Patent ID: 12218393

These and other features, aspects, and advantages of the present invention will become better understood when the following detailed description is read with reference to the accompanying drawings described herein. Reference is also made to the accompanying drawings that form a part of the present disclosure and shown by way of illustration of specific embodiments in which the invention may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice what is claimed and are not limiting. Instead, it is to be understood that other embodiments may be utilized and that logical, mechanical, and electrical changes may be made without departing from the spirit and scope of the invention and/or claims.

DETAILED DESCRIPTION

The present disclosure is directed to systems and methods of enclosing a fuel cell or fuel cell stack in a fuel cell based power generating device, apparatus, or system that is protected from degrading or deteriorating elements. Specifically, the present disclosure is directed to a fuel cell based power generating device or system that is easy to manufacture, assemble, and/or service. The present disclosure is also directed to systems and methods of preventing thermal loss from an enclosure housing comprising more than one fuel cell or fuel cell stack. The present disclosure is further directed to configuring and operating one or more fuel cell based power generating devices to produce large amounts of power in order to support large-scale applications.

The fuel cell based power generating device of the present disclosure may comprise one or more fuel cell stacks. The fuel cell based power generating device of the present disclosure may comprise one or more fuel cell systems. The fuel cell stack and/or fuel cell system may comprise one or more fuel cells.

The one or more fuel cells of the present disclosure may include, but are not limited to, a phosphoric acid fuel cell (PAFC), a molten carbonate fuel cell (MCFC), a proton exchange membrane fuel cell (PEMFC), and a solid oxide fuel cell (SOFC). In at least one embodiment, the fuel cell is a SOFC. In at least one exemplary embodiment, each fuel cell of the one or more fuel cells is a SOFC.

The fuel cell based power generating device or system of the present disclosure, and many of the components described herein, could benefit any type of fuel cell or fuel cell system. However, particular benefits related to thermal regulation and preservation of the fuel cell, which is necessary for optimal fuel cell function and operation, is provided to SOFCs that operate at high temperatures (800° C. to about 1000° C.) by components of the fuel cell based power generating device (e.g., a hot box area824, a hot box802, an insulation cover800). Since PEMFC and other types of fuel cells do not operate at high temperatures such that thermal conservation is not such a concern, these fuel cells more readily benefit from the proximity and location of the electrical or electronics power plants and mechanical plants, as well as the plumbing architecture of the fuel cell based power generating device or system.

The fuel cell based power generating device, apparatus, or system of the present disclosure includes a fuel cell utility product assembly1000, such as a hot box assembly1000, as shown inFIG.1. The fuel cell utility product assembly or hot box assembly1000includes a foundational frame assembly100, a network of primary or main plumbing200, a network of intermediate plumbing300, a layer of floor insulation400, a power electronics enclosure assembly500, a mechanical enclosure assembly600, a plurality of fuel cell assemblies700, and an insulation cover800(e.g., a hot box insulation cover800). In other embodiments, the fuel cell utility product assembly1000may comprise lesser components or more additional components.

The eight major components100,200,300,400,500,600,700, and/or800, in any combination, serve as the major building blocks that may be used for manufacturing the fuel cell utility product assembly1000at a high volume production. Alternatively, one or more of these individual major components100,200,300,400,500,600,700, and/or800may be pre-assembled individually and then assembled to form the larger fuel cell utility product assembly1000

The entire fuel cell utility product assembly1000, including any one or more of components200-800, may be built upon the foundational frame assembly100. Components of the fuel cell utility product assembly1000(e.g.,200-800) may be coupled, attached, or otherwise connected, such as through fasteners (e.g., bolts, rivets, screws, etc.), welding (e.g., laser, MIG, TIG, etc.), latches, or any other methods or combinations thereof, to the foundational frame assembly100. The foundational frame assembly100may be made of and/or comprise any structural material known in the art to be used for foundational support, including but not limited to, metal (e.g., steel), composite, concrete, rebar, and/or combinations thereof.

In one exemplary embodiment, the foundational frame assembly100is made of structural steel. The foundational frame assembly100may be a unitary or single element or component. Alternatively, the foundational frame assembly100may include multiple foundational frame components, such as those shown inFIG.2A, coupled together to create a single foundational frame100structure. The foundational frame assembly100may also comprise foundational reinforcing components tailored to specific applications for desired strength and/or durability targets.

Foundational reinforcing components, such as gussets and/or stiffening ribs (not shown), may be coupled to the foundational frame assembly100. These foundational reinforcing components may comprise similar or different material as the foundational frame assembly100(e.g., steel or concrete), such as to increase or reinforce the strength of the foundational frame assembly100. These foundational reinforcing components may be located and/or attached to the frame assembly100in specific or particular areas, such as corners and structural transitions, to support the full weight of the present fuel cell utility product assembly.

The size of the foundational frame assembly may be any size or length necessary to support fuel cell assemblies700needed to meet the desired or requested power demand Referring toFIG.2A, in one illustrative embodiment, the dimensions of the foundational frame assembly100may be about 5.7 m in length, about 2.2 m in width, and about 0.3 m in height. In one embodiment, the length150of the foundational frame assembly100may range from about 1 m to about 10 m. In one embodiment, the width152of the foundational frame assembly100may range from about 1 m to about 5 m. In one embodiment, the height154of the foundational frame assembly100may range from about 0.1 m to about 0.5 m.

The foundational frame assembly100may comprise one or two, at least two, about two, or two or more frame rails130and120. As shown inFIG.2A, the assembly100includes a first frame rail120and a second frame rail130. The second frame rail130is offset from and generally parallel to the first frame rail120.

Each frame rail130,120may have a “C” shape, such that its cross-sectional area178also defines a “C”-shaped channel180, as shown inFIGS.2A and2B. To form this “C”-shaped channel180, each frame rail130,120may include a top ledge156, a main body162, and a bottom ledge160that span the full length of both sides of the foundational frame assembly100. A “C”-shaped cross-sectional channel180along the longitude of the frame assembly100is created For example, each frame rail130and120may comprise an extruding top ledge156, an indented main body162, and an extruding bottom ledge160where the extruding top ledge156and the extruding bottom ledge160span either side of the foundational frame assembly100in order to form the “C”-shaped channel180therebetween.

In one embodiment, shown inFIGS.2A and2B, the extruding top ledge156and the extruding bottom ledge160extend outward or outboard away from the indented main body162along both sides of the foundational frame assembly100in order to form the “C”-shaped channel180within the indented main body162comprising a cross-section2A-2A178. Referring toFIG.2B, in some embodiments, the “C”-shaped frame rails130and120may allow another component/element to be nested within the cross-section178of the indented main body162, such as within the “C”-shaped channel180.

The “C”-shaped channel180and/or cross-section178defines an open longitudinal section along and within the frame assembly100that facilitates serviceability of all assembly1000components in the field, such that the fuel cell utility product assembly1000does not have to be disassembled for service. Specifically, the “C”-shaped channel180may have channel openings182where valves (e.g., control valves), wiring, fuel or air supply components from the primary plumbing200and/or intermediate plumbing300may be accessed. In some embodiments, the channel gaps or channel openings182are covered by frame rail cover plates172that prevent direct access and therefore protect components (e.g., valves, wiring, etc.) inside the channel gaps or channel openings182.

Similarly, a main or primary air plumbing128and/or a main or primary fuel plumbing126may be nested within the cross-section178of the indented main body162, as shown in cross-section2A-2A178ofFIG.2B. Such an embodiment provides structural benefit in that the fuel cell utility product assembly1000has a reduced physical footprint since the plumbing and other components are integrated within the foundational frame assembly100.

Referring toFIG.2B, in one embodiment, the length150of the cross-section2A-2A178may range from about 1 m to about 10 m. In one embodiment, the width155of the cross-section2A-2A178may range from about 0.1 m to about 0.5 m. In one embodiment, the height158of the cross-section2A-2A178may range from about 0.1 m to about 0.5 m. In one embodiment, the length158and width155of the cross-section2A-2A178may be the same.

For example, the “C”-shaped frame rails130and120may enable easy assembly and service of electronic control components. Exemplary electronic control components may comprise those configured to control the main air plumbing128, the main fuel plumbing126, fuel gas plumbing132, and the one or more fuel and air control valves112. The one or more fuel or air control valves112may be located within the “C”-shaped channel180of the indented main body162, as shown inFIG.2B, of the frame rails130and120.

Further, one or more electrical conduits124may be routed within the “C”-shaped cross-section178of the frame rails130and120. Such electrical conduit(s)124may connect inputs and outputs of various sensors and actuators to a control system. Additional or other types of electrical or fluid piping, wiring, tubing, channeling components may also be integrated into the “C”-shaped cross-section178of the frame rails130and120.

