Abstract: An integrated fuel cell unit (10) includes an annular array (12) of fuel cell stacks (14), an annular cathode recuperator (20), an annular anode recuperator (22), a reformer (24), and an anode exhaust cooler (26), all integrated within a common housing structure (28).

Abstract: The present invention provides, among other things, a method of operating a solid oxide fuel cell system including a fuel cell stack. The method can include the acts of combining an exhaust flow from an anode side of the fuel cell stack and an exhaust flow from a cathode side of the fuel cell stack, transferring heat from the combined exhaust flow to a first air flow, and combining a second air flow and the heated first air flow upstream from the fuel cell stack to control a temperature of the combined air flow entering the cathode side of the solid oxide fuel cell.

Abstract: A condenser (10) and method for separating a fluid flow is provided. The condenser (10) maybe used for separating a cathode exhaust flow (60) into a condensed liquid (86) and a non-condensed gas (70). The condenser (10) includes a vertical inlet (14), a vertical outlet (16), a gas flow path (20), a liquid flow path (22), a non-condensed gas outlet (24) and a condensed liquid outlet (26).

Abstract: A coolant system includes a heat exchange circuit capable of being in a heat exchange relationship with a heat generating component, such as an engine, to remove thermal energy from the engine and transfer the thermal energy to a coolant, and an insulated tank in fluid communication with the heat exchange circuit. The system also includes a control and associated conduits and valves for passing coolant through the heat exchange circuit and the insulated tank so as to fill the tank with a first volume of coolant in a first operational state, for passing an additional amount of coolant from the heat exchange circuit into the insulated tank so as to fill the insulated tank with a second volume of coolant which is greater than the first volume of coolant in a second operational state, and for passing the additional amount of coolant from the insulated tank to the heat exchange circuit in a third operational state. A method of operating the coolant system to store thermal energy is also provided.

Abstract: A heat exchanger (50) is provided for transferring heat between first and second fluids (52) and (54) having a maximum operating mass flow rate through the heat exchanger (50) and mass flow rates that are substantially proportional to each other. The heat exchanger (50) provides essentially constant outlet temperatures for the first and second fluids (52,54) for all of the flow rates within the operating spectrum of the heat exchanger (50) without the use of an active control system. The heat exchanger (50) is of particular use in the fuel processing system (36) of proton exchange membrane type fuel cell systems.

Abstract: Energy consumption is minimized in the fuel cell system including a fuel cell 10 having a fuel inlet 14, an oxidant inlet 12, a cathode gas outlet 16 and an anode tail gas outlet 18. At least one humidifier 52,70; 54,72, is interposed between a source of air or fuel and includes an interior energy containing medium flow path 60,61; 62,64; 78,80; 72,84 in heat exchange relation with a reactant flow path 56,58; 74,76 together with a source 46 of water connected to the reactant flow path 56;58; 74,76 to be vaporized therein. The energy containing medium flow path 60,61; 62,64; 78,80; 82,84 is connected to one of the outlets 16,18 to receive a heated fluid therefrom to provide the heat of vaporization to the aqueous material.

Abstract: A vaporizer, a fuel cell system including the vaporizer, and a method of vaporizing fuel in a fuel cell system are disclosed. The fuel cell system includes a fuel reservoir (24) for storing a liquid fuel and a fuel cell (10) for consuming a fuel and generating electricity therefrom. A fuel vaporizer (28) is interposed between the fuel reservoir (24) and the fuel cell (10) for receiving liquid fuel and vaporizing it and delivering it ultimately to the fuel cell (10). The fuel vaporizer (28) includes a heat exchanger which includes a hot fluid inlet (65), a hot fluid outlet (67) and a core (50) interconnecting the inlet (65) and the outlet (68). The core (50) has alternating fuel flow structures (68) and hot fluid structures (69) with the fuel flow structures (68,69) having an inlet (56) and an outlet (58).

