Apparatus and method for a gas storage system

Abstract

A hydrogen gas storage unit includes at least two hydrogen gas storage chambers. The hydrogen gas storage unit comprises a cylindrical vessel having end anvils at each end. The at least two hydrogen gas storage chambers are separated by a middle anvil and at least one spacer disk. The middle anvil has a channel that allows hydrogen gas to flow between the two hydrogen gas storage chambers. The spacer disk extends radially outward from the middle anvil and secures a partition wall in position within at least one of the hydrogen gas storage chambers. A metal alloy capable of storing hydrogen gas is disposed between an outer surface of the partition wall and an inner surface of the cylindrical vessel.

Description

[Technical field]

[0001] (Related Applications)

[0001] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 317,413, filed March 7, 2022, the entire contents of which are incorporated herein by reference.

[0002] TECHNICAL FIELD

[0002] Embodiments of the present technology generally relate to a gas storage system including multiple gas storage chambers, each chamber comprising a metal alloy material. [Background technology]

[0003]

[0003] Hydrogen is an important research subject as an alternative fuel source to fossil fuels. Hydrogen is attractive because (i) it can be produced from a wide variety of energy sources, (ii) it has a high energy content by weight (about three times that of gasoline), and (iii) it has a zero carbon emissions footprint - the by-products of hydrogen combustion are oxygen and water.

[0004]

[0004] However, hydrogen has physical properties that make it difficult to store in large quantities without occupying a significant amount of space. Despite its high gravimetric energy content, hydrogen has a low energy content by volume. This makes it difficult to store, for example, especially within the size and weight constraints of a vehicle. Another major obstacle is the flammability of hydrogen, and the associated safe storage.

[0005]

[0005] Known hydrogen storage technologies directed to high pressure tanks, including compressed hydrogen gas and / or cryogenic liquid hydrogen storage, have drawbacks because the risk of explosion still exists. These approaches require heavy pressurized vessels and high energy input characteristics that impair commercial viability.

[0006]

[0006] Metal alloy hydrogen storage devices are based on materials that can reversibly absorb and release hydrogen. Metal alloy hydrogen storage devices offer high volumetric energy content, reducing the risk of explosion and eliminating the need for high pressure tanks and insulating devices. However, metal alloy hydrogen storage devices suffer from low gravimetric energy content.

[0007]

[0007] Examples of hydrogen storage devices using metal alloys are described in U.S. Patent No. 9,841,147 to Kernene. However, further advances to improve the amount and efficiency with which hydrogen can be stored in metal alloy storage devices would be beneficial. In particular, storage devices that improve energy density and facilitate the use of stored hydrogen in various applications would be useful. Additionally, a modular system for storing hydrogen gas would be desirable so that the modular system could be deployed in vehicles, portable generators, and energy storage systems. Accordingly, examples of improved hydrogen storage systems and embodiments are described herein. Although the examples described herein relate primarily to the storage of hydrogen, it should be understood that the storage systems disclosed herein may be used to store other gases as well. [Prior art documents] [Patent documents]

[0008] [Patent Document 1] U.S. Pat. No. 9,841,147 Summary of the Invention [Means for solving the problem]

[0009]

[0008] The present disclosure is generally directed to improved gas storage units for storing hydrogen and other gases. In one exemplary embodiment, the gas storage unit may include a cylindrical vessel with first and second end anvils surrounding the cylindrical vessel. An intermediate anvil may be disposed within the cylindrical vessel between the first end anvil and the second end anvil. A first gas storage chamber may be disposed within the cylindrical vessel between the first end anvil and the intermediate anvil. The first gas storage chamber may include a first cylindrical partition and a first metal alloy material disposed in a first annulus between the first cylindrical partition and an inner surface of the cylindrical vessel. Similarly, the second gas storage chamber may include a second cylindrical partition and a second metal alloy material disposed in a second annulus between the second cylindrical partition and an inner surface of the cylindrical vessel.

[0010]

[0009] Exemplary embodiments of the aforementioned gas storage unit may include one or more of the following exemplary features. In one example, hydrogen gas may be stored in a first metal alloy material of the first gas storage chamber and a second metal alloy material of the second gas storage chamber. The first gas storage chamber may be in fluid communication with the second gas storage chamber via a first anvil channel passing through the intermediate anvil. The gas storage unit may further include a spacer disk disposed between the first gas storage chamber and the second gas storage chamber. The first bulkhead may include a flange disposed between a raised inner flange of the spacer disk and the intermediate anvil.

[0011] In the following exemplary embodiment, the intermediate anvil may be disposed between the spacer disk and the second spacer disk. The intermediate anvil may have an equatorial portion disposed between the raised flange of the spacer disk and the raised flange of the second spacer disk. The intermediate anvil may have a first side disposed in the first gas storage chamber and a second side disposed in the second gas storage chamber, the first side and the second side of the intermediate anvil each having a frustoconical shape. The equatorial portion of the intermediate anvil may have a radial channel extending from the intermediate anvil channel to a periphery of the equatorial portion. Hydrogen gas may pass through the radial channel for storage in and release from the first and second metal alloys.

[0012]

[0011] In the above-described exemplary embodiment, hydrogen gas can pass through a first cylindrical partition for storage in and release from the first metal alloy, and can pass through a second cylindrical partition for storage in and release from the second metal alloy.