The control valves112for air and fuel may be located on opposite sides of the foundational frame assembly100. For example, the control valves and/or plumbing for air128may be comprised within the “C”-shaped channel180of the indented main body162of a first (e.g., a left) frame rail120, while the control valves and/or plumbing for fuel126may be comprised within the “C”-shaped channel180of the indented main body162of a second (e.g., a right) frame rail130or vice versa. Such placement may enhance the packaging, ease of assembly and service of fuel cells comprised within the fuel cell utility product assembly1000, while reducing the physical footprint of the assembly.

The number of cross members122may be tailored based on the number, size, and/or weight of fuel cell assemblies700comprised in the fuel cell utility product assembly1000and/or the length of the foundational frame assembly100. As shown inFIG.2A, the foundational frame assembly100includes an end cross member122, which interconnects each pair of ends of the frame rails130,120, and seven interior cross members122provided between the two end cross members122and interconnecting the frame rails130,120at separate locations. However, for other embodiments, the foundational frame assembly100may comprise any number of frame cross members122.

In another embodiment, the foundational frame assembly100may comprise about 1 to about 20 frame cross members122, including any number comprised therein. In an exemplary embodiment, the foundational frame assembly100may comprise about 2 to about 10 frame cross members122. In other embodiments, the assembly100may comprise about 6 to about 11 cross members122, such as about 2, 3, 4, 5, 6, 7, 8, 9, 10, or about 11 frame cross members122. The frame cross members122may couple the “C”-shaped frame rails130and120together in a “ladder” like construction (seeFIG.2A).

The foundational frame assembly100may comprise one or more lifting locations170, which may be used to hoist the entire fuel cell utility product assembly1000during transportation and/or installation at a plant site, such as a customer or user site. As shown inFIG.2A, the foundational frame assembly100includes four lifting locations170, each located in a corner proximate to interconnected ends of one frame rail130,120and one cross member122. Each lifting location170includes a hook, loop or similar feature for attaching an object (e.g., chain, rope, etc.) to support the assembly during movement. In other embodiments, the frame assembly100may include any number of lifting locations, which may be positioned at one or more corners, along one or more sides (e.g., proximate one or more centers), and/or any other location of the frame assembly100.

The foundational frame assembly100may comprise one or more pass-through openings168located in one or more rails or members, such as the “C”-shaped frame rails130and120. Such pass-through openings168are configured to allow air and fuel plumbing to pass from inside the cross-section2A-2A178of the “C”-shaped frame rails130and120(see, e.g.,FIG.2B) to the internal space148of the foundational frame assembly100or vice versa. For example, the pass-through openings168allow plumbing within the internal space148between two consecutive cross members122and/or within the cross-section2A-2A178. The pass-through openings may be any shape, including rectangular, square, oblong, oval, and/or circular.

Therefore, the size of the pass-through openings168is determined by the size of the plumbing (e.g., intermediate or primary plumbing) that must traverse the pass-through opening. The pass-through openings168may extend the full length between two consecutive cross members122. For example, the size of the pass-through openings168may range from about 0.2 m to about 0.5 m, including any length comprised therein. In other embodiments, the size of the pass-through openings168may be less than the length between two consecutive cross members122. The size, shape, and location of the pass-through openings should be designed to ensure that integrity and strength of the foundational frame assembly100is maintained and able to support the weight of the fuel cell utility product assembly1000and its components.

The embodiment shown inFIG.2Aincludes a pass-through opening168between every pair of consecutive cross members122. In other embodiments, the foundational frame assembly100may not include a pass-through opening168between one or more pairs of select consecutive cross members122. In further embodiments, the foundational frame assembly100may include one or more pass-through openings168only on one side of the frame rail (e.g., frame rail120or130), or may include at least one pass-through opening168on each side (e.g., in each frame rail120and130) The foundational frame assembly100may also comprise portals176to access the customer connections to the power electronics enclosure assembly500and/or the mechanical enclosure assembly600.

The primary or main plumbing200and the intermediate plumbing300have distinct purposes. The primary plumbing200runs the length of the foundational frame assembly100in order to connect and provide air and fuel to all of the fuel cell stacks in the fuel cell utility product assembly1000from one or more manifolds742and744. The intermediate plumbing is located within each fuel cell stack700, and are positioned and located perpendicular to the foundational frame assembly100in order to connect into one or more manifold (e.g., an inlet manifold742or an outlet manifold744).

The design and layout of the primary or main plumbing200in relation to the intermediate plumbing300within the foundational frame assembly100have distinct benefits. In addition to being housed within the foundational frame assembly100and its “C”-shaped cross-section178, the design and layout of the primary plumbing200in relation to the intermediate plumbing300is simple or uncomplicated, meaning fuel and air plumbing is separately routed into and out of the fuel cell stack assemblies700to exhaust. The fuel and air plumbing of the primary plumbing200and intermediate plumbing300layout within the foundational frame assembly100provide the necessary balanced and uniform input of fuel and air to the fuel cell stack or assembly700to ensure proper function of the fuel cell.

In some embodiments, the fuel and air plumbing and/or the main or primary plumbing200and intermediate plumbing300do not intersect, cross, or overlap with one another. Specifically, the plumbing design incorporates a single inlet or inlet manifold742for fluids (e.g., air and fuel) and gases on one side of the foundational frame assembly100and a single outlet or outlet manifold744on the opposite side of the foundational frame assembly100to exhaust fluids. Importantly, the primary plumbing200is responsible for delivering the fluids to the fuel cell stack or assembly700. The intermediate plumbing300is responsible for doing the necessary splitting, overlapping, or crossover to balance fluids and heat within the fuel cell assembly700to allow proper function of the fuel cell.

This modular design of the primary plumbing200and intermediate plumbing300enables easy changes or modification of the number of fuel cell assemblies700to increase or decrease without having to change the plumbing design within the fuel cell utility product assembly1000. Since the intermediate plumbing300remains the same for all fuel cell stacks700, addition or removal of fuel cell assemblies700, such as the linear stacking or array of fuel cell assemblies700, remains constant and does not require plumbing redesign or further plumbing considerations for proper fuel cell function. Therefore the present fuel cell utility product assembly1000enables a simplistic, modular, stackable, and/or scalable configuration to house and protect variable number of fuel cell assemblies700based on their size and weight.

Referring toFIG.1, in some embodiments, placing the primary plumbing200inside the foundational frame assembly100may protect the primary plumbing200from potential damage during transportation and/or operation. Placing the intermediate plumbing300between the foundational frame assembly100and the floor insulation400may also protect the intermediate plumbing300from potential damage during transportation and/or operation.

A frame rail cover plate172may engage with the frame rails120and130of the foundational frame assembly100to protect and seal the components housed within the “C”-shaped frame rails130and120. The frame rail cover plates172may cover the pass-through openings168and/or portals176(individually or collectively). The frame rail cover plates172may be easily removable for servicing any component of the fuel cell utility product assembly1000located within the indented main body162of the frame rails120and130.

The “C”-shaped frame rails130and120of the foundational frame assembly100may comprise one or more mounting brackets196and198. The mounting brackets196and198are configured to engage with the power electronics enclosure assembly500and/or the mechanical enclosure assembly600and secure them to the foundational frame assembly100. More specifically, the power electronics enclosure assembly500and/or the mechanical enclosure assembly600may be coupled to the mounting brackets196and198to secure those components to the foundational frame assembly100.

The foundational frame assembly100may comprise one or more mounting stands164. As shown inFIG.2A, a plurality of mounting stands164are positioned atop each cross member122. However, the assembly can include any number of mountings stands164(e.g., 1, 2, 12, 28, etc.) located on any cross members122or other structure of the frame assembly. The one or more mounting stands164may engage with one fuel cell, fuel cell stack, fuel cell system, or fuel cell assembly700to securely position the fuel cell assembly700onto the foundational frame assembly100.

The one or more mounting stands164may elevate the one or more fuel cell assemblies700above, away from, and/or off of the cross members122in order to allow room for other components, such as the floor insulation400. For example, in some embodiments, a layer of the floor insulation400lies between the fuel cell assembly700and the cross members122of the foundational frame assembly100. Specifically, a layer of floor insulation400may be located on top of the foundational frame assembly100and below the one or more fuel cell assemblies700.

In some embodiments, the foundational frame assembly100may comprise one or more mounting stands164on each cross member122. In some embodiments, the foundational frame assembly100may comprise about 1 to about 6 mounting stands164on each cross member122, including any number of mounting stands comprised therein. In other embodiments, the foundational frame assembly100may comprise a different number or any number of mounting stands164on different cross members122.

