U.S. patent application number 11/772383 was filed with the patent office on 2008-03-20 for humidifier device and method of forming the same.
Invention is credited to Alexander Gofer, Konstantin Korytnikov.
Application Number | 20080067700 11/772383 |
Document ID | / |
Family ID | 39187750 |
Filed Date | 2008-03-20 |
United States Patent
Application |
20080067700 |
Kind Code |
A1 |
Korytnikov; Konstantin ; et
al. |
March 20, 2008 |
HUMIDIFIER DEVICE AND METHOD OF FORMING THE SAME
Abstract
A humidifier of the present invention includes a bundle of
hollow porous tubes made of synthetic material disposed in a
housing having a plurality of inlet and outlet ports. The
humidifier of the present invention is used to control humidity in
a fuel cell and is used in various industrial applications. A
method of producing the humidifier is disclosed herein.
Inventors: |
Korytnikov; Konstantin;
(Hollywood, FL) ; Gofer; Alexander; (Pompano
Beach, FL) |
Correspondence
Address: |
HOWARD & HOWARD ATTORNEYS, P.C.
THE PINEHURST OFFICE CENTER, SUITE #101
39400 WOODWARD AVENUE
BLOOMFIELD HILLS
MI
48304-5151
US
|
Family ID: |
39187750 |
Appl. No.: |
11/772383 |
Filed: |
July 2, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60817991 |
Jun 30, 2006 |
|
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|
Current U.S.
Class: |
261/119.2 |
Current CPC
Class: |
H01M 2008/1095 20130101;
H01M 8/04149 20130101; Y02E 60/50 20130101 |
Class at
Publication: |
261/119.2 |
International
Class: |
C10J 1/08 20060101
C10J001/08 |
Claims
1. A humidifier device for a fuel cell adaptable for balancing
fluids therein, said humidifier comprising: a tubular housing
presenting a central axis and having terminal ends and a pair of
housing ports; a pair of caps covering each of said terminal ends
with each said cap exposed to a cap port; a plurality of polymer
tubes each presenting terminal openings with said polymer tubes
being adjacent one and another and disposed in said tubular housing
for processing and balancing fluids introduced therein thereby
controlling humidity inside said humidifier; and a pair of rings
for peripherally affixing said plurality of polymer tubes about
said terminal opening thereby expanding said polymer tubes
extending beyond said rings with said polymer tubes abutting said
tubular housing thereby eliminating gaps between said tubular
housing and said polymer tubes for balancing fluids
therethrough.
2. A humidifier device as set forth in claim 1 including an
adhesive compound at least partially extending internally into each
of said terminal openings of each said polymer tube and externally
covering at least part of each said polymer tubes at said terminal
openings for withstanding pressure of fluids in each said polymer
tubes as said polymer tubes process and balance fluids introduced
therein.
3. A humidifier device as set forth in claim 2 wherein said
adhesive compound is epoxy adhesive.
4. A humidifier device as set forth in claim 4 wherein said tubular
housing presents an annular wall integrally extending a main
portion for aligning said unitary member and a pair of fittings
extending generally perpendicular to said central axis at each of
said terminal ends.
5. A humidifier device as set forth in claim 4 wherein each said
pair of fittings further extend to cap engaging portions,
respectively, extending generally parallel said central axis with
each of said rings disposed between said polymer tubes forming a
unitary member and each said cap engaging portions with each said
cap engaging portions presenting a mechanical connection with said
caps.
6. A humidifier device as set forth in claim 1 including a
plurality of fitting tubes mechanically engaged with said housing
ports and said cap port for receiving fluids into said and
releasing fluid from said humidifier device.
Description
RELATED APPLICATIONS
[0001] This non-provisional application claims priority to a
provisional application Ser. No. 60/817,991 filed on Jun. 30, 2006
and incorporated by reference herein in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to a humidifier for a fuel
cell systems, and specifically to the humidifier utilizing hollow
fibers and a method of forming the same.
BACKGROUND OF THE INVENTION
[0003] A typical fuel cell presents is an electrochemical energy
conversion device for producing electricity from external supplies
of fuel and oxidant in the presence of an electrolyte. Generally,
the reactants flow in and reaction products flow out while the
electrolyte remains in the fuel cell. One of the benefits of the
fuel cell over, for example, a battery, is the ability of the fuel
cell to operate virtually continuously as long as necessary flows
are maintained. Unlike the battery, which store electrical energy
chemically in a closed system, the fuel cells consume reactants,
which must be replenished. Additionally, while the electrodes
within the battery react and change as a battery is charged or
discharged, the electrodes of the fuel cell are catalytic and
relatively stable.
