Source: http://www.google.com/patents/US20050186455?dq=6,049,612
Timestamp: 2017-12-16 20:55:20
Document Index: 472095580

Matched Legal Cases: ['§119', 'Application No. 60', '§119', 'Application No. 60', '§119', 'Application No. 60']

Patent US20050186455 - Micro fuel cell system start up and shut down systems and methods - Google Patents
Described herein are fuel cell systems and methods of using fuel cell systems. The systems include a fuel cell that generates electrical energy using hydrogen and a fuel processor that produces hydrogen from a fuel source. The fuel processor includes a reformer and a burner that heats the reformer. One...http://www.google.com/patents/US20050186455?utm_source=gb-gplus-sharePatent US20050186455 - Micro fuel cell system start up and shut down systems and methods
Publication number US20050186455 A1
Application number US 10/877,769
Also published as EP1639660A2, EP1639660A4, US7763368, US8043757, US20050008909, US20050014040, US20080038601, US20080171241, US20090123797, WO2005001960A2, WO2005001960A3, WO2005004257A2, WO2005004257A3
Publication number 10877769, 877769, US 2005/0186455 A1, US 2005/186455 A1, US 20050186455 A1, US 20050186455A1, US 2005186455 A1, US 2005186455A1, US-A1-20050186455, US-A1-2005186455, US2005/0186455A1, US2005/186455A1, US20050186455 A1, US20050186455A1, US2005186455 A1, US2005186455A1
Inventors Ian Kaye, Gerry Tucker
Original Assignee Ultracell Corporation, A California Corporation
Patent Citations (92), Referenced by (49), Classifications (138), Legal Events (4)
Micro fuel cell system start up and shut down systems and methods
US 20050186455 A1
1. A method for starting a fuel processor including a reformer and a burner that provides heat to the reformer, the method comprising:
generating heat using an electrical heater that is configured to heat the burner or a fuel source provided to the burner;
supplying the fuel source to the burner;
catalytically generating heat in the burner to heat the reformer;
supplying the fuel source to the reformer; and
generating hydrogen in the reformer.
2. The method of claim 1 wherein the heat is generated by the electrical heater for at least 50 milliseconds before the fuel source is supplied to the burner.
3. The method of claim 1 wherein the heat is generated by the electrical heater until the burner reaches a threshold start temperature.
4. The method of claim 1 further comprising mixing air with the fuel source before the fuel source reaches the electrical heater.
5. The method of claim 4 wherein the electrical heater heats the air and the fuel source before the air and the fuel source enters the burner.
6. The method of claim 1 further comprising turning off the electrical heater after the fuel source is supplied to the burner.
7. The method of claim 1 further comprising providing hydrogen from the reformer to the burner.
8. The method of claim 1 further comprising catalytically generating heat in the burner using the hydrogen.
9. The method of claim 1 further comprising recharging a capacitor or battery that powers the electrical heater using electrical energy provided by a fuel cell that receives hydrogen from the reformer.
10. The method of claim 1 wherein the electrical heater vaporizes the fuel source.
11. The method of claim 1 wherein the fuel source comprises methanol.
12. A system for heating a fuel source before catalytic heat generation within a burner included in a fuel processor, the system comprising:
an electric heater configured to heat the burner or the fuel source provided to the burner.
13. The system of claim 12 further comprising a capacitor or battery that is recharged by the fuel cell and that powers the electrical heater.
14. The system of claim 12 wherein the electric heater is disposed in the burner.
15. The system of claim 12 wherein air mixes with the fuel source before the fuel source reaches the burner.
16. The system of claim 15 wherein the electric heater is disposed outside the burner.
17. The system of claim 12 further comprising a catalyst disposed on an outside surface of the electric heater that facilitates the generation of heat in the presence of the fuel source.
18. The system of claim 12 further comprising a boiler configured to heat the fuel source before the reformer receives the fuel source.
