Fuel cartridge for fuel cells

• US 20040151962A1
• Filed: 01/31/2003
• Published: 08/05/2004
• Est. Priority Date: 01/31/2003
• Status: Active Grant

• Current Assignee: Intelligent Energy Limited (Lb-shell Plc)
• Original Assignee: Societe BIC
• Inventors: Adams, Paul
• Granted Patent: US 7,147,955 B2
• Time in Patent Office: Days
• US Class Current: 429/34
• CPC Class Codes: H01M 2250/20 Fuel cells in motive systems, e.g. vehicle, ship, plane
• CPC Class Codes: H01M 8/04186 of liquid-charged or electrolyte-charged reactants
• CPC Class Codes: H01M 8/04208 Cartridges, cryogenic media or cryogenic reservoirs
• CPC Class Codes: H01M 8/04216 characterised by the choice for a specific material, e.g. carbon, hydride, absorbent
• CPC Class Codes: H01M 8/1011 Direct alcohol fuel cells [DAFC], e.g. direct methanol fuel cells [DMFC]
• CPC Class Codes: Y02E 60/50 Fuel cells
• CPC Class Codes: Y02T 90/40 Application of hydrogen technology to transportation, e.g. using fuel cells

Abstract

A versatile fuel cartridge for storing methanol and water, methanol/water mixture or methanol/water mixtures of varying concentrations is disclosed. The present invention utilizes a filler insert preferably occupying a small portion of the volume of the fuel cartridge, so that the fuel cartridge may hold more fuel to ensure a long life of the fuel cartridge. The filler insert is capable of wicking and transporting the fuel to the MEA. Additionally, the filler insert remains in physical contact with the fuel in any orientation of the fuel cartridge and at any fuel level in the fuel cartridge. The fuel cartridge may have more than one chamber, and preferably each chamber contains a different concentration of fuel. Optionally, the fuel cartridge may also include a pump to initiate fuel flow from the fuel reservoir. The pump may also regulate the flow of fuel and importantly to shut off the flow of fuel, when necessary.

Claims

1. A fuel cartridge containing fuel suitable for use with a fuel cell comprising a first free space portion and a filler insert, wherein the filler insert comprises an absorbent material capable of wicking fuel contained within the cartridge by capillary action, and wherein the filler insert is substantially in contact with the fuel at any orientation of the cartridge and at any fuel level.

2. The fuel cartridge of claim 1, wherein the filler insert comprises less than about 67% of the volume of the cartridge.

3. The fuel cartridge of claim 2, wherein the filler insert comprises less than about 50% of the volume of the cartridge.

4. The fuel cartridge of claim 3, wherein the filler insert comprises less than about 33% of the volume of the cartridge.

5. The fuel cartridge of claim 1, wherein the filler insert comprises a connecting column and at least two disks.

6. The fuel cartridge of claim 5, wherein the disks are located at the ends of the connecting column.

7. The fuel cartridge of claim 5, wherein the connecting column is covered by a fluid impermeable film.

8. The fuel cartridge of claim 5, wherein at least a portion of one disk is covered by a fluid impermeable film.

9. The fuel cartridge of claim 5, wherein the filler insert comprises a third disk disposed between the at least two disks.

10. The fuel cartridge of claim 1, wherein the filler insert further comprises an outlet port.

11. The fuel cartridge of claim 10, wherein the outlet port comprises a second absorbent material.

12. The fuel cartridge of claim 10, wherein the outlet port comprises a capillary needle.

13. The fuel cartridge of claim 10, wherein the outlet port comprises a bundle of capillary tubes.

14. The fuel cartridge of claim 1, wherein the filler insert comprises a connecting column and a plurality of spokes.

15. The fuel cartridge of claim 14, wherein the filler insert further comprises a plurality of rings, wherein the spokes connect the connecting column to the rings.

16. The fuel cartridge of claim 1, wherein the filler insert comprises a shell covering at least a portion of the inner surface of the cartridge.

17. The fuel cartridge of claim 16, wherein the filler insert further comprises at least one disk connected to the shell.

18. The fuel cartridge of claim 16, wherein the filler insert further comprises a connecting column connected to the shell.

19. The fuel cartridge of claim 1, wherein the filler insert covers substantially the entire inner surface of the cartridge.

20. The fuel cartridge of claim 1, wherein the absorbent material is made from polymeric fibers.

21. The fuel cartridge of claim 20, wherein the polymeric fibers are polyester, polyethylene, polyolefin, polyacetal, or polypropylene fibers.

22. The fuel cartridge of claim 1, wherein the absorbent material is made from plant-based fibers.

23. The fuel cartridge of claim 22, wherein the plant-based fibers are hemp, cotton, or cellulose acetate.

24. The fuel cartridge of claim 1 further comprising an air vent.

25. The fuel cartridge of claim 1 further comprising a refillable valve.

26. The fuel cartridge of claim 1, wherein the fuel cartridge is operatively connectable to a pump to control the flow of fuel from the cartridge.