[0004] Alluding to the above, the fuel cells generate electrical
power that can be used in a variety of applications. One of the
most reliable types of the fuel cell is a proton exchange membrane
(PEM) fuel cell. The core element of modern PEM fuel cell is the
membrane electrode assembly (MEA) including the ion exchange
membrane, which acts as a solid electrolyte and thin catalytic
layers deposed on both sides of the membrane acting as anode and
cathode electrodes. The PEM fuel cell gas diffusion layers (GDL)
support MEA and distribute reactants to the electrodes and flow
plates directing reactants and an electrical current. To produce
electricity through an electrochemical reaction, hydrogen-rich fuel
is supplied to the anode (mainly the hydrogen) and the oxidant gas
(mainly the air) is supplied to the cathode.
[0005] An electrochemical reaction between hydrogen and the oxygen
contained in the air produces the electrical current, water and
heat as the reaction products. Water is removed from the cathode to
make the catalytic layer accessible for the oxygen. On the other
hand, the air introduced to the cathode supposed to be rich in
water vapor to prevent drying out of the PEM, which results in
failure of the fuel cell failure. In some fuel cell systems the
hydrogen, delivered to the anode, is also subject for
humidification. A humidifier of the fuel cell presents the main
device to keep the correct water balance in the fuel cell, thereby
transferring the moisture across an internal membrane permeable for
water molecules from water carrier to gas introduced into the fuel
cell as the reactant. The major sources of water intended for the
humidification are DI water or an exhaust gas from the fuel cell
cathode.
[0006] Alluding to the above, a dialyzer, as know to those skilled
in the art, utilizes membranes of various designs, fabricated from
polysulfone, polycarbonate, polyamide, and the like. The high
chemical stability and sufficient mechanical durability of these
materials allow to the differential pressure commonly used in the
hemodialysis, which can exceed 10 psi thereby allowing to
re-process the reusable dialyzer. The membrane presents a
micro-porous structure and does not expand to the same degree as
hygroscopic membranes because water fills the voids in the material
instead of creating swelling or volume displacement.
[0007] For the humidification process the most acceptable dialysis
membrane is low flux type having the lowest permeability (10
ml/hr/mmHg) to prevent the mixing the reactant with liquid water,
(in case of humidification by means of water) or with humid exhaust
gas (gas to gas humidification). A dialyzer can be modified in a
manner that it can be applicable as a humidifier for fuel cell
systems and other applications wherein air humidification is
required. The use of a properly modified dialyzer advantageous in
that it is a widely distributed and inexpensive device. A
humidifier design is highly dependable on the application of a fuel
cell system, its concept, etc.
[0008] The art is replete with various humidifier designs as taught
by the U.S. Pat. No. 4,801,385 to Sachtler et al. and the U.S. Pat.
No. 4,381,267 to Jackson. One of the most effective membrane
package is presented by a multitude of hollow tubes arranged in a
bundle inserted into a housing wherein the ends of the tubes
encapsulated in a resin. The typical membrane type used in the fuel
cell humidifiers is Nafion.RTM.. Water transport between fluid
streams in these humidifiers occurs via a hygroscopic polymer,
whose water absorption properties are due to chemical affinity.
Although effective humidification is accomplished with these
devices, several detriments exist to their use. Among these is the
issue of polymer expansion with water uptake, which results in a
fragile, failure prone device. During operation, Nafion.RTM.
polymer membrane expands and contracts as varying levels of
humidity are absorbed, which leads to detachment of the tubes from
the bonding resin. The pressure difference between fluid streams
can results in cracks, tears, fractures and collapsing the tubes.
Maximal differential pressure specified for the humidifiers based
on Nafion.RTM. can not exceed 2 psi, which is in the range of
possible pressure fluctuation.
[0009] As such, there is a constant need in the area of a
humidifiers for an improved design and a method of forming the
humidifier thereby eliminating problems associated with current
designs of prior art humidifiers.
SUMMARY OF THE INVENTION
[0010] A humidifier device (the humidifier) of the present
invention is used with a fuel cell for balancing fluids therein.
The humidifier includes a tubular housing presenting a central axis
and terminal ends and a pair of housing ports defined therein. A
pair of caps cover each of the terminal ends with each cap being
exposed to a cap port. A plurality of polymer tubes presenting
terminal openings are adjacent one and another and are disposed in
the tubular housing for processing and balancing fluids introduced
therein. A covering element formed from an epoxy solution at least
partially extends into each of the terminal openings of each
polymer tube. The covering element also covers exterior of each
said polymer tube at the terminal openings. Each covering element
of each polymer tube is homogeneously connected with one another
for withstanding pressure of fluids in each polymer tube as the
polymer tubes process and balance fluids introduced therein.
