Stationary cartridge based fuel cell system, fuel cell power supply system, and method of activating the fuel cell

Description

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention is further described in the detailed description which follows, in reference to the noted plurality of drawings by way of non-limiting examples of exemplary embodiments of the present invention, in which like reference numerals represent similar parts throughout the several views of the drawings, and wherein:

FIG. 1 schematically shows a first embodiment of a power system which includes a fuel cell, a cartridge, a system for connecting the cartridge to the fuel cell, and a frame system for supporting these components;

FIG. 2 schematically shows the first embodiment of FIG. 1 after the cartridge has been connected to the fuel cell with the system for connecting the cartridge to the fuel cell;

FIG. 3 schematically shows the frame system and connecting system of the first embodiment of FIG. 1 with the cartridge and fuel cell removed;

FIG. 4 schematically shows the fuel cell used in the first embodiment of FIG. 1;

FIG. 5 schematically shows the cartridge used in the first embodiment of FIG. 1;

FIG. 6 schematically shows a second embodiment of a power system which includes a fuel cell, a cartridge, a system for connecting the cartridge to the fuel cell, and a frame system for supporting these devices;

FIG. 7 schematically shows a third embodiment of a power system which includes a fuel cell, a cartridge, a system for connecting the cartridge to the fuel cell, and a frame system for supporting these components;

FIG. 8 schematically shows a fourth embodiment of a power system which includes a fuel cell, a cartridge, a system for connecting the cartridge to the fuel cell, and an enclosure system for housing these components;

FIG. 9 schematically shows the fourth embodiment of FIG. 8 after the cartridge has been connected to the fuel cell with the system for connecting the cartridge to the fuel cell;

FIG. 10 schematically shows another embodiment of a fuel cell and cartridge which can be used in the invention. The fuel cell utilizes a single anode, a single cathode, a fuel chamber, and an electrolyte chamber;

FIG. 11 schematically shows another embodiment of a fuel cell and cartridge which can be used in the invention. The fuel cell utilizes two anodes, two cathodes, a fuel chamber, and two electrolyte chambers;

FIG. 12 schematically shows another embodiment of a fuel cell which can be used in the invention. The fuel cell utilizes a cylindrical anode, a cylindrical cathode, a cylindrical fuel chamber, and an annular electrolyte chamber;

FIG. 13 schematically shows one non-limiting way in which the fuel cell of FIG. 12 can be connected with a cylindrical cartridge;

FIG. 14 schematically shows one non-limiting fuel cell opening for receiving the cartridge. The opening is square-shaped and the fuel cell utilizes two entry ports arranged at the bottom of the opening, one in fluid communication with a fuel chamber and one in fluid communication with an electrolyte chamber;

FIG. 15 schematically shows how the fuel cell opening of FIG. 14 can receive therein the cartridge. The figure shows the cartridge in an aligned position prior to being inserted into the opening;

FIG. 16 schematically shows the fuel cell opening of FIG. 14 with the cartridge installed therein;

FIG. 17 schematically shows one non-limiting way in which the fuel cell can be connected in series with other fuel cells;

FIG. 18 schematically shows another non-limiting way in which the fuel cell can be connected in parallel with other fuel cells;

FIG. 19 schematically shows one non-limiting way in which a number of fuel cells can be connected in series and in parallel with other fuel cells;

FIG. 20 schematically shows one non-limiting way in which the power system of the invention can be connected to an exemplary load such as a cell tower;

FIG. 21 schematically shows one non-limiting embodiment of a cartridge. The cartridge is shown in cross-section and utilizes two chambers separated by a horizontal puncturable thin or membrane wall as well as a puncturable thin or membrane cap. Once the membrane wall is punctured, the contents of the two chambers can start to mix with each other in the cartridge;

FIG. 22 schematically shows another non-limiting embodiment of a cartridge. The cartridge is shown in cross-section and utilizes two chambers separated by a vertical puncturable thin or membrane wall as well as a puncturable thin or membrane cap. Once the membrane wall is punctured, the contents of the two chambers can start to mix with each other in the cartridge;

FIG. 23 schematically shows another non-limiting embodiment of a cartridge. The cartridge is shown in cross-section and utilizes two chambers separated by a diagonal puncturable thin or membrane wall as well as a puncturable thin or membrane cap. Once the membrane wall is punctured, the contents of the two chambers can start to mix with each other in the cartridge;

FIG. 24
a schematically shows another non-limiting embodiment of a cartridge. The cartridge is shown in cross-section and utilizes two chambers. One of the chambers is located within a puncturable thin or membrane bag while the other chamber constitutes the volume of the cartridge outside of the bag. The cartridge also utilizes a puncturable thin or membrane cap. Once the membrane bag is punctured, the contents of the two chambers can start to mix with each other in the cartridge;

FIG. 25 schematically shows another non-limiting embodiment of a cartridge. The cartridge is shown in cross-section and utilizes one chamber arranged within a housing which has a variable volume. The cartridge also utilizes a puncturable thin or membrane cap;

FIG. 24
b schematically shows another non-limiting embodiment of a cartridge. The cartridge is shown in cross-section and utilizes two chambers. Each of the chambers is located within a puncturable thin or membrane bag. The cartridge also utilizes a puncturable thin or membrane cap. Once the membrane bags are punctured, the contents of the two chambers can start to mix with each other in the cartridge;

FIG. 26 schematically shows one non-limiting way in which a cartridge can be connected with a fuel cell such that the connection causes the membrane cap of the cartridge to be punctured;

FIG. 27 schematically shows the cartridge and fuel cell of FIG. 26 after the cartridge is connected to the fuel cell and illustrates the membrane cap of the cartridge being punctured;

FIG. 28 schematically shows another non-limiting way in which a cartridge can be connected with a fuel cell such that the connection causes both the membrane cap and the membrane wall of the cartridge to be punctured;

FIG. 29 schematically shows the cartridge and fuel cell of FIG. 28 after the cartridge is connected to the fuel cell;

FIG. 30 schematically shows another non-limiting way in which a cartridge can be connected with a fuel cell such that the connection causes both the membrane cap and the membrane wall of the cartridge to be punctured. In this embodiment, the cartridge contains a solvent and a paste. The cartridge and fuel cell each also utilize a sealing member;

FIG. 31 schematically shows the cartridge and fuel cell of FIG. 30 as the cartridge is moved towards a fully connected state with the fuel cell;

FIG. 32 schematically shows the cartridge and fuel cell of FIG. 30 after the cartridge is fully connected with the fuel cell;

FIG. 33 schematically shows another non-limiting way in which a cartridge can be connected with a fuel cell such that the connection causes both the membrane cap and the membrane wall of the cartridge to be punctured. In this embodiment, the cartridge contains a solvent and a paste. The cartridge and fuel cell each also utilize a sealing member;

FIG. 34 schematically shows the cartridge and fuel cell of FIG. 33 as the cartridge is moved towards a fully connected state with the fuel cell;

FIG. 35 schematically shows the cartridge and fuel cell of FIG. 33 after the cartridge is fully connected with the fuel cell;

FIG. 36 shows one non-limiting port/valve configuration for placing one or more of the chambers of the cartridge into fluid connection with one or more ports of the fuel cell;

FIG. 37 shows a first spring and plunger valve which is utilized in the fuel cell valve/port;

FIG. 38 shows a second spring and ball valve which is utilized in the cartridge valve/port;

FIG. 39 shows a partial view of the two valves/ports in an assembled state prior to being connected to each other;

FIG. 40 shows a partial view of the two valves/ports in a connected state and in a state which allows for fluid communication between the cartridge and fuel cell;

FIG. 41 shows a partial view of another valve/port embodiment wherein the outer portions of the valve sleeves are arranged adjacent to one another;

FIG. 42 shows a first spring and plunger valve which is utilized in the fuel cell valve;

FIG. 43 shows side cross-sectional and front end views of a pierceable washer which is utilized in the cartridge valve;

FIG. 44 shows a partial view of the two valves in an assembled state prior to being connected to each other;

FIG. 45 shows a partial view of the two valves in a connected state and in a state which allows for fluid communication between the cartridge and fuel cell. The pierceable washer is shown in a pierced state and the plunger valve is shown in a retracted position caused by fluid pressure sufficient to overcome the biasing force of the first spring, i.e., the fluid pressure caused by the fluid being forced from the cartridge and into the fuel cell;

FIG. 46 shows a top view of a fuel cell embodiment which can be used in the power system of the invention;

FIG. 47 shows a side cross-section view of the fuel cell shown in FIG. 25. The anode and cathodes are not shown;

FIG. 48 shows a bottom view of a cartridge without the pierceable washer and sealing ring installed thereon;

FIG. 49 shows a side cross-section view of the cartridge shown in FIG. 48. The pierceable washer and sealing ring are shown in an uninstalled state;

FIG. 50 shows a side cross-section view of the cartridge shown in FIGS. 48 and 49, and the disposable fuel cell shown in FIGS. 46 and 47. The cartridge contains the fuel component(s) and the sealing ring and the pierceable washer are shown in an installed state. The cartridge is arranged in an aligned position prior to being connected to the fuel cell;

FIG. 51 shows a side cross-section view of the cartridge and fuel cell shown in FIG. 50 in a non-removably fully connected state. The cartridge is shown with its pierceable washers being pierced by the piercing members of the fuel cell;

FIG. 52 shows a side cross-section view of the cartridge and fuel cell shown in FIG. 51. The pistons of the cartridge are shown in a lowermost position after having moved automatically under the influence of the springs. The fuel component(s) of the cartridge has been transferred to the fuel cell;

FIG. 53 shows a side cross-section view of another cartridge and fuel cell system in a fully non-removably connected state. This embodiment is similar to the embodiment shown in FIGS. 46-52 except that it includes flexible variable-volume chambers in the cartridge;

FIG. 54 shows an enlarged partial view of FIG. 53;

FIG. 55 shows a side cross-section view of another cartridge and fuel cell system in a fully non-removably connected state. This embodiment is similar to the embodiment shown in FIGS. 46-52 except that it utilizes a mechanical piston actuation system in place of the springs and except that it utilizes one-way cartridge valves in place of piercing washers;

FIG. 56 shows an enlarged partial view of FIG. 55;

FIG. 57 shows an enlarged partial view of an alternative fuel port/cartridge port connection. The connection utilizes two O-rings and the pierceable washer;

FIG. 58 shows a side cross-section view of another cartridge and fuel cell system in a fully connected state. This embodiment uses a valve system to connect the cartridge to the fuel cell and a control system to control the valve system;

FIG. 59 shows a schematic side cross-section view of a cartridge-free fuel cell with separating devices and a activation device combination; and

FIG. 60 shows a schematic side cross-section view of another cartridge-free fuel cell with separating devices and two activation devices. This fuel cell has an opening in the fuel chamber which makes it possible to introduce a fuel component that is not yet contained in the fuel chamber.

DETAILED DESCRIPTION OF THE PRESENT INVENTION

The particulars shown herein are by way of example and for purposes of illustrative discussion of the embodiments of the present invention only and are presented in the cause of providing what is believed to be the most useful and readily understood description of the principles and conceptual aspects of the present invention. In this regard, no attempt is made to show structural details of the present invention in more detail than is necessary for the fundamental understanding of the present invention, the description taken with the drawings making apparent to those skilled in the art how the several forms of the present invention may be embodied in practice.

FIGS. 1-5 show a first non-limiting embodiment of a stand-alone fuel cell power system PS. The power system PS utilizes fuel cell FC and cartridge C arrangement and/or system. The fuel cell FC includes an outer housing which can be generally rectangular in shape. Of course, the fuel cell FC can have any other desired shape including, but not limited to polygonal, linear, oval, round, and/or curvilinear shapes. A plurality of wires W can have one end connected directly to the housing of the fuel cell FC or alternatively to a bus bar (not shown) which itself is electrically connected to the fuel cell FC. The bus bar or fuel cell FC can then be connected to a main bus bar or power circuit which feeds the source (e.g., a cell phone tower) electrical power for operation. As is shown in FIG. 1, the cartridge C is arranged above the fuel cell FC in a position which will allow the cartridge C to be correctly positioned within and/or mounted to the fuel cell FC at a desired time. Since the cartridge C contains certain active ingredients (e.g., fuel or fuel concentrate and optionally electrolyte) which the fuel cell FC needs to begin producing electrical power, until the cartridge C is mated with the fuel cell FC and until the contents of the cartridge C are transferred to the proper chambers of the fuel cell FC, the fuel cell FC does not produce power and provides an open circuit to wires W. When it is desired to place the fuel cell FC into operation, the cartridge C can be lowered into position within and/or on the fuel cell FC such that the contents of the cartridge C are safely and properly transferred to the fuel cell FC.

According to the non-limiting embodiment of FIGS. 1-5, the cartridge C is mounted to a guiding arrangement GA which ensures that the cartridge C is correctly aligned with the desired mating configuration of the fuel cell FC. In this way, when it is desired to connect the cartridge C to the fuel cell FC, the guiding arrangement GA ensures that the port(s) (which will be described in detail later on) of the cartridge C are properly mated with the port(s) of the fuel cell FC. In this regard, the guiding arrangement GA can ensure that the cartridge C has the correct rotational position as well as the correct vertical and horizontal position when the cartridge C is moved from the position shown in FIG. 1 to the final or connected position shown in FIG. 2. The guiding arrangement GA is coupled to a connecting system CS which is configured to cause the cartridge C to be connected to the fuel cell FC at a desired point in time and/or under certain desired predetermined conditions.