As shown inFIGS.3and7, one or more fuel cell assembly700is placed on the mounting stands164of the foundational frame assembly100. More specifically, the fuel cell stack support base798of the fuel cell assembly700may engage with the mounting stands164to secure the fuel cell700to the foundational frame assembly100(e.g., the fuel cell stack support base798of the fuel cell assembly700may be coupled to the mounting stands164to secure the fuel cell700to the foundational frame assembly100).

The fuel cell utility product assembly1000of the present disclosure may comprise any number of fuel cell assemblies necessary to meet the power demand of a user or an operator. In one embodiment, the fuel cell utility product assembly1000includes about 1 to about 24 fuel cell assemblies700connected to the foundational frame assembly100, including any number of fuel cell assemblies700comprised therein. The fuel cell utility product assembly1000may comprise about 12 fuel cell assemblies700. Each fuel cell assembly700may be secured to the foundational frame assembly100using fasteners such as bolts.

Referring toFIG.3, the fuel cell assembly700includes one or more of a fuel cell stack support base798, a heat exchanger assembly792, a reformer796, and a fuel cell stack790. The fuel cell stack790may comprise a plurality of fuel cells. Each fuel cell assembly700may include access to air and fuel through inlets and outlets (not shown) at its support base798.

Support structures of the fuel cell stack790, such as the fuel cell stack support base798, may need to withstand shock or vibration loads, including but not limited to environmental (e.g., seismic) and/or transportation loads. The fuel cell stack support base798may comprise at least four support legs788. Multiple support legs788(e.g., about 2 to about 4 legs) provides additional support to the fuel cell stack support base798positioned atop the mounting stands164in order to more effectively withstand damaging shock and vibration loads that could negatively affect the life and functionality of the fuel cell stack790.

The fuel cell stack support base798may be comprised of a single component cast of metal (e.g. iron, steel) (not shown). A single component cast comprising the fuel cell stack support base798may be designed to be stronger than if the fuel cell stack support base798was comprised of multiple parts (e.g., weldment). The fuel cell stack support base798may comprise an internal ledge778to securely position the heat exchanger assembly792upon the fuel cell stack support base798.

The fuel cell assembly700may comprise one or more thermal isolation devices to isolate and separate the thermal conductivity between the fuel cell stack assemblies700that operate at high temperatures (e.g., 800-850° C.) from the foundational frame assembly100and prevent heat from the fuel cell assembly700to be transferred to the foundational frame assembly100, which can be detrimental to the strength and integrity of the frame100. In some embodiments, the one or more thermal isolation devices may include one or more thermally-insulative washers794. In other exemplary embodiments, the washers794may be made of materials that are not or are minimally thermally conducive, such as ceramic.

The thermally-insulative washer794(e.g., ceramic washer) may be located between the support leg788or the support base798of the fuel cell assembly700and the foundational frame assembly100. In addition, the thermal isolation provided by these thermally-insulative washers794may allow the foundational frame assembly100to be constructed out of more cost-effective materials, such as widely available structural steel versus more costly heat resistant metals. These thermally-insulative washers help prevent heat egress and escape from the hot box assembly800to the foundational frame assembly100, which could damage the frame100(e.g., enable bending of the frame) such that its unable to support the fuel cell product utility assembly1000. Importantly, the frame100must maintain its physical structure without compromise (bending, cracking, etc.) in order to prevent damage from occurring to a hot box area824, a hot box802, and the fuel cell assemblies800located therein.

One embodiment of a hot box assembly1000, such as shown inFIGS.4A and5, includes the hot box insulation cover800(or a portion thereof) that is configured to removably couple to the system, such that the frame assembly100defines a hot box area824therebetween. The hot box area824further defines or includes a hot box802, both of which are configured to receive other components, such as the fuel cell assemblies700. Sealing of the hot box area824to prevent egress or escape of heat from the hot box area824and the hot box802, as well as ingress of environmental elements (e.g., water, moisture, dust, debris, etc.) into the hot box area824and the hot box802is a key feature of the present hot box assembly1000effectuated by one or more types of seals (e.g., a weather seal and/or a temperature seal).

The hot box insulation cover800may comprise one or more of an inner hot box structure812, a cover insulation820, and an outer hot box shell814. Preferred embodiments of the hot box insulation cover800comprise all three components812,820, and814. The hot box insulation cover800is configured to enclose a hot box802. The hot box802includes the internal spatial region of the inner hot box structure812that directly covers and receives the fuel cell assemblies700previously described as the hot box area824.

The inner hot box structure812, the cover insulation820, and the outer hot box shell814may each be made of a single piece and/or material. In other embodiments, the inner hot box structure812, the cover insulation820, and the outer hot box shell814may each include multiple pieces, parts, and/or materials (e.g., panels) configured to be connected, attached, or assembled together to form the outer hot box shell814. For example, the inner hot box structure812, the cover insulation820, and the outer hot box shell814may each comprise multiple pieces or panels of a material that are attached, connected, bolted, welded, or latched together to form the hot box insulation cover800for the fuel cell assemblies700.

The inner hot box structure or layer812provides support to the other layers820and814of the hot box insulation cover800. The inner hot box layer812may be constructed of any material known to provide structural support, such as a metal (e.g., steel). In an exemplary embodiment, the material of the inner hot box structure812is stainless steel. Stainless steel is advantageous as the material of the inner hot box structure812since it may be directly and functionally subjected to the high temperatures of about 700° C. to about 1000° C. due to the fuel cell assemblies700during operation. The inner hot box structure812may be optionally removed, particularly when the cover insulation820and the outer hot box shell820together provide enough structure to support any insulating materials. However, the functionality of each layer of the hot box insulation cover800whether present as a distinct layer or not is imperative.

The inner hot box structure812may be externally surrounded by the cover insulation820that insulates the hot box802and hot box area824to prevent heat loss from those critical regions. The cover insulation820is primarily used to reduce heat loss from the hot box802to the atmosphere by comprising an insulating material822to retain and/or absorb heat. The cover insulation820may be made of a powder or fibrous insulating material822comprising silica. Insulating layers of the cover insulation820may comprise any percentage or proportion of multiple or combinations of different insulating materials822to achieve the desired heat insulation performance, packaging, and cost target for optimal and efficient performance of the fuel cell assemblies700.

For example, the cover insulation820may comprise a single layer or multiple layers826of the insulating material822. The presence of multiple layers826in the cover insulation820enable heat retention within the hot box area824, and allows for a user to safely handle the hot box insulation cover800externally. In one embodiment, the cover insulation820will comprise multiple distinct insulating layers826, such as one, two, three, or more distinct layers. The multiple insulating layers826of the cover insulation820may also be configured into one insulating layer826, such as by mechanical (e.g., compression) or chemical (e.g. dehydration) processes or mechanisms.

Alternatively, multiple layers826of the cover insulation820material822may comprise at least two, about two, two or more, about three, about four, about five, about six, and six or more insulating layers826. The insulating layers826may comprise varying thicknesses ranging from about 0.01 m to about 0.30 m, including any thickness comprised therein. The sum of the thicknesses of each insulating layer826comprising insulating material822defines the thickness of the cover insulation820provided to the present hot box insulation cover800.

The cover insulation820may be encapsulated by an outer hot box shell814. The outer hot box shell814protects the hot box802and hot box area824, including the fuel cell assemblies700, from the atmospheric and/or external environment (e.g., weather, dust, moisture, and other elements or conditions). The outer hot box shell814may be weathertight, such that it is sealed, airtight, waterproof, physically stable, etc. For example, the hot box insulation cover800and/or outer hot box shell814can be hermetically sealed. In one embodiment, a weather seal is provided to connect or attach the hot box shell814and/or the foundational frame assembly100to provide a gap-free seal and weathertight protection to the fuel cell assemblies700comprised within the hot box area824and the hot box802.

The outer hot box shell814may be constructed of fiberglass or any other structurally protective material, such as aluminum, steel, or stainless steel. In some embodiments, the outer hot box shell814may provide protection to the more fragile and sensitive cover insulation820, which should not get wet. The outer hot box shell814may be styled produced according to the overall design aesthetic of the fuel cell utility product assembly1000. For example, the outer hot box shell814may comprise markings, logos, and/or instructions.

Both ends of the hot box802and the hot box insulation cover800may be capped off and/or sealed by one or more divider insulation walls830and840. The divider insulation walls830and840help to separate the power electronics enclosure assembly500and the mechanical enclosure assembly600from the hot box802. The divider insulation walls830and840also insulate and protect each of the power electronics enclosure assembly500and the mechanical enclosure assembly600compartments.

