US20090071072A1 - Planar micro fuel processor - Google Patents
Planar micro fuel processor Download PDFInfo
- Publication number
- US20090071072A1 US20090071072A1 US12/276,129 US27612908A US2009071072A1 US 20090071072 A1 US20090071072 A1 US 20090071072A1 US 27612908 A US27612908 A US 27612908A US 2009071072 A1 US2009071072 A1 US 2009071072A1
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- US
- United States
- Prior art keywords
- reformer
- fuel
- fuel processor
- dewar
- burner
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
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- C01B2203/0227—Processes for making hydrogen or synthesis gas containing a reforming step containing a catalytic reforming step
- C01B2203/0233—Processes for making hydrogen or synthesis gas containing a reforming step containing a catalytic reforming step the reforming step being a steam reforming step
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- C01B2203/0244—Processes for making hydrogen or synthesis gas containing a reforming step containing a catalytic reforming step the reforming step being an autothermal reforming step, e.g. secondary reforming processes
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- C01B2203/0261—Processes for making hydrogen or synthesis gas containing a partial oxidation step containing a catalytic partial oxidation step [CPO]
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- C01B2203/0805—Methods of heating the process for making hydrogen or synthesis gas
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- C01B2203/0816—Heating by flames
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- C01B2203/0827—Methods of heating the process for making hydrogen or synthesis gas by combustion of fuel at least part of the fuel being a recycle stream
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- C01B2203/0844—Methods of heating the process for making hydrogen or synthesis gas by heat exchange with exothermic reactions, other than by combustion of fuel the non-combustive exothermic reaction being another reforming reaction as defined in groups C01B2203/02 - C01B2203/0294
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- C01B2203/1223—Methanol
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- H—ELECTRICITY
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- H01M2008/1095—Fuel cells with polymeric electrolytes
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
- Y02E60/30—Hydrogen technology
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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- Y02P20/129—Energy recovery, e.g. by cogeneration, H2recovery or pressure recovery turbines
Definitions
- a dewar includes one or more dewar chambers that receive inlet process gases or liquids before a reactor receives them.
- the dewar is arranged such that air passing through the dewar chamber intercepts heat generated in the burner before the heat escapes the fuel processor. Passing air through a dewar chamber in this manner performs two functions: a) active cooling of the burner before it reaches outer portions of the fuel processor, and b) heating of the air before receipt by the burner.
- the burner relies on catalytic combustion to produce heat, heat generated in the burner warms cool air in the burner according to the temperature of the incoming air.
- FIG. 1A illustrates a fuel cell system for producing electrical energy in accordance with one embodiment of the present invention.
- FIG. 2D illustrates a side cross section of the fuel processor of FIG. 2A taken through line A-A.
- FIG. 2H illustrates a front cross section of the fuel processor of FIG. 2A taken through line C-C.
- FIG. 1A illustrates a fuel cell system 10 for producing electrical energy in accordance with one embodiment of the present invention.
- Fuel cell system 10 comprises storage device 16 , fuel processor 15 and fuel cell 20 .
- a ‘reformed’ hydrogen supply processes a fuel source to produce hydrogen.
- the reformed hydrogen supply comprises a fuel processor 15 and a fuel source storage device 16 .
- Storage device 16 stores fuel source 17 , and may include a portable and/or disposable fuel cartridge.
- a disposable cartridge offers instant recharging to a consumer.
- the cartridge includes a collapsible bladder within a hard plastic dispenser case.
- a separate fuel pump typically controls fuel source 17 flow from storage device 16 . If system 10 is load following, then a control system meters fuel source 17 to deliver fuel source 17 to processor 15 at a flow rate determined by the required power level output of fuel cell 20 .
- the anode includes the hydrogen gas distribution layer, hydrogen catalyst and bi-polar plate.
- the anode acts as the negative electrode for fuel cell 20 and conducts electrons that are freed from hydrogen molecules so that they can be used externally, e.g., to power an external circuit.
- the bi-polar plates are connected in series to add the potential gained in each layer of the stack.
- the cathode includes the oxygen gas distribution layer, oxygen catalyst and bi-polar plate. The cathode represents the positive electrode for fuel cell 20 and conducts the electrons back from the external electrical circuit to the oxygen catalyst, where they can recombine with hydrogen ions and oxygen to form water.
- the hydrogen catalyst separates the hydrogen into protons and electrons.
- the ion conductive membrane blocks the electrons, and electrically isolates the chemical anode (hydrogen gas distribution layer and hydrogen catalyst) from the chemical cathode.
- the ion conductive membrane also selectively conducts positively charged ions. Electrically, the anode conducts electrons to a load (electricity is produced) or battery (energy is stored). Meanwhile, protons move through the ion conductive membrane, to combine with oxygen. The protons and used electrons subsequently meet on the cathode side, and combine with oxygen to form water.
- the oxygen catalyst in the oxygen gas distribution layer facilitates this reaction.
- One common oxygen catalyst comprises platinum powder very thinly coated onto a carbon paper or cloth. Many designs employ a rough and porous catalyst to increase surface area of the platinum exposed to the hydrogen and oxygen.
- a flow sensor or valve 23 situated on line 29 between storage device 16 and fuel processor 18 detects and communicates the amount of methanol 17 transfer between storage device 16 and reformer 32 .
- pump 21 b regulates methanol 17 provision from storage device 16 to reformer 32 .
- reformer channels 37 , burner channels 31 and/or boiler channels 35 are formed in a silicon substrate using an etch process, such as a DRIE etch or a wet etch.
- each substrate 40 , 42 and 44 comprises a silicon alloy, silicon carbide, or a metal such as Stainless Steel, Titanium or Inconel. The metal facilitates heat transfer between burner 32 and reformer 30 and between burner 32 and boiler 34 .
- MEMs manufacturing techniques such as layering and etching may also be used to fabricate substrates 40 , 42 and 44 and channels disposed therein.
- Boiler 34 heats methanol before reformer 32 receives the methanol.
- Boiler 34 comprises a set of boiler channels 35 disposed in a face 40 a of substrate 40 .
- a plate 41 attaches to face 40 a and covers the open side of each channel 35 .
- Boiler 34 includes a volume determined by the cumulative size of boiler channels 35 in the set.
- Reformer 32 comprises a set of reformer channels 37 disposed in a face 42 b of substrate 42 .
- a plate 49 attaches to face 42 b and covers the open side of each channel 37 .
- Reformer 32 includes a volume determined by the cumulative volume and size of reformer channels 37 in the set. More specifically, reformer 32 includes a segmented volume that includes contributions from multiple channels 37 .
- channels 37 are substantially rectangular in cross section.
- Channels 37 widths 37 b from about 20 to about 400 microns are suitable for many applications.
- channels 37 include a width 37 b of about 100 microns.
- One or more aspect ratios may also be used to characterize the size of channels 37 .
- Spacer 130 maintains separation of substrate 42 and substrate 44 . This reduces heat transfer from substrate 42 to a cooler substrate 44 and permits more heat to remain in substrate 42 and transfer to reformer 32 (e.g., catalyst 102 or the methanol in channels 37 ).
- spacer 130 comprises a rigid and low heat conductance material such as a ceramic.
- spacer 130 may comprise another layer of compliant material 110 to further control forces in fuel processor 15 and protect substrates 40 and 42 and plates 41 and 49 .
- Dock 38 also includes inlet and outlet ports for gaseous and liquid communication in and out of fuel processor 15 .
