# US 8,541,078 B2 · Fuel supplies for fuel cells

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- Number: US 8,541,078 B2
- Document ID: US8541078B2
- Status: Granted
- Kind: B2
- Application number: 10/913,715
- Filed: 2004-08-06
- Published: 2006-02-09
- Granted: 2013-09-24
- Earliest claimed: 2004-08-06
- Assignees: Societe BIC
- Applicants: Paul Adams; Andrew J. Curello; Floyd Fairbanks; Alain Rosenzweig
- Inventors: Paul Adams; Andrew J. Curello; Floyd Fairbanks; Alain Rosenzweig
- Web page: https://patentgrep.com/patent/US8541078B2

## CPC

- H01M 8/04201: {Reactant storage and supply, e.g. means for feeding, pipes}
- H01M 8/04208: {Cartridges, cryogenic media or cryogenic reservoirs}
- Y02E 60/50: Fuel cells
- Y02P 70/50: Manufacturing or production processes characterised by the final manufactured product
- Y10T 428/1352: Polymer or resin containing [i.e., natural or synthetic]
- Y10T 428/1372: Randomly noninterengaged or randomly contacting fibers, filaments, particles, or flakes
- Y10T 428/1376: Foam or porous material containing
- Y10T 428/1379: Contains vapor or gas barrier, polymer derived from vinyl chloride or vinylidene chloride, or polymer containing a vinyl alcohol unit
- Y10T 428/1383: Vapor or gas barrier, polymer derived from vinyl chloride or vinylidene chloride, or polymer containing a vinyl alcohol unit is sandwiched between layers [continuous layer]
- Y10T 428/1386: Natural or synthetic rubber or rubber-like compound containing
- Y10T 428/139: Open-ended, self-supporting conduit, cylinder, or tube-type article
- H01M: PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- Y02E: REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

Fuel cartridges for fuel cells are disclosed. One fuel cartridge has an outer casing, an inner liner containing fuel, and a valve component adapted to transport fuel from the fuel supply to a fuel cell. The outer casing and the inner liner are made by blow molding and as the fuel is transported from the fuel supply, the inner liner pulls away from the outer casing. Another fuel cartridge includes an outer casing, an inner liner containing fuel, and a valve component adapted to transport fuel from the fuel supply to a fuel cell. The inner liner is integral to the outer casing at a region proximate to the location of the valve component. The inner liner and/or the outer casing can be fluorinated, coated with a barrier material or wrapped with a barrier film to reduce vapor permeation.

## Claims

### Claim 1

A fuel supply for a fuel cell comprising:
an outer casing,
a collapsible inner liner containing liquid fuel, and
a valve component adapted to transport fuel from the fuel supply to a fuel cell, wherein the outer casing and the inner liner comprise polymers that are incompatible to each other, wherein incompatible polymers do not adhere to each other in their molten state and wherein as the fuel is transported from the fuel supply to the fuel cell, the inner liner at least partially collapses, wherein one of the outer casing and inner liner comprises a polar resin and the other one of the outer casing and inner liner comprises a non-polar resin.

### Claim 2 (depends on 1)

The fuel supply of claim 1, wherein the polar resins comprise acrylonitrile butadiene styrene, thermoplastic polyesters, polycarbonates, polyvinyl chloride, polyamides, polyarylene ethers, or thermoplastic polyurethanes.

### Claim 3 (depends on 2)

The fuel supply of claim 2, wherein the thermoplastic polyesters comprise polyethylene terephthalate (PET).

### Claim 4 (depends on 2)

The fuel supply of claim 2, wherein the polyamides comprise nylon, polysulfones or polyarylene sulfides.

### Claim 5 (depends on 2)

The fuel supply of claim 2, wherein the polyarylene ethers comprise polyphenylene oxide, polyether ketones, polyetherether ketones, acetate, or acrylic-polyvinyl chloride copolymer.

### Claim 6 (depends on 1)

The fuel supply of claim 1, wherein the non-polar resins comprise high density polyethylene (HDPE), polypropylene or polystyrene.

