US20050162122A1 - Fuel cell power and management system, and technique for controlling and/or operating same - Google Patents

Abstract

There are many inventions described and illustrated herein. In one aspect, the present invention is directed to a portable fuel cell power and management system (for example, hydrogen and/or methanol based systems), components and/or elements thereof, as well as techniques for controlling and/or operating such systems. The fuel cell power management system (and method of controlling and/or operating same) actively monitors, manages and/or controls one or more operating parameter(s) of the fuel cell system. For example, the system monitors, manages and/or controls the consumption and/or the rate of consumption of fuel by the system, and in response thereto, may provide and/or alert the user to amount of fuel remaining, consumed, the rate of consumption and/or the time (or estimation thereof remaining until all of the fuel is spent. In this way, the user may schedule or plan accordingly.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS
• This application claims priority to U.S. Provisional Application Ser. No. 60/538,646, entitled “Integrated Fuel Management System for Fuel Cells”, filed Jan. 22, 2004 (hereinafter “the Provisional Application”). The contents of the Provisional Application are incorporated by reference herein in their entirety.
BACKGROUND OF THE INVENTION
• This invention relates to fuel cell power and management systems, and techniques for controlling and/or operating such systems; and more particularly, in one aspect, to fuel cell power and management systems, for example, hydrogen and/or methanol based systems, as well as components, elements and/or subsystems therefore.
• Generally, small portable electrical and electronic devices often employ batteries as a power source. However, conventional batteries have limited energy storage capacity and must either be discarded or recharged after they have depleted their limited energy storage capacity. If thrown away, conventional batteries present environmental hazards because of the toxic material used in manufacturing the batteries. If recharged, the recharging process of conventional batteries is time consuming and as the age of these batteries increases it becomes more and more difficult to determine the state of charge of the battery. In this regard, the life becomes unpredictable and unreliable, and so the user often discards the batteries before the useful life is complete, thus incurring additional cost by the user having to carry extra batteries. Applications like professional video cameras, laptop computers, and cell phones often require longer runtimes than conventional batteries can provide.
• In addition to battery based systems, fuel cell systems may be employed to provide a portable source of electrical power. In one embodiment, fuel cell systems employ, for example, hydrogen, hydrogen rich gas, hydrogen containing compound or a substance from which hydrogen can be extracted on demand (i.e., a hydride storage cartridge). Such fuel cell systems typically include an anode end for splitting hydrogen atoms into electrons and protons, a current bearing portion providing a pathway for the electrons, a medium such as a proton exchange membrane providing a pathway for the protons, and a cathode end for rejoining the electrons and protons into water molecules in the presence of oxygen. Conventional fuel cells often generate electricity over a longer time period than conventional batteries, provided that the fuel (for example, hydrogen) in the storage container is periodically refreshed. (See, for example, U.S. Pat. Nos. 5,683,828; 5,858,567; 5,863,671; and 6,051,331).
SUMMARY OF THE INVENTION
• There are many inventions described and illustrated herein as well as many aspects and embodiments of those inventions. In a first principal aspect, the present invention is a hydrogen-based fuel cell management system comprising a hydrogen-based fuel cartridge to store hydrogen-based fuel and a power unit, coupled to the hydrogen-based fuel cartridge, to generate electrical power from the hydrogen-based fuel. The hydrogen-based fuel cartridge, in this aspect of the invention, includes a fuel vessel adapted to store hydrogen-based fuel, memory to store data which is representative of at least one operating parameter of the hydrogen-based fuel cartridge, and control circuitry (for example, a microprocessor or microcontroller). The power unit includes a hydrogen-based fuel cell, adapted to receive the hydrogen-based fuel and generate electrical power therefrom.
• The at least one operating parameter may be the amount of hydrogen-based fuel that is remaining in the fuel vessel. In one embodiment, the control circuitry may monitor the amount of hydrogen-based fuel that is remaining in the fuel vessel using an amount of time the hydrogen-based fuel cartridge provides hydrogen-based fuel to power unit. In another embodiment, the control circuitry monitors the amount of hydrogen-based fuel that is remaining using data which is representative of the pressure and temperature of the fuel in the fuel vessel.
• The at least one operating parameter may be the rate of consumption of the hydrogen-based fuel by the power unit. In one embodiment, the control circuitry monitors the rate of consumption of the hydrogen-based fuel by the power unit using one or more sensors that provides data which is representative of the rate of flow of the fuel, the pressure of the fuel in the vessel and the temperature of the fuel in the vessel.
• In one embodiment, the memory further stores data which is representative of one or more unique characteristics of hydrogen-based fuel cartridge. The one or more unique characteristics of hydrogen-based fuel cartridge may include at least one of a serial number of the fuel cartridge, date of manufacture of the fuel cartridge, date of assembly of the fuel cartridge, type of fuel contained in fuel vessel, fuel capacity of the fuel cartridge, and number of refill operations the fuel cartridge has undergone.
• Notably, the memory may also store data which is representative of general characteristics of hydrogen-based fuel cartridge.
• In one embodiment, the hydrogen-based fuel cartridge may also include a display to visually display information which is representative of the at least one operating parameter.
• The control circuitry of the fuel cartridge may intermittently, continuously or periodically determines the at least one operating parameter of the hydrogen-based fuel cartridge and intermittently, continuously or periodically store data which is representative of the at least one operating parameter of the hydrogen-based fuel cartridge in the memory. In one embodiment, the memory and the control circuitry are disposed on the same integrated circuit device.
• The power unit may also include control circuitry to determine the at least one operating parameter of the hydrogen-based fuel cartridge (for example, the amount of hydrogen-based fuel that has been consumed from the fuel vessel). In this embodiment, the control circuitry of the power unit may intermittently, continuously or periodically determines the at least one operating parameter of the hydrogen-based fuel cartridge and intermittently, continuously or periodically store data which is representative of the at least one operating parameter of the hydrogen-based fuel cartridge in the memory of the fuel cartridge.
• Where the at least one operating parameter is the amount of hydrogen-based fuel that is remaining in the fuel vessel, in one embodiment, the control circuitry of the power unit may determine the amount of hydrogen-based fuel that is remaining in the fuel vessel using an amount of time the hydrogen-based fuel cartridge provides hydrogen-based fuel to power unit. In another embodiment, the control circuitry of the power unit determines the amount of hydrogen-based fuel that is remaining using data which is representative of the pressure and temperature of the fuel in the fuel vessel.
• The hydrogen-based fuel cartridge of this aspect of the invention may also include communication circuitry to provide data which is representative of the at least one operating parameter of the hydrogen-based fuel cartridge to external circuitry. The communication circuitry may employ wireless communications techniques.
• In another principal aspect, the present invention is a hydrogen-based fuel cell management system comprising a hydrogen-based fuel cartridge to store hydrogen-based fuel, a power unit, coupled to the hydrogen-based fuel cartridge, to generate electrical power from the hydrogen-based fuel, and a refill unit, adapted to connect with the hydrogen-based fuel cartridge, to provide fuel to the hydrogen-based fuel cartridge for storage in the fuel vessel. The hydrogen-based fuel cartridge, in this aspect of the invention, includes a fuel vessel adapted to store hydrogen-based fuel, memory to store data which is representative of at least one operating parameter of the hydrogen-based fuel cartridge, and control circuitry (for example, a microprocessor or microcontroller). The power unit includes a hydrogen-based fuel cell, adapted to receive the hydrogen-based fuel and generate electrical power therefrom.
• The at least one operating parameter may be the amount of hydrogen-based fuel that is remaining in the fuel vessel. In one embodiment, the power unit includes control circuitry to determine the amount of hydrogen-based fuel that is remaining in the fuel vessel using an amount of time the hydrogen-based fuel cartridge provides hydrogen-based fuel to power unit. The control circuitry of the power unit may monitor the amount of hydrogen-based fuel that is remaining in the fuel vessel using an amount of time the hydrogen-based fuel cartridge provides hydrogen-based fuel to power unit. In another embodiment, the control circuitry of the power unit may monitor the amount of hydrogen-based fuel that is remaining using data which is representative of the pressure and temperature of the fuel in the fuel vessel. The at least one operating parameter may be the rate of consumption of the hydrogen-based fuel by the power unit.
• The memory may store data which is representative of one or more unique characteristics of hydrogen-based fuel cartridge and/or general characteristics of hydrogen-based fuel cartridge. The one or more unique characteristics of hydrogen-based fuel cartridge may include at least one of a serial number of the fuel cartridge, date of manufacture of the fuel cartridge, date of assembly of the fuel cartridge, type of fuel contained in fuel vessel, fuel capacity of the fuel cartridge, and number of refill operations the fuel cartridge has undergone.
• In one embodiment, the hydrogen-based fuel cartridge may include a display to visually display information which is representative of the at least one operating parameter.
• The power unit may include control circuitry to determine the at least one operating parameter of the hydrogen-based fuel cartridge. Indeed, the control circuitry of the power unit may intermittently, continuously or periodically determine the at least one operating parameter of the hydrogen-based fuel cartridge and intermittently, continuously or periodically store data which is representative of the at least one operating parameter in the memory of the fuel cartridge.
• The refill unit may include control circuitry to determine the at least one operating parameter of the hydrogen-based fuel cartridge. In this regard, the control circuitry of the refill unit may intermittently, continuously or periodically determine the at least one operating parameter of the hydrogen-based fuel cartridge and intermittently, continuously or periodically store data which is representative of the at least one operating parameter in the memory of the fuel cartridge. Where the at least one operating parameter is the amount of hydrogen-based fuel that is remaining in the fuel vessel, the control circuitry of the refill unit may determine the amount of hydrogen-based fuel that is remaining in the fuel vessel using an amount of time the hydrogen-based fuel cartridge receives hydrogen-based fuel from refill unit. In addition or in lieu thereof, the control circuitry of the refill unit may determine the amount of hydrogen-based fuel that is remaining using data which is representative of the pressure and temperature of the fuel in the fuel vessel. Notably, the at least one operating parameter may be, among other things, the amount of hydrogen-based fuel that has been consumed from the fuel vessel.
• In another principal aspect, the present invention is a hydrogen-based fuel cell management system comprising a hydrogen-based fuel cartridge to store hydrogen-based fuel, a power unit, coupled to the hydrogen-based fuel cartridge, to generate electrical power from the hydrogen-based fuel. In this aspect, the hydrogen-based fuel cartridge includes a fuel vessel adapted to store hydrogen-based fuel, a cartridge interface including a mechanical interface, a cartridge valve assembly, control circuitry, and memory to store data which is representative of a plurality of operating parameters of the hydrogen-based fuel cartridge. The power unit of this aspect of the invention includes a power unit interface, including a mechanical interface to mechanically connect to the mechanical interface of the cartridge interface, and a power unit valve assembly to engage the cartridge valve assembly and to enable hydrogen-based fuel to flow from the hydrogen-based fuel cartridge to the power unit. The power unit also includes a hydrogen-based fuel cell, coupled to the power unit valve assembly to receive the hydrogen-based fuel from the fuel cartridge and to generate electrical power therefrom.
• In one embodiment, at least one of the plurality of operating parameters is the amount of hydrogen-based fuel that is remaining in the fuel vessel. In another embodiment, at least one of the plurality of operating parameters is the rate of consumption of hydrogen-based fuel by the power unit.
• The memory may store data which is representative of one or more unique characteristics of hydrogen-based fuel cartridge and/or data which is representative of general characteristics of hydrogen-based fuel cartridge. The one or more unique characteristics of hydrogen-based fuel cartridge includes at least one of a serial number of the fuel cartridge, date of manufacture of the fuel cartridge, date of assembly of the fuel cartridge, type of fuel contained in fuel vessel, fuel capacity of the fuel cartridge, and number of refill operations the fuel cartridge has undergone.
• In one embodiment, the hydrogen-based fuel cartridge further includes a display to visually display information which is representative of one or more of the plurality of operating parameters of the hydrogen-based fuel cartridge.
• In one embodiment, the power unit includes control circuitry to intermittently, continuously or periodically determine one or more of the plurality of operating parameters of the hydrogen-based fuel cartridge. The control circuitry of the power unit may intermittently, continuously or periodically store the data which is representative of one or more of the plurality of operating parameters in the memory of the fuel cartridge.
• Again, there are many inventions described and illustrated herein, as well as many aspects and embodiments of those inventions. This Summary of the Invention is not exhaustive of the scope of the present invention. Moreover, this Summary of the Invention is not intended to be limiting of the invention and should not be interpreted in that manner. While certain embodiments, features, attributes and advantages of the inventions have been described in this Summary of the Invention, it should be understood that many others, as well as different and/or similar embodiments, features, attributes and/or advantages of the present inventions, which are apparent from the description, illustrations and claims, which follow.