- port 81 and socket 82 described above dock 38 permits transport of methanol to reformer 32 from outside fuel processor 15 though wall 128 b .
- port 87 and socket 101 described above dock 38 permits transport of hydrogen from reformer to outside the fuel processor though a wall included in the dock. Dock 38 thus also provides gaseous and liquid interconnection for components held by dock 38 .
- FIG. 3D illustrates a cross sectional view of a multipass dewar 300 in accordance with another embodiment of the present invention.
- Dewar 300 comprises four dewar walls 302 a - d that connect to a housing wall 304 .
- Dewar wall 302 a and housing wall 304 enclose monolithic structure 100 , which includes burner 30 .
- Dewar wall 302 b and housing wall 304 enclose dewar wall 302 a and burner 30 .
- dewar wall 302 c and housing wall 304 enclose dewar wall 302 b
- dewar wall 302 d and housing wall 304 enclose dewar wall 302 c .
- Dewar walls 302 a - d form four volumes for incoming air to pass over warmer walls and receive heat.
Abstract
Description
- This application is a divisional of U.S. patent application Ser. No. 10/877,804, entitled “Planar Micro Fuel Processor”, filed Jun. 25, 2004, which claims priority under 35 U.S.C. § 119(e) from co-pending U.S. Provisional Patent Application No. 60/482,996, entitled “Fuel Cell System Startup Procedure and Self-heating Apparatus”, filed Jun. 27, 2003, and from co-pending U.S. Provisional Patent Application No. 60/483,416 entitled “Fuel Preheat in Portable Electronics Powered by Fuel Cells”, filed Jun. 27, 2003, which are all incorporated herein by reference in their entirety for all purposes.
- The present invention relates to fuel cell technology. In particular, the invention relates to fuel processors that generate hydrogen and are suitable for use in portable applications.
- A fuel cell electrochemically combines hydrogen and oxygen to produce electricity. The ambient air readily supplies oxygen. Hydrogen provision, however, calls for a working supply. Gaseous hydrogen has a low energy density that reduces its practicality as a portable fuel. Liquid hydrogen, which has a suitable energy density, must be stored at extremely low temperatures and high pressures, making storing and transporting liquid hydrogen burdensome.
- A reformed hydrogen supply processes a fuel source to produce hydrogen. The fuel source acts as a hydrogen carrier. Currently available liquid fuel sources include methanol, ethanol, gasoline, propane and natural gas. Liquid hydrocarbon fuel sources offer high energy densities and the ability to be readily stored and transported. A fuel processor reforms the hydrocarbon fuel source and to produce hydrogen.
- Fuel cell evolution so far has concentrated on large-scale applications such as industrial size generators for electrical power back-up. Consumer electronics devices and other portable electrical power applications currently rely on lithium ion and similar battery technologies. Fuel processors for portable applications such as electronics would be desirable but are not yet commercially available. In addition, techniques that reduce fuel processor size or increase fuel processor efficiency would be highly beneficial.
- The present invention relates to a fuel processor that produces hydrogen from a fuel source. The fuel processor comprises a reformer, boiler and burner. The reformer includes a catalyst to facilitate the production of hydrogen from the fuel source. A boiler heats the fuel source before receipt by the reformer. The burner provides heat to the reformer and to the boiler. The fuel processor may also comprise a dock that maintains the position of the reformer and boiler within the fuel processor. The dock also applies a compliant securing force that holds components of the fuel processor.
- Dewars are also described that improve thermal management of a fuel processor by reducing heat loss and increasing burner efficiency. A dewar includes one or more dewar chambers that receive inlet process gases or liquids before a reactor receives them. In one embodiment, the dewar is arranged such that air passing through the dewar chamber intercepts heat generated in the burner before the heat escapes the fuel processor. Passing air through a dewar chamber in this manner performs two functions: a) active cooling of the burner before it reaches outer portions of the fuel processor, and b) heating of the air before receipt by the burner. When the burner relies on catalytic combustion to produce heat, heat generated in the burner warms cool air in the burner according to the temperature of the incoming air. This steals heat from the reformer, reduces heating efficiency of a burner and typically results in greater consumption of the fuel source for catalytic heat generation. The dewar thus pre-heats incoming air before arrival in the burner so the burner loses less heat to the incoming air that would otherwise transfer to the reformer.
- In one aspect, the present invention relates to a fuel processor for producing hydrogen from a fuel source. The fuel processor comprises a reformer that includes a set of reformer channels disposed in a first substrate. The reformer also includes a reformer catalyst that facilitates the production of hydrogen from the fuel source. The fuel processor further comprises a boiler including a set of channels disposed in a second substrate and configured to heat the fuel source before the reformer receives the fuel source. The fuel processor also comprises a burner configured to provide heat to the reformer and configured to provide heat to the boiler. The fuel processor additionally comprises a dock configured to maintain position of the reformer and boiler within the fuel processor by applying a compliant securing force that passes through a portion of the first substrate and a portion of the second substrate.
- In another aspect, the present invention relates to a fuel processor for producing hydrogen from a fuel source. The fuel processor comprises a reformer that includes a set of reformer channels disposed in a first substrate. The reformer also includes a reformer catalyst that facilitates the production of hydrogen from the fuel source. The fuel processor further comprises a boiler including a set of channels disposed in a second substrate and configured to heat the fuel source before the reformer receives the fuel source. The fuel processor also comprises a catalytic burner including a catalyst that facilitates the production of heat using the fuel source, configured to provide heat to the first substrate and the second substrate, and including a set of channels disposed in one of the first substrate and the second substrate.
- In yet another aspect, the present invention relates to a fuel processor for producing hydrogen from a fuel source. The fuel processor comprises a reformer that includes a set of reformer channels disposed in a first substrate. The reformer also includes a reformer catalyst that facilitates the production of hydrogen from the fuel source. The fuel processor further comprises a burner configured to provide heat to the reformer. The fuel processor also comprises a dewar that contains the reformer and the burner and includes a set of dewar walls that form a dewar chamber configured to receive the fuel source or oxygen before the reformer receives the fuel source or oxygen.
- These and other features and advantages of the present invention will be described in the following description of the invention and associated figures.
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FIG. 1A illustrates a fuel cell system for producing electrical energy in accordance with one embodiment of the present invention. -
FIG. 1B illustrates schematic operation for the fuel cell system ofFIG. 1A in accordance with a specific embodiment of the present invention. -
FIG. 2A illustrates a top view of fuel processor in accordance with one embodiment of the present invention. -
FIG. 2B illustrates a side cross section of the fuel processor ofFIG. 2A taken through line K-K. -
FIG. 2C illustrates a side cross section of the fuel processor ofFIG. 2A taken through line L-L. -
FIG. 2D illustrates a side cross section of the fuel processor ofFIG. 2A taken through line A-A. -
FIG. 2E illustrates a side cross section of the fuel processor ofFIG. 2A taken through line M-M. -
FIG. 2F illustrates a side cross section of the fuel processor ofFIG. 2A taken through line N-N. -
FIG. 2G illustrates a front cross section of the fuel processor ofFIG. 2A taken through line B-B. -
FIG. 2H illustrates a front cross section of the fuel processor ofFIG. 2A taken through line C-C. -
FIG. 2I illustrates a front cross section of the fuel processor ofFIG. 2A taken through line D-D. -
FIG. 2J illustrates an expanded view of a portion of the shown inFIG. 2G . -
FIG. 3A illustrates a side cross-sectional view of a fuel processor and movement of air created by a dewar in accordance with one embodiment of the present invention. -
FIG. 3B illustrates a front cross-sectional view of a fuel processor and demonstrates thermal management benefits gained by the dewar. -
FIG. 3C shows a thermal diagram of the heat path produced by a dewar wall. -
FIG. 3D illustrates a dewar in accordance with another embodiment of the present invention. - The present invention is described in detail with reference to a few preferred embodiments as illustrated in the accompanying drawings. In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present invention. It will be apparent, however, to one skilled in the art, that the present invention may be practiced without some or all of these specific details. In other instances, well known process steps and/or structures have not been described in detail in order to not unnecessarily obscure the present invention.
