Fuel cell powered line-replaceable thrust module

Patent metadata

Field	Value
Publication number	US-11414199-B2
Application number	US-201916290704-A
Country	US
Kind code	B2
Filing date	Mar 1, 2019
Priority date	Mar 1, 2019
Publication date	Aug 16, 2022
Grant date	Aug 16, 2022

Abstract

A line-replaceable thrust module includes a nacelle configured to be mechanically connected to an anchoring location of an unmanned aerial vehicle (UAV), an electric motor coupled to the nacelle, an electric speed controller configured to control the speed of the electric motor and configured to be electrically connected to a communication network of the UAV, and a fuel cell system configured to produce electrical energy from an electrochemical reaction between hydrogen and oxygen. The fuel cell system includes a fuel cell, a hydrogen tank, a pressure regulator coupled to the hydrogen tank, and a supply line coupled between the pressure regulator and the fuel cell.

First claim

What is claimed is:

1. A line-replaceable thrust module, comprising:
a nacelle configured for mechanical connection to an unmanned aerial vehicle (UAV), the nacelle comprising an upstream end and a downstream end;
an electric motor coupled to the nacelle, wherein the electric motor is configured to convert electrical energy into rotational energy imparted to a shaft extending therefrom;
an electronic speed controller configured to control the speed of the electric motor, wherein the electronic speed controller is configured for electrical connection to a communication network of the UAV; and
a fuel cell system disposed at least partially within the nacelle, wherein the fuel cell system is configured to produce electrical energy from an electrochemical reaction between hydrogen and oxygen, the fuel cell system comprising:
a fuel cell including a cathode, an anode, and an electrolyte therebetween;
a hydrogen tank comprising an upstream end and a downstream end wherein the upstream end is relatively closer to the fuel cell as compared to the downstream end, wherein the hydrogen tank is disposed within the nacelle, and wherein the hydrogen tank is configured to store hydrogen fuel;
a pressure regulator coupled to the hydrogen tank; and
a supply line coupled to the pressure regulator and configured to deliver hydrogen fuel from the hydrogen tank to the anode of the fuel cell; and
an air channel configured to direct air from outside of the nacelle to the cathode of the fuel cell, the air channel comprising an inlet and an outlet, wherein the outlet is located relatively closer to the upstream end of the nacelle as compared to the downstream end of the hydrogen tank.

2. The line-replaceable thrust module of claim 1 , wherein the fuel cell system further comprises a battery or a supercapacitor.

3. The line-replaceable thrust module of claim 2 , further comprising:
a connection interface configured to cooperatively engage a corresponding connection interface on the UAV, wherein the cooperative engagement therebetween creates the mechanical connection between the nacelle and the UAV and the electrical connection between the electronic speed controller and the communication network of the UAV.

4. The line-replaceable thrust module of claim 3 , wherein the connection interface is configured to engage with any one of four corresponding connection interfaces of the UAV.

5. The line-replaceable thrust module of claim 4 , wherein the electrical connection is configured to allow the fuel cell system to transmit the electrical energy produced by the fuel cell to the UAV.

6. The line-replaceable thrust module of claim 1 , further comprising:
a filling port configured to enable refilling of the hydrogen tank with hydrogen fuel without removing the hydrogen tank from the nacelle.

7. A line-replaceable thrust module, comprising:
a nacelle removably coupled to an unmanned aerial vehicle (UAV);
a propulsion system, comprising:
an electric motor coupled to the nacelle, wherein the electric motor is configured to convert electrical energy into rotational energy imparted to a shaft extending therefrom;
an electronic speed controller configured to control the speed of the electric motor; and
a rotor assembly coupled to the shaft of the electric motor, the rotor assembly including a plurality of rotor blades extending therefrom; and

a fuel cell system disposed at least partially within the nacelle, wherein the fuel cell system is configured to produce electrical energy from an electrochemical reaction between hydrogen and oxygen, the fuel cell system comprising:
a fuel cell including a cathode, an anode, and an electrolyte therebetween;
a supply line coupled to the anode of the fuel cell; and
an electrical energy storage device configured to store and release the electrical energy produced by the fuel cell; and

an air channel comprising an upstream inlet and a downstream outlet, wherein at least a portion of the downstream outlet is located downstream relative to a most downstream portion of the fuel cell.