19. The system of claim 12 wherein the reformer comprises a reformer chamber having a volume greater than about 0.1 cubic centimeters and less than about 50 cubic centimeters.
20. A method for shutting down a fuel cell system comprising a fuel cell that received hydrogen from a fuel processor including a reformer and a burner that provided heat to the reformer, the method comprising:
stopping electrical energy generation in the fuel cell;
discontinuing a supply of a fuel source to the reformer, which is configured to receive the fuel source and output hydrogen;
generating heat in the burner to heat to the reformer after discontinuing the supply of the fuel source to the reformer;
discontinuing heat generation in the burner; and
flushing the burner with air.
21. The method of claim 20 further comprising discontinuing hydrogen supply to the fuel cell.
22. The method of claim 21 further comprising providing air to a cathode gas distribution system in the fuel cell after the discontinuing hydrogen supply to the fuel cell.
23. The method of claim 20 further comprising cooling the fuel cell.
24. The method of claim 23 wherein cooling the fuel cell comprises turning on a fan that moves air through the fuel cell.
25. The method of claim 24 wherein the air moves across a heat transfer appendage included in the fuel cell, wherein the heat transfer appendage a) includes a portion arranged external to a fuel cell stack included in the fuel cell and b) is in conductive thermal communication with an internal portion of the fuel cell stack
26. The method of claim 20 wherein heat is generated in the burner to heat to the reformer until for greater than about 30 seconds after discontinuing the supply of the fuel source to the reformer.
27. The method of claim 20 wherein the burner includes an inlet to receive the fuel source from a second supply of the fuel source and the burner catalytically generates heat using the fuel source.
28. The method of claim 27 wherein discontinuing heat generation in the burner comprises discontinuing the second supply of the fuel source.
29. A fuel cell system for producing electrical energy, the fuel cell system comprising:
a fuel cell including a fuel cell stack configured to produce electrical energy using hydrogen output by the fuel processor, and including a heat transfer appendage that a) includes a portion arranged external to the fuel cell stack and b) is in conductive thermal communication with an internal portion of the fuel cell stack; and
control logic configured to regulate heat transfer or temperature for one or more components within the fuel cell system.
30. The system of claim 29 wherein the control logic is further configured to generate heat in the burner to heat to the reformer after discontinuing the supply of the fuel source to the reformer.
31. The system of claim 30 wherein the control logic is further configured to discontinue heat generation in the burner.
32. The system of claim 31 wherein the control logic is further configured to flush the burner with air.
This application claims priority under 35 U.S.C. §119(e) from co-pending U.S. Provisional Patent Application No. 60/482,996 entitled “Fuel cell system startup procedure and self-heating apparatus”, which is incorporated by reference for all purposes; this application also claims priority under 35 U.S.C. §119(e) from co-pending U.S. Provisional Patent Application No. 60/483,416 entitled “Fuel Preheat in Portable Electronics Powered by Fuel Cells”, which is incorporated by reference for all purposes; and this application additionally claims priority under 35 U.S.C. §119(e) from co-pending U.S. Provisional Patent Application No. 60/482,981 entitled “Micro machined fuel stack with integral cooling and humidification”, which is incorporated by reference for all purposes
In yet another aspect, the present invention relates to a method for starting a fuel processor including a reformer and a burner that provides heat to the reformer. The method comprises generating heat using an electrical heater that is configured to heat the burner or a fuel source provided to the burner. The method also comprises supplying the fuel source to the burner. The method further comprises catalytically generating heat in the burner to heat the reformer. The method additionally comprises supplying the fuel source to the reformer. The method also comprises generating hydrogen in the reformer.
FIG. 10B illustrates a process flow for starting a fuel processor in accordance with one embodiment of the present invention.