[0011] In another aspect of the present invention, a medical device
for treating a human is disclosed. The medical device processes
fluids, such as for example blood, from the human body with a
dialyzing solution thereby treating fluids before fluids are
re-introduces to the human body. The medical device includes a
semipermeable membrane presenting a central axis and having
terminal ends and a pair of housing ports and a pair of caps
covering each of the terminal ends with each cap exposed to a cap
port.
[0012] A plurality of polymer tubes each presenting terminal
openings are adjacent one and another and are disposed in the
semipermeable membrane for processing and balancing fluids and the
dialyzing solution introduced therein. A covering element at least
partially extends into each of the terminal openings of each the
polymer tube and covers at least part of each polymer tube at the
terminal openings for withstanding pressure of fluids and the
dialyzing solution in each polymer tube as the polymer tubes
process and balance fluids and the dialysis solution introduced
therein. Dializer fittings and connected to the tubular housing are
designed to flow the dialyzing solution and blood.
[0013] An apparatus for fabricating the aforementioned humidifier
and the medical device is also disclosed in the present invention.
The apparatus has at least a frame for engaging the housing of the
humidifier and the medical device at the respective terminal ends.
The frame presents opposite inlet ports exposed to the terminal
openings of the polymer tubes. At least one container for holding a
solution, such as an epoxy adhesive, is connected to the frame and
is fluidly communicated to each of the opposite inlet ports for
transferring the solution to the housing through the terminal ends.
An activator is connected to the frame for rotating the same about
a rotational axis thereby generating a centrifugal force thereby at
least partially introducing the solution internally into each of
the terminal openings of the polymer tube for bonding the polymer
tubes.
[0014] The polymer tubes of the inventive humidifier present
invention are hollow fibers, having water-permeable and micro-pores
structure and are fabricated from polysulfone, polycarbonate,
polyamide, and the like, adaptable to exchange humidity between two
fluid streams, i.e. gas to gas or liquid to gas. The water
permeability of the membrane is not higher than 10 ml/hr/mmHg to
minimize the leakage of water carrier (DI water, humid gas) into
the gas stream subject for the humidification.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] Other advantages of the present invention will be readily
appreciated as the same becomes better understood by reference to
the following detailed description when considered in connection
with the accompanying drawings wherein:
[0016] FIG. 1 is a cross sectional view of an inventive
humidifier;
[0017] FIG. 2 is a cross sectional view of an alternative
embodiment of the humidifier shown in FIG. 1;
[0018] FIG. 3 is a cross sectional view of a second alternative
embodiment of the humidifier of FIG. 1;
[0019] FIG. 4 is a schematic view of fiber tubes of the humidifier
interconnected by a pair of retaining rings, shown in a cross
section, to form a bundle or a unitary member;
[0020] FIG. 5A shows the bundle of FIG. 4 and a container with
epoxy adhesive adjacent the bundle is for briefly introduced into
the epoxy adhesive before the humidifier is completely
fabricated;
[0021] FIG. 5B is a cross sectional view of the fiber tubes before
introduction into the epoxy adhesive;
[0022] FIG. 6A shows the bundle of FIG. 4 wherein terminal ends of
the bundle are briefly introduced into the epoxy adhesive before
the humidifier is completely fabricated;
[0023] FIG. 6B is a cross sectional view of the fiber tubes being
introduced into the epoxy adhesive;
[0024] FIG. 7A shows the bundle of FIG. 4 wherein terminal ends of
the bundle are removed from the epoxy adhesive after the same are
briefly introduced into the epoxy adhesive;
[0025] FIG. 7B is a cross sectional view of the fiber tubes after
the terminal ends had been introduced into the epoxy adhesive;
[0026] FIGS. 8 through 10 illustrate a cross sectional view of an
apparatus for forming the humidifier of the present invention;
[0027] FIG. 11A is a cross sectional view of the humidifier with
the terminal ends of the fiber tubes being completely encapsulated
by the epoxy adhesive;
[0028] FIG. 11B is a cross sectional view of terminal ends of the
fiber tubes of FIG. 11A;
[0029] FIG. 12A is a cross sectional view of the humidifier with
the terminal ends of the fiber tubes being completely encapsulated
by the epoxy adhesive;
[0030] FIG. 12B is a cross sectional view of terminal ends of the
fiber tubes of FIG. 12A; and
[0031] FIG. 13 is perspective view of a medical device
incorporating the humidifier of the present invention for treating
a patient.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0032] Referring to the Figures, wherein like numerals indicate
like or corresponding parts, a humidifier device (the humidifier)
of the present invention is generally shown at 10. The humidifier
10 is used with a fuel cell (not shown) for balancing fluids
therein. The humidifier 10 includes a tubular housing, generally
indicated at 12, presenting a central axis A and terminal ends 14
and 16. A pair of housing ports 18 and 20 are defined therein.
