Fuel cell compressor system

Abstract

A multi-stage fuel cell centrifugal compressor system comprising a motor, including a shaft, and a compressor connected to the motor. The compressor includes a first stage inlet; first housing fluidly connected to the first stage inlet; and first impeller driven by the shaft for imparting fluid flow through a first stage of the system. The compressor further includes a first stage outlet fluidly connected to the first housing; a second stage inlet; a second housing fluidly connected to the second stage inlet; a second impeller for imparting fluid flow through a second stage; a second stage outlet fluidly connected to the second housing; and a pipe extending between the first stage outlet and the second stage inlet. The pipe fluidly connects the first stage outlet to the second stage inlet, thereby directing at least a portion of fluid from the first stage to the second stage of the system.

1 . A multi-stage fuel cell compressor system, comprising: 
 a motor, including a shaft driven by the motor; and    a compressor connected to the motor, the compressor including: 
 a first stage inlet;  
 a first housing fluidly connected to the first stage inlet;  
 a first impeller at least partially surrounded by the first housing, the first impeller driven by the shaft for imparting fluid flow through a first stage of the system;  
 a first stage outlet fluidly connected to the first housing;  
 a second stage inlet;  
 a second housing fluidly connected to the second stage inlet;  
 a second impeller at least partially surrounded by the second housing, the second impeller driven by the shaft for imparting fluid flow through a second stage of the system;  
 a second stage outlet fluidly connected to the second housing; and  
 a pipe extending between the first stage outlet and the second stage inlet for fluidly connecting the first stage outlet to the second stage inlet thereby directing at least a portion of a fluid from the first stage to the second stage of the system.  
   
   
   
       2 . A system in accordance with  claim 1 , wherein the motor comprises an electric motor.  
   
   
       3 . A system in accordance with  claim 1 , wherein the first stage inlet is at a non-axial angle relative to the shaft.  
   
   
       4 . A system in accordance with  claim 1 , wherein the first stage outlet is at a non-axial angle relative to the shaft.  
   
   
       5 . A system in accordance with  claim 1 , wherein the second stage inlet is substantially aligned with the shaft.  
   
   
       6 . A system in accordance with  claim 1 , wherein the second stage outlet is at a non-axial angle relative to the shaft.  
   
   
       7 . A system in accordance with  claim 3 , wherein the non-axial angle is substantially perpendicular.  
   
   
       8 . A system in accordance with  claim 1 , wherein the first impeller and the second impeller are arranged back-to-back.  
   
   
       9 . A system in accordance with  claim 1 , wherein the motor is located upstream of the first stage.  
   
   
       10 . A system in accordance with  claim 1 , wherein at least a portion of the fluid flows axially into the first stage.  
   
   
       11 . A system in accordance with  claim 1 , further comprising one or more bearings disposed within the motor.  
   
   
       12 . A system in accordance with  claim 1 , further comprising one or more bearings disposed within the compressor.  
   
   
       13 . A system in accordance with  claim 1 , further comprising a drive coupling for coupling the motor to the compressor.  
   
   
       14 . A system in accordance with  claim 13 , wherein the drive coupling includes a plurality of pins.  
   
   
       15 . A system in accordance with  claim 14 , wherein the coupling includes three pins that are angularly spaced.  
   
   
       16 . A system in accordance with  claim 1 , further comprising a nose cone disposed within the second housing.  
   
   
       17 . A system in accordance with  claim 1 , wherein a first portion and a second portion of the first housing are connected using a plurality of fasteners disposed about an outer surface portion of each of the first and second portions.  
   
   
       18 . A system in accordance with  claim 1 , wherein a first portion and a second portion of the first housing are connected about an outer surface of each of the first and second portions by a secondary operation.  
   
   
       19 . A system in accordance with  claim 18 , wherein the secondary operation includes crimping, welding, gluing or using adhesive, or a combination of two or more of the foregoing.  
   
   
       20 . A system in accordance with  claim 18 , wherein the outer surface substantially comprises the perimeter of one or both of the first and second portions.  
   
   
       21 . A system in accordance with  claim 1 , wherein at least a portion of the pipe is an external cross-over pipe.  
   
   
       22 . A system in accordance with  claim 1 , wherein at least a portion of the pipe is comprised of a polymer or plastic material.  
   
   
       23 . A system in accordance with  claim 22 , wherein at least a portion of the pipe is comprised of polypropylene or acrylonitrile butadiene styrene (ABS).  
   
   
       24 . A method of manufacturing a fuel cell centrifugal compressor, comprising: 
 forming a first piece of a volute;    forming a second piece of a volute; and    connecting the first piece and second piece to form a volute including a compressor outlet, wherein the volute includes an inner surface that extends from a first side of the compressor outlet, includes a curved portion, and extends to a second side of the compressor outlet.    
   
   
       25 . A method in accordance with  claim 24 , wherein the forming comprises die-casting, forging, or stamping.