Apparatus and method for hybrid power module systems

• US 20050249989A1
• Filed: 06/23/2004
• Published: 11/10/2005
• Est. Priority Date: 05/07/2004
• Status: Abandoned Application

• Current Assignee: Ballard Power Systems Corporation (Superior Plus Corporation)
• Original Assignee: Ballard Power Systems Corporation (Superior Plus Corporation)
• Inventors: Pearson, Martin T.
• Application Number:
  US10/875,797
• Publication Number:
  US 20050249989A1
• Time in Patent Office: Days
• US Class Current: 429/431
• CPC Class Codes: H01M 10/44 Methods for charging or discharging circuits for charging H02J7/00
• CPC Class Codes: H01M 10/46 Accumulators structurally combined with charging apparatus circuits for charging H02J7/00
• CPC Class Codes: H01M 16/006 of fuel cells with rechargeable batteries
• CPC Class Codes: H01M 8/04373 of auxiliary devices, e.g. reformers, compressors, burners
• CPC Class Codes: H01M 8/04395 of cathode reactants at the inlet or inside the fuel cell
• CPC Class Codes: H01M 8/04447 of anode reactants at the inlet or inside the fuel cell
• CPC Class Codes: H01M 8/04559 of fuel cell stacks
• CPC Class Codes: H01M 8/04567 of auxiliary devices, e.g. batteries, capacitors
• CPC Class Codes: H01M 8/04589 of fuel cell stacks
• CPC Class Codes: H01M 8/04597 of auxiliary devices, e.g. batteries, capacitors
• CPC Class Codes: H01M 8/0491 of fuel cell stacks
• CPC Class Codes: H02J 2300/30 The power source being a fuel cell
• CPC Class Codes: H02J 7/34 Parallel operation in networks using both storage and other dc sources, e.g. providing buffering H02J7/14 takes precedence
• CPC Class Codes: Y02E 60/10 Energy storage using batteries
• CPC Class Codes: Y02E 60/50 Fuel cells

Abstract

A hybrid power module suitable for use in an array of hybrid power modules comprises a fuel cell stack, an energy storage device, charger circuit operable to charge the energy storage device from the fuel cell stack and/or an external power source at approximately a defined voltage; a stack disconnect switch operable to provide and remove an electrical path between the fuel cell stack and a terminal of the power module, and a unidirectional current flow device electrically coupled to provide a unidirectional current path from the charger circuit to the terminal of the power module when forward biased.

Claims

1. A hybrid power module suitable for use in an array of hybrid power modules, the hybrid power module comprising:

a module power bus comprising at least a first terminal and a second terminal;

a plurality of fuel cells electrically coupled to one another as a fuel cell stack, the fuel cell stack comprising a first pole and a second pole, the fuel cell stack selectively operable to produce electrical power, and electrically couplable to provide the electrical power on the module power bus;

a plurality of battery cells electrically coupled to one another as a battery, the battery comprising a first pole and a second pole; and

operable to store and release electrical power;

a charger circuit electrically coupled across the battery and operable to supply electrical power to the battery at approximately a defined voltage, the charger circuit comprising a first pole and a second pole, the first pole of the charger circuit electrically couplable to the first pole of the fuel cell stack and electrically couplable to the first terminal of the module power bus;

a stack disconnect switch operable to selectively provide and remove an electrical path between the second terminal of the module power bus and the fuel cell stack in a first state and a second state, respectively; and

a unidirectional current flow device electrically coupled to provide a unidirectional current path from the second pole of the charger circuit to the second terminal of the module power bus when the unidirectional current flow device is forward biased.

2. The hybrid power module of claim 1 wherein the stack disconnect switch is a transistor and the unidirectional current flow device is a body diode of the transistor.

3. The hybrid power module of claim 1, further comprising:

a stack protection diode electrically coupled between the fuel cell stack and the first terminal of the module power bus such that the stack protection diode substantially protects the fuel cell stack from currents received via the first terminal from the battery.