According to the non-limiting embodiment of FIGS. 1-5, the connecting system CS utilizes a piston P which is connected to a piston rod PR and which is slidably and sealingly engaged with a cylinder CY. A biasing member BM can optionally be utilized to bias the guiding arrangement GA downward towards a connected position. A venting system VS is used to cause the guiding arrangement GA to move downwards thereby ensuring that the cartridge C is properly connected to the fuel cell FC. The venting system VS can function as follows: until the venting system VS is opened, the fluid medium (e.g., air, liquid, or other flowable materials) located in the cylinder CY underneath the piston P prevents the piston P (and also the guiding arrangement GA and the cartridge C) from moving downwards. However, when opened, the medium can flow out of the cylinder CY and the venting system VS owing to the force of gravity (due mainly to the weight of the cartridge C) and/or under the biasing force of the biasing member BM. This allows the piston P to descend downwards within the cylinder CY. Because the guiding arrangement GA and the cartridge C are connected to the piston P, e.g., via the piston rod PR, the guiding arrangement GA and the cartridge C also descend downwards. Once venting is started, the cartridge C will descend until it becomes connected to the fuel cell FC. As will be described later on, once the cartridge C fully mates with the fuel cell FC, the contents of the cartridge C can automatically transfer to the fuel cell FC.

In the embodiment of FIGS. 1-5, the fuel cell FC and the cartridge C are arranged on a frame system FS which can be removably statically mounted to a particular location (e.g., within a portion of the cell tower). The frame system FS utilizes a base member BM which supports the fuel cell FC and which can include stops (not shown) which ensure that the fuel cell FC is correctly located below the cartridge C. The frame system FS also utilizes a vertical member VM which supports a support member SM. The support member SM supports the connecting system CS. It is preferred that the system shown in FIG. 1 be installed as a modular unit. This way, the system PS can function, when activated, to the point when the fuel cell FC has substantially exhausted of its power capabilities (or reaches the point where the voltage and/or current drop to a predetermined point) and/or is utilized a single time. Then, the unit can be sent back to, e.g., the manufacturer, for possible refurbishment. A new unit can then be installed in place of the used unit.

According to one aspect of the invention, the fuel cell system PS of FIGS. 1-5 is a stand-alone, stationary unit, which can generate from the 10s of watts to the 1,000s of watts. The fuel cell FC preferably incorporates one or more of the components and technologies which are described, e.g., in U.S. Pat. Nos. 6,554,877, 6,758,871 and 7,004,207 and in pending U.S. Patent Application Nos. US2002/0076602 A1, US2002/0142196 A1, 2003/0099876 A1, Ser. No. 10/757,849 (US2005/0155279 A1), Ser. No. 10/758,081 (US2005/0155668 A1), Ser. No. 10/634,806 (US2005/0058882 A1), Ser. No. 10/758,080 (US2005/0158609 A1), Ser. No. 10/803,900 (US2005/0206342 A1), Ser. No. 10/824,443 (US2005/0233190 A1), Ser. No. 10/796,305 (US2004/0241521 A1), Ser. No. 10/849,503 (US2005/0260481 A1), Ser. No. 11/132,203 (US2006/0047983 A1), Ser. No. 10/959,763 (US2006/0078783 A1), Ser. No. 10/941,020 (US2006/0057435 A1), Ser. No. 11/226,222 (US2006/0057437 A1), Ser. Nos. 11/384,364, 11/384,365, 11/325,466, 11/325,326 and 60/781,340. The power system PS is also more preferably a high powered fuel cell system for portable, auxiliary and remote power requirements. Preferably, the fuel cell system PS has a target power output of between approximately 20 watts to approximately 5000 watts for a limited use time of between approximately 1 hour and approximately 500 hours.

FIG. 6 shows a second non-limiting embodiment of a stand-alone fuel cell power system PS′. As in the previous embodiment, the power system PS′ utilizes a fuel cell FC and cartridge C arrangement. The fuel cell FC includes an outer housing which can be generally rectangular in shape. Of course, the fuel cell FC can have any other desired shape including, but not limited to polygonal, linear, oval, round, and/or curvilinear shapes. A plurality of wires W can have one end connected directly to the housing of the fuel cell FC or alternatively to a bus bar (not shown) which itself is electrically connected to the fuel cell FC. The bus bar or fuel cell FC can then be connected to a main bus bar or power circuit which feeds the source (e.g., a cell phone tower) electrical power for operation. As is shown in FIG. 6, the cartridge C is arranged above the fuel cell FC in a position which will allow the cartridge C to be correctly positioned within and/or mounted to the fuel cell FC at a desired time. Since the cartridge C contains certain active ingredients (e.g., fuel or fuel concentrate and optionally electrolyte) which the fuel cell FC needs to begin producing electrical power, until the cartridge C is mated with the fuel cell FC and until the contents of the cartridge C are transferred to the proper chambers of the fuel cell FC, the fuel cell FC does not produce power and provides an open circuit to wires W. When it is desired to place the fuel cell FC into operation, the cartridge C can be lowered into position within and/or on the fuel cell FC such that the contents of the cartridge C are safely and properly transferred to the fuel cell FC.

According to the non-limiting embodiment of FIG. 6, the cartridge C is mounted to a guiding arrangement GA′ which ensures that the cartridge C is correctly aligned with the desired mating configuration of the fuel cell FC. In this way, when it is desired to connect the cartridge C to the fuel cell FC, the guiding arrangement GA′ ensures that the port(s) (which will be described in detail later on) of the cartridge C are properly mated with the port(s) of the fuel cell FC. In this regard, the guiding arrangement GA′ can ensure that the cartridge C has the correct rotational position as well as the correct vertical and horizontal position when the cartridge C is moved from the position shown in FIG. 6 to the final or connected position (not shown). The guiding arrangement GA is coupled to a connecting system CS′ which is configured to cause the cartridge C to be connected to the fuel cell FC at a desired point in time and/or under certain desired predetermined conditions.

According to the non-limiting embodiment of FIG. 6, the connecting system CS′ utilizes a pneumatic or hydraulic piston/cylinder unit HC which is in fluid connection (e.g., via one or more conduits) to a pneumatic or hydraulic pump HP. The pump HP can be activated by a pivotally mounted lever arrangement LA such that movement of the lever LA downwards causes the pump HP to move downward, which in turn causes the medium in the pump HP to transfer under pressure into the piston/cylinder unit HC. A biasing member BM₁can optionally be utilized to bias the guiding arrangement GA′ downward towards a connected position. To counteract the spring force of biasing mechanism BM₁and to ensure that the cartridge C is not inadvertently caused to mate with the fuel cell FC, another biasing member BM₂is arranged within the pump HP and prevents inadvertent downward movement of the piston of the pump HP. The lever arrangement LA can function as follows: until the lever arrangement LA is moved downwards, the fluid medium (e.g., air, liquid, or other flowable materials) located in the pump HP is prevented by the biasing member BM₂from moving or transferring into the unit HC. However, when moved downwards, the medium is forced out of the pump HP and into the unit HC owing to the hydraulic pressure generated within the pump HP. This transfer of fluid under pressure forces the piston of the unit HC to descend downwards within the cylinder of unit HC. Because the guiding arrangement GA′ and the cartridge C are connected to the piston, e.g., via a piston rod, the guiding arrangement GA′ and the cartridge C also descend downwards. The cartridge C should then descend until it becomes connected to the fuel cell FC. As will be described later on, once the cartridge C fully mates with the fuel cell FC, the contents of the cartridge C can automatically transfer to the fuel cell FC.

As was the case with the previous embodiment, the embodiment of FIG. 6 arranges the fuel cell FC and the cartridge C on a frame system FS which can be removably statically mounted to a particular location (e.g., within a portion of the cell tower). The frame system FS utilizes a base member BM which supports the fuel cell FC and which can include stops (not shown) which ensure that the fuel cell FC is correctly located below the cartridge C. The frame system FS also utilizes a vertical member VM which supports a support member SM. The support member SM supports the connecting system CS. It is preferred that the system shown in FIG. 6 be installed as a modular unit. This way, the system PS′ can function, when activated, to the point when the fuel cell FC has substantially exhausted of its power capabilities (or reaches the point where the voltage and/or current drop to a predetermined point) and/or is utilized a single time. Then, the unit can be sent back to, e.g., the manufacturer, for possible refurbishment. A new unit can then be installed in place of the used unit.

According to one aspect of the invention, the fuel cell system PS′ of FIG. 6 is a stand-alone, stationary unit, which can generate from the 10s of watts to the 1,000s of watts. The fuel cell FC preferably incorporates components and telchnologies which are described, e.g., in U.S. Pat. Nos. 6,554,877, 6,758,871 and 7,004,207 and in pending U.S. patent application Ser. No. 10/757,849 (US2005/0155279), Ser. No. 10/758,081 (US2005/0155668), Ser. No. 10/634,806 (US2005/0058882 A1), Ser. No. 10/758,080 (US2005/0158609 A1), Ser. No. 10/803,900 (US2005/0206342 A1) Ser. No. 10/824,443 (US2005/0233190 A1), Ser. No. 10/796,305 (US2004/0241521 A1) Ser. No. 10/849,503 (US2005/0260481 A1), Ser. No. 11/132,203 (US2006/0047983 A1), Ser. No. 10/959,763 (US2006/0078783 A1), Ser. No. 10/941,020 (US2006/0057435 A1), Ser. No. 11/226,222 (US2006/0057437 A1), US2002/0076602 A1, US2002/0142196 A1, 2003/0099876 A1, Ser. Nos. 11/384,364, 11/384,365, 11/325,466, 11/325,326 and 60/781,340. The power system PS′ is also more preferably a high powered fuel cell system for portable, auxiliary and remote power requirements. Preferably, the fuel cell system PS′ has a target power output of between approximately 20 watts to approximately 5,000 watts for a limited use time of between approximately 1 hour and approximately 500 hours.

FIG. 7 shows a third non-limiting embodiment of a stand-alone fuel cell power system PS′. As in the previous embodiment, the power system PS′ utilizes a fuel cell FC and cartridge C arrangement. The fuel cell FC includes an outer housing which can be generally rectangular in shape. Of course, the fuel cell FC can have any other desired shape including, but not limited to polygonal, linear, oval, round, and/or curvilinear shapes. A plurality of wires W can have one end connected directly to the housing of the fuel cell FC or alternatively to a bus bar (not shown) which itself is electrically connected to the fuel cell FC. The bus bar or fuel cell FC can then be connected to a main bus bar or power circuit which feeds the source (e.g., a cell phone tower) electrical power for operation. As is shown in FIG. 7, the cartridge C is arranged above the fuel cell FC in a position which will allow the cartridge C to be correctly positioned within and/or mounted to the fuel cell FC at a desired time. Since the cartridge C contains certain active ingredients (e.g., fuel or fuel concentrate and optionally electrolyte) which the fuel cell FC needs to begin producing electrical power, until the cartridge C is mated with the fuel cell FC and until the contents of the cartridge C are transferred to the proper chambers of the fuel cell FC, the fuel cell FC does not produce power and provides an open circuit to wires W. When it is desired to place the fuel cell FC into operation, the cartridge C can be lowered into a position within and/or on the fuel cell FC such that the contents of the cartridge C are safely and properly transferred to the fuel cell FC.

According to the non-limiting embodiment of FIG. 7, the cartridge C is mounted to a guiding arrangement GA″ which ensures that the cartridge C is correctly aligned with the desired mating configuration of the fuel cell FC. In this way, when it is desired to connect the cartridge C to the fuel cell FC, the guiding arrangement GA″ ensures that the port(s) (which will be described in detail later on) of the cartridge C are properly mated with the port(s) of the fuel cell FC. In this regard, the guiding arrangement GA″ can ensure that the cartridge C has the correct rotational position as well as the correct vertical and horizontal position when the cartridge C is moved from the position shown in FIG. 7 to the final or connected position (not shown). The guiding arrangement GA″ is coupled to a connecting system CS″ which is configured to cause the cartridge C to be connected to the fuel cell FC at a desired point in time and/or under certain desired predetermined conditions.

According to the non-limiting embodiment of FIG. 7, the connecting system CS″ utilizes a damping piston/cylinder unit HC′ which ensures that the cartridge C is guided downwardly at a predetermined rate of speed via. The unit HC utilizes vent openings VH₁and VH₂which allows a controlled amount of air to enter into the unit HC′. This ensures that the cartridge C is moved downwardly with a predetermined speed. The unit HC′ can be activated by a release of pin RP which, in the position shown in FIG. 7, engages flanges fixed to the support member SM and flanges fixed to the guiding arrangement GA″. When the release pin RP is pulled and/or moved out of engagement with the flanges, the guiding arrangement GA″ becomes free to move downwards, limited only by the damping provided by the unit HC′. A biasing member BM can optionally be utilized to bias the guiding arrangement GA″ downward towards a connected position. The pin RP thus prevents inadvertent downward movement of the cartridge C. The connecting system CS″ can function as follows: until the pin RP is moved out of engagement with the flanges of member SP and arrangement GA″, the piston of the unit HC′ is prevented from moving. However, when the pin RP is removed, the piston of the unit HC′ is allowed to move downwards owing to the force of gravity (due mainly to the weight of the cartridge C). Because the guiding arrangement GA″ and the cartridge C are connected to the piston, e.g., via a piston rod, the guiding arrangement GA″ and the cartridge C also descend downwards. The cartridge C will then continue to descend until it becomes connected to the fuel cell FC. As will be described later on, once the cartridge C fully mates with the fuel cell FC, the contents of the cartridge C can automatically transfer to the fuel cell FC.

