US 20160244684A1 (19) United States (12) Patent Application Publication (10) Pub. No.: US 2016/0244684 A1 Vanstaan (43) Pub. Date: Aug. 25, 2016

(54) FUEL AND PROPELLANT COMPOSITION Publication Classification FOR COMBUSTION TOOLS (51) Int. Cl. (71) Applicant: ILLINOIS TOOL WORKS INC., CIOL3/00 (2006.01) Glenview, IL (US) C09K3/30 (2006.01) CIOL3/02 (2006.01) (72) Inventor: Valery H. Vanstaan, Highland Park, IL (52) U.S. Cl. (US) CPC. CI0L3/00 (2013.01); CIOL3/02 (2013.01); C09K3/30 (2013.01); CIOL 2270/08 (2013.01) (57) ABSTRACT (21) Appl. No.: 14/631,314 A combustion tool fuel cell is provided having enhanced low temperature operation, including a fuel composition compris ing at least one hydrocarbon component with a total vapor (22) Filed: Feb. 25, 2015 pressure equal or above 95 psig at 21°C. Patent Applica ion Publiicat ion Aug. 25, 2016 Sheet 1 of 3 US 2016/0244684 A1

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FUEL AND PROPELLANT COMPOSITION temperatures, usually below 40°F./5°C. These performance FOR COMBUSTION TOOLS problems make the tool less desirable to users, who need to work efficiently in a variety of weather conditions. BACKGROUND 0008 Thus, there is a need for an improved combustion 0001. The subject of this invention is fuel and propellant tool fuel that enhances tool performance at low temperatures. composition of fuel containers/cells, used for gas combustion powered tools, including powered fastener driving tools, and SUMMARY more specifically changes to the formulations of Such fuels 0009. The present invention specifically addresses the for enhancing tool performance. issue of improving performance of combustion powered 0002 Combustion powered fastening tools are widely tools, especially at lower ambient temperatures. By providing used in construction and other industries and many consumer an improved fuel cell fuel mixture, the present fuel has been applications. Suitable examples of such tools are described in found to improve combustion tool performance at lower tem U.S. Pat. Nos. 4,403,722; 4.483,474; 4,522,162; and 8,302, peratures by reducing the percentage of missed shots, and in 831, all of which are incorporated by reference. Combustion Some conditions, missed shots were eliminated. tools are usually powered by liquefied hydrocarbon fuel, 0010 Combustion fuel cells typically store the fuel in stored in aerosol dispensers, sometimes called fuel cells, con pressurized liquid form. In a typical work cycle of a combus tainers or cartridges, delivering fuel in aerosol form to a tool tion tool, a metered dose of fuel is released from the fuel combustion chamber to be mixed with air and ignited to container/valve for each cycle/shot. The fuel travels under its combust and provide energy for inserting a fastener into a own pressure through the delivery system of the tool and is workpiece. Inside the fuel cell container, the fuel is stored in ultimately injected into a combustion chamber in the tool. As a flexible bag or pouch with an outlet valve configured for the boiling point/temperature of fuel is usually lower than the connection with a fuel delivery system for metering doses of air temperature in the combustion chamber, the fuel evapo fuel to the combustion chamber. Exemplary fuel cells are rates, and mixes with the air. Combustion occurs for driving described in U.S. Pat. Nos. 5,115,944 and 7,661,568 which the fastener once the user pulls the trigger and causes a spark are incorporated by reference. to be generated by the tool spark plug. 0003. Usually, the fuel contained in a collapsible bag of 0011 A proper mix of air and vaporized fuel, character Such fuel cells includes a single component or a mixture of ized by the air-fuel ratio, at this point must be present in the two or more components, typically liquefied hydrocarbon spark plug vicinity. Proper ignition requires that the air/fuel gases, plus a small amount of a lubricant. A propellant, con mix reaches the proper ratio. So, the time needed for fuel to tained within the cell but outside the collapsible fuel bag, is travel from the valve to, and evaporate in, the combustion usually also a single component or a mixture of two or more chamber and the sparkplug area is critical. If the fuel takes too liquefied hydrocarbons, in combination with air, nitrogen, or long to reach the combustion chamber, tool performance will other gases. The propellant has a higher vapor pressure than be sluggish and unacceptable to a user. the fuel pressure and maintains the fuel in a liquefied State 0012. Thus, since the fuel travel time and evaporation is during operation. temperature dependent, combustion tool performance is 0004 One commonly used fuel used to power combustion enhanced at higher ambient temperature, when fuel evapo powered fastening tools, on market since 2001, is a two rates faster. In conventional combustion tools, these opera component fuel sold by ITW Paslode. The ITW fuel includes tional characteristics hinder low temperature performance as its main components, propylene (137 psig at 21°C.) and and reduce user productivity. 