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FIG. 1A illustrates afuel cell system 10 for producing electrical energy in accordance with one embodiment of the present invention.Fuel cell system 10 comprisesstorage device 16,fuel processor 15 andfuel cell 20. - A ‘reformed’ hydrogen supply processes a fuel source to produce hydrogen. As shown, the reformed hydrogen supply comprises a
fuel processor 15 and a fuelsource storage device 16.Storage device 16 stores fuelsource 17, and may include a portable and/or disposable fuel cartridge. A disposable cartridge offers instant recharging to a consumer. In one embodiment, the cartridge includes a collapsible bladder within a hard plastic dispenser case. A separate fuel pump typically controlsfuel source 17 flow fromstorage device 16. Ifsystem 10 is load following, then a control systemmeters fuel source 17 to deliverfuel source 17 toprocessor 15 at a flow rate determined by the required power level output offuel cell 20. -
Fuel source 17 acts as a carrier for hydrogen and can be processed to separate hydrogen.Fuel source 17 may include any hydrogen bearing fuel stream, hydrocarbon fuel or other hydrogen fuel source such as ammonia. Currently availablehydrocarbon fuel sources 17 suitable for use with the present invention include methanol, ethanol, gasoline, propane, butane and natural gas, for example. Several hydrocarbon and ammonia products may also produce asuitable fuel source 17.Liquid fuel sources 17 offer high energy densities and the ability to be readily stored and shipped.Storage device 16 may contain a fuel mixture. When thefuel processor 15 comprises a steam reformer,storage device 16 may contain a fuel mixture of a hydrocarbon fuel source and water. Hydrocarbon fuel source/water fuel mixtures are frequently represented as a percentage fuel source in water. In one embodiment,fuel source 17 comprises methanol or ethanol concentrations in water in the range of 1%-99.9%. Other liquid fuels such as butane, propane, gasoline, military grade “JP8” etc. may also be contained instorage device 16 with concentrations in water from 5-100%. In a specific embodiment,fuel source 17 comprises 67% methanol by volume. -
Fuel processor 15 processes thehydrocarbon fuel source 17 and outputs hydrogen. Ahydrocarbon fuel processor 15 heats and processes ahydrocarbon fuel source 17 in the presence of a catalyst to produce hydrogen.Fuel processor 15 comprises a reformer, which is a catalytic device that converts a liquid or gaseoushydrocarbon fuel source 17 into hydrogen and carbon dioxide. As the term is used herein, reforming refers to the process of producing hydrogen from a fuel source.Fuel processor 15 may output either pure hydrogen or a hydrogen bearing gas stream.Fuel processor 15 is described in further detail below. -
Fuel cell 20 electrochemically converts hydrogen and oxygen to water, generating electricity and heat in the process. Ambient air commonly supplies oxygen forfuel cell 20. A pure or direct oxygen source may also be used for oxygen supply. The water often forms as a vapor, depending on the temperature offuel cell 20 components. The electrochemical reaction also produces carbon dioxide as a byproduct for many fuel cells. - In one embodiment,
fuel cell 20 is a low volume polymer electrolyte membrane (PEM) fuel cell suitable for use with portable applications such as consumer electronics. A polymer electrolyte membrane fuel cell comprises amembrane electrode assembly 40 that carries out the electrical energy generating electrochemical reaction. Themembrane electrode assembly 40 includes a hydrogen catalyst, an oxygen catalyst and an ion conductive membrane that a) selectively conducts protons and b) electrically isolates the hydrogen catalyst from the oxygen catalyst. A hydrogen gas distribution layer contains the hydrogen catalyst and allows the diffusion of hydrogen therethrough. An oxygen gas distribution layer contains the oxygen catalyst and allows the diffusion of oxygen and hydrogen protons therethrough. The ion conductive membrane separates the hydrogen and oxygen gas distribution layers. In chemical terms, the anode comprises the hydrogen gas distribution layer and hydrogen catalyst, while the cathode comprises the oxygen gas distribution layer and oxygen catalyst. - A PEM fuel cell often includes a fuel cell stack having a set of bi-polar plates. A membrane electrode assembly is disposed between two bi-polar plates.
Hydrogen distribution 43 occurs via a channel field on one plate whileoxygen distribution 45 occurs via a channel field on a second facing plate. Specifically, a first channel field distributes hydrogen to the hydrogen gas distribution layer, while a second channel field distributes oxygen to the oxygen gas distribution layer. The ‘term ‘bi-polar’ refers electrically to a bi-polar plate (whether comprised of one plate or two plates) sandwiched between two membrane electrode assembly layers. In this case, the bi-polar plate acts as both a negative terminal for one adjacent membrane electrode assembly and a positive terminal for a second adjacent membrane electrode assembly arranged on the opposite face of the bi-polar plate. - In electrical terms, the anode includes the hydrogen gas distribution layer, hydrogen catalyst and bi-polar plate. The anode acts as the negative electrode for
fuel cell 20 and conducts electrons that are freed from hydrogen molecules so that they can be used externally, e.g., to power an external circuit. In a fuel cell stack, the bi-polar plates are connected in series to add the potential gained in each layer of the stack. In electrical terms, the cathode includes the oxygen gas distribution layer, oxygen catalyst and bi-polar plate. The cathode represents the positive electrode forfuel cell 20 and conducts the electrons back from the external electrical circuit to the oxygen catalyst, where they can recombine with hydrogen ions and oxygen to form water. - The hydrogen catalyst separates the hydrogen into protons and electrons. The ion conductive membrane blocks the electrons, and electrically isolates the chemical anode (hydrogen gas distribution layer and hydrogen catalyst) from the chemical cathode. The ion conductive membrane also selectively conducts positively charged ions. Electrically, the anode conducts electrons to a load (electricity is produced) or battery (energy is stored). Meanwhile, protons move through the ion conductive membrane, to combine with oxygen. The protons and used electrons subsequently meet on the cathode side, and combine with oxygen to form water. The oxygen catalyst in the oxygen gas distribution layer facilitates this reaction. One common oxygen catalyst comprises platinum powder very thinly coated onto a carbon paper or cloth. Many designs employ a rough and porous catalyst to increase surface area of the platinum exposed to the hydrogen and oxygen.