BRIEF DESCRIPTION OF THE DRAWINGS
• In the course of the detailed description to follow, reference will be made to the attached drawings. These drawings show different aspects of the present invention and, where appropriate, reference numerals illustrating like structures, components, materials and/or elements in different figures are labeled similarly. It is understood that various combinations of the structures, components, materials and/or elements, other than those specifically shown, are contemplated and are within the scope of the present invention.
• FIG. 1A is a block diagram representation of a portable fuel cell power and management system, including a fuel cartridge and power unit, according to a first aspect of the present invention;
• FIG. 1B is a block diagram representation of a portable fuel cell power and management system, including a fuel cartridge (rechargeable-type), power unit and refill unit, according to a second aspect of the present invention;
• FIG. 2 is a block diagram representation of selected mechanical elements of a fuel cartridge according to one aspect of one embodiment of the present invention;
• FIGS. 3A and 3B are perspective and cross-sectional views, respectively, of a fuel vessel of a fuel cartridge according to one aspect of one embodiment of the present invention, including exemplary dimensions of certain aspects pertaining to the fuel vessel (see,FIG. 3B);
• FIG. 3C is a cross-sectional view of a fuel vessel of a fuel cartridge according to one aspect of one embodiment of the present invention, in conjunction with the cartridge valve assembly and cartridge collar assembly;
• FIG. 4A illustrates a perspective exploded view of a poppet assembly, wherein the burst disc and retainer are separated from the remaining elements of the poppet assembly, according to one aspect of one embodiment of the present invention;
• FIG. 4B illustrates a perspective assembled view of the exemplary poppet assembly ofFIG. 4A;
• FIG. 4C illustrates a side view of the exemplary poppet assembly ofFIG. 4B;
• FIG. 4D illustrates a cross-section view of the exemplary poppet assembly ofFIG. 4C sectioned along lines A-A;
• FIG. 4E illustrates an end view (from the distal end) of the exemplary poppet assembly ofFIG. 4B;
• FIG. 5A illustrates a perspective exploded view of a cartridge valve assembly, according to one aspect of one embodiment of the present invention;
• FIG. 5B illustrates a perspective assembled view of the exemplary cartridge valve assembly ofFIG. 5A;
• FIG. 5C illustrates a side view of the exemplary cartridge valve assembly ofFIG. 5B;
• FIG. 5D illustrates a cross-section view of the exemplary cartridge valve assembly ofFIG. 5C sectioned along lines A-A, wherein the cartridge valve assembly is in the closed state;
• FIG. 5E illustrates an end view (from the distal end) of the exemplary cartridge valve assembly ofFIG. 5B;
• FIG. 6A illustrates a perspective view of the exemplary cartridge valve assembly ofFIG. 5B, according to one aspect of one embodiment of the present invention;
• FIG. 6B illustrates a cross-sectional view of certain components of the exemplary cartridge valve assembly ofFIG. 6A when the valve is in a closed state;
• FIG. 6C illustrates a cross-sectional view of certain components of the exemplary cartridge valve assembly ofFIG. 6A when the valve is in an open state;
• FIG. 7A illustrates a perspective exploded view of a cartridge valve assembly, according to another embodiment of an aspect of the present invention;
• FIG. 7B illustrates a perspective assembled view of the exemplary cartridge valve assembly ofFIG. 7A;
• FIG. 7C illustrates an end view (from the distal end) of the exemplary cartridge valve assembly ofFIG. 7B;
• FIG. 7D illustrates a side view of the exemplary cartridge valve assembly ofFIG. 7B;
• FIG. 7E illustrates a cross-section view of the exemplary cartridge valve assembly ofFIG. 7D sectioned along lines A-A, wherein the cartridge valve assembly is in the closed state;
• FIG. 7F illustrates a cross-section view of the exemplary cartridge valve assembly ofFIG. 7D sectioned along lines A-A, wherein the cartridge valve assembly is in the open state;
• FIGS. 8A and 8B illustrate an exploded perspective and a perspective view, respectively, of the fuel cartridge according to one embodiment of an aspect of the present invention wherein the fuel cartridge includes cartridge collar assembly;
• FIGS. 9A and 10A illustrate exploded perspective views of the cartridge collar assembly, according to one embodiment, in conjunction with portions of the cartridge interface, cartridge electronics and cartridge display;
• FIGS. 9B and 10B illustrate perspective views of the cartridge collar assembly, according to one embodiment, in conjunction with portions of the cartridge interface and cartridge display;
• FIG. 11A is a perspective view of the electrical interface of the cartridge interface, according to one embodiment, in conjunction with the cartridge collar assembly and a portion of the electrical interface of the power unit or refill unit (if applicable), wherein contacts of the power unit or refill unit engage the contact pads of the electrical interface of the cartridge interface of the fuel cartridge;
• FIG. 11B is a perspective view of the electrical interface, according to one exemplary embodiment of an aspect of the present invention;
• FIG. 12 is a perspective view of the mechanical interface of the cartridge interface, according to one embodiment, in conjunction with the cartridge collar assembly and a portion of the mechanical interface of the power unit or refill unit (if applicable);
• FIG. 13A illustrates a perspective exploded view of certain components of the cartridge electronics and cartridge display of the fuel cartridge, according to one exemplary embodiment of the present invention;
• FIG. 13B illustrates a perspective assembled view of certain components of the exemplary cartridge electronics and cartridge display ofFIG. 13A;
• FIG. 13C illustrates a side view of the exemplary cartridge electronics and cartridge display ofFIG. 13B;
• FIGS. 14A, 14B and14C are schematic block diagrams of the cartridge electronics, in conjunction with the cartridge display, according to exemplary embodiments of one aspect of the present invention;
• FIGS. 14D, 14E and14F are schematic block diagrams of the cartridge electronics according to other exemplary embodiments of one aspect of the present invention;
• FIG. 15 illustrates a schematic representation of components of the cartridge electronics and cartridge display, according to another exemplary embodiment of an aspect of the present invention;
• FIG. 16A illustrates a side, perspective view of a power unit having one port to receive a fuel cartridge, in conjunction with and coupled to the fuel cartridge, in accordance with one exemplary embodiment of the present invention;
• FIG. 16B illustrates a front, perspective view of a port of the power unit ofFIG. 16A, wherein the port includes an electrical and mechanical interface to receive, engage and secure a fuel cartridge;
• FIGS. 17A, 17B,17C,17D and17E are schematic block diagrams of the power unit electronics, in conjunction with the power unit display and the electrical interface of the power cartridge (among other things), according to exemplary embodiments of aspects of the present invention;
• FIG. 18A illustrates a perspective view of a refill unit, having four refill ports, in accordance with an exemplary embodiment of an aspect of the present invention;
• FIG. 18B illustrates a front, perspective view of a refill port of the refill unit ofFIG. 18A;
• FIGS. 19A, 19B,19C,19D, and19E are schematic block diagrams of the refill unit electronics, in conjunction with the electrical interface of the power cartridge (among other things), according to exemplary embodiments of aspects of the present invention; and
• FIG. 20 illustrates a perspective partial cross-sectional view of a cartridge valve assembly, including temperature sensor-relief port assembly, according to one exemplary embodiment of the present invention.
DETAILED DESCRIPTION
• There are many inventions described and illustrated herein. In one aspect, the present invention is directed to a portable fuel cell power and management system (for example, hydrogen and/or methanol based systems), components and/or elements thereof, as well as techniques for controlling and/or operating such systems. The fuel cell power management system (and method of controlling and/or operating same) actively monitors, manages and/or controls one or more operating parameter(s) of the fuel cell system. For example, the system monitors, manages and/or controls the consumption and/or the rate of consumption of fuel by the system, and in response thereto, may provide and/or alert the user to amount of fuel remaining, consumed, the rate of consumption and/or the time (or estimation thereof) remaining until all of the fuel is spent. In this way, the user may schedule or plan accordingly.
• In one embodiment, the present invention includes a fuel cartridge and a power unit. The fuel cartridge contains the fuel to be employed by the power unit to generate electricity therefrom. The fuel cartridge connects to the power unit to provide the fuel to a fuel cell in or on the power unit. In one embodiment, the fuel is hydrogen or methanol. However, the present invention may be implemented in conjunction with any fuel and fuel cell system, whether now known or later developed; as such; all portable fuel cell type systems (whether rechargeable or not) are intended to fall within the scope of the present invention. Notably, while this application is often couched in the context of a hydrogen or methanol fuel, it is to be understood that the invention is applicable to other fuels and associated management systems.
• As mentioned above, the fuel cell power management system (and method of monitoring, managing and/or controlling and/or operating same) of the present invention actively monitors, manages and/or controls one or more operating parameter(s) of the fuel cell system. These operating parameters may be, for example, fuel consumption and/or rate thereof, temperature (of, for example, the fuel cartridge), pressure (of, for example, the fuel in the fuel cartridge), electrical power consumption (including, for example, voltage and current generation by the power unit and/or output thereby, and/or current consumption), and/or any malfunctions or faults (for example, a fuel leak, mechanical, electrical and/or electronic interface fault) of the system, or components, elements and/or subsystems thereof.
• Notably, the fuel cartridge and/or power unit may actively monitor, manages and/or controls one or more operating parameter(s) of the fuel cell system. In this regard, the fuel cartridge and/or power unit may be enabled and/or configured to monitor, manages and/or controls one or more operating parameters of the fuel cell system. The monitoring, managing and/or control process assigned to the fuel cartridge and/or power unit may be fixed, preset, predetermined, programmed and/or configurable (in situ or otherwise). In one embodiment, a user or external device (via wireless and/or wired communications) may enable, disable, program and/or configure the monitoring, management and/or control operation(s) of the operating parameter(s) of the fuel cartridge and/or power unit of the fuel cell system.
• In another embodiment, the present invention also includes a refill unit to replenish and/or store fuel in the fuel cartridge. In this regard, the fuel cartridge may be connected to the refill unit to, periodically, intermittently and/or as needed, replenish and/or store fuel in a storage vessel of the fuel cartridge. The refill unit may, in addition to the fuel cartridge or in lieu thereof, may monitor, manage and/or control one or more operating parameter(s) of the refill process. Indeed, in addition to the fuel cartridge and/or power unit (or in lieu thereof), the refill unit may be employed by the user or external device to enable, disable, program and/or configure the monitoring, manage and/or control of the operating parameter(s) of the other subsystems (for example, the power unit or fuel cartridge) of the fuel cell system. As such, in this embodiment, the fuel cell power and management system is portable and rechargeable and the fuel cartridge, power unit and/or refill unit may actively monitor, manage and/or control one or more operating parameter(s) of the fuel cell system.
• With reference toFIG. 1A, in one embodiment, fuel cell power andmanagement system10 of the present invention includesfuel cartridge100 andpower unit200. Thefuel cartridge100 includescartridge interface102 andcartridge valve assembly104 that facilitates communication of fuel betweenfuel cartridge100 andpower unit200. Thecartridge interface102 includes a mechanical interface that “mates” with the interface ofpower unit200. Thecartridge valve assembly104, in conjunction with the mechanical interface ofcartridge interface102, facilitates a controlled exchange of fuel fromfuel cartridge100 topower unit200.
• In one embodiment,fuel cartridge100 also includescartridge electronics106 andcartridge display108. Thecartridge electronics106 includes circuitry to monitor, manage, control and/or store one or more operating parameter(s) of, for example,fuel cartridge100. Thecartridge display108, for example, an LCD or LED display, may be appropriately disposed on or infuel cartridge100 to facilitate exchange of information, for example, the status of the one or more operating parameter(s), fromcartridge electronics106 to a user or operator. In this way, a user or operator may visually examine such information. Notably,fuel cartridge100 may include (in addition to or in lieu of cartridge display108) an audible indicator (not illustrated) to audibly provide such information to the user or operator.
• Thepower unit200 includespower unit interface202 and powerunit valve assembly204 to securely engage or connect withfuel cartridge100 and receive fuel fromfuel cartridge100. Thepower unit interface202 includes a mechanical interface that “mates” with the mechanical interface offuel cartridge100. The powerunit valve assembly204 facilitates a safe and controlled exchange of fuel fromfuel cartridge100 topower unit200.
• In one embodiment, a hose or tubing may be inserted betweenfuel cartridge100 andpower unit200 to facilitate fuel flow fromfuel cartridge100 topower unit200. The hose or tubing may include the appropriate connection interfaces or be adapted to connect to the appropriate connection interfaces to thereby provide suitable fluid (and/or electrical) communication betweenfuel cartridge100 andpower unit200.
• In one embodiment,power unit200 also includespower unit electronics206 andpower unit display208. Thepower unit electronics206 includes circuitry to monitor, manage, control and/or store one or more operating parameter(s) of, for example,fuel cartridge100 and/orpower unit200.
• Thepower unit display208, for example, an LCD or LED display, may be appropriately disposed on or in (for example, in a recessed manner)power unit200 to permit a user or operator to obtain information, for example, the status of the one or more operating parameter(s) offuel cartridge100 and/orpower unit200, frompower unit electronics206 and/orfuel cartridge electronics106. In this regard, the information may be calculated, determined and/or measured bypower unit electronics206 and/or provided topower unit display208 byfuel cartridge electronics106 via the electrical interfaces ofcartridge interface102 andpower unit interface202.