In one embodiment, fuel processor 15 is a steam reformer that only needs steam to produce hydrogen. Several types of reformers suitable for use in fuel cell system 10 include steam reformers, auto thermal reformers (ATR) or catalytic partial oxidizers (CPOX). ATR 10 and CPOX reformers mix air with the fuel and steam mix. ATR and CPOX systems reform fuels such as methanol, diesel, regular unleaded gasoline and other hydrocarbons. In a specific embodiment, storage device 16 provides methanol 17 to fuel processor 15, which reforms the methanol at about 250° C. or less and allows fuel cell system 10 use in applications where temperature is to be minimized.
System 400 comprises all components of system 10 described with respect to FIG. 1B and also comprises plumbing configured to transport a heating medium from fuel processor 15 to fuel cell 20. As the term is used herein, plumbing may comprise any tubing, piping and/or channeling that communicates a gas or liquid from one location to a second location. The plumbing may also comprise one or more valves, gates or other devices to facilitate and control flow. A fan or pump may also be included to pressurize a line and move the heating medium. Plumbing between burner 30 and fuel cell 20 includes an outlet 402 on fuel processor 15 that exhausts heated gases from burner 30 to a line 41, which transmits the heated gases to fuel cell 20. A ‘line’ refers to tubing, piping and/or channeling that is dedicated for fluid or gas communication between two locations.
When connector 104 and mating connector 140 interface, fuel cell system controller 214 digitally communicates with memory 106 using link 217 for bidirectional communication therebetween. In another embodiment, controller 214 uses a wireless interrogator to communicate with an RFID antennae and memory 206 included in storage device 16. Controller 214 may read any information stored in memory 206 such as a fuel type stored in the storage device 16, a model number for storage device 16, a volume capacity for bladder 205 or storage device 16, a number of refills provided to storage device 16, the last refill date, the refilling service provider, and a current volume for the storage device. Controller 214 estimates the remaining power in storage device 16 by comparing the fuel source 17 level since last use or refill against a consumption rate for a particular laptop computer. Controller 214 may also write transient information to memory 106, such as an updated volume for the storage device. The controller 214 communicates with a main controller 210 for computer 202 and computer memory 218 via communications bus 212. Computer memory 218 may store instructions for the control of fuel system 10 such as read and write protocol and instructions for communication with a digital memory 106.
FIG. 10B illustrates a process flow 820 for starting a fuel processor in accordance with one embodiment of the present invention. The fuel processor includes a reformer and a burner that provides heat to the reformer. A fuel cell receives hydrogen produced by the fuel processor.
Process flow 820 begins by generating heat using an electrical heater that is configured to heat the burner or a fuel source provided to the burner (822). The electrical heater may also be configured to heat the reformer or a fuel source provided to the reformer. The heat may vaporize the fuel source. The electrical heater generates heat for a set duration or until a particular operating condition is reached. In one embodiment, the electrical heater generates heat for at least 50 milliseconds before the fuel source is supplied to the burner. Some fuel processors may be heated for 30 seconds, up to a minute, or even longer. A threshold start temperature may also be used to determine the heating duration. A temperature sensitive catalyst, burner or reformer may require that the electrical heater generate heat until the catalyst, burner or reformer reaches a threshold start temperature. Some burner catalysts include a threshold start temperature above 60 degrees Celsius. Some reformer catalysts include a threshold start temperature above 100 degrees Celsius. Alternatively, the electrical heater generates heat until the reformer walls reach 150 degrees Celsius or some other operating temperature. In one embodiment, air and the fuel source mix before the fuel source reaches the burner and electrical heater. In this case, the electrical heater may be disposed outside the burner to pre-heat the fuel source before entering the burner.
Process flow 820 then supplies the fuel source to the burner (822). Typically, a pump moves the fuel source and turns on via a system controller. The controller may also turn on a fan that provides air to the burner. A catalyst in the burner then catalytically generates heat in the burner to heat the reformer (824). The fuel source enters the burner before the reformer reaches its operating temperature. If the burner catalyst requires a lower operating temperature than the reformer catalyst, catalytic heat generation in the burner may be used to continue heating the reformer—and the electric heater is turned off after the fuel source is supplied to the burner. If the reformer has not yet reached its operating temperature, the reformer exhaust may comprise a high concentration of CO and unprocessed fuel (‘dirty hydrogen’) that is unsuitable for use in a fuel cell. As described above, the hydrogen may be routed from a reformer outlet to a burner inlet to react with a thermal catalyst in the burner and generate additional heat in the burner to expedite the time needed for the reformer to reach operating temperature.
