700136572
TECHNICAL FIELD
[0001] The present invention relates to a fuel cell vehicle. More particularly,
the present invention relates to a fuel cell system and method for operating the same.
5 BACKGROUND
[0002] The automobile industry is realizing the commercial feasibility of
powering electric vehicles with hydrogen-oxygen fueled fuel cells. Fuel cell vehicles have a significant potential to reduce emissions from the transportation sector, because they do not emit any greenhouse gases (GHGs) during vehicle 10 operation. Fuel cell works on simple principle that hydrogen reacts with oxygen to produce water and electricity.
[0003] Fuel cells are categorized as high temperature fuel cell and low
temperature fuel cell. In high temperature fuel cell, the membrane requires high temperature to start the process. The electricity generated by the fuel cell is used 15 to run an electric motor and the torque produced by it is transmitted to the vehicle wheels.
[0004] In a conventional fuel cell system of the fuel cell vehicle, heating
pads powered by batteries are used for initial heating of fuel cells. The heating pads are provided at two ends or sides of fuel cell, it cannot directly heat the 20 membrane so it consumes more time for the membrane to reach its operating temperature.
[0005] In a known fuel cell powered vehicle, the fuel cell is heated upon
starting by supplying hydrogen gas from a hydrogen tank to hydrogen adsorbing alloy tank so as to be adsorbed therein. The hydrogen adsorbing alloy tank 25 adsorbs the hydrogen gas with generation of heat. The heat thus generated is circulated to the fuel cell by cooling water circulating between hydrogen absorbing alloy tank and fuel cell, whereby the temperature increases.
[0006] In another known fuel cell powered vehicle, a temperature regulating
system for a fuel cell powered electric motor vehicle assists in maintaining the
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temperature of fuel cell stack within a temperature range that provides satisfactory fuel cell performance.
[0007] In some other known fuel cell powered vehicle, a hydrogen storage
tank includes an intake valve for connecting with an external hydrogen source to fill the tank. A hydrogen supply line is provided for supplying hydrogen to the fuel cell from storage tank. Heat expelled by the storage tank during filling is captured and transferred to the fuel cell.
[0008] The fuel cell vehicles using high temperature fuel cell faces problems
of membrane heating at the starting of the vehicle. Also, the heating pads provided at two ends or sides of fuel cell cannot directly heat the membrane so it consumes more time for the membrane to reach its operating temperature. Therefore, there is a need of providing an initial source of heating the fuel cell system of the vehicle which involves less start time to heat and hence, to start the vehicle and additionally stores heat for further operating of the fuel cell system.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The detailed description is described with reference to the
accompanying figures. The same numbers are used throughout the drawings to reference like features and components.
[00010] Fig. 1. shows a block diagram illustrating a fuel cell system of a vehicle as per one embodiment of the present invention.
[00011] Fig. 2. illustrates a method of operating fuel cell system in the vehicle as per one embodiment of the present invention.
DETAILED DESCRIPTION
[00012] Governmental regulations and environmental concerns have dictated the need for automobile manufacturers to introduce fuel cell vehicles in the market to control pollution due to increasing harmful emissions from petrol or diesel. The fuel cell vehicle is more efficient than conventional internal combustion engine vehicles and produces no harmful tailpipe exhaust.
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[00013] The fuel cell vehicle comprises of a fuel cell system powered by a fuel cell. The fuel cell is of two types, a high temperature fuel cell and a low temperature fuel cell. In the high temperature fuel cell, the membrane requires high temperature to start a process of the fuel cell system to start the vehicle.
5 [00014] The fuel cell provides an environmentally friendly source of electrical
current. The electricity generated by the fuel cell is used to run a motor and the
• torque produced by it is transmitted to the vehicle wheels. Unlike many devices
for generating electricity, fuel cells do not require combustion. This enables fuel
cells to operate at relatively high efficiencies and to produce relatively low
10 emissions, making them an attractive source of electrical energy.