The divider insulation walls830and840may be constructed of either a single layer or multiple layers of insulation. The insulating material822used for the divider insulation walls830and840is the same or similar to the insulating material822used for the cover insulation820. The divider insulation walls830and840may also be constructed of a different type of insulation material822compared to the cover insulation820.

The hot box insulation cover800may be configured to comprise wheel assemblies828that are attached or connected to the cover800. In some embodiments the hot box insulation cover800includes multiple pieces, parts, and/or portions (e.g., one or more panels858) configured to be connected or attached together by standard mechanisms to form the single cover800. Each panel858of the cover may comprise the inner hot box structure812, the cover insulation820, and the outer hot box shell814. Each panel858of the hot box insulation cover may also configured to include one or more wheel assemblies828to enable the lifting and movement of each panel858of the cover800along the wheel tracks166and174.

For example, in an embodiment where the hot box insulation cover800is made of two panels (e.g., Panel A and Panel B), Panel A will have one or more wheel assemblies828to enable the lifting and movement of that portion of the cover800along the wheel tracks166and174. Similarly, Panel B will have one or more wheel assemblies828, that are separate and distinct from the wheel assemblies828dedicated to Panel A, in order to enable the lifting and movement of that Panel B portion of the cover800along the wheel tracks166and174. The wheel assemblies828of the multiple cover panels858may be configured to lift vertically off of and away from the hot box area824and move each panel858horizontally along the wheel tracks166and174in the same or opposite directions in order to access the fuel cell assemblies700or other hot box assembly1000components.

In one embodiment, one or more hot box wheel assemblies828may be mounted to the inner hot box structure812. The one or more hot box wheel assemblies828may allow the hot box insulation cover800comprising the inner hot box structure812, the cover insulation820, and the outer hot box shell814to move. Mobility is a key feature of the hot box insulation cover800that allows ease of access to inner fuel cell assembly700components, such as during repair and/or maintenance, without complete, partial, or any disassembly of the hot box assembly1000.

Specifically, the wheel assemblies828comprise wheels846that engage each other such that the wheels846roll upon the wheel tracks166and174. The wheel assemblies828aid in rolling the hot box insulation cover800along the wheel tracks166of the frame rail120and130. However, before doing so, the wheel assemblies828are configured to first mechanically or manually move the cover800up, off, and away from the hot box802so as to break, disengage, or disassociate any seal (e.g., weather and/or temperature seal) connecting the hot box insulation cover800to the frame assembly100. More specifically, the wheels846located and attached to the base of the cover800of the fuel cell utility product assembly1000may be moved (e.g., translated) and/or translocated fore and aft along the wheel tracks166, as depicted by arrows832and833ofFIG.4A, such as is necessary to access the hot box802or hot box area824during assembly, servicing, transportation, and/or testing of the fuel cell assemblies700comprised therein.

The wheel assemblies828and wheel tracks166and174of the frame rail120and130also define the outer boundary of the hot box floor400. The hot box floor400, when connected, attached, and/or sealed to the divider insulation walls830,840and the cover insulation820, form the internal hot box802or the hot box area824. In the embodiment shown inFIG.4B, the hot box floor400includes an insulation material822. The insulation material of the hot box floor400may be the same, similar, or different from the insulating material822used for the divider insulation walls830,840and/or the cover insulation820.

The hot box floor insulation400may form a final barrier and retention mechanism for any heat lost from the base of the fuel cell utility product assembly1000. The hot box floor insulation400may comprise one or more tiles866,868,864. The hot box floor insulation tiles may comprise one or more fuel cell lower insulation tiles864. The hot box floor insulation tiles may comprise one or more bus bar insulation tiles866. The hot box floor insulation tiles may comprise one or more outer insulation tile868. The hot box floor insulation400may comprise any number of tiles, such as a total number of tiles ranging from about 2 to about 80 number of tiles, including any number of tiles comprised therein.

The hot box floor insulation400may comprise a single insulation tile. In a preferred embodiment, the hot box floor insulation400may comprise multiple segmented tiles866,868,864. Segmented tiles, as shown inFIG.4B, are typically not produced in a single piece. Instead segmented tiles866,868,864may be configured to engage with one another by adhesion, attachment, connection using any means in order to form a single hot box floor insulation400unit.

Segmented tiles866,868,864are preferable because they allow for easy production assembly and/or operational service access to piping and/or plumbing located between the foundational frame assembly100and the hot box802comprising fuel cell assemblies700. A particular advantage of the use of segmented tiles866,868,864in the present the fuel cell utility product assembly1000allows for removal of one or more specific tiles866,868,864in specific regions of the hot box floor insulation400in order to access, service, and/or repair specific components, plumbing, and/or features of the hot box802or fuel cell assemblies700without removing or disassembling the whole, entire, or a significant portion of the hot box floor insulation400.

Specifically, the segmented tile approach comprised by the present fuel cell utility product or hot box assembly1000may allow for local replacement and servicing of the hot box802and fuel cell assemblies700that would not be permissible with a larger single or one-piece structure. Local replacement and servicing may allow the access and servicing of a single fuel cell assembly700without moving, touching, and/or accessing other fuel cell assemblies700in the hot box802, which is an advantageous feature of the present disclosure.

Referring toFIGS.1,4A, and4B, an outer insulation tile868is used to route and/or access the primary plumbing200and/or the intermediate plumbing300below the fuel cell assembly700. In some embodiments, a fuel cell lower insulation tile864may be located directly under the fuel cell assembly700, such that the fuel cell lower insulation tile864may be removed by a user, an operator, or a technician to allow access to any plumbing directly under the fuel cell assembly700and its components (e.g., for service or repair).

In one embodiment, as shown inFIGS.4B and7, a plurality of bus bar insulation tiles866are located over a center channel706. The center channel706is generally positioned down the middle of the hot box floor insulation400, similar to the bus bar insulation tiles866. The center channel706and the bus bar insulation tiles866are located between fuel cell assemblies700, which are typically located on the left and right sides of the hot box floor insulation400(seeFIG.4B). The center channel706will route the bus bars770to the power electronics enclosure assembly500.

Various pass through provisions874and876may be incorporated into the hot box floor insulation400in order to mount fuel cell assemblies700and to enable and allow plumbing and/or piping connections to enter and exit the hot box802(seeFIG.4B). In some embodiments, unwanted gaps between the segmented tiles866,868,864may be reduced and/or mitigated with “stepped” interfaces or flexible insulation880utilized around and between the tile joints878, which can help to seal and prevent heat loss from the hot box802through the floor400. The flexible insulation880can be the same, substantially the same, or similar to or different from the material of the high temperature flexible seals870utilized on the hot box insulation cover800for the same purposes.

FIG.5illustrates further details regarding the fuel cell utility product assembly1000, including the integration of the hot box insulation cover800, the foundational frame assembly100, a network of primary plumbing200, a network of intermediate plumbing300, the power electronics enclosure assembly500, the mechanical enclosure assembly600, and the one or more fuel cell assemblies700. As shown, in addition to the foundational frame assembly100and the divider insulation walls830and840, the primary support for the hot box insulation cover800during operational use is provided by two support hoops886and894.

Each support hoop886and894is positioned outside of or exterior to one associated divider insulation wall830,840and may be made of any material that reinforces, supports, and/or holds stable the hot box insulation cover800, particularly during operation. For example, the two support hoops886and894may comprise or be made of one or more metals (e.g. steel). In one embodiment, the hot box insulation cover800is configured to close and/or seal the hot box802by contacting and securely fitting over the divider insulation walls830and840and the two support hoops886and894(seeFIG.5).

The hot box insulation cover800may include one or more weather seals834and888, which may be positioned at either end of the hot box insulation cover800near the power electronics enclosure assembly500and the mechanical enclosure assembly600. Typically, the weather seal888may also be positioned outside of or exterior of the hot box802and/or the hot box area824. As shown inFIG.5, the weather seal834may be positioned outside of or exterior to (e.g., relative to the fuel cell assemblies) the support hoop886. The weather seal888may also be positioned outside of or exterior to the support hoop894.

In another embodiment, the one or more weather seals834and888may be positioned at any point along the outer edge or periphery of the hot box insulation cover800. In one such embodiment, the one or more weather seals834and888may be positioned completely along the periphery of the hot box insulation cover800, such as where the cover800meets or contacts the foundational frame assembly100, the power electronics enclosure assembly500, and/or the mechanical enclosure assembly600. The weather seals834and888help enable the hot box insulation cover800to removably, repeatedly, and organically (e.g., without external manipulation) come to a resting point atop the foundational frame assembly100in order to seal and protect the fuel cell assemblies700comprised therein.