27. The fuel cartridge of claim 26, wherein the pump comprises a microelectromechanical system pump.

28. The fuel cartridge of claim 27, wherein the microelectromechanical pump comprises a field-induced pump.

29. The fuel cartridge of claim 28, wherein the microelectromechanical pump comprises an electrical field applied to the fuel to pump the fuel.

30. The fuel cartridge of claim 29, wherein the electrical field is generated by a DC voltage.

31. The fuel cartridge of claim 29, wherein the electrical field is generated by an AC voltage.

32. The fuel cartridge of claim 28, wherein the microelectromechanical pump comprises a magnetic field applied to a working fluid to pump the fuel.

33. The fuel cartridge of claim 27, wherein the microelectromechanical pump comprises an electrohydrodynamic pump.

34. The fuel cartridge of claim 33, wherein the electrohydrodynamic pump applies an AC voltage to the fuel to pump the fuel.

35. The fuel cartridge of claim 27, wherein the microelectromechanical pump comprises an electrohydrodynamic pump and an electro-osmotic pump.

36. The fuel cartridge of claim 27, wherein the microelectromechanical pump comprises a magnetohydrodynamic pump.

37. The fuel cartridge of claim 36, wherein the magnetohydrodynamic pump applies a magnetic field to a working fluid to pump the fuel.

38. The fuel cartridge of claim 27, wherein the pump comprises an electro-osmotic pump.

39. The fuel cartridge of claim 38, wherein the electro-osmotic pump applies a DC electrical potential across the filler insert.

40. The fuel cartridge of claim 38, wherein the electro-osmotic pump applies a DC electrical potential across an outlet port of the cartridge.

41. The fuel cartridge of claim 38, wherein the electro-osmotic pump is operatively connected to a controller to vary a DC electrical potential of the pump to control the flow rate of the pump.

42. The fuel cartridge of claim 41, wherein the controller reverses the electrical potential to reverse the flow direction of the pump.

43. The fuel cartridge of claim 41, wherein the controller shuts off the electrical potential to turn off the pump.

44. The fuel cartridge of claim 27, wherein the microelectromechanical pump is a membrane-displacement pump.

45. The fuel cartridge of claim 44, wherein the microelectromechanical pump comprises a membrane and a force is applied to the membrane causing the membrane to move to pump the fuel.

46. The fuel cartridge of claim 27, wherein the pump comprises an electrostatic pump.

47. The fuel cartridge of claim 46, wherein the electrostatic pump comprises a membrane and an electrical voltage is applied directly to the membrane causing the membrane to move to pump the fuel.

48. The fuel cartridge of claim 27, wherein the pump comprises a thermopneumatic pump.

49. The fuel cartridge of claim 48, wherein the thermopneumatic pump comprises a membrane and a heating element, wherein the heat generated by the heating element expands a working fluid and such expansion moves the membrane to pump the fuel.

109. The fuel cartridge of claim 1 further comprising a shut-off valve.

113. The fuel cartridge of claim 27, wherein the pump is reversible to reverse the flow of fuel.

50. A fuel cartridge containing fuel suitable for use with a fuel cell comprising a filler insert and the fuel cartridge is operatively connectable to a microelectromechanical pump to control the flow of fuel out of the cartridge, wherein the filler insert comprises an absorbent material capable of wicking fuel contained within the cartridge by capillary action, and wherein the filler insert is substantially in contact with the fuel at any orientation of the cartridge and at any fuel level.

51. The fuel cartridge of claim 50 further comprising a first free space portion and a second space portion, wherein the filler insert occupies the second space portion.

52. The fuel cartridge of claim 51, wherein the filler insert comprises less than about 67% of the volume of the cartridge.

53. The fuel cartridge of claim 52, wherein the filler insert comprises less than about 50% of the volume of the cartridge.

54. The fuel cartridge of claim 53, wherein the filler insert comprises less than about 33% of the volume of the cartridge.

55. The fuel cartridge of claim 51, wherein the filler insert comprises a connecting column and at least two disks.

56. The fuel cartridge of claim 51, wherein the filler insert comprises a shell covering at least a portion of the inner surface of the cartridge.

57. The fuel cartridge of claim 51, wherein the filler insert comprises an outlet port.

58. The fuel cartridge of claim 51, wherein the filler insert comprises a connecting column and a plurality of spokes.

59. The fuel cartridge of claim 58, wherein the filler insert further comprises a plurality of rings, wherein the spokes connect the connecting column to the rings.

60. The fuel cartridge of claim 50, wherein the absorbent material is made from polymeric fibers.

61. The fuel cartridge of claim 50, wherein the absorbent material is made from plant-based fibers.

62. The fuel cartridge of claim 50, wherein the cartridge further comprising an air vent.

63. The fuel cartridge of claim 50, wherein the cartridge further comprising a refillable valve.

64. The fuel cartridge of claim 50, wherein the microelectromechanical pump comprises a field-induced pump.

65. The fuel cartridge of claim 64, wherein the microelectromechanical pump comprises an electrical field applied to the fuel to pump the fuel.

66. The fuel cartridge of claim 65, wherein the electrical field is generated by a DC voltage.

67. The fuel cartridge of claim 65, wherein the electrical field is generated by an AC voltage.

68. The fuel cartridge of claim 64, wherein the microelectromechanical pump comprises a magnetic field applied to a working fluid to pump the fuel.