[00015] In an existing fuel cell powered vehicle with the high temperature fuel cell, the heating pads powered by the batteries are used for initial heating of the fuel cells as high temperature fuel cell membrane requires minimum 80 degree Celsius to start the vehicle. However , the heating pads provided at two ends or 15 sides of fuel cell, cannot directly heat the membrane and.also it consumes more time for the membrane to reach its operating temperature. The fuel ceil operating temperature is high and so-called high-temperature fuel cells. Therefore, the vehicles using the high-temperature fuel cells faces problems of membrane heating at the starting of the vehicle.
20 [00016] With the above objectives in view, the present invention discloses a vehicle with a fuel cell system and method of operating the fuel cell system for initial heating of fuel cells and hence once the fuel cell starts functioning, the need of external heating is eliminated.
[00017] The present invention suggests a new way to heat the membrane 25 using the temperature of a motor. Once the fuel cell vehicle starts, the motor starts working and it will get heated up. This heat can be stored in a thermal storage unit in a form of a bed of particulate solid material matter called zeolite. The zeolite is more efficient in storing heat compared to water as it can store heat for an indefinite period of time. When kept in a heated environment, the zeolite absorbs
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heat energy and releases water. This stored energy in the zeolite can again be extracted by pouring water to it which results in heat release and water absorption.
[00018] As per one embodiment of the present invention, the fuel cell system includes a water storage tank, a pump, a motor, the zeolite and the fuel cell. The 5 valve VI and V2 are valves and one or more temperature controller TCs for maintaining the temperature of the fuel cell and the motor. A first temperature controller TC of said one or more temperature controllers is provided at the fuel cell and connected to the valve VI so that once the fuel cell reach its temperature and starts functioning, the flow automatically stops and the other valve V2 to 10 motor starts after certain time period. The temperature of the motor should not go beyond 120 degree Celsius and it needs to be controlled. The only way to control the temperature is through cooling by supplying cold water by the pump from the water storage tank.
[00019] The present invention is related to thermal management in the fuel 15 cell vehicles. As per one embodiment of the present invention, a pre-heated said thermal storage unit is introduced in the vehicle for initial heating of the fuel cell system of the fuel cell vehicle. With present system and method of heating the fuel cell system, the present invention has advantage over the existing fuel system that the zeolite is low cost and thus allow to store thermal energy.
20 [00020] As per the one embodiment of the present invention, said first temperature controller TC of said one or more temperature controllers TCs is configured for determining the temperature of the fuel cell and the motor. The first temperature controller TC directs heat transfer from said thermal storage unit to said fuel cell. In one embodiment, a second temperature controller TC of said
25 one or more temperature controllers TCs directs heat transfer from said motor to said thermal storage unit by maintaining the temperature in the fuel cell and the motor. As per one embodiment of the present invention, when said zeolite comes into contact with water, a chemical reaction adsorbs the water and emits heat. When heat is applied to the zeolite, the process is reversed and the water is
30 released. The zeolite store the heat with hardly any losses, are environmentally
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friendly and cost-effective. The thermal storage unit with said bed of particulate solid material as zeolite store water vapor within their large internal surface areas. This releases heat. Conversely, water is released again when heat is added.
[00021] According to one embodiment of the present invention, the zeolite is 5 placed between the motor and fuel cell. Initially, heated zeolite is introduced in the vehicle as an initial source of heating the fuel' cell. Later, as vehicle starts, motor get heated up and by providing coils around motor, the heat can be extracted through water. This hot water when circulated around said zeolite, it will absorb heat and release water. Before starting the fuel cell, water is passed 10 through the zeolite so that it will absorb water and release heat. This hot water is used in heating the fuel cell. As per one embodiment of the present invention, there is no loss of heat from the zeolite as it can store heat for unlimited period of time due to its characteristics features.
[00022] The invention suggests a system that includes the water storage tank, 15 the pump, the motor, the thermal storage unit with the bed of zeolite and the fuel cell. Once the vehicle starts, the cold water is pumped from tank and allowed to circulate via the thermal storage unit to supply hot water to provide heat to the fuel cell.
