Apparatus and method for a hydrogen-powered generator including a large-capacity hydrogen storage device

Abstract

A hydrogen-powered generator includes at least one fuel cell, a power conversion device that receives raw power from the at least one fuel cell and outputs converted power, and a hydrogen storage assembly that supplies hydrogen to the at least one fuel cell. In one example, the hydrogen storage assembly includes a first hydrogen storage unit and a second hydrogen storage unit, each of which includes a torus containing a metal alloy material that absorbs and releases hydrogen gas. In another example, the hydrogen storage assembly includes a first hydrogen storage unit and a second hydrogen storage unit, each of which includes a storage volume defined by an outer cylinder, an inner cylinder, a top flange attached to the inner cylinder, and a bottom flange attached to the inner cylinder, the storage volume configured to contain a metal alloy material that absorbs and releases hydrogen gas.

Description

[Technical Field]

[0001] (Related Applications)

[0001] This application claims priority to U.S. Provisional Patent Application No. 63 / 378,125, filed October 3, 2022, the entire contents of which are incorporated herein by reference.

[0002] TECHNICAL FIELD

[0002] Embodiments of the present technology generally relate to electrical generators that include a power conversion device, at least one fuel cell, and a hydrogen storage assembly. [Background technology]

[0003]

[0003] Hydrogen is an important research topic 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 (approximately 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 energy content by weight, hydrogen has a low energy content by volume. This makes it difficult to store hydrogen, especially within the size and weight constraints of a vehicle, for example. Another major obstacle is the flammability of hydrogen and the associated safe storage.

[0005] Known hydrogen storage technologies, which rely on 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 their commercial viability.

[0006]

[0006] Metal alloy hydrogen storage is based on materials capable of absorbing and releasing hydrogen. Metal alloy hydrogen storage achieves high energy content per volume, reduces the risk of explosion, and eliminates the need for high-pressure tanks and insulating devices. An example of a hydrogen storage device using a metal alloy is described in U.S. Patent No. 9,841,147 to Kernene.

[0007]

[0007] Harnessing the benefits of hydrogen requires systems that facilitate wider use of hydrogen as an energy source. Portable hydrogen-powered generators represent one type of system that can facilitate wider use of hydrogen as an energy source. [Prior art documents] [Patent documents]

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

[0009]

[0008] The present disclosure is generally directed to a generator powered by hydrogen gas. In one exemplary embodiment, the hydrogen-powered generator can include at least one fuel cell, a power conversion device that receives raw power from the at least one fuel cell and outputs converted power, and a hydrogen storage assembly that supplies hydrogen to the at least one fuel cell, the hydrogen storage assembly including a first hydrogen storage unit in fluid communication with the at least one fuel cell and a second hydrogen storage unit in fluid communication with the at least one fuel cell. The first hydrogen storage unit and the second hydrogen storage unit can include a torus containing a metal alloy material that absorbs and releases hydrogen gas.

[0010] In another exemplary embodiment, the present disclosure is directed to a generator powered by hydrogen gas. In one exemplary embodiment, the hydrogen-powered generator can include at least one fuel cell, a power conversion device that receives raw power from the at least one fuel cell and outputs converted power, and a hydrogen storage assembly that supplies hydrogen to the at least one fuel cell, the hydrogen storage assembly including a first hydrogen storage unit in fluid communication with the at least one fuel cell and a second hydrogen storage unit in fluid communication with the at least one fuel cell. The first hydrogen storage unit and the second hydrogen storage unit can include a storage volume defined by an outer cylinder, an inner cylinder, a top flange attached to the inner cylinder, and a bottom flange attached to the inner cylinder, the storage volume being configured to contain a metal alloy material that absorbs and releases hydrogen gas.

[0011] 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.

[0012]

[0011] The accompanying drawings merely illustrate exemplary embodiments of hydrogen-driven generators and, therefore, should not be considered to limit the scope of the present disclosure. The principles illustrated in the exemplary embodiments of the drawings may be applied to alternative methods and apparatus. Furthermore, the elements and features illustrated in the drawings are not necessarily to scale, emphasis instead being placed on clearly illustrating the principles of the exemplary embodiments. Emphasis may be placed on specific dimensions or locations to help visually convey such principles. In the drawings, the same reference numerals used in various embodiments indicate similar or corresponding, but not necessarily identical, elements. [Brief explanation of the drawings]

[0013] [Figure 1]

[0012] FIG. 1 is a block diagram showing a generator and a portable distribution box according to the prior art. [Figure 2] FIG. 1 is a block diagram of a hydrogen-driven generator according to an exemplary embodiment of the present disclosure. [Figure 3]

[0014] 1 is a diagram of a hydrogen-powered generator according to an exemplary embodiment of the present disclosure; [Figure 4] 1 is a diagram of a hydrogen-powered generator according to an exemplary embodiment of the present disclosure; [Figure 5] 1 is a diagram of a hydrogen-powered generator according to an exemplary embodiment of the present disclosure; [Figure 6]