• Notably, likepower unit display208,cartridge display108 may provide the status of the one or more operating parameter(s) offuel cartridge100 and/orpower unit200. In this regard, the information to be displayed may be calculated, determined and/or measured byfuel cartridge electronics106, as mentioned above, and/or provided tocartridge display108 bypower unit electronics206 via the electrical interfaces ofpower unit interface202 andcartridge interface102. In this way, a user or operator may visually examine one or more operating parameter(s) offuel cartridge100 and/or power unit200) usingcartridge display108 in addition to or in lieu ofpower unit display208.
• As withfuel cartridge100,power unit200 may also include (in addition to or in lieu of power unit display208) an audible indicator (not illustrated) to audibly provide one or more operating parameter(s) offuel cartridge100 and/or power unit200) to the user or operator.
• Thepower unit200 also includesfuel cell210 to convert the fuel provided byfuel cartridge100 to electrical power. Thefuel cell210 provides electrical power to an external device, for example, a camera or computer, via an electrical interface ofpower unit electronics206. Notably, in the context of a hydrogen based fuel cell,fuel cell210 generally includes an anode end for splitting hydrogen atoms into electrons and protons, a current bearing portion providing a pathway for the electrons, a medium such as a proton exchange membrane providing a pathway for the protons, and a cathode end for rejoining the electrons and protons into water molecules in the presence of oxygen. Thefuel cell210 will be discussed in considerably more detail below.
• Fuel Vessel110: With reference toFIGS. 2, 3A,3B, and3C in one embodiment,fuel cartridge100 includesfuel vessel110 for storing fuel, for example, hydrogen or methanol, at an elevated pressure. Thevessel110 is preferably designed to be a cylinder having a thickness that is sufficient to withstand typical pressures at which the particular fuel is stored. For example, in the context of hydrogen,cartridge100 may typically store hydrogen at a pressure up to 5,500 pounds per square inch (PSI). The nominal operating pressure offuel vessel110 containing hydrogen is about 250 PSI with the maximum operating pressure of about 600 PSI, with a nominal test pressure of about 2,200 PSI and a nominal burst pressure of 5,100 PSI.
• With continued reference toFIGS. 3A, 3B and3C, in one embodiment, the material offuel vessel110 is aluminum such as 6061 aluminum. Thevessel110 is of a conventional shape including a necked-down area112 that hasinternal threads114 that act as a securing element forcartridge valve assembly104.
• Thefuel vessel110 also includes a collar-attachingmechanism116, illustrated as threads. The collar-attachingmechanism116 facilitates connectingcartridge collar assembly118 tofuel vessel110 via reciprocal threads ofcartridge collar assembly118 and the threads of collar-attachingmechanism116. (See,FIG. 3C). As discussed in detail below,cartridge collar assembly118 is a mechanism to attachcartridge electronics106 andcartridge display108 tofuel vessel110.
• In the case of a hydrogen based fuel cell system, withinchamber110aoffuel vessel110 will be particles of hydride material, not shown, that absorbs hydrogen to aid in the storage of hydrogen and/or enhance the capacity of storage of hydrogen invessel110.
• Cartridge Valve Assembly104: Thecartridge valve assembly104 that allows a controlled exchange of fuel, in the form of a fluid, fromfuel cartridge100 topower unit200. Thecartridge valve assembly104 may be securely fixed tofuel vessel110 via threads that mate withinternal threads114 offuel vessel110. (See, for example,FIG. 3C). In operation,cartridge valve assembly104 includes at least two states, including a first or activated state, whereby fuel may flow either out of or intochamber110aoffuel cartridge100. In a second or inactive state,cartridge valve assembly104 prevents or prohibits fuel flow and, as such the fuel is contained withinchamber110a. Thecartridge valve assembly104 includesvalve seal128 which is designed to prevent fluid leakage fromchamber110aoffuel cartridge100. (See, for example,FIG. 3C).
• Notably, fuel flows out offuel cartridge100 when, for example,fuel cartridge100 is employed as a fuel source forpower unit200. In the event thatfuel cartridge100 is rechargeable, fuel may flow intofuel cartridge100 when, for example,fuel cartridge100 is being filled or refilled (for example, periodically, intermittently, or as needed).
• With reference to FIGS.3C and4A-4D, in one embodiment,cartridge valve assembly104 includespoppet assembly122. Thepoppet assembly122 includes adistal end122aand aproximal end122b. In operation, the position offlange124, relative tocartridge valve assembly104, permits the flow of gas (i.e., flow around flange124). In this embodiment,flange124 is multisided, including at least oneflat side124aaround the edge offlange124. Notably, the number of sides may be any number but is generally greater than two. In the illustrative embodiment,flange124 includes three flat sides along with threecurved sides124b. Notably, other designs are suitable and will be apparent to one of skill in the art, in view of this description. For example, notched, scalloped and/or drilled hole designs may be implemented.
• Thepoppet assembly122 further includes aninternal fluid passage126. In this illustrative embodiment,internal fluid passage126 extends the length ofpoppet assembly122. Other designs ofinternal fluid passage126 are suitable and will be apparent to one of skill in the art, in view of this description. Indeed, other embodiments ofinternal fluid passage126 are discussed below.
• Thepoppet assembly122 may also include sealingring128 to enhance or provide a sufficient seal whenpoppet assembly122 is disposed in combination with the other elements ofcartridge valve assembly104.
• Afluid conduit126aextends frominternal fluid passage126 to the external surface atdistal end122aofpoppet assembly122. Aburst disc130 is located atproximal end122bofpoppet assembly122 and is retained in place byretainer130awhich may be specifically designed or suitable forburst disc130. Notably, burstdisk130 andretainer130amay be separate components or may be manufactured as a unitary component. Theretainer130afits ontoproximal end122bofpoppet assembly122 by means of threads that reciprocate with the internal threads onretainer130aor other means apparent to one of skill in the art in view of this description. (See,FIG. 4A). A “circle” of solder may be disposed on burstdisk130 andretainer130ais fitted onto the threads atproximal end122bofpoppet assembly122 and thereafter heated to further secureburst disk130 andretainer130atoproximal end122bofpoppet assembly122. Theburst disk130 may also be secured by crimping in place theretainer130ato theproximal end122bofpoppet assembly122.
• Notably, burstdisk130 may also function as a pressure relief device. In this regard, burstdisk130 may be designed to open at a preset pressure and close when the pressure drops below a predetermined pressure. In one embodiment, burstdisc130 may be rated at a certain pounds per square inch rating which is less than the rating for fuel vessel110 (illustrated inFIGS. 3A-3C). Generally, burstdisc130 may be rated from 500-3,000 lbs. per square inch.
• With reference toFIGS. 5A-5E,cartridge valve assembly104 further includesvalve assembly housing132 havingdistal end132aand aproximal end132b. Anassembly housing cavity134 extends the length of elongatevalve assembly housing132. Thevalve assembly housing132 includes aradially extending flange136 located atdistal end132aofhousing132. Theexternal surface132cofvalve assembly housing132 includes threads for securingcartridge valve assembly104 to fuel vessel (viainternal threads114 as illustrated inFIG. 3C). An internal shoulder invalve assembly housing132 restrictsinternal cavity134 to facilitate secure “seating” and/or placement of sealingring128 ofpoppet assembly122.
• Thecartridge valve assembly104 further includesspring138 that fits againstpoppet assembly122 and pushes againstflange124. Afastener140a, illustrated in this example as a snap ring, fits againstwasher140bandspring138 to retain the washer-spring poppet assembly and sealingring128 withinhousing cavity134 ofvalve assembly housing132. Once the snap ring is in place,multi-sided flange124 fits against the shoulder ofvalve assembly housing132 with sealingring128 positioned to seal the internal section ofcartridge valve assembly104.
• Aparticle filter142 maybe positioned atproximal end132b(when assembled) ofvalve assembly housing132 designed to maintain and/or retain any particulate matter that is incavity110aoffuel vessel110. Theparticle filter142 allows fuel in the form of a fluid (for example, hydrogen or methanol), to flow through while retaining any solids inside vessel110 (for example, hydride).
• Notably, one or more sealing rings144 (144aand144binFIG. 7A) may be positioned insidedistal end132aofhousing cavity134 to enhance the integrity ofcartridge valve assembly104 when combined with the other components offuel cartridge100. In this way, the seal of the fuel or fluid path betweenfuel cartridge100 and power unit200 (orrefill station300 if applicable), when engaged or connected, is enhanced.
• With reference toFIG. 6B, in operation,cartridge valve assembly104 is in the closed state when flange124 ofpoppet assembly122 and sealingring128 are pushed against the internal shoulder ofhousing cavity134 byspring138. In this condition, fuel (i.e., fluid) contained inchamber110aoffuel cartridge vessel110 is prevented from flowing intochamber110aor out ofchamber110a. Theproximal end132bfits insidevessel110. Theparticle filter142 located, positioned and designed to allow fluid flow but prevent and/or minimize any particulate matter from escapingvessel110.
• With reference toFIG. 6C,cartridge valve assembly104 is in an open state (whereby fluid may flow into or out ofchamber110a) whenflange124 ofpoppet assembly122 and sealing ring128 (i.e. atdistal end122aof poppet assembly122) are forced or pushed away from the internal shoulder ofhousing cavity134. In this way, a void146 forms betweenflange124/sealing ring128 and the internal shoulder ofhousing cavity134 thereby allowing fluid or fuel (for example, hydrogen) to flow under pressure (into or out ofchamber110a) betweenparticle filter142,internal cavity134 ofhousing132,spring138, aroundgap148 intovoid146 and throughfluid conduit126atointernal fluid passage126.
• Notably, in operation,distal end122aofpoppet assembly122 is pushed by pins (not illustrated) ofpower unit200 orrefill unit300 that protrude intocartridge valve assembly104 on a front surface offlange136. This action or operation will be described and illustrated in detail below.
• The cartridge valve assembly may be implemented using many different designs. Such alternative designs are intended to fall within the scope of this invention. Indeed, all types of cartridge vale assemblies are intended to fall within the scope of this invention.
• Notably, many modifications may be made to the exemplary cartridge valve assembly ofFIGS. 4A-4E,5A-5E and6A-6C. Such modifications are intended to fall within the scope of the present invention. For example, with reference toFIGS. 7A-7C, in one alternative design,cartridge valve assembly104 includespoppet assembly122 having an internal fluid passage that is closed bycap150 so that the passage does not extend the entire length ofpoppet assembly122, but the passage still communicates withfluid conduit126a. In addition a flange orshoulder152 is located atdistal end122aofpoppet assembly122.
• Thecartridge valve assembly104 of this embodiment also includesspring154 that fits overtip150 ofpoppet assembly122. Thespring154 is designed to be a “weaker” spring thanspring138 and, as such,spring154 tends to compress before and at a greater rate thanspring138. When assembled, cap158afits overspring154 andsnap ring156 fits aroundspring154.
• With reference toFIGS. 7E and 7F, becausespring138 is stronger thanspring154, the closed state or position will be the natural position or non-enabled state taken bycartridge valve assembly104. In this regard, in operation,spring138 will push or forcepoppet assembly122 that sealingring128 lodges against the shoulder ofvalve assembly housing132 thereby effectively preventing any flow of fluid throughhousing cavity134.
• With reference toFIG. 7F,cartridge valve assembly104 is placed in an open state whenfront surface158bofcap158aofcartridge valve assembly104 is engaged by a pin or stub component (not illustrated) of eitherpower system200 or refill unit300 (as discussed in detail below) viahousing cavity134 atdistal end132aofvalve assembly housing132. In response,spring154 is compressed and forces or pushes cap158ato bottom out onsnap ring156 ofvalve assembly104. In addition, the pin or stub component (not illustrated) has a further extension or finger that extends from its tip and is of a diameter that will extend through an opening onfront surface158bofcap158a. The force againstcap158aandtip150 is sufficient to movepoppet valve122 to a position as illustrated inFIG. 7F. In this way, fluid (for example, gas) fromcartridge valve assembly104 flows throughpassage148 and outvoid146 intohousing cavity134 atdistal end132aofvalve assembly housing132.
• In operation, whenfuel cartridge100 is connected topower unit200 and/orrefill unit300,cartridge valve assembly104 is automatically opened by connection at the interface ofunit200 and/orrefill unit300. In this regard, a male-type extension on the interface ofpower unit200 and/orrefill unit300 engages a female-type receptacle ofmechanical interface102boffuel cartridge100 at adistal end132aofcartridge valve assembly104 to engage, activate and/or pushpoppet assembly122 from a closed position or state (see, for example,FIGS. 6B and 7E) to an open position or state (see, for example,FIGS. 6C and 7F). Whenmechanical interface102bis disconnected from the mechanical interface ofpower unit200 and/orrefill unit300,cartridge valve assembly104 automatically closes to thereby seal and/or retain the fluid/fuel invessel110 and maintain an appropriate pressure of the fuel infuel cartridge100.
• In particular, a pin or stub component of powerunit valve assembly204 or refill unit valve assembly304 (discussed below with respect topower unit200 andrefill unit300, respectively) having two segments, one that is positioned against the top ofcap158aand a finger or extension that fits through the opening onfront surface158bofcap158a, several advantages may be gained, including: (1) the valve is protected from dirt, etc. by the presence ofcap158a; (2)cap158ais designed to be of such a distance that even if it is pushed down by foreign object such as a pen tip, the tip of the pen does not contactpoppet tip150; and (3) even if a sharp item such as a paper clip were inserted intovalve104 there would not be sufficient leverage on contacting therounded poppet tip150 to open it (thereby presenting safety feature against the improper discharge of fuel).
• Cartridge Collar Assembly118: Thecartridge collar assembly118 is a mechanism that secures or attachescartridge interface102,cartridge electronics106 andcartridge display108 tofuel vessel110. With reference toFIGS. 8A and 8B, in one embodiment,cartridge collar assembly118 is attached to necked-down area112 offuel vessel110. Theelectrical interface102a,mechanical interface102band display are fixed on, in and/or tocartridge collar assembly118 to facilitate communication to other components of fuel cell power andmanagement system10. In addition, an opening incartridge collar assembly118 exposescartridge valve assembly104, when secured tofuel vessel110, to allow fluid communication betweencartridge valve assembly104 and, for example,power unit200 and/orrefill unit300.