[00023] As per one embodiment of the present invention, the heating of the
20 fuel cells during starting of vehicle can be done by opening the valve VI from
water storage tank to the thermal storage unit having the bed of particulate solid
material as the zeolite. The fuel cell once reaches the temperature equal and
greater than a pre-determined fuel temperature that is 80 degree Celsius, it
produces electric power. The electric power is transmitted to the motor to produce
25 torque and run the vehicle. The temperature of motor should not go beyond 120
degree Celsius and it needs to be controlled. The only way to control the
temperature is by cooling, either air or liquid. So this helps in cooling the motor
by heating fuel cells.Once the motor temperature reaches temperature equal and
greater than a pre-determined the motor temperature that is 120 degree Celsius ,
30 the cold water is pumped from the water storage tank and allowed to circulate
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around the motor through coils to cool it. The hot water released after the cooling process of the motor is then passed through the outside covering of the zeolite so that the zeolite absorbs the heat and water coming out is send to a tank provided with cooler. Thus the water keeps on circulating. As per one embodiment, said first temperature controller TC of said one or more temperature controllers TCs is provided at the fuel cell connected to the valve VI so that once the fuel cell reach its temperature and starts functioning, the flow automatically stops and the other valve V2 to motor starts after certain time period.
[00024] As per one embodiment of the present invention, when starting up such fuel cell system, the pre-heated said thermal storage unit with the bed of the zeolite material is introduced in the vehicle as said initial source of heating the fuel cell of the fuel cell system of said fuel cell vehicle. Thus, the fuel cell is firstly heated by the zeolite to a temperature of greater and equal to 80 degree Celsius for the vehicle to start. The heated fuel cell is used to run the motor and the torque produced by it is transmitted to the vehicle wheels. When said motor reaches a temperature greater and equal to 120 degree Celsius, the cold water is supplied from said water storage tank by the pump for cooling the motor. The hot water released after cooling said motor is supplied to said zeolite. The zeolite stores the heat for providing further source of heating for the vehicle, hence the cycle continues.
[00025] As per one embodiment of the present invention, the thermal storage unit with zeolite bed is being used as the source of heating the fuel cell, hence there is no further need of heating pads. The motor heat is recycled thus no extra energy required for heating fuel cell.
[00026] According to the present invention, the fuel cell system includes said water storage tank, said pump, said motor, said thermal storage unit with said bed of particulate material called zeolite and the fuel cell for operating the fuel cell powered vehicle. The method of operating the fuel cell vehicle may be described in the general context of computer executable instructions, and communications sent and received to other elements in the system. Generally, computer executable
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instructions can include routines, programs, objects, components, data structures, procedures, modules, functions, and the like that perform particular functions or implement particular abstract data types. The order in which the method is described is not intended to be construed as a limitation, and any number of the 5 described method blocks can be combined in any order to implement the method, or alternate methods. Additionally, individual blocks may be deleted-from the method without departing from the spirit and scope of the subject matter described herein. Furthermore, the method can be implemented in any suitable hardware, software, firmware, or combination thereof as will be explained in another embodiment. Furthermore, the method can be implemented in other similar systems albeit with a few variations as will be best understood by a person skilled in the art.
[00027] Although the present invention has been exemplified for the fuel ceil system being heated by hot water, it is not restricted only for the hot water for heating the fuel cell of the fuel cell system. Application of the present invention may be extended to moist air instead of water in the fuel cell system. The fuel cell system where moist air is used, the motor can be cooled using air and that hot air can be passed through the zeolite for heating it. Similarly while discharging of the zeolite; the moist air can be passed through it to provide hot air that can be passed through the membranes of the fuel cell to heat it.
[00028] Exemplary embodiments detailing features of the fuel cell powered vehicle, in accordance with the present invention will be described hereunder. Application of the present invention will be extended to two-wheeled vehicles, three-wheeled vehicles and four -wheeled vehicles.
