Abstract:
A fuel cell electric power generation system using air as both a coolant and an oxidant comprises an electric power generation subsystem, an air filter subsystem, a power and control electronics unit (PEU) subsystem comprising a DC/DC converter, and an air fan subsystem. The subsystems are arranged such that air circulation through the system is improved and the risk of moisture damage to sensitive PEU components is reduced. In one embodiment, the air filter subsystem is positioned ahead of the PEU subsystem, which is positioned ahead of the power generation subsystem, which is positioned ahead of the air fan subsystem in the direction of air flow, such that air is drawn by the air fan subsystem through the air filter subsystem, over the PEU subsystem, and through the electric power generation subsystem providing filtered air to cool the PEU prior to entering the fuel cell stack to provide oxygen for the electrochemical reaction.

Description:
BACKGROUND OF THE INVENTION 
     Field of the Invention 
     The invention relates to a fuel cell electric power generating system. More specifically, to a fuel cell system using air cooling. 
     Description of the Related Art 
     Fuel cells are electrochemical devices that generate power from a chemical reaction. Hydrogen and oxygen are typically the primary fuel and oxidant, respectively, involved in the reaction. The reaction takes place at a membrane electrode assembly (MEA). The MEA has an anode and a cathode electrode and a membrane electrolyte for letting protons pass through. An additional product of the reaction is heat. Fuel cells have a load-dependent electrical efficiency of about 50%. The heat losses must be carried off by a corresponding cooling system. In most cases this is accomplished by means of water circulation with an external cooler. Air-cooled cells or stacks are also known. Air-cooled systems, where the air serves both as a coolant and as an oxidant, are especially advantageous because they can be designed more cheaply by not requiring separate systems for coolant and oxidant supply. An example of a fuel cell for use in such an ambient air and coolant system is described in Magnet Motor reference WO98/39809. This reference also discloses the use of an additional gas diffusion barrier (GDB) layer as part of the gas diffusion electrodes. The GDB layer prevents the drying out of the fuel cell membranes that would otherwise occur under continuous operation. However, air that is moved away from the reaction sites of these systems can still pick up some of the water involved in the chemical process and experience an increase in moisture content as it cools the system. The architectural layouts of fuel cell systems of the prior art have consisted of moving air throughout the system in a manner that increases the risk that moist air will cause damage to the sensitive components such as the power and control electronics unit (PEU) or that air heated by the fuel cell stack will not sufficiently cool the PEU and thus increase the risk of premature failure of the PEU. 
     Accordingly, there remains a need for a fuel cell system where air is moved throughout the air cooled system while reducing the risk of moisture damage to the PEU and also preventing the fuel cell stack from heating the air prior to it cooling the PEU. 
     BRIEF SUMMARY OF THE INVENTION 
     A fuel cell electric power generation system using air as both a coolant and an oxidant comprises an electric power generation subsystem, an air filter subsystem, a power electronics unit (PEU) subsystem comprising a DC/DC converter, and an air fan subsystem. The subsystems are arranged such that air circulation through the system is improved and the risk of moisture damage to sensitive PEU components is reduced. In one embodiment, the air filter subsystem is positioned ahead of the PEU subsystem, which is positioned ahead of the power generation subsystem, which is positioned ahead of the air fan subsystem in the direction of air flow, such that air is drawn by the air fan subsystem through the air filter subsystem, over the PEU subsystem, and through the electric power generation subsystem, providing filtered air to cool the PEU prior to entering the fuel cell stack to provide oxygen for the electrochemical reaction. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The provided FIGURES illustrate certain non-optimized aspects of the invention, but should not be construed as limiting in any way. 