• It should be noted that there are many techniques and architectures to securecartridge interface102,cartridge electronics106 and/or cartridge display108 (or any other components) tofuel vessel110. Thecartridge collar assembly118 illustrated and described herein is an exemplary technique/architecture that is a compact, lightweight and efficient design. It is intended that all techniques and architectures to securecartridge interface102,cartridge electronics106 and/or cartridge display108 (and/or any other components) tofuel vessel110 offuel cartridge100, whether now known or later developed, fall within the scope of the present invention. Indeed, in those instances where one or more of such components need not be fixed to, for example,fuel vessel110, in order to provide a unitary and/orintegrated fuel cartridge100,cartridge collar assembly118 may not be necessary and/or advantageous.
• With reference toFIGS. 8A, 8B,9A and9B, in one embodiment,cartridge interface102,cartridge electronics106 andcartridge display108 are disposed on, in and/or tocartridge collar assembly118. In this regard,cartridge display108 may be a visual display of information (for example, an LCD or LED device) that provides or affords the user or operator the ability to view, for example, various parameters offuel cartridge100 and/or other units of fuel cell power andmanagement system10. A protective cover ormembrane108amay be disposed overcartridge display108. In addition,contact switch108b(for example, a contact button) may be employed to activatecartridge display108 in those instances wheredisplay108 is not continuously “on” (for example, whenfuel cartridge100 is in a “power saver” mode and/or whenfuel cartridge100 is idle).
• In one embodiment, power source160 (for example, a battery) may be employed to provide power to, for example, the circuitry ofcartridge electronics106 andcartridge display108. Thepower source160 may be disposable, non-renewable or renewable. Acover plate162 protects the battery from damage, securespower source160 to or incartridge collar assembly118 and, in the context of a battery, facilitates removal and replacement thereof. In addition,battery compression pad162amay be employed to maintainpower source160 in the appropriate position as well as ensure or enhance sufficient electrical contact betweenpower source160 and other circuitry offuel cartridge100.
• With reference toFIGS. 8A, 8B,9A and9B,electrical interface102aincludes circuit board164 (illustrated in this exemplary embodiment as a ring printed circuit board) to provide electrical interconnection between the circuitry offuel cartridge100. Thecircuit board164 may be fitted with a plurality of electrical contact points (illustrated as electrical contact pads166) to facilitate electrical communication to devices external tofuel cartridge100. In the exemplary embodiment, there are three equally spaced distances aroundcircuit board164. Acircuit board cover164a, having suitably located “cut-out” areas oropenings164bis fitted so thatcontacts166 are exposed whencircuit board cover164ais disposed oncircuit board164.
• Moreover, electrical contact pads166 (ofelectrical interface102a) are disposed and located oncircuit board164 and externally exposed via openings incartridge collar assembly118. (See, for example,FIG. 11B). In this way, contact pins ofelectrical interface202aand302aofpower unit200 andrefill unit300, respectively, may engageelectrical contacts166 to provide suitable electrical communication and/or connection therebetween. (See, for example,FIGS. 11A, 16B and18B).
• In this embodiment,circuit board164 includes three sets ofcontact pads166 at three positions or locations oncircuit board164. (See, for example,FIG. 11B). These positions or locations are consistent with or conform to the mating operation of the mechanical interfaces ofpower unit200 andrefill unit300. However, one skilled in the art, in view of this disclosure, will recognize that one set ofcontact pads166 is sufficient to provide electrical communication betweenfuel cartridge100 and power unit200 (or refill unit300).
• In one embodiment,contact pads166 are gold plated for easy contact. For safety considerations, a ground first contact arrangement may be advantageous; however, other arrangements are suitable.
• Notably, a retention ring may be attached to an adapter guide using screws, detent springs and balls. The adapter guide and the retention ring may be press fit withincartridge collar assembly118, and then “sandwiched” betweenfuel vessel110 andcartridge collar assembly118. In this way, various components (for example,circuit board164 andcircuit board cover164a) may be securely housed and/or retained withincartridge collar assembly118.
• As mentioned above,fuel cartridge100 also includesmechanical interface102bto “mate” with the mechanical interface ofpower unit200 or refill unit300 (for example, whenfuel cartridge100 is a rechargeable-type) to facilitate a controlled, continuous and/or uninterrupted exchange of fuel fromfuel cartridge100 to power unit200 (or to fuelcartridge100 fromrefill unit300, if applicable). In one embodiment,mechanical interface102bis disposed incartridge collar assembly118 to provide a relatively compact design that facilitates attachment of fuel cartridge100 (and, in particular,fuel vessel110 and cartridge valve assembly104) to, for example,power unit200 orrefill unit300. (See, for example,FIGS. 12, 16B and18B). Anadapter guide168, which is part of cartridgemechanical interface102b, may be fitted intocartridge collar assembly118 to aid in securing infuel cartridge100 topower unit200 orrefill unit300.
• With reference toFIG. 12, cartridgemechanical interface102bincludes a female-type receptacle to engage a male-typemechanical interface202bandmechanical interface302bofpower unit200 andrefill unit300, respectively. Although discussed in detail below, the exemplary male-type mechanical interface includes an “ear” having a beveled edge that fits into the recess of the female-type receptaclemechanical interface102b. The “ear”, and in particular the beveled edge, is designed to meet with a shoulder of the female-type receptaclemechanical interface102b. Thereafter, an approximate quarter turn securesfuel cartridge100 intopower unit200 orrefill unit300. This interface design requires little twisting motion and force to securefuel cartridge100 intopower unit200 orrefill unit300 and is designed to be oriented at any one of three positions. As such, this design prevents push back offuel cartridge100 by mechanically engaging the female-type receptacle ofmechanical interface102bbefore openingcartridge valve assembly104 offuel cartridge100.
• Notably,mechanical interface102boffuel cartridge100 includes several elements that facilitate a “smooth” interface offuel cartridge100 withpower unit200 and/orrefill unit300. In this regard,mechanical interface102b, in this embodiment, is a “female-type receptacle” that cooperates withcartridge valve assembly104 offuel cartridge100. Themechanical interface102bis designed to receive a male extension ofpower unit200 and/orrefill unit300, as illustrated inFIG. 12. The female-type receptacle ofmechanical interface102bprovides a way to align, insert, captivate, and retainfuel cartridge100 inpower unit200 and/orrefill unit300. Moreover, the design ofmechanical interface102balso facilitates the actuation ofcartridge valve assembly104 to permit or prevent the flow of fluid in or out offuel cartridge100.
• As discussed in more detail below, associated with the female-type receptacle ofmechanical interface102bis a male-type extension ofmechanical interface202bofpower unit200 and/ormechanical interface302bofrefill unit300. (See, for example,FIG. 12). The male-type extensionmechanical interface202bofpower unit200 and/ormechanical interface302bofrefill unit300 is designed to engage female-type receptacle ofmechanical interface102boffuel cartridge100 to provide a means for the alignment, insertion, captivation, and retention offuel cartridge100 therein.
• Electrical Interface102aand Cartridge Electronics106: With reference to FIGS.11B,13A-13C, in one exemplary embodiment,cartridge display108 andcartridge electronics106 are mounted oncircuit board164. Thecircuit board164 includes electrical traces to interconnect the various components, includingcartridge display108,cartridge electronics106 andelectrical interface102a.
• Theconnector170, shown as a 4-circuit connector, is located on the underside ofcircuit board164. Theconnector170 may be employed to, among other things, test various components and features ofcartridge display108 andcartridge electronics106 are mounted oncircuit board164.
• Thepower source contact172 engages power source160 (for example, a battery) to provide a suitable voltage and current to the circuitry and components interconnected by the electrical traces oncircuit board164.
• With reference toFIG. 14A, in one embodiment,cartridge electronics106 includescontrol circuitry174 to determine, monitor, manage and/or control one or more operating parameters offuel cartridge100,power unit200 and/or fuel cell power andmanagement system10. Thecontrol circuitry174 may be a combination of discrete components or may be an integrated circuit(s), for example, one or more suitably programmed (whether in situ or prior to deployment) microprocessors, microcontrollers, state machines and/or field programmable gate arrays (“FPGAs”). Thecontrol circuitry174 receives electrical power from power source160 (for example, a rechargeable or non-rechargeable battery).
• In one embodiment,cartridge electronics106 also includesmemory176, for example, SRAM, DRAM, ROM, PROM, EPROM and/or EEPROM. In this embodiment, data or information representative of one or more operating parameters and/or microcode may be stored in, for example, an SRAM, DRAM, ROM or EEPROM. The data or information representative of one or more operating parameters may include a current status and/or historical data. It should be noted thatmemory176 may be comprised of discrete component(s) or may reside on or in an integrated circuit that performs other non-memory operations, for example,control circuitry174.
• In one embodiment,cartridge memory176 may store or retain one or more attributes of the associatedfuel cartridge100. For example,cartridge memory176 may store data that uniquely identifies the associated fuel cartridge100 (for example, an associated serial number, date of manufacture and/or assembly, data pertaining to the supplier of one or more components offuel cartridge100, fuel capacity, number of refills (if applicable) and dates thereof, revision or series of electronics/software, and/or type of fuel) and/or more generally identifies the associated fuel cartridge100 (for example, model number). Moreover,cartridge memory176 may also include a filling algorithm forcartridge100. In this way, whencartridge100 is connected to refillunit300 orpower unit200,cartridge memory176 may have available the unique and general characteristics (for example, capacity and type of fuel) ofcartridge100 to be provided topower unit200, refill unit300 (if applicable) or a user/operator, which can confirm, verify or ensure proper operation and integration.
• As mentioned above,control circuitry174 may determine, monitor, manage and/or control one or more operating parameters, for example, the amount of fuel remaining and/or consumed, the rate of fuel consumption, the temperature and pressure of the fuel infuel vessel110a, temperature of the exterior offuel vessel110a, and the operating status of fuel cartridge100 (for example, whether any faults or errors have been registered). For example,control circuitry174 may calculate, determine and/or monitor the amount of fuel remaining and/or consumed, as well as the rate of fuel consumption, based on an amount oftime fuel cartridge100 has been connected to and providing fuel topower unit200 and/or connected to and receiving fuel from refill unit300 (wherefuel cartridge100 is a rechargeable type). This status may be periodically updated and/or stored inmemory176 for access by, for example,power unit200 and/orrefill unit300.
• With reference toFIG. 14B, in addition to, or in lieu thereof,control circuitry174 may receive, sample and/or acquire data from sensors178 (for example, temperature, pressure and/or flow rate type sensors) disposed on, in or nearcartridge vessel110a,cartridge valve assembly104, and/orcartridge interface102. Thecontrol circuitry174 may employ data fromsensors178 to calculate one or more operating parameters offuel cartridge100 using mathematical relationships and/or modeling. For example,control circuitry174 may obtain data which is representative of the temperature and pressure of the fuel infuel cartridge vessel110aand, based thereon, calculate/estimate the amount of fuel consumed from and remaining infuel cartridge vessel110a. Indeed,control circuitry174 may obtain data which is representative of the flow rate of fluid throughcartridge valve assembly104 and, using time data, calculate the amount of fuel remaining infuel cartridge vessel110aand amount of time until all fuel is spent fromfuel cartridge100.
• Thesensors178 may be discrete elements, such as one or more micro electromechanical (“MEMS”) devices, or sensors that are integrated intocartridge vessel110a,cartridge valve assembly104, and/orcartridge interface102, or into components thereof (for example, one or more temperature elements integrated into and disposed within the walls ofcartridge vessel110aor in valve assembly housing132). Notably, any type of sensor (for example, MEMS), whether now known or later developed, may be implemented herein.
• In one embodiment,control circuitry174 may receive instructions and/or data from circuitry external tofuel cartridge100, for example, from a user or an operator via an external device (computer or PDA), and/or frompower unit200 orrefill unit300. In this regard,control circuitry174 may be instructed to, for example, determine, measure, sample one or more operating parameters, and thereafter control and/or manage the operation offuel cartridge100 and/or power unit200 (for example, adjust and/or modify the rate of fuel consumption and/or the temperature of the exterior offuel vessel110a(and indirectly the temperature of the fuel infuel vessel110a) by engaging a cooling unit disposed onpower unit200.
• In one embodiment,control circuitry174 provides and/or communicates the measured, sampled, sensed and/or determined operating parameter(s) topower unit200,refill unit300 and/or a user or an operator. For example,control circuitry174 may determine the state of fill or amount of fuel remaining infuel vessel110a(using the techniques described above) and, thereafter, provide data which is representative of that operating parameter topower unit200. In response,power unit200 may adjust one or more of its operating parameters, for example, reduce the rate of power/fuel consumption.
• Alternatively, an operator or a user (or external device) may receive data which is representative of the state of fill or amount of fuel remaining infuel vessel110afromfuel cartridge100 and, in response thereto, modify or change the operating characteristics of power unit200 (directly or remotely). In this way, one or more operating parameters (for example, reduce the fuel consumption and/or electrical power output/generation, or engage a cooling unit to influence the temperature offuel vessel110a) may be modified and/or changed.
• The modification or change to the operating characteristics ofpower unit200 may be preset, predetermined and/or pre-programmed. In this way, the response is present, predetermined and/or pre-programmed based on the conditions, operating characteristics and/or operating parameters ofpower unit200 and/orfuel cartridge100. Alternatively, or in addition thereto, instructions defining the modification or change to the operating characteristics may be transmitted or provided by the operator, user or external device (for example, the user determines the appropriate modification or change based on one or more considerations, factors, constraints and/or objectives).