[0015] FIG. 2 is a front view of a hydrogen-driven generator according to another exemplary embodiment of the present disclosure. [Figure 7] FIG. 2 is a top view of a hydrogen-driven generator according to another exemplary embodiment of the present disclosure. [Figure 8]

[0016] FIG. 10 is a front view of a hydrogen-driven generator according to yet another exemplary embodiment of the present disclosure. [Figure 9] FIG. 10 is a top view of a hydrogen-driven generator according to yet another exemplary embodiment of the present invention. [Figure 10]

[0017] 1 illustrates an exterior view of a hydrogen storage unit according to an exemplary embodiment of the present disclosure. [Figure 11]

[0018] FIG. 11 is an exploded view illustrating components of the hydrogen storage unit of FIG. 10 according to an exemplary embodiment of the present disclosure. [Figure 12]

[0019] FIG. 10 illustrates an exterior view of a hydrogen storage unit according to another exemplary embodiment of the present disclosure. [Figure 13]

[0020] FIG. 13 is an exploded view illustrating components of the hydrogen storage unit of FIG. 12 according to an exemplary embodiment of the present disclosure. [Figure 14]

[0021] FIG. 10 illustrates an exterior view of a hydrogen storage unit according to yet another exemplary embodiment of the present disclosure. [Figure 15]

[0022] 15 illustrates components of a coupler with a hydrogen storage unit of FIG. 14 according to an exemplary embodiment of the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0014]

[0023] Exemplary embodiments disclosed herein are directed to a hydrogen-powered generator. Specifically, hydrogen is absorbed and stored by a metal alloy material within a plurality of hydrogen storage units. The plurality of hydrogen storage units are stored within the generator and supply hydrogen to one or more fuel cells when needed. The fuel cells provide power to a power converter that can convert and output power at a desired voltage, amperage, and phase. The generator may be used for primary power or may be stored for long periods of time to provide backup power when needed. The flexibility of a hydrogen-powered generator offers several advantages.

[0015]

[0024] Prior art generators are typically paired with a portable distribution box to provide power at a desired voltage, amperage, and phase as needed for a particular application. However, prior art generators and distribution boxes are typically not configurable. In other words, if a particular installation requires power in a different form than that provided by the local distribution box, it is necessary to obtain a separate distribution box to couple with the generator. In contrast, the hydrogen-driven generators described herein have integrated power conversion equipment that corresponds to interchangeable blades. Each of the blades may be configured to provide power with a specific voltage, current, and phase, thus making the power output from the hydrogen-driven generator configurable.

[0016]

[0025] The design of the hydrogen-powered generator allows the hydrogen storage unit to be easily recharged with hydrogen when the stored hydrogen is depleted. The hydrogen storage unit contains a metal alloy material, and hydrogen gas is adsorbed and absorbed by the metal alloy material to create a metal hydride. The metal hydride stored in the hydrogen storage unit is highly stable, allowing it to be easily transported and stored for several years with little hydrogen loss. The shape of the hydrogen storage unit is optimized to promote heat transfer during filling and emptying of the hydrogen storage unit with hydrogen, and to promote hydrogen flow into and out of the hydrogen storage unit, to maximize the amount of hydrogen stored within the unit's volume. The hydrogen storage unit can be easily combined into assemblies with multiple hydrogen storage units. The configuration of the hydrogen storage unit facilitates the use of hydrogen in the generators described herein. As further explained in the examples below, the methods and apparatus described herein improve upon conventional approaches for using hydrogen as a power source.

[0017]

[0026] While the exemplary embodiments described herein are directed to generators powered by stored hydrogen gas, it should be understood that the generators described herein may also be powered using other types of gases. Examples of gases that may be stored in a storage unit to power the generators described herein include hydrogen, methane, ethane, propane, butane, hythane (hydrogen / methane), and combinations of the foregoing.

[0018]

[0027] In the following paragraphs, specific embodiments are described in further 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, reference to various features of embodiments does not imply that all embodiments must include the referenced features.

[0019]

[0028] Referring to FIG. 1 , an example of a prior art system is shown. The prior art system 100 includes a power source, such as a generator 102, that provides electrical power generated by an internal combustion engine that burns a fuel, such as gasoline or propane. The generator 102 can have one or more output receptacles that provide an output voltage, such as 120 VAC or 240 VAC. The generator 102 is coupled to a portable distribution box 105. The portable distribution box 105 has an input connector 107 for receiving input power from the generator 102. The portable distribution box 105 also includes one or more power conversion devices, such as a transformer, a buck converter, or a rectifier, to modify the input power and provide output power at an output receptacle 109. The output power can be provided to a load 112 and a load 114.