         FIG. 1   a  is a schematic view showing the overall system architecture of an electrochemical fuel cell power generation system employing ambient air as the oxidant and coolant. 
         FIG. 1   b  is a component diagram of a fuel supply system of an electrochemical fuel cell power generation system employing ambient air as the oxidant and coolant. 
         FIG. 2  is a section view of various MEA structure construction details suitable for use in an electrochemical fuel cell power generation system employing ambient air as the oxidant and coolant. 
         FIGS. 3A and 3B  illustrate alternative embodiments of a MEA seal design for use in an electrochemical fuel cell power generation system employing ambient air as the oxidant and coolant. 
         FIGS. 4A and 4B  illustrate alternative embodiments of a plate design for use in an electrochemical fuel cell power generation system employing ambient air as the oxidant and coolant. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     As illustrated in FIG. 1 a , an ambient air and oxidant cooling system consists of an air filter ( 10 ), a power electronics unit (PEU) ( 20 ), a fuel cell stack ( 30 ), a fuel supply system ( 56 ), and a fan ( 40 ). Although only a single air filter or fan is depicted, configurations with more than one air filter or fan can also be envisioned. Also, the fan can be provided with a tachometer that can serve as both a fan speed measurement device or as a system on/off indicator. 
     The PEU of the ambient air and oxidant cooling system depicted in  FIG. 1   a  comprises a power supply with a DC/DC converter that can have an architecture and a power conversion methodology as shown in patent application US20040217732. The power supply comprises a main power converter architecture that allows the fuel cell stack to operate independently of a desired output voltage. The fuel cell stack may be directly connected to the main power converter eliminating high current switches and diodes. Switches are operable to selectively power an auxiliary component such as the cooling fan to the fuel cell stack or to a storage device via an auxiliary power A single auxiliary power converter can replace a dedicated cooling fan power supply. Also, the power supply can operate in a variety of states. 
     The ambient air and oxidant cooling system of  FIG. 1   a  further comprises a fuel supply system ( 56 ), depicted in more detail in  FIG. 1   b . Fuel is brought into the fuel supply system at fuel system inlet port ( 54 ) and filtered through sintered filter ( 51 ). A pressure relief valve ( 52 ) is provided on the high pressure side of solenoid valve ( 53 ) to guard against overpressure situations above about 240 kPa. When the solenoid valve is activated by a controller, the fuel proceeds through a pressure regulator ( 55 ) before exiting through fuel system outlet port ( 58 ) to the fuel cell stack via fuel supply line ( 59 ). The low pressure side of the regulator also is equipped with a pressure relief valve ( 57 ) set to be operable at pressures over about 0.5 kPa. The pressure regulator can be advantageously controlled with a photoswitch ( 59 ) that is less costly than comparable mechanical pressure transducers. 
     In one embodiment of the present invention, as shown in  FIG. 1   a , the air filter ( 10 ) is positioned ahead of the PEU ( 20 ) which is ahead of the fuel cell stack ( 30 ) which is ahead of the fan ( 40 ) in the direction of air flow ( 15 ). All the components are contained in a housing ( 50 ). This arrangement allows for filtered air, free of airborne particulates, SOx, NOx and chemical contaminants, to cool the PEU. Also, the air is neither heated nor moistened from the exhaust of the fuel cell stack before it reaches the PEU and thus the risk of damage to the PEU is reduced. Because the fan is sucking air through the electricity generating system, the air is thought to flow in a more laminar fashion than if it were blown through and cooling is also optimized in this fashion. This arrangement also permits a more aesthetically pleasing final system configuration because the fan can be mounted in the rear of the unit where it is not as visible. 