- In one embodiment,
fuel cell 20 comprises a set of bi-polar plates that each includes channel fields on opposite faces that distribute the hydrogen and oxygen. One channel field distributes hydrogen while a channel field on the opposite face distributes oxygen. Multiple bi-polar plates can be stacked to produce a ‘fuel cell stack’ in which a membrane electrode assembly is disposed between each pair of adjacent bi-polar plates. Since the electrical generation process infuel cell 20 is exothermic,fuel cell 20 may implement a thermal management system to dissipate heat from the fuel cell.Fuel cell 20 may also employ a number of humidification plates (HP) to manage moisture levels in the fuel cell. Further description of a fuel cell suitable for use with the present invention is included in commonly owned co-pending patent application entitled “Micro Fuel Cell Architecture” naming Ian Kaye as inventor and filed on the same day as this patent application, which is incorporated by reference for all purposes. - While the present invention will mainly be discussed with respect to PEM fuel cells, it is understood that the present invention may be practiced with other fuel cell architectures. The main difference between fuel cell architectures is the type of ion conductive membrane used. In one embodiment,
fuel cell 20 is phosphoric acid fuel cell that employs liquid phosphoric acid for ion exchange. Solid oxide fuel cells employ a hard, non-porous ceramic compound for ion exchange and may be suitable for use with the present invention. Generally, any fuel cell architecture may benefit from fuel processor improvements described herein. Other such fuel cell architectures include direct methanol, alkaline and molten carbonate fuel cells. -
Fuel cell 20 generates dc voltage that may be used in a wide variety of applications. For example, electricity generated byfuel cell 20 may be used to power a motor or light. In one embodiment, the present invention provides ‘small’ fuel cells that are designed to output less than 200 watts of power (net or total). Fuel cells of this size are commonly referred to as ‘micro fuel cells’ and are well suited for use with portable electronics. In one embodiment,fuel cell 20 is configured to generate from about 1 milliwatt to about 200 watts. In another embodiment,fuel cell 20 generates from about 3 W to about 20W. Fuel cell 20 may also be a stand-alone fuel cell, which is a single unit that produces power as long as it has an a) oxygen and b) hydrogen or a hydrocarbon fuel supply. Afuel cell 20 that outputs from about 40 W to about 100 W is well suited to power a laptop computer. -
FIG. 1B illustrates schematic operation forfuel cell system 10 in accordance with a specific embodiment of the present invention. As shown,fuel cell system 10 comprisesfuel container 16,hydrogen fuel source 17,fuel processor 15,fuel cell 20, multiple pumps 21 andfans 35, fuel lines and gas lines, and one ormore valves 23. -
Fuel container 16 stores methanol as ahydrogen fuel source 17. Anoutlet 26 offuel container 16 providesmethanol 17 into hydrogenfuel source line 25. As shown,line 25 divides into two lines: afirst line 27 that transportsmethanol 17 to aburner 30 forfuel processor 15 and asecond line 29 that transportsmethanol 17 toreformer 32 infuel processor 15.Lines Separate pumps lines system 10 is suitable in this embodiment. A flow sensor orvalve 23 situated online 29 betweenstorage device 16 and fuel processor 18 detects and communicates the amount ofmethanol 17 transfer betweenstorage device 16 andreformer 32. In conjunction with the sensor orvalve 23 and suitable control, such as digital control applied by a processor that implements instructions from stored software, pump 21 b regulatesmethanol 17 provision fromstorage device 16 toreformer 32. -
Fan 35 a delivers oxygen and air from the ambient room throughline 31 to regenerator 36 offuel processor 15.Fan 35 b delivers oxygen and air from the ambient room throughline 33 to regenerator 36 offuel processor 15. In this embodiment, a model AD2005DX-K70 fan as provided by Adda USA of California is suitable to transmit oxygen and air forfuel cell system 10. Afan 37 blows cooling air overfuel cell 20 for cooling. -
Fuel processor 15 receivesmethanol 17 fromstorage device 16 and outputs hydrogen.Fuel processor 15 comprisesburner 30,reformer 32,boiler 34 anddewar 150.Burner 30 includes an inlet that receivesmethanol 17 fromline 27 and a catalyst that generates heat with methanol presence. In one embodiment,burner 30 includes an outlet that exhausts heated gases to a line that transmits the heated gases over heat transfer appendages included infuel cell 20 to pre-heat the fuel cell and expedite warm-up time needed when initially turning onfuel cell 20. An outlet ofburner 30 may also exhaust heated gases into the ambient room. -
Boiler 34 includes an inlet that receivesmethanol 17 fromline 29. The structure offuel processor 15 permits heat produced inburner 30 to heatmethanol 17 inboiler 34 beforereformer 32 receives themethanol 17.Boiler 34 includes an outlet that providesheated methanol 17 toreformer 32. -
Reformer 32 includes an inlet that receivesheated methanol 17 fromboiler 34. A catalyst inreformer 32 reacts with themethanol 17 and produces hydrogen and carbon dioxide. This reaction is slightly endothermic and draws heat fromburner 30. A hydrogen outlet ofreformer 32 outputs hydrogen toline 39. -
Dewar 150 pre-heats air before the air entersburner 30.Dewar 150 also reduces heat loss fromfuel cell 15 by heating the incoming air before it escapesfuel processor 15. In one sense,dewar 150 acts as a regenerator that uses waste heat infuel processor 15 to increase thermal management and thermal efficiency of the fuel processor. Specifically, waste heat fromburner 30 may be used to pre-heat incoming air provided toburner 30 to reduce heat transfer to the air in the burner so more heat transfers toreformer 32.Dewar 150 is described in further detail below. - In one embodiment,
fuel processor 15 is a steam reformer that only needs steam to produce hydrogen. Several types of reformers suitable for use infuel cell system 10 include steam reformers, auto thermal reformers (ATR) or catalytic partial oxidizers (CPOX). ATR and CPOX reformers mix air with the fuel and steam mix. ATR and CPOX systems reform fuels such as methanol, diesel, regular unleaded gasoline and other hydrocarbons. In a specific embodiment,storage device 16 providesmethanol 17 tofuel processor 15, which reforms the methanol at about 250° C. or less and allowsfuel cell system 10 use in applications where temperature is to be minimized. -
Line 39 transports hydrogen fromfuel processor 15 tofuel cell 20.Gaseous delivery lines line 39 to detect and communicate the amount of hydrogen being delivered tofuel cell 20. In conjunction with the hydrogen flow sensor and suitable control, such as digital control applied by a processor that implements instructions from stored software,fuel processor 15 regulates hydrogen gas provision tofuel cell 20. -
Fuel cell 20 includes an hydrogen inlet port that receives hydrogen fromline 39 and delivers it to a hydrogen intake manifold for delivery to one or more bi-polar plates and their hydrogen distribution channels. An oxygen inlet port offuel cell 20 receives oxygen fromline 33 and delivers it to an oxygen intake manifold for delivery to one or more bi-polar plates and their oxygen distribution channels. An anode exhaust manifold collects gases from the hydrogen distribution channels and delivers them to an anode exhaust port, which outlets the exhaust gases into the ambient room. A cathode exhaust manifold collects gases from the oxygen distribution channels and delivers them to a cathode exhaust port. - The schematic operation for