[0020]

[0029] As shown in FIG. 1 , one of the drawbacks of the prior art system 100 is that the generator must be coupled to a portable distribution box to match the generator's power to the voltage, amperage, and phase requirements of the receiving facility. The power requirements of on-site facilities can vary widely. If a suitable distribution box is not available, another distribution box must be obtained that provides the power in the required form. In contrast, as explained further below, the hydrogen-driven generator described herein provides a single system that integrates a clean power source with a power conversion device. The clean power provided by the hydrogen and fuel cell can be safely stored for long periods of time. Furthermore, the storage assembly of the hydrogen-driven generator can be easily recharged with additional hydrogen when the stored hydrogen gas is depleted. Further advantages of the hydrogen-driven generator will become apparent in the following description of exemplary embodiments.

[0021]

[0030] Referring now to FIG. 2 , a block diagram illustrating the major components of a hydrogen-driven generator 205 according to an exemplary embodiment of the present disclosure is provided. The hydrogen-driven generator 205 includes a hydrogen storage assembly 210 that stores hydrogen to be used in one or more fuel cells 225. As previously mentioned and further described below, the hydrogen storage assembly 210 can include one or more hydrogen storage units that contain a metal alloy material that absorbs and adsorbs gaseous hydrogen to form a metal hydride. The metal hydride is of a stable composition that can be safely stored for months or years. When power is needed, the hydrogen can be released from the hydrogen storage unit and used by the one or more fuel cells 225 to generate power.

[0022]

[0031] The fuel cell 225 typically outputs DC power. The hydrogen-driven generator 205 includes one or more power converters 230 to modify the power output by the fuel cell 225 to a specific voltage, current, and phase. The power converters may be one or more blades that slide in and out of the hydrogen-driven generator. Each blade may include electrical components, such as one or more transformers, inverters, and boost or buck converters, needed to convert the power from the fuel cell, as well as metering components to measure the amount of power delivered. In some cases, the blades may resemble a backplane, with slots for the power conversion components and one or more processors to intelligently control the power conversion and delivery. The power converters 230 may be configured so that the blades can easily slide in and out of the power converter to meet various power requirements. Once the converters modify the power, the output power is delivered to one or more output receptacles 235.

[0023]

[0032] 3, 4, and 5, another exemplary embodiment of a hydrogen-driven generator is shown. FIG. 3 provides a front view of the exterior of an exemplary hydrogen-driven generator 305. In FIG. 4, the front panel of the generator's outer housing has been removed to show more of the interior. In FIG. 5, the top panel of the generator's outer housing has been removed, revealing an internal view of the top of the generator. The hydrogen-driven generator 305 includes a storage assembly 310, fuel cells 325 (325-1, 325-2, 325-3, and 325-4), one or more power conversion devices 330, and an output receptacle 335.

[0024]

[0033] The storage assembly 310 includes four stacks of hydrogen storage units 316, each containing a metal alloy material that absorbs and / or adsorbs hydrogen gas. In certain embodiments, one of the side panels or the top panel of the generator's exterior housing may be opened to provide access to the hydrogen storage units to facilitate maintenance or replacement of the storage units. In the example generator 305, each of the hydrogen storage units 316 includes a coupler at the top of the unit through which hydrogen can be injected into and released from the storage unit. In alternative embodiments, the hydrogen storage units may have couplers at the bottom as well as the top of the unit. As shown in FIGS. 4 and 5 , each coupler at the top of the hydrogen storage units 316 may be connected to a hydrogen conduit 318. One end of the hydrogen conduit 318 may be coupled to a fuel cell 325 to supply hydrogen and generate electricity. The opposite end of the hydrogen conduit 318 may be coupled to a hydrogen fill port 312 disposed on the external housing of the generator 305. The hydrogen fill port 312 allows for the pumping of fresh hydrogen gas into the storage unit 316 when the hydrogen in the storage unit 316 is depleted. In certain embodiments, gauges may be disposed on the external housing of the generator to indicate the amount of hydrogen pumped to the storage unit 316 and the amount of hydrogen consumed from the storage unit 316. It should be understood that the configuration of the hydrogen storage unit 316 and the hydrogen conduit 318 depicted in Figures 3-5 is an example, and that in alternative embodiments, these components may have other shapes and configurations.

[0025]

[0034] 4 and 5 also show a vibration device 338 adjacent to the hydrogen storage unit 316 within the generator 305. The vibration device 338 can include a mechanical element that provides either vibrational or percussive loading of the hydrogen gas into the gas storage unit.

[0026]

[0035] In one embodiment, the vibration device 338 can inject pressurized hydrogen gas into the hydrogen storage unit 316. The pressurized hydrogen gas can be injected through a coupler on the hydrogen storage unit 316. The pressurized hydrogen gas can be injected into the hydrogen storage unit at a pressure ranging between 55 kPa (8 psi) and 2758 kPa (400 psi), or a narrower range therein, including, but not limited to, 69 kPa (10 psi) and 2414 kPa (350 psi) or 276 kPa (psi) and 1388 kPa (200 psi).