Referring toFIG.5, the one or more weather seals834and888may be comprised of any material that seals, waterproofs, and/or protects the fuel cell assemblies700inside of the hot box802. For example, the one or more weather seals834and888may prevent ingress of water, dust, moisture, rain, wind, snow, insects and/or other elements that may cause damage, degradation, and/or deterioration of the fuel cell assemblies700from migrating into the hot box802. The one or more weather seals834and888may comprise a flexible “rubber” like material.

In one embodiment, the hot box insulation cover800may additionally or alternatively comprise one or more high temperature flexible seals870, also called a hot seal (seeFIG.5). The hot seal or high temperature flexible seal870may be constructed of a material that is able to withstand the high operational temperatures (e.g., 700° C. to 950° C.) of the fuel cell assemblies700within the hot box802. The high temperature flexible seal870enables flexibility and mobility of the cover800during operations while sealing the interfaces of the hot box insulation cover800with all other elements or components (e.g., the frame100, the power electronics enclosure assembly500, and/or the mechanical enclosure assembly600).

The hot seal or high temperature flexible seal870helps enable the hot box insulation cover800to removably, repeatedly, and organically (e.g., without external manipulation) come to a resting point atop the foundational frame assembly100in order to provide a gap-free seal and insulated protection of the fuel cell assemblies700comprised therein from heat loss. The material of the high temperature flexible seal870may be a woven material and/or a fibrous material. For example, the material of the high temperature flexible seal870may be wool, ceramic, fiber, etc.

The flexibility provided by the high temperature flexible seal870may also account for any manufacturing part-to-part variation that may otherwise create an undesirable gap between panels of the hot box insulation cover800, the power electronics enclosure assembly500, the mechanical enclosure assembly600, the hot box floor insulation400, and/or the foundational frame assembly100. The divider insulation walls830and840, the hot box floor insulation400, and/or the high temperature flexible seal870may each independently and/or collectively contribute to the improvement and/or maintenance of the thermal integrity of the hot box802and prevent or reduce thermal losses. This is important since any heat loss from the hot box802directly results in fuel cell assembly700efficiency losses or inefficiencies in the fuel cell utility product assembly1000.

Weather seals834and888or high temperature flexible seals870may be independently utilized in the fuel cell utility product assembly1000. In a preferred embodiment, both the one or more weather seals834and888and hot seals870are comprised in the hot box insulation cover800of the fuel cell utility product assembly1000. Such embodiments may be formed in one or more layers and/or comprising one or more materials to satisfy functions of both the weather seals and the hot seal. Typically, the weather seals834and888are located on the exterior of the hot box802or hot box area824, while the temperature seals870are located on the interiors of the hot box802or hot box area824. When the weather834and888and temperature seals870are combined into one structure, that combined seal may be located internal or external to the hot box802and hot box area824.

The hot box insulation cover800of the fuel cell utility product assembly1000is designed to have a slant or a draft angle804along its periphery. The draft angle804of the cover800is the angle by which the hot box insulation cover mates or engages with the foundational frame assembly100via the seals (e.g., the weather and/or hot seals). The draft angle804further defines the angle of the incline of a cover interface surface806, the inner perimeter surface of the cover800, as measured from a cover base808or the bottom of the cover800to the top surface810of the cover800(seeFIG.4A). The cover interface surface806is the portion of the hot box insulation cover800that is configured to connect with or attach to other components of the assembly1000, such as the foundational frame assembly100, the power electronics enclosure assembly500, and the mechanical enclosure assembly600.

The draft angle804is less than 180 degrees, such that the hot box insulation cover800does not include a straight vertical angle or sides that causes the weather and/or temperature seals to be difficult or unable to be disengaged or disassociated. Preferably, the draft angle804will range from about 5 to 45 degrees, comprising any specific or range of sizes of angles provided therein. In one embodiment the draft angle804is at or about 10 degrees. Notably, an optimal draft angle804will improve the sliding of the cover800across the foundational frame assembly100. Said differently, a positive slope increases the effectiveness of the weather and temperature seals and ensures that the weather and temperature seals of the assembly will “lock” and/or seal the cover800into place upon the frame100.

Importantly, the draft angle804is made to sealably mate or engage the cover interface surfaces806of the cover800with the surfaces of each of the other components of the assembly1000, such as the foundational frame assembly100, the power electronics enclosure assembly500, and the mechanical enclosure assembly600via the seals. The draft angle804allows the weather and hot seals to ease disengagement of the seals when lifting and/or rolling the cover800off and away from the hot box area824.

The draft angle804also helps prevent damage to the seals and increases durability of the cover800by minimizing the rubbing of the assembly1000components by way of the seals. The draft angle804may be designed or tailored specifically to house any number of fuel cell assemblies700to meet a power demand For example, the weight of the cover800and the height the cover800must be considered. Specifically the height of the cover800must be lifted to be physically above the weather and/or temperature seals on the cover interface surfaces806, the wheel tracks166and172, and the foundational frame assembly100, which must be considered in specifying the draft angle804. The length the cover800will roll in order to make sure it does not cover the exhaust or intake points, such as the outlet manifolds744and inlet manifolds742of the assembly1000must also be considered in specifying the draft angle804.

As previously mentioned, the hot box insulation cover800may include an integral mechanical lifting mechanism838, which may comprise one or more hot box wheel assemblies828. The one or more hot box wheel assemblies828enable the hot box insulation cover800to be lifted vertically after disengaging or disassociating a weather seal888,834and/or temperature seal870and removed from the hot box802. The one or more hot box wheel assemblies828also enable the hot box insulation cover800to be moved horizontally on and along the wheel tracks166and174.

Each hot box wheel assembly828may include one or more wheels846and a sliding bar system848. The wheels846mount to the sliding bar system848by any known mechanism (e.g., bolts, screws, etc.). For example, an exemplary sliding bar system848is a four (4)-bar mechanism that allows the hot box cover800to be lifted and removed from the hot box802and hot box area824by moving the centerline of the wheels846. The sliding bar system848includes one or more horizontal linkage bars844and/or one or more angled linkage bars884.

The horizontal linkage bars844are utilized to interconnect all wheels846of the wheel assembly828so they act (e.g., roll) in unison. The angled linkage bars884are utilized to lift and remove the hot box insulation cover800from the hot box802. Together, the angled linkage bars884are first engaged to lift the cover800vertically up away from the hot box area824. Subsequently, the horizontal linkage bars are engaged to roll the wheels846of the cover800along the wheel tracks166to expose the hot box802and hot box area824, including the fuel cell assemblies700.

Referring again toFIG.5, in one embodiment, the top ledge156of the foundational frame assembly100may comprise wheel tracks166. The wheel tracks166are configured to allow movement and/or translocation of the hot box insulation cover800in order that the fuel cells assemblies700and other components comprised therein may be exposed and accessed, such as during any service event. More specifically, the wheel tracks166and174are configured to allow the hot box insulation cover800to be opened and closed by rolling or sliding the hot box insulation cover800along the wheel tracks166and174.

The wheel tracks166may be manufactured or produced as a part of the top ledge156. The wheel tracks166may be affixed, attached, and/or connected to the top ledge156of the “C”-shaped frame rails130and120by any mechanism. The wheel assemblies828along the wheel tracks166are connected to one or more power screws882(shown inFIG.5) to move the hot box insulation cover800.

A power screw882may be actuated by a gear box842that is turned via a drive mechanism852. The drive mechanism852may be positioned at an external drive point872that can be activated manually, such as by a hand crank. The external drive point872may also be activated electro-mechanically, such as by an integral electric motor interface that is activated by an automatic, electronic, or manual command.

Rotation of the power screw882may cause the angled linkage bars884to rotate the one or more hot box wheel assemblies828down to engage the wheel tracks166and174on the foundational frame assembly100. In an exemplary embodiment, there is a wheel assembly838located along the two “C”-shaped frame rails130and120. Further rotation of the power screw882may cause the angled linkage bars884to further shift the wheels846of the wheel assembly828toward the mechanical enclosure assembly600, such that the hot box insulation cover800is unsealed, opened, and/or lifted from the hot box802.

The hot box insulation cover800may further be raised up and along locating pins890and892, such as those positioned atop the two support hoops886and894, as shown inFIG.5. Continued rotation of the power screw882may further raise or levitate the hot box insulation cover800off the locating pins890and892and the hot box area824to allow the hot box insulation cover800to be freely rolled fore and aft along the wheel tracks166and174, such as is necessary during inspection and service of the fuel cell assemblies700within the hot box802.

The lifting mechanism may be a mechanical linkage, such as described above, or may be enabled by pneumatic or hydraulic cylinders directly or indirectly attached to the hot box wheel assembly828. The lifting mechanism may also be enabled by electrical mechanisms, such as solenoids or motors. In other embodiments, additional connections may be established between both sides of the lifting mechanism positioned along the two “C”-shaped frame rails130and120in order to achieve synchronized motion of the wheel assemblies828.