[0013]

[0012] In the above-mentioned exemplary embodiment, the inner surface of the cylindrical container may be provided with a flute and the spacer disk may be provided with a periphery having a protrusion, the protrusion of the spacer disk fitting into the groove in the inner surface of the cylindrical container.

[0014] In the aforementioned exemplary embodiment, the gas storage unit may be coupled to at least one other gas storage unit along a longitudinal axis of the gas storage unit.

[0015] In another exemplary embodiment, the present disclosure is directed to a hydrogen storage assembly comprising a first hydrogen storage unit in fluid communication with a second hydrogen storage unit, the first hydrogen storage unit and the second hydrogen storage unit each having the features of the gas storage unit described in the preceding paragraph.

[0016]

[0015] In the above example of the hydrogen storage assembly, the hydrogen storage assembly may have a capacity of 6 to 42 kg of hydrogen and 203 to 1415 kWh of power. In another example, the hydrogen storage assembly may have a capacity of 3,000 to 4,500 kg of hydrogen and 100 to 200 MWh of power. In the above example, the hydrogen storage assembly may be disposed in a shipping container. In the above example, the first hydrogen storage unit and the second hydrogen storage unit may be coupled in series.

[0017] In yet another exemplary embodiment, the present disclosure is directed to a hydrogen-powered generator comprising a fuel cell, a power conversion device, and a hydrogen storage assembly comprising a first hydrogen storage unit in fluid communication with a second hydrogen storage unit, the first hydrogen storage unit and the second hydrogen storage unit each having the features of the gas storage unit described above.

[0018]

[0017] The foregoing embodiments are non-limiting examples, and other aspects and embodiments are described herein. The foregoing Summary is provided to introduce a variety of concepts further described below in the Detailed Description. This Summary is not intended to identify required or essential features of the claimed subject matter, nor is it intended to limit the scope of the claimed subject matter.

[0019]

[0018] The accompanying drawings merely illustrate exemplary embodiments of a gas storage system and therefore should not be considered as limiting the scope of the present disclosure. The principles illustrated in the exemplary embodiments of the drawings may be applied to alternative methods and apparatus for gas storage systems. Furthermore, the elements and features illustrated in the drawings are not necessarily drawn to scale, with emphasis instead being placed on clearly illustrating the principles of the exemplary embodiments. Some dimensions or positions may be exaggerated to help visually convey such principles. In the drawings, the same reference numbers used in various embodiments indicate similar or corresponding, but not necessarily identical, elements. [Brief description of the drawings]

[0020] [Figure 1] 1 is a perspective view of a hydrogen storage unit according to an exemplary embodiment of the present disclosure. [Diagram 2] 2 is a cross-sectional view of the hydrogen storage unit of FIG. 1 according to an exemplary embodiment of the present disclosure. [Diagram 3]

[0021] FIG. 2 is a perspective view of the cylindrical container of FIG. 1 according to an exemplary embodiment of the present disclosure. [Figure 4]

[0022] 2 is an enlarged cross-sectional view of a portion of the hydrogen storage unit of FIG. 1 according to an exemplary embodiment of the present disclosure. [Diagram 5]

[0023] 2 is an enlarged cross-sectional view of a portion of the hydrogen storage unit of FIG. 1 according to an exemplary embodiment of the present disclosure. [Figure 6]

[0024] 2 is a perspective view of a portion of the hydrogen storage unit of FIG. 1 according to an exemplary embodiment of the present disclosure. [Figure 7]

[0025] 2 is another perspective view of a portion of the hydrogen storage unit of FIG. 1 according to an exemplary embodiment of the present disclosure. [Figure 8]

[0026] 1 is a cross-sectional view of an assembly of a hydrogen storage unit according to an exemplary embodiment of the present disclosure. [Figure 9]

[0027] FIGURE 9A illustrates a further configuration for assembly of a hydrogen storage unit according to an exemplary embodiment of the present disclosure; FIGURE 9B illustrates a further configuration for assembly of a hydrogen storage unit according to an exemplary embodiment of the present disclosure; FIGURE 9C illustrates a further configuration for assembly of a hydrogen storage unit according to an exemplary embodiment of the present disclosure; FIGURE 9D illustrates a further configuration for assembly of a hydrogen storage unit according to an exemplary embodiment of the present disclosure; FIGURE 9E illustrates a further configuration for assembly of a hydrogen storage unit according to an exemplary embodiment of the present disclosure; [Figure 10]

[0028] 10A and 10B are diagrams illustrating a larger scale assembly of a hydrogen storage unit according to an exemplary embodiment of the present disclosure; [Figure 11]

[0029] FIG. 1 illustrates a generator housing one or more hydrogen storage units according to an exemplary embodiment of the present disclosure. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0021]

[0030] Exemplary embodiments discussed herein are directed to gas storage units for storing hydrogen and other gases with improved efficiency and adaptability. Exemplary embodiments described herein optimize the storage of hydrogen gas in multiple storage chambers within the gas storage unit. Hydrogen is adsorbed and / or absorbed by metal alloys that produce metal hydrides that can be stored in the storage units described herein. The metal hydrides stored in the gas storage units are highly stable, allowing them to be easily transported with little hydrogen loss and stored for several years. The hydrogen storage units are also optimized to maximize the amount of hydrogen stored in the volume of the unit. The hydrogen storage units can be easily combined into assemblies with multiple hydrogen storage units. The configuration of the hydrogen storage units facilitates the use of hydrogen as a fuel source in vehicles, as a fuel source in generators as a primary or backup power source, or as a power source that can be used in remote locations lacking an electrical grid, for example. As further illustrated in the examples below, the methods and apparatus described herein improve upon conventional approaches for storing hydrogen.