[0027]

[0036] In another embodiment, the vibration device 338 imparts a vibration force to the hydrogen gas and the metal alloy material in the storage unit 316 as hydrogen gas is injected into the storage device during filling. A mechanical element of the vibration device 338 can provide the vibration motion, and examples of the mechanical element include a solenoid, a microdrive, a vibration motor, a linear resonant actuator, and a piezoelectric drive. Applying a vibration force to the metal alloy material during filling of the hydrogen storage unit 316 can enhance the metal alloy material's ability to store hydrogen. Resonance of the metal alloy material can result in supersaturation of hydrogen solubility in the metal alloy material, particularly in nickel- or tin-based alloys. Furthermore, in some examples, the frequency of the vibration device can be adjusted during filling of the storage device with hydrogen such that the frequency of the vibration force approaches the resonant frequency of the metal alloy material.

[0028]

[0037] 4 and 5, the vibration device 338 is disposed external to each of the hydrogen storage units 316 and applies a force to a coupler attached to the exterior surface of each of the units. However, in other embodiments, the vibration device may be located internal to the hydrogen storage unit.

[0029]

[0038] Turning to the fuel cell 325, as shown in FIGS. 4 and 5, the fuel cell 325 can be stacked adjacent to the hydrogen storage unit 316. The fuel cell 325 combines hydrogen from the storage unit with oxygen to output electricity and water, as known to those in the field of hydrogen fuel cells. The fuel cell typically includes a delivery valve system to control the flow of hydrogen to the fuel cell, a safety valve used in the event of a pressure buildup, and a power controller to control the raw power output from the fuel cell. The raw power generated by the fuel cell is in the form of DC current. As one example, each fuel cell can generate 48 VDC raw power. If the generator has multiple fuel cells, the raw power output of the fuel cells is configured in parallel so that one fuel cell can be taken off line for maintenance or replacement while the other fuel cells and trays continue to deliver power.

[0030]

[0039] The power converter 330 can receive raw power from the fuel cell 325 and convert the raw power to the type of output power required by the equipment connected to the generator 305. As shown in FIG. 4 , the power converter 330 can include blades that house appropriate power conversion components, such as one or more of a transformer, inverter, and boost or buck converter, needed to convert the power from the fuel cell. In certain embodiments, the power converter 330 can include multiple blades, each providing a different output power to meet various requirements. The blades can be configured to easily slide in and out of the front or side panels of the generator 305 so that they can be replaced with other blades providing other types of power when needed. The blades can be configured with contacts that connect to conductive tabs that electrically couple the blades to the fuel cell. Output power from the power converter 330 is made available at one or more output receptacles 335 located on the exterior of the generator 305.

[0031]

[0040] For a given output power from generator 305, each of the hydrogen storage units 316 can store 3 to 4 kilograms of hydrogen. Thus, the 12 hydrogen storage units 316 in generator 305 can store 36 to 48 kilograms of hydrogen, which equates to a storage capacity of 1,198 to 1,598 kW-hours for generator 305. Assuming fuel cell 325 operates at 50% efficiency, the generator can provide 599 to 799 kW-hours of power. In some examples, generators can be grouped or stacked to obtain a greater amount of total output power.

[0032]

[0041] Referring now to FIGS. 6 and 7, another exemplary embodiment of a hydrogen-driven generator is shown. FIG. 6 shows the internal components of hydrogen-driven generator 405 after the front panel of the external housing has been removed. In FIG. 7, the top panel of the external housing has been removed to provide a top view of the internal components of hydrogen-driven generator 405. Hydrogen-driven generator 405 includes major components similar to those of the exemplary embodiments already described. For components having the same last two digits in their reference numbers as the component reference numbers in the examples of FIGS. 3-5, it should be inferred that the component in generator 405 is similar or equivalent to the component in generator 305, and a detailed description of that component will not be repeated.

[0033]

[0042] Similar to hydrogen-driven generator 305, hydrogen-driven generator 405 includes a hydrogen fill port 412 that is used to inject hydrogen into hydrogen storage units 416, which contain a metal alloy material that absorbs and / or adsorbs hydrogen gas. Hydrogen is injected into fill port 412, flows through hydrogen conduit 418, and enters hydrogen storage units 416 through couplers attached to each hydrogen storage unit. Hydrogen storage units 416 can have an inlet coupler for injecting hydrogen into storage unit 416 and an outlet coupler for releasing hydrogen from storage unit 416. Alternatively, hydrogen storage units 416 may be configured with a two-way coupler that allows hydrogen to flow into storage unit 416 during filling and out of storage unit 416 during hydrogen discharge.