As was the case with the previous embodiment, the embodiment of FIG. 7 arranges the fuel cell FC and the cartridge C on a frame system FS which can removably statically mounted to a particular location (e.g., within a portion of the cell tower). The frame system FS utilizes a base member BM which supports the fuel cell FC and which can include stops (not shown) which ensure that the fuel cell FC is correctly located below the cartridge C. The frame system FS also utilizes a vertical member VM which supports a support member SM. The support member SM supports the connecting system CS″. It is preferred that the system shown in FIG. 7 be installed as a modular unit. This way, the system PS′ can function, when activated, to the point when the fuel cell FC has substantially exhausted of its power capabilities (or reaches the point where the voltage and/or current drop to a predetermined point) and/or is utilized a single time. Then, the unit can be sent back to, e.g., the manufacturer, for possible refurbishment. A new unit can then be installed in place of the used unit.

According to one aspect of the invention, the fuel cell system PS′ of FIG. 7 is a stand-alone, stationary unit, which can generate from the 10s of watts to the 1,000s of watts. The fuel cell FC preferably incorporates components and telchnologies which are described, e.g., in U.S. Pat. Nos. 6,554,877, 6,758,871 and 7,004,207 and pending U.S. patent application Ser. No. 10/757,849 (US2005/0155279), Ser. No. 10/758,081 (US2005/0155668), Ser. No. 10/634,806 (US2005/0058882), Ser. No. 10/758,080 (US2005/0158609), Ser. No. 10/803,900 (US2005/0206342) Ser. No. 10/824,443 (US2005/0233190), Ser. No. 10/796,305 (US2004/0241521) Ser. No. 10/849,503 (US2005/0260481), Ser. No. 11/132,203 (US2006/0047983), Ser. No. 10/959,763 (US2006/0078783), Ser. No. 10/941,020 (US2006/0057435), Ser. No. 11/226,222 (US2006/0057437), Ser. Nos. 11/384,364, 11/384,365, 11/325,466, 11/325,326 and 60/781,340. The power system PS′ is also more preferably a high powered fuel cell system for portable, auxiliary and remote power requirements. Preferably, the fuel cell system PS′ has a target power output of between approximately 20 Watts to approximately 5,000 Watts for a limited use time of between approximately 1 hour and approximately 500 hours.

FIGS. 8 and 9 show a fourth non-limiting embodiment of a stand-alone fuel cell power system PS^III. As in the previous embodiment, the power system PS^IIIutilizes a fuel cell FC and cartridge C arrangement. The fuel cell FC includes an outer housing which can be generally rectangular in shape. Of course, the fuel cell FC can have any other desired shape including, but not limited to polygonal, linear, oval, round, and/or curvilinear shapes. A plurality of wires W can have one end connected directly to the housing of the fuel cell FC or alternatively to a bus bar (not shown) which itself is electrically connected to the fuel cell FC. The bus bar or fuel cell FC can then be connected to a main bus bar or power circuit which feeds the source (e.g., a cell phone tower) electrical power for operation. As is shown in FIG. 8, the cartridge C is arranged above the fuel cell FC in a position which will allow the cartridge C to be correctly positioned within and/or mounted to the fuel cell FC at a desired time. Since the cartridge C contains certain active ingredients (e.g., fuel or fuel concentrate and optionally electrolyte) which the fuel cell FC needs to begin producing electrical power, until the cartridge C is mated with the fuel cell FC and until the contents of the cartridge C are transferred to the proper chambers of the fuel cell FC, the fuel cell FC does not produce power and provides an open circuit to wires W. When it is desired to place the fuel cell FC into operation, the cartridge C can be lowered into position within and/or on the fuel cell FC (see FIG. 9) such that the contents of the cartridge C are safely and properly transferred to the fuel cell FC. This embodiment is similar to that of FIGS. 1-5 except that the frame system FS is replaced with an enclosure system ES to prevent tampering with the power system PS^III. Although not shown, the power system PS′ can utilize a mechanism which indicates to a user that the power system PS^IIIhas been previously activated and must be replaced. Such a mechanism can be as simple as making one of the walls of the enclosure ES transparent so that the user can visually see that the cartridge C has been moved into engagement with the fuel cell FC.

FIG. 10 shows one non-limiting embodiment of the fuel cell FC which can be utilized in the power supply systems disclosed herein. The fuel cell FC shown in FIG. 10 is a single configuration type which includes a single anode 1 and a single cathode 2. A fuel chamber 3 is arranged on the anode side and an electrolyte chamber 4 is arranged between the anode 1 and the cathode 2. Cathode 2 may be (and preferably is) an air-breathing cathode. The fuel chamber 3 is configured to receive the fuel contents of the cartridge C once the cartridge C is mated with the fuel cell FC. The electrolyte chamber 4 is configured to receive the electrolyte contents of the cartridge C once the cartridge C is mated with the fuel cell FC. Prior to insertion of the cartridge C into the fuel cell FC, the fuel chamber 3 and electrolyte chamber 4 remain essentially empty or free of the fuel and electrolyte. Alternatively, the fuel chamber 3 may contain at least a part of the liquid diluent (e.g., water) for a fuel concentrate in the cartridge C and/or the electrolyte chamber 4 may contain at least a part of the electrolyte (e.g., a gel electrolyte) or at least a component of the electrolyte (e.g., water or a solid alkali metal hydroxide).

By way of non-limiting example, one or more of the fuel cells FC shown in FIG. 10 can be used on any of the herein disclosed power supply systems, and can have the following characteristics: Watt-hour output range from approximately 500 to approximately 50,000; voltage from approximately 2 volts to approximately 250 volts, e.g., from approximately 2 volts to approximately 20 volts, or from approximately 110 volts to approximately 230 volts; the exposed area of the anode 1 of the fuel cell FC can be from approximately 200 cm²to approximately 2,000 cm²; the exposed area of the cathode 2 can be from approximately 200 cm²to approximately 2,000 Cm²; the volume of fuel chamber 3 can be from approximately 0.5 liters to approximately 20 liters for each fuel cell FC and from approximately 2 liters to approximately 200 liters for the entire power supply system (when utilizing a plurality of fuel cells); the volume of the electrolyte (e.g., liquid or gel electrolyte) chamber 4 of each fuel cell unit can be from approximately 0.01 liters to approximately 2 liters, and from approximately 0.2 liters to approximately 40 liters for the entire stationary power supply system (when utilizing a plurality of fuel cells).

FIG. 11 shows another non-limiting embodiment of the fuel cell FC′ which can be utilized in the power supply systems disclosed herein. The fuel cell FC′ shown in FIG. 11 is a dual configuration type which includes two anodes 1a and 1b and two cathodes 2a and 2b. A fuel chamber 3 is arranged between the anodes 1a and 1b and two electrolyte chambers 4a and 4b are arranged between the anodes 1a and 1b and the cathodes 2a and 2b. The fuel chamber 3 is configured to receive the fuel contents of the cartridge C once the cartridge C is mated with the fuel cell FC′. The electrolyte chambers 4a and 4b are configured to receive the electrolyte contents of the cartridge C once the cartridge C is mated with the fuel cell FC′. Prior to insertion of the cartridge C into the fuel cell FC′, the fuel chamber 3 and electrolyte chambers 4a and 4b remain essentially empty or free of the fuel and electrolyte.

By way of non-limiting example, one or more of the fuel cells FC′ shown in FIG. 11 can be used on any of the herein disclosed power supply systems, and can have the following characteristics: Watt-hour output range from approximately 500 to approximately 50,000; voltage from approximately 2 volts to approximately 250 volts, e.g., from approximately 2 volts to approximately 20 volts, or from approximately 110 volts to approximately 230 volts; the exposed area of the anodes 1a and b of the fuel cell FC′ can be from approximately 200 cm²to approximately 2,000 cm²; the exposed area of the cathodes 2a and 2b can be from approximately 200 cm²to approximately 2,000 cm²; the volume of the fuel chamber 3 can be from approximately 0.5 liters to approximately 20 liters for each fuel cell FC′ and from approximately 2 liters to approximately 200 liters for the entire power supply system (when utilizing a plurality of fuel cells); the total volume of electrolyte (e.g., liquid or gel electrolyte) chambers 4a and 4b of each fuel cell unit can be from approximately 0.01 liters to approximately 2 liters, and from approximately 0.2 liters to approximately 40 liters for the entire stationary power supply system (when utilizing a plurality of fuel cells).

FIGS. 12 and 13 show still another non-limiting embodiment of the fuel cell FC″ and cartridge C′ which can be utilized in the power supply systems disclosed herein. The fuel cell FC″ shown in FIGS. 12 and 13 is a cylindrical module configuration type which includes a cylindrical anode 1 and a cylindrical cathode 2. A cylindrical fuel chamber 3 is arranged within the anode cylinder 1 and an electrolyte chamber 4 is arranged between the anode cylinder 1 and the cathode cylinder 2. The fuel chamber 3 is configured to receive the fuel contents of the cartridge C′ once the cartridge C′ is mated with the fuel cell FC″. The electrolyte chamber 4 is configured to receive the electrolyte contents of the cartridge C′ once the cartridge C′ is mated with the fuel cell FC″. Prior to mating of the cartridge C′ onto the fuel cell FC″, the fuel chamber 3 and electrolyte chamber 4 remain essentially empty or free of the fuel and electrolyte. Transfer of the fuel from the fuel chamber of the cartridge C′ to the fuel chamber 3 of the fuel cell FC″ occurs via fuel ports FP and transfer of the electrolyte from the electrolyte chamber of the cartridge C′ to the electrolyte chamber 4 of the fuel cell FC″ occurs via electrolyte ports EP.

By way of non-limiting example, one or more of the fuel cells FC″ shown in FIGS. 12 and 13 can be used on any of the herein disclosed power supply systems, and can have the following characteristics: Watt-hour output range from approximately 500 to approximately 50,000; voltage from approximately 2 volts to approximately 250 volts, e.g., from approximately 2 volts to approximately 20 volts, or from approximately 110 volts to approximately 230 volts; the exposed area of the anode 1 of the fuel cell FC″ can be from approximately 200 cm²to approximately 2,000 cm²; the exposed area of the cathode 2 can be from approximately 200 cm²to approximately 2,000 cm²; the volume of fuel chamber 3 can be from approximately 0.5 liters to approximately 20 liters for each fuel cell FC″ and from approximately 2 liters to approximately 200 liters for the entire power supply system (when utilizing a plurality of fuel cells); the volume of the electrolyte (e.g., liquid or gel electrolyte) chamber 4 of each fuel cell unit can be from approximately 0.01 liters to approximately 2 liters, and from approximately 0.2 liters to approximately 40 liters for the entire stationary power supply system (when utilizing a plurality of fuel cells).

FIGS. 14-16 show one non-limiting way in which the fuel cell FC/FC′ and cartridge C/C′ described above can interface with each other so that the fuel or fuel components and electrolyte or electrolyte components are safely and properly transferred from the cartridge to the fuel cell. The fuel cell FC/FC′ has a generally rectangular-shaped opening which is sized to receive (with a clearance) the correspondingly shaped cartridge C/C′. To facilitate insertion of the cartridge C/C′ into the opening of the fuel cell FC/FC′, the opening can include a tapered entrance. The corresponding shape of the opening and the cartridge C/C′ ensure that the fuel ports FP and electrolyte ports EP of the cartridge C/C′ and the fuel cell FC/FC′ are aligned and mate in the proper sealed manner. The fuel cell FC/FC′ utilizes integrally formed passages PA which allow the contents of the proper chambers of the cartridge C/C′ to flow to the proper chambers of the fuel cell FC/FC′. For example, the fuel chamber of the fuel cell FC/FC′ will receive the fuel contents of the cartridge C/C′ once the cartridge C/C′ is mated with the fuel cell FC/FC′ and the electrolyte chamber of the fuel cell FC/FC′ will receive the electrolyte contents of the cartridge C/C′ once the cartridge C/C′ is mated with the fuel cell FC/FC′. Prior to mating of the cartridge C/C′ onto the fuel cell FC/FC′, the fuel chamber and electrolyte chamber of the fuel cell FC/FC′ remain essentially empty or free of the fuel and electrolyte. Alternatively, the fuel chamber 3 may contain at least a part of the liquid diluent (e.g., water) for a fuel concentrate in the cartridge C/C′ and/or the electrolyte chamber 4 may contain at least a part of the electrolyte (e.g., a gel electrolyte) or at least a component of the electrolyte (e.g., water or solid alkali metal hydroxide).

FIG. 17 shows one non-limiting way in which the fuel cell power supply system can be configured. According to this embodiment, a number of fuel cell units FC are arranged or connected (with e.g., electrical conduits, wires, etc.) in series such that at least one of the units FC (i.e., the unit which is shown in broken lines) can be activated as described herein. Since the configuration is arranged in series, power supply from all of the units can be prevented until the designated unit(s) are intentionally activated.

FIG. 18 shows another non-limiting way in which the fuel cell power supply system can be configured. According to this embodiment, a number of fuel cell units FC are arranged or connected in parallel such that at least one of the units FC (i.e., the unit which is shown in broken lines) can be activated as described herein. Since the configuration is arranged in parallel, power supply occurs from all of the units except for the designated unit(s), which can then be intentionally activated when additional power is required.