[00029] Fig. 1 illustrates the fuel cell system (100) for the fuel cell vehicle as per one embodiment of the present invention. The fuel cell system (100) for the vehicle comprises said fuel cell (10) for generating electric power, said motor (14) serving as a drive source for said vehicle, said water storage tank (18) disposed on said vehicle for supplying water (21) to said fuel cell (10) and said motor (14), said pump PI (23) for causing the water to circulate from said water storage tank
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(18) to said fuel cell system (100), a battery (22) powering said pump PI (23) to operate, said one or more temperature controllers TC (11), (13) configured to determine temperature of the fuel cell (10) and the motor (14), respectively. As per one embodiment of the present invention, said fuel cell system (100) further 5 comprises the thermal storage unit (20) placed between said fuel cell (10) and said motor (14). The thermal storage unit (20) comprises said bed of particulate solid material as the zeolite for storing heat therein and releasing heat for heating the fuel cell (10) of the vehicle. The fuel cell system (100) further comprises of a heated said thermal storage unit (20) introduced in said vehicle for providing an
10 • initial source of heating for said fuel cell (10) in the vehicle. According to one embodiment of the present invention, the fuel cell system (100) comprises a high temperature fuel cell (10). The first temperature controller TC (11) of said one or more temperature controllers TCs (11), (13) directs heat transfer from .said. thermal storage unit (20) to said fuel cell (10) by maintaining the temperature in
15 the fuel cell (10). In one embodiment, said second temperature controller (13) of said one or more temperature controllers TCs (11), (13) directs heat transfer from said motor (14) to said thermal storage unit (20) by maintaining the temperature in the motor (14). As per one embodiment of the present invention, the thermal storage unit (20) is a concentric cylindrical module comprising said bed of
20 particulate solid material zeolite.
[00030] In one embodiment, the fuel cell system (100) includes the water storage tank (18), the pump PI (23), the motor (14), said one or more temperature controllers TCs (11), (13). The fuel cell (10) generates electric power and transmits it to the motor (14) to generate the torque, which in turn starts the
25 vehicle. The cold water (19) pumped from the water storage tank (18) is allowed to circulate around the motor (14) through coils to cool it. The hot water (12) is then passed through the outside covering of the thermal storage unit (20) so that the bed of zeolite absorbs the heat and water coming out is send to water storage tank (18). The heating of the fuel cell (10) during starting of vehicle can be done
30 by opening the valve VI (17) from water storage tank (18) to the thermal storage unit (20). Once the valve VI (17) is opened, the cold water (19) flows through the

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thermal storage unit (20) and gets heated. This hot water (21) is then passed through the bipolar plates between the fuel cell (10) to heat the membrane directly.
[00031] Further, per one embodiment of the present invention, the first 5 temperature controller TC (11) provided at the fuel cell (10) is connected to the valve VI (17) so that once the fuel cell (10) reach temperature and starts functioning, the flow automatically stops and the other valve V2 (16) to the motor (14) starts after certain time period. The temperature of motor (14) once reaches the predetermined motor temperature that is equal and greater than 120 degree 10 Celsius then the valve VI. (17) closes and the valve V2 (16) opens to circulate cold water (15) from said water storage tank (18) for cooling the motor (14).
[00032] As per one embodiment of the present invention , the thermal storage unit (20) serves to heat the fuel cell (10) when the cold water (19) by the pump PI (23) from said water storage tank (18) flows to said fuel cell (10) via said thermal
15 storage material (20) being said zeolite. The pre-heated or charged said thermal storage unit (20) is introduced in said fuel cell vehicle as the initial source of heating the fuel cell (10) and hence starting the vehicle. When the cold water (19) passes the thermal storage unit (20), it gets converted to hot water (21) as the thermal heat storage unit (20) releases the heat. Thus, the hot water (21) circulates
20 to said fuel cell (10) to heat the fuel cell (10) to temperature equal and greater than the predetermined fuel temperature. Once the fuel cell (10) reaches the predetermined fuel temperature by the first temperature controller TC (11), the vehicle starts, thus, the cold water released as a result of heating the fuel cell (10) is returned to said water storage tank (18) for the process to continue. As per one
25 embodiment of the present invention, the fuel cell (10) after getting heated to said temperature of equal and greater than the predetermined fuel temperature that is 80 degree Celsius, generates electrical energy which is used to run the motor (14) and thus the torque produced by the motor (14) is transmitted to the vehicle wheels and hence the vehicle starts.