1-butene, mixed in different percentages to meet local condi 0013. It has been found that fuels having higher vapor tions and regulation requirements of particular markets. The pressure/lower boiling points, are able to travel relatively highest vapor pressure mix of this fuel family is known at 90 faster to the combustion chamber and evaporate more quickly psig at 21°C. A variation with a three-component fuel also at lower temperatures. More specifically, a combustion tool has vapor pressure at 90 psig at 21°C. The propellant in these fuel cell having enhanced low temperature operation is pro cases is propylene with or without atmospheric air. Conven vided and includes a fuel composition having at least one tional fuel cell fuels do not have vapor pressures exceeding 90 hydrocarbon component with a total vapor pressure equal or psig at 21°C. above 95 psig at 21°C. 0005 U.S. Pat. No. 8.205,777 describes the work of a fuel 0014. In another embodiment, a propellant is provided for cell/container, and claims fuel formulations of 40-95% of use in a combustion tool fuel cell comprising at least one 1-butene plus 60-5% of and also 56-96% of 1-butene hydrocarbon component with a total vapor pressure equal or plus 44-4% of propylene. For the purpose of this application, above 140 psig at 21°C. In a further embodiment, a combus it should be noticed that in the 777 patent, none of the tion tool fuel cell fuel composition is provided, including a claimed combinations produces fuel with vapor pressure fuel having a vapor pressure of at least 95 psig at 21°C., the higher than 82 psig at 21°C. fuel including at least 53 weight percent of one of propylene 0006 U.S. Pat. No. 6,800,104 discloses a combustion tool and propane; and a propellanthaving at least one hydrocarbon fuel composition having a fragrance to mask the often component with a total vapor pressure equal or above 140 unpleasant odor of conventional fuels. While dealing mostly psig at 21°C. with fuel fragrances of 3-component fuels, this reference fails 0015. Another design factor in providing an effective to disclose fuel component combinations to exceed 90 psig at combustion tool fuel relates to the propellant. Combustion 21°C. Notably, propylene is disclosed in the preferred com tool fuel cells typically include a propellant enclosed in a position in approximately 10 percent by weight. second compartment separate from the fuel. Providing a pres 0007. A common problem of users of combustion tools is sure difference between the propellant and the fuel through a that tool performance degrades as temperatures fall. It has variety of work conditions during the operational life of the been found that the rate of tool misfire increases at lower fuel container is usually a challenge, especially within the US 2016/0244684 A1 Aug. 25, 2016

can/container strength constrains. This invention provides above and the rest is, but not limited to, either 1-butene, formulations of propellants to support the proposed n- or , or a mix of them. In a further embodi “boosted fuel for two and more compartment fuel cells/ ment of fuel composition in this case is the mix of 90 weight containers. % or above of propane and the rest is, but not limited to, either 1-butene, n-butane or isobutane, or a mix of them. In another BRIEF DESCRIPTION OF THE DRAWINGS embodiment of the invention, a fuel composition consists of propane in the amount of 90 weight% or above and the rest is 0016 FIG. 1 is a graphic representation of changes in . combustion tool performance at various temperatures com 0024. In addition to having a fuel with a high vapor pres pared based on fuel vapor pressure; Sure, a preferred type of propellant composition is provided 0017 FIG. 2 is a plot of low temperature tool performance with 1, 2 or more hydrocarbon components with a total vapor for various fuel mixtures plotted as percentage Successful pressure equal or above 140 psig at 21°C. In one embodi shots against temperature; and ment, a propellant composition includes ethane, , or 0018 FIG. 3 is a graphical representation of tool perfor a mix of them as one of the primary components. A preferred mance at various temperatures and using various fuel mix embodiment of propellant composition in this case is the mix tures. of 10 weight% or above of ethane with the balance of com ponents, bringing the total vapor pressure to 170 psig or DETAILED DESCRIPTION above. In another embodiment of the invention, a propellant 0019. The present inventor has found that combustion tool composition contains 1, 2 or more hydrocarbon components performance at low temperatures is significantly improved and a compressed gas at or over 15 psig (before filling). In the when the fuel in the fuel cell has a total vapor pressure at or latter case, the propellant composition in this case includes above 95 psig at 21°C. In the present application, “total vapor hydrocarbon components and either nitrogen, air or carbon pressure” refers to a combined vapor pressure value for all of dioxide or a mix of them at 15 psig or above pressure. the various fuel ingredients or constituents. In some cases, the 0025 Referring now to FIG. 1, tests were conducted using fuel is a blend of various ingredients, such as propylene or two models of combustion fastening nailers. The tools were propane and n-butane or 1-butene. In other cases, the fuel is a each placed in a temperature-controlled chamber, and fired single ingredient, such as propylene or propane. repeatedly at a speed of one shot every 2 seconds using each 0020. As is known in the art, the main ingredients of com of several test blends of fuel. The control fuel was FUEL 90 bustion tool fuel cell fuel include but are not limited to pro described above. Another test fuel was FUEL 110 having 71 pylene, propane and MAPP gas, which itself is a blend of weight percent propylene and 29 weight percent 1-butene. Yet gases well known in the art. For the purpose of this applica