[0022]

[0031] Although the exemplary embodiments described herein are directed to storage units for hydrogen gas, it should be understood that the storage units described herein may also be used to store other types of gases. Examples of gases that may be stored in the storage units described herein include hydrogen, methane, ethane, propane, butane, hythane (hydrogen / methane), and combinations thereof.

[0023]

[0032] In the following paragraphs, specific embodiments are described in more detail, by way of example, with reference to the drawings. In the description, well-known components, methods, and / or processing techniques are omitted or briefly described. Furthermore, references to various features of the embodiments do not imply that all embodiments must include the referenced features.

[0024]

[0033] Figures 1-7 show an embodiment of an exemplary hydrogen gas storage unit 100 comprising multiple hydrogen gas storage chambers. Figure 8 shows an example of an assembly of a hydrogen gas storage unit. Figures 9A-9E show further example configurations for assembly of a hydrogen storage unit. Figures 10A and 10B show examples of larger scale assembly of a hydrogen storage unit. Finally, Figure 11 shows an example of a generator housing one or more hydrogen storage units.

[0025]

[0034] 1, an exterior perspective view of an exemplary gas storage unit 100 is shown. The gas storage unit 100 has a length 110 and is generally rotationally symmetric about a central longitudinal axis 107. The gas storage unit 100 comprises an interior cylindrical cavity formed by a cylindrical vessel 101, a first end anvil 102, and a second end anvil 103. When attached to the cylindrical vessel 101, the first end anvil 102 and the second end anvil 103 form an enclosure for storing hydrogen or other gas. The first end anvil 102 and the second end anvil 103 comprise couplers 105 and 108, respectively, which can connect the gas storage unit 100 to another gas storage unit, a fuel cell, a pump, a hydrogen source, or other suitable equipment. The couplers can include valves for controlling the flow of hydrogen gas to and from the gas storage unit 100. By way of example, when filling the gas storage unit 100 with hydrogen, hydrogen may be pumped into one or both of the couplers 105, 108 at pressures ranging from 55 kPa (8 psi) to 2758 kPa (400 psi). One or both of the end anvils may be removably coupled to the cylindrical vessel 101 using fasteners such as bolts, screws, clips, detents, or other types of fastening devices. Additionally, the end anvils 102, 103 may also include shock absorbers 104 that protect the gas storage unit 100 from impacts. The vessel 101 is cylindrical with a generally circular shape when a cross section is taken perpendicular to the central longitudinal axis 107 in the example of FIG. 1, however, it should be understood that in alternative embodiments, the vessel may take other shapes such as being elliptical or polygonal in cross section.

[0026]

[0035] Referring now to FIG. 2, the gas storage unit 100 is shown in cross section along the central longitudinal axis 107. As can be seen in FIG. 2, the gas storage unit 100 comprises four gas storage chambers - a first chamber 112, a second chamber 113, a third chamber 114, and a fourth chamber 115. In other embodiments, the gas storage unit may comprise a fewer or greater number of gas storage chambers. The gas storage chambers are separated by an intermediate anvil and a spacer disk. The gas storage chambers comprise a partition wall, which will be described in more detail below. The following description provides details regarding the first chamber 112. It should be understood that the second, third, and fourth chambers are similar to the first chamber, and thus the description of the first chamber is also applicable to the features of the second, third, and fourth chambers.

[0027]

[0036] 2, the first chamber 112 is defined by the end anvil 102, the first intermediate anvil 128, and the inner surface of the cylindrical vessel 101. A first spacer disk 124 is adjacent to the end anvil 102, and a second spacer disk 125 is adjacent to the first intermediate anvil 128. A septum 120 extends from the end anvil 102 and the first spacer disk 124 at one end of the first chamber 112 to the first intermediate anvil 128 and the second spacer disk 125 at the other end of the first chamber 112. In the example shown in the figure, the septum has a generally cylindrical shape with a longitudinal axis coaxial with the axis 107 of the cylindrical vessel 101. An interior portion of the chamber, referred to as the septum chamber 121, is defined by the inner surface of the septum and anvils disposed at the opposite ends of the septum. The outer portion of the chamber, referred to as metal alloy chamber 123, is annular in shape and is defined by the outer surface of the septum, the inner surface of the cylindrical vessel, and spacer disks disposed at opposite ends of the septum. Metal alloy material 122 is positioned in metal alloy chamber 123 between the outer surface of the septum and the inner surface of the cylindrical vessel 101. In this manner, the septum and spacer disks hold the metal alloy in place within each gas storage chamber.

[0028]

[0037] The metal alloy 122 is of a type capable of absorbing hydrogen gas to form metal hydrides. The metal alloy may include any combination of the following materials: nickel, tin, aluminum, manganese, iron, cobalt, copper, titanium, antimony, and rare earth metals such as yttrium, lanthanum, cerium, praseodymium, and neodymium. The metal alloy is typically a granular material that forms a porous composition and may also include a binder. The metal alloy granules may have a D50 particle size of 1.0 micron, or 1.5 micron, or 2.0 micron to 2.5 micron, or 3.0 micron, or 4.0 micron, or 5.0 micron. In one example, the D50 particle size of the metal alloy granules ranges from 1.5 micron to 2.0 micron. The term "D50" refers to the median diameter of the metal alloy granules such that 50% of the sample weight exceeds the stated particle diameter.