[0034]

[0043] When power is needed, the hydrogen storage unit 416 can supply hydrogen to the fuel cells 425-1, 425-2, 425-3, and 425-4 via couplers and hydrogen conduits 418, which combine the hydrogen with oxygen to generate electricity. The raw power output from the fuel cells is converted by a power converter 430, which uses one of converter blades 432 to convert the electricity into the form (voltage, amperage, AC / DC) required by the load. The power is output by the generator 405 at an output receptacle 435. The generator 405 differs from the generator 305 in that the fuel cell 425 is located at the center of the generator, while the stacked hydrogen storage units 416 are located at the corners of the generator. As seen in the top view of FIG. 7 , two vibration devices 438 and 439 can be used to apply a vibration force to the couplers attached to each hydrogen storage unit 416 as it fills with hydrogen.

[0035]

[0044] Referring now to FIGS. 8 and 9, another exemplary embodiment of a hydrogen-powered generator is shown. The exemplary generator shown in FIGS. 8 and 9 is the same as the generator shown in FIGS. 6 and 7, except that the generator's external housing has been modified. Specifically, the generator 405 shown in FIGS. 8 and 9 has a curved external housing 440. As seen in the top view of FIG. 9, the corners of the curved external housing 440 are rounded to correspond to the rounded shape of the stacked hydrogen storage units 416. The curved external housing 440 can improve heat transfer between the external environment and the hydrogen storage units 416, which can improve the hydrogen storage capacity of the hydrogen storage units 416. The remaining components of the generator shown in FIGS. 8 and 9 are the same as those shown and described in connection with FIGS. 6 and 7. Therefore, a detailed description of those components will not be repeated.

[0036]

[0045] 10 and 11, an exemplary hydrogen storage unit 316 will be described in further detail. The details of the hydrogen storage unit 316 are representative of the type of hydrogen storage unit that may be used in any of the hydrogen storage generators described herein. Starting with the external view of the hydrogen storage unit 316 in FIG. 10, the unit is cylindrical in shape, having a height and diameter. While typical dimensions for the height (16 inches) and diameter (24 inches) are shown in FIG. 10, it should be understood that other dimensions for the height and / or diameter are within the scope of the present disclosure. The cylindrical ratio shown in FIG. 10, i.e., the diameter is 1.5 times greater than the height, is preferred to optimize the performance of the hydrogen storage unit 316. One benefit of these ratios for the storage unit is that the relatively large surface areas of the unit's top and bottom surfaces improve heat transfer between the device and the environment, which optimizes the capacity for storing hydrogen in the storage unit. Another benefit of these ratios is that they minimize hydrogen reabsorption. Hydrogen reabsorption occurs during discharge of the storage unit; during discharge, hydrogen gas is released from one portion of the metal alloy within the unit; but as the hydrogen gas travels toward the unit's outlet valve, it is reabsorbed by another portion of the metal alloy before reaching the outlet valve, thereby gradually impairing the performance of the storage unit 316 and the generator. However, the ratio of the exemplary storage unit 316 is optimized to address this issue in that its height is less than its diameter, so that during discharge, hydrogen released from the metal alloy has a relatively short distance to travel to the outlet valve, thereby reducing the likelihood that the hydrogen gas will be reabsorbed by the metal alloy before reaching the outlet valve.

[0037]

[0046] As shown in the external view of FIG. 10 , the hydrogen storage unit 316 comprises a cylindrical vessel 350 closed at the top by a top anvil 354 and at the bottom by a bottom anvil similar to the top anvil 354. When attached to the cylindrical vessel 350, the top anvil 354 and the bottom anvil form a cylindrical cavity that can contain a metal alloy material capable of storing and releasing hydrogen gas. The top anvil 354 has a top coupler 356, and the bottom anvil has a similar bottom coupler (not visible in FIG. 10 ), which can connect the hydrogen storage unit 316 to the hydrogen conduit previously described or to another storage unit or other suitable equipment. The coupler can include a valve for controlling the flow of hydrogen into and out of the gas storage unit 316. The valve can be either unidirectional or bidirectional. As an example, when filling the hydrogen storage unit 316 with hydrogen, hydrogen may be pumped into one or both of the top and bottom couplers 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 350 using fasteners, such as bolts or other types of fastening devices. Additionally, the end anvils may include shock absorbers or other features that protect the gas storage unit 316 from impacts. The components of the hydrogen storage unit 316, including the cylindrical vessel 350, the end anvils, and the couplers, may be made from any of a variety of metallic, polymeric, or composite materials that are durable enough to withstand the pressure cycling that occurs when filling and emptying the storage unit 316 with hydrogen. It should be understood that although the storage unit 316 is cylindrical having a generally circular shape when cross-sectioned perpendicular to the central longitudinal axis in the example of FIG. 10, in alternative embodiments the storage unit can take other shapes such as being oval or polygonal in cross-section.