FIG. 19 shows another non-limiting way in which the fuel cell power supply system can be configured. According to this embodiment, the fuel cell power supply system combines units FC arranged in series with units FC arranged in parallel. By way of non-limiting example, a plurality of sub-power-supply arrangements PSA₁, PSA₂, PSA₃, and PSA₄are arranged in series wherein each of the sub-power-supply arrangements PSA₁, PSA₂, PSA₃, and PSA₄comprise a plurality of fuel cell units FC arranged in parallel. At least one of the sub-power-supply arrangements PSA₃can be activated as described herein. That is, all of the units FC of the designated power-supply arrangement PSA₃can be activated (i.e., simultaneously connected with a cartridge as described herein) when it is desired to utilize power from all of the series connected power-supply arrangements PSA₁, PSA₂, PSA₃, and PSA₄. Since the configuration is arranged in series, power supply from all of the power-supply arrangements PSA₁, PSA₂, PSA₃, and PSA₄can be prevented until the designated power-supply arrangement(s) PSA₃is intentionally activated.

FIG. 20 shows one non-limiting application of the back-up power supply system connected to a cell phone tower. The system utilizes controller CSM which functions to initiate or activate the back-up power system BPSS of the type described above. The back-up power system BPSS is configured and generally matched to provide the necessary power (voltage and current) requirement generally provided by the main power supply system MPSS, i.e., the power typically provided by a utility company. Until the back-up power supply BPSS is activated, the cell tower (or other device requiring back-up power), is powered by the main power source MPSS via input circuit breaker arranged in an electrical box of the cell tower. The cell tower can utilize, among other things, filtering inductors and switches. During normal operation, the cell tower receives continuous current and remains operating by the main power source MPSS. The system controller CSM monitors and controls the state of the switches, the input circuit breaker and the back-up power system BPSS. The system controller CSM can also monitor frequency, voltage and current at several points in the system to maintain a continuous status of the line power available to the cell tower. A number of parameters may be monitored, e.g., voltage and current, via the sensing system SS.

In the event of a voltage deviation or outage (a power interrupt condition), the back-up power system BPSS becomes the power supply for the cell tower. If necessary, an inverter may be utilized to convert the direct current voltage of the back-up power system BPSS to a stable alternating current voltage which is required by the cell tower. Of course, if the cell tower operates by DC current, the back-up power system BPSS can be connected directly to the electrical box of the cell tower. If the system controller CSM determines that line power deviation exceeds a predetermined threshold, the input circuit breaker can be opened, isolating any main power source parasitic loads and the back-up power system BPSS is activated. Rapid, coordinated switching provides for a relatively seamless transfer of power from the main power source MPSS to the inverter and/or the back-up power system BPSS. Preferably, the system is configured to keep the system from initiating the back-up power system BPSS, as would be the case, for example, where there is a very brief transitory outage in voltage.

Any rectifiers which are utilized are preferably operable over a wide frequency and voltage range. Any inverters which are used should also be operable over a wide input range in order to convert the direct current voltage to a stable alternating current voltage while maintaining .+−0.0.5 Hz frequency deviation under the direction of the system controller CSM. Although many conversion techniques are known to those skilled in the art, a preferred technique for conversion from direct to alternating current voltage is to use pulse-width modulation. By properly designing the system, the power supplied to the cell tower in back-up mode should minimize the period of time for bridging the time interval between the detection of power outage, and the start and stabilization of the back-up power system BPSS. Once the main power source MPSS is restored, the system controller CSM can preferably detect its presence and initiate a coordinated sequence to transfer power from the back-up power system BPSS back to the main power source MPSS. Techniques for performing this feature are known to those skilled in the art and, as such, will not be discussed in further detail.

FIGS. 21-26 show non-limiting configurations for the cartridge module C^II, C^III, C^IV, C^VI, C^VII. The cartridge module C^II, C^III, and C^IVis preferably divided (via e.g., a membrane wall MW) into at least two separate chambers for the two fuel components (see FIGS. 21-23); one chamber can contain fuel concentrate, e.g., fuel paste, and another chamber can contain liquid diluent for the concentrate. An optional third chamber can be provided in the cartridge for storing liquid electrolyte. Each chamber has a sealable opening (via e.g., a membrane cap MC) and/or an opening which can be accessed to allow the transfer of the contents of the cartridge into the appropriate or corresponding chambers in the fuel cell module.

A number of non-limiting options for storing the components in the cartridge chambers may be utilized as follows: the chambers can be arranged within a rigid housing containing a lower seal tab MC and a vertical (see FIG. 22), a horizontal (see FIG. 21), and a diagonal (see FIG. 23) membrane MW separating the paste from its diluent; the chambers can also be arranged within a rigid housing containing a lower seal tab MC and can include a “floating” membrane bag MB containing one component which is surrounded by the second component inside the rigid housing (see FIG. 24a); the chambers can be arranged within a rigid housing, with or without a lower seal tab MC, containing two “floating” membrane bags MB₁, MB₂for each component (see FIG. 24b); one or more chambers can be arranged within a non-rigid and/or “concertina” type housing that can be compressed vertically with any one of the above-noted options (see FIG. 25).

The cartridge and fuel cell module housings can be produced primarily from lightweight, low-cost materials. Due to cost considerations, the cartridge and fuel cell module housings can preferably be made of polymer materials which are capable of withstanding exposure to the chemicals to be contained therein. Preferred examples of polymer materials include, but are not limited to (optionally filled) PVC, PP, ABS, polycarbonate, polyurethane, etc. In practice, substantially all components (other than those with specific mechanical requirements such as springs, puncturing devices, etc.) are preferably made from such polymer materials. As set forth above, other materials such as, e.g., metals or alloys thereof can be used as well. Exemplary dimensions of cartridge module housings are, for example, from about 5 cm×5 cm×5 cm up to about 20 cm×25 cm×100 cm. Exemplary dimensions for fuel cell module housings are from about 10 cm×10 cm×10 cm up to about 40 cm×50 cm×200 cm.

FIGS. 26-35 shows a number of non-limiting ways for connecting the cartridge units to the fuel cell units: the cartridge unit C can be connected to a mating interface of the fuel cell unit FC in an aligned manner so that, when connected, a puncturing device PD of the fuel cell FC punctures (see FIG. 27) the sealing membrane cap MC so that the contents of the cartridge C can be transferred to the fuel cell FC via the force of gravity. A sealing member or ring SR can be utilized to provide sealing between cartridge C and fuel cell FC to thereby ensure that none of the contents of the cartridge C spill out or leak out during transfer. FIGS. 28 and 29 show a configuration similar to that of FIGS. 26 and 27 except that the puncturing device is longer and capable of severing the membrane wall arranged within the cartridge C; according to FIGS. 30-32, the cartridge unit C can be connected to a mating interface of the fuel cell unit FC in an aligned manner so that, when connected, a puncturing device PD of the fuel cell FC punctures (see FIGS. 31 and 32) both the sealing membrane cap MC and the membrane wall MW so that the contents of the chambers of the cartridge C can be transferred to the fuel cell FC via the force of gravity. Two sealing members or rings SR₁and SR₂can be utilized to provide sealing between cartridge C and fuel cell FC to thereby ensure that none of the contents of the cartridge C spill out or leak out during transfer; according to FIGS. 33-35, the cartridge unit C can be connected to a mating interface of the fuel cell unit FC in an aligned manner so that, when connected, a puncturing device PD of the fuel cell FC punctures (see FIGS. 34 and 35) the sealing membrane cap MC and destroys the membrane wall MW so that the contents of the chambers of the cartridge C can be transferred to the fuel cell FC via the force of gravity. Two sealing members or rings SR₁and SR₂can be utilized to provide sealing between cartridge C and fuel cell FC to thereby ensure that none of the contents of the cartridge C spill out or leak out during transfer.

By way of one non-limiting example, each of the cartridge embodiments disclosed herein can have one or more valve ports 22 which mate with one or more valve ports 6 of the fuel cell embodiments disclosed herein. FIGS. 36-40 show one non-limiting way in which the ports 6 of the fuel cell can be mated with the ports 22 of the cartridge. FIG. 39 shows the fuel cell valve 6 and cartridge valve 22 in a state prior to being connected to each other. In this state, a plunger valve PV prevents fluid and/or other substances from entering (as well as exiting) the fuel cell by virtue of its tapered surface TS being in sealing contact and/or engagement with correspondingly tapered surface 6c of the valve sleeve 6a. A partially compressed first spring FS acts to bias the plunger valve PV so that sealing contact is maintained between surfaces TS and 6c. The first spring FS is a tapered spring whose larger diameter end is configured to abut against an internal cylindrical shoulder 6b of the sleeve 6a. The smaller diameter portion of the first spring FS is sized to receive therein a rear projection RP of the plunger valve PV and to abut against a rear shoulder RS. The sleeve 6a is generally cylindrical in shape and includes a front cylindrical opening 6f which is sized to receive therein a front cylindrical portion 22a of the cartridge valve 22. In order to ensure that the valve 22 is sealed with respect to the valve 6, the valve 22 includes a tapered surface 22e whose taper corresponds to the tapered surface 6d of the valve 6 (see FIG. 40). The plunger valve PV and first spring FS are both arranged within cylindrical section 6e and can move axially within this opening (compare FIGS. 39 and 40).

In a similar arrangement, a ball valve BV prevents fluid from exiting the cartridge by virtue of its spherical surface being in sealing contact and/or engagement with tapered surface 22d of the valve sleeve 22a. A partially compressed second spring SS acts to bias the ball valve BV so that sealing contact is maintained between the spherical surface of the ball valve BV and tapered surface 22d. The second spring SS is a cylindrical wire spring whose rear end is configured to abut against an internal cylindrical shoulder 22b of the sleeve 22a. The front end of the second spring SS is sized to receive therein a portion of the spherical surface of the ball valve BV (see FIG. 39). The sleeve 22a is generally cylindrical in shape and includes a front cylindrical opening 22c which is sized to receive therein the ball valve BV and second spring SS. As noted above, the valve 22 can be sealed with respect to the valve 6 when the tapered surface 22e engages the tapered surface 6d of the valve 6 (see FIG. 40). The ball valve BV and second spring SS are arranged within cylindrical section 22c and can move axially within this opening (compare FIGS. 39 and 40).

In the position shown in FIG. 39, the valves 6 and 22 are closed and not connected to each other. However, in FIG. 40, the valve 22 has been inserted fully into the valve 6 and both valves 6 and 22 are in an open state to allow fluid communication between the cartridge and the fuel cell. In this opened position, it can be seen that the small diameter projecting portion PP has forced the ball valve BV to move axially away from sealing engagement with tapered surface 22d. This has occurred by causing the second spring SS to compress even more. Similarly, it can be seen that the biasing forces of the springs FS and SS are such that the second spring SS also forces the plunger valve PV, and specifically surface TS, to move axially away from sealing engagement with tapered surface 6c. This has occurred by causing the first spring FS to compress even more. Although not shown, each valve 6 and 22 may also include therein a sleeve or shoulder which allows the plunger valve PV and/or ball valve BV to move away from sealing engagement only a limited amount, thereby ensuring both valves PV and BV are unseated and placed in the opened position reliably and/or essentially simultaneously.

Although not shown, the front of the valve 6 can be slotted, i.e., with slots 6′g shown in FIG. 41), a plurality of spring fingers are formed which deflect outwards when the valve 22 is inserted into the valve 6 (see FIG. 45). This deflection occurs because the projections (which can be similar to projections 6′h in FIG. 45) engage with the cylindrical surface 22a during insertion. When the valve 22 reaches the position shown in FIG. 40, the projections drop into a circumferential recess (similar to recess 22f of FIG. 45). At this point, the valve 22 is fully inserted into and non-removably connected to the valve 6. As is evident from these figures, the valves function to seal the fuel cell and cartridge when they are not connected (see FIG. 39). Of course, the valve arrangement shown in FIGS. 36-40 are but one possible example or embodiments of the valves 6 and 22. The invention contemplates other valve arrangements which allow for the one-time connection and opening of the valves and for the closing of the valves. The various parts of the valves 6 and 22 can be made of any desired material whether conventional or otherwise such as metal, plastic, and/or composites. Additionally, the invention may also utilize valves similar to those used in copending application Ser. No. 10/796,305 (US2004/0241521 A1).

By way of another non-limiting example, the cartridge valve 22 and fuel cell valve 6 may instead have the arrangement shown in FIGS. 41-45. FIG. 44 shows the fuel cell valve 6′ and cartridge valve 22′ in a state prior to being connected to each other. In this state, the plunger valve PV prevents fluid from entering (as well as exiting) the fuel cell by virtue of its tapered surface TS being in sealing contact and/or engagement with correspondingly tapered surface 6′c of the valve sleeve 6′a. A partially compressed first spring FS acts to bias the plunger valve PV so that sealing contact is maintained between surfaces TS and 6′c. The first spring FS is a tapered spring whose larger diameter end is configured to abut against an internal cylindrical shoulder 6′b of the sleeve 6′a. The smaller diameter portion of the first spring FS is sized to receive therein a rear projection RP of the plunger valve PV and to abut against a rear shoulder RS. The sleeve 6′a is generally cylindrical in shape and includes a front cylindrical opening 6′f which is sized to receive therein a front cylindrical portion 22′a of the cartridge valve 22′. In order to ensure that the valve 22′ is sealed with respect to the valve 6′, the valve 22′ includes a tapered surface 22′e whose taper corresponds to the tapered surface 6′d of the valve 6 (see FIG. 45). The plunger valve PV and first spring FS are both arranged within cylindrical section 6′e and can move axially within this opening (compare FIGS. 44 and 45).