[0029]

[0038] Upon each filling and discharging of the gas storage unit, hydrogen can flow between the coupler 105 and the metal alloy 122. Considering the filling of the gas storage unit 100 as an example, hydrogen gas can enter the cylindrical vessel 101 through the coupler 105 and the end anvil channels in the end anvils 102, reach the bulkhead chamber 121, pass through the anvil channels of each intermediate anvil, and flow into the next bulkhead chamber of the second, third, and fourth chambers. The flow of hydrogen between the bulkhead chambers and the metal alloy can take one or more paths depending on the particular embodiment of the gas storage unit 100.

[0030]

[0039] In one exemplary embodiment, each septum comprises a semi-permeable material that retains the metal alloy within the metal alloy chamber while allowing gaseous hydrogen to pass through the septum and between the septum chamber and the metal alloy chamber during filling and discharging of the gas storage unit 100. Hydrogen gas passes from the interior portion of the chamber through the semi-permeable membrane of each septum and is stored in the metal alloy material in the exterior portion of each chamber. Examples of semi-permeable materials for the septum include, but are not limited to, polymeric materials such as polyethylene and polypropylene, and composite materials.

[0031]

[0040] In another exemplary embodiment, hydrogen gas may pass between the bulkhead chamber and the metal alloy chamber via one or more radial channels 127 disposed in the intermediate anvils. As shown in FIG. 2, each intermediate anvil includes an anvil channel, such as anvil channel 129, that extends along the longitudinal axis 107 of the gas storage unit. Additionally, each intermediate anvil may include one or more radial channels 127 that provide a passageway for hydrogen gas to flow between the anvil channel and the metal alloy chamber. Although not seen in FIG. 2, a filter within or adjacent to the radial channel may prevent metal alloy material from leaking out of the radial channel while allowing hydrogen gas to flow.

[0032]

[0041] In yet another exemplary embodiment, the intermediate anvil and spacer disk may include one or more ports that allow hydrogen flow between the bulkhead chamber and the metal alloy chamber. Additionally, other exemplary embodiments may include combinations of the foregoing examples, such as an embodiment that includes both a hydrogen permeable membrane and radial channels in the intermediate anvil, such that there are two or more paths for hydrogen to flow within each chamber.

[0033]

[0042] Once absorbed by the metal alloy material, hydrogen gas can be stored in a stable and safe manner. When releasing hydrogen from the gas storage unit 100, hydrogen gas can flow from the metal alloy material of each chamber through one of the paths described above to the bulkhead chamber and exit from the bulkhead chamber through a channel passing through each anvil.

[0034]

[0043] Referring to the first gas storage chamber 112, the septum 120 is held in place between the end anvil 102 and a first intermediate anvil 128. A first disk spacer 124 is mounted on the inner surface of the end anvil 102 and further secures one end of the septum 120. At the opposite end of the first gas storage chamber 112, a second disk spacer 125 surrounds the first intermediate anvil 128 coaxially with the first intermediate anvil 128 and secures the opposite end of the septum 120. Each of the second chamber 113, third chamber 114, and fourth chamber 115 have a similar arrangement as the first gas storage chamber 112.

[0035]

[0044] Examples of suitable materials for the cylindrical vessel 101, the end anvils 102, 103, the intermediate anvil 128, and the spacer disks 124, 125, 126 include metals, polymeric materials, nanomaterials, and combinations thereof. Examples of suitable metals include aluminum, aluminum alloys, copper, steel, and combinations thereof. Examples of suitable polymeric materials for the cylinder include carbon fiber, polyolefins, polycarbonates, acrylates, fiberglass, Ultem, and combinations thereof. The cylindrical vessel and its components may also be combinations of metals and polymeric materials, such as, for example, a metal liner heat cured in a polymeric resin.

[0036]

[0045] In one embodiment, the cylindrical vessel 101 is constructed of a thermally conductive material. A metal alloy is packed in contact with the inner surface of the cylindrical vessel 101 to facilitate heat exchange. The thermally conductive material aids in heat dissipation (cooling) during filling of the gas storage unit with hydrogen and also aids in warming during release of hydrogen from the gas storage unit. In this manner, the cylindrical vessel functions as a heat exchanger and the gas storage unit eliminates the need for a separate heat exchanger and / or a separate cooling system. The structure and construction of the gas storage unit advantageously facilitates energy efficiency, ease of use, ease of production, and reduced weight.

[0037]

[0046] 3-7, further details of the gas storage unit 100 will be described. As shown in FIGS. 3, 5, and 6, the disk spacer is configured to fit into fluting along the inner surface 131 of the cylindrical vessel 101. In the example gas storage unit 100, the fluting extends continuously along the length 110 of the inner surface 131 of the cylindrical vessel 101. The fluting increases the surface area of ​​the inner surface of the cylindrical vessel 101, thereby enhancing heat exchange through the cylindrical vessel 101 during filling and discharging of the gas storage unit. Extending the fluting along the entire length of the inner surface of the cylindrical vessel optimizes the increased surface area. The valleys and peaks of each groove of the fluting may be curved or pointed and may have various dimensions. In a particular gas storage unit, the dimensions of each groove will typically be consistent with respect to the inner circumference of the vessel 101. For example, in the case of curved grooves, each groove may have a radius of curvature within the range of 0.1 mm to 200 mm.