[0038]

[0047] 11 , an exploded view of an exemplary hydrogen storage unit 316 is shown. As shown, a cylindrical vessel 350 has a grooved vessel surface 352 therein. Within the cylindrical vessel 350 is an inner cylinder 358 and a torus 360. When assembled, the inner cylinder 358 is positioned at the center of the cylindrical vessel 350, thus defining an annulus between the grooved vessel surface 352 and the outer surface of a sidewall 359 of the inner cylinder 358. In certain embodiments, the inner cylinder 358 may be attached to the inner surface of one or both of the top and bottom anvils when the storage unit 316 is assembled. In the example of FIG. 11 , the sidewall 359 of the inner cylinder 358 has a grooved outer surface similar to the grooved vessel surface of the cylindrical vessel 350 to improve heat transfer. Although other embodiments of the storage unit may have a smooth interior surface instead of the grooved container surface 352, and / or a smooth exterior surface of the inner cylinder 358, the grooved surface may improve the performance of the storage unit in that the increased surface area increases heat transfer between the storage unit and the external environment during filling and emptying of the storage unit. Furthermore, it should be understood that if the surface is grooved, the fluting may take a variety of forms and shapes that optimize the surface area for heat transfer.

[0039]

[0048] The material of the inner cylinder 358 may be an elastomer that flexes similarly to the septum when the storage unit 316 is filled with and emptied of hydrogen. However, in other embodiments, the inner cylinder 358 may comprise a rigid material, such as a ceramic. The inner cylinder 358 may be permeable to hydrogen gas so that hydrogen passes through the inner cylinder 358 when filling or emptying the metal alloy material within the torus 360. Alternatively, the inner cylinder 358 may be impermeable to hydrogen gas, allowing hydrogen gas to enter the metal alloy material through a vent or other feature. Finally, a representative diameter of 4 inches for the inner cylinder 358 is shown in FIG. 11. In other embodiments, this diameter of the inner cylinder 358 may be larger or smaller, but it is generally preferred that the diameter be no larger than 4 inches to maximize the volume within the storage unit for storing hydrogen.

[0040]

[0049] Referring to the torus 360, the torus 360 is made of a flexible material that defines an interior storage volume 368 that contains a metal alloy material 366. The metal alloy material 366 forms a metal hydride upon absorbing hydrogen. 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 material 366 is typically a granular material that forms a porous composition and may include a binder. The metal alloy grains may have a D50 grain 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 grain size of the metal alloy grains ranges from 1.5 micron to 2.0 micron. The term "D50" refers to the median diameter of metal alloy grains such that 50% of the sample weight exceeds the stated particle diameter.

[0041]

[0050] The torus 360 is intended to minimize leakage of the metal alloy material 366 from the storage unit 316. The torus 360 is made of a flexible material to accommodate expansion of the metal alloy material as it absorbs hydrogen. The flexibility of the torus 360 allows the torus inner wall to press against the outer surface of the inner cylinder 358 and the torus outer wall 364 to press against the inner surface of the cylindrical vessel 350 (the grooved vessel wall 352), enhancing heat transfer. Although the torus 360 is made of a flexible material, the torus outer wall 364 may be formed with a generally flat surface to promote contact with the grooved vessel surface 352, as shown in FIG. 11 . The torus inner wall 362 may have pores through which hydrogen gas passes to fill and drain the storage unit 316. As one example, the torus inner wall 362 may comprise a metal film containing pores to accommodate the flow of hydrogen.

[0042]

[0051] Each time the gas storage unit is filled and discharged, hydrogen can flow between one or both of the top and bottom couplers and the metal alloy material 366. Considering filling the storage unit 316 as an example, hydrogen gas can enter the chamber inside the inner cylinder 358 through a valve in the top coupler 356, pass through the permeable material of the inner cylinder 358, and pass through the pores in the torus inner wall 362, where it is absorbed and / or adsorbed by the metal alloy material 366.

[0043]

[0052] 12 and 13, another example of a hydrogen storage unit 416 is shown. The hydrogen storage unit 416 may be used in any of the exemplary hydrogen-driven generators previously described. The exterior of the hydrogen storage unit 416 is similar to the hydrogen storage unit 316 in that it includes a cylindrical vessel 450, a top anvil 454, and a bottom anvil (not seen in FIG. 12), which together form a sealed cylindrical volume for containing a metal alloy material. Also, like the storage unit 316, the storage unit 416 has a ratio such that the diameter is greater than the height of the storage unit, preferably 1.5 times greater than the height. The dimensions provided in FIG. 12 are examples; in other embodiments, the diameter and height may have different dimensions while maintaining the same or approximately the same ratio. The storage unit 416 also includes a top coupler 456 and a bottom coupler (not seen in FIG. 12), which function in a manner similar to the couplers previously described.

