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Fuel cell system comprising modular design featuresRelated Patent Categories: Chemistry: Electrical Current Producing Apparatus, Product, And Process, Fuel Cell, Subcombination Thereof Or Methods Of Operating, Automatic Control MeansFuel cell system comprising modular design features description/claimsThe Patent Description & Claims data below is from USPTO Patent Application 20060188763, Fuel cell system comprising modular design features. Brief Patent Description - Full Patent Description - Patent Application Claims
CROSS-REFERENCE TO RELATED APPLICATIONS [0001] The present application is related to commonly assigned pending U.S. patent application entitled "Integrated Fuel Cell Power Module", filed on Sep. 24, 2004 and bearing Ser. No. 10/948,794, the content of which is hereby incorporated by reference. TECHNICAL FIELD [0002] The present invention relates to devices which produce an electrical current by means of a chemical reaction or change in physical state, and more specifically, electrochemical fuel cell power generation systems comprising multiple subsystems including fuel processing, fuel cell stack, power conditioning, electronics and controls as well as the components of balance of plant. BACKGROUND OF THE INVENTION [0003] Fuel Cells (FC's) are electrochemical devices that directly convert the chemical energy of a fuel into electricity. In contrast to energy storage batteries, fuel cells operate continuously as long as they are provided with reactant gases. In the case of hydrogen/oxygen fuel cells such as proton exchange membrane fuel cells, which are the focus of most research activities today, the only by-product is water and heat if pure hydrogen is used. The high efficiency of fuel cells and the prospects of generating electricity without pollution have made them a serious candidate to power the next generation of vehicles, houses and mobile devices. More recently, focus of fuel cell development has extended to remote power supply and applications, in which the current battery technology reduces availability because of high recharging times compared to a short period of power supply (e.g. cellular phones). [0004] There are basically three major applications of fuel cells, namely, transportation, stationary and portable powers. In the case of transportation applications, pure hydrogen appears to be the most desirable fuel rather than on-board hydrogen production from hydrocarbon fuels, given the factors such as complexity, cost and slow start-up. This suggests that a fuel cell power system without fuel processing is most appropriate for transportation applications. In the case of stationary applications, especially in the low power range (<10 kW), two types of application, i.e. residential and backup power (or uninterruptible power units) are typical, with the former being generally installed with both a fuel processor and a fuel cell power system, and the latter only a fuel cell power system. Depending on the applications, fuel cell manufacturers have been putting their resources on either transportation, residential or backup. The products developed and manufactured in such cases cannot be transferable, i.e. each product requires a separate, lengthy and costly process of development, manufacturing and assembly. [0005] Still, one of the most important issues impeding the commercialization of fuel cells is the cost. Besides the material, the complexity in the present designs shares a significant portion of the high cost. As it is well known in the field, a fuel cell power plant commonly comprises of hundreds (if not thousands) of components, with all of these components being properly connected, integrated, and housed in a chamber. It is a common feature that these multiple components have been made to best utilize the space inside the chamber in order to make the fuel cell system more compact. However, this feature has led to poor manufacturability, poor accessibility for assembling and poor serviceability. It is often the case that the whole system or subsystem (such as fuel processor, fuel cell stack) must be replaced even though there is only one part that has actually failed. SUMMARY OF THE INVENTION [0006] It is therefore an objective of the present invention to provide a fuel cell system and a method to design and manufacture the same. [0007] According to the present invention, the fuel cell system will be suitable as a stand-alone product for hydrogen production, pure hydrogen based transportation and backup power systems and fossil fuel residential applications as a result of disclosed modular design features. The functionally grouped and mechanically integrated modules can be separately manufactured, and serviced. Once manufactured, these modules can be easily installed and integrated to form a fuel processor, a fuel cell backup power system, or a residential fuel cell combined heat and power system. It provides the great degree of flexibility in manufacturing, assembly, and service. Each module can be easily replaced once it fails without sacrificing the entire system. [0008] While this invention will be discussed mostly in relation to a Proton Exchange Membrane Fuel Cells (PEMFC), operated at either commonly referred low-temperature (e.g. <100.degree. C.) or high-temperature (e.g. 120-250.degree. C.) conditions, it is also applicable to other types of fuel cells such as alkaline fuel cell (AFC), phosphoric acid fuel cell (PAFC), molten carbonate fuel cell (MCFC), and solid oxide fuel cell (SOFC). [0009] The present invention discloses a fuel cell system that is comprised of functionally