[0038]

[0047] An additional advantage of having fluting extending along the entire length of the inner surface is that it provides flexibility in that the cylindrical container can be divided into various numbers of chambers as required for a particular application. For example, the exemplary gas storage unit 100 of Figures 1-8 is divided into four chambers, but the fluting along the length of the inner surface allows the gas storage unit to be reconfigured so that there are more or fewer chambers of different lengths.

[0039]

[0048] Yet another advantage of the fluting along the inner surface 131 of the cylindrical vessel 101 is that the fluting forms a semi-cylindrical shape at the outer surface of the metal alloy where the metal alloy meets the inner surface 131. The semi-cylindrical shape of the outer surface of the metal alloy creates a helical flow path for the hydrogen as it passes through the metal alloy in a direction parallel to the longitudinal axis 107. The helical flow path can be beneficial because it can encourage further absorption of hydrogen as the hydrogen spends more time circulating through the metal alloy.

[0040]

[0049] Finally, yet another advantage of the fluting extending along the length of the inner surface is that the fluting maintains symmetry about the central longitudinal axis 107. Maintaining a symmetrical interior volume of the gas storage unit can enhance the hydrogen storage capacity of the unit when a reciprocating element operating at a resonant frequency is used to pump hydrogen into the gas storage unit 100. The reciprocating element may be a solenoid, a vibration motor, a linear actuator, a piezoelectric drive, or a similar component. The reciprocating element may be located within the gas storage unit 100, for example as a component of an end anvil, or may be located external to the gas storage unit 100 and coupled to a coupler 105 or 108. An optional external reciprocating element 138 is shown by way of example in FIG. 4. When the reciprocating element vibrates at the resonant frequency of the metal alloy 122 while hydrogen is pumped into the gas storage unit 100, the reciprocating element imparts a vibrational or percussive force to the hydrogen and metal alloy, resulting in the expansion of interstitial spaces in the metal alloy lattice structure and causing the metal alloy to achieve a supersaturated state for storing additional hydrogen.

[0041]

[0050] 5 and 6, the spacer disks have protrusions along their periphery that engage with fluting along the inner surface 131 of the cylindrical vessel 101. For example, the first spacer disk 124 has an outer periphery 141 that includes protrusions that fit into grooves in the grooved inner surface 131 of the cylindrical vessel 101. Similarly, the second spacer disk 125 has an outer periphery 144 that includes protrusions that fit into grooves in the grooved inner surface 131 of the cylindrical vessel 101. The engagement with the grooved inner surfaces helps to maintain the spacer disks in their position, which helps to hold the metal alloy in place within the metal alloy chambers of each of the chambers 112, 113, 114, and 115 in the gas storage unit 100.

[0042]

[0051] As shown in Figures 4, 5, and 6, the septum 120 has a ribbed cylindrical shape including a flange at each end. Figure 4 shows a septum flange 135 adjacent the end anvil 102 and a septum flange 136 adjacent the first intermediate anvil 128. As further shown in Figures 4 and 5, each septum flange is held in place by a spacer disk. Specifically, each spacer disk includes an inner periphery that defines a central opening of the spacer disk in addition to the outer periphery previously described. The spacer disk further includes a spacer flange, which is a raised portion along the inner periphery of the spacer disk, that holds the septum flange against the adjacent anvil. For example, Figure 5 shows a first spacer flange 140 along the inner periphery of the first spacer disk 124, that holds the septum flange 135 against the end anvil 102. Similarly, the second spacer disk 125 has a spacer flange along its inner periphery which retains the bulkhead flange 136 against the first intermediate anvil 128 .

[0043]

[0052] The spacer disks also provide other benefits. They hold each of the intermediate anvils in place and facilitate assembly of the gas storage unit. The spacer disks can be installed at various locations along the length of the gas storage unit to determine the length and number of chambers in the gas storage unit. FIGS. 4, 5, and 6 show further details regarding the spacer disks that hold the intermediate anvils in the desired positions. The intermediate anvils include frustoconical portions on opposing sides of the intermediate anvil and an equatorial portion between the frustoconical portions. The equatorial portion extends radially outward from the intermediate anvil. For example, FIG. 6 shows the first intermediate anvil 128 with an equatorial portion 150 positioned between the frustoconical portions 146 and 148. As further shown in FIGS. 4 and 5, the spacer flanges along the inner periphery of the second spacer disk 125 and the third spacer disk 126 obscure the equatorial portion 150 of the first intermediate anvil 128. Additionally, the frusto-conical portions 146 and 148 fit into central openings in the second spacer disk 125 and the third spacer disk 126, respectively. Accordingly, the second spacer disk 125 and the third spacer disk 126 thereby hold the first intermediate anvil 128 in place.