fuel cell system 10 shown inFIG. 1B is exemplary and other variations on fuel cell system design, such as reactant and byproduct plumbing, are contemplated. In addition to the components shown in shown inFIG. 1B ,system 10 may also include other elements such as electronic controls, additional pumps and valves, added system sensors, manifolds, heat exchangers and electrical interconnects useful for carrying out functionality ofsystem 10 that are known to one of skill in the art and omitted herein for sake of brevity. -
FIGS. 2A-2J illustrate afuel processor 15 in accordance with one embodiment of the present invention.FIG. 2A illustrates a top view offuel processor 15.FIGS. 2B-2F illustrate side cross sections offuel processor 15 taken at various profiles.FIGS. 2G-2J illustrate front cross sections offuel processor 15 taken at various profiles.FIG. 2J illustrates an expanded side cross section view of a portion offuel processor 15 shown inFIG. 2G . -
Fuel processor 15 comprisesreformer 32,burner 30,boiler 34,dock 38,shell 75,preferential oxidizer 50 andplates FIG. 2J ). Although the present invention will now be described with respect to methanol consumption for hydrogen production, it is understood that fuel processors of the present invention may consume another fuel source, as one of skill in the art will appreciate. -
Fuel processor 15 includessubstrates substrate substrate substrates substrates reformer 32,burner 30,boiler 34 andpreferential oxidizer 50. A channel refers to a trench formed in the substrate. Each channel guides the movement of a gas or liquid passed therein.Silicon substrates fuel processor 15. In a specific embodiment,reformer channels 37,burner channels 31 and/orboiler channels 35 are formed in a silicon substrate using an etch process, such as a DRIE etch or a wet etch. In another embodiment, eachsubstrate burner 32 andreformer 30 and betweenburner 32 andboiler 34. MEMs manufacturing techniques such as layering and etching may also be used to fabricatesubstrates - Referring to
FIGS. 2B , 2G and 2J,boiler 34 heats methanol beforereformer 32 receives the methanol.Boiler 34 comprises a set ofboiler channels 35 disposed in aface 40 a ofsubstrate 40. Aplate 41 attaches to face 40 a and covers the open side of eachchannel 35.Boiler 34 includes a volume determined by the cumulative size ofboiler channels 35 in the set. -
Boiler 34 is disposed in proximity toburner 30 to receive heat generated inburner 30. In the embodiment shown,boiler channels 35 are disposed on anopposite face 40 a ofsubstrate 40 from theface 40 b ofsubstrate 40 including burner channels 31 (FIG. 2J ). Heat then transfers 1) via conduction throughsubstrate 40 fromburner 30 toboiler 34 and 2) via convection fromboiler channel 35 walls to the methanol passing therethrough. In one embodiment,boiler 34 is configured to vaporize liquid methanol. Gaseousmethanol exiting boiler 34 then passes toreformer 32 for gaseous interaction withcatalyst 102. -
Boiler 34 receives methanol via fuel source inlet 81 (FIG. 2B ), which couples to themethanol supply line 27 ofFIG. 1B .Inlet 81 comprises asocket 82 disposed in awall 128 b ofdock 38 and configured to receive atube 27 that transports methanol tofuel processor 15. Aninlet manifold 84 transports liquid methanol fromsocket 82 tosubstrate 40 andreformer channels 35 insubstrate 40.Manifold 84 comprises an aperture or hole that passes throughcompliant material 110,substrates plate 41. Compression ofmaterial 110,substrates plate 41 byscrew 126 seals manifold 84 between the components. -
Reformer 32 comprises a set ofreformer channels 37 disposed in aface 42 b ofsubstrate 42. Aplate 49 attaches to face 42 b and covers the open side of eachchannel 37.Reformer 32 includes a volume determined by the cumulative volume and size ofreformer channels 37 in the set. More specifically,reformer 32 includes a segmented volume that includes contributions frommultiple channels 37. In one embodiment,channels 37 are substantially rectangular in cross section.Channels 37widths 37 b from about 20 to about 400 microns are suitable for many applications. In a specific embodiment,channels 37 include awidth 37 b of about 100 microns. One or more aspect ratios may also be used to characterize the size ofchannels 37. Alength 37 c towidth 37 b ratio describes the planar area ofchannels 37 on the face of a substrate.Channels 37 having a length to width ratio from about 10000:1 to about 10:1 are suitable for many applications. In a specific embodiment,channels 37 include a length to width ratio of about 200:1. Adepth 37 a towidth 37 b ratio describes the cross sectional size ofchannels 37 along theirlength 37 c.Channels 37 including a depth to width ratio from about 2:1 to about 100:1 are suitable for many applications. In a specific embodiment,channels 37 include a depth to width ratio of about 30:1. The set of channels includes at least one channel. The number and size ofchannels 37 forreformer 32 may vary with a desired hydrogen output forfuel processor 15, e.g., based on the production capacity of the fuel source andreformer catalyst 102. -
Reformer 32 is configured to receive methanol after it has passed throughboiler 34.Reformer 32 receives the methanol viaconduit 71, which transports methanol output fromchannels 35 ofboiler 34 tochannels 37 of reformer 32 (FIG. 2B ). More specifically,conduit 71 communicates methanol fromface 40 a ofsubstrate 40, traverses throughsubstrates channels 37 onface 42 b ofsubstrate 42. - A
catalyst 102 inreformer 32 facilitates the production of hydrogen.Catalyst 102 reacts withmethanol 17 and facilitates the production of hydrogen gas and carbon dioxide. In one embodiment,catalyst 102 comprises a wash coat disposed over eachchannel 37. A wash coat of the desired catalyst may be sputtered or sprayed onto the substrate and etched back to maintain aflat surface 42 b. Thecatalyst 102 then forms as thin layer over the walls of eachchannel 37. Onesuitable catalyst 102 includes CuZn when methanol is used as a hydrocarbon fuel source. Other materials suitable forcatalyst 102 include platinum, palladium, a platinum/palladium mix, and other precious metal catalysts for example. A combination of the following materials may also be used in catalyst 102: Cu, Zn, Pt, Ru, Rh, aluminum Oxides, calcium oxides, silicon oxides, and/or iridium. - A
preferential oxidizer 50intercepts reformer 32 hydrogen exhaust and decreases the amount of carbon monoxide in the exhaust (FIG. 2G ).Preferential oxidizer 50 comprises a set ofoxidizer channels 51 disposed in aface 44 b of substrate 44 (FIG. 2J ). Aplate 53 attaches to face 44 b and covers the open side of eachoxidizer channel 51.Preferential oxidizer 50 includes a volume determined by the cumulative size ofboiler channels 51 in the set.Preferential oxidizer 50 employs oxygen from an air inlet 107 (FIG. 2C ). -
Air inlet 107 receives air from the ambient room and comprises asocket 111 andmanifold 112.Socket 111 is disposed in awall 128 b ofdock 38 and sized to receive a tube that transports air tofuel processor 15.Socket 111 opens tomanifold 112, which transports the air tochannels 51 insubstrate 44. More specifically,manifold 112 traverses throughcompliant material 110, throughplate 40, throughsubstrates plate 49, throughspacer 130 and throughsubstrate 44 to open tochannels 51. Acatalyst 114 is wash coated onto the walls ofchannels 51 and may comprise one or a combination of the following materials: Cu, Zn, Pt, Ru, Rh, an aluminum oxide, a calcium oxide, a silicon oxide, iridium and/or another catalyst that is preferential to carbon monoxide over carbon dioxide. - An
outlet port 87 communicates hydrogen formed inreformer 32 outside of fuel processor 15 (FIG. 2E ). Infuel cell system 10 ofFIG. 1B ,port 87 communicates hydrogen to line 39 for hydrogen provision tofuel cell 20.Port 87 is disposed in a wall ofdock 38 and includes asocket 101 andmanifold 103 that open throughwall 128.Socket 101 is sized to receive a metal or plastic tube forline 39 for hydrogen communication fromfuel processor 15. An adhesive may fix the tube to an inner wall ofsocket 101. Alternatively, a metal tube may be brazed to an inner wall ofsocket 101. Whenfuel processor 15 includespreferential oxidizer 50 as shown, manifold 103 transports hydrogen frompreferential oxidizer 50, throughsubstrate 44, throughspacer 130, throughplate 49, throughsubstrates plate 40, throughcompliant material 110 and to socket 101 (FIG. 2B ). - In another embodiment,
