초록 ▼

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 d

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.

대표청구항 ▼

1. An integrated condenser/separator for condensing and separating a condensate from a cathode exhaust gas flow in a fuel cell system, the condenser/separator comprising:a housing including a gas flow inlet, a gas flow outlet, a condensate outlet, a coolant inlet, and a coolant outlet;a baffle plate

1. An integrated condenser/separator for condensing and separating a condensate from a cathode exhaust gas flow in a fuel cell system, the condenser/separator comprising:a housing including a gas flow inlet, a gas flow outlet, a condensate outlet, a coolant inlet, and a coolant outlet;a baffle plate positioned in the housing to divide an interior of the housing into a first gas flow chamber and a second gas flow chamber, the baffle plate having a coolant opening to allow a flow of coolant through the baffle plate and a gas flow opening to allow a gas flow through the baffle plate;a first condensate drain in the first gas flow chamber to drain condensate from the first gas flow chamber; anda plurality of heat exchange units arranged as a first stack of the heat exchange units positioned in the first gas flow chamber and a second stack of the heat exchange units positioned in the second gas flow chamber,the first stack including a first plurality of coolant channels interleaved with a first plurality of gas flow channels, a first inlet manifold to direct coolant into the first plurality of coolant channels, a first outlet manifold to receive coolant from the first plurality of coolant channels, and a first gas flow manifold to communicate gas flow with the first plurality of gas flow channels,the second stack including a second plurality of coolant channels interleaved with a second plurality of gas flow channels, a second inlet manifold to direct coolant into the second plurality of coolant channels, a second outlet manifold that receives coolant from the second plurality of coolant channels, and a second gas flow manifold to communicate gas flow with the second plurality of gas flow channels. 2. The integrated condenser/separator of claim 1 wherein the first and second gas flow manifolds are aligned with the gas flow opening in the baffle plate whereby the gas flow makes one pass through the first plurality of gas flow channels and another pass through the second plurality of gas flow channels. 3. The integrated condenser/separator of claim 2 wherein the gas flow inlet opens into the first gas flow chamber whereby the gas flow makes a first pass from the first gas flow chamber through the first plurality of gas flow channels to the first gas flow manifold, flows from the first gas flow manifold through the gas flow opening to the second gas flow manifold, and makes a second pass from the second gas flow manifold through the second plurality of gas flow channels to the second gas flow chamber. 4. The integrated condenser/separator of claim 1 wherein the housing comprises cylindrical side walls surrounding the peripheries of the first and second stack of heat exchanger units. 5. The integrated condenser/separator of claim of claim 1 further comprising a coalescing member positioned upstream of the first and second plurality of gas flow channels. 6. The integrated condenser/separator of claim 1 further comprising:a condensate manifold in fluid communication with the condensate outlet and the first condensate drain to direct condensate from the condensate drain to the condensate outlet. 7. The integrated condenser/separator of claim 6 wherein the condensate manifold comprises a wall that surrounds at least parts of the first and second gas flow chambers to define an exterior surface of the housing. 8. The integrated condenser/separator of claim 1 wherein said housing comprises a first downwardly converging conical side wall surrounding the periphery of the first stack of heat exchanger units, and a second downwardly converging conical side wall surrounding the periphery of the second stack of heat exchanger units. 9. The integrated condenser/separator of claim 1 wherein the second outlet manifold and the first inlet manifold are aligned with the coolant opening in the baffle plate to allow coolant flow from the second outlet manifold to the first inlet manifold whereby the coolant makes a pass through the second plurality of cool ant channels and an additional pass through the first plurality of coolant channels. 10. The integrated condenser/separator of claim 1 wherein:the baffle plate has an additional coolant opening;the first and second inlet manifolds are aligned with one of the coolant opening in the baffle plate to allow coolant flow between the first and second inlet manifolds,the first and second outlet manifolds are aligned with the other coolant opening in the baffle plate to allow coolant flow between the first and second outlet manifolds. 