[0044]

[0053] Also seen in Figures 4, 5, 6, and 7 are radial channels 127 that extend radially outward at the equatorial portion 150 of the first intermediate anvil 128. As can be seen, the radial channels 127 provide a passageway from the first anvil channel 129 to the outer periphery of the equatorial portion 150. Hydrogen gas can pass from the first anvil channel 129 through the radial channels 127 and exit through the openings of the radial channels at the periphery of the equatorial portion 150, and then the hydrogen gas can flow between the spacer disks 125 and 126 into the metal alloy. As a non-limiting example, hydrogen gas can flow from the anvil channels through the radial channels when filling the hydrogen storage unit, and then enter the metal alloy through spaces at the ends of the spacer disks or through perforations in the spacer disks. When discharging the hydrogen storage unit, the gas follows the same path in reverse, flowing from the metal alloy into the radial channels, into the bulkhead chamber, and then out through one or both anvil channels. As shown in FIG. 2, the other middle anvil of the gas storage unit 100 includes similar radial channels.

[0045]

[0054] 5 also shows a relief valve 133 and a relief valve channel 134 in the end anvil 102. The relief valve 133 may be adjusted to release hydrogen from the interior of the gas storage unit if the pressure within the unit exceeds a predetermined level. In other embodiments, the pressure relief valve and the relief valve channel may be located in other locations in the gas storage unit 100.

[0046]

[0055] As shown in Figures 6 and 7, the anvil includes a recess that receives the grooved cylindrical shape of the septum. Fluting of the septum is optional, but provides several advantages. First, the septum is typically constructed of a flexible, resilient material that can flex as the metal alloy absorbs hydrogen, allowing the volume of the metal alloy to expand. Providing fluting in the flexible material of the septum provides additional stiffness and strength to the septum. Second, the fluting of the septum creates a semi-cylindrical pattern on the inner surface of the metal alloy, similar to the effect of the grooved inner surface 131 of the cylindrical container 101 on the outer surface of the metal alloy. As previously mentioned, this semi-cylindrical pattern of the metal alloy can promote a helical flow pattern as hydrogen passes through the metal alloy in a direction generally parallel to the axis 107 of the hydrogen storage unit, thereby aiding in further absorption of hydrogen by the metal alloy. In some exemplary embodiments, the fluting of the partition can have the same shape as, and can be aligned with, the fluting along the inner surface 131 of the cylindrical vessel 101 such that the metal alloy has a shape generally similar to a collection of connected cylinders surrounding the partition.

[0047]

[0056] The grooved feature of the septum 120 is received in the end anvil recess 154 and the intermediate anvil recess 147. While the grooved feature of the septum is received in the recesses of the end anvils, the septum flange 135 is held between the end anvil 102 and the first spacer flange 140, and at the opposite end of the chamber, the septum flange 136 is held between the first intermediate anvil 128 and the spacer flange of the second spacer disk 125. Thus, the arrangement of the anvil recesses and spacer disks holds the septum in place, and the septum holds the metal alloy in place within the metal alloy chamber of the gas storage chamber.

[0048]

[0057] The truncated cone portions of the end anvil 102 and the first intermediate anvil 128 are also seen in Figures 6 and 7. The end anvil 102 includes an end anvil cone portion 152 that sits on a raised portion of the end anvil 102. The raised portion allows the first spacer disk 124 to sit in firm contact with the end anvil 102 as shown in Figure 5. The end anvil cone portion 152 has a truncated cone shape that fits through a central opening in the first spacer disk 124. An end anvil recess 154 is located along the base of the end anvil cone portion 152 and adjacent the raised portion of the end anvil 102. In Figure 7, the end anvil channel 132 and the relief valve channel 134 are seen at the truncated end of the end anvil cone portion 152. The first intermediate anvil 128 has a similar configuration but includes two frusto-conical portions 146 and 148 connected by an equatorial portion 150. The frusto-conical portion 146 has an intermediate anvil recess 147 along its base adjacent to the equatorial portion 150. Opposite the equatorial portion 150, the frusto-conical portion 148 has an intermediate anvil recess 149 along its base adjacent to the equatorial portion 150.

[0049]

[0058] FIG. 8 shows an exemplary configuration for multiple gas storage units. On the left is the exemplary gas storage unit 100 described in connection with FIGS. 1-7. As previously mentioned, the gas storage unit 100 comprises four chambers 112, 113, 114, and 115. On the right is a gas storage unit 200 similar to unit 100, including components and features such as four chambers 212, 213, 214, and 215. The combined units may be referred to as a gas storage assembly 300, or a stalk of gas storage units. The two gas storage units are coupled by a unit coupler 160, which allows hydrogen to flow between the first unit 100 and the second unit 200. The unit coupler 160 may include a valve that controls the flow of hydrogen gas between the units. Hydrogen gas may enter or exit the gas storage assembly 300 through one or both ends of the gas storage assembly 300. 8, it should be understood that additional gas storage units may be added to assembly 300. Additionally, while assembly 300 includes two gas storage units coupled in series, it should be understood that the gas storage units may be combined in parallel or combined both directly and in parallel and coupled by appropriate unit couplers or manifolds.

[0050]

[0059] The exemplary gas storage assembly shown in FIG. 8 and subsequent figures has various advantages. The gas storage assembly has a storage density of at least 126.4 grams of hydrogen per liter. The input pressure required to fill the assembly with hydrogen is in the range of 1-40 bar, and once filled, the assembly stores and subsequently releases hydrogen at near atmospheric pressure. Given the stability of the gas storage unit, the operation of the gas storage unit is quiet (less than 55 dB) and the only emission of the gas storage unit is water, allowing the gas storage unit to be used either indoors or outdoors as a primary or backup power source. Furthermore, the gas storage assembly has a life cycle of approximately 20,000 breaths (cycles of filling and releasing hydrogen) and can safely store hydrogen for several years with little hydrogen loss.