Unlike the arrangement shown in FIGS. 36-40, the cartridge valve 22′ in this arrangement does not utilize a one-way valve. Instead, a pierceable washer PW is used to prevent fluid from exiting the cartridge. The pierceable washer PW can be made of thin materials such as, e.g., plastic or aluminum, and may be press fit (or attached in other ways such as by adhesives) into a cylindrical recess 22′b formed in a front portion of the valve 22′. This can occur after the cartridge is initially filled. As can be seen in FIG. 45, the pierceable washer PW is designed to be pierced by the projecting portion PP of the plunger valve PV. To ensure that this occurs reliably, the projecting portion PP may have a sharpened tip (not shown). As can be seen in FIG. 43, the pierceable washer PW is circular and has the form of a cap. The sleeve 22′a is generally cylindrical in shape and includes a front cylindrical opening 22′c which allows the fluid to pass into the valve 6′ of the fuel cell. As noted above, the valve 22′ can be sealed with respect to the valve 6′ when the tapered surface 22′e engages the tapered surface 6′d of the valve 6′ (see FIG. 45).

In the position shown in FIG. 44. the valves 6′ and 22′ are closed and not connected to each other. However, in FIG. 45, the valve 22′ has been inserted fully into the valve 6′ and both valves 6′ and 22′ are in an open state to allow fluid communication between the cartridge and fuel cell. In this opened position, it can be seen that the small diameter projecting portion PP has pierced the pierceable washer PW. This has occurred because the biasing force of the first spring FS is strong enough to causing piercing of the washer PW. On the other hand, the pressure flow from the cartridge to the fuel cell is sufficient to overcome the biasing force of the first spring FS, such that the pressure forces the plunger valve PV, and specifically surface TS, to move axially away from sealing engagement with tapered surface 6′c. This has occurred by causing the first spring FS to compress. Once the pressure in the cartridge is reduced below the biasing force (which occurs after the fluid is transferred from the cartridge to the fuel cell), the valve 6′ will close off. That is, the plunger valve PV, and specifically surface TS, will move axially towards sealing engagement with tapered surface 6′c. Although not shown, the valve 6′ may also include therein a sleeve or shoulder which allows the plunger valve PV to move away from sealing engagement only a limited amount, thereby ensuring the valve PV is unseated and placed in the opened position more reliably.

Because the front of the valve 6′ is slotted, i.e., with slots 6′g, a plurality of spring fingers are formed which deflect outwards when the valve 22′ is inserted into the valve 6′ (see FIG. 45). This deflection occurs because the projections 6′h engage with the cylindrical surface 22′a during insertion. When the valve 22′ reaches the position shown in FIG. 45, the projections 6′h drop into a circumferential recess 22′d. At this point, the valve 22′ is fully inserted into and non-removably connected to the valve 6′. As is evident from these figures, the valves 6′ and 22′ function to seal the fuel cell and cartridge when they are not connected (see FIG. 44). Of course, the valve arrangement shown in FIGS. 41-45 are but one possible example or embodiment of the valves or connecting ports which may be used on the fuel cell and cartridge disclosed herein. The invention contemplates other valve arrangements which allow for the one-time connection and opening of the valves and for the closing of the valves. The various parts of the valves 6′ and 22′ can be made of any desired material whether conventional or otherwise such as metal, plastic, and/or composites.

FIGS. 46-52 schematically illustrate another non-limiting embodiment of the cartridge and fuel cell which can be used in the stand-alone single-use disposable fuel cell back-up power supply system. By way of non-limiting example, the fuel cell 110 includes two chambers FCH and ECH which are separated from each other and the cartridge 120 includes two chambers CEC and CFC which separated from each other. This embodiment is designed so that the fuel cell 110 and a cartridge 120 can be arranged within the frames or housings shown in FIGS. 1-9. In this embodiment, once the arrangement connects the cartridge 120 to the fuel cell 110, the cartridge 120 becomes non-removably connected to the fuel cell 110 so that the back-up power supply system cannot be reused or is used only a single time. This embodiment, as was the case with the previous embodiments, has the advantage that the unit can be stored for relatively long periods of time and then, when desired, the fuel cell 110 can be filled and used at a desirable point in time as described with regard to other embodiments noted above. Once filled, the fuel cell 110 with the connected cartridge 120 is used until it is exhausted, i.e., it stops generating the desired level of power. Then, one can simply discard and/or recycle the fuel cell 110/cartridge 120 as a unit or send it back for refurbishment. The design of the fuel cell 110/cartridge 120 is such that it cannot be refilled and/or its contents cannot be easily removed from the fuel cell 110 without destroying the fuel cell 110 and cartridge 120. This arrangement is ensured when the cartridge 120 is connected to the fuel cell 110 (see FIGS. 51-52) because the cartridge 120 becomes non-removably connected to the fuel cell 110 when fully connected. As will be described herein, this connection also automatically triggers the transfer of fluids between the cartridge 120 and the fuel cell 110. By ensuring that, once fully connected, the cartridge 120 is essentially permanently connected to the fuel cell 110, a user will not be able to refill and/or reuse the fuel cell 110 without likely destroying or damaging it in the attempt to do so. The fuel cell 110 is thus usable only once and may then be discarded or recycled/refurbished.

The two ports 110c (one for the fuel chamber FCH and one for the electrolyte chamber ECH) are arranged within a main recess 110a of the fuel cell 110. These ports 110c can be integrally formed with the fuel cell body by, e.g., injection molding the body in two parts. Alternatively, the ports 110c can be separately formed therefrom and then attached thereto by, e.g., adhesives or a threaded connection (not shown). The ports 110c include a plurality of openings 110d arranged to allow fluid to enter into the fuel chamber FCH and the electrolyte chamber ECH. The ports 110c also include a cylindrical portion whose annular free end is configured to sealingly engage with a sealing ring SR arranged within a cylindrical opening 120g of the cartridge ports 120c. The sealing ring SR may have any desired shape and may be made of a material such as, e.g., Viton. The two ports 120c (one for the fuel chamber CFC and one for the electrolyte chamber CEC) project from a bottom wall of the cartridge 120. The ports 120c and connecting portion 120a (as can be the case with ports 110c and recess 110a) can be integrally formed with the cartridge body by, e.g., injection molding the body in two parts. Alternatively, the ports 120c can be separately formed therefrom and then attached thereto by, e.g., adhesives or a threaded connection (not shown). The ports 120c each include a main opening 120d arranged to allow fluid to enter into the fuel chamber CFC and the electrolyte chamber CEC during initial filling and thereafter allow the fluids to exit and enter into the fuel cell 110 once the piercing washers PW are pierced. By way of non-limiting example, the chambers CFC and CEC can be initially filled with the fluids (e.g., fuel or fuel concentrate and liquid diluent and electrolyte) entering under a fluid pressure which is capable of compressing the springs 120f. Then, the openings 120h are sealed with the piercing washers PW. The ports 120c include a cylindrical portion whose annular free end is configured to receive therein a sealing ring SR and a respective fuel cell port 110c. The ports 120c also include a cylindrical portion 120h which is configured to receive therein a piercing washer PW. The piercing washer PW can be secured to the opening 120h in any desired way as long as it is securely and sealingly connected to the cartridge 120 and as long as it can be pierced by the projecting portions 110e. This can occur by, e.g., a press fit connection or by using an adhesive connection.

In performing the filling process, the arrangement to which the cartridge and fuel cell are mounted aligns the cartridge 120 with the fuel cell 110 (see FIG. 50). Then, the arrangement moves the cartridge 120 into full engagement and/or connection with the fuel cell 110 (see FIG. 51). This causes the piercing plungers 110e of the fuel cell 110 to pierce the piercing washers PW, which in turn automatically triggers the fluid transfer from the cartridge 120 to the fuel cell 110 under the biasing or expansion action of the piston springs 120f1, 120f2, 120f3, and the cartridge pistons 120e1 and 120e2. Then, the fuel cell 110 is filled. Once filled, the piston springs 120f1, 120f2, 120f3, and the cartridge pistons 120e1 and 120e2 ensure that the fluids in the fuel cell 110 cannot flow back into the cartridge 120. Moreover, because the cartridge 120 is non-removably connected to the fuel cell 110, the user will not be able to reuse and refill of the fuel cell 110. To provide this non-removable connection, the cartridge 120 utilizes projections 120b which engage corresponding recesses 110b in the fuel cell 110. The design of the projections 120b and recesses 110b are such that the cartridge 120 cannot be removed from the fuel cell 110 without destroying the fuel cell 110. Of course, the cartridge 120 can also be non-removably secured to the fuel cell 110 in other ways such as by utilizing, e.g., pressure sensitive adhesives or by utilizing projections on the fuel cell 110 and recesses on the cartridge 120.

The fuel cell 110 and cartridge 120 may each be generally rectangular in shape and may be made of an (optionally filled) plastic material such as, e.g., ABS (acrylonitrile-butadiene-styrene), PVC, polypropylene, polyethylene (e.g., HDPE), polycarbonate and polyurethane. Of course, the fuel cell 110 and cartridge 120 can have any other desired shape including, but not limited to any other polygonal or any other linear and/or curvilinear shape. Although not shown, the fuel cell 110, like the fuel cell shown in previous embodiments, includes one or more cathodes, one or more anodes, defines an optional electrolyte chamber, and utilizes a fuel chamber. The fuel cell 110 also includes all of the features otherwise required to produce power. The cartridge 120 is not limited to any particular spring 120f and piston 120e arrangement and/or configuration. The important aspect of this embodiment is that the cartridge 120 has the ability of transferring its contents to the fuel cell 110 automatically once the cartridge is fully, sealingly and non-removably connected to the fuel cell 110. The arrangement shown in FIGS. 46-52 can also be modified so that the chambers CEC and CFC utilize flexible material enclosures, e.g., flexible polymer bags, which are in fluid communication with the openings 120d and which can be compressed by the springs 120f to cause their contents to be expelled out of the cartridge 120 and into the fuel cell 110 (i.e., similar to the arrangement shown in FIG. 53).

FIGS. 53 and 54 schematically illustrate another non-limiting embodiment of the cartridge and fuel cell which can be used in a stand-alone single-use disposable back-up power supply system. By way of non-limiting example, the fuel cell 1010 includes two chambers FCH and ECH which are separated from each other and the cartridge 1020 includes two chambers CEC and CFC which separated from each other. This embodiment is also designed so that the fuel cell 1010 and a cartridge 1020 can be purchased already installed on the arrangement for connecting these devices such that the cartridge and fuel cell remain an unconnected unit with the fresh fuel component(s) or fluids being contained only in the cartridge 1020. The system then connects the cartridge 1020 to the fuel cell 1010 when it is desired to use the fuel cell 1010. This embodiment has the advantage that the system can be stored for relatively long periods of time and then, when required, the fuel cell 1010 can be filled at a desirable point in time. Once filled, the fuel cell 1010 is used with the non-removably connected cartridge 1020 until it is exhausted, i.e. it stops generating the desired level of power. Then, the system can simply be discarded and/or recycled. The design of the fuel cell 1010/cartridge 1020 is such that it cannot be refilled and/or its contents cannot be easily removed from the fuel cell 1010 without destroying the fuel cell 1010. This condition is ensured when the arrangement fully non-removably connects the cartridge 1020 to the fuel cell 1010 (see FIG. 53). This non-removable connection system is similar to that of the embodiment shown in, e.g., FIGS. 46-52. As is evident from FIG. 53, a full connection between the cartridge 1020 and the fuel cell 1010 automatically triggers the transfer of fluids between the cartridge 1020 and the fuel cell 1010. By ensuring that, once fully connected, the cartridge 1020 is sealingly connected to the fuel cell 1010 and by ensuring that the fluids in the fuel cell 1010, once placed therein, cannot be removed, the user will not be able to refill and/or reuse the fuel cell 1010 without likely destroying or damaging it in the attempt to do so. The fuel cell 1010 is thus usable only once and may then be discarded or recycled/refurbished.

As with many of the previously described embodiments, the two ports 1010c (one for the fuel chamber FCH and one for the electrolyte chamber ECH) are arranged within a main recess 1010a of the fuel cell 1010. The ports 1010c can be separately formed therefrom and then attached thereto by, e.g., adhesives and/or a threaded connection (not shown). The ports 1010c include a plurality of openings 1010d arranged to allow fluids to enter into the fuel chamber FCH and the electrolyte chamber ECH. The ports 1010c also include a cylindrical portion whose annular free end is configured to sealingly engage with a sealing ring SR arranged within a cylindrical opening of the cartridge ports 1020c. The sealing ring SR may have any desired shape and may be made of a material such as, e.g., Viton. The two ports 1020c (one for the fuel chamber CFC and one for the electrolyte chamber CEC) project from a bottom wall of the cartridge 1020. The ports 1020c and connecting portion 1020a can be integrally formed with the cartridge body by, e.g., injection molding the body in two parts. Alternatively, the ports 1020c can be separately formed therefrom and then attached thereto by, e.g., adhesives or a threaded connection. The ports 1020c each include a main opening 1020d arranged to allow fluids to enter into the flexible fuel chamber or enclosure FFE and the flexible electrolyte chamber or enclosure FEE during initial filling and thereafter allow the fluids to exit and enter into the fuel cell 1010 once the piercing washers PW are pierced. By way of non-limiting example, the flexible chambers FFE and FEE can be initially filled with the fluids (e.g., fuel or fuel concentrate and liquid diluent and electrolyte) entering under a fluid pressure which is capable of compressing the springs 1020f. Then, the openings are sealed with the piercing washers PW. The ports 1020c include a cylindrical portion whose annular free end is configured to receive therein a sealing ring SR and a respective fuel cell port 1010c. The ports 1020c also include a cylindrical portion which is configured to receive therein a piercing washer PW. The piercing washer PW can be secured to the opening in any desired way as long as it is securely and sealingly connected to the cartridge 1020 and as long as it can be pierced by the projecting portions 1010e. This can occur by, e.g., a press fit connection or by using an adhesive connection.