[0033] Alluding to the above, the tubular housing 12 presents an
annular wall 24 integrally extending a main portion 26 for aligning
a unitary member, generally indicated at 28. The tubular housing 12
further defined a pair of cap engaging portion 30 and 31. A pair of
fittings 32 and 34 are integral with and extend generally
perpendicular to the central axis A from the main portion 26 at
each of the terminal ends 36 and 38 of the tubular housing 12. Each
fitting 32 and 34 further extend to the cap engaging portions 30
and 31. A pair of caps 38 and 40 cover each of the terminal ends 36
and 38. Each cap 38 and 40 are exposed to respective cap ports 42
and 44. The caps 38 and 40 are mechanically connected to the
respective cap engaging portions 30 and 31.
[0034] Alluding to the above, FIGS. 2 and 3 show alternative
embodiments of the present invention, generally shown at 200 and
300, respectively. The humidifiers 200 and 300 present the cap
ports 202, 204, and 302 and 304 being mechanically engaged with the
respective caps 206, 208 and 306 and 308. The humidifiers 200 and
300 also present the fittings 210, 212, and 310 and 312 being
mechanically engaged and/or bonded with the main portion of the
respective humidifiers 200 and 300. The mechanical connection
defined between the aforementioned elements illustrated in FIGS. 2
and 3 are not intended to limit the scope of the present
invention.
[0035] The unitary member 28 is defined by a plurality of polymer
tubes, generally indicated at 50 being adjacent one and another and
disposed in the tubular housing 12 for processing and balancing
fluids introduced therein. The polymer tubes 50 of the inventive
humidifier 10 acting as a membrane, are hollow fibers, having
water-permeable and micro-pores structure and are fabricated from
polysulfone, polycarbonate, polyamide, and the like, adaptable to
exchange humidity between two fluid streams, i.e. gas to gas or
liquid to gas. The water permeability of the membrane is not higher
than 10 ml/hr/mmHg to minimize the leakage of water carrier (DI
water, humid gas) into the gas stream subject for the
humidification.
[0036] A pair of retainer rings 51 and 53 keep the tubes 50 as a
unitary member before the tubes 50 are placed inside the housing
12. The rings 51 and 53 peripherally affix the polymer tubes 50
about the terminal opening thereby expanding the polymer tubes 50
extending beyond the rings 51 and 53 with the polymer tubes 50
abutting the tubular housing 12 thereby eliminating gaps between
the tubular housing 12 and the polymer tubes 50 for balancing
fluids therethrough. The tubes 50 are bonded by a covering element
or sealing compound, generally indicated at 60 in such a fashion to
exposed internal capillaries of the tubes 50 to opposite chambers
62 and 64 defined between the sealing compounds 60 and the caps 38
and 40. The covering element 60 is formed from an epoxy compound
and at least partially extends into each of the terminal openings
64 of each polymer tube 50. The covering element 60 also covers
exterior of each polymer tube 50 at the terminal openings, as best
illustrated in FIGS. 6A, 6B, 7A, and 7B. Each covering element 60
of each polymer tube 50 is homogeneously connected with one another
for withstanding pressure of fluids in each polymer tube 50 as the
polymer tubes 50 process and balance fluids introduced therein.
[0037] As illustrated in FIG. 13, the humidifier 10 is incorporated
into a medical device, such as, for example, a dialysis machine 70
for treating a human. The dialysis machine 70 processes fluids,
such as for example blood, from the human body with a dialyzing
solution thereby treating fluids before fluids are re-introduces to
the human body. In particular, the dialysis machine 70 mixes and
monitors the dialysate, i.e. fluid that helps remove the unwanted
waste products from human's blood and helps get your electrolytes
and minerals to their proper levels in the human's body. The
dialysis machine 70 holds a plastic jug device 71 hold the liquids
used to mix the dialysate. The dialysis machine 70 mixes the
dialysate, which is made up of an acidified solution, bicarbonate
and purified water. The acidified solution contains electrolytes
and minerals.