[0051]

[0060] 9A, 9B, 9C, 9D, and 9E show exemplary configurations of gas storage assemblies with multiple gas storage units such as the types described above. It should be understood that the following are representative examples and other configurations of gas storage units are within the scope of this disclosure. Gas storage assembly 405 is a bundle of gas storage units in a cylindrical shell having dimensions of 25 inches wide by 29 inches high, storing 14 kg of hydrogen capable of supplying 471 kWh. Gas storage assembly 410 is a bundle of gas storage units in a cylindrical shell having dimensions of 25 inches wide by 85.5 inches high, storing 42 kg of hydrogen capable of supplying 1,415 kWh. Gas storage assembly 415 is suitable for vehicles and is a bundle of gas storage units in a cylindrical shell having dimensions of 24 inches wide by 16 inches high, storing 10.3 kg of hydrogen capable of delivering 346 kWh. Gas storage assembly 420 is suitable for larger vehicles and is a bundle of gas storage units in a cylindrical shell having dimensions of 24 inches wide by 64 inches high, storing 41.25 kg of hydrogen capable of delivering 1,386 kWh. Finally, gas storage assembly 425 is suitable for aircraft and heavy machinery and is a bundle of gas storage units in a cylindrical shell having dimensions of 24 inches wide by 80 inches high, storing 51.5 kg of hydrogen capable of delivering 1,730 kWh.

[0052]

[0061] With reference to Figures 10A and 10B, an example of a larger system for hydrogen storage and transportation is shown. The transport containers 505 and 510 shown in Figures 10A and 10B can store many of the gas storage assemblies described above to obtain large amounts of hydrogen ranging from 3,000 kg to 5,000 kg. The transport containers can include connections for breathing (filling and discharging) hydrogen from the gas storage units stored therein. Given the stability of the gas storage units, the transport containers are self-contained and do not require external infrastructure such as temperature or pressure control facilities. Furthermore, the transport containers can be stored above ground or underground.

[0053]

[0062] Referring now to FIG. 11, an example of a generator 605 is shown. The generator may include a plurality of the aforementioned gas storage units as an energy source. The generator also includes a fuel cell for converting hydrogen to electricity. A power conversion device such as a boost converter and / or an inverter may be used to convert the electricity for a particular application. The generator 605 may include a programmable controller for controlling the operation of the generator. The controller may include a processor, memory, and a communication interface that allows a user to program aspects such as the number of fills and discharges of the gas storage units in the generator and the characteristics of the electricity the generator provides (e.g., AC, DC, voltage levels, current levels). In certain embodiments, the communication interface supports wireless communication, allowing remote monitoring and control of the generator.

[0054]

[0063] For any device shown and described herein, one or more of the components may be omitted, added, repeated, and / or substituted. Thus, an embodiment shown in a particular figure should not be considered limited to the specific arrangement of components shown in such figure. Furthermore, if a component in a figure is described but not explicitly shown or labeled in that figure, the label used for the corresponding component in another figure may be extrapolated to that component. Conversely, if a component in a figure is labeled but not described, the description for such component may be substantially the same as the description for the corresponding component in another figure.

[0055]

[0064] With general reference to the examples herein, the components of the devices described herein (e.g., container, anvil, spacer disk) may be made from a single piece (e.g., from molding, injection molding, die casting, 3-D printing, extrusion, tamping, or other prototyping methods). Additionally or alternatively, the components of the devices may be made from multiple parts that are mechanically coupled to each other. In such cases, the multiple parts may be mechanically coupled to each other using one or more of a number of coupling methods, including but not limited to epoxy, welding, clamping devices, compression joints, mating threads, and slot joints. The one or more parts that are mechanically coupled to each other may be coupled to each other in one or more of a number of ways, including but not limited to couplings that are fixed, hinged, removable, sliding, and threaded.

[0056]

[0065] Terms such as "first," "second," "top," "bottom," "side," "distal," "proximal," and "within" are merely used to distinguish one component (or a portion of a component or a state of a component) from another component. Such terms are not intended to imply a preference or a particular orientation, and are not intended to limit the embodiments described herein. In the exemplary embodiments described herein, numerous specific details are described to provide a more thorough understanding of the invention. However, it will be apparent to one skilled in the art that the invention may be practiced without these specific details. In other instances, well-known features have not been described in detail to avoid unnecessarily complicating the description.

[0057]

[0066] Although exemplary embodiments have been described herein, it should be recognized by those skilled in the art that various modifications are well within the scope of the present disclosure. Those skilled in the art will recognize that the exemplary embodiments described herein are not limited to any application specifically discussed, and that the embodiments described herein are illustrative and not restrictive. From the description of the exemplary embodiments, equivalents of the elements shown therein will occur to those skilled in the art, and methods of constructing other embodiments using the present disclosure will occur to practitioners of the art. Thus, the scope of the exemplary embodiments is not limited herein.