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U.S. Classification 429/424, 422/198, 423/650, 422/199, 429/441, 429/429, 429/454, 429/423
International Classification H01M8/10, B01J19/24, C08F4/636, C01B3/24, C08F4/649, C08F4/651, C01B3/38, H01M, H01M8/04, B01J19/00, C08F4/654, H01M8/06
Cooperative Classification Y02P70/56, Y02P20/128, C01B2203/142, C01B2203/066, B01J8/0242, B01J2219/00835, B01J2208/00309, C01B3/323, C01B2203/1247, B01J2219/2467, H01M8/0618, C01B3/38, C01B2203/0233, C01B2203/82, B01J2219/00873, C01B2203/0844, H01M8/0258, H01M8/04626, B01J8/0221, B01J2219/2459, H01M8/04731, C01B2203/1223, H01M8/04067, B01J8/0438, H01M8/04589, H01M8/04604, H01M8/04776, C01B2203/0805, B01J2219/247, H01M8/0267, B01J2208/00415, C01B2203/0811, B01J2219/2481, B01J8/0484, H01M8/04365, C01B2203/0827, B01J8/0214, B01J2208/00504, H01M8/04268, C01B2203/0244, B01J2208/00716, H01M8/0435, H01M8/04388, B01J2219/2462, B01J2208/00398, H01M8/04955, H01M8/04007, H01M8/0662, B01J2219/2458, H01M8/04037, B01J2219/2479, B01J2208/00061, B01J2219/2465, B01J8/0285, C01B2203/0261, C01B2203/0866, H01M8/04738, B01J19/0093, H01M8/0247, C01B2203/0822, B01J2219/2482, H01M8/04298, H01M8/04559, B01J19/249, H01M8/04373, B01J2219/00783, H01M8/04022, B01J2208/00407, B01J2208/00646, B01J2219/00907, H01M2008/1095, B01J2219/2475, H01M8/0631, H01M8/04223, H01M8/0228, H01M8/04425, H01M8/04619, H01M8/04768, H01M8/04753, B01J2219/2453
European Classification H01M8/04H6B8, H01M8/04H4B8, H01M8/04H4K6, H01M8/04H4K6D, H01M8/04H6D8, H01M8/04H4K6F, H01M8/04H6D6, H01M8/04H6D2, H01M8/04B6, H01M8/02C6, H01M8/04H4B12, B01J8/04B4D, B01J8/02B2, H01M8/02C2K2, H01M8/06B2B2, H01M8/04B14, H01M8/04H4D12, B01J8/02D, H01M8/04H6B10, H01M8/04H6K6H, H01M8/02C8, H01M8/04C8, C01B3/32B, H01M8/04H4K2D, B01J8/04D4D, B01J8/02H, H01M8/04H4K4D, B01J8/02B4, H01M8/04H4D2, H01M8/06B2A, H01M8/04H4B14, H01M8/02C10, H01M8/04B, H01M8/04H, B01J19/00R, C01B3/38, B01J19/24R4, H01M8/04B2C
Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:KAYE, IAN;TUCKER, GERRY;REEL/FRAME:015148/0206;SIGNING DATES FROM 20040802 TO 20040820
Free format text: CORRECTIVE ASSIGNMENT TO CORRECT THE STATE OF INCORPORATION OF THE ASSIGNEE PREVIOUSLY RECORDED ONREEL 015148 FRAME 0206;ASSIGNORS:KAYE, IAN W.;TUCKER, GERRY;REEL/FRAME:022820/0996