality of retainers, wherein each of the retainers is in contact with at least one other of the plurality of retainers, wherein each cartridge is surrounded by a compressible material; and

outlet port means for connecting the filter assembly to an oxidant intake port of a fuel cell or other device that requires clean ambient air.

17. A method for constructing a fuel cell cathode air filter assembly, the method comprising the steps of:

attaching a filter assembly to an air intake port, the filter assembly comprising a plurality of individually configurable and separately removable filter cartridges arranged within a filter housing comprising a plurality of retainers and a removable panel that permits access to the filter housing, wherein each cartridge fits within one of the retainers of the filter housing and wherein each filter cartridge is surrounded by a compressible material attaching the filter assembly to an oxidant intake port of a fuel cell or other device that requires clean ambient air; and

replacing at least one of the plurality of individually configurable and separately removable filter cartridges when a service life indicator associated with the at least one of the plurality of filter cartridges indicates that the cartridge requires replacement.

18. The method of claim 17, wherein the filter assembly is constructed and configured for the fuel cell so that gaseous oxidant stream enters the intake port, passes through the filter assembly, passes through the plurality of individually configurable and separately removable filter cartridges sequentially within the filter assembly, and exits at outlet port.

19. The method of claim 17, wherein the filter assembly is constructed and configured such that no external air ingress is permitted and where no gases are permitted to escape around the filter cartridges without passing through the filtration cartridges.

20. The method of claim 17, wherein the filter assembly further comprises:

one or more chemical adsorbent filter cartridges selected for removal of specific contaminants and one or more filter cartridges comprising a water management system.