Referring back toFIG.5, in one embodiment, a power electronics enclosure assembly500may be located at one end of the hot box insulation cover800on the foundational frame assembly100. The power electronics enclosure assembly500may house an electronic signal conditioning hardware854and/or a main electronic control system856for the fuel cell utility product assembly1000. The control system856of the present fuel cell utility product assembly1000may comprise one or more controllers, processors, memories, etc. to send and/or receive command(s), operations, and functional signals from the multiple different components, actuators and sensors of the fuel cell utility product assembly1000.

A mechanical enclosure assembly600may be located at the other end of the hot box insulation cover800on the foundational frame assembly100opposite the power electronics enclosure assembly500. The location or end that the power electronics enclosure assembly500and the mechanical enclosure assembly600are located on or at are interchangeable. The mechanical enclosure assembly600may house any mechanical hardware that supplies the input mass flow of fuel (e.g., natural gas, H2, etc.) or oxidant (e.g., air or O2) to the more than one fuel cell assemblies700. In addition, the mechanical enclosure assembly600may comprise thermal and cooling system components (radiators, heaters, coolants, etc.) that are separated from the fuel cell assemblies700of the hot box802and hot box area824.

The dedicated power electronics enclosure assembly500and dedicated mechanical enclosure assembly600of the present the fuel cell utility product assembly1000advantageously enable a completely separate production line or the opportunity to engage a different supplier to manufacture these components for eventual assembly into the larger fuel cell utility product assembly1000. It may also be advantageous that the electronics enclosure assembly500and/or the mechanical enclosure assembly600are separate from each other and the rest of the fuel cell utility product assembly1000as it may enable an efficient and clean production environment for each component. Separation of the power electronics enclosure assembly500and mechanical enclosure assembly600(e.g., each being a “dedicated” system) enables a modular approach to the fuel cell utility product assembly1000, such that the eight major components of the assembly (100-900) may be separately manufactured and assembled.

FIG.6illustrates an embodiment of the mechanical enclosure assembly600that houses an air blower608and a fuel blower604. The air blower608may be supplied filtered fresh air through the system air inlet duct or vent632. After air is transported through the system, particularly the fuel cell assemblies700, the air may migrate into the main air outlet pipe606and then out of the system air outlet duct or exhaust vent630to the atmosphere. In other embodiments, parasitic devices, such as blowers and pumps are not utilized in the fuel cell utility product assembly1000.

The mechanical enclosure assembly600may optionally include a secondary scavenge tube836, which may extend into the area covered by the hot box insulation cover800(e.g., the hot box802) such as to retrieve and exhaust any excess air or fuel that has leaked into the hot box802. To exhaust excess air, the secondary scavenge tube836may be connected to the main air outlet pipe606at junction602. The secondary scavenge tube836uses the exhaust flow as a venturi to purge the hot box volume, which aids to prevent excess gas buildup. A blower, pump, or other parasitic devices may not be used to exhaust the excess hot air in some embodiments.

The geometry of junction602may be designed to passively pull air from the hot box802area covered by the hot box insulation cover800via the natural flow of air out of the system air outlet duct or vent630. In other embodiments, this passive exhaust flow of excess air may also provide an outlet to exhaust any gaseous leaks that could develop in the hot box802area. Therefore, the air exhaust mechanisms of the mechanical enclosure assembly600provide a mechanism to exhaust both air, gases, and fuel.

The mechanical enclosure assembly600may comprise an emergency stop tank672. In some embodiments, the emergency stop tank672may comprise a urea catalyst. The emergency stop tank672may also allow for an emergency shut down of the fuel cell utility product assembly1000by releasing the urea catalyst. The fuel blower604may circulate fuel throughout the system to be combined with air from the air blower608within the fuel cell assemblies700. In a solid oxide fuel cell, the fuel may be natural gas that is reformed in the reformer796to produce the hydrogen needed in a fuel cell chemical reaction.

Additionally,FIG.12is an illustration of another embodiment of a fuel cell utility product assembly800comprising the mechanical enclosure assembly600that is distinctly separated from the fuel cell stack, system, and assembly components700. In this embodiment, the mechanical enclosure assembly600houses a cooling system and/or a thermal management system620. In this embodiment ofFIG.12, the power electronics enclosure assembly500is optionally absent.

Preferably, the power electronics enclosure assembly500is positioned on the opposite end of the hot box area824and the hot box802as the mechanical enclosure assembly600, as previously shown inFIGS.1,5, and6. In other embodiments, the power electronics enclosure assembly500separated from the fuel cell stack, system, and assembly components700could be optionally positioned on the opposite end of the hot box area824and the hot box802, with the mechanical enclosure assembly600absent.

For example,FIG.12demonstrates a side-by-side positioning layout of the thermal management system620comprising one or more radiators18that are located on the same surface and/or in the same plane, but different compartments than the fuel cell system700. Similarly, the radiators18may include or be configured to be connectably linked or attached to one or more fans22. The fans22may be located on the same surface and/or in the same plane, on in a plane, surface, or area that is above or below the radiators18, the latter of which is shown inFIG.12. The thermal management system620comprising the radiator18and fans22is located on or atop the same foundational frame assembly100as the fuel cell assemblies700that are also located on or atop the same foundational frame assembly100.

The radiator18of the thermal management system620and the fuel cell assemblies100may also be positioned or located on the same plane and in any position or location that provides operational efficiency, assessment, maintenance, and/or repair of the fuel cells by lifting, rolling, and/or removing the hot box insulation cover800for the hot box area824comprising the hot box802. Notably, the fuel cell utility product assembly1000of the present disclosure demonstrates an advantageous side-by-side system layout embodiment.

In one such embodiment, the fuel cell stacks or fuel cells of the fuel cell assembly700are distinctly and separately located adjacent to main cooling or heating system components of the thermal management system620(e.g., fans, blowers, heaters, coolant, etc.). In other embodiments, the thermal management system620does not comprise parasitic devices for heating and cooling (e.g., fans, blowers, heaters, etc.). This side-by-side layout design comprising the thermal management system620located adjacent to and separately from the fuel cell assemblies700provides some benefits over other layout embodiments that are not side-by-side.

Importantly, the side-by-side layout of the present fuel cell utility product assembly1000demonstrated inFIGS.1,5,9,10, and12, and described herein, allows for the hot box area824, hot box802, and the fuel cells assemblies700to be more easily accessible for servicing without significant disturbance to the cooling and other sub-systems of the thermal management system620in the mechanical enclosure assembly600, as well as the powers electronic enclosure assembly500. This side-by-side layout of the fuel cell utility product assembly1000also facilitates redesign, resizing, and/or repositioning of one or both of the thermal management (e.g., cooling) system620and the fuel cells of the fuel cell assemblies700, which can be increased or decreased independently of each other, if required. This additional flexibility of the side-by-side positioning of the hot box area824, hot box802, and the fuel cells assemblies700, the thermal management system620of the mechanical enclosure assembly600, as well as the powers electronic enclosure assembly500significantly reduces the time and number of components that would need to be redesigned in any new fuel cell system.

Importantly, the side-by-side design of the fuel cell utility product assembly1000having the hot box area824and the hot box802, including the fuel cell assemblies700, next to and/or sandwiched between the mechanical enclosure assembly600and/or the powers electronic enclosure assembly500lies in that the fuel cell assemblies700remain separated from the cooling or thermal management systems620.

In some embodiments, the fuel cell assemblies700and thermal management system620of the mechanical enclosure assembly600are separated by a distinct, uniform, or non-uniformly shaped separation distance184that ranges from about 0.5 inch to about 12 inches in width, including any and all specific or range of distances comprised therein. In some embodiments, the separation distance184is uniformly shaped, such as in a straight line, that has a separation distance or thickness184. The thickness or distance of the separation distance184ranges from about 0.5 inch to about 12 inches thick, including all specific or range of thickness184comprised therein.

The separation distance184, located between the fuel cell assembly700and the mechanical enclosure assembly600that comprises the thermal management system620, may range from about 0.5 to about 12 inches long, including all specific or range of distances comprised therein. Side-by-side and distinct separation of the fuel cells of the fuel cell assembly700from the radiators and other components of the thermal management system620enable easy accessibility to the fuel cells or fuel cell assembly700components comprised in the hot box area824and hot box802for servicing. The side-by-side positioning of the fuel cell assembly700next to the mechanical enclosure assembly600and the thermal management system620also minimizes or reduces the amount or need for disassembly of other components and disturbing significant parts of other subsystems in order to reach the fuel cells of the fuel cell assemblies700.