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[00033] Referring to Fig. 1, further the fuel cell system (100) represents the blocks as per one embodiment of the present invention. In one embodiment, Fig.l illustrates the fuel cell system (100) comprising of the fuel cell (10), the motor (14), the water storage tank (18), the thermal storage unit (20), valves VI (17) and 5 V2 (16) and said one or more temperature controllers TC (11), (13) for maintaining the temperature of the fuel cell (10) and the motor (14) respectively. As per embodiment of the present invention, at block 111, the pre-heated said thermal storage unit (20) is introduced in the vehicle. The heat stored in the bed of the zeolite of the thermal storage unit (20) provides initial source of heat to the
10 fuel cell (10) at block 101 to get heated and generate electrical energy for producing torque and hence running the motor (14). At block 105, the motor (14) is surrounded by coils through which the cold water (15) at block 106 is flowing. At block 110, the water storage tank (18) is disposed on the vehicle. In one embodiment, said first temperature controller (11) and said second temperature
15 controller (13) at block 102 and at block 104 respectively, are configured to determine the temperature of the fuel cell (10) and the motor (14). The valve V2 (16) at block 107 is open. Thus, the water from the water storage tank (18) present at block 110 circulates by said pump PI (23) to said fuel cell (10) at block 101 via said thermal storage unit (20) at block 111.
20 [00034] As per one embodiment of the present invention, the battery (22) at block 113 powers said pump PI (23) to operate. The pre-heated said thermal storage unit (20) introduced in said vehicle comprises of the zeolite, thus the cold water (19) represented by block 109 and flowing via said thermal storage unit (20) is converted to said hot water (21) represented by block 112 by a heat released by
25 said thermal storage unit 111. The hot. water (21) thus through said pump PI (23) from said water storage tank (18) at block 110 is circulated to said fuel cell (10) represented at block 101 to heat said fuel cell (10). At block 111, the thermal storage unit (20) comprises said bed of particulate matter as zeolite which includes concentric pipes inside is packed with the zeolite and outside is a
30 covering through which hot water (12), (21) circulates.The temperature controller TC(ll) at block 102 determines the temperature of fuel cell (10). Once the fuel
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cell (10) reaches the predetermined fuel temperature equal and greater than 80 degree Celsius, the electrical energy gets transmitted to the motor (14) hence the vehicle starts. Thus, at block 101, after the fuel cell (10) gets heated, the cold water (19) is returned to the water storage tank (18) at block 110.
5 [00035] According to one embodiment of the present invention, in fuel cell
• system (100), once said motor (14) reaches the predetermined motor temperature
that is equal and greater than 120 degree Celsius, the cooling of the motor (14)
represented by block 104 is done by the cold water (15) represented at block 106
and transferred by the water storage tank (18), thus the hot water (12) represented
10 by block 12 is released after cooling the motor (14) and hence passes to the thermal storage unit (20) at block 111. As per one embodiment, said thermal storage unit (20) stores the heat in the bed of zeolite and thus the cold water (15) is passed to the water storage tank (18) at block 110. At block 111, the thermal' storage unit (20) with the zeolite bed releases the heat once cold water circulated
15 from the water storage tank (18) by the pump PI (23) comes in contact with the zeolite. As per embodiment of the present invention, at block 111, the thermal storage unit (20) is said concentric cylindrical module with concentric pipes, and inside is packed with zeolite.
[00036] Referring to Fig 2, a flowchart (200) illustrating a method operating 20 the fuel cell system (100) of the vehicle as per one embodiment of the present invention. The method of operating the fuel cell system (100) includes said fuel cell (10) for generating electric power, the motor (14) serving as a drive source for said vehicle, the water storage tank (18) disposed on said vehicle for supplying cold water (15), (19) to said fuel cell system (100), and said one or more 25 temperature controllers TC (11), (13) configured to determine temperature of the fuel cell (10) and the motor (14), respectively.