preferential oxidizer 50 is not used infuel processor 15 andreformer 32 is configured to directly output hydrogen fromfuel processor 15. In this case,channels 37 inreformer 32 provide gas tomanifold 103 for hydrogen communication fromfuel processor 15. Whenfuel processor 15 does not include a preferential oxidizer, manifold 103 transports hydrogen fromreformer channels 37 insubstrate 42, throughsubstrates plate 40, throughcompliant material 110 and tosocket 101. - Hydrogen production in
reformer 32 is slightly endothermic and draws heat fromburner 30.Burner 30 generates heat and is configured to provide heat toreformer 32.Burner 30 comprises two sets of burner channels 31: a first set ofchannels 31 a disposed in aface 42 a ofsubstrate 42 and a second set ofchannels 31 b disposed in aface 40 b ofsubstrate 40.Substrates channels opposite faces Burner 30 includes a volume determined by the cumulative size ofburner channels 31 a andchannels 31 b. -
Burner 30,boiler 34 andpreferential oxidizer 50 each include a volume determined by the cumulative volume and size of channels in their respective channel set(s). Channel dimensions as described above with respect toreformer channels 37 may also be used forchannels 35 ofboiler 34,channels 31 ofburner 30, andchannels 51 ofpreferential oxidizer 50. Thus, channel widths, channel length to width ratios and channel depth to width ratios described above forchannels 37 are also suitable forchannels 35,channels 31 andchannels 51. - In one embodiment,
burner 30 employs catalytic combustion to produce heat. Acatalyst 104 inburner 30 helps a burner fuel passed through the chamber generate heat. In one embodiment, methanol produces heat inburner 30 andcatalyst 104 facilitates the methanol production of heat using methanol. Suitablemethanol burner catalysts 104 may include platinum, palladium, iron, tin oxide, other noble-metal catalysts and reducible oxides. Othersuitable catalyst 104 materials include one or a combination of the following materials: Cu, Zn, Pt, Ru, Rh, an aluminum oxide, a calcium oxide, a silicon oxide, and/or iridium. In another embodiment, waste hydrogen fromfuel cell 20 produces heat in the presence ofcatalyst 104.Catalyst 104 is commercially available from a number of vendors known to those of skill in the art. In one embodiment,catalyst 104 comprises a wash coat disposed over eachchannel 31. A wash coat of the desiredcatalyst 104 may injected into the micro-channels using well known mixing, injection, evaporation and reduction methods. Thecatalyst 104 then forms as thin, porous and high surface area layer over the walls of eachchannel 31. -
Burner 30 includes aninlet 114 that receives methanol 17 (FIG. 2F ).Burner inlet 114 comprises asocket 116 disposed in awall 128 b ofdock 38 and configured to receive a tube 27 (FIG. 1B ) that transports methanol tofuel processor 15. Amethanol inlet manifold 118 transports methanol fromsocket 116 toburner channels 31 insubstrates - Air including oxygen enters
dock 38 via air inlet port 91 (FIG. 2F ).Burner 30 uses the oxygen for catalytic combustion of methanol. A burner outlet port 120 (FIG. 2D ) communicates exhaust formed inburner 30 outside offuel processor 15.Burner outlet port 120 comprises asocket 122 disposed in a wall ofdock 38 and configured to receive a tube that transports the exhaust away fromfuel processor 15. Aburner outlet manifold 124 transports the exhaust fromchannels 31 tosocket 116. - Some fuel sources generate additional heat in
burner 30, or generate heat more efficiently, with elevated temperatures. In one embodiment,fuel processor 15 includes a boiler that heats methanol beforeburner 30 receives the fuel source. In this case, the boiler receives the methanol viafuel source inlet 114. The boiler is disposed in proximity toburner 30 to receive heat generated inburner 30. -
Burner 30 is configured to provide heat toreformer 32 and configured to provide heat toboiler 34. Disposing a set ofburner channels 31 a insubstrate 42 allows heat generated in eachburner channel 31 a to transfer via conduction throughsubstrate 42 toreformer 32 andchannels 37 ofreformer 32. The heat then conducts fromsubstrate 42 in the vicinity of eachchannel 37 intocatalyst 102. The heat may also convect into thechannels 37 and heat the methanol. Disposing a set ofburner channels 31 b insubstrate 40 allows heat generated in eachchannel 31 b to transfer via conduction throughsubstrate 40 toboiler 34 andchannels 35 ofboiler 34. Situatingburner 30 andreformer 32 on the same chip and in close proximity to each other allows heat to flow directly from theburner catalyst 104 through athin separating substrate 42, and into thereformer catalyst 102. Since the heat transfer is conducted from one catalyst structure, through a thin solid into the next catalyst microstructure,fuel processor 15 does need a large heat transfer area to transfer heat fromburner 30 toreformer 32. This reduces the overall volume offuel processor 15.Burner 30 need not includeburner channels 31 in bothsubstrate 40 andsubstrate 42. If only one substrate includes a set ofburner channels 31, then heat may conduct from the substrate having the set of burner channels to the other substrate and then toboiler 34 orreformer 32. - Although
fuel processor 15 has so far been described with respect to acatalytic burner 32, it is understood that some embodiments of the present invention may employ anelectric burner 30 configured to provide heat to the reformer and configured to provide heat to the boiler. Theelectric burner 30 includes an resistive heating element that produces heat in response to input current. Theelectric burner 30 may be disposed betweensubstrates substrates -
Plates plate plate plates fuel processor 15. -
Dock 38 maintains position ofreformer 32 andboiler 34 withinfuel processor 15. Dock comprisesscrew 126, a set ofdock walls 128,spacer 130,compliant material 110, andsockets reformer 32,burner 30 andboiler 34.Dock walls 128 include a securingwall 128 a,wall 128 b that opposes securingwall 128 a and one or more side walls wall 128 c that extend between securingwall 128 a andwall 128 b (FIG. 2C ). Securingwall 128 a includes a threaded hole for receivingscrew 126. In place ofscrew 126, a spring may also be used to push the chipset againstcompliant material 110 anddock 38.Dock walls 128 combine to form an enclosure that partially surround a portion ofreformer 32,boiler 34 andburner 30.Dock walls 128 may comprise, for example, mica glass, a ceramic, a glass filled polyester, or a metal such as copper. -
Dock 38 applies a compliant securing force that passes through a portion ofsubstrate 40 and a portion ofsubstrate 42. Screw 126 threads through securingwall 128 a, or the spring compresses, until it applies a compressive force ontoplate 53. This compressiveforce locks substrates plates Wall 128 b geometrically opposes securingwall 128 a and provides a resistive force to the compressive force provided byscrew 126 as it translates through components in the stack therebetween. Aline 132 between wherescrew 126 meetsplate 53 andwall 128 b may be used to roughly describe a compressive force path betweenscrew 126 andwall 128 b (FIG. 2G ). The compressive force generates in the threads ofscrew 126, transmits through a portion ofplate 53 near whereplate 53 meetsscrew 126, transmits through a portion ofsubstrate 44 nearline 132, through a portion ofspacer 130 nearline 132, through a portion ofplate 49 nearline 132, through a portion ofsubstrate 42 nearline 132, through a portion ofsubstrate 40 nearline 132, through a portion ofplate 41 nearline 132, through a portion ofcompliant material 110 nearline 132, and to wall 128 b. In this case, portions ofsubstrates screw 126 comprise an end that nears where the compressive force propagates through the substrates. In one embodiment,substrates plates -