     The ambient air and oxidant cooling system of  FIG. 1   a  further comprises a fuel cell stack ( 30 ) that can have MEA constructions as illustrated in FIG.  2 . As shown in a first embodiment in FIG.  2 (l), the MEA can be constructed from a 1-layer anode comprising a gas diffusion layer (GDL) with a porous base substrate ( 60   a ) and a smoothed carbon sublayer ( 70 ), a catalyst coated membrane comprising a membrane ( 90 ) and catalyst layers ( 80 ), and a 2 layer cathode comprising a GDL with a porous base substrate ( 60   b ) and a smoothed carbon sublayer ( 70 ) and a gas diffusion barrier (GDB) ( 100 ). In another embodiment as shown in FIG.  2 (2), the MEA can be constructed from a 2-layer anode comprising a GDB ( 100 ) and a GDL with a porous base substrate ( 60  i a), a catalyst-coated membrane (CCM) comprising a membrane ( 90 ) and catalyst layers ( 80 ), and a 2-layer cathode comprising a GDB ( 100 ) and a GDL with a porous base substrate ( 60   b ). In a further embodiment as shown in FIG.  2 (3), the MEA can be constructed from a 1-layer anode comprising a GDB ( 100 ), a CCM comprising a membrane ( 90 ) and catalyst layers ( 80 ), and a 2-layer cathode comprising a GDL with a porous base substrate ( 60 b) and a GDB ( 100 ). In yet another embodiment as shown in FIG.  2 (4), the MEA can be constructed from a 1-layer anode comprising a GDL with a porous base substrate ( 60   a ) and a smoothed carbon sublayer ( 70 ), a CCM comprising a membrane ( 90 ) and catalyst coats ( 80 ), and a 2-layer cathode comprising a GDL with a thick porous base substrate ( 110 ) and a GDB ( 100 ). The thicker porous base substrate ( 110 ) provides better diffusion to the landings of the fuel cell, yet maintains a good barrier. 
     Various fuel cells according to the embodiments of the MEA structures depicted in  FIG. 2  were built and tested to determine both the cell voltages that can be achieved with these structures and the operating temperatures at which they can be achieved. Table 1 provides results for achieved cell voltage at a load of 350 mA/cm 2  and the corresponding recorded optimum operating temperature (Topt) for various specific material combinations based on the example structures of FIG.  2 . All data was obtained using the identical test protocol. The cells were conditioned at 530 m A/cm 2  for at least 36 hours with air starvations in between load ramps to accelerate conditioning. The air stoichiometry ratio during test was set to 100 while the fuel stoichiometry ratio was set at 1.2. The stoichiometry ratio for the gases fed to the fuel cell is defined as the ratio of the feed rate to the consumption rate. A stoichiometry ratio of 1.0, for example, implies that there is no exit stream flow rate of the reactant. Also, the cells were operated at the open circuit voltage (OCV) point to oxidize contaminants. 
     Table 1 discloses various examples of GDBs, CCMs, and GDLs that can be used in the MEA structures of FIG.  2 . For example, two different types of GDBs are shown in Table 1. Types 5.5’ and 12’ refer, respectively, to two different types of proprietary exfoliated graphite. As another example, two different types of CCMs are disclosed. Types 5700’ and 5800’ refer, respectively, to different proprietary membrane series. Series 5700 is an 18 μm CCM and was platinum loaded at 0.1/0.4 mg Pt/cm 2  on the anode and cathode sides respectively. Series 5800 is an 18 μm CCM and was platinum loaded at 0.1/0.3 mg Pt/cm 2 . As another example, five different types of GDL are disclosed; types ‘A’, ‘B’, ‘C’, ‘D’, and ‘E’. Type ‘A’ comprises Ballard Material Products (BMP) substrate P75T-13  with 13% PTFE (polytetrafluoroethylene) and a calendered sublayer of 80 g/m 2  KS15/Shawinigan carbon in a ratio of 95/5 with 50% PTFE. Type ‘B’ comprises BMP substrate P50T-33 with 33% PTFE. Type ‘C’ comprises BMP substrate P50T-24 with 24% PTFE and a calendered sublayer of 50 g/m 2  KS15/Shawinigan carbon in a ratio of 95/5 with 18% PTFE. Type ‘D’ comprises BMP substrate P50T-33 with 33% PTFE, a 1 st  not calendered sublayer coat of 20 g/m 2  KS75/Shawinigan carbon in a ratio of 95/5 with 18% PTFE, and a 2 nd  calendered sublayer coat of 30 g/m 2  KS15/Shawinigan carbon in a ratio of 95/5 with 18% PTFE. Type ‘E’ comprises BMP substrate P75T-13 with 13% PTFE and a calendered sublayer of 20 g/m 2  KS15/Shawinigan carbon in a ratio of 95/5 with 50% PTFE. 
     