For example, the present side-by-side layout of the fuel cell assemblies700, the mechanical enclosure assembly600, and the power electronics enclosure assembly500of the fuel cell utility product assembly1000is an improvement over the fuel cell layouts known or currently in the art. Illustratively, the side-by-side layout of the fuel cell assembly700and the mechanical enclosure assembly600including the thermal management system620is advantageous over alternative layouts, wherein the radiators may be located or positioned over top, atop, or on top of the fuel cell systems or assemblies700. Such a layout thereby requires that the cooling or thermal management system620be moved or removed before the fuel cell assembly700components are accessible for assessment, maintenance, and/or repair. Therefore, the present side-by-side layout of the fuel cell assembly700, the mechanical enclosure assembly600, and/or the power electronics enclosure assembly500, as shown inFIGS.1,5,9,10, and12, also facilitates the design of other iterations of the present invention as the fuel cell and cooling systems can be increased or decreased in scope and size, independently.

For example, if more cooling or heating is needed because the presently claimed system and methods are going to be deployed in a part of the world having hot, ambient temperature, the side-by-side positioning of the present the fuel cell assembly700, the mechanical enclosure assembly600, and/or the power electronics enclosure assembly500would easily allow or enable expansion of the cooling or thermal management system620on its distinct side to include longer or larger radiators. In turn, expanding or enlarging the radiators or other cooling mechanisms in the mechanical enclosure assembly600to allow for the required cooling in hot temperatures could be conducted without affecting the components of the fuel cell assembly700on its side. The independent ability to access the fuel cell assembly700, the mechanical enclosure assembly600, and/or the power electronics enclosure assembly500separately and independently also thereby advantageously minimizes any redesign efforts and increasing cooling and thermal management620efficiency.

FIG.7illustrates a path for a flow of electrical power generated by the fuel cell assemblies700out of the hot box802. In one embodiment, proximal ends of the high temperature bus bars770are connected to the top of the fuel cell assemblies700either through welded or bolted connections780. The high temperature bus bars770may be subject to the high internal temperatures of about 700° C. to about 850° C. generated by the fuel cell assemblies700in the hot box802.

The high temperature bus bars770may be constructed of any high temperature resistant material. For example, the high temperature bus bars770may be constructed of a steel. The steel used to construct the high temperature bus bars may be stainless steel.

The high temperature bus bars770may be completely located inside the hot box802. One or more distal ends of the high temperature bus bars770may extend out of the hot box802and through the hot box floor insulation400. For example, in one embodiment, the bus bar insulation tile866of the hot box floor insulation400are positioned at a level location724above the distal ends of the high temperature bus bars770. In one embodiment, one or more proximal ends of the high temperature bus bars770are located in the hot box802and the other distal ends of the high temperature bus bars770are located in the foundational frame assembly100.

The high temperature bus bars770may attach to the top of a fuel cell stack790and dive down below the hot box floor insulation400so the bus bars770exit the hot box802with minimal length. Minimizing the exit distance of the bus bars770from the hot box802may improve the conductivity and the life of the bus bars770. The bus bars770may then travel inside the hot box floor insulation400to cool down by the time they enter the foundational frame assembly100and travel on to the power enclosure assembly500.

In one embodiment, the high temperature bus bars770may be allowed to cool over a defined length720(e.g., a cooling length). The high temperature bus bars770may cool to an appropriate temperature that is well below the fuel cell operational temperature and nearer to external environment temperature (e.g., 20-40° C.). Once the high temperature bus bars770have sufficiently cooled, they may be connected to one or more low temperature bus bars722at location782.

The low temperature bus bars722may be constructed of a lower grade material that are more standardized and cost effective. The cooling length720may depend on the temperature of the hot box802, the ambient temperature, and/or the materials used to make the high and low temperature bus bars770and722. The high temperature bus bars770and low temperature bus bars722may migrate towards and transition into the power electronics enclosure assembly500at location718.

FIGS.8A-8Cillustrate an embodiment of the intermediate plumbing300that is configured to route between the frame cross members122of the foundational frame assembly100, such as shown inFIG.5. In one embodiment, the intermediate plumbing300may be configured in three specific “stacked” levels to allow the desired pathways to cross over one another without interfering. As shown inFIG.8A, the first or top level340is configured for fuel plumbing, the second or middle level342is configured for air plumbing, and the third or bottom level344is configured for optional bypass plumbing. In an exemplary embodiment, the plumbing on the first or top level340is in a totally or partially different plane than the plumbing on the second or middle level342, which is in a totally or partially different plane than the plumbing for the third or bottom level344.

In other embodiments of the intermediate plumbing300routing, any of the three levels may comprise fuel plumbing, air plumbing, or bypass plumbing, as long as each level is dedicated to only one specific type of plumbing (e.g., air, fuel, or bypass). For embodiments where no bypass plumbing is utilized, a maximum of two “stacked” levels of intermediate plumbing300routing will be utilized. In a further embodiment of the intermediate plumbing300routing, multiple types of plumbing may be comprised in a single level (e.g., both the air and fuel plumbing may be located in the first or top level340), such that not all three levels are utilized.

Referring toFIGS.8A and8C, the intermediate plumbing air inlet378may feed two fuel cell assemblies700in parallel at the fuel cell air heat exchanger inlets358and360through the intermediate air inlet plumbing tube346. After flowing through the fuel cell stack assemblies700, air may be collected at points354and356in the intermediate air outlet plumbing tube336and routed to the main air outlet plumbing at connection384. In one embodiment, there may be a primary air flow path from one “C”-shaped frame rails130or120to a second “C”-shaped frame rails130or120. This layout may avoid flow splitting or a “Y” shaped split to get air to both sides of the foundational frame assembly100, and may be more reliable and cost effective.

Referring toFIG.8B, the intermediate plumbing fuel inlet382may feed two fuel cell assemblies700in parallel at the fuel cell inlet366and the fuel heat exchanger inlet368through the intermediate fuel inlet plumbing tube330. After flowing through the fuel cell stack of the assembly700, fuel may be collected at points370and372in the intermediate fuel outlet plumbing tube348. Fuel may then be routed to the main fuel outlet plumbing at connection380.

The intermediate plumbing may optionally include air bypass tubes332and334. In some embodiments, air may bypass the air heat exchanger through the air heat exchanger bypass tube332by taking air from the main air inlet plumbing at connection374and distributing it at locations350and352.

In other embodiments, air may bypass the fuel cell stack assembly700through air fuel cell bypass tube334by taking air from the main air inlet plumbing at connection376and distributing it at locations362and364. In some embodiments, the bypass plumbing may be deployed fully (as shown), partially configured, or completely omitted or removed depending on the performance and control requirements of the fuel cell utility product assembly1000.

In one embodiment, the fuel cell utility product assembly1000may comprise at least one configuration of two fuel cell assemblies700plumbed in parallel. Two fuel cell assemblies700in parallel may advantageously require fewer control valves112while allowing the fuel cell assemblies700to be connected in electrical series, which increases the voltage to the power electronics assembly500. In some embodiments, one fuel cell assembly700may be upside down so that the bottom of each fuel cell assembly700is connected to a center ground. In other embodiments, the fuel cell assemblies700may not be connected in series. For example, in some embodiments, each fuel cell assembly700could be similarly oriented (e.g., right side up), and the base of the fuel cell assemblies700may be at ground potential.

FIG.9illustrates an embodiment of a system for increasing the power output by placing multiple fuel cell utility product assemblies1000together to create a megawatt output configuration1100. Importantly, multiple units of the fuel cell utility product assembly1000may be configured in a layout on a portion of a surface (e.g., a land surface) to maximize the power output. The multiple units of the fuel cell utility product assembly1000can be arranged in one or more rows.

The fuel cell utility product assemblies1000are positioned to provide a first minimal distance1002between the ends of consecutive assemblies1000in the same row (e.g., end-to-end configuration). The first distance1002is minimized to maximize the number of assemblies1000that are able to be placed in one row upon a limited surface area (seeFIG.9). In addition, the assemblies1000are placed such that the power electronics enclosure assembly500or the mechanical enclosure assembly600of one unit is directly located next to the power electronics enclosure assembly500or the mechanical enclosure assembly600of the next assembly1000in the row. In one embodiment, the first distance1002ranges from about 3 inches to about 24 inches, including any specific or ranges of distance comprised therein.