Compliant material 110 intercepts the securing force provided byscrew 126 and establishes an upper limit for the compliant securing force. As shown inFIG. 2D ,compliant material 110 is disposed betweenplate 41 andwall 128 b intercepts the securing force betweenplate 41 andwall 128 b.Compliant material 110 includes a material of known and predetermined compliance that sets an upper limit for the compressive force applied byscrew 126. In one embodiment,material 110 comprises a rigidity or elastic modulus less than the rigidity or elastic modulus ofsubstrates material 110 then allows stresses ontosubstrates material 110. This reduces localized stresses onsubstrates substrates substrates material 110 prevents functional compromise offuel processor 15 by increasing mechanical buffering and protection ofsubstrates substrates plates compliant material 110 reduces translation of mechanical stress betweensubstrates dock 38. Deformation ofcompliant material 110 may reduce also pressure variations in portions ofsubstrates material 110.Compliant material 110 also reduces stresses induced betweensubstrates plates reformer 32,boiler 34 andburner 30. Materials suitable for use withcompliant material 110 include high temperature silicone, Teflon, or any other material with a suitable compliance and ability to handle the elevated temperatures used infuel processor 15. In a specific embodiment, thecompliant material 110 comprises Grafoil as provided by GrafTech International of Wilmington Del. - In one embodiment,
compliant material 110 acts as a gasket that seals the inlet and exit ports betweenplate 40 and the inside ofwall 128 b. In addition to sealing the gas streams, the gasket also thermally isolates the chipset fromdock 38 and dewar 150 (see below), thereby reducing the overall heat loss fromfuel processor 15. -
Spacer 130 maintains separation ofsubstrate 42 andsubstrate 44. This reduces heat transfer fromsubstrate 42 to acooler substrate 44 and permits more heat to remain insubstrate 42 and transfer to reformer 32 (e.g.,catalyst 102 or the methanol in channels 37). In one embodiment,spacer 130 comprises a rigid and low heat conductance material such as a ceramic. Alternatively,spacer 130 may comprise another layer ofcompliant material 110 to further control forces infuel processor 15 and protectsubstrates plates -
Dock walls 128 provide mechanical protection for internal components offuel processor 15 such assubstrates plates reformer 32,burner 30 andboiler 34.Shell 75 attaches to dock 38 and also provides mechanical protection for internal components offuel processor 15.Shell 75 includes a set ofwalls 77 that at least partially containreformer 32,burner 30 andboiler 34.Walls 77 comprise a suitably stiff material such as a metal, ceramic or a rigid polymer, for example.Shell 75 may attach to dock 38 using an adhesive or via one or more screws.Shell 75 anddock 38 collectively encapsulatereformer 32,burner 30 andboiler 34. As described below with respect todewar 150,shell 75 anddock 38 may also contribute thermal management benefits forfuel processor 15. - Although
fuel processor 15 includes ascrew 126 to provide a compressive force, it is contemplated that other mechanical means may be used to apply a force to maintain position of the reformer and boiler within the fuel processor. For example, screw 126 may be replaced with a spring clip or shim configured to provide a compressive force onto a chipset. -
Dock 38 also includes inlet and outlet ports for gaseous and liquid communication in and out offuel processor 15. Viaport 81 andsocket 82 described above, dock 38 permits transport of methanol toreformer 32 fromoutside fuel processor 15 thoughwall 128 b. Similarly, viaport 87 andsocket 101 described above, dock 38 permits transport of hydrogen from reformer to outside the fuel processor though a wall included in the dock.Dock 38 thus also provides gaseous and liquid interconnection for components held bydock 38. - A
burner 30 in fuel processor generates heat and typically operates at an elevated temperature.Burner 30 operating temperatures greater than 200 degrees Celsius are common. Standards for the manufacture of electronics devices typically dictate a maximum surface temperature for a device. Electronics devices such as laptop computers often include cooling, such as a fan or cooling pipe, to manage and dissipate internal heat. A fuel processor internal to an electronics device that loses heat into the device calls upon the device's cooling system to handle the lost heat. - In another embodiment, fuel processors of the present invention include a dewar that improves thermal management of a fuel processor by reducing heat loss and increasing burner efficiency.
FIG. 3A illustrates a side cross-sectional view offuel processor 15 and movement of air created bydewar 150 in accordance with one embodiment of the present invention.FIG. 3B illustrates a front cross-sectional view offuel processor 15 and demonstrates thermal management benefits gained bydewar 150. While thermal management techniques described herein will now be described as fuel processor components, those skilled in the art will recognize that the present invention encompasses methods of thermal management as described below. - In one embodiment,
fuel processor 15 comprises adewar 150 to improve thermal management forfuel processor 15.Dewar 150 at least partially thermally isolates components internal tohousing 152—such asburner 30—and contains heat withinfuel processor 15.Dewar 150 reduces heat loss fromfuel processor 15 and helps manage the temperature gradient betweenburner 30 and outer surface ofhousing 152. And as will be described below,dewar 150 also pre-heats air before it is received byburner 30. -
Dewar 150 at least partially containsburner 30 andreformer 32 and includes a set ofdewar walls 154 that help form adewar chamber 156 and achamber 158. The set ofwalls 154 includesside walls bottom walls FIG. 3B ; and includes twoend walls 154 e and 154 f that combine with top andbottom walls FIG. 3A .End wall 154 f includes apertures that permit the passage of inlet andoutlet ports 85, 87 and 89 therethough. -
Dewar chamber 156 is formed withindewar walls 154 and comprises all space within thedewar walls 154 not occupied bymonolithic structure 100. As shown inFIG. 3B ,dewar chamber 156 boxes inshell 75 anddock 38.Chamber 156 comprises ducts betweenshell 75 anddock 38 andwalls 154 on all four sides ofdewar 150. In addition,chamber 156 comprises air pockets between end walls ofdewar 150 and outside surfaces ofend plates FIG. 3A ). -
Chamber 158 is formed outsidedewar walls 154 betweendewar 150 andhousing 152.Chamber 158 comprises all space withinhousing 152 not occupied bydewar 150. As shown inFIG. 3B ,housing 152 boxes indewar 150 and the furtherinternal shell 75 anddock 38.Chamber 158 comprises ducts betweenwalls 154 on all four sides ofdewar 150 andhousing 152. In addition,chamber 158 comprisesair pockets 167 betweendewar 150 andhousing 152 on both ends that prevent contact and conductive heat transfer betweendewar 150 and housing 152 (FIG. 3A ). -
Dewar 150 is configured such that air passing throughdewar chamber 156 receives heat generated inburner 30.Dewar 150 offers thus two functions for fuel processor 15: a) it permits active cooling of components withinfuel processor 15 before the heat reaches an outer portion of the fuel processor, and b) it pre-heats the air going toburner 30. For the former, air moves throughfuel processor 15 and acrosswalls 154 ofdewar 150 such that the cooler air absorbs heat from thewarmer fuel processor 15 components. - As shown in