[0044]

[0053] Turning to Figure 13, an exploded view is provided showing some of the internal components of hydrogen storage unit 416. Cylindrical vessel 450 can have a grooved interior vessel surface 452 similar to cylindrical vessel 350 of Figures 10 and 11. Additionally, storage unit 416 has an inner cylinder 470 similar to inner cylinder 370 already described. As in the previous example, inner cylinder 470 has a sidewall 471 that can include grooves in one or both of the exterior and interior surfaces of inner cylinder 470.

[0045]

[0054] In one embodiment, the interior of storage unit 416 differs from storage unit 316 in that it does not use a torus to contain the metal alloy material. Instead, inner cylinder 470 has top and bottom flanges 472 and 473 that, together with inner cylinder 470 and cylindrical vessel 450, define a storage volume that contains the metal alloy material. The positioning of the metal alloy material is indicated using reference numeral 476, although the metal alloy material is not shown in FIG. 13 to simplify the illustration. Metal alloy material 476 is similar to the metal alloy materials previously described herein.

[0046]

[0055] Top flange 472 includes vent 474, and bottom flange 473 includes vent 476. The vents allow hydrogen to flow into metal alloy material 476 when storage unit 416 is filling, and allow hydrogen to exit metal alloy material 476 when storage unit 416 is draining. Vents 474 and 476 allow hydrogen to flow to valves at the top and bottom couplers on the exterior of hydrogen storage unit 416. Additionally, other exemplary embodiments, such as embodiments that include both a hydrogen permeable inner cylinder and vents so that there are two or more paths for hydrogen to flow in and out of the storage unit, may include combinations of features from the foregoing examples.

[0047]

[0056] Once absorbed by the metal alloy material, hydrogen gas can be stored in a stable and reliable manner. When hydrogen gas is discharged from the storage unit, it can flow from the metal alloy material through one of the paths already described into the partition chamber and exit from the partition chamber through the valves in each coupler.

[0048]

[0057] Referring now to FIGS. 14 and 15, another exemplary embodiment of the previously described vibration device is shown. In contrast to the external vibration device previously described in connection with FIGS. 4-9, the vibration device of FIGS. 14 and 15 is a reed 388 mounted within the coupler of a storage unit. The hydrogen storage unit 380 is similar to the previously described storage units in that it has a cylindrical shape with a diameter greater than its height. The hydrogen storage unit 380 also includes a cylindrical container 382, ​​a top anvil 384, a top coupler 386, and a bottom anvil and coupler (not visible in FIG. 14). FIG. 15 shows that the top coupler 386 includes a reed 388 along with a valve 387. As hydrogen flows through the top coupler 386 and valve 387 into the storage unit 380, the reed vibrates, applying a vibration load to the metal alloy material within the storage unit 380. Thus, similar to the previously described vibration device, the vibration of the reed 388 can enhance the metal alloy material's ability to store hydrogen. In one application, a storage unit 380 including a reed 388 is used in a configuration in which hydrogen is circulated through the storage unit 380 by a pump 390 while the storage unit 380 is being filled, such that a continuous flow of hydrogen vibrates the reed 388. In other embodiments, vibration of the reed can be implemented with the storage unit in other configurations.

[0049]

[0058] Examples of suitable materials for the cylindrical container, end anvils, and couplers 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, glass fiber, Ultem, and combinations thereof. The cylindrical container and its components may also be a combination of metal and polymeric materials, such as a metal liner thermoset in a polymeric resin.

[0050]

[0059] Materials for the storage unit that enhance thermal conductivity may be preferred. Thermally conductive materials facilitate heat dissipation (cooling) during filling of the storage unit with hydrogen and also facilitate warming during evacuation of hydrogen from the 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 configuration of the gas storage unit advantageously promotes energy efficiency, ease of use, ease of manufacture, and reduced weight.

[0051]

[0060] For any device shown and described herein, one or more of the components may be omitted, added, repeated, and / or substituted. Accordingly, an embodiment shown in a particular figure should not be construed as limited to the specific arrangement of components shown in such figure. Furthermore, if a component in one figure is described but not explicitly shown or labeled in that figure, the label used for the corresponding component in another figure may be inferred for that component. Conversely, if a component in one 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.

[0052]

[0061] With general reference to the examples herein, any component of the devices described herein may be made from a single piece (e.g., from a mold, injection mold, die casting, 3-D printing, extrusion, stamping, other prototyping method, etc.). Additionally, or alternatively, a component of the device may be made from multiple parts that are mechanically coupled to one another. In such cases, the multiple parts may be mechanically coupled to one another using one or more of a number of coupling methods, including, but not limited to, epoxy, welding, locking devices, compression fittings, interlocking threads, and slotted fittings. The one or more parts that are mechanically coupled to one another may be coupled to one another in one or more of a number of ways, including, but not limited to, fixed joints, hinged joints, detachable joints, sliding joints, and threaded joints.

