Fuel cell mechanical components

Patent metadata

Field	Value
Publication number	US-10840535-B2
Application number	US-201414447944-A
Country	US
Kind code	B2
Filing date	Jul 31, 2014
Priority date	Sep 24, 2010
Publication date	Nov 17, 2020
Grant date	Nov 17, 2020

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.

First claim

The invention claimed is:

1. A modular fuel cell system, comprising:
modular base sections interlocked with one another to form a common base; power modules arranged in a row on the common base; and
a fuel processing module and a power conditioning module arranged on at least one end of the row on the common base; wherein:
each power module comprises a separate cabinet comprising at least one fuel cell stack located in a hot box;
the power modules are electrically and fluidly connected to the fuel processing and the power conditioning modules through electrical and fluid channels formed in the modular base sections of the common base
wherein at least one power module comprises a cabinet comprising at least one fuel cell stack located in a hot box; wherein the cabinet comprises: a cabinet housing; and
a door mounted on the cabinet housing, wherein the door is configured to open with a vertical swing that is within 0 to 30 degrees of a vertical direction and then with a horizontal swing that is within 0 to 30 degrees of a horizontal direction, such that the door is at least partially disposed above the cabinet housing.

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 at least one of the power conditioning modules 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 each of the modular base sections comprise a pre-cast base section formed from one of: concrete, geopolymer, and steel, each of the pre-cast base sections comprising the electrical and fluid channels which contain electrical bus bar conduits, input and output fuel conduits and at least one water conduit which extend between the interconnected modular base sections to the system, from the system, or between the power modules, the fuel processing modules and the power conditioning 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.

15. The system of claim 1 , wherein the modular base sections comprise pre-cast concrete or geopolymer sections.

16. 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.

17. The system of claim 16 , 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.

18. The system of claim 17 , 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.

19. The system of claim 17 , further comprising a species sensor to detect sulfur or other contaminant that has broken through a vessel in the fluid series.

20. The system of claim 1 , wherein the common base is formed by:
pre-casting modular base section material into patterned molds;
removing pre-cast modular base sections from the molds;
transporting the pre-cast modular base sections from the location of the molds to a location of the fuel cell system; and
aligning and assembling the pre-cast modular base sections at the location of the fuel cell system to interlock the pre-cast modular base sections to each other to form the common base.

21. A modular fuel cell system, comprising:
a base; and
at least one power module arranged on the base, wherein the at least one power module comprises a cabinet comprising at least one fuel cell stack located in a hot box;
wherein the cabinet comprises:
a cabinet housing; and
a door mounted on the cabinet housing, wherein the door is configured to open with a vertical swing that is within 0 to 30 degrees of a vertical direction and then with a horizontal swing that is within 0 to 30 degrees of a horizontal direction, such that the door is at least partially disposed above the cabinet housing.

Assignees

• Bloom Energy Corp

Inventors

• Richards Gilbert
• Trevisan David
• Lee Michael
• Mahler Jessica
• Parker Ross
• Clarabut Alex
• Pearson Chad
• Ballantine Arne
• Weingaertner David
• Hixson Jason
• Mitlitsky Fred

Classifications

• Y10T29/49623

  Static structure, e.g., a building component · CPC title

• H01M8/0662

  Treatment of gaseous reactants or gaseous residues, e.g. cleaning · CPC title

• Y02B90/10

  Applications of fuel cells in buildings · CPC title

• H01M8/24

  Grouping of fuel cells, e.g. stacking of fuel cells · CPC title

• Y10T29/49819

  with conveying of work or disassembled work part · CPC title