Multi-stage filtration system for fuel cell hybrid propulsion system

Patent metadata

Field	Value
Publication number	US-12458913-B2
Application number	US-202318136220-A
Country	US
Kind code	B2
Filing date	Apr 18, 2023
Priority date	Apr 19, 2022
Publication date	Nov 4, 2025
Grant date	Nov 4, 2025

Abstract

A filtration system for a fuel cell hybrid propulsion system includes a first stage filter, a second stage filter positioned downstream of the first stage filter, and a third stage filter positioned downstream of the second stage filter and configured to be positioned upstream of a fuel cell system. The first stage filter has first pores with a first mean pore size. The second stage filter has second pores with a second mean pore size. The third stage filter has third pores with a third mean pore size. The second mean pore size is less than the first mean pore size. The third mean pore size is less than or equal to the second mean pore size. The first, second, and third stage filter are structured to filter an airflow prior to being received by the fuel cell system.

First claim

The invention claimed is:

1 . A system for a machine having a fuel cell hybrid propulsion system, the system comprising:
a filtration assembly including:
a first stage filter having first pores with a first mean pore size;
a second stage filter positioned downstream of the first stage filter, the second stage filter having second pores with a second mean pore size; and
a third stage filter positioned downstream of the second stage filter and configured to be positioned upstream of a fuel cell assembly, the third stage filter having third pores with a third mean pore size, wherein the second mean pore size is less than the first mean pore size, and wherein the third mean pore size is less than or equal to the second mean pore size, and wherein the first stage filter, the second stage filter, and the third stage filter are structured to filter an airflow prior to being received by the fuel cell assembly;
a plurality of pressure sensors positioned to acquire pressure data regarding a pressure differential across at least one of the first stage filter or the second stage filter; one or more chemical sensors positioned to acquire chemical data regarding at least one of a presence, a quantity, or a type of chemical downstream of at least one of the first stage filter or the second stage filter; and a controller having programmed instructions to:
monitor the pressure data and the chemical data;
provide a first notification in response to the pressure data indicating that at least one of the first stage filter or the second stage filter is in a plugged condition; and
provide a second notification in response to the chemical data indicating that at least one of the first stage filter or the second stage filter is chemically saturated.

2 . The system of claim 1 , wherein the one or more chemical sensors includes a single chemical sensor positioned downstream of the second stage filter and upstream of the third stage filter, and wherein the controller has programmed instructions to provide the second notification in response to the chemical data indicating that the second stage filter is chemically saturated.

3 . The system of claim 1 , wherein each of the first stage filter and the second stage filter includes a chemical catalyst that reacts with one or more chemicals, wherein the one or more chemical sensors includes (i) a first chemical sensor positioned downstream of the first stage filter and upstream of the second stage filter and (ii) a second chemical sensor positioned downstream of the second stage filter and upstream of the third stage filter, wherein the chemical data includes (i) first chemical data regarding at least one of a first presence, a first quantity, or a first type of chemical downstream of the first stage filter and (ii) second chemical data regarding at least one of a second presence, a second quantity, or a second type of chemical downstream of the second stage filter, and wherein the controller has programmed instructions to:
provide the second notification in response to the first chemical data indicating that the first stage filter is chemically saturated; and provide the second notification in response to the second chemical data indicating that the second stage filter is chemically saturated.

4 . The system of claim 1 , wherein the pressure data includes first pressure data regarding a first pressure differential across the first stage filter and second pressure data regarding a second pressure differential across the second stage filter, and wherein the controller has programmed instructions to:
provide the first notification in response to the first pressure data indicating that the first stage filter is in the plugged condition; and provide the first notification in response to the second pressure data indicating that the second stage filter is in the plugged condition.

5 . The system of claim 1 , wherein the third stage filter includes a plurality of third stage filters in parallel with the first stage filter and the second stage filter, and wherein each of the plurality of third stage filters is configured to be associated with a respective fuel cell stack of the fuel cell assembly.

6 . The system of claim 1 , wherein the filtration assembly includes a magnetic device positioned upstream of the first stage filter.

7 . The system of claim 1 , wherein the first mean pore size is between 30 and 50 microns, and wherein the second mean pore size is between 5 and 15 microns.

8 . The system of claim 1 , further comprising a plurality of air inlets positioned upstream of the first stage filter, wherein each of the plurality of air inlets is independently and selectively closable or restrictable.

9 . The system of claim 8 , wherein the controller has programmed instructions to:
acquire air quality data regarding an air quality of air upcoming, proximate, or entering the plurality of air inlets; close or restrict a first air inlet of the plurality of air inlets in response to the air quality data indicating that the air upcoming, proximate, or entering the first air inlet is of a quality lower than a quality threshold to prevent dirty ambient air from entering the filtration assembly; and open or keep open a second air inlet of the plurality of air inlets in response to the air quality data indicating that the air upcoming, proximate, or entering the second air inlet is of a quality greater than the quality threshold.

10 . The system of claim 1 , further comprising:
an air inlet positioned upstream of the first stage filter that is selectively closable or restrictable; and a battery configured to provide power to an electric motor of the machine when the air inlet is closed or restricted and to restrict an ability of the fuel cell assembly in generating electricity.

11 . The system of claim 10 , wherein the controller has programmed instructions to transition from (i) a fuel cell power generation mode where the fuel cell assembly generates the electricity for use by the machine to (ii) an electric only mode where the battery is not charged by the fuel cell assembly and the electric motor is not powered by the fuel cell assembly, but rather the electric motor is powered by stored energy in the battery.

12 . The system of claim 11 , wherein the controller has programmed instructions to switch from the fuel cell power generation mode to the electric only mode in response to at least one of (i) the air inlet being closed or restricted, (ii) an onboard air storage of the machine being empty, or (iii) the fuel cell assembly being deactivated or turned off (a) due to air quality conditions or (b) if the filtration assembly reaches a plugged or chemical saturation condition.

13 . The system of claim 12 , further comprising the onboard air storage configured to store an air supply and facilitate selectively providing the air supply to the filtration assembly or the fuel cell assembly when not empty and when the air inlet is closed or restricted.

14 . The system of claim 1 , further comprising:
an air inlet positioned upstream of the first stage filter that is selectively closable or restrictable; and an onboard air storage configured to store an air supply and facilitate selectively providing the air supply to the filtration assembly or the fuel cell assembly when the air inlet is closed or restricted.

15 . The system of claim 14 , wherein the controller has programmed instructions to:
acquire air quality data regarding an air quality of air upcoming, proximate, or entering the air inlet; close or restrict the air inlet in response to the air quality data ind

Assignees

• Cummins Inc

Inventors

• Ancimer Richard J
• Chandraraj Joseph P
• Genter David P
• Landes Brian K
• Turlapati Agneya

Classifications

• H01M8/0662

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

• H01M8/0687

  Reactant purification by the use of membranes or filters · CPC title

• Y02E60/50

  Fuel cells · CPC title

• B01D2257/708

  Volatile organic compounds V.O.C.'s · CPC title

• B01D2253/102

  Carbon · CPC title