• With reference toFIG. 14C, such instructions and/or data may be received or transmitted viacommunication circuitry180. In this regard,communication circuitry180 may employ well known wired (for example, a serial input/output port) and/or wireless techniques (for example, infrared, radio frequency, cellular phone, bluetooth techniques). Indeed, the instructions and/or data may be provided remotely via wireless techniques. Notably, any communication technique, whether now known or later developed, is intended to fall within the scope of the present invention.
• In one embodiment,communication circuitry180 may be employed to transmit data and/or commands topower unit200,refill unit300 and/or other external devices (for example, to a local or remote computer). The data may be representative of one or more operating parameters (that were measured, sampled, sensed bysensors178 and/or determined by control circuitry174) such as temperature, pressure, rate of fuel consumption bypower unit200, and/or amount of remaining fuel infuel cartridge100. The data may also be representative of the overall status offuel cartridge100. As mentioned above,communication circuitry180 may employ wired or wireless techniques.
• With reference toFIG. 14D, in another embodiment,cartridge electronics106 includesmemory176 to store and/or retain data provided bypower unit200,refill unit300 and/or circuitry external tosystem10. In this embodiment,power unit200 and/or refill unit300 (where applicable) may, among other things, determine, monitor and/or control one or more operating parameters, for example, the amount of fuel remaining and/or consumed, the rate of fuel consumption and/or the temperature and pressure of the fuel infuel vessel110a. Thepower unit200 and/or refill unit300 (where applicable) may periodically or intermittently store data which is representative of the one or more operating parameters inmemory176. In this way, the status of the fuel cartridge (for example, the amount of fuel remaining) is retained within the fuel cartridge's memory (i.e., memory176) so that it may be available for recall bypower unit200,refill unit300 and/or circuitry external tosystem10. Notably, it may be advantageous to includecommunication circuitry180 in order to facilitate access tomemory176. (See, for example,FIG. 14E).
• Notably,control circuitry174 performs or executes routines or programs that implement particular tasks and/or operations described herein. The functionality of the routines or programs may be combined or distributed. Such programming is well known to those skilled in the art, particularly in view of this disclosure. All programming techniques, and implementations thereof, to determine, monitor, manage and/or control one or more operating parameters and/or characteristics offuel cartridge100,power unit200 and/orrefill unit300, whether now known or later developed, are intended to fall within the scope of the present invention.
• With reference toFIG. 15, in one embodiment,control circuitry174 is a microcontroller integrated circuit having EEPROM resident therein. Thepower source160, in this embodiment, is a battery that provides electrical power to the circuitry/devices of cartridge electronic106 (for example, microcontroller) and cartridge display108 (for example, an LCD or LED display). Where an LCD display is implemented, it may be advantageous to include abacklight108cwhich provides suitable lighting when the ambient light may not be sufficient. Thecontact switch108benablesbacklight108c. That is, whencontact switch108bis depressed,backlight108cwill illuminate the LCD display.
• Exemplary Assembly of Fuel Cartridge100: In those instances where fuel cartridge employs a hydride material, after fabrication offuel vessel110, an appropriate hydride material may be disposed therein. Such material is well known in the art. Thereafter,cartridge valve assembly104 may be inserted and secured tovessel110 viainternal threads114 and corresponding threading132convalve assembly housing132. (See, for example,FIG. 8A). Thecartridge collar assembly118 may be secured tovessel110 via collar-attaching mechanism116 (for example, by screwingcollar assembly118 onto cartridge vessel110).
• Thereafter or before,cartridge electronics106 may be configured to determine, monitor, manage and/or control one or more operating parameters of fuel cell power and management system10 (for example, to characterize the state of fill of fuel cartridge100). For example,cartridge electronics106 may be configured to determine, monitor, manage and/or control one or more operating parameters in situ (i.e., in the field or when deployed).
• Power Unit200: In one aspect of the invention, fuel cell power andmanagement system10 includespower unit200 to generate electricity using fuel stored in and provided fromfuel cartridge100. Thepower unit200 includes an interface and valve assembly that connects to or mates with corresponding components of one or more fuel cartridge(s)100. In this way, the fuel (for example, hydrogen or methanol) stored infuel vessel110 is supplied, under pressure, topower unit200 which generates electricity therefrom.
• With reference toFIGS. 1A and 16B, in one embodiment,power unit200 includespower unit interface202 and powerunit valve assembly204 which are configured to connect to or mate withfuel cartridge100. Thepower unit200 also includespower unit electronics206 andpower unit display208. Briefly,power unit electronics206 includes circuitry to determine, monitor, control and/or store one or more operating parameter(s) of, for example,fuel cartridge100 and/orpower unit200. Thepower unit display208, for example, an LCD or LED display, may be conveniently located onhousing212 to facilitate observation by and/or exchange information with a user, for example, the status of the one or more operating parameter(s), fromcartridge electronics106 and/orpower unit electronics206 to a user or an operator. In this way, a user or an operator may, for example, view data which is representative of the status of the one or more operating parameter(s) offuel cartridge100 and/or power unit200 (for example, the amount of fuel remaining and/or consumed, the rate of fuel consumption, the temperature and pressure of the fuel infuel vessel110a, and the operating status offuel cartridge100, for example, any faults or errors therein).
• Notably,power unit200 may include (in addition to or in lieu of display208) an audible indicator (not illustrated) to audibly provide information which is representative of status of the one or more operating parameter(s), to the user or operator.
• Thepower unit200 also includesfuel cell210. Thefuel cell210 employs that fuel (for example, hydrogen, hydride or methanol) to generate electricity. Thefuel cell210 includes a fuel cell stack. The fuel cell stack described and illustrated in U.S. patent application Ser. No. 10/328,709, filed Dec. 24, 2002 (which are incorporated herein by reference in their entirety), may be implemented infuel cell210 ofpower unit200. Moreover, the fuel cell stacks and fuel cell stack technology described and illustrated in U.S. Pat. Nos. 5,683,828; 5,858,567; 5,863,671; and 6,051,331; and U.S. Patent Application Publication No. U.S. 2002/0022170A1 (all of which are incorporated herein by reference in their entirety) may also be implemented in fuel cell210 (with or without modification). There are many designs, architectures and modes of operation of fuel cell stacks and fuel cell stack technology. Indeed, all fuel cell stacks, whether now known or later developed, are intended to fall with in the scope of the present invention.
• Notably, a particularly preferred fuel cell power system is the one that is described in U.S. patent application Ser. No. 10/328,709, filed Dec. 24, 2002, which, as mentioned above, is incorporated herein by reference in its entirety. Briefly, this application describes, among other things, a forced air fuel cell system in which an air moving device configured to direct atmospheric air towards the cathode end of the plurality of fuel cells is positioned and thus convectively cools the fuel cell as it supplies atmospheric air to the cathode end which aids in the generation of electricity.
• With reference toFIGS. 16A and 16B, in one embodiment,power unit200 includes a housing havingcartridge port214 to receivefuel cartridge100. Thepower unit200 of this embodiment secures or is connected (electrically and/or mechanically) to an external device (not illustrated) that receives electrical power from (and generated by)power unit200.
• Theelectrical interface202aandmechanical interface202bofpower unit interface202 are disposed incartridge port214. Theelectrical interface202ais designed to connect withelectrical interface102aoffuel cartridge100. In particular, in one embodiment, electrically conductive contact pins216 ofelectrical interface202a, which is disposed onhousing212, engagecontacts166 ofelectrical interface102a. (See, for example,FIG. 11A). In this way,control circuitry174 and/ormemory176 ofcartridge electronics106 may communicate (for example, provide data which is representative of one or more operating parameter(s) and/or determine, monitor, manage and/or control one or more operating parameter(s)) with, for example, power unit electronics206 (control circuitry (if any) and/or memory (if any)) and/orpower unit display208.
• Notably, in this illustrative embodiment,power unit200 includes only onecartridge port214 to receive onefuel cartridge100. As mentioned above, however,power unit200 may include a plurality ofcartridge ports214 to accommodate and receive more than onefuel cartridge100.
• The contact pins216 are preferably a miniature pogo pin style with a significant cycle life, for example, more than 100,000 cycles. In one embodiment,electrical interface202aincludes five pins to provide a plurality of electrical signals, including power and ground, a thermistor sensor output signal, and data via a serial interface. Thecartridge electronics106 andpower unit electronics206 are designed to be “on” when afuel cartridge100 is inpower unit200.
• Notably, a triplicate contact pad configuration offuel cartridge100 is provided to support multi-orientation insertion and ease of operation in conjunction with electrically conductive contact pins216. As such, contact pins216 may engage any one of the three contact pads onelectrical interface102aoffuel cartridge100.
• Themechanical interface202bis designed to hold, retain and engage at least onefuel cartridge100. In this way, powerunit valve assembly204 may connect to provide fluid communication fromfuel cartridge100 to fuel cell210 (and in particular the fuel cell stack of fuel cell210). With continued reference toFIG. 16B,mechanical interface202bincludes a male-type interface to engage the female-type receptacle of cartridgemechanical interface102boffuel cartridge100. The exemplary male-type mechanical interface includes an “ear” ortab220 having abeveled edge220athat fits into the recess of the female-type receptaclemechanical interface102b. (See, for example,FIG. 12). Thebeveled edge220aoftab220 meets with a shoulder of the female-type receptaclemechanical interface102b. Thereafter, an approximate quarter turn securesfuel cartridge100 intopower unit200. Notably, this design prevents push back offuel cartridge100 by mechanically engaging the female-type receptacle ofmechanical interface102bbefore openingcartridge valve assembly104 offuel cartridge100.
• With continued reference toFIG. 16B, whilemechanical interface202bengagesmechanical interface102boffuel cartridge100, (see, for example,FIG. 12),actuating pin222 engages (for example, pushes)distal end122aofpoppet assembly122 by protruding intocartridge valve assembly104 on a front surface of flange136 (see, for example,FIGS. 7E and 7F). As mentioned above, this action or operation placescartridge valve assembly104 in an open state. Oncefuel cartridge100 is securely in place inpower unit200, fuel is then allowed to flow fromcartridge100 topower unit200 to allowfuel cell210 to operate.
• Notably,power unit200 includes a conduit that extends from powerunit valve assembly204 tofuel cell210. The powerunit valve assembly204 includes a valve, having a regulator that is connected to the conduit to regulate pressure and/or control the flow of fuel to the fuel cell stack offuel cell210. The regulator selects and regulates fuel pressure including parameters for feeding fuel contained infuel cartridge100 to the fuel cell stack. Accordingly, while fuel may be capable of flowing, under pressure, afterfuel cartridge100 is securely in place inpower unit200, the regulator in powerunit valve assembly204 regulates the pressure of fuel feed to thefuel cell210.
• With reference toFIG. 17A, in one embodiment,power unit electronics206 includescontrol circuitry224 to determine, monitor, manage and/or control one or more operating parameters offuel cartridge100,power unit200 and/or fuel cell power andmanagement system10. Thecontrol circuitry224 may be implemented and/or configured likecontrol circuitry174 offuel cartridge100. Accordingly, the discussion pertaining to the features, implementation, embodiments, operation and configuration ofcontrol circuitry174 is fully applicable to controlcircuitry224; that is,control circuitry224 may be implemented or configured in the same or similar manner, and/or perform the same or similar operations ascontrol circuitry174. For the sake of brevity, those discussions will not be repeated but will be summarized below in connection withcontrol circuitry224.
• Thecontrol circuitry224 determines, monitors, manages and/or controls one or more operating parameters, for example, the amount of fuel remaining and/or consumed, the rate of fuel consumption, the temperature and pressure of the fuel infuel vessel110a, temperature of the exterior offuel vessel110a, and the operating status of fuel cartridge100 (for example, whether any faults or errors have been registered) and/or the operating status ofpower unit200. In one embodiment,control circuitry224 may calculate, determine and/or monitor the amount of fuel remaining infuel cartridge110, as well as the rate of fuel consumption, using information pertaining to the amount oftime fuel cartridge100 is connected to and providing fuel topower unit200.
• In addition to, or in lieu thereof,control circuitry224 may receive, sample and/or acquire data fromsensors178 and/or sensors230 (for example, temperature, pressure and/or flow rate type sensors) disposed on, in or nearcartridge vessel110a,cartridge valve assembly104 and/or powerunit valve assembly204. (See, for example,FIG. 17B). Thecontrol circuitry224 may employ data fromsensors178 and/orsensors230 to calculate one or more operating parameters using mathematical relationships and/or modeling. For example,control circuitry224 may obtain data which is representative of the temperature and pressure of the fuel infuel cartridge vessel110aand, based thereon, calculate/estimate the amount of fuel consumed from and/or remaining infuel cartridge vessel110a. Indeed,control circuitry224 may obtain data which is representative of the flow rate of fluid through fuelcartridge valve assembly104 and, using time data, calculate the amount of fuel remaining infuel cartridge vessel110aand amount of time until all fuel is spent fromfuel cartridge100.
• Notably,control circuitry224 may be a combination of discrete components or may be an integrated circuit(s), for example, one or more suitably programmed (whether in situ or prior to deployment) microprocessors, microcontrollers, state machines and/or FPGAs.
• In one embodiment,power unit electronics206 also includesmemory226, for example, SRAM, DRAM, ROM, PROM, EPROM and/or EEPROM. In this way, data or information which is representative of one or more operating parameters and/or microcode (used by control electronics224) may be stored in, for example, an SRAM, DRAM, ROM or EEPROM. The data or information representative of one or more operating parameters may include a current status and/or historical data. It should be noted thatmemory226 may be comprised of discrete component(s) or may reside on or in an integrated circuit that performs other non-memory operations, for example,control circuitry224.