The assemblies1000are further positioned having a second distance1004between adjacent assemblies1000in different rows. The second distance1004is correlated with the minimal distance or space required for a service provider to be able to locate and access the hot box802comprising the fuel cell assemblies700, the foundational frame assembly100, the power electronics enclosure assembly500, the mechanical enclosure assembly600, and/or other components or compartments of the assembly unit1000. In one embodiment, the second distance1004ranges from about 2 feet to about 18 feet, including any specific or ranges of distance comprised therein. In the illustrative embodiment ofFIGS.9-11, the second distance1004is about 9 feet.

FIG.9illustrates multiple fuel cell utility product assemblies1000located in a layout configuration1100with the hot box insulation cover800in a closed position such that the hot box802is not exposed or immediately ready to be serviced.FIG.10illustrates multiple fuel cell utility product assemblies1000located in the layout configuration1100with the hot box insulation cover800in an open service position1010.

The system air inlet duct or vent632and system air outlet duct or vent630may be configured to enable continuous operation of a neighboring fuel cell utility product assembly1000while one (or more) of the units is undergoing service, repair, and/or maintenance. As previously described, the hot box insulation cover800may be raised up using the one or more hot box wheel assemblies828sliding or rolling along the wheel tracks166and continuously onto the neighboring fuel cell utility product assembly1000.

Referring back toFIGS.5and10, raising the hot box insulation cover800before moving it ensures that no damage is done to any of the insulation seals870,834and888or components. In some embodiments, the hot box insulation cover800that slides or rolls continuously onto the neighboring fuel cell utility product assembly1000to expose the hot box802and fuel cell assemblies700may not block or overlap the system air inlet duct or vent632or the system air outlet duct or vent630of the neighboring fuel cell utility product assembly1000.

Removing the insulation cover800entirely from the fuel cell utility product assembly1000may take up valuable space in the limited distance between rows. Depending on the embodiment, the hot box802may be accessed without removing the hot box insulation cover from the foundational frame assembly100. The hot box802may also be accessed without removing any panels from the insulation cover800.

Instead, the fuel cell utility product assembly1000of the present disclosure enables the insulation cover800to be raised and slid or rolled across the wheel tracks166of the foundational frame assembly100without having to completely remove the cover800, which is advantageous. In some embodiments, the insulation cover800may roll on the wheel tracks166and174on the foundational frame assembly100. The insulation cover800may roll horizontally on the wheel tracks166in either direction to gain access to half the fuel cell assemblies700at any given time. This opening and rolling ability of the hot box insulation cover800also provides the benefit of a lifting device or means (e.g., a crane) to have overhead and/or direct access to the fuel cell assemblies700of the hot box802in order to remove and/or replace the fuel cell assemblies700.

FIG.11illustrates one embodiment of a layout of a megawatt output configuration1100. The fuel cell utility product assemblies1000may be configured end-to-end while making room for one or more service access pathways1110and1120. The service pathways are configured to run both horizontally1110and/or perpendicularly1120to the fuel cell utility product assembly1000.

In some embodiments, about 2 to about 5 fuel cell utility product assembly1000may be configured end-to-end to form fuel cell utility product assembly units1130. In other embodiments, multiple such fuel cell utility product assembly units1130may be aligned horizontally1110and/or perpendicularly1120. In some other embodiments, such multiple fuel cell utility product assembly units1130may be separated from adjacent fuel cell utility product assembly units1130by a distance of about 5 ft. to about 20 ft. from each other, including any specific or range of distances comprised therein. For example, in one embodiment shown inFIG.11, the distance may be from about 7.5 to about 20 ft., from about 9 ft. to about 18 ft., from about 10 ft. to about 15 ft.

In one embodiment, a megawatt output configuration1100may enable a high-power density while allowing easy service and/or replacement of parts or components of the fuel cell utility product assembly1000in the field. In other embodiments, multiple fuel cell utility product assembly1000may be configured to be organized in a different layout with or without horizontal1110and/or perpendicular1120service access pathways.

In one embodiment, a method of operating a fuel cell utility product assembly1000may include configuring a fuel cell utility product assembly1000, including a foundational frame assembly100, a hot box802comprising one of more fuel cell assemblies700, a power electronics enclosure assembly500, a mechanical enclosure assembly600, a network of primary air and fuel plumbing200, and a network of intermediate air and fuel plumbing300to generate power (e.g., electricity). The method of operating a fuel cell utility product assembly1000may further include an insulation cover800covering the hot box802. The hot box insulation cover800may move, roll, or slide in a horizontal direction to enable and/or increase access to the fuel cell assemblies700or service, repair, maintenance, etc. The network of primary air and fuel plumbing200and the network of intermediate air and fuel plumbing300may be enclosed in “C”-shaped rails of the foundational frame assembly100.

In one embodiment, the method of operating a fuel cell utility product assembly1000may include operating the fuel cell utility product assembly1000in association with one or more other fuel cell utility product assembly1000. The method of operating a fuel cell utility product assembly1000may include more than one fuel cell utility product assemblies1000organized in a layout with or without horizontal1110or perpendicular1120service access pathways.

As used herein, an element or step recited in the singular and proceeded with the word “a” or “an” should be understood as not excluding plural of said elements or steps, unless such exclusion is explicitly stated. Furthermore, references to “one embodiment” of the presently described subject matter are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features. Specified numerical ranges of units, measurements, and/or values comprise, consist essentially or, or consist of all the numerical values, units, measurements, and/or ranges including or within those ranges and/or endpoints, whether those numerical values, units, measurements, and/or ranges are explicitly specified in the present disclosure or not.

Unless defined otherwise, technical and scientific terms used herein have the same meaning as is commonly understood by one of ordinary skill in the art to which this disclosure belongs. The terms “first”, “second”, “third” and the like, as used herein do not denote any order or importance, but rather are used to distinguish one element from another. The term “or” is meant to be inclusive and mean either or all of the listed items. In addition, the terms “connected” and “coupled” are not restricted to physical or mechanical connections or couplings, and can include electrical connections or couplings, whether direct or indirect.

Moreover, unless explicitly stated to the contrary, embodiments “comprising”, “including,” or “having” an element or a plurality of elements having a particular property may include additional such elements not having that property. The term “comprising” or “comprises” refers to a composition, compound, formulation, or method that is inclusive and does not exclude additional elements, components, and/or method steps. The term “comprising” also refers to a composition, compound, formulation, or method embodiment of the present disclosure that is inclusive and does not exclude additional elements, components, or method steps.

The phrase “consisting of” or “consists of” refers to a compound, composition, formulation, or method that excludes the presence of any additional elements, components, or method steps. The term “consisting of” also refers to a compound, composition, formulation, or method of the present disclosure that excludes the presence of any additional elements, components, or method steps.

The phrase “consisting essentially of” or “consists essentially of” refers to a composition, compound, formulation, or method that is inclusive of additional elements, components, or method steps that do not materially affect the characteristic(s) of the composition, compound, formulation, or method. The phrase “consisting essentially of” also refers to a composition, compound, formulation, or method of the present disclosure that is inclusive of additional elements, components, or method steps that do not materially affect the characteristic(s) of the composition, compound, formulation, or method steps.

Approximating language, as used herein throughout the specification and claims, may be applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term or terms, such as “about”, and “substantially” is not to be limited to the precise value specified. In some instances, the approximating language may correspond to the precision of an instrument for measuring the value. Here and throughout the specification and claims, range limitations may be combined and/or interchanged. Such ranges are identified and include all the sub-ranges contained therein unless context or language indicates otherwise.

As used herein, the terms “may” and “may be” indicate a possibility of an occurrence within a set of circumstances; a possession of a specified property, characteristic or function; and/or qualify another verb by expressing one or more of an ability, capability, or possibility associated with the qualified verb. Accordingly, usage of “may” and “may be” indicates that a modified term is apparently appropriate, capable, or suitable for an indicated capacity, function, or usage, while taking into account that in some circumstances, the modified term may sometimes not be appropriate, capable, or suitable.

It is to be understood that the above description is intended to be illustrative, and not restrictive. For example, the above-described embodiments (and/or aspects thereof) may be used individually, together, or in combination with each other. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the subject matter set forth herein without departing from its scope. While the dimensions and types of materials described herein are intended to define the parameters of the disclosed subject matter, they are by no means limiting and are exemplary embodiments. Many other embodiments will be apparent to those of skill in the art upon reviewing the above description. The scope of the subject matter described herein should, therefore, be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled.

This written description uses examples to disclose several embodiments of the subject matter set forth herein, including the best mode, and also to enable a person of ordinary skill in the art to practice the embodiments of disclosed subject matter, including making and using the devices or systems and performing the methods. The patentable scope of the subject matter described herein is defined by the claims, and may include other examples that occur to those of ordinary skill in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.

While only certain features of the invention have been illustrated and described herein, many modifications and changes will occur to those skilled in the art. It is, therefore, to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit of the invention.