[00037] As per one embodiment of the present invention the method of
operating fuel cell system (100) comprises the following steps: in step 201, the
pre- heated said thermal'storage unit (20) is placed between said motor (14) and
30 the fuel cell (10) of the fuel cell vehicle. The valve VI (17) is open for circulating
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. cold water (19) by the pump PI (23) from said water storage tank (18) through the thermal storage unit (20) to release hot water (21). In step 202, the cold water (19) supplied by the pump PI (23) from the water storage tank (18) for heating the fuel cell (10) is circulated via said thermal storage unit (20) that is through the zeolite 5 bed of thermal storage unit (20) and releases hot water (21). In step 203, the hot water (21) released by the thermal storage unit (20) flows through the bipolar plates in the fuel cell (10), thus heating the fuel cell (10) for producing the electric power and running the motor (14).
[00038] As per one embodiment of the present invention, in step 204, the first
10 temperature controller TC (11) checks that whether the fuel cell (10) temperature is greater and equal to the predetermined fuel cell temperature that is equal and greater than the pre-determined fuel cell temperature that is 80 degree Celsius. In step 205, iffuel cell temperature greater and equal to the predetermined fuel cell temperature then the electric power generated by the fuel is transferred to the
15 motor (14) and valve VI (17) is closed. The motor (14) is powered by the electric power generated by the fuel cell (10), hence the torque produced by the vehicle is transmitted to the vehicle wheels to start the vehicle. In step 206, the fuel cell (10) transmits the electric power to the motor (14) to run and produce torque thus resulting in the vehicle to start and thus the cold water (15) released by heating the
20 fuel cell (10) in the form of the hot water (21) is returned by the pump PI (23) from said fuel cell (10) to said water storage tank (18). However, if fuel temperature less than the predetermined fuel cell temperature then the valve VI (17) continues to be open in step 202, such that the supply cold water (19) from said water storage tank (18) is circulated via said thermal storage unit (20) and
25 continues till the fuel cell (10) attains temperature equal and greater than the predetermined fuel cell temperature that is 80 degree Celsius.
[00039] As per one embodiment of the present invention, in step 207, the
second temperature controller TC (13) checks whether the motor temperature is
equal and greater than the predetermined motor temperature that is 120 degree
30 Celsius. In step 208, Valve V2 (16) is open if the motor.(14) temperature is equal
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and greater than the predetermined motor temperature. The cooling of the motor
(14) is done by supplying the cold water to said motor (14) for cooling it by
opening the valve V2 (16) in step 208. In step 209, the hot water release after
cooling the motor circulates to the thermal storage unit (20). The heat from the hot
water (12) gets extracted by the zeolite bed of the thermal storage unit (21) and
gets stored therein. Hence, the cold water (15) released after the heat gets
extracted by the thermal storage unit (20) as in step 209 is returned to the water
storage tank (18) and hence, the methodology continues for heating the fuel cell
and operating the fuel cell system (100). However, if motor temperature less than
the predetermined motor temperature that is 120 degree Celsius , then in step 210
the Valve V2 (16) remains closed thus restricting the flow of the cold water (15)
from the water storage tank (18) to the motor (14) till the motor temperature
reaches 120 degree Celsius or greater than it. - _
[00040] Advantageously, as per one embodiment of the present invention, the thermal storage unit with the zeolite bed of particulate solid material can store heat for indefinite period, hence introducing the zeolite material as the initial source of heating the fuel cell results in increased efficiency of the fuel cell vehicle.With the present system' and method of heating the fuel cell system, the present invention has advantage over the existing fuel system that the zeolite is low cost and thus allow to store thermal energy. As per one embodiment of the present invention, the thermal storage unit directly provides heat to the fuel cell thus resulting overall less time consumption to reach the operating temperature of the fuel cell system. Further, the heat produced by the motor can be recycled thus no extra energy required for heating fuel cell.
[00041] Improvements and modifications may be incorporated herein without deviating from the scope of the invention.
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