• With reference toFIG. 17B,sensors230 may be discrete elements, such as one or more micro electromechanical (“MEMS”) devices, or sensors that are disposed nearcartridge vessel110a, and/or disposed in powerunit valve assembly204, and/orcartridge interface202, or into components thereof (for example, one or more temperature elements integrated into and disposed in the housing of valve assembly204).
• In one embodiment,control circuitry224 may receive instructions and/or data from, for example, a user or an operator. In this regard,control circuitry224 may be instructed to, for example, determine one or more operating parameters, and thereafter control and/or manage the operation offuel cartridge100 and/or power unit200 (for example, adjust and/or modify the rate of fuel consumption and/or the temperature of the exterior offuel vessel110a(and indirectly the temperature of the fuel infuel vessel110a) by engaging a cooling unit disposed on power unit200). In this way, the efficiency and/or control ofsystem10 is enhanced.
• In one embodiment,control circuitry224 provides and/or communicates the measured, sampled, sensed and/or determined operating parameter(s) to a user or an operator. For example,control circuitry174 may acquire data fromsensors178 and/orsensors230 and thereafter determine the state of fill or amount of fuel remaining infuel vessel110a. Thecontrol circuitry224 may provide data which is representative of that operating parameter to the user or operator. In response, the user or operator may adjust one or more of the operating parameters ofpower unit200, for example, reduce the amount of power/fuel consumption and/or reduce or adjust the output power offuel cell210.
• Alternatively, an operator or a user (or external device) may receive data which is representative of the state of fill or amount of fuel remaining infuel vessel110afrom control circuitry224 (as calculated therein) and, in response thereto, instructpower unit200 to modify or change its operating characteristics (directly or remotely), for example, reduce the fuel consumption and/or electrical power output/generation, or engage a cooling or a heating unit to influence the temperature offuel vessel110a(for example, in those instances where the temperature of the fuel during operation may not be suitable and/or optimum). The modification or change to the operating parameters ofpower unit200 may be preset, predetermined and/or pre-programmed. The modification or change may also be in accordance with instructions transmitted or provided to control circuitry224 (for example, the user determines the appropriate modification or change based on one or more considerations, factors, constraints and/or objectives).
• With reference toFIG. 17C, such instructions and/or data may be received or transmitted viacommunication circuitry228. In this regard,communication circuitry228 may employ well known wired (for example, a serial input/output port) and/or wireless techniques (for example, infrared techniques). Indeed, the instructions and/or data may be provided remotely via wireless techniques.
• In one embodiment,communication circuitry228 may be employed to transmit data and/or commands topower unit200,refill unit300 and/or other external devices (for example, to a local or remote computer). The data may be one or more operating parameters (that were measured, sampled, sensed bysensors178 and/or determined by control circuitry224) such as temperature, pressure, rate of fuel consumption bypower unit200, and/or amount of remaining fuel infuel cartridge100. The data may also be representative of the overall status ofpower unit200 and/orfuel cartridge100.
• Notably, it may be advantageous, from a cost and weight perspective, to implement control circuitry in eitherfuel cartridge100 orpower unit200—but not both. For example, with reference toFIG. 17D, in one embodiment,power unit200 includes power unit electronic206 as described above, (see, for example,FIGS. 17A, 17B and/or17C), andfuel cartridge100 includes memory176 (see, for example,FIGS. 14D and 14E) to store and/or retain data provided bypower unit electronics206. In this embodiment,control circuitry224 may, among other things, monitor one or more operating parameters, for example, the amount of fuel remaining and/or consumed, the rate of fuel consumption, the temperature and pressure of the fuel infuel vessel110a, temperature of the exterior offuel vessel110a, and/or the operating status of fuel cartridge100 (for example, whether any faults or errors have been registered). Thecontrol circuitry224 may periodically or intermittently store data which is representative of the one or more operating parameters inmemory176. In this way, the status of the fuel cartridge (for example, the amount of fuel remaining) is retained within the fuel cartridge's memory (i.e., memory176) so that it may be available for recall by power unit200 (for example, anotherpower unit200 that has no “history” of the status of a given fuel cartridge100) and/orrefill unit300.
• Thecontrol circuitry224 may also determine, monitor, manage and/or control other characteristics or operations ofpower unit200, for example, thermal management, fuel leak detection, fuel purge, over-current protection and/or voltage regulation. In this regard,control circuitry224 may receive information representative of the temperature of one or more elements of power unit200 (for example, fuel cell210) and in response thereto adjust and/or manage the operation of power unit200 (for example, adjust the rate of fuel consumption and/or generation of electricity).
• Thesensors230 may include fuel leak sensors to provide data of the status of the integrity of the fuel path (i.e., whether a leak is present) to controlcircuitry224. In response thereto,control circuitry224 may alert the user/operator of the leak (or possible leak) and/or may safely terminate operation ofpower unit200.
• Alternatively,control unit224 may, based on data fromsensors230, determine the existence of a (or potential) fuel leak. Thecontrol circuitry224 may employ various techniques, which are well known to those skilled in the art, to assess whether there is a fuel leak. Again,control circuitry224 may alert the user/operator of the leak (or possible leak) and/or may immediately and safely terminate operation ofpower unit200.
• Thecontrol circuitry224 may also monitor the status of over-current protection and/or voltage regulation to assess the status of the power generation byfuel cell210. In one embodiment,control circuitry224 may receive information representative of the current consumption and/or voltage levels fromsensors230 that provide information pertaining to the generation of electricity and/or consumption thereof. In response,control circuitry224 may appropriately manage and/or control the operation ofpower unit200.
• Notably,control circuitry224 may perform or execute routines or programs that implement particular tasks and/or operations described herein. The functionality of the routines or programs may be combined or distributed. Such programming is well known to those skilled in the art, particularly in view of this disclosure. All programming techniques, and implementations thereof, to determine, monitor, manage and/or control one or more operating parameters and/or characteristics offuel cartridge100 and/orpower unit200, whether now known or later developed, are intended to fall within the scope of the present invention.
• Refill Unit: With reference toFIG. 1B, in one embodiment, fuel cell power andmanagement system10 include, in addition tofuel cartridge100 andpower unit200,refill unit300. In this regard, in those instances where fuel cartridge is a refillable type, fuel cartridge may be filled with fuel (for example, hydrogen, methanol or other hydrogen containing compound) after some or all of the fuel is depleted from fuel cartridge100 (for example, consumed by power unit200) usingrefill unit300.
• In one embodiment,refill unit300 includesrefill unit interface302, refillunit valve assembly304,refill unit electronics306 and refill unit display308 (for example, a 24 character by two line LCD device). Briefly, with reference toFIG. 1B, in one embodiment,refill unit interface302 and refillunit valve assembly304 are configured to connect to or mate with associated or corresponding components offuel cartridge100. (See, for example,FIGS. 11A and 12). The configuration, architecture and design ofrefill unit interface302 and refillunit valve assembly304 may be the same aspower unit interface202 and powerunit valve assembly204, respectively. For the sake of brevity that discussion will not be repeated.
• Therefill unit300 may be a stand alone table top or wall mounted device, which may be installed, for example, at a facility or in a vehicle and thereby provide refilling capabilities for one ormore fuel cartridges100. With reference toFIGS. 18A and 18B, in one embodiment,refill unit300 includes one or more refill ports310 (four refill ports are illustrated) to accommodate one ormore fuel cartridges100. As mentioned above,refill unit300, in operation, replenishes one or moredepleted fuel cartridges100 and returnsfuel cartridges100 to a more filled state or a completely refilled state for use inpower unit200.
• In those instances whererefill unit300 includes more than onerefill port310, eachrefill port310 may function and/or may be operated independently of the other ports. In this way,fuel cartridges100 having different fuel fill and/or capacity conditions may be returned to a more filled or completely refilled state independently. Moreover,fuel cartridges100 may be randomly installed inrefill ports310.
• Therefill port310 includes an independent solenoid valve for providing fluid or fuel shutoff when not in use and a switch to sense whether afuel cartridge100 is inserted. The solenoid/switch combination permits random access to anyrefill port310, semi-automatic initiation and termination of the refilling operation and provides positive fluid supply shutoff. It may be advantageous to maintainrefill unit300 in a position wherebyfuel cartridges100 are in a mostly horizontal orientation with respect to the center axis offuel vessel110a. In this way, it may prevent the introduction of foreign matter into the area ofvalve assembly304 and refillport310 and reduce and/or minimize possible malfunction or damage to the components in and nearrefill port310 as a result of such foreign matter.
• In one embodiment,refill unit300 includes main fuel/fluid input port314 to connect to a primary compressed fuel source (for example, a “K” bottle size tank). The main fuel/fluid input port314 may be located on an outer surface ofhousing312 to facilitate connection to the primary compressed fuel source. The main fuel/fluid input port314 may provide local pressure regulation, for example, 250 PSI, and include a fluid shutoff to isolate the input of the primary compressed fuel source fromrefill unit300 and/orfuel cartridge100. Moreover, main fuel/fluid input port314 may also provide passive overpressure protection to prevent inadvertent overpressure exposure to refillunit300 and/orfuel cartridge100 which may be disposed therein.
• Notably,refill unit300 may also include an auxiliary fuel/fluid output port316 to facilitate expansion and operation of one or moreadditional refill units300 without site modification (for example, modification of plumbing on the large fuel tank supportingrefill unit300 to accommodate additional refill units300). The auxiliary fuel/fluid output port316 may be located and/or mounted on an outer surface ofhousing312 for connection to one or more additional refill units300 (not illustrated). In this way, a series of fluid connection may be daisy chained from one refill unit to another and connected to one large fuel tank supply (for example, a “K” bottle size tank).
• Therefill unit300 may include one or more input pressure regulators to accept low pressure regulated gas from a high pressured tank, a normally closed main shut off solenoid valve with over pressure protection, and a gas distribution manifold to provide fluid to each of the plurality ofrefill ports310. A plurality of solenoid valves may be employed to provide shutoff capabilities to eachrefill port310 when in use. Notably, in one embodiment, the plurality of electrical pins may be used to sense the presence of afuel cartridge100 in a givenrefill port310.
• In one embodiment, it may be advantageous to include a ventilation or cooling unit318 (for example, active or passive type unit) to remove heat fromfuel cartridge100 which is produced or generated during the refill operation. In this regard, controlling the temperature of one ormore fuel cartridges100 during the refill process may increase the efficiency of refill and thereby reduce the refill time. For example, coolingunit318 may employ one or more cooling circulation fans that are appropriately located to remove heat from one ormore fuel cartridges100 while connected to refillunit300 and being re-filled.
• Notably,refill unit300 may include a heating unit (not illustrated) to accommodate those instances where the temperature during the refill operation may not be suitable and/or optimum. In this regard, the heating unit may apply heat to thefuel cartridge100 to, for example, increase the efficiency of the refill operation and thereby reduce the refill time.
• Therefill unit300 may be electrically powered using a number of techniques including an unregulated external AC wall/desk transformer connected to the DC Power Input Port located on an outer surface ofhousing312, a battery, and/or a fuel cell that employs the same fuel used to replenish one ormore fuel cartridges100. In one embodiment, a maximum preferred voltage output required from a transformer will be 12 Volts Direct Current (VDC). Notably, all techniques for poweringrefill unit300 are intended to fall within the scope of the present invention.
• In one embodiment,refill unit electronics306 includes user interface320 to facilitate monitoring, managing and controlling the refill operation. In this regard, user interface320 may include a plurality of button switches, and a plurality ofbi-color LEDs322, having multiple color capabilities (for example, orange/green color capabilities for indicating refilling (orange) or filled (green)), for eachrefill port310. Thebi-color LEDs322 may be disposed in a region associated with acorresponding refill port310 to reflect the state of the refill operation. (See, for example,FIG. 18B).
• Moreover, it may be advantageous for user interface320 to include a bi-color LED322 (for example, red/green color) to reflect or indicate the power state ofrefill unit300. In this regard, power “on” may be indicated by green and power on alarm may be indicated by red.
• The user interface320 also permits the user or operator to select, program and/or set various functions to be accomplished byrefill unit300. For example, the user or operator may initiate fuel cartridge refill cycles, enable and/or set alarm limits, clear alarms, enable/disable the audible alarm, and monitor fuel sensor activity using interface320.
• Therefill unit electronics306 may be enabled to monitor the internal environment ofrefill unit300 and/or one ormore fuel cartridges100 disposed inrefill ports310. For example, refillunit electronics306 may measure the internal temperature of refill unit300 (using internal ambient temperature sensor) or measure, detect or receive data which is representative of the temperature of one ormore fuel cartridges100 disposed inrefill ports310. In response to the temperature exceeding a predetermined value or limit,refill unit electronics306 may enable coolingunit318. In addition, refill unit electronics includes one or more gas detection sensors (for example, hydrogen detection sensors). Under these circumstances, in the event of a leak,refill unit electronics306 may sense a concentration of fuel that exceeds a predetermined limit. In the event an alarm is triggered, an appropriate alarm message may be displayed onrefill unit display308. In addition to or in lieu thereof, an audible alarm may sound.