Abstract: An evaporative heat exchanger (10) is provided for the transfer of heat to a first fluid (30) from a second fluid (28) and a third fluid (22) to vaporize the first fluid (30). The heat exchanger (10) includes a core (40), a first flow path (60) in the core for the first fluid (30), a second flow path (66) in the core (40) for the second fluid (28), and a third flow path (68) in the core (40) for the third fluid (22). The core (40) includes a first section (42), a second section (44), and a third section (46), with the second section (44) connecting the first and third sections (42, 46). The first flow path (60) extends through all of the sections (42, 44, 46), the second flow path (66) extends through the first section (42), and the third flow path (68) extends through the third section (46).

Abstract: Degradation of membranes in fuel cells 10 due to dehydration by relatively dry incoming reactant gases is avoided through the use of a humidifier 56,58 in the incoming reactant streams, 12,14. At least one of the humidifiers 56,58 is formed in a stack 66 having alternating flow passages 68,70 with the former receiving reactant gases and including fins 102 therein and the latter receiving hot coolant from the fuel cell 10. The fins 102 in the flow spaces 68 are provided with a hydrophilic coating to foster filmwise evaporation of water introduced through a nozzle 82. The humidifier causes the reactant gas to attain a desired dewpoint before it is provided to the membranes of the fuel cell 10.

Abstract: A low volume, high capacity latent heat storage device is achieved in a construction including a salt case (12) with an optional outer jacket (10) surrounding the salt case (12) in spaced relation thereto to define an insulating space (14) between the two. Inlet and outlet conduits (38), (42), (44), (46), extend from the exterior of the outer jacket (10) to the interior of the salt case (12) and at least one tube (20) is located within the salt case and has a plurality of straight, parallel runs (21) defining a matrix with an exterior and a phase change material is sealed within the tube (20). The tube runs (21) inwardly of the matrix exterior are in a regular or equilateral polygonal pattern with each run (21) abutting a plurality of adjacent runs (21) and each run (21) at the exterior of the matrix additionally engaging the salt jacket (12).

Abstract: A method and system (10) are provided for humidifying a cathode inlet gas flow (18) in a fuel cell system (12) including a fuel cell (14) and a compressor (16) for supplying the cathode inlet gas flow (18) to a cathode side (20) of the fuel cell (14). According to the method and system (10) heat is transferred from the cathode inlet gas flow (18) to a cathode exhaust flow (24) at a first flow location with respect to the cathode inlet gas flow (18), and water vapor is transferred from the cathode exhaust flow (24) to the cathode inlet gas flow (18) at a downstream flow location from the first flow location with respect to the cathode inlet gas flow (18).

Abstract: An integrated condenser/separator (10) is provided for condensing and separating a condensate (11) from a cathode exhaust gas flow (12) in a fuel cell system (14). The condenser/separator includes a housing (16) and one or more baffle plates (18, 20) positioned in the housing (16) to divide the interior of the housing (16) into two or more gas flow chambers (24, 26, 28) each containing a stack (32, 34, 36) of heat exchange units (30). A condensate drain (106, 108) is provided in each of the gas flow chambers (24, 26) to drain condensate therefrom. The condenser/separator (10) can be configured into any reasonable and independent number of coolant and gas side passes as maybe required to meet the thermodynamic and pressure drop requirements of each particular application.

Abstract: A heat exchanger including a first header having an inlet therein, a second header, an outlet in one of the first and second headers, and a plurality of flat tubes extending between the first and second headers for carrying a fluid between the first and second headers. A first connector is also provided for connecting a first exterior line to one of the first and second headers, the first connector being proximate and substantially parallel to an end of one of the flat tubes. In a compact cooling system, such heat exchangers may be disposed about a radial fan directing air flow outwardly away from the fan axis. One of a system inlet and a system outlet are connected via the first exterior lines to the first connectors of at least two of the heat exchangers.

Abstract: An evaporative heat exchanger (10) is provided for the transfer of heat to a first fluid (30) from a second fluid (28) and a third fluid (22) to vaporize the first fluid (30). The heat exchanger (10) includes a core (40), a first flow path (60) in the core for the first fluid (30), a second flow path (66) in the core (40) for the second fluid (28), and a third flow path (68) in the core (40) for the third fluid (22). The core (40) includes a first section (42), a second section (44), and a third section (46), with the second section (44) connecting the first and third sections (42, 46). The first flow path (60) extends through all of the sections (42, 44, 46), the second flow path (66) extends through the first section (42), and the third flow path (68) extends through the third section (46).