8. The line-replaceable thrust module of claim 7 , wherein the nacelle includes an access door configured to provide access to an interior of the nacelle, and wherein the interior of the nacelle is configured to removably couple a hydrogen tank therein.

9. The line-replaceable thrust module of claim 7 , wherein the propulsion system further comprises a gimbal coupled between the nacelle and the electric motor, wherein the gimbal is configured to rotate the electric motor relative to the nacelle.

10. The line-replaceable thrust module of claim 7 , wherein the line-replaceable thrust module is utilized in any one of four locations on the UAV.

11. The line-replaceable thrust module of claim 7 , wherein the line-replacement thrust module is configured such that coupling the nacelle to the UAV creates an electrical connection enabling data transmission and/or power transmission between the line-replaceable thrust module and the UAV.

12. The line-replaceable thrust module of claim 7 , further comprising:
an aerosurface rotatably coupled to the nacelle.

13. The line-replaceable thrust module of claim 7 , further comprising:
a sensor configured to transmit data to a flight control system on the UAV.

14. An unmanned aerial vehicle (UAV), comprising:
a first wing having a connection interface;
a flight control system;
a communication network coupled between the flight control system and the connection interface of the first wing; and
a first line-replaceable thrust module, comprising:
a nacelle having a corresponding connection interface removably coupled to the connection interface of the first wing;
an electric motor coupled to the nacelle, wherein the electric motor is configured to convert electrical energy into rotational energy imparted to a shaft extending therefrom;
an electronic speed controller configured to control the speed of the electric motor; and
a fuel cell system disposed at least partially within the nacelle, wherein the fuel cell system is configured to produce electrical energy from an electrochemical reaction between hydrogen and oxygen, the fuel cell system comprising:
a fuel cell including a cathode, an anode, and an electrolyte therebetween; and
an electrical energy storage device configured to store and release the electrical energy produced by the fuel cell; and

an air channel comprising an upstream inlet and a downstream outlet, at least a portion of the downstream outlet being located further downstream than a most downstream portion of the fuel cell system.

15. The UAV of claim 14 , wherein the first line-replaceable thrust module further comprises:
a rotor assembly coupled to the shaft of the electric motor, the rotor assembly including a plurality of rotor blades extending therefrom; and
a gimbal coupled between the nacelle and the electric motor, wherein the gimbal is configured to rotate the electric motor relative to the nacelle.

16. The UAV of claim 15 , wherein:
air channel is configured to direct air driven by the plurality of rotor blades to the cathode of the fuel cell.

17. The UAV of claim 16 , wherein the first line-replaceable thrust module further comprises:
a hydrogen tank disposed within the nacelle, wherein the hydrogen tank is configured to store hydrogen fuel therein;
a pressure regulator coupled to the hydrogen tank;
a supply line coupled between the pressure regulator and the anode of the fuel cell; and
a filling port coupled to the pressure regulator, wherein the filling port is configured to permit

Assignees

• Bell Helicopter Textron Inc
• Textron Innovations Inc

Inventors

• Rainville Joseph Dean
• Mccullough John Richard

Classifications

• B64D31/18

  for hybrid-electric power plants · CPC title

• B64D29/06 Primary

  Attaching of nacelles, fairings or cowlings · CPC title

• B60L50/75 Primary

  using propulsion power supplied by both fuel cells and batteries · CPC title

• B64C29/02

  having its flight directional axis vertical when grounded · CPC title

• Y02T90/16

  Information or communication technologies improving the operation of electric vehicles · CPC title