• Notably, one or more input/output (I/O) port may be located on an outside surface ofhousing310 ofrefill unit300. The I/O port(s) may be employed by the user or operator to enable certain functions, operations, programming and/or testing ofrefill unit300.
• Notably, wherefuel cartridge100 include hydride-type fuel, it may be advantageous to operate fuel cell power andmanagement system10 between temperatures of about 30° F. to 125° F. (0° C.−+52° C.) and relative humidity of 10% to 95%. Although the various components of fuel cell power andmanagement system10 may be exposed to storage and/or operating environments in excess of these ranges, appropriate supplementary protection measures may be employed under those conditions.
• With reference toFIG. 19A, in one embodiment,refill unit electronics306 includescontrol circuitry324 to determine, monitor, manage and/or control one or more operating parameters offuel cartridge100,refill unit300 and/or fuel cell power andmanagement system10. Thecontrol circuitry324 may be implemented and/or configured likecontrol circuitry174 offuel cartridge100 or likecontrol circuitry224 ofpower unit200. Accordingly, the discussion pertaining to the features, implementation, embodiments, operation and configuration of the control circuitry offuel cartridge electronics106 and/orpower unit electronics206 is fully applicable to controlcircuitry324; that is,control circuitry324 may be implemented or configured in the same or similar manner, and/or perform the same or similar operations ascontrol circuitry174 and/orcontrol circuitry224. For the sake of brevity, those discussions will not be repeated but will be summarized in connection withcontrol circuitry324.
• Thecontrol circuitry324 ofrefill unit electronics306 may determine, monitor, manage and/or control one or more operating parameters, for example, the amount of fuel remaining infuel vessel110a, the temperature and pressure of the fuel infuel vessel110a, temperature of the exterior offuel vessel110a, and/or the operating status of fuel cartridge100 (for example, whether any faults or errors have been registered). In one embodiment,control circuitry324 may calculate, determine and/or monitor the amount of fuel infuel cartridge110, based on data inmemory176, the flow rate of fuel invalve assembly104 and/or304, and/or an amount oftime fuel cartridge100 has been connected to refillunit300.
• With reference toFIGS. 19B and 19C, in addition to, or in lieu thereof,control circuitry324 may receive, sample and/or acquire data fromsensors178 and/or sensors330 (for example, temperature, pressure and/or flow rate type sensors) disposed on, in or nearcartridge vessel110a, refillunit valve assembly304, and/or refillunit interface302. Thecontrol circuitry324 may employ data fromsensors178 and/orsensors330 to calculate one or more operating parameters using mathematical relationships and/or modeling. For example,control circuitry324 may obtain data which is representative of the temperature and pressure of the fuel infuel cartridge vessel110aand, based thereon, calculate/estimate the amount of fuel infuel cartridge vessel110a. This information may be employed to determine a time required to refillfuel cartridge vessel110a.
• Moreover, in response to data which is representative of the temperature of the fuel infuel cartridge vessel110a(for example, fromsensors178 or sensors330),control circuitry324 may engage coolingunit318 ofrefill unit300. The cooling unit318 (for example, a fan, heat sink, thermoelectric device or refrigeration unit) may be employed to remove heat fromfuel cartridge vessel110aduring the refilling process. In this way, the efficiency of the refill process may be enhanced and the time required therefore, reduced.
• In one embodiment,refill unit electronics306 also includesmemory326, for example, SRAM, DRAM, ROM, PROM, EPROM and/or EEPROM. Thememory326 may store data or information representative of one or more operating parameters and/or microcode (used by control electronics324) may be stored in, for example, an SRAM, DRAM, ROM or EEPROM. It should be noted thatmemory326 may be comprised of discrete component(s) or may reside on or in an integrated circuit that performs other non-memory operations, for example,control circuitry324.
• With reference toFIGS. 19B and 19C,sensors330 may be discrete elements, such as one or more micro electromechanical (“MEMS”) devices, or sensors that are integrated into refillunit valve assembly304, and/or refillunit interface302, or into components thereof (for example, one or more temperature elements integrated into and disposed within the walls of valve assembly304).
• In one embodiment,control circuitry324 may receive instructions and/or data from, for example, a user or an operator. In this regard,control circuitry324 may be instructed to, for example, measure, sample and/or sense one or more operating parameters, and thereafter control and/or manage the operation offuel cartridge100 and/or refill unit300 (for example, adjust and/or modify the rate of refill of fuel and/or the temperature of the exterior offuel vessel110a(and indirectly the temperature of the fuel infuel vessel110a) by engaging cooling unit318).
• In one embodiment,control circuitry324 provides and/or communicates the measured, sampled, sensed and/or determined operating parameter(s) to a user or an operator. For example,control circuitry324 may instructsensors178 orsensors330 to measure, sample, sense and/or determine the state of fill or amount of fuel remaining infuel vessel110a. Thereafter,control circuitry324 may provide data which is representative of the operating parameter to the user and/or provide data which is representative of the anticipated refill time. In response, the user or operator may instructrefill unit300 to modify or change one or more of its operating characteristics (directly or remotely), for example, increase/decrease the flow rate of fuel intovessel110 and/or engage coolingunit318 to influence the temperature of the fuel infuel vessel110a.
• Notably, the modification or change to the operating parameters ofrefill unit300 may be preset, predetermined and/or pre-programmed. Alternatively, the modification or change may be in accordance with instructions transmitted or provided with the instructions (for example, the user determines the appropriate modification or change based on one or more considerations, factors, constraints and/or objectives).
• In one embodiment,memory176 may store and/or retain data provided bypower unit electronics206 andrefill unit electronics306, for example, data which is representative of one or more operating parameters such as the state of fill offuel cartridge100. (See, for example,FIGS. 14D, 14E and19D). In this regard,control circuitry324 may, among other things, monitor one or more operating parameters, for example, the amount of fuel remaining infuel vessel110a. Thecontrol circuitry324 may periodically or intermittently store data which is representative of the one or more operating parameters inmemory176. In this way, the status of the fuel cartridge (for example, the amount of fuel remaining) is retained within the fuel cartridge's memory (i.e., memory176) so that it may be available for recall bypower unit200 and/orrefill unit300.
• Notably,control circuitry324 may perform or execute routines or programs that implement particular tasks and/or operations described herein. The functionality of the routines or programs may be combined or distributed. Such programming is well known to those skilled in the art, particularly in view of this disclosure. All programming techniques, and implementations thereof, to determine, monitor, manage and/or control one or more operating parameters and/or characteristics offuel cartridge100,power unit200 and/orrefill unit300, whether now known or later developed, are intended to fall within the scope of the present invention.
• Indeed,control circuitry324 may also determine, monitor, manage and/or control other operations or characteristics ofrefill unit300, for example, fuel leak detection and/or fuel purge. In this regard,sensors330 may include fuel leak sensors to provide data of the status of the integrity of the fuel path (i.e., whether a leak is present) to controlcircuitry324. In response thereto,control circuitry324 may alert the user/operator of the leak (or possible leak) and/or may safely terminate operation ofrefill unit300.
• Alternatively,control unit324 may, based on data fromsensors330, determine the existence of a (or potential) fuel leak. Thecontrol circuitry324 may employ various techniques, which are well known to those skilled in the art, to assess whether there is a fuel leak. Again,control circuitry324 may alert the user/operator of the leak (or possible leak) and/or may immediately and safely terminate operation ofrefill unit300.
• Notably,control circuitry324 may perform or execute routines or programs that implement particular tasks and/or operations described herein. The functionality of the routines or programs may be combined or distributed. Such programming is well known to those skilled in the art, particularly in view of this disclosure. All programming techniques, and implementations thereof, to determine, monitor, manage and/or control one or more operating parameters and/or characteristics offuel cartridge100,power unit200 and/orrefill unit300, whether now known or later developed, are intended to fall within the scope of the present invention.
• There are many inventions described and illustrated herein. While certain embodiments, features, materials, configurations, attributes and advantages of the inventions have been described and illustrated, it should be understood that many other, as well as different and/or similar embodiments, features, materials, configurations, attributes, structures and advantages of the present inventions that are apparent from the description, illustration and claims (are possible by one skilled in the art after consideration and/or review of this disclosure). As such, the embodiments, features, materials, configurations, attributes, structures and advantages of the inventions described and illustrated herein are not exhaustive and it should be understood that such other, similar, as well as different, embodiments, features, materials, configurations, attributes, structures and advantages of the present inventions are within the scope of the present invention.
• For example, it is therefore desirable to develop a hydrogen fuel cell electricity generation device capable of supplying electricity for a longer period of time than conventional batteries. It is also desirable to develop a standardized hydride storage cartridge that can readily be provided and secured to a fuel cell system to supply hydrogen for conversion to electricity and to be provided and secured to a hydrogen refill unit to be rapidly refilled with hydrogen. It is further desirable to provide a hydrogen cartridge that provides a relatively accurate readout of its state-of-fill so that a user knows how much energy is available from the hydrogen cartridge.
• In addition, it will be recognized by one skilled in the art in view of this disclosure that afuel cartridge100 may be integrated into the integrated modular BSP/MEA/manifold plates and compliant contacts for fuel cells as described in International Publication No. WO02/19451A2, which is incorporated herein by reference. Moreover, the fault tolerant fuel cell network power system of U.S. patent application Ser. No. 10/382,549 filed Mar. 5, 2003 may also be modified in accordance with the teachings of this invention to includefuel cartridge100 of this invention into the system described therein. For the sake of brevity, those discussions will not be repeated. Indeed, another fuel cell system in which a hydride cartridge and other accessories may be integrated into is described in U.S. patent application Ser. No. 10/402,726 filed Mar. 28, 2003. These U.S. Patent Applications are incorporated herein by reference in their entirety.
• Moreover, many modifications may be made to cartridge valve assembly. All such modifications are intended to fall within the scope of the present invention. For example, with reference toFIG. 20, in one embodiment, temperature sensor-relief port assembly194 may be integrated and/or incorporated intovalve assembly housing132 ofcartridge valve assembly104. The temperature sensor-relief port assembly194 is designed to providepassage192 fromfuel vessel cavity110a(and thereby relieve unacceptable pressure that may develop infuel vessel cavity110a) by melting or evaporatingplug194 which is comprised of a temperature sensitive material. In one embodiment, plug194 is comprised of a solder based material that melts well before the pressure withinfuel vessel cavity110areach dangerous or unacceptable limits.
• In addition,control circuitry174 may also determine, monitor, manage and/or control other operations or characteristics offuel cartridge100, for example, fuel leak detection and/or fuel purge. In this regard,sensors178 may include fuel leak sensors to provide data of the status of the integrity of the seal bycartridge valve assembly104 and/orfuel vessel110 to controlcircuitry174. In response thereto,control circuitry174 may alert the user/operator of the leak (or possible leak) and/or may safely terminate operation offuel cartridge100 and/orpower unit200 or refill unit300 (if applicable).
• Alternatively,control unit174 may, based on data fromsensors178,230 and/or330 to determine the existence of a (or potential) fuel leak. Thecontrol circuitry178 may employ various techniques, which are well known to those skilled in the art, to assess whether there is a fuel leak. Again,control circuitry178 may alert the user/operator of the leak (or possible leak) and/or may immediately and safely terminate operation offuel cartridge100 and/orpower unit200 or refill unit300 (if applicable).
• The above embodiments of the present invention are merely exemplary embodiments. They are not intended to be exhaustive or to limit the inventions to the precise forms, techniques, materials and/or configurations disclosed. Many modifications, permutations and variations are possible in light of the above teaching. For example,fuel cartridge100,power unit200 and/orrefill unit300 may or may not include a one or more electrical or mechanical components such as, for example, a display unit. (See,FIGS. 14E, 17D and19D). Thus, it is to be understood that other embodiments may be utilized and operational changes may be made without departing from the scope of the present inventions. As such, the foregoing description of the exemplary embodiments of the invention has been presented for the purposes of illustration and description. Many modifications and variations are possible in light of the above teaching. It is intended that the scope of the invention not be limited solely to this detailed description.
• Notably, optional interconnections in the illustrations are represented in a dashed line format.
• It should be further noted that the term “circuit” may mean, among other things, a single component or a multiplicity of components (whether in integrated circuit form or otherwise), which are active and/or passive, and which are coupled together to provide or perform a desired function. The term “circuitry” may mean, among other things, a circuit (whether integrated or otherwise), a group of such circuits, one or more processors, one or more state machines, one or more processors implementing software, or a combination of one or more circuits (whether integrated or otherwise), one or more state machines, one or more processors, and/or one or more processors implementing software. The term “data” may mean, among other things, a current or voltage signal(s) whether in an analog or a digital form.