[0038] While the human 72 is dialyzing, dialysate and blood flow
through a semipermeable membrane 72 or dyalizer catridge presented
by the polymer tubes 50 as set forth above, adaptable to withstand
pressure of fluids and the dialyzing solution in each polymer tube
50 as the polymer tubes 50 process and balance fluids and the
dialysis solution introduced therein. having identical structural
characteristics as the humidifier 10 presents. Fresh dialysate from
the dialysis machine 70 enters the dialyzer catridge 72 throughout
your treatment. Impurities are filtered out of your blood into the
dialysate. Dialysate containing unwanted waste products and excess
electrolytes leave the dialyzer catridge 72 and are washed down the
drain (not shown). A pair of tubes 74 are cooperable with the
dyalizer catridge 72 for circulating the dialyzing solution and
blood to and from the human body. Dializer fittings 76 and 78 are
connected to the dyalizer catridge 72 and are designed to flow the
dialyzing solution and blood.
[0039] An apparatus for fabricating the aforementioned humidifier
10 is also disclosed in the present invention and is generally
shown at 80 in FIGS. 8 through 10. The apparatus 80 has at least
one frame, generally indicated at 82, for engaging the housing 12
of the humidifier 10 at the respective terminal ends. The frame 82
presents opposite inlet ports 84 and 86 exposed to the terminal
openings of the polymer tubes 50. A pair of containers 88 and 90
for holding a solution 92, such as an epoxy adhesive, are connected
to the frame 82 and is fluidly communicated to each of the opposite
inlet ports 84 and 86 for transferring the solution 92 to the
housing 12 through the terminal ends. The frame 82 may include
several parts, such as, for example, the opposite inlet ports 84
and 86.
[0040] Alternatively, the frame may present a unitary piece (not
shown). An activator 100 is connected to the frame 82 or to the
housing 12 for rotating the same about a rotational axis B thereby
generating a centrifugal force to introduce the solution 92
internally into each of the terminal openings of the polymer tube
50 through pipe conduit members 102 and 104 thereby bonding the
polymer tubes 50.
[0041] The process of forming the humidifier 10 for the medical
device 70 is clearly illustrated in FIGS. 4 through 7B and begins
with affixing the tubes 50 with the aforementioned retainer rings
51 and 53 to form a bundle or the unitary piece thereby forming a
dense package of the tubes 50 to prevent the tubes 50 from being
loose. Each terminal end of the tubes 50 is then briefly applied
into a second epoxy solution 94 hold in a container 96 to fill tips
of internal capillaries 98 of the tubes 50 with the epoxy solution
94 whereby the retainer rings 51 and 53 restricts submerging the
hollow polymer tubes 50 into the epoxy solution 94, as best shown
in FIGS. 6A and 6B.
[0042] Alluding to the above, the duration of the exposure of the
terminal ends of the tubes 50 into the epoxy solution 94 depends on
the viscosity of the epoxy solution 94 and the capillary capability
to force the epoxy solution 94 into the internal capillaries 98
and, is generally between 2 and 5 seconds, without limiting the
scope of the present invention. The expose of the terminal ends of
the tubes 50 to the epoxy solution 94 is necessary for the
penetration of the epoxy solution 94 in the tubes 50 without
entering the tubes 50 beyond the level the rings 51 and 53, as
shown in FIG. 6A. FIGS. 7A and 7B illustrate the next stage of the
method also knows as curing the epoxy solution 94 to clogg the
internal capillaries 98.
[0043] FIGS. 8 through 10 illustrate the next step of the formation
of the humidifier 10. The housing 12 with the tubes 50 disposed
therein is placed into the frame 82 of the apparatus 80. As the
frame 82 is rotated about the rotational axis B by the activator
100, the centrifugal force generated thereby forces the solution 92
internally into each of the terminal openings of the polymer tube
50 through the pipe conduit members 102 and 104 thereby bonding the
polymer tubes 50 presents opposite inlet ports 84 and 86 exposed to
the terminal openings of the polymer tubes 50. The volume of the
solution 92 placed in the containers 88 and 90 is predetermined
based upon configuration and volume of the humidifier 10. The
application of the centrifugal force continues until the curing
process of the epoxy is complete. All of the aforementioned
components of the apparatus 80 are fabricated from a non-adhesive
to the epoxy solution material which allows them to be reusable
after the housing 12 and the tubes 50 disposed therein are removed
from the apparatus 80.
[0044] While the invention has been described with reference to an
exemplary embodiment, it will be understood by those skilled in the
art that various changes may be made and equivalents may be
substituted for elements thereof without departing from the scope
of the invention. In addition, many modifications may be made to
adapt a particular situation or material to the teachings of the
invention without departing from the essential scope thereof.
Therefore, it is intended that the invention not be limited to the
particular embodiment disclosed as the best mode contemplated for
carrying out this invention, but that the invention will include
all embodiments falling within the scope of the appended
claims.
* * * * *