Humidifier, for Example for a Fuel Cell

Abstract

A humidifier comprises hollow shell and humidifier core. The humidifier core includes a transfer sheet, a plurality of first channels, and a plurality of second channels. The transfer sheet comprises a permeable material having a plurality of sections and a plurality of layers of spacing materials. The plurality of first channels are configured to allow air flow in a first direction and to prevent airflow in a second direction that is different from the first direction. The plurality of second channels are configured to allow air flow in the second direction and to prevent airflow in the first direction. The humidifier comprises a stack of alternating first channels and second channels, and the first channels are configured to transfer liquid from air flowing in at least one of the first channels to air flowing in at least one of the second channels. The humidifier is suitable for use in fuel cell stack.

What is claimed is: 
     
         1 . A humidifier part comprising:
 a humidifier core comprising;   a first end plate comprising first alignment features;   a second end plate comprising second alignment features;   at least one sealing plate comprising a first porous media over molded with an elastomer seal and, the elastomer seal includes alignment holes;   at least one first inlet transfer plate comprising a second porous media over molded with a polymer frame having inlets and outlets for allowing a flow of liquid or gas in a first direction on one sides of the porous media, wherein the polymer frame include first mating features for mating with the first alignment features, the alignment holes, or the second alignment features; and   at least one second inlet transfer plate comprising the second porous media over molded with a polymer frame having inlets and outlets for allowing a flow of liquid or gas in a second direction on one side of the porous media, wherein the polymer frame include second mating features for mating with the first alignment features, the alignment holes, or the second alignment features;   wherein the alignment holes in the at least one sealing plate acts as a mating feature with at least one of the first alignment features, the second alignment features, the first mating features, and the second mating features;   wherein the humidifier core comprises a stack of the first endplate, a first sealing plate stacked on the first endplate, a first inlet transfer plate stacked on the first sealing plate and the first alignment features orient the first inlet transfer plate to enable a flow of gas or liquid in the first direction, a second sealing plate stacked on the first inlet transfer plate, a second inlet transfer plate stacked on the second sealing plate and the second alignment features orient the second inlet transfer plate to enable a flow of gas or liquid in the second direction substantially perpendicular to the first direction, a third sealing plate stacked on the second inlet transfer plate, and the second end plate stacked on the third sealing plate.   
     
     
         2 . A humidifier part according to  claim 1 , wherein the first inlet transfer plate receives a flow of wet air, the second inlet plate receives a flow of dry air, and the first porous media and the second porous media transfer moisture from the wet air to the dry air. 
     
     
         3 . A humidifier part according to  claim 1 , wherein the first inlet transfer plate receives a flow of dry air, the second inlet plate receives a flow of wet air, and the first porous media and the second porous media transfer moisture from the wet air to the dry air. 
     
     
         4 . A humidifier part according to  claim 1 , further comprising:
 a support media provided between the first sealing plate and the first inlet transfer plate, between the first inlet transfer plate and the second sealing plate, between the second sealing plate and the second inlet transfer plate, and between the second inlet transfer plate and the third sealing plate.   
     
     
         5 . A humidifier part according to  claim 4 , wherein the support media comprises a porous spun bond thermoplastic polymer configured to provide a turbulent flow path to help distribute the stream of liquid or gas. 
     
     
         6 . A humidifier part according to  claim 1 , wherein the first inlet transfer plate further comprises a plurality of media support structures molded into the polymer frame. 
     
     
         7 . A humidifier part according to  claim 6 , wherein the plurality of media support structures comprise a plurality of ribs oriented in the first direction. 
     
     
         8 . A humidifier part according to  claim 7 , wherein the plurality of ribs have a pattern configured provide a turbulent flow path to help distribute the stream of liquid or gas. 
     
     
         9 . A humidifier part according to  claim 1 , wherein the elastomer seal comprises a thermoplastic elastomer seal configured to seal between the first inlet plate and the second inlet plate. 
     
     
         10 . A humidifier part according to  claim 1 , wherein the alignment holes are arranged to that the at least one first transfer plate can only be oriented to allow liquid or gas flow in the first direction and the at last one second transfer plate can only be oriented to allow liquid or gas to flow in the second direction. 
     
     
         11 . A humidifier part according to  claim 1 , wherein the frame comprises a thermoplastic polymer having snap fit features configured to mate the frame with at least one elastomer seal. 
     
     
         12 . The humidifier part according to  claim 1 , further comprising:
 at least one inlet cap having an inlet end port; and   at least one outlet cap having an outlet end port, wherein the inlet end cap and the outlet end cap are attached to humidifier core.   
     
     
         13 . The humidifier part according to  claim 12 , wherein the at least one inlet end cap is attached to the humidifier core by welding process. 
     
     
         14 . The humidifier part according to  claim 13 , wherein the welding process comprises one of hot plate welding, vibration welding, ultrasonic welding, and hot gas welding. 
     
     
         15 . A humidifier part comprising:
 a humidifier core located within the space of the hollow shell, wherein the humidifier core comprises;   a first end plate comprising first alignment features;   a second end plate comprising second alignment features;   a plurality of sealing plates, each sealing plate comprising a first porous media over molded with an elastomer seal and alignment holes;   at least two first inlet transfer plates comprising a second porous media over molded with a polymer frame having inlets and outlets for allowing a flow of liquid or gas in a first direction on a side of the porous media, wherein the polymer frame include first mating features for mating with the first alignment features, the alignment holes, or the second alignment features; and   at least two second inlet transfer plates comprising the second porous media over molded with a polymer frame having inlets and outlets for allowing a flow of liquid or gas in a second direction on a side of the porous media, wherein the polymer frame include second mating features for mating with the first alignment features, the alignment holes, or the second alignment features;   wherein the alignment holes in the at least one sealing plate acts as a mating feature with at least one of the first alignment features, the second alignment features, the first mating features, and the second mating features;   wherein the humidifier core comprises a stack of the first endplate, a first sealing plate stacked on the first endplate, a first inlet transfer plate stacked on the first sealing plate and the first alignment features orient the first inlet transfer plate to enable a flow of gas or liquid in the first direction, a second sealing plate stacked on the first inlet transfer plate, a second inlet transfer plate stacked on the second sealing plate and the second alignment features orient the second inlet transfer plate to enable a flow of gas or liquid in the second direction perpendicular to the first direction, a third sealing plate stacked on the second inlet transfer plate, another first transfer plate stacked on the third sealing plate, a fourth sealing plate stacked on the another first transfer plate, another second transfer plate stacked on the fourth sealing plate, a fifth sealing plate stacked on the another second transfer plate, and the second end plate stacked on the fifth sealing plate.