another test fuel was FUEL 136, with propylene as the major tion, "MAPP gas” includes other similar “naturally” derived ingredient. FIG. 1 plots in Summary fashion fuel vapor pres multi-component hydrocarbon mixtures. Standard combus Sure at room temperature, 70°F. or 21°C., against a change in tion tool fuel, referred to as the control in the present appli low temperature limit of a tools performance. It will be seen cation, is also referred to as FUEL 90. This fuel comprises as that as fuel vapor pressure increases, the combustion tool is its main ingredients propylene at 52 weight%, and 1-butene able to work more effectively at lower temperatures. at 48 weight %, and is commercially available from ITW 0026 Referring now to FIG. 2, actual data points of the Paslode. The "90 refers to the total gas vapor pressure. It was two tools designated Block A and Block B due to their struc found that the tool users desire to be able to work at even tural configurations relating to the fuel delivery system, are lower ambient temperatures than they can now with fuels/ shown each with FUEL 136 and FUEL 90. Tool performance cells currently available on the market. is plotted as the percentage of successful shots out of 100 0021. In one embodiment of the invention, a single hydro consecutive shots. In this graph, 94 percent Successful shots carbon component with a vapor pressure equal or above 95 was arbitrarily used as the measure of a successful operational psig at 21°C. is used. This can be, but not limited to, propy session. It will be seen that exchanging FUEL 90 for FUEL lene with a vapor pressure of 136 psig, propane with a vapor 136 resulted in an extra 25° F. of efficient tool operation, pressure of 109 psig, MAPP gas with a vapor pressure of 98 extending down to the range of 20° F. psig (all at 21°C.) or similar “naturally” derived multi-com (0027. Referring now to FIG.3, a comparison of FUEL 90, ponent hydrocarbon mixtures having Suitable vapor pressure FUEL 110 and FUEL 136 is shown. In this case, using the values. same test combustion tool with all three fuels, FUEL 110 0022. In another embodiment, a fuel composition includes provided a decrease of about 5°F. in operational temperature, two components, one of them being propylene in the amount while FUEL 136 provided a reduction of about 12° F in of 53 weight% or above and the remainder is, but not limited operational temperature. Thus, results clearly show that by to, either 1-butene, n-butane or isobutane, or a mix of them. changing only fuel vapor pressure with everything else being Another suitable embodiment of fuel composition in this case the same provides a significant improvement in tool low is the mix of 63 weight% or above of propane and the rest is, temperature performance. but not limited to, either 1-butene, n-butane or isobutane, 0028. While the embodiments of the present combustion dimethyl ether or a mix of them. In a still further preferred tool fuel mixture disclosed above are presently considered to embodiment, a fuel composition includes propylene in the be preferred, various modifications and improvements are amount of 43 weight% or above and the rest is dimethyl ether contemplated without departing from the spirit and scope of at 61 psig at 21°C. the invention. The scope of the invention is presented by the 0023. One preferred embodiment of fuel composition in following claims. this case is the mix of 55 weight% or above of propane and What is claimed: the rest is dimethyl ether. In one embodiment, a fuel compo 1. A combustion tool fuel cell having enhanced low tem sition consists of propane in the amount of 76 weight % or perature operation, comprising: US 2016/0244684 A1 Aug. 25, 2016

a fuel composition comprising at least one hydrocarbon 8. A propellant for use in a combustion tool fuel cell com component with a total vapor pressure equal or above 95 prising at least one hydrocarbon component with a total vapor psig at 21°C. pressure equal or above 140 psig at 21°C. 2. The fuel composition of claim 1, wherein said at least 9. The propellant of claim 8, including as primary compo one hydrocarbon component is one of propylene or propane nents at least one of ethane and acetylene. and is the Sole hydrocarbon component. 3. The fuel composition of claim 1, wherein said at least 10. The propellant of claim8, further including at least one one hydrocarbon component is MAPP gas provided as the hydrocarbon components and a compressed gas at or over 15 sole hydrocarbon component psig. 4. The fuel composition of claim 1, comprising at least 53 11. The propellant of claim 10, wherein the compressed gas weight% of propylene, with the remainder being at least one is at least one of nitrogen, carbon dioxide and air. of 1-butene, n-butane and isobutane. 12. A combustion tool fuel cell fuel composition, compris 5. The fuel composition of claim 1, comprising at least 43 ing: weight% of propylene and a second major component being a fuel having a vapor pressure of at least 95 psig at 21°C., dimethyl ether. said fuel including at least 53 weight percent of one of 6. The fuel composition of claim 1, comprising at least 76 propylene and propane; and weight '% of propane and a remainder being at least one of 1-butene, n-butane and isobutane. a propellant comprising at least one hydrocarbon compo 7. The fuel composition of claim 1, comprising at least 63 nent with a total vapor pressure equal or above 140 psig weight% of propane and a second primary component being at 21° C. dimethyl ether.