Claims

1. A cylindrical container; a first end anvil at a first end of the cylindrical container; a second end anvil at a second end of the cylindrical container; an intermediate anvil disposed within the cylindrical container between the first end anvil and the second end anvil; a first gas storage chamber disposed within the cylindrical vessel between the first end anvil and the middle anvil, the first gas storage chamber comprising a first cylindrical partition and a first metal alloy material disposed in a first annulus between the first cylindrical partition and an inner surface of the cylindrical vessel; a second gas storage chamber disposed within the cylindrical vessel between the middle anvil and the second end anvil, the second gas storage chamber comprising a second cylindrical partition and a second metal alloy material disposed in a second annulus between the second cylindrical partition and the inner surface of the cylindrical vessel; A gas storage unit comprising:

2. 10. The gas storage unit of claim 1, wherein hydrogen gas is stored in the first metal alloy material in the first gas storage chamber and in the second metal alloy material in the second gas storage chamber.

3. The gas storage unit of claim 1 , wherein the first gas storage chamber is in fluid communication with the second gas storage chamber via a first anvil channel that passes through the middle anvil.

4. 4. The gas storage unit of claim 3, further comprising a spacer disk disposed between the first gas storage chamber and the second gas storage chamber.

5. 5. The gas storage unit of claim 4, wherein the first cylindrical bulkhead comprises a first bulkhead flange disposed between an inner flange of the spacer disk and the middle anvil.

6. The gas storage unit of claim 4 , wherein the intermediate anvil is disposed between the spacer disc and a second spacer disc.

7. 7. The gas storage unit of claim 6, wherein the intermediate anvil comprises an equatorial portion disposed between a flange of the spacer disk and a flange of the second spacer disk.

8. 8. The gas storage unit of claim 7, wherein the intermediate anvil comprises a first side disposed within the first gas storage chamber and a second side disposed within the second gas storage chamber, the first side and the second side of the intermediate anvil each having a frusto-conical shape.

9. The gas storage unit of claim 7 , wherein the equatorial portion of the intermediate anvil comprises a radial channel extending from a intermediate anvil channel to a periphery of the equatorial portion.

10. 10. The gas storage unit of claim 9, wherein hydrogen gas passes through the radial channels for storage in and release from the first and second metal alloy materials.

11. 2. The gas storage unit of claim 1, wherein hydrogen gas passes through the first cylindrical partition for storage in and release from the first metal alloy material and passes through the second cylindrical partition for storage in and release from the second metal alloy material.

12. the inner surface of the cylindrical container comprises a groove; the spacer disk having a periphery with a protrusion; the protrusions of the spacer disks fit into the grooves in the inner surface of the cylindrical container; 5. The gas storage unit of claim 4.

13. 10. The gas storage unit of claim 1, wherein the gas storage unit is coupled to at least one other gas storage unit along a longitudinal axis of the gas storage unit.

14. a first hydrogen storage unit in fluid communication with a second hydrogen storage unit via a fluid connector, the first hydrogen storage unit and the second hydrogen storage unit comprising: A cylindrical container; a first end anvil at a first end of the cylindrical container; a second end anvil at a second end of the cylindrical container; an intermediate anvil disposed within the cylindrical container between the first end anvil and the second end anvil; a first hydrogen storage chamber disposed within the cylindrical vessel between the first end anvil and the middle anvil, the first hydrogen storage chamber comprising a first cylindrical partition and a first metal alloy material disposed in a first annulus between the first cylindrical partition and an inner surface of the cylindrical vessel; a second hydrogen storage chamber disposed within the cylindrical vessel between the middle anvil and the second end anvil, the second hydrogen storage chamber comprising a second cylindrical partition and a second metal alloy material disposed in a second annulus between the second cylindrical partition and the inner surface of the cylindrical vessel; 13. A hydrogen storage assembly comprising:

15. The hydrogen storage assembly of claim 14, wherein the hydrogen storage assembly has a capacity of 6 to 42 kg of hydrogen and 203 to 1415 kWh of power.

16. The hydrogen storage assembly of claim 14 , wherein the hydrogen storage assembly is disposed in a transport container.

17. The hydrogen storage assembly of claim 14, wherein the hydrogen storage assembly has a capacity of 3,000 to 4,500 kg of hydrogen and 100 to 200 MWh of power.

18. The hydrogen storage assembly of claim 14 , wherein the first hydrogen storage unit and the second hydrogen storage unit are coupled in series.

19. fuel cell, A power conversion device, and A hydrogen storage assembly comprising a first hydrogen storage unit in fluid communication with a second hydrogen storage unit via a fluid connector. The first hydrogen storage unit and the second hydrogen storage unit include: A cylindrical container; a first end anvil at a first end of the cylindrical container; a second end anvil at a second end of the cylindrical container; an intermediate anvil disposed within the cylindrical container between the first end anvil and the second end anvil; a first hydrogen storage chamber disposed within the cylindrical vessel between the first end anvil and the middle anvil, the first hydrogen storage chamber comprising a first cylindrical partition and a first metal alloy material disposed in a first annulus between the first cylindrical partition and an inner surface of the cylindrical vessel; a second hydrogen storage chamber disposed within the cylindrical vessel between the middle anvil and the second end anvil, the second hydrogen storage chamber comprising a second cylindrical partition and a second metal alloy material disposed in a second annulus between the second cylindrical partition and the inner surface of the cylindrical vessel; a hydrogen-driven generator,

20. 20. The hydrogen-powered generator of claim 19, wherein the power conversion device is one of an inverter, a boost converter, and a switching power supply.

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