69. The fuel cartridge of claim 50, wherein the microelectromechanical pump comprises an electrohydrodynamic pump.

70. The fuel cartridge of claim 50, wherein the microelectromechanical pump comprises an electrohydrodynamic pump and an electro-osmotic pump.

71. The fuel cartridge of claim 50, wherein the microelectromechanical pump comprises a magnetohydrodynamic pump.

72. The fuel cartridge of claim 50, wherein the pump comprises an electro-osmotic pump.

73. The fuel cartridge of claim 50, wherein the microelectromechanical pump comprises a membrane-displacement pump.

74. The fuel cartridge of claim 73, wherein the microelectromechanical pump comprises a membrane and a force is applied to the membrane causing the membrane to move to pump the fuel.

75. The fuel cartridge of claim 50, wherein the pump comprises an electrostatic pump.

76. The fuel cartridge of claim 50, wherein the pump comprises a thermopneumatic pump.

107. The fuel cartridge of claim 55, wherein the connecting column is covered by a fluid impermeable film.

108. The fuel cartridge of claim 55, wherein at least a portion of one disk is covered by a fluid impermeable film.

110. The fuel cartridge of claim 50 further comprising a shut-off valve.

77. A fuel cartridge containing fuel suitable for use with a fuel cell comprising a plurality of chambers, wherein each chamber has a predetermined concentration of fuel and wherein each chamber comprises a filler insert made from an absorbent material capable of wicking fuel contained within the chamber by capillary action, and wherein the filler insert is substantially in contact with the fuel at any orientation of the chamber and at any fuel level.

78. The fuel cartridge of claim 77, wherein the concentrations of fuel in the chambers are different from each other.

79. The fuel cartridge of claim 78, wherein the concentration of fuel range from about 100% fuel and 0% water to about 0% fuel and 100% water.

80. The fuel cartridge of claim 77, wherein the chambers are arranged side-by-side.

81. The fuel cartridge of claim 77, wherein the chambers are arranged end-to-end.

82. The fuel cartridge of claim 77, wherein at least one chamber comprises a first free space portion and a second space portion, wherein the filler insert occupies the second space portion.

83. The fuel cartridge of claim 82, wherein the filler insert comprises less than about 67% of the volume of the chamber.

84. The fuel cartridge of claim 83, wherein the filler insert comprises less than about 50% of the volume of the chamber.

85. The fuel cartridge of claim 84, wherein the filler insert comprises less than about 33% of the volume of the chamber.

86. The fuel cartridge of claim 77, wherein each chamber comprises an outlet port.

87. The fuel cartridge of claim 82, wherein the filler insert of said at least one chamber comprises a connecting column and at least two disks.

88. The fuel cartridge of claim 82, wherein the filler insert of said at least one chamber comprises a shell covering at least a portion of the inner surface of the cartridge.

89. The fuel cartridge of claim 82, wherein the filler insert of said at least one chamber comprises a connecting column and a plurality of spokes.

90. The fuel cartridge of claim 89, wherein the filler insert of said at least one chamber further comprises a plurality of rings, wherein the spokes connect the connecting column to the rings.

91. The fuel cartridge of claim 77, wherein the absorbent material is made from polymeric fibers.

92. The fuel cartridge of claim 77, wherein the absorbent material is made from plant-based fibers.

93. The fuel cartridge of claim 77 further comprising at least one air vent.

94. The fuel cartridge of claim 77 further comprising at least one refillable valve.

95. The fuel cartridge of claim 77, wherein the fuel cartridge is connectable to a microelectromechanical pump to control the flow of fuel.

96. The fuel cartridge of claim 95, wherein the fuel in each chamber is pumped out of the chamber by the microelectromechanical pump.

97. The fuel cartridge of claim 96, wherein the fuel in each chamber is pumped at a different rate.

98. The fuel cartridge of claim 96, wherein the fuels from the chambers are mixed after being pumped from the chambers.

99. The fuel cartridge of claim 95, wherein the microelectromechanical pump is a field-induced pump.

100. The fuel cartridge of claim 99, wherein the microelectromechanical pump comprises an electrical field applied to the fuel to pump the fuel.

101. The fuel cartridge of claim 95, wherein the microelectromechanical pump comprises an electrohydrodynamic pump and an electro-osmotic pump

102. The fuel cartridge of claim 95, wherein the microelectromechanical pump is an electro-osmotic pump.

103. The fuel cartridge of claim 95, wherein the microelectromechanical pump is a membrane-displacement pump.

104. The fuel cartridge of claim 77, wherein the fuel cartridge is connectable to a pump to control the flow of fuel.

105. The fuel cartridge of claim 87, wherein the connecting column is covered by a fluid impermeable film.

106. The fuel cartridge of claim 87, wherein at least a portion of one disk is covered by a fluid impermeable film.

111. The fuel cartridge of claim 77 further comprising at least one shut-off valve.

112. The fuel cartridge of claim 82 wherein the at least one chamber comprises a shut-off valve.