As is evident in FIG. 54, the flexible enclosures FFE and FEE have an open end which is fixed to a connecting ring BCR. Each ring BCR includes an external projection which securely and sealingly engages with a corresponding internal recess in the cartridge body.

In performing the filling process, the arrangement simply aligns the cartridge 1020 with the fuel cell 1010. Then, the arrangement is activated to move the cartridge 1020 into full engagement and/or connection with the fuel cell 1010. This causes the piercing plungers 1010e of the fuel cell 1010 to pierce the piercing washers PW, which in turn automatically triggers the fluid transfer from the cartridge 1020 to the fuel cell 1010 under the biasing or expansion action of the piston springs 1020f and the cartridge pistons 1020e. The pistons 1020e act to compress the flexible chambers FFE and FEE which forces their contents into the fuel cell 1010. With this arrangement, the fuel cell 1010 can be filled without any of the fluids ever moving back into the cartridge 1020. Once filled, the piston springs 1020f and the cartridge pistons 1020e remain in a lowermost position. On the other hand, the cartridge 1020 remains non-removably connected to the fuel cell 1010. At the same time, the user will not be able to reuse and refill of the fuel cell 1010.

The fuel cell 1010 and cartridge 1020 may each be generally rectangular in shape and may be made of an (optionally filled) plastic material such as, e.g., ABS (acrylonitrile-butadiene-styrene), PVC, polypropylene, polyethylene (e.g., HDPE), polycarbonate and polyurethane. Of course, the fuel cell 1010 and cartridge 1020 can have any other desired shape including, but not limited to any other polygonal or any other linear and/or curvilinear shape (as in other disclosed embodiments). Although not shown, the fuel cell 1010, like the fuel cell discussed above, includes one or more cathodes, one or more anodes, and defines an electrolyte chamber and a fuel chamber. The fuel cell 1010 also includes all of the features otherwise required to produce power. The cartridge 1020 is not limited to any particular spring 1020f and piston 1020e arrangement and/or configuration. The important aspect of this embodiment is that the cartridge 1020 has the ability of transferring its contents to the fuel cell 1010 automatically once the cartridge 1020 is fully, sealingly and non-removably connected to the fuel cell 1010. The arrangement shown in FIGS. 53 and 54 can also be modified so that the cartridge body is formed in two parts which are attached to each other by locking latch mechanisms which include a deflectable locking latch fixed to the upper part and a locking projection fixed to the lower part (see FIGS. 51-52 of US 2005/0260481).

FIGS. 55 and 56 schematically illustrate another non-limiting embodiment of the cartridge and fuel cell which can be used in a stand-alone single-use disposable power supply system. By way of non-limiting example, the fuel cell 1110 includes two chambers FCH and ECH which are separated from each other and the cartridge 1120 includes two chambers CEC and CFC which separated from each other. This embodiment is designed so that the fuel cell 1110 and a cartridge 1120 are together placed in an arrangement and are already connected to each other. However, the fresh fuel component(s) or fluids are contained only in the cartridge 1120. The arrangement is not required to connect the cartridge 1120 to the fuel cell 1110 as in previous embodiments. Instead, the arrangement functions to cause the transfer of the fluids from the cartridge 1120 to the fuel cell 1110. This embodiment also has the advantage that the unit can be stored for relatively long periods of time and then, when activation is desired, the fuel cell 1110 can be filled and used. Once filled, the fuel cell 1110 generates power with the non-removably connected cartridge 1120 connected to it until it is exhausted, i.e. it stops generating the desired level of power. Then, one can simply discard and/or recycle the entire arrangement or remove the fuel cell 1110/cartridge 1120 as a unit and replace it with a new one in the arrangement. The design of the fuel cell 1110/cartridge 1120 is such that it cannot be refilled and/or its contents cannot be easily removed from the fuel cell 1110 without destroying the fuel cell 1110. This condition is ensured when the cartridge 1120 is connected to the fuel cell 1110 (e.g., in a factory setting). Because the cartridge 1120 contains one-way valves 1120i and 1120j, this embodiment can dispense with the need for valves in the fuel cell 1110 or with the piercing washer PW. As is evident from FIG. 56, a full connection between the cartridge 1120 and the fuel cell 1110 does not automatically trigger the transfer of fluids between the cartridge 1120 and the fuel cell 1110, as was the case with many of the previously described embodiments. Instead, this embodiment allows the pressing or connecting arrangement (i.e., the connecting arrangement used in the devices shown in FIGS. 1-9) to physically and mechanically control the fluid transfer by moving the piston rods 1120f. To facilitate this movement, the handle which connects the two rods 1120f is moved in the direction of the fuel cell 1110. At a lowermost position, the handle non-releasably locks to the cartridge 1120 so that the user will not be able to cause the fluids to move back into the cartridge 1120 from the fuel cell 1110. As can be seen in FIG. 55, this locking can occur by utilizing two deflectable locking members 1120g fixed to the cartridge body and two locking projections 1120h fixed to the rods 1120f. By ensuring that the cartridge 1120 is sealingly connected to the fuel cell 1110 and by ensuring that the fluids in the fuel cell 1110, once placed therein, cannot be removed, the user will not be able to refill and/or reuse the fuel cell 1110 without likely destroying or damaging it in the attempt to do so. The fuel cell 1110 is thus usable only once and may then be discarded or recycled/refurbished.

As with many of the previously described embodiments, the two ports 1110c (one for the fuel chamber FCH and one for the electrolyte chamber ECH) are arranged within a main recess 1110a of the fuel cell 1110. The ports 1110c can be separately formed therefrom and then attached thereto by, e.g., adhesives and/or a threaded connection. The ports 1110c include a plurality of openings 1110d arranged to allow fluids to enter into the fuel chamber FCH and the electrolyte chamber ECH. The ports 1110c also include a cylindrical portion whose annular free end is configured to sealingly engage with a sealing ring SR arranged within a cylindrical opening of the cartridge ports 1120c. The sealing ring SR may have any desired shape and may be made of a material such as, e.g., Viton. The two ports 1120c (one for the fuel chamber CFC and one for the electrolyte chamber CEC) project from a bottom wall of the cartridge 1120. The ports 1120c and connecting portion 1120a can be integrally formed with the cartridge body by, e.g., injection molding the body in two parts. Alternatively, the ports 1120c can be separately formed therefrom and then attached thereto by, e.g., adhesives or a threaded connection. The ports 1120c each include a main opening 1120d arranged to allow fluids to enter into the fuel chamber CFC and the electrolyte chamber CEC during initial filling and thereafter allow the fluids to exit and enter into the fuel cell 1110 once the valves 1120j and 1120i are forced open under fluid pressure. By way of non-limiting example, the chambers CFC and CEC can be initially filled with the fluids (e.g., fuel and electrolyte) entering under a fluid pressure which is capable of filling the volume up to the pistons 1120e. Then, the openings are sealed with the sealing disk 1120j, spring 1120i and retaining washer 1120k (which can be press-fit into the cylindrical opening of the ports 1120c). The ports 1120c include a cylindrical portion whose annular free end is configured to also receive therein a sealing ring SR and a respective fuel cell port 1110c.

In performing the filling process, the unit shown in FIG. 55 is arranged within an arrangement of the type shown in FIGS. 1-9. Then, when activated, the arrangement causes the handle connected to the piston rods 1120f to move down towards the fuel cell 1110. This, in turn, causes the fluid transfer from the cartridge 1120 to the fuel cell 1110 under the action of the cartridge pistons 1120e. The fluids force open the sealing disks 1120j, i.e., causing them to move away from the openings 1120d, by overcoming the biasing force of the spring 1120i. This occurs because the fluid pressure in the cartridge 1120 is sufficient to overcome the biasing force of the spring 1120i. The springs 1120i otherwise bias the sealing disks 1120j towards a position closing off the openings 1120d. This occurs by placing the spring 1120i in a compressed state between the sealing disk 1120j and a retaining washer 1120k which is held in place by, e.g., a press fit connection or an adhesive connection. With this arrangement, the fuel cell 1110 can be filled without any of the fluids ever moving back into the cartridge 1120. Once filled, the cartridge pistons 1120e remain in a lowermost position owing to the locking system 1120g/1120h. On the other hand, because the cartridge 1120 is non-removably connected to the fuel cell 1110, one cannot disconnect the cartridge 1120. At the same time, a user will not be able to reuse and refill the fuel cell 1110.

The fuel cell 1110 and cartridge 1120 may each be generally rectangular in shape and may be made of an (optionally filled) plastic material such as, e.g., ABS (acrylonitrile-butadiene-styrene), PVC, polypropylene, polyethylene (e.g., HDPE), polycarbonate and polyurethane. Of course, the fuel cell 1110 and cartridge 1120 can have any other desired shape including, but not limited to any other polygonal or any other linear and/or curvilinear shape. Although not shown, the fuel cell 1110 includes one or more cathodes, one or more anodes, and defines an electrolyte chamber and a fuel chamber. The fuel cell 1110 also includes all of the features otherwise required to produce power. The cartridge 1120 is not limited to any particular piston 1120e arrangement and/or configuration. The important aspect of this embodiment is that the cartridge 1120 has the ability of non-reversibly transferring its contents to the fuel cell 1110 under the action of the activating arrangement. The arrangement shown in FIGS. 55 and 56 can also be modified so that the chambers CEC and CFC utilize flexible material enclosures, e.g., flexible polymer bags, which are in fluid communication with the openings 1120d and which can be compressed by the pistons 1120e to cause their contents to be expelled out of the cartridge 1120 and into the fuel cell 1110 (i.e., similar to the arrangement shown in FIG. 53).

As with many of the previously described embodiments, the two ports 1110c (one for the fuel chamber FCH and one for the electrolyte chamber ECH) are arranged within a main recess 1110a of the fuel cell 1110. The ports 1110c can be separately formed therefrom and then attached thereto by, e.g., adhesives and/or a threaded connection. The ports 1110c include a plurality of openings 1110d arranged to allow fluids to enter into the fuel chamber FCH and the electrolyte chamber ECH. The ports 1110c also include a cylindrical portion whose annular free end is configured to sealingly engage with a sealing ring SR arranged within a cylindrical opening of the cartridge ports 1120c. The sealing ring SR may have any desired shape and may be made of a material such as, e.g., Viton. The two ports 1120c (one for the fuel chamber CFC and one for the electrolyte chamber CEC) project from a bottom wall of the cartridge 1120. The ports 1120c and connecting portion 1120a can be integrally formed with the cartridge body by, e.g., injection molding the body in two parts. Alternatively, the ports 1120c can be separately formed therefrom and then attached thereto by, e.g., adhesives or a threaded connection. The ports 1120c each include a main opening 1120d arranged to allow fluid to enter into the fuel chamber CFC and the electrolyte chamber CEC during initial filling and thereafter allow the fluid to exit and enter into the fuel cell 1110 once the valves 1120j and 1120i are forced open under fluid pressure. By way of non-limiting example, the chambers CFC and CEC can be initially filled with the fluids (e.g., fuel or fuel concentrate and liquid diluent and electrolyte) entering under a fluid pressure which is capable of filling the volume up to the pistons 1120e. Then, the openings are sealed with the sealing disk 1120j, spring 1120i and retaining washer 1120k (which can be press-fit into the cylindrical opening of the ports 1120c). The ports 1120c include a cylindrical portion whose annular free end is configured to also receive therein a sealing ring SR and a respective fuel cell port 1110c.

FIG. 57 shows an alternative non-limiting arrangement for the fluid-tight connection between the ports of the fuel cell FC and those of the cartridge C. This arrangement can be used in any of the previous embodiments such as the ones shown in., e.g., FIGS. 46-56. This arrangement uses two O-rings RW arranged within two O-ring grooves ORG in place of the sealing SR. The O-rings OR sealingly engage with an outer cylindrical surface of the fuel cell ports.

FIG. 58 shows still another non-limiting embodiment of a disposable fuel cell FC and cartridge C. The stand-alone power system is designed so that it can be purchased or procured as a unit assembly including a cartridge containing the fuel component(s) separated from a fuel cell which does not contain the fuel component(s). The user can then install and/or connect the power system to the desired load, e.g., a cell phone tower. Unlike the previous embodiments which require connection of the cartridge C with the fuel cell FC, this embodiment provides for a valve or pump system VS and a control system CSM. The fuel cell FC and cartridge C need not be connected directly to each other and can each instead be connected to the valve or pump system VS. When it is desired to activate the fuel cell FC, the control system CSM issues a command to the valve or pump system VS to open and/or to start transferring the contents from the cartridge C to the fuel cell FC. The system VS also prevents the fuel component(s) from moving back from the fuel cell FC to the cartridge C, as with the previously described embodiments. By way of non-limiting example, the fuel cell FC has an anode AN, a cathode CA, an electrolyte chamber ECH and a fuel chamber FCH. The width of the electrolyte chamber “x”, the width “y” of the fuel chamber FCH, the volume of the electrolyte chamber ECH and the volume of the fuel chamber FCH depend on the desired power. The cartridge C may also utilize spring P actuated pistons to cause the transfer of the fluids in the electrolyte chamber CEC and the fuel chamber CFC to the corresponding chambers ECH and FCH of the fuel cell FC.