Claims (48)

1. A hydrogen-based fuel cell management system comprising:

a hydrogen-based fuel cartridge to store hydrogen-based fuel, the hydrogen-based fuel cartridge including:

a fuel vessel adapted to store hydrogen-based fuel;

memory to store data which is representative of at least one operating parameter of the hydrogen-based fuel cartridge; and

control circuitry; and

a power unit, coupled to the hydrogen-based fuel cartridge, the power unit including:

a hydrogen-based fuel cell, adapted to receive the hydrogen-based fuel and generate electrical power therefrom.

2. The system ofclaim 1 wherein the at least one operating parameter is the amount of hydrogen-based fuel that is remaining in the fuel vessel.

3. The system ofclaim 2 wherein the control circuitry monitors the amount of hydrogen-based fuel that is remaining in the fuel vessel using an amount of time the hydrogen-based fuel cartridge provides hydrogen-based fuel to power unit.

4. The system ofclaim 2 wherein the control circuitry monitors the amount of hydrogen-based fuel that is remaining using data which is representative of the pressure and temperature of the fuel in the fuel vessel.

5. The system ofclaim 1 wherein the at least one operating parameter is the rate of consumption of the hydrogen-based fuel by the power unit.

6. The system ofclaim 5 wherein the control circuitry monitors the rate of consumption of the hydrogen-based fuel by the power unit using one or more sensors that provides data which is representative of the rate of flow of the fuel, the pressure of the fuel in the vessel and the temperature of the fuel in the vessel.

7. The system ofclaim 1 wherein the memory further stores data which is representative of one or more unique characteristics of hydrogen-based fuel cartridge.

8. The system ofclaim 7 wherein the one or more unique characteristics of hydrogen-based fuel cartridge includes at least one of a serial number of the fuel cartridge, date of manufacture of the fuel cartridge, date of assembly of the fuel cartridge, type of fuel contained in fuel vessel, fuel capacity of the fuel cartridge, and number of refill operations the fuel cartridge has undergone.

9. The system ofclaim 1 wherein the memory further stores data which is representative of general characteristics of hydrogen-based fuel cartridge.

10. The system ofclaim 1 wherein the hydrogen-based fuel cartridge further includes a display to visually display information which is representative of the at least one operating parameter.

11. The system ofclaim 1 wherein the control circuitry is a microprocessor or microcontroller.

12. The system ofclaim 11 wherein the control circuitry intermittently, continuously or periodically determines the at least one operating parameter of the hydrogen-based fuel cartridge and intermittently, continuously or periodically stores data which is representative of the at least one operating parameter of the hydrogen-based fuel cartridge in the memory.

13. The system ofclaim 11 wherein the memory and the control circuitry are disposed on the same integrated circuit device.

14. The system ofclaim 1 wherein the power unit further includes control circuitry to determine the at least one operating parameter of the hydrogen-based fuel cartridge.

15. The system ofclaim 14 wherein the control circuitry of the power unit intermittently, continuously or periodically determines the at least one operating parameter of the hydrogen-based fuel cartridge and intermittently, continuously or periodically stores data which is representative of the at least one operating parameter of the hydrogen-based fuel cartridge in the memory of the fuel cartridge.

16. The system ofclaim 14 wherein the at least one operating parameter is the amount of hydrogen-based fuel that is remaining in the fuel vessel.

17. The system ofclaim 16 wherein the control circuitry of the power unit determines the amount of hydrogen-based fuel that is remaining in the fuel vessel using an amount of time the hydrogen-based fuel cartridge provides hydrogen-based fuel to power unit.

18. The system ofclaim 16 wherein the control circuitry of the power unit determines the amount of hydrogen-based fuel that is remaining using data which is representative of the pressure and temperature of the fuel in the fuel vessel.

19. The system ofclaim 14 wherein the at least one operating parameter is the amount of hydrogen-based fuel that has been consumed from the fuel vessel.

20. The system ofclaim 1 wherein the hydrogen-based fuel cartridge further includes communication circuitry to provide data which is representative of the at least one operating parameter of the hydrogen-based fuel cartridge to external circuitry.

21. The system ofclaim 20 wherein the communication circuitry uses wireless communications techniques.

22. A hydrogen-based fuel cell management system comprising:

a hydrogen-based fuel cartridge to store hydrogen-based fuel, the hydrogen-based fuel cartridge including:

a fuel vessel adapted to store hydrogen-based fuel;

memory to store data which is representative of at least one operating parameter of the hydrogen-based fuel cartridge; and

control circuitry;

a power unit, coupled to the hydrogen-based fuel cartridge, the power unit including:

a hydrogen-based fuel cell, adapted to receive the hydrogen-based fuel and to generate electrical power therefrom; and

a refill unit, adapted to connect with the hydrogen-based fuel cartridge, to provide fuel to the hydrogen-based fuel cartridge for storage in the fuel vessel.

23. The system ofclaim 22 wherein the at least one operating parameter is the amount of hydrogen-based fuel that is remaining in the fuel vessel of the hydrogen-based fuel cartridge.

24. The system ofclaim 23 wherein the power unit includes control circuitry to determine the amount of hydrogen-based fuel that is remaining in the fuel vessel using an amount of time the hydrogen-based fuel cartridge provides hydrogen-based fuel to power unit.

25. The system ofclaim 22 wherein the at least one operating parameter is the rate of consumption of the hydrogen-based fuel by the power unit.

26. The system ofclaim 22 wherein the memory further stores data which is representative of one or more unique characteristics of hydrogen-based fuel cartridge.

27. The system ofclaim 26 wherein the one or more unique characteristics of hydrogen-based fuel cartridge includes at least one of a serial number of the fuel cartridge, date of manufacture of the fuel cartridge, date of assembly of the fuel cartridge, type of fuel contained in fuel vessel, fuel capacity of the fuel cartridge, and the number of refill operations the fuel cartridge has undergone.

28. The system ofclaim 22 wherein the memory further stores data which is representative of general characteristics of hydrogen-based fuel cartridge.

29. The system ofclaim 22 wherein the hydrogen-based fuel cartridge further includes a display to visually display information which is representative of the at least one operating parameter.

30. The system ofclaim 22 wherein the power unit includes control circuitry to determine the at least one operating parameter of the hydrogen-based fuel cartridge.

31. The system ofclaim 30 wherein the control circuitry of the power unit intermittently, continuously or periodically determines the at least one operating parameter of the hydrogen-based fuel cartridge and intermittently, continuously or periodically stores data which is representative of the at least one operating parameter in the memory of the fuel cartridge.

32. The system ofclaim 31 wherein the at least one operating parameter is the amount of hydrogen-based fuel that is remaining in the fuel vessel and wherein the control circuitry of the power unit determines the amount of hydrogen-based fuel that is remaining in the fuel vessel using an amount of time the hydrogen-based fuel cartridge provides hydrogen-based fuel to power unit.

33. The system ofclaim 31 wherein the control circuitry of the power unit determines the amount of hydrogen-based fuel that is remaining using data which is representative of the pressure and temperature of the fuel in the fuel vessel.

34. The system ofclaim 31 wherein the at least one operating parameter is the amount of hydrogen-based fuel that has been consumed from the fuel vessel.

35. The system ofclaim 22 wherein the refill unit includes control circuitry to determine the at least one operating parameter of the hydrogen-based fuel cartridge.

36. The system ofclaim 35 wherein the control circuitry of the refill unit intermittently, continuously or periodically determines the at least one operating parameter of the hydrogen-based fuel cartridge and intermittently, continuously or periodically stores data which is representative of the at least one operating parameter in the memory of the fuel cartridge.

37. The system ofclaim 35 wherein the at least one operating parameter is the amount of hydrogen-based fuel that is remaining in the fuel vessel and wherein the control circuitry of the refill unit determines the amount of hydrogen-based fuel that is remaining in the fuel vessel using an amount of time the hydrogen-based fuel cartridge receives hydrogen-based fuel from refill unit.

38. The system ofclaim 35 wherein the control circuitry of the refill unit determines the amount of hydrogen-based fuel that is remaining using data which is representative of the pressure and temperature of the fuel in the fuel vessel.

39. The system ofclaim 35 wherein the at least one operating parameter is the amount of hydrogen-based fuel that has been consumed from the fuel vessel.

40. A hydrogen-based fuel cell management system comprising:

a hydrogen-based fuel cartridge to store hydrogen-based fuel, the hydrogen-based fuel cartridge including:

a fuel vessel adapted to store hydrogen-based fuel;

a cartridge interface including a mechanical interface;

a cartridge valve assembly;

control circuitry; and

memory to store data which is representative of a plurality of operating parameters of the hydrogen-based fuel cartridge; and

a power unit, coupled to the hydrogen-based fuel cartridge, the power unit including:

a power unit interface including a mechanical interface to mechanically connect to the mechanical interface of the cartridge interface;

a power unit valve assembly to engage the cartridge valve assembly and to enable hydrogen-based fuel to flow from the hydrogen-based fuel cartridge to the power unit; and

a hydrogen-based fuel cell, coupled to the power unit valve assembly to receive the hydrogen-based fuel from the fuel cartridge and to generate electrical power therefrom.

41. The system ofclaim 40 wherein at least one of the plurality of operating parameters is the amount of hydrogen-based fuel that is remaining in the fuel vessel.

42. The system ofclaim 40 wherein at least one of the plurality of operating parameters is the rate of consumption of hydrogen-based fuel by the power unit.

43. The system ofclaim 40 wherein the memory stores data which is representative of one or more unique characteristics of hydrogen-based fuel cartridge.

44. The system ofclaim 43 wherein the one or more unique characteristics of hydrogen-based fuel cartridge includes at least one of a serial number of the fuel cartridge, date of manufacture of the fuel cartridge, date of assembly of the fuel cartridge, type of fuel contained in fuel vessel, fuel capacity of the fuel cartridge, and number of refill operations the fuel cartridge has undergone.

45. The system ofclaim 43 wherein the memory stores data which is representative of general characteristics of hydrogen-based fuel cartridge.

46. The system ofclaim 40 wherein the hydrogen-based fuel cartridge further includes a display to visually display information which is representative of one or more of the plurality of operating parameters of the hydrogen-based fuel cartridge.

47. The system ofclaim 40 wherein the power unit further includes control circuitry to intermittently, continuously or periodically determine one or more of the plurality of operating parameters of the hydrogen-based fuel cartridge.

48. The system ofclaim 47 wherein the control circuitry of the power unit intermittently, continuously or periodically stores data which is representative of one or more of the plurality of operating parameters in the memory of the fuel cartridge.

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