grouped and mechanically integrated modules at all levels of system, subsystem and components, with the objective to increase the manufacturability, assembling ability and serviceability. Another objective is to increase the simplicity, and compactness of fuel cell systems. Yet another objective is to reduce the costs associated with fuel cell manufacturing, assembly, maintenance and service. Still another objective is to provide a method that allows quick development of various fuel cell products, e.g. fossil fuel residential or stationary CHP units, direct hydrogen fueled backup power units, and hydrogen production fuel processor. [0010] The fuel cell power generation system is an integrated package from some or all of four major subsystems including fuel process subsystem, fuel cell subsystem, power conditioning subsystem and heat recovery subsystem. Furthermore, the fuel processor subsystem consists of three modules: fuel processor module, balance of plant module and electronics and controls module. Similarly, the fuel cell subsystem is made of three modules: fuel cell module, balance of plant module and electronics and controls module. The fuel processor module and fuel cell module each contain several separately manufactured and serviceable component modules, which are appropriately integrated. Linkage between the modules can be flexible and/or quick-connectable type. All the modules from component, subsystem to system are designed and constructed separately, and once manufactured they are linked or somehow stacked together according to the flow scheme to form an integrated compact device. The modular design feature as presented in this invention allows ease of manufacturing, leak testing, assembling and maintenance. It also allows repairing or replacing individual modules easily and cost effectively, once a failure has been detected. [0011] In accordance with the present invention, there is provided a fuel cell power system including a fuel processor subsystem, a fuel cell subsystem, and a power conditioning subsystem. The fuel processor subsystem comprises a main module for producing hydrogen rich streams from a hydrocarbon fuel, a balance of plant module for auxiliary components, and a control and electronic module for monitoring and controlling the fuel processor subsystem. The fuel cell subsystem comprises a main module for generation of electric power and thermal energy from hydrogen rich streams produced by the fuel processor module and air, a balance of plant module for auxiliary components, and a control and electronic module for monitoring and controlling the fuel cell subsystem. Each module has individual components attached thereto, the modules being designed and manufactured separately and assembled together to form the respective subsystems. [0012] In accordance with a second broad aspect of the present invention, there is provided a fuel cell power system including a fuel processor module, a fuel cell module, and a power conditioning module, wherein a balance of plant module regroups all system balance of plant components and is separate from the fuel processor module, fuel cell module, and power conditioning module; and an electrical and control module regroups all electrical and control devices to control and operate the system and is separate from the fuel processor module, fuel cell module, and power conditioning module. BRIEF DESCRIPTION OF THE DRAWINGS [0013] Further features and advantages of the present invention will become apparent from the following detailed description, taken in combination with the appended drawings, in which: [0014] FIG. 1. is a block diagram of the fuel cell power generation system in accordance with a preferred embodiment of the present invention; [0015] FIG. 2a illustrates the separate modules that make up the fuel processor subsystem in accordance with a preferred embodiment of the present invention; [0016] FIG. 2b illustrates the separate modules that make up the fuel processor subsystem in accordance with another preferred embodiment of the present invention; [0017] FIG. 3a illustrates the separate modules that make up the fuel cell subsystem in accordance with a preferred embodiment of the present invention; [0018] FIG. 3b illustrates the separate modules that make up the fuel cell subsystem in accordance with another preferred embodiment of the present invention; [0019] FIG. 4 illustrates the separate modules that make up the power conditioning subsystem in accordance with a preferred embodiment of the present invention; Continue reading about Fuel cell system comprising modular design features... Full patent description for Fuel cell system comprising modular design features Brief Patent Description - Full Patent Description - Patent Application Claims Click on the above for other options relating to this Fuel cell system comprising modular design features patent application. ###  How KEYWORD MONITOR works... a FREE service from FreshPatents1. Sign up (takes 30 seconds). 2. Fill in the keywords to be monitored. 3. Each week you receive an email with patent applications related to your keywords. Start now! - Receive info on patent apps like Fuel cell system comprising modular design features or other areas of interest. ### Previous Patent Application: Thermally efficient hydrogen storage system Next Patent Application: Fuel cell generation system Industry Class: Chemistry: electrical current producing apparatus, product, and process ### FreshPatents.com Support Thank you for viewing the Fuel cell system comprising modular design features patent info. 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