4. The hybrid power module of claim 1, further comprising:

a linear regulator element electrically coupled between the first pole of the fuel cell stack and the first terminal of the module power bus, and operable to regulate a flow of current from the fuel cell stack to the first terminal.

5. The hybrid power module of claim 4 wherein the linear regulator element comprises a plurality of regulating transistors electrically coupled in parallel with one another between the first pole of the fuel cell stack and the first pole of the charger circuit.

6. The hybrid power module of claim 5, further comprising:

a pulsing switch electrically coupled across the first and the second poles of the fuel cell, stack, the pulsing switch selectively operable to produce an electrical short circuit path across the fuel cell stack in a closed state and to remove the electrical short circuit path across the fuel cell stack in an open state.

7. The hybrid power module of claim 6, further comprising:

a controller communicatively coupled to control states of the stack disconnect switch, the linear regulator element, and the pulsing switch based on a number of system operational parameters.

8. The hybrid power module of claim 1, further comprising:

at least one module disconnect switch electrically coupled between the first terminal and the first pole of the battery, and operable to electrically isolate the hybrid power module from other hybrid power modules in the array of hybrid power modules, if any.

9. The hybrid power module of claim 1 wherein the charger circuit comprises an inductor and a switch electrically coupled in a flyback converter configuration.

10. The hybrid power module of claim 9, further comprising:

a redundancy diode electrically coupled between the first pole of the battery and the first terminal of the module power bus to allow current to flow from the first pole of the battery to the first terminal when the redundancy diode is forward biased.

11. The hybrid power module of claim 9, further comprising:

a back rush diode electrically coupled across the battery to protect other hybrid power modules in the array of hybrid power modules against shorted battery cells in the battery, if any.

12. A method of operating a hybrid power module comprising a fuel cell stack including a first pole and a second pole, an energy storage device including a first pole and a second pole, and a charger circuit, the hybrid power module electrically couplable e via a first terminal and a second terminal to an external power bus of an array of hybrid power modules, the method comprising:

during one time,

providing an electrical current path from the first pole of the fuel cell stack to the first terminal;

providing an electrical current path from the second terminal to the second pole of the fuel cell stack via a stack disconnect switch in a closed state;

producing electrical power from the fuel cell stack while the electrical current path from the second terminal to the second pole of the fuel cell stack is provided via the stack disconnect switch; and

converting electrical power from the fuel cell stack to approximately a defined voltage via the charger circuit; and

during another time,

removing the electrical current path from the second terminal to the second pole of the fuel cell stack via the stack disconnect switch in an open state; and

providing a unidirectional electrical current path from the second pole of the charger circuit to the second terminal of the module power bus via a unidirectional current flow device while the unidirectional current flow device is forward biased; and

converting electrical power received via the first and the second terminals to approximately the defined voltage via the charger circuit;

from time-to-time, storing electrical power converted by the charger circuit to the energy storage device; and

from time-to-time, releasing the electrical power stored in the energy storage device.

13. The method of claim 12, further comprising:

linearly regulating a flow of current from the first pole of the fuel cell stack to the first terminal during the one time.

14. The method of claim 13, further comprising:

unidirectionally limiting current flow on a portion of the electrical current path between the first pole of the fuel cell stack and the first terminal.

15. The method of claim 14, further comprising:

selectively operating at least one power module disconnect switch to electrically couple the hybrid power module to the external power bus in a first state of the power module disconnect switch, and to electrically uncouple the hybrid power module from the external power bus in a second state of the power module disconnect switch.

16. The method of claim 15, further comprising:

from time-to-time, repeatedly closing and opening a pulsing switch to produce a number of short circuit conditions across the fuel cell stack.

17. A method of operating a hybrid power module comprising a fuel cell stack, an energy storage device, a charger circuit electrically coupled in parallel with the fuel cell stack and electrically coupled in parallel with the energy storage device, a first terminal and a second terminal to make electrical connections with an external power bus, the method comprising:

operating a stack disconnect switch to selectively provide a bidirectional current path between a floating ground node and the second terminal in a first state of the stack disconnect switch and a unidirectional current path from the floating ground node to the second terminal in a second state of the stack disconnect switch, where the floating ground node is an electrical coupling between the second pole of the fuel cell stack and the second pole of the charger circuit;

providing electrical power from the fuel cell stack to the charger circuit during at least a portion of a time when the stack disconnect switch is in the first state; and

providing electrical power from the external power bus to the charger circuit during at least a portion of a time when the stack disconnect switch is in the second state.