11. The integrated condenser/separator of claim 1 further comprising:a second baffle plate positioned in the housing to divide the interior of the housing into a third gas flow chamber adjacent the second gas flow chamber, the second baffle plate having a second coolant opening to allow a flow of coolant through the second baffle plate and a second gas flow opening to allow a gas flow through the second baffle plate;a second condensate drain in the second gas flow chamber to drain condensate from the second gas flow chamber; anda third stack of the heat exchange units positioned in the third gas flow chamber, the third stack including a third plurality of the coolant channels interleaved with a third plurality of gas flow channels, a third inlet manifold to direct coolant into the third plurality of coolant channels, a third outlet manifold to receive coolant from the third plurality of coolant channels, and a third gas flow manifold to communicate gas flow with the third plurality of gas flow channels. 12. An integrated condenser/separator for condensing and separating a condensate from a cathode exhaust gas flow in a fuel cell system, the condenser/separator comprising:a housing having an interior, an exterior, a gas flow inlet, a gas flow outlet, a condensate outlet, a coolant inlet, and a coolant outlet;a baffle plate positioned in the housing to divide the interior of the housing into a first gas flow chamber and a second gas flow chamber, the baffle plate having first and second coolant openings to allow a flow of coolant through the baffle plate, and a gas flow opening to allow a gas flow through the baffle plate;a first condensate drain in the first gas flow chamber to drain condensate from the first gas flow chamber; anda plurality of heat exchange units arranged as a first stack of the heat exchange units positioned in the first gas flow chamber and a second stack of the heat exchange units positioned in the second gas flow chamber;each heat exchange unit comprising a pair of plates sealing joined at peripheral edges to define a coolant channel in each said unit, the first stack having a first plurality of the coolant channels and the second stack having a second plurality of the coolant channels,the heat exchange units being spaced from each other to define a plurality of gas flow channels between the heat exchange units, the first stack having a first plurality of the gas flow channels between the heat exchange units, the first stack having a first plurality of the gas flow channels interleaved with the first plurality of coolant channels, the second stack having a second plurality of the gas flow channels interleaved with the second plurality of coolant channels;the heat exchange units of the first stack having respective sets of interconnected openings defining a firs inlet manifold to direct coolant into the first plurality of coolant channels and a first outlet manifold to receive coolant from the first plurality of coolant channels,the heat exchange units of the second stack having respective sets of interconnected openings defining a second inlet manifold to direct coolant into the second plurality of coolant channels and a second outlet manifold that receives coolant from the second plurality of coolant channels,the first and second inlet manifolds aligned with the first coolant opening in the baffle plate to allow coolant flow between the first and second inlet manifolds,the first and second inlet manifolds aligned with the first coolant opening in the baffle plate to allow coolant flow between the first and second inlet manifolds,the first and second outlet manifolds aligned with the second coolant opening in the baffle plate to allow coolant flow between the first and second outlet manifolds,the first stack having another set of interconnected openings defining a first gas flow manifold to communicate gas flow with the first plurality of gas flow channels, andthe second stack having another set of interconnected openings defining a second gas flow manifold to communicate gas flow with the second plurality of gas flow channels. 13. The integrated condenser/separator of claim 12 wherein the first and second gas flow manifolds are aligned with the gas flow opening in the baffle plate whereby the gas flow makes one pass through the first plurality of gas flow channels and another pass through the second plurality of gas flow channels. 14. The integrated condenser/separator of claim 13 wherein the gas flow inlet opens into the first gas flow chamber whereby the gas flow makes a first pass from the first gas flow chamber through the first plurality of gas flow channels to the first gas flow manifold, flows from the first gas flow manifold through the gas flow opening to the second gas flow manifold, and makes a second pass from the second gas flow manifold through the second plurality of gas flow channels to the second gas flow chamber. 