### Claim 7

A fuel supply for a fuel cell comprising:
an outer casing,
a collapsible inner liner containing liquid fuel, and
a valve component adapted to transport fuel from the fuel supply to a fuel cell, wherein the outer casing and the inner liner comprise polymers that are incompatible to each other, wherein incompatible polymers do not adhere to each other in their molten state and wherein as the fuel is transported from the fuel supply to the fuel cell, the inner liner at least partially collapses, wherein one of the polymers is a thermoplastic elastomer.

### Claim 8 (depends on 7)

The fuel supply of claim 7, wherein the thermoplastic elastomer comprises butyl rubber.

### Claim 9 (depends on 8)

The fuel supply of claim 8, wherein the inner liner comprises butyl rubber.

### Claim 10 (depends on 7)

The fuel supply of claim 7, wherein the other polymer comprises acetal.

### Claim 11 (depends on 7)

The fuel supply of claim 7, wherein the other polymer comprises polyvinylchloride.

### Claim 12

A fuel supply for a fuel cell comprising:
an outer casing,
a collapsible inner liner containing liquid fuel, and
a valve component adapted to transport fuel from the fuel supply to a fuel cell, wherein the outer casing and the inner liner comprise polymers that are incompatible to each other, wherein incompatible polymers do not adhere to each other in their molten state and wherein as the fuel is transported from the fuel supply to the fuel cell, the inner liner at least partially collapses, wherein at least one of the outer casing and inner liner comprises polyethylene, and wherein the other one of the outer casing and inner liner comprises a slip agent.

### Claim 13 (depends on 12)

The fuel supply of claim 12, wherein the slip agent comprises a long chain fatty acid amide.

### Claim 14 (depends on 13)

The fuel supply of claim 13, wherein the long chain fatty acid amide is oleamide.

### Claim 15 (depends on 13)

The fuel supply of claim 13, wherein the long chain fatty acid amide is erucamide.

### Claim 16

A fuel supply for a fuel cell comprising:
an outer casing,
a collapsible inner liner containing liquid fuel, and
a valve component adapted to transport fuel from the fuel supply to a fuel cell, wherein the outer casing and the inner liner comprise polymers that are incompatible to each other, wherein incompatible polymers do not adhere to each other in their molten state and wherein as the fuel is transported from the fuel supply to the fuel cell, the inner liner at least partially collapses, wherein at least one of the outer casing and inner liner comprises hydrophilic filler.

### Claim 17 (depends on 16)

The fuel supply of claim 16, wherein the hydrophilic filler is talc.

### Claim 18 (depends on 16)

The fuel supply of claim 16, wherein the hydrophilic filler is calcium carbonate.

### Claim 19

A fuel supply for a fuel cell comprising:
an outer casing,
a collapsible inner liner containing liquid fuel, and
a valve component adapted to transport fuel from the fuel supply to a fuel cell, wherein the outer casing and the inner liner comprise polymers that are incompatible to each other, wherein incompatible polymers do not adhere to each other in their molten state and wherein as the fuel is transported from the fuel supply to the fuel cell, the inner liner at least partially collapses, wherein the fuel supply further comprises an intermediate layer disposed between the outer casing and the inner liner wherein the intermediate layer is incompatible with at least one of the outer casing or inner liner.

### Claim 20 (depends on 19)

The fuel supply of claim 19, wherein the intermediate layer is made from a wax.

### Claim 21 (depends on 20)

The fuel supply of claim 20, wherein the wax comprises paraffin wax, microcrystalline wax or synthetic wax.

### Claim 22

A fuel supply for a fuel cell comprising:
an outer casing,
a collapsible inner liner containing liquid fuel, and
a valve component adapted to transport fuel from the fuel supply to a fuel cell, wherein the outer casing and the inner liner comprise polymers that are incompatible to each other, wherein incompatible polymers do not adhere to each other in their molten state and wherein as the fuel is transported from the fuel supply to the fuel cell, the inner liner at least partially collapses, wherein the outer casing and the inner liner comprise sequentially blow molded outer casing and inner liner, wherein the fuel supply further comprises an intermediate layer disposed between the outer casing and the inner liner wherein the intermediate layer is incompatible with at least one of the outer casing or inner liner, and intermediate layer comprises a blow molded layer.

### Claim 23 (depends on 22)

The fuel supply of claim 22, wherein the intermediate layer is made from a wax.

