Integrated charge air heat exchanger

A fuel cell system comprising:

• a fuel cell stack;
• an integrated charge air heat exchanger unit in fluid communication with the fuel cell stack, the unit including:
• a plurality of coolant conduit adapted for a coolant fluid to flow therethrough, one of the coolant conduit having a first surface and a second surface,
• a plurality of heating elements, one of the heating elements disposed on the first surface of each of the coolant conduits and adapted to transfer heat to the coolant fluid,
• a plurality of fin elements adapted for an air stream to flow therearound, one of the fin elements disposed on the second surface of each of the coolant conduits and adapted to transfer heat from the air stream to the coolant fluid,
• a busbar having a plurality of fingers, each of the fingers abutting and in electrical communication with one of the heating elements, the busbar disposed adjacent each of the plurality of coolant conduits, and
• an insulating material disposed on the busbar to electrically insulate the busbar from the plurality of coolant conduits;
• and
• an electrical power source in electrical communication with the plurality of heating elements via the plurality of fingers of the busbar.

A method for regulating a temperature of a fuel cell stack, comprising the steps of:

• providing an integrated charge air heat exchanger unit in fluid communication with the fuel cell stack, the unit including a plurality of coolant conduit adapted for a coolant fluid to flow therethrough, one of the coolant conduit having a first surface and a second surface, a plurality of heating elements, one of the heating elements disposed on the first surface of each of the coolant conduits and adapted to transfer heat to the coolant fluid, a plurality of fin elements adapted for an air stream to flow therearound, one of the fin elements disposed on the second surface of each of the coolant conduits and adapted to transfer heat from the air stream to the coolant fluid, a busbar having a plurality of fingers, each of the fingers abutting and in electrical communication with one of the heating elements, the busbar disposed adjacent each of the plurality of coolant conduits, and an insulating material disposed on the busbar to electrically insulate the busbar from the plurality of coolant conduits, and an electrical power source in electrical communication with the plurality of heating elements via the plurality of fingers of the busbar;
• starting the fuel cell stack;
• supplying the coolant fluid to the fuel cell stack through the coolant conduit;
• and
• maintaining a coolant fluid temperature within a desired range by one of heating the coolant fluid using the heating element and heating the coolant fluid using a charge air stream flowing around the fin element.