FIG. 3A ,housing 152 includes anair inlet port 91 or hole that permits the passage of air fromoutside housing 152 into air intochamber 158. A fan may provide the air to fuelprocessor 15 and pressurize the air coming throughport 97. Top andbottom walls chamber 158 todewar chamber 156. Air flow throughfuel processor 15 then flows: inair inlet port 97, throughchamber 158 along the length of thedewar 150, throughholes 172 inwalls chamber 156 back along the length of thedewar 150 in the opposite direction as in throughchamber 158, and intoair inlet ports 91 that allow the air to enterburner 30. Inchamber 158, the air a) moves across the outside surface ofdewar walls 154 and picks up heat convectively fromdewar walls 154, and b) moves across the inside surface ofhousing 152 and picks up heat convectively from thehousing 152 walls (whenhousing 152 is at a greater temperature than the air). Inchamber 156, the air a) moves across the outside surface ofshell 75 anddock 38 and picks up heat convectively from the walls ofshell 75 anddock 38, and b) moves across the inside surface ofdewar 150 and picks up heat convectively fromdewar walls 154. -
Dewar 150 is thus configured such that air passing through the dewar receives heat generated inburner 30 via direct convective heat transfer fromwalls shell 75 anddock 38 to air passing throughdewar chamber 156.Dewar 150 is also configured to such that air passing throughchamber 156 receives heat indirectly fromburner 30. Indirectly in this sense refers to heat generated inburner 30 moving to another structure infuel processor 15 before receipt by the air. -
FIG. 3C illustrates a thermal diagram of the heat path produced by awall 154 ofdewar 150. Heat fromburner 30 conducts throughshell 75 anddock 38 to a surface that opens intodewar chamber 156. From here, the heat a) conducts into the air passing throughdewar chamber 156, thereby heating the air; b) radiates to theinner wall 155 ofdewar wall 154, from which the heat convects into the air passing throughdewar chamber 156; c) radiates to theinner wall 155 ofdewar wall 154, conducts throughwall 154 to the outer surface 157 ofdewar wall 154, from which the heat convects into the air passing throughdewar chamber 158, and d) radiates to theinner wall 155 ofdewar wall 154, conducts throughwall 154 to the outer surface 157 ofdewar wall 154, radiates to a wall ofhousing 152, from which the heat convects into the air passing throughdewar chamber 158. -
Dewar 150 thus provides two streams of convective heat dissipation and active air-cooling involumes - Reflectance of heat back into
chamber 156 decreases the amount of heat lost fromfuel processor 150 and increases the heating of air passing throughchamber 156. To further improve the radiative reflectance back intochamber 156, an inside surface ofdewar wall 154 may include aradiative layer 160 to decrease radiative heat transfer into wall 154 (seeFIG. 3B or 3C).Radiative layer 160 is disposed on aninner surface 155 on one or more ofwalls 154 to increase radiative heat reflectance of theinner surface 155. Generally, the material used inradiative layer 160 has a lower emissivity than the material used inwalls 154. Materials suitable for use withwalls 154 ofdewar 150 include nickel or a ceramic, for example.Radiative layer 160 may comprise gold, platinum, silver, palladium, nickel and the metal may be sputter coated onto theinner surface 155.Radiative layer 160 may also include a low heat conductance. In this case,radiative layer 160 may comprise a ceramic, for example. - When
dewar 150 fully encapsulatesshell 75 anddock 38, the dewar then bounds heat loss from the structure and decreases the amount of heat passing out ofdewar 150 andhousing 152.Fuel processors 15 such as that shown inFIGS. 3A and 3B are well suited to contain heat withinhousing 152 and manage heat transfer from the fuel processor. As mentioned above,shell 75 anddock 38 collectively encapsulatereformer 32,burner 30 andboiler 34. If air is routed withinshell 75 anddock 38 before receipt byburner 30, then shell 75 anddock 38 may also contribute to thermal management as described with respect todewar 150. - In one embodiment, burner operates at a temperature greater than about 200 degrees Celsius and the outer side of the housing remains less than about 50 degrees Celsius. In embodiments for portable applications where
fuel processor 15 occupies a small volume,volumes volumes burner 30 on monolithic structure is no greater than 10 millimeters from a wall ofhousing 152. The thermal benefits gained by use ofdewar 150 also permit the use of higher temperature burning fuels as a fuel source for hydrogen production, such as ethanol and gasoline. In one embodiment, the thermal management benefits gained by use ofdewar 150permit reformer 32 to process methanol at temperatures well above 100 degrees Celsius and at temperatures high enough that carbon monoxide production inreformer 32 drops to an amount such that a preferential oxidizer is not needed. - As mentioned above,
dewar 150 offers a second function forfuel processor 15 by pre-heating the air going to a burner.Burner 30 relies on catalytic combustion to produce heat. Oxygen in the air provided toburner 30 is consumed as part of the combustion process. Heat generated in theburner 30 will heat cool incoming air, depending on the temperature of the air. This heat loss to incoming cool air reduces the heating efficiency ofburner 30, and typically results in a greater consumption of methanol. To increase the heating efficiency ofburner 30, the present invention heats the incoming air so less heat generated in the burner passes into the incoming air. In other words, chambers and air flow formed bydewar 150 allow waste heat from the burner to pre-heat air before reaching the burner, thus acting as a regenerator forfuel cell 15. - While
fuel processor 15 ofFIGS. 3A and 3B showsdewar 150 encapsulatingshell 75 anddock 38, the present invention may also employ other architectures fordewar 150 and relationships betweenburner 30 orreformer 32 anddewar 150 that carry out one or both of the dewar functions described above. In another embodiment,dewar 150 comprises a spiral wall that elongates the convective path for cool air flow over a warmer dewar wall. -
FIG. 3D illustrates a cross sectional view of amultipass dewar 300 in accordance with another embodiment of the present invention.Dewar 300 comprises four dewar walls 302 a-d that connect to ahousing wall 304.Dewar wall 302 a andhousing wall 304 enclosemonolithic structure 100, which includesburner 30.Dewar wall 302 b andhousing wall 304 enclose dewar wall 302 a andburner 30. Similarly,dewar wall 302 c andhousing wall 304 enclosedewar wall 302 b, whiledewar wall 302 d andhousing wall 304 enclosedewar wall 302 c. Dewar walls 302 a-d form four volumes for incoming air to pass over warmer walls and receive heat. Air entersdewar inlet port 310 and flows throughdewar chamber 308 a and intodewar chamber 308 b throughport 312 after travelling through substantially thewhole chamber 308 a. Air then serially passes into and throughchambers - While this invention has been described in terms of several preferred embodiments, there are alterations, permutations, and equivalents that fall within the scope of this invention which have been omitted for brevity's sake. It is therefore intended that the scope of the invention should be determined with reference to the appended claims.
Claims (20)
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Also Published As
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US20110020197A1 (en) | 2011-01-27 |
US7462208B2 (en) | 2008-12-09 |
US7807129B2 (en) | 2010-10-05 |
US7807130B2 (en) | 2010-10-05 |
EP1644111A4 (en) | 2011-02-09 |
US7276096B2 (en) | 2007-10-02 |
US20070294941A1 (en) | 2007-12-27 |
JP2007524562A (en) | 2007-08-30 |
US20080008646A1 (en) | 2008-01-10 |
WO2005004256A3 (en) | 2005-08-25 |
US20050005521A1 (en) | 2005-01-13 |
US20050022448A1 (en) | 2005-02-03 |
WO2005004256A2 (en) | 2005-01-13 |
US7604673B2 (en) | 2009-10-20 |
US20050011125A1 (en) | 2005-01-20 |
EP1644111A2 (en) | 2006-04-12 |
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