### Claim 24 (depends on 23)

The fuel supply of claim 23, wherein the wax comprises paraffin wax, microcrystalline wax or synthetic wax.

### Claim 25

A fuel supply for a fuel cell comprising:
an outer casing,
a collapsible inner liner containing liquid fuel, and
a valve component adapted to transport fuel from the fuel supply to a fuel cell, wherein the outer casing and the inner liner comprise polymers that are incompatible to each other, wherein incompatible polymers do not adhere to each other in their molten state and wherein as the fuel is transported from the fuel supply to the fuel cell, the inner liner at least partially collapses, wherein at least one of the outer casing or inner liner is coated with a gas barrier material.

### Claim 26

A fuel supply for a fuel cell comprising:
an outer casing,
a collapsible inner liner containing liquid fuel, and
a valve component adapted to transport fuel from the fuel supply to a fuel cell, wherein the outer casing and the inner liner comprise polymers that are incompatible to each other, wherein incompatible polymers do not adhere to each other in their molten state and wherein as the fuel is transported from the fuel supply to the fuel cell, the inner liner at least partially collapses, wherein at least one of the outer casing or inner liner is wrapped with a gas barrier film.

### Claim 27

A fuel supply for a fuel cell comprising:
an outer casing,
a collapsible inner liner containing liquid fuel, and
a valve component adapted to transport fuel from the fuel supply to a fuel cell,
wherein the inner liner and the outer casing merge together and become substantially one integral mass at a region proximate to the location of the valve component and wherein as the fuel is transported from the fuel supply to the fuel cell, the inner liner at least partially collapses.

### Claim 28 (depends on 27)

The fuel supply of claim 27, wherein the outer casing comprises a blow molded outer casing and the inner liner comprises a blow molded inner liner.

### Claim 29 (depends on 28)

The fuel supply of claim 28, wherein the outer casing and the inner liner are co-extruded, blow molded outer casing and inner liner.

### Claim 30 (depends on 28)

The fuel supply of claim 28, wherein the outer casing and the inner liner comprise sequentially blow molded outer casing and inner liner.

### Claim 31

A fuel supply for a fuel cell comprising:
an outer casing,
a collapsible inner liner containing liquid fuel, and
a valve component adapted to transport fuel from the fuel supply to a fuel cell, wherein the inner liner and the outer casing merge together and become substantially one integral mass at a region proximate to the location of the valve component and wherein as the fuel is transported from the fuel supply to the fuel cell, the inner liner at least partially collapses,
wherein the outer casing comprises a blow molded outer casing and the inner liner comprises a blow molded inner liner,
wherein the outer casing and the inner liner comprise sequentially blow molded outer casing and inner liner, and
wherein the outer casing and the inner liner are made from the same polymer.

### Claim 32

A fuel supply for a fuel cell comprising:
an outer casing,
a collapsible inner liner containing liquid fuel, and
a valve component adapted to transport fuel from the fuel supply to a fuel cell, wherein the inner liner and the outer casing merge together and become substantially one integral mass at a region proximate to the location of the valve component and wherein as the fuel is transported from the fuel supply to the fuel cell, the inner liner at least partially collapses,
wherein the outer casing comprises a blow molded outer casing and the inner liner comprises a blow molded inner liner,
wherein the outer casing and the inner liner comprise sequentially blow molded outer casing and inner liner, and
wherein the outer casing and the inner liner are made from polar polymers.

### Claim 33

A fuel supply for a fuel cell comprising:
an outer casing,
a collapsible inner liner containing liquid fuel, and
a valve component adapted to transport fuel from the fuel supply to a fuel cell, wherein the inner liner and the outer casing merge together and become substantially one integral mass at a region proximate to the location of the valve component and wherein as the fuel is transported from the fuel supply to the fuel cell, the inner liner at least partially collapses,
wherein the outer casing comprises a blow molded outer casing and the inner liner comprises a blow molded inner liner,
wherein the outer casing and the inner liner comprise sequentially blow molded outer casing and inner liner, and
wherein the outer casing and the inner liner are made from non-polar polymers.

### Claim 34 (depends on 27)

The fuel supply of claim 27, wherein at least one of the outer casing or inner liner is coated with a gas barrier material.