Abstract: A heat exchanger (50) is provided for transferring heat between first and second fluids (52) and (54) having a maximum operating mass flow rate through the heat exchanger (50) and mass flow rates that are substantially proportional to each other. The heat exchanger (50) provides essentially constant outlet temperatures for the first and second fluids (52,54) for all of the flow rates within the operating spectrum of the heat exchanger (50) without the use of an active control system. The heat exchanger (50) is of particular use in the fuel processing system (36) of proton exchange membrane type fuel cell systems.

Abstract: Energy consumption is minimized in the fuel cell system including a fuel cell 10 having a fuel inlet 14, an oxidant inlet 12, a cathode gas outlet 16 and an anode tail gas outlet 18. At least one humidifier 52,70; 54,72, is interposed between a source of air or fuel and includes an interior energy containing medium flow path 60,61; 62,64; 78,80; 72,84 in heat exchange relation with a reactant flow path 56,58; 74,76 together with a source 46 of water connected to the reactant flow path 56;58; 74,76 to be vaporized therein. The energy containing medium flow path 60,61; 62,64; 78,80; 82,84 is connected to one of the outlets 16,18 to receive a heated fluid therefrom to provide the heat of vaporization to the aqueous material.

Abstract: A compact heat exchanger system including a radial fan directing air flow outwardly away from the fan axis and a plurality of heat exchangers disposed around the radial fan. At least two of the heat exchangers include headers with longitudinal walls extending generally in the same direction as the fan axis with one of the heat exchangers disposed with its outlet header longitudinal wall adjacent the longitudinal wall of the inlet header of a second of the heat exchangers. A flow opening is provided between the adjacent longitudinal walls of the outlet header of the one heat exchanger and the inlet header of the second heat exchanger.

Abstract: A vaporizer, a fuel cell system including the vaporizer, and a method of vaporizing fuel in a fuel cell system are disclosed. The fuel cell system includes a fuel reservoir (24) for storing a liquid fuel and a fuel cell (10) for consuming a fuel and generating electricity therefrom. A fuel vaporizer (28) is interposed between the fuel reservoir (24) and the fuel cell (10) for receiving liquid fuel and vaporizing it and delivering it ultimately to the fuel cell (10). The fuel vaporizer (28) includes a heat exchanger which includes a hot fluid inlet (65), a hot fluid outlet (67) and a core (50) interconnecting the inlet (65) and the outlet (68). The core (50) has alternating fuel flow structures (68) and hot fluid structures (69) with the fuel flow structures (68,69) having an inlet (56) and an outlet (58).

Abstract: Degradation of membranes in fuel cells 10 due to dehydration by relatively dry incoming reactant gases is avoided through the use of a humidifier 56,58 in the incoming reactant streams, 12,14. At least one of the humidifiers 56,58 is formed in a stack 66 having alternating flow passages 68,70 with the former receiving reactant gases and including fins 102 therein and the latter receiving hot coolant from the fuel cell 10. The fins 102 in the flow spaces 68 are provided with a hydrophilic coating to foster filmwise evaporation of water introduced through a nozzle 82. The humidifier causes the reactant gas to attain a desired dewpoint before it is provided to the membranes of the fuel cell 10.

Abstract: An integrated condenser/separator (10) is provided for condensing and separating a condensate (11) from a cathode exhaust gas flow (12) in a fuel cell system (14). The condenser/separator includes a housing (16) and one or more baffle plates (18, 20) positioned in the housing (16) to divide the interior of the housing (16) into two or more gas flow chambers (24, 26, 28) each containing a stack (32, 34, 36) of heat exchange units (30). A condensate drain (106, 108) is provided in each of the gas flow chambers (24, 26) to drain condensate therefrom. The condenser/separator (10) can be configured into any reasonable and independent number of coolant and gas side passes as maybe required to meet the thermodynamic and pressure drop requirements of each particular application.