18. The method of claim 17, further comprising:

linearly regulating a flow of current from the fuel cell stack to the first terminal and to the charger circuit while providing power from the fuel cell stack to the charger circuit.

19. The method of claim 18, further comprising:

converting the electrical power supplied to the charger circuit from the fuel cell stack and from the external power bus; and

supplying the converted electrical power to the energy storage device.

20. A power system, comprising:

a housing comprising a plurality of positions, each of the positions sized and dimensioned to mount a respective one of a number of hybrid power modules;

a system power bus carried by the housing, the system power bus comprising at least a first and a second current path, and a plurality of pairs of selectively releasable connectors, each pair of selectively releasable connectors located with respect to a respective one of the positions to permit electrical couplings between the current paths of the system power bus and a respective one of the hybrid power modules mounted at the position; and

a plurality of unidirectional circuit elements, each of the unidirectional circuit elements electrically coupled across a respective pair of the selectively releasable connectors to provide a series bypass of the respective pair of selectively releasable connectors.

21. The power system of claim 20 wherein the unidirectional circuit devices each comprise a respective Zener diode.

22. The power system of claim 21 wherein the unidirectional circuit devices each further comprises a respective resistor electrically coupled in series with the respective one of the Zener diodes.

23. The power system of claim 20 wherein the unidirectional circuit devices comprises a transistor electrically coupled as a Zener diode equivalent circuit.

24. The power system of claim 20 where the housing takes the form of a rack.

25. The power system of claim 20 where the system power bus further comprises a pair of terminals, each of the terminals electrically coupled to a respective one of the first and the second current paths, for making electrical couplings to the first and the second current paths by at least one external load.

26. The power system of claim 20, further comprising:

at least one reservoir, the reservoir mounted at one of the positions of the housing to collect by product from electrical power generation.

27. The power system of claim 20, further comprising:

a first hybrid power module mounted in a first one of the positions of the housing and electrically coupled to a first pair of the plurality of pairs of selectively releasable connectors, the first hybrid power module comprising a fuel cell stack, an energy storage device, and a charger circuit electrically couplable in parallel with the fuel cell stack and the energy storage device and operable to supply power to the energy storage device of the first hybrid power module from the fuel cell stack of the first hybrid power module at a defined voltage, and further operable to supply power to the energy storage device of the first hybrid power module from the system power bus at the defined voltage; and

a second hybrid power module mounted in a second one of the positions of the housing and electrically coupled to a second pair of the plurality of pairs of selectively releasable connectors, the second hybrid power module comprising a fuel cell stack, an energy storage device, and a charger circuit electrically couplable in parallel with the fuel cell stack and the energy storage device and operable to supply power to the energy storage device of the second hybrid power module from the fuel cell stack of the second hybrid power module at a defined voltage, and further operable to supply power to the energy storage device of the second hybrid power module from the system power bus at the defined voltage.

28. The power system of claim 27 wherein the energy storage device of the first hybrid power module is a first type, and the energy storage device of the second hybrid power module is a second type, different from the first type, and the charger circuit of the first hybrid power module is a trickle charger and the charger circuit of the second hybrid power module is not a trickle charger.

29. The power system of claim 27 wherein the energy storage device of the first hybrid power module is a first type of battery, and the energy storage device of the second hybrid power module is a second type of battery, different from the first type of battery, and the charger circuit of the first hybrid power module is a trickle charger and the charger circuit of the second hybrid power module is not a trickle charger.

30. The power system of claim 27, further comprising:

at least one reservoir, the reservoir mounted at one of the positions of the housing and fluidly coupled to at least one of the hybrid power modules to collect byproducts of electrical power generation by operation of the fuel cell stack of the hybrid power module.