### Claim 35

A fuel supply for a fuel cell comprising:
an outer casing,
a collapsible inner liner containing liquid fuel, and
a valve component adapted to transport fuel from the fuel supply to a fuel cell, wherein the inner liner and the outer casing merge together and become substantially one integral mass at a region proximate to the location of the valve component and wherein as the fuel is transported from the fuel supply to the fuel cell, the inner liner at least partially collapses,
wherein at least one of the outer casing or inner liner is coated with a gas barrier material wherein the barrier material comprises epoxy-amine.

### Claim 36

A fuel supply for a fuel cell comprising
an enclosed outer casing,
a collapsible inner liner containing liquid fuel disposed inside the enclosed outer casing, and
a valve component adapted to transport fuel from the fuel supply to the fuel cell adapted to provide electricity for an electronic device,
wherein as the fuel is transported from the fuel supply to the fuel cell, the inner liner at least partially collapses and wherein the inner liner has a volume capacity higher than that of the outer casing and wherein the inner liner has at least one fold formed thereon, wherein at least one of the outer casing or inner liner is wrapped with a gas barrier film.

### Claim 37

A fuel supply for a fuel cell comprising
an enclosed outer casing,
a collapsible inner liner containing liquid fuel disposed inside the enclosed outer casing, and
a valve component adapted to transport fuel from the fuel supply to the fuel cell adapted to provide electricity for an electronic device.,
wherein as the fuel is transported from the fuel supply to the fuel cell, the inner liner at least partially collapses and wherein the inner liner has a volume capacity higher than that of the outer casing and wherein the inner liner has at least one fold formed thereon, wherein at least one of the outer casing or inner liner is fluorinated.

### Claim 38 (depends on 37)

The fuel supply of claim 37, wherein said at least one of the outer casing or inner liner is made from a polymer containing at least one antioxidant.

### Claim 39

A fuel supply for a fuel cell comprising
an enclosed outer casing,
a collapsible inner liner containing liquid fuel disposed inside the enclosed outer casing, and
a valve component adapted to transport fuel from the fuel supply to the fuel cell adapted to provide electricity for an electronic device,
wherein as the fuel is transported from the fuel supply to the fuel cell, the inner liner at least partially collapses and wherein the inner liner has a volume capacity higher than that of the outer casing and wherein the inner liner has at least one fold formed thereon, wherein at least one of the outer casing or inner liner is made from a polymer containing at least one antioxidant.

### Claim 40

A fuel supply for a fuel cell comprising
an outer casing,
a collapsible inner liner containing liquid fuel, and
a valve component adapted to transport fuel from the fuel supply to the fuel cell adapted to provide electricity for an electronic device, and
a non-metallic coating on an outermost surface of at least one of the outer casing or inner liner to increase its vapor barrier and wherein as the fuel is transported from the fuel supply to the fuel cell, the inner liner at least partially collapses wherein the non-metallic coating comprises a gas barrier coating, wherein the gas barrier coating comprises epoxy-amine.

### Claim 41

A fuel supply for a fuel cell comprising
an outer casing,
a collapsible inner liner containing liquid fuel, and
a valve component adapted to transport fuel from the fuel supply to the fuel cell adapted to provide electricity for an electronic device, and
a non-metallic coating on an outermost surface of at least one of the outer casing or inner liner to increase its vapor barrier and wherein as the fuel is transported from the fuel supply to the fuel cell, the inner liner at least partially collapses wherein the non-metallic coating comprises a gas barrier coating, wherein the gas barrier coating comprises silicone oxide.

### Claim 42

A fuel supply for a fuel cell comprising
an outer casing,
a collapsible inner liner containing liquid fuel, and
a valve component adapted to transport fuel from the fuel supply to the fuel cell adapted to provide electricity for an electronic device, and
a non-metallic coating on an outermost surface of at least one of the outer casing or inner liner to increase its vapor barrier and wherein as the fuel is transported from the fuel supply to the fuel cell, the inner liner at least partially collapses wherein the non-metallic coating comprises a gas barrier coating, wherein the gas barrier coating comprises a material selected from a group consisting of a substantially ungelled resin or reaction product formed from reacting an epoxy functional polyester with an amine, a carboxylated amide polymers and a water based coating composition prepared by dissolving or dispersing in aqueous medium and at least a partially neutralized reaction product of a polyepoxide and an amino acid.