15. An integrated condenser/separator for condensing and separating a condensate from a cathode exhaust gas flow in a fuel cell system, the condenser/separator comprising:a housing including a gas flow inlet, a gas flow outlet, a condensate outlet, a coolant inlet, and a coolant outlet;first and second baffle plates positioned in the housing to divide an interior of the housing into a first, second, and a third gas flow chambers, each of the baffle plates having a coolant opening to allow a flow of coolant through the baffle plate and a gas flow opening to allow a gas flow through the baffle plate;a first condensate drain in the first gas flow chamber to drain condensate from the first gas flow chamber;a second condensate drain in the second gas flow chamber to drain condensate from the second gas flow chamber; anda plurality of heat exchange units arranged as a first stack of the heat exchange units positioned in the first gas flow chamber, a second stack of the heat exchange units positioned in the second gas flow chamber, and a third stack of heat exchange units positioned in the third gas flow chamber,the first stack including a first plurality of coolant channels interleaved with a first plurality of gas flow channels, a first inlet manifold to direct coolant into the first plurality of coolant channels, a first outlet manifold to receive coolant from the first plurality of coolant channels, and a first gas flow manifold to communicate gas flow with the first plurality of gas flow channels,the second stack including a second plurality of coolant channels interleaved with a second plurality of gas flow channels, a second inlet manifold to direct coolant into the second plurality of coolant channels, a second outlet manifold that receives coolant from the second plurality of coolant channels, and a second gas flow manifold to communicate gas flow with the second plurality of gas flow channels,the third stack including a third plurality of coolant channels interleaved with a third plurality of gas flow channels, a third inlet manifold to direct coolant into the third plurality of coolant channels, a third outlet manifold that receives coolant from the third plurality of coolant channels, and a third gas flow manifold to communicate gas flow with the third plurality of gas flow channels,the first outlet manifold and the second inlet manifold aligned with the coolant opening in the baffle plate to allow coolant flow from the first outlet manifold to the second inlet manifold whe reby the coolant makes a first pass through the first plurality of coolant channels and a second pass through the second plurality of coolant channels, andthe second outlet manifold and the third inlet manifold are aligned with the coolant opening in the second baffle plate to allow coolant flow from the second outlet manifold to the third inlet manifold whereby the coolant makes a third pass through the third plurality of coolant channels. 16. The integrated condenser/separator of claim 15 wherein the gas flow inlet opens into the first gas flow chamber, the first and second gas flow manifolds are aligned with the gas flow opening in the first baffle plate, and the third gas flow manifold is blocked by an imperforate portion of the second baffle plate whereby the gas flow makes a first pass from the first gas flow chamber through the first plurality of gas flow channels to the first gas flow manifold, flows from the first gas flow manifold through the gas flow opening in the opening baffle plate to the second gas flow manifold, makes a second pass from the second gas flow manifold through the second plurality of gas flow channels to the second gas flow chamber, flows from the second gas flow chamber through the gas flow opening in the second baffle plate to the third gas flow chamber, and makes a third pass from the third gas flow chamber through the third plurality of gas flow channels to the third gas flow manifold. 17. An integrated condenser/separator for condensing and separating a condensate from a cathode exhaust gas flow in a fuel cell system, the condenser/separator comprising:a housing including a gas flow inlet, a gas flow outlet, a condensate outlet, a coolant inlet, and a coolant outlet;a baffle plate positioned in the housing to divide an interior of the housing into a first gas flow chamber and a second gas flow chamber, the baffle plate having a coolant opening to allow a flow of coolant through the baffle plate and a gas flow opening to allow a gas flow through the baffle plate;a first condensate drain in the first gas flow chamber to drain condensate from the first gas flow chamber; anda plurality of heat exchange units arranged as a first stack of the heat exchange units positioned in the first gas flow chamber and a second stack of the heat exchange units positioned in the second gas flow chamber,each heat exchange unit comprising a pair of plates sealing joined at peripheral edges to define a coolant channel in each said unit, the first stack having a first plurality of the coolant channels and the second stack having a second plurality of the coolant channels,the heat exchange units being spaced from each other to define a plurality of gas flow channels between the heat exchange units, the first stack having a first plurality of the gas flow channels interleaved with the first plurality of coolant channels, the second stack having a second plurality of the gas flow channels interleaved with the second plurality of coolant channels;the heat exchange units of the first stack having respective sets of interconnected openings defining a first inlet manifold to direct coolant into the first plurality of coolant channels and a first outlet manifold to receive coolant from the first plurality of coolant channels,the heat exchange units of the second stack having