[0053]

[0062] Terms such as "first," "second," "top," "bottom," "side," "distal," "proximal," and "within" are only used to distinguish one component (or part of a component or the state of a component) from another component. Such terms are not intended to imply 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 set forth to provide a more thorough understanding of the present invention. However, it will be apparent to those skilled in the art that the present 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.

[0054]

[0063] Although exemplary embodiments are 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 of the applications 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. at least one fuel cell; a power converter that receives raw power from the at least one fuel cell and outputs converted power; a hydrogen storage assembly for supplying hydrogen to the at least one fuel cell, the hydrogen storage assembly comprising: a first hydrogen storage unit in fluid communication with the at least one fuel cell; and a second hydrogen storage unit in fluid communication with the at least one fuel cell, the first hydrogen storage unit and the second hydrogen storage unit each comprising a torus containing a metal alloy material that absorbs and releases hydrogen gas; A hydrogen-driven generator comprising:

2. 2. The hydrogen-driven generator of claim 1, wherein the first hydrogen storage unit and the second hydrogen storage unit are each cylindrical in shape with a height and a diameter, the diameter being at least 1.5 times the height.

3. 3. The hydrogen-driven generator of claim 2, further comprising a housing having a base, a top, and at least one sidewall, the at least one sidewall being curved to accommodate the cylindrical shape of the first and second hydrogen storage units.

4. 2. The hydrogen-driven generator of claim 1, wherein the first hydrogen storage unit and the second hydrogen storage unit each comprise an interior volume, and the metal alloy material within the torus fills between 50% and 85% of the interior volume.

5. The hydrogen-powered generator of claim 1 , wherein the torus of the first hydrogen storage unit and the second hydrogen storage unit comprises a flexible material.

6. 10. The hydrogen-powered generator of claim 1, wherein the torus of the first and second hydrogen storage units comprises an inner porous wall and an outer generally flat wall.

7. 2. The hydrogen-driven generator of claim 1, wherein the first hydrogen storage unit and the second hydrogen storage unit have couplers for injecting hydrogen into the first hydrogen storage unit and the second hydrogen storage unit and for releasing hydrogen from the first hydrogen storage unit and the second hydrogen storage unit, respectively.

8. The hydrogen-powered generator of claim 7 , further comprising a vibration device disposed within the coupler of each of the first and second hydrogen storage units.

9. 2. The hydrogen-driven generator of claim 1, wherein the first hydrogen storage unit and the second hydrogen storage unit comprise an inlet coupler and an outlet coupler at opposite ends of the first hydrogen storage unit and the second hydrogen storage unit, respectively, the inlet coupler being connected to a hydrogen fill port and the outlet coupler being connected to the at least one fuel cell.

10. 10. The hydrogen-powered generator of claim 1, wherein the hydrogen storage assembly stores a sufficient amount of hydrogen to output between 250 kilowatt hours and 2 megawatt hours of energy.

11. at least one fuel cell; a power converter that receives raw power from the at least one fuel cell and outputs converted power; a hydrogen storage assembly for supplying hydrogen to the at least one fuel cell, the hydrogen storage assembly comprising: a first hydrogen storage unit in fluid communication with the at least one fuel cell; and a second hydrogen storage unit in fluid communication with the at least one fuel cell, each of the first hydrogen storage unit and the second hydrogen storage unit comprising a storage volume defined by an outer cylindrical container, an inner cylinder, a top flange attached to the inner cylinder, and a bottom flange attached to the inner cylinder, the storage volume being configured to contain a metal alloy material that absorbs and releases hydrogen gas; A hydrogen-driven generator comprising:

12. 12. The hydrogen-driven generator of claim 11, wherein the first hydrogen storage unit and the second hydrogen storage unit are each cylindrical in shape with a height and a diameter, the diameter being at least 1.5 times the height.

13. 13. The hydrogen-driven generator of claim 12, further comprising a housing having a base, a top, and at least one sidewall, the at least one sidewall being curved to accommodate the cylindrical shape of the first and second hydrogen storage units.

14. The hydrogen-driven generator of claim 11 , wherein for each of the first and second hydrogen storage units, the metal alloy material fills between 50% and 85% of the storage volume.

15. The hydrogen-powered generator of claim 11 , wherein the top flange and the bottom flange include vents through which the hydrogen gas passes.

16. 12. The hydrogen-powered generator of claim 11, wherein the outer surface of the inner cylinder is grooved and the inner surface of the outer cylindrical vessel is grooved.

17. 12. The hydrogen-driven generator of claim 11, wherein the first and second hydrogen storage units have couplers for injecting hydrogen into and releasing hydrogen from the first and second hydrogen storage units, respectively.

18. 18. The hydrogen-powered generator of claim 17, further comprising a vibration device disposed within the coupler of each of the first and second hydrogen storage units.

19. 12. The hydrogen-driven generator of claim 11, wherein the first hydrogen storage unit and the second hydrogen storage unit comprise an inlet coupler and an outlet coupler at opposite ends of