### Claim 43

A fuel supply for a fuel cell comprising
an outer casing,
a collapsible inner liner containing liquid fuel, and
a valve component adapted to transport fuel from the fuel supply to the fuel cell adapted to provide electricity for an electronic device, and
a non-metallic coating on an outermost surface of at least one of the outer casing or inner liner to increase its vapor barrier and wherein as the fuel is transported from the fuel supply to the fuel cell, the inner liner at least partially collapses wherein the non-metallic coating comprises a gas barrier coating, wherein the gas barrier coating comprises xylylene.

### Claim 44 (depends on 43)

The fuel supply of claim 43, wherein the xylylene comprises poly-monochloro-para-xylylene.

### Claim 45 (depends on 43)

The fuel supply of claim 43, wherein the xylylene comprises poly-para-xylylene.

### Claim 46 (depends on 43)

The fuel supply of claim 43, wherein the xylylene comprises poly-dichloro-para-xylylene.

### Claim 47

A fuel supply for a fuel cell comprising
an outer casing,
a collapsible inner liner containing liquid fuel, and
a valve component adapted to transport fuel from the fuel supply to the fuel cell adapted to provide electricity for an electronic device, and
a non-metallic coating on an outermost surface of at least one of the outer casing or inner liner to increase its vapor barrier and wherein as the fuel is transported from the fuel supply to the fuel cell, the inner liner at least partially collapses wherein the non-metallic coating comprises a gas barrier film wrapped around at least one of the outer casing or inner liner.

### Claim 48 (depends on 47)

The fuel supply of claim 47, wherein the gas barrier film comprises polyethylene teraphthalate.

### Claim 49 (depends on 48)

The fuel supply of claim 48, wherein the polyethylene teraphthalate is coated with apolyvinylidene chloride copolymer.

### Claim 50 (depends on 48)

The fuel supply of claim 48, wherein the polyethylene teraphthalate is coated with silicone dioxide.

### Claim 51 (depends on 48)

The fuel supply of claim 48, wherein the polyethylene teraphthalate forms a part of a laminate.

### Claim 52 (depends on 47)

The fuel supply of claim 47, wherein the gas barrier film's vapor transmission rate is substantially the same as that of polyurethane or lower.

### Claim 53 (depends on 52)

The fuel supply of claim 52, wherein the gas barrier film's vapor transmission rate is lower than that of polyurethane.

### Claim 54 (depends on 47)

The fuel supply of claim 47, wherein the gas barrier film is selected from a group consisting of polyvinyl alcohol (PVOH), ethylene vinyl alcohol (EVOH), EVOH bonded to a polyester substrate, polyvinylidene chloride copolymers (PVDC or Saran), nylon resins, fluoro-polymers, polyacrylonitrile (PAN), polyethylene naphthalate (PEN), poly(trimethlylene terephthalate) (PTT), resorcinol copolymers, liquid crystal polymers, aliphatic polyketones (PK), and blends and copolymers of these materials.

### Claim 55

A fuel supply for a fuel cell comprising
an outer casing,
a collapsible inner liner containing liquid fuel, and
a valve component adapted to transport fuel from the fuel supply to the fuel cell adapted to provide electricity for an electronic device, wherein the at least one of the outer casing or inner liner contains at least one antioxidant to increase its vapor barrier and wherein as the fuel is transported from the fuel supply to the fuel cell, the inner liner at least partially collapses.

### Claim 56 (depends on 55)

The fuel supply of claim 55, wherein the antioxidant comprises a quinoline type antioxidant.

### Claim 57 (depends on 55)

The fuel supply of claim 55, wherein the antioxidant comprises an amine type antioxidant.

### Claim 58 (depends on 55)

The fuel supply of claim 55, wherein the antioxidant comprises a phenolic type antioxidant.

### Claim 59 (depends on 55)

The fuel supply of claim 55, wherein the antioxidant comprises a phosphite type antioxidant.

### Claim 60 (depends on 55)

The fuel supply of claim 55, wherein the at least one of the outer casing or inner liner comprises a fluorinated polymer.