FIG. 59 shows a schematic cross-section of a non-limiting example of a cartridge-free fuel cell FC. This fuel cell already contains all of the components that are required for the operation of the fuel cell. The fuel cell FC comprises four puncturable membranes ME₁to ME₄. Membrane ME₁divides the fuel chamber FCH into two sections FCH_s1and FCH_s2. These two sections each contain one of two components of a two-component liquid fuel, e.g., a fuel concentrate and a liquid diluent for diluting the concentrate. For example, the fuel concentrate may be present in section FCH_s1and the liquid diluent may be present in section FCH_s2. Of course, if the liquid fuel is a single-component fuel, there is no need for the presence of membrane ME₁. Membrane ME₂separates the contents of fuel chamber FCH and in particular, the contents of fuel chamber section FCH_s2from anode AN, thereby preventing contact between the contents of fuel chamber section FCH_s2and anode AN. Membrane ME₄separates the contents of electrolyte chamber ECH (i.e., the electrolyte) from anode AN, thereby preventing contact between the contents of electrolyte chamber ECH and anode AN. Membrane ME₃separates the contents of electrolyte chamber ECH from the cathode CA, thereby preventing contact between the contents of electrolyte chamber ECH and cathode CA. Of course, if the electrolyte is a two-component electrolyte, it may be desirable to arrange an additional membrane (not shown in FIG. 59) which separates the two electrolyte components from each other in electrolyte chamber ECH. Further, if there is no risk that anode AN and/or cathode CA will be adversely affected by a prolonged contact with the electrolyte or a component thereof (e.g., during storage of fuel cell FC), one or both of membranes ME₃and ME₄may be dispensed with. For example, if the electrolyte is a gel electrolyte, it may not be necessary or even desirable to provide any of these two membranes (rendering knife K₂superfluous).

The fuel cell FC also comprises two knives K₁and K₂which are connected by a plunger PL. When plunger PL is pressed down, knife K₁simultaneously rips membranes ME₁and ME₂, and at the same time knife K₂simultaneously rips membranes ME₃and ME₄(of course, each of knives K₁and K₂may be divided into two separate knives which may or may not be connected by a common plunger). Accordingly, the fuel cell is activated and able to supply power because there will no longer be a mixing barrier for the contents of fuel chamber sections FCH_s1and FCH_s2and there will also no longer be contact barriers between anode AN and the contents of fuel chamber FCH and electrolyte chamber ECH and between cathode CA and the contents of electrolyte chamber ECH.

FIG. 60 shows a schematic cross-section of another non-limiting example of a cartridge-free fuel cell FC. This fuel cell differs from the fuel cell described in connection with FIG. 59 essentially only in that one of the components of a multi-component (e.g., two-component) liquid fuel (e.g., a liquid diluent for a fuel concentrate that is already present in the fuel chamber FCH) still needs to be added to fuel chamber FCH. Accordingly, there is no need for any membrane that divides fuel chamber FCH into two or more sections. Since a component of the fuel still needs to be added to fuel chamber FCH, the latter is provided with an opening which can be (re)sealed with a cap CP (e.g., a screw cap). Once it is desired to operate fuel cell FC, the missing (e.g., liquid) component of the fuel can be introduced into fuel chamber FCH through the opening thereof and thereafter the opening can be sealed again with cap CP. The missing fuel component can be introduced into fuel chamber FCH, for example, manually with the aid of a funnel. Alternatively, it is also possible to connect the opening of fuel chamber FCH to a container (cartridge) which contains the desired amount of the missing component. This connection may, for example, be accomplished by a transferring system and valve system as described in connection with the cartridge/fuel cell combination. This system may be activated manually or automatically, e.g., in response to a predetermined condition.

Before or after the introduction of the missing fuel component, plungers PL₁and PL₂may be pressed down either simultaneously or sequentially to cause knives K₁and K₂to rip membrane ME₂which prevents contact between the contents of fuel chamber FCH and anode AN and membranes ME₃and ME₄which prevent contact between the contents of electrolyte chamber ECH and cathode CA and anode AN. Of course, plungers PL₁and PL₂may also be combined in a single plunger (as schematically illustrated in FIG. 59). As in the case of the fuel cell discussed in connection with FIG. 59, if there is no risk that anode AN and/or cathode CA would be adversely affected by a prolonged contact with the electrolyte or a component thereof (e.g., during storage of fuel cell FC), one or both of membranes ME₃and ME₄may be dispensed with. For example, if the electrolyte is a gel electrolyte, it may not be necessary or even desirable to provide any of these two membranes (rendering knife K₂superfluous).

It is noted that the fuel cell, the cartridge and the transferring system are all preferably disposable and are preferably made of light-weight (and preferably inexpensive) materials. It should also be noted that the exemplary dimensions, values, sizes, volumes, etc., disclosed herein are not intended to be limiting and may vary by as much as, e.g., 50% less to 150% more. The majority of parts of the cartridge can be made of polymer materials which are suitable for the fuel cell environment and which can withstand contact/exposure with fuel and electrolyte from a fuel cell and/or similar chemicals. Examples of non-limiting polymer materials include optionally filled PVC, PP, PE, ABS, polycarbonate and polyurethane, etc. Further, while the above-described exemplary and non-limiting embodiments of the cartridge/fuel cell power supply system of the present invention have been shown mostly in the form of a (preferred) vertical arrangement of the cartridge relative to the fuel cell, other arrangements are, of course, possible such as, e.g., a horizontal arrangement. Still further, while most of the above-described exemplary and non-limiting embodiments of the power supply system of the present invention have been indicated to be non-reusable after exhaustion of the contents thereof, each of the shown embodiments and any other embodiments within the scope of the present invention may as well be designed in a way which allows the cartridge to be detached from the fuel cell after the contents thereof have been discharged into the fuel cell. This may in some instances facilitate a recycling and/or refurbishment of the cartridge and/or the fuel cell after use thereof.

By way of non-limiting example, all types of fuels, electrolytes and electrodes which are known for use with (direct) liquid fuel cells and the like are contemplated for use by the present invention. Non-limiting examples of fuels, electrolytes and electrodes which are suitable for use in the present invention are disclosed in, e.g., U.S. Pat. Nos. 6,554,877 and 6,758,871 and in pending U.S. Patent Application Nos. US2002/0076602 A1, US2002/0142196 A1, 2003/0099876 A1, Ser. No. 10/757,849 (US2005/0155279 A1), Ser. No. 10/634,806 (US2005/0058882 A1), Ser. No. 10/758,080 (US2005/0158609 A1), Ser. No. 10/959,763 (US2006/0078783 A1), Ser. No. 10/941,020 (US2006/0057435 A1), Ser. Nos. 11/384,364, 11/384,365, 11/325,466, 11/325,326 and 60/781,340. For example, all desirable liquid electrolytes (including those of very high and very low viscosity) may be utilized in each of the disclosed embodiments. Solid electrolytes may also be utilized as well as ion exchange membranes. Matrix electrolytes can also be utilized such as, e.g., a porous matrix impregnated by a liquid electrolyte. Additionally, gel-like electrolytes can also be utilized with any one or more of the disclosed embodiments. The invention also contemplates using hydrogen elimination systems in the fuel cell and/or cartridge. Non-limiting examples of fuel cell arrangements/systems with hydrogen removal are disclosed in co-pending U.S. patent application Ser. Nos. 10/758,080 (US2005/0158609 A1) and Ser. No. 11/226,222 (US2006/0057437 A1).

It is noted that the foregoing examples have been provided merely for the purpose of explanation and are in no way to be construed as limiting of the present invention. While the present invention has been described with reference to an exemplary embodiment, it is understood that the words which have been used herein are words of description and illustration, rather than words of limitation. Changes may be made, within the purview of the appended claims, as presently stated and as amended, without departing from the scope and spirit of the present invention in its aspects. Although the present invention has been described herein with reference to particular means, materials and embodiments, the present invention is not intended to be limited to the particulars disclosed herein; rather, the present invention extends to all functionally equivalent structures, methods and uses, such as are within the scope of the appended claims.