       
         
               
               
               
               
               
               
             
               
               
               
               
               
               
               
               
             
               
               
               
               
               
               
               
               
             
           
               
                   
               
               
                 MEA 
                   
                   
                   
                 Cell voltage 
                 Topt at 
               
               
                 Structure 
                   
                   
                   
                 at 350 
                 350 
               
               
                 (from 
                 Anode 
                   
                 Cathode 
                 mA/cm 2   
                 mA/cm 2   
               
             
          
           
               
                 FIG. 2) 
                 GBD 
                 GDL 
                 CCM 
                 GDL 
                 GDB 
                 (mV) 
                 (° C.) 
               
               
                   
               
             
          
           
               
                 1 
                 None 
                 A 
                 5700 
                 D 
                 5.5 
                 696 
                 58 
               
               
                   
                   
                   
                   
                   
                   
                 671 
                 60 
               
               
                 2 
                 12   
                 B 
                 5800 
                 B 
                 5.5 
                 643 
                 65 
               
               
                 2 
                 5.5 
                 B 
                 5700 
                 B 
                 5.5 
                 678 
                 60 
               
               
                   
                   
                   
                   
                   
                   
                 660 
                 65 
               
               
                   
                   
                   
                   
                   
                   
                 673 
                 60 
               
               
                 2/4 
                 5.5 
                 C 
                 5700 
                 E 
                 5.5 
                 665 
                 63 
               
               
                 3 
                 5.5 
                 None 
                 5700 
                 B 
                 5.5 
                 647 
                 60 
               
               
                 4 
                 None 
                 A 
                 5700 
                 E 
                 5.5 
                 678 
                 62 
               
               
                   
                   
                   
                   
                   
                   
                 695 
                 60 
               
               
                   
                   
                   
                   
                   
                   
                 679 
                 60 
               
               
                   
               
             
          
         
       
     
     MEAS built with structures as shown in  FIG. 2 , for example, must be sealed to prevent the fuel used in the chemical reaction from escaping the fuel cell stack. 
     The MEAs must be sealed both along their edges and also sealed with respect to the anode/fuel side of their adjacent separator plates. In one embodiment, a seal design between an MEA, as illustrated in  FIG. 3A , and a plate as illustrated in  FIG. 4A  is disclosed. In  FIG. 3A , the MEA comprises a CCM ( 160 ), a cathode GDB ( 140 ), a cathode GDL ( 150 ), and an anode GDL ( 170 ). The MEA is sealed along its edge with a bridge seal ( 120 ) and an adhesive layer (l 30 ). In  FIG. 4A , two views of a plate assembly suitable for sealing with the MEA of  FIG. 3A  are shown; the isometric exploded bottom view of the cathode/air side and the isometric exploded top view of the anode/fuel side. The anode/fuel side of the fuel cell plate assembly ( 220 ) has serpentine fuel flow channels ( 260 ) and is sealed against the bridge seal of the adjacent MEA with perimeter seal ( 230 ) which rests in seal groove ( 210 ). The cathode/air side of the plate assembly has air flow channels ( 270 ) that are perpendicular to the fuel flow channels ( 260 ) and are open to the air flow on both ends of the plate. The ports of the plate on each end can be sealed with port seals ( 200 ) which rest within port seal grooves ( 190 ). In a further embodiment, the port seals ( 200 ) can be replaced with either port plugs ( 240 ) or port plugs with tabs ( 250 ) to advantageously adapt the plate assemblies to the ends of the fuel cell stack where ports are not required such that two different types of plates are not needed. 
     In yet another embodiment, a seal design between an MEA, as illustrated in  FIG. 3B , and a plate as illustrated in  FIG. 4B  is disclosed. In  FIG. 3B , the MEA comprises a CCM ( 160 ), a cathode GDB ( 140 ), a cathode GDL ( 150 ), and an anode GDL ( 170 ), The MEA is sealed along its edge with an encapsulation layer ( 180 ), In  FIG. 4B , two views of a plate assembly suitable for sealing with the MEA of  FIG. 3B  are shown; the isometric exploded bottom view of the cathode/air side and the isometric exploded top view of the anode/fuel side. The anode/fuel side of the fuel cell plate assembly ( 340 ) has short, straight serpentine fuel flow channels ( 260 ) and is sealed against the adjacent MEA encapsulation layer with perimeter seal ( 330 ) which rests in seal groove ( 210 ). The cathode/air side of the plates comprises bridges ( 300 ) that seat against the MEA encapsulation layer on the opposite side of the perimeter seal ( 330 ) which allows the seal to span the air channels of the plate. The port ends of the anode/fuel side are covered by port bridges ( 310 ) which allow the ports of the plate on each end to be sealed with port seals ( 320 ) which rest within port seal grooves ( 350 ). The cathode/air side of the plate assembly also has air flow channels ( 270 ) that are perpendicular to the fuel flow channels ( 260 ). 
     All of the above U.S. patents, U.S. patent application publications, U.S. patent applications, foreign patents, foreign patent applications and non-patent publications referred to in this specification and/or listed in the Application Data Sheet, are incorporated herein by reference, in their entirety. 
     From the foregoing it will be appreciated that, although specific embodiments of the invention have been described herein for purposes of illustration, various modifications may be made without deviating from the spirit and scope of the invention. Accordingly, the invention is not limited except as by the appended claims.