respective sets of interconnected openings defining a second inlet manifold to direct coolant into the second plurality of coolant channels and a second outlet manifold that receives coolant from the second plurality of coolant channels,the first outlet manifold and the second inlet manifold aligned with the coolant opening in the baffle plate to allow coolant flow from the first outlet manifold to the second inlet manifold whereby the coolant makes a first pass through the first plurality of coolant channels and a second pass through the second plurality of coolant channels, the first stack having another set of interconnected openings defining a first gas flow manifold to communicate gas flow with the first plurality of gas flow channels, andthe second stack having another set of interconnected openings defining a second gas flow manifold to communicate gas flow with the second plurality of gas flow channels. 18. The integrated condenser/separator of claim 17 wherein the first and second gas flow manifolds are aligned with the gas flow opening in the baffle plate whereby the gas flow makes one pass through the first plurality of gas flow channels and another pass through the second plurality of gas flow channels. 19. The integrated condenser/separator of claim 18 wherein the gas flow inlet opens into the first gas flow chamber whereby the gas flow makes a first pass from the first gas flow chamber through the first plurality of gas flow channels to the first gas flow manifold, flows from the first gas flow manifold through the gas flow opening to the second gas flow manifold, and makes a second pass from the second gas flow manifold through the second plurality of gas flow channels to the second gas flow chamber. 20. The integrated condenser/separator of claim 17 further comprising:a second baffle plate positioned in the housing to divide the interior of the housing into a third gas flow chamber adjacent the second gas flow chamber, the second baffle plate having a second coolant opening to allow a flow of coolant through the second baffle plate and a second gas flow opening to allow a gas flow through the second baffle plate;a second condensate drain in the second gas flow chamber to drain condensate from the second gas flow chamber; anda third stack of the heat exchange units positioned in the third gas flow chamber,the third stack including a third plurality of the coolant channels interleaved with a third plurality of gas flow channels,the heat exchange units of the third stack having respective sets of interconnected openings defining a third inlet manifold to direct coolant into the third plurality of coolant channels and a third outlet manifold to receive coolant from the third plurality of coolant channels,the second outlet manifold and the third inlet manifold aligned with the second coolant opening in the second baffle plate to allow coolant flow from the second outlet manifold to the third inlet manifold whereby the coolant makes a third pass through the third plurality of coolant channels,the third stack having another set of interconnected openings defining a third gas flow manifold to communicate gas flow with the third plurality of gas flow channels. 21. An integrated condenser/separator for condensing and separating a condensate from a cathode exhaust gas flow in a fuel cell system, the condenser/separator comprising:a housing including a gas flow chamber, a gas flow inlet, a gas flow outlet, a condensate outlet, a coolant inlet, and a coolant outlet;a condensate drain in the gas flow chamber to drain condensate from the gas flow chamber;a stack of heat exchange units positioned in the gas flow chamber and having a plurality of coolant channels interleaved with a plurality of gas flow channels, an inlet manifold to direct coolant into the plurality of coolant channels, an outlet manifold to receive coolant from the plurality of coolant channels, and a gas flow manifold to communicate gas flow with the plurality of gas flow channels; anda coalescing member positioned in at least one of the gas flow chamber and the gas flow inlet upstream of the plurality of gas flow channels. 22. An integrated condenser/separator for condensing and separating a condensate from a cathode exhaust gas flow in a fuel cell system, the condenser/separator comprising:a housing including a gas flow chamber, a gas flow inlet, a gas flow outlet, a condensate outlet, a coolant inlet, and a coolant outlet;a condensate drain in the gas flow chamber to drain condensate from the gas flow chamber;a stack of heat exchange units positioned in the gas flow chamber and having a plurality of coo lant channels interleaved with a plurality of gas flow channels, an inlet manifold to direct coolant into the plurality of coolant channels, an outlet manifold to receive coolant from the plurality of coolant channels, and a gas flow manifold to communicate gas flow with the plurality of gas flow channels; anda condensate manifold in fluid communication with the condensate outlet and the drain to direct condensate from the condensate drain to the condensate outlet, the condensate manifold including a wall that surrounds a wall of the gas flow chamber to define an exterior surface of the housing.