Fuel cell cartridge and fuel delivery system

• US 20060006108A1
• Filed: 07/07/2005
• Published: 01/12/2006
• Est. Priority Date: 07/08/2004
• Status: Abandoned Application

• Current Assignee: Direct Methanol Fuel Cell Corp. (VIASPACE, Inc.)
• Original Assignee: Direct Methanol Fuel Cell Corp. (VIASPACE, Inc.)
• Inventors: Kukkonen, Carl Allan, Beckmann, Gerhard, Arias, Jeffrey Lynn, Dinh, Huyen Ngoc, Kukkonen, Carl Allan III
• Application Number:
  US11/177,234
• Publication Number:
  US 20060006108A1
• Time in Patent Office: Days
• US Class Current: 210/232
• CPC Class Codes: F17C 2205/037 Quick connecting means, e.g. couplings
• CPC Class Codes: F17C 2270/0763 Fuel cells
• CPC Class Codes: H01M 2008/1095 Fuel cells with polymeric electrolytes
• CPC Class Codes: H01M 8/04208 Cartridges, cryogenic media or cryogenic reservoirs
• CPC Class Codes: H01M 8/04313 characterised by the detection or assessment of variables; characterised by the detection or assessment of failure or abnormal function
• CPC Class Codes: H01M 8/04365 of other components of a fuel cell or fuel cell stacks
• CPC Class Codes: H01M 8/04447 of anode reactants at the inlet or inside the fuel cell
• CPC Class Codes: H01M 8/04559 of fuel cell stacks
• CPC Class Codes: H01M 8/04589 of fuel cell stacks
• CPC Class Codes: H01M 8/04753 of fuel cell reactants
• CPC Class Codes: H01M 8/0612 from carbon-containing material
• CPC Class Codes: H01M 8/0643 Gasification of solid fuel
• CPC Class Codes: H01M 8/1009 with one of the reactants being liquid, solid or liquid-charged H01M8/12 takes precedence
• 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

Abstract

The subject matter described herein relates to a fuel cell cartridge for providing fuel to a fuel cell. Also described are fuel delivery systems, fuel cells, and related techniques.

Claims

1. A fuel cartridge for use in a fuel delivery system in a fuel cell, the fuel cartridge comprising:

a fuel reservoir locatable within a fuel container to dispense fuel through a coupling device into the fuel cell;

wherein the reservoir comprises a housing with an anterior wall and a posterior wall, an external surface and an internal surface, fuel outlet provided in the anterior wall and connectable to the fuel cell through the coupling device.

2. A fuel cartridge as in claim 1 wherein the fuel cartridge is multi-walled to house fuel in segregated chambers.

3. A fuel cartridge as in claim 1 wherein the reservoir is made of a corrugated material on at least a portion thereof to provide a compressible/expandable bellows to evacuate fuel therefrom.

4. A fuel cartridge as in claim 1 wherein the reservoir comprises a flexible volume defining chamber provided within a rigid housing.

5. A fuel cartridge as in claim 1 wherein the reservoir comprises a removable barrier to cover the fuel outlet.

6. A fuel cartridge as in claim 1 wherein the reservoir comprises a locking portion at the fuel outlet to secure the cartridge to a coupling device.

7. A fuel cartridge as in claim 1 wherein the cartridge is also provided with a coupling sensor to detect coupling therebetween and a coupling device.

8. A fuel cartridge as in claim 1 further comprising a coupling sensor selected from a group comprising:

a micro-switch residing on the housing of the cartridge and actuated on mating of the cartridge and coupling device, a magnetic switch actuated on mating of the cartridge and coupling device, a pair of electrical contacts in contact with a metal portion of the fuel cartridge, and a light detection sensor selected in turn from an optical sensor.

9. A fuel cartridge as in claim 1 wherein the cartridge comprises at least one positive pressure inducing element to dispense fuel therefrom selected from a group consisting an internal-pressure-providing element inside the cartridge, a mechanical force inducing element, and a combination thereof.