Claims

1. A power supply system comprising: at least one liquid fuel cell which comprises at least one fuel chamber for holding a liquid fuel and at least one electrolyte chamber for holding an electrolyte;at least one cartridge comprising at least one substance selected from a liquid fuel or a component thereof and a liquid electrolyte or a component thereof; anda transfer system for transferring the contents of the at least one cartridge to the at least one liquid fuel cell;
2. The system of claim 1, wherein the system is designed as at least one of a stand-alone unit, a modular unit, and a back-up power supply system.
3. The system of claim 1, wherein the system is capable of providing an electrical energy of at least about 1,000 watt-hour.
4. The system of claim 1, wherein the system is capable of providing an electrical energy of at least about 5,000 watt-hour.
5. The system of claim 1, wherein the system is capable of providing a voltage of at least about 2 V.
6. The system of claim 1, wherein the system is capable of providing a voltage of at least about 20 V.
7. The system of claim 1, wherein the system is capable of providing a voltage of at least about 100 V.
8. The system of claim 1, wherein the system comprises at least two liquid fuel cells.
9. The system of claim 8 wherein the at least two liquid fuel cells are electrically connected in series to each other.
10. The system of claim 8, wherein the at least two liquid fuel cells are electrically connected in parallel to each other.
11. The system of claim 8, wherein each of the at least two liquid fuel cells is capable of providing an electrical energy of at least about 20 watt-hour.
12. The system of claim 1, wherein the system comprises at least about four liquid fuel cells.
13. The system of claim 1, wherein the at least one fuel chamber is substantially empty and the liquid fuel or components thereof are present in one or more cartridges.
14. The system of claim 1, wherein the at least one electrolyte chamber is substantially empty and the electrolyte or components thereof are present in one or more cartridges.
15. The system of claim 1, wherein both the at least one fuel chamber and the at least one electrolyte chamber are substantially empty and the liquid fuel or components thereof and the electrolyte or components thereof are present in one or more cartridges.
16. The system of claim 1, wherein the at least one electrolyte chamber contains an electrolyte or a component thereof.
17. The system of claim 1, wherein the electrolyte chamber comprises a gel electrolyte.
18. The system of claim 1, wherein the at least one electrolyte chamber comprises a liquid electrolyte.
19. The system of claim 1, wherein the at least one electrolyte chamber contains a first component of a liquid electrolyte and the at least one cartridge contains a second component of the liquid electrolyte which in combination with the first component affords the liquid electrolyte.
20. The system of claim 1, wherein the liquid fuel comprises a fuel concentrate and a liquid for diluting the concentrate and wherein both the fuel concentrate and the liquid are present in one or more cartridges.
21. The system of claim 1, wherein the liquid fuel comprises a fuel concentrate and a liquid for diluting the concentrate and wherein at least a part of the liquid is present in the at least one fuel chamber and the concentrate is present in the at least one cartridge.
22. The system of claim 1, wherein the at least one cartridge comprises in separate sections thereof at least two of (i) a liquid fuel or a concentrate thereof, (ii) a liquid for diluting the fuel concentrate and (iii) a liquid electrolyte or a liquid component thereof.
23. The system of claim 24, wherein the at least one cartridge comprises in separate sections thereof a liquid fuel concentrate and a liquid for diluting the fuel concentrate.
24. The system of claim 25, wherein the at least one cartridge comprises a liquid electrolyte in a section thereof which is separate from the sections for the concentrate and the liquid.
25. The system of claim 1, wherein the at least one cartridge comprises at least one puncturable cap.
26. The system of claim 1, wherein the at least one cartridge comprises at least one puncturable separating wall dividing the cartridge into at least two separate sections.
27. The system of claim 1, wherein the at least one fuel cell comprises at least one device for puncturing at least one of a puncturable separating wall and a puncturable cap of the at least one cartridge.
28. The system of claim 1, wherein the at least one cartridge is connected to the at least one fuel cell by the transfer system.
29. The system of claim 1, wherein the at least one cartridge is non-removably connected to the at least one fuel cell by the transfer system.
30. The system of claim 28, wherein the transfer system connects the at least one fuel cell to more than one cartridge.
31. The system of claim 28, wherein the transfer system connects the at least one cartridge to more than one fuel cell.
32. The system of claim 1, wherein the transfer system comprises a frame and a device for at least one of (a) moving, (b) automatically moving upon activation, (c) allowing upon activation, and (d) guiding upon activation, the at least one cartridge from a first position wherein the at least one cartridge is not connected to the at least one fuel cell to a second position wherein the at least one cartridge is connected to the at least one fuel cell.
33. The system of claim 1, wherein the transfer system comprises a frame and a device for forcing, upon activation, the contents of the at least one cartridge into the at least one fuel cell.
34. The system of claim 1, wherein the transfer system comprises a frame and a device for moving, upon activation, the at least one cartridge from a first position wherein the at least one cartridge is not connected to the at least one fuel cell to a second position wherein the at least one cartridge is connected to the at least one fuel cell, whereby the contents of the at least one cartridge in the second position are automatically transferred to the at least one fuel cell.
35. The system of claim 33, wherein the system further comprises an enclosure for housing the at least one cartridge and the at least one fuel cell.
36. The system of claim 34, wherein the system further comprises an enclosure for housing the at least one cartridge and the at least one fuel cell.
37. The system of claim 1, wherein the system is configured to allow the contents of the at least one cartridge to be transferred to the at least one fuel cell due at least partially to gravity.
38. The system of claim 1, wherein the system is configured for transferring the contents of the at least one cartridge to the at least one fuel cell due at least partially to a biasing force.
39. The system of claim 1, wherein the at least one cartridge is configured to slide into an opening in the at least one fuel cell.
40. The system of claim 1, wherein the system is designed to cause the transfer system to transfer the contents of the at least one cartridge to the at least one fuel cell based on a predetermined condition.
41. The system of claim 40, wherein the system further comprises a sensing system for sensing the predetermined condition.
42. The system of claim 40, wherein the system further comprises an activation system for activating the transfer system based on the predetermined condition.
43. The system of claim 41, wherein the system further comprises an activation system for activating the transfer system based on a sensing of the predetermined condition by the sensing system.
44. The system of claim 1, wherein the system further comprises a valve system which connects the at least one cartridge to the at least one fuel cell.
45. The system of claim 1, wherein the transfer system comprises a valve system connected to each of the at least one cartridge and the at least one fuel cell.
46. The system of claim 45, wherein the valve system comprises a plurality of entrance ports and exit ports which are in fluid communication with each of the at least one cartridge and the at least one fuel cell.
47. The system of claim 1, wherein a volume of the at least one fuel chamber of the at least one fuel cell is at least about 0.5 liters.
48. The system of claim 1, wherein a total fuel chamber volume of the entire system is at least about 2 liters.
49. The system of claim 1, wherein the at least one cartridge comprises up to about 50 liters of liquid fuel or of a fuel concentrate plus a liquid for diluting the fuel concentrate.
50. The system of claim 1, wherein the at least one cartridge comprises up to about 10 liters of a liquid electrolyte or a component thereof.
51. The system of claim 1, wherein the at least one fuel cell comprises a generally rectangular housing.
52. The system of claim 51, wherein the at least one cartridge comprises a generally rectangular housing.
53. The system of claim 1, wherein the at least one fuel cell comprises a generally cylindrical housing.
54. The system of claim 53, wherein the at least one cartridge comprises a generally cylindrical housing.
55. The system of claim 1, wherein the liquid fuel comprises at least one of a hydride compound and a borohydride compound.
56. The system of claim 1, wherein the liquid fuel comprises at least one borohydride compound and comprises a concentrate and a liquid for diluting the concentrate.
57. The system of claim 56, wherein the at least one borohydride compound is selected from NaBH4, KBH4, LiBH4, NH4BH4, Be(BH4)2, Ca(BH4)2, Mg(BH4)2, Zn(BH4)2, AI(BH4)3, polyborohydrides, (CH3)3NBH3, and NaCNBH3.
58. The system of claim 56, wherein the concentrate comprises one or more borohydride compounds in a total concentration of at least about 0.5 mole per liter of concentrate.
59. The system of claim 1, wherein the electrolyte comprises an alkali metal hydroxide.
60. The system of claim 1, wherein the system comprises a plurality of liquid fuel cells and comprises liquid fuel cells which are electrically connected in parallel to each other and liquid fuel cells which are electrically connected in series to each other.
61. The system of claim 1, wherein the system further comprises a battery which is capable of supplying power during a time where the at least one fuel cell is powered up.
62. The system of claim 1, wherein the system further comprises a DC to AC converter.
63. A power supply system comprising: at least one liquid fuel cell which comprises at least one fuel chamber for holding a liquid fuel and at least one electrolyte chamber for holding an electrolyte;at least one cartridge comprising at least one substance selected from a liquid fuel or a component thereof and a liquid electrolyte or a component thereof; anda transfer system for transferring the contents of the at least one cartridge to the at least one liquid fuel cell;
64. The system of claim 63, wherein the system further comprises an activation system for activating the transfer system based on the predetermined condition.
65. The system of claim 64, wherein the system further comprises a sensing system for sensing the predetermined condition.
66. A power supply system comprising: at least one liquid fuel cell which comprises at least one fuel chamber for holding a liquid fuel and at least one electrolyte chamber for holding an electrolyte;at least one cartridge comprising at least one substance selected from a liquid fuel or a component thereof and a liquid electrolyte or a component thereof; anda transfer system for transferring the contents of the at least one cartridge to the at least one liquid fuel cell;the transfer system comprising a frame and (i) a device for forcing, upon activation, the contents of the at least one cartridge into the at least one fuel cell or (ii) a device for at least one of (a) moving, (b) automatically moving upon activation, (c) allowing upon activation, and (d) guiding upon activation, the at least one cartridge from a first position wherein the at least one cartridge is not connected to the at least one fuel cell to a second position wherein the at least one cartridge is connected to the at least one fuel cell.
67. A power supply system comprising: at least one direct liquid fuel cell; anda system or device for transferring liquid fuel or a component thereof to the at least one fuel cell,wherein the power supply system is capable of providing an electrical energy of at least about 500 watt-hour.
68. The power supply system of claim 67, wherein the system comprises a liquid fuel which comprises at least one borohydride compound.
69. A load in electrical contact with a power supply system, wherein the power supply system comprises at least one direct liquid fuel cell which comprises at least one fuel chamber for holding a liquid fuel and at least one electrolyte chamber for holding an electrolyte;at least one cartridge comprising at least one substance selected from a liquid fuel or a component thereof and a liquid electrolyte or a component thereof; anda transfer system for transferring the contents of the at least one cartridge to the at least one liquid fuel cell;and wherein the load has an electric power of at least about 20 watts and the power supply system is capable of powering the load and providing an electrical energy of at least about 100 watt-hour.
70. The load of claim 69, wherein the load comprises a hospital or facility thereof, a store or facility thereof, an office or facility thereof, a communications system, or a home.
71. The load of claim 69, wherein the load comprises at least one of a cell phone tower, an industrial motor, a life support system, a computer system, a facsimile machine, an emergency lighting system, an air conditioner, a furnace fan, a space heater, a water heater, a freezer, a refrigerator, a range, a hotplate, a microwave oven, a water well pump, a sump pump, and a battery charger.
72. The load of claim 69, wherein the system comprises a liquid fuel which comprises at least one borohydride compound.
73. A method of generating electrical power during a power outage, wherein the method comprises activating the power supply system of claim 1.
74. The method of claim 73, wherein the method comprises activating the power supply system based on a predetermined condition.
75. A method of generating electrical energy during a power outage, wherein the method comprises activating a power supply system for one-time use which comprises at least one direct liquid fuel cell and a hydride or borohydride containing liquid fuel and is capable of providing an electrical energy of at least about 100 watt-hour.
76. The method of claim 75, wherein the power supply system comprises at least about four direct liquid fuel cells which are electrically connected to each other.
77. The method of claim 75, wherein the method comprises automatically activating the system when the power outage is detected.
78. A method of supplying a customer with an emergency power supply, wherein the method comprises supplying the customer with a power supply system for one-time use or a component thereof, the system comprising at least one direct liquid fuel cell.
79. The method of claim 78, wherein the system further comprises at least one cartridge comprising at least one substance selected from a liquid fuel or a component thereof and a liquid electrolyte or a component thereof.
80. The method of claim 79, wherein the system further comprises a transfer system for transferring the contents of the at least one cartridge to the at least one fuel cell.
81. The method of claim 79, wherein the liquid fuel comprises at least one of a hydride compound and a borohydride compound.
82. The method of claim 78, wherein the power supply system is capable of providing an electrical energy of at least about 100 watt-hour.
83. The method of claim 78, wherein the method further comprises providing the customer with an opportunity to return the used power supply system or component thereof.
84. The method of claim 78, further comprising providing the customer with an opportunity to exchange a used power supply system or component thereof for an operational power supply system or component thereof.
85. The method of claim 83, wherein the method further comprises refurbishing a returned power supply system or component thereof and offering the refurbished system or component thereof for sale to the same or a different customer.
86. The method of claim 78, wherein the method further comprises offering to at least one of deliver and install the power supply system or a component thereof at a location specified by the customer.
87. The method of claim 86, wherein the method further comprises offering to pick up a used power supply system or component thereof and replace it by a new power supply system or component thereof.
88. The method of claim 86, wherein the method further comprises offering to refurbish a used power supply system or component thereof at the location.
89. The method of claim 86, wherein the method further comprises offering to check and, if needed, repair an installed power supply system at the location in periodic intervals to ensure operability thereof at the time of use.
90. The method of claim 78, wherein the customer is a private customer.
91. The method of claim 78, wherein the customer is a commercial customer.
92. A power supply system comprising at least one liquid fuel cell, wherein the at least one fuel cell comprises a cathode, an anode, a fuel chamber comprising a liquid fuel or at least one component thereof on one side of the anode and an electrolyte chamber comprising an electrolyte or at least one component thereof between the anode and the cathode, and wherein at least the contents of the fuel chamber are separated from the anode by a first separating device which is at least one of removable from the anode and puncturable and wherein the system further comprises a first activation device by which the first separating device can be at least one of removed from the anode and punctured to allow the contents of the fuel chamber to contact the anode.
93. The system of claim 92, wherein the contents of the electrolyte chamber are separated from the anode by a second separating device which is at least one of removable from the anode and puncturable and wherein the system further comprises a second activation device by which the second separating device can be at least one of removed from the anode and punctured to allow the contents of the electrolyte chamber to contact the anode.
94. The system of claim 92, wherein the contents of the electrolyte chamber are separated from the cathode by a third separating device which is at least one of removable from the cathode and puncturable and wherein the system further comprises a third activation device by which the third separating device can be at least one of removed from the cathode and punctured to allow the contents of the electrolyte chamber to contact the cathode.
95. The system of claim 92, wherein the liquid fuel comprises a fuel concentrate and a liquid for diluting the concentrate and wherein the fuel chamber is divided into at least a first fuel chamber section and a second fuel chamber section by a fourth separating device which is at least one of puncturable and removable, one of the first and second fuel chamber sections comprising the concentrate and the other one of the first and second fuel chamber sections comprising the liquid, and wherein the system further comprises a fourth activation device by which the fourth separating device can be at least one of punctured and removed to allow the concentrate and the liquid to mix.
96. The system of claim 92, wherein the electrolyte comprises a first liquid component and a second component and wherein the fuel chamber is divided into at least a first electrolyte chamber section and a second electrolyte chamber section by a fifth separating device which is at least one of puncturable and removable, one of the first and second electrolyte chamber sections comprising the first component and the other one of the first and second electrolyte chamber sections comprising the second component, and wherein the system further comprises a fifth activation device by which the fifth separating device can be at least one of punctured and removed to allow the first and second components to mix.
97. The system of claim 92, wherein the first separating device comprises a membrane.
98. The system of claim 97, wherein the first activation device comprises a blade.
99. The system of claim 93, wherein the second separating device comprises a membrane.
100. The system of claim 99, wherein the second activation device comprises a blade.
101. The system of claim 93, wherein the first and second activation devices are combined in a single activation device.
102. The system of claim 95, wherein the fourth separating device comprises a membrane.
103. The system of claim 102, wherein the fourth activation device comprises a blade.
104. The system of claim 95, wherein the first and fourth activation devices are combined in a single activation device.
105. The system of claim 92, wherein the system is capable of providing an electrical energy of at least about 500 watt-hour.
106. The system of claim 92, wherein the system is designed as at least one of a stand-alone unit, a modular unit, and a back-up power supply system.
107. The system of claim 92, wherein the system comprises a plurality of fuel cells which are electrically connected at least one of in series to each other and parallel to each other.
108. The system of claim 92, wherein the at least one liquid fuel cell is capable of providing an electrical energy of at least about 20 watt-hour.
109. The system of claim 92, wherein the electrolyte chamber comprises a gel electrolyte.
110. The system of claim 92, wherein the electrolyte chamber comprises a liquid electrolyte.
111. The system of claim 92, wherein the system is designed to cause the first activation device to at least one of puncture and remove the first separating device based on a predetermined condition.
112. The system of claim 111, wherein the system further comprises a sensing system for sensing the predetermined condition.
113. The system of claim 111, wherein the system further comprises an activation system for activating the first activation system based on the predetermined condition.
114. The system of claim 92, wherein a volume of the fuel chamber of the at least one fuel cell is at least about 0.5 liters.
115. The system of claim 92, wherein a volume of the fuel chamber of the at least one fuel cell is not larger than about 20 liters.
116. The system of claim 92, wherein a total fuel chamber volume of the entire system is at least about 2 liters.
117. The system of claim 92, wherein the liquid fuel comprises at least one of a hydride compound and a borohydride compound.
118. The system of claim 117, wherein the liquid fuel comprises at least one borohydride compound selected from NaBH4, KBH4, LiBH4, NH4BH4, Be(BH4)2, Ca(BH4)2, Mg(BH4)2, Zn(BH4)2, AI(BH4)3, polyborohydrides, (CH3)3NBH3, and NaCNBH3.
119. The system of claim 117, wherein the electrolyte comprises an alkali metal hydroxide.
120. The system of claim 92, wherein the liquid fuel comprises a fuel concentrate and a liquid for diluting the concentrate, wherein the fuel chamber comprises the concentrate and wherein the fuel cell has an opening for transferring the liquid to the fuel chamber.
121. The system of claim 92, wherein the electrolyte comprises a first liquid component and a second component, wherein the electrolyte chamber comprises the second component and wherein the fuel cell has an opening for transferring the first liquid component to the electrolyte chamber.

Stationary cartridge based fuel cell system, fuel cell power supply system, and method of activating the fuel cell

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CPC

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