10. A fuel cartridge as in claim 1 further comprising a positive pressure inducing element to dispense fuel therefrom comprising a high vapor pressure hydrocarbon added to the fuel.

11. A fuel cartridge as in claim 10 wherein the fuel is methanol and the high vapor pressure hydrocarbon is selected from a group comprising:

butane, dimethyl ether and propane.

12. A fuel cartridge as in claim 1 further comprising a positive pressure inducing element to dispense fuel therefrom selected from a group comprising:

a piston operable using at least one actuation element selected from a group comprising;

spring, a screw, a motor, pneumatic pressure and hydraulic pressure;

a portion of the reservoir housing, and an elastomer foam.

13. A fuel cartridge as in claim 1 further comprising a foam with a constant porosity within the container to provide a capillary force.

14. A fuel cartridge as in claim 1 further comprising a foam with a porosity gradient within the container to provide a capillary force.

15. A fuel cartridge as in claim 1 further comprising one or more visco-elastic fluids provided within the container to provide a capillary force.

16. A fuel cartridge as in claim 1 further comprising one or more capillary tubes located within the container to provide a capillary force.

17. A fuel cartridge as in claim 1 wherein the fuel is evacuatable by a gas provided within the cartridge, a gas vent element being incorporated on the cartridge.

18. A fuel cartridge as in claim 1 wherein the cartridge comprises one or more gas storage elements to store a propellant segregated from the fuel.

19. A fuel cartridge as in claim 18 wherein the gas storage element is selected from a group comprising:

a bladder, bag, expandable vessel, rupturable capsule, piston separating gas and fuel and compartment coupled to a pressure responsive valve.

20. A fuel cartridge as in claim 1 wherein the cartridge comprises a metering element to control the rate of fuel discharge therefrom.

21. A fuel cartridge as in claim 20 wherein the metering element is selected from a group comprising:

metering orifice, porous material, porous element located at the fuel outlet, wicking material located at the outlet of the container and a flow restriction valve.

22. A fuel cartridge as in claim 1 wherein the cartridge comprises a release mechanism to relieve pressure within the cartridge on reaching a predetermined level.

23. A fuel cartridge as in claim 22 wherein the release mechanism is a valve that is opened when a pre-determined pressure level is reached comprising a pressure-sensitive rubber plug mounted within an orifice of the cartridge.

24. A fuel cartridge as in claim 22 wherein the release mechanism is assisted by a foam or a gelling agent located within the fuel to slow release of fuel out from the cartridge.

25. A fuel cartridge as in claim 22 wherein the release mechanism is a pressure-sensitive vent or a selectively permeable membrane.

26. A fuel cartridge as in claim 1 wherein the fuel outlet comprises two or more segregated concentric or coaxial tubes to enable circulation of a portion or all of the fuel stream through the cartridge and to enable exit of fuel and entrance of a gas or liquid.

27. A fuel cartridge as in claim 1 wherein the cartridge comprises a securing element to secure the cartridge against a docking station sealing surface.

28. A fuel cartridge as in claim 27 wherein the securing element is selected from a group comprising:

bayonet type lock for a cylindrical cartridge and a molded plastic end cap adhesively attachable for an aerosol can type cartridge.

29. A fuel cartridge as in claim 28 wherein the molded plastic end cap comprises an element to enable grasp and turn to selectively engage or disengage from the docking station sealing surfaces.

30. A fuel cartridge as in claim 28 wherein the bayonet lock comprises a safety element and has a high torque requirement for disengagement.

31. A fuel cartridge as in claim 28 wherein the bayonet lock is a pin and notch type arrangement wherein either the pin or the notch are located on the cartridge external surface and engage with a corresponding notch or pin on the fuel docking station sealing surface.

32. A fuel cartridge for use in a fuel delivery system in a fuel cell, the fuel cartridge comprising:

a fuel reservoir locatable within a fuel container to dispense fuel through a coupling device into a fuel feed loop of a fuel cell;

wherein the reservoir comprises a housing with an anterior wall and a posterior wall, an external surface and an internal surface, fuel outlet provided in the anterior wall and connectable to the fuel cell through the coupling device,

and wherein fuel evacuation is enabled by a capillary action element comprising a foam.

33. A fuel cartridge as in claim 32 wherein the capillary action element further comprises at least one of aero gel, porous ceramics, and porous silicon.

34. A fuel cartridge as in claim 32 wherein the foam has an open cell structure of 50% to 99% porosity, and is of a material that is hydrophilic and compatible with the fuel.

35. A fuel cartridge as in claim 32 wherein the foam is a polyurethane foam with a porosity of 60 to 80 pores per inch.

36. A fuel cartridge as in claim 32 wherein the foam is wedge shaped and is compelled into the cartridge in order to achieve graduated porosity with smaller pores near the fuel outlet.

37. A fuel cartridge as in claim 32 wherein pellets with pores smaller than the pores of the foam are inserted into the pores through the fuel outlet.

38. A fuel cartridge as in claim 32 wherein the foam is used in combination with the high vapor pressure hydrocarbon in order to achieve progressively high capillary forces towards the fuel outlet.

39. A fuel cartridge as in claim 32 wherein the foam material comprises a plurality of foam blocks of differing porosities.

40. A fuel cartridge as in claim 39 wherein each foam block nearer the fuel outlet has a smaller pore size than the previous foam block.

41. A fuel cartridge as in claim 39 wherein the foam blocks comprise foams of different porosities provided in an annular or concentric manner, the smallest-pore foam being in the center and connected to the fuel outlet.

42. A fuel cartridge as in claim 39 wherein the foam blocks comprise a conical-shaped piece of foam inserted into a flexible foam with a larger-pore-size, thereby compressing the foam pores in the flexible foam nearest the outlet.

43. A fuel cartridge for use in a fuel delivery system in a fuel cell, the fuel cartridge comprising:

a fuel reservoir locatable within a fuel container to dispense fuel through a coupling device into a fuel cell;

wherein the reservoir comprises a housing with an anterior wall and a posterior wall, an external surface and an internal surface, fuel outlet provided in the anterior wall and connectable to the fuel feed loop through the coupling device,

the housing comprising an opening towards one end and an end piece towards an end opposite the opening, the opening being provided with an interlocking element to secure the cartridge to a coupling device, the end piece being securable to the housing with a fuel compatible adhesive material or being integral therewith.

44. A fuel cartridge for use in a fuel delivery system in a fuel cell, the fuel cartridge comprising:

a fuel reservoir locatable within a fuel container to dispense fuel through a coupling device into a fuel feed loop of a fuel cell;

wherein the reservoir comprises a housing with an anterior wall and a posterior wall, an external surface and an internal surface, fuel outlet provided in the anterior wall and connectable to the fuel feed loop through the coupling device,

the reservoir being provided with discrete containers to house fuel and a propellant therein.

45. A fuel cartridge as in claim 44 wherein the reservoir comprises an aluminum container incorporating a bladder to separate a pressurized gas and the fuel.

46. A fuel cartridge as in claim 44 wherein the reservoir comprises a piston disposed to separate a pressurized gas and the fuel.

47. A fuel cartridge as in claim 44 further comprising a motion detecting element to calculate movement of the piston.

48. A fuel cartridge as in claim 44 wherein the fuel is methanol and the pressurized gas is carbon dioxide.

49. A fuel cartridge for use in a fuel delivery system in a fuel cell, the fuel cartridge comprising:

a fuel reservoir locatable within a fuel container to dispense fuel through a coupling device into a fuel feed loop of a fuel cell;

wherein the reservoir comprises a housing with an anterior wall and a posterior wall, an external surface and an internal surface, fuel outlet provided in the anterior wall and connectable to the fuel feed loop through the coupling device,

the cartridge being actuated through an opening in the wall by one or more pressure inducing elements to evacuate fuel therefrom.

50. A fuel cartridge as in claim 49 wherein the fuel is contained in bellows or a bladder and the cartridge housing being provided with one or more plates or pistons in contact with the bladder or bellows and actuatable by an actuation element in order to depress the bellows or bladder and thereby evacuate fuel through the fuel outlet of the cartridge.

51. A fuel cartridge as in claim 50 wherein the actuation element comprises one or more external springs operatively associated with the one or more plates or pistons through the one or more slots provided on the cartridge housing.

52. A fuel cartridge as in claim 50 wherein the actuation element comprises a combination of a spring and a plunger element, the plunger element being in operational contact with the plate or piston to depress the bellows or bladder and thereby evacuate fuel through the fuel outlet.

53. A fuel cartridge as in claim 50 wherein the actuation element comprises a threaded activating rod drivable by a rotating motor and screw, thereby pushing on one or more plates or pistons within the cartridge and thereby depressing the bellows thereby resulting in external mechanical pressurization.

54. A fuel cartridge as in claim 49 wherein the pressure inducing element comprises a fuel-filled bladder in the cartridge, a small external orifice provided on the cartridge and a seal therefore to press against a sealing surface of a fuel cell to provide pressurized air.

55. A fuel cartridge as in claim 49 wherein the pressure inducing element comprises one or more hydrocarbons located within the fuel to pressurize the cartridge.

56. A fuel cartridge as in claim 55 wherein the hydrocarbon is used as a mixture within the fuel, and further comprising a separation element being provided to separate the fuel and the hydrocarbon within the cartridge.

57. A fuel cartridge as in claim 55 wherein the additional hydrocarbon is stored external to a bladder containing the fuel.

58. A fuel cartridge as in claim 55 wherein the additional hydrocarbon is stored within a balloon located within the bladder containing the fuel and is used to pressurize the bladder.

59. A fuel cartridge for use in a fuel delivery system in a fuel cell, the fuel cartridge comprising:

a fuel reservoir locatable within a fuel container to dispense fuel through a coupling device into the fuel cell;

wherein the reservoir comprises a housing with an anterior wall and a posterior wall, an external surface and an internal surface, a fuel outlet provided in the anterior wall and connectable to the fuel cell through the coupling device, a fluid inlet connectable to a fluid pressurizing element.

60. A fuel cartridge as in claim 59, further comprising a bladder enveloping fuel and wherein a pressurizing fluid is introduced between the bladder and the internal surface of the fuel reservoir through the fluid inlet.

61. A fuel cartridge as in claim 59, wherein the fluid inlet comprises a plug within one of the anterior and posterior walls of the reservoir.

62. A fuel cartridge as in claim 59, further comprising a plug within the posterior wall of the reservoir and a piston disposed between the plug and the fuel outlet.

63. A fuel cartridge as in claim 62, further comprising a position sensor for monitoring movement of the piston.

64. A fuel cartridge as in claim 63, further comprising a processor coupled to the position sensor for estimating an amount of fuel within the processor based on a position of the piston.

65. An apparatus comprising:

a housing forming a fuel reservoir; and

a spring activated valve that releases fuel within the fuel reservoir in a first position and maintains fuel within the fuel reservoir in a second position, wherein the spring activated valve includes a biasing element for maintaining the valve in the second position and a receiving portion for engaging an external member to oppose the biasing element and cause the valve to shift to the first position when the fuel container is coupled to a fuel cell.

66. A fuel cartridge comprising:

a housing configured to couple to a fuel cell;

an orifice in the housing;

an inlet in the orifice for receiving fuel from a fuel source; and

an outlet segregated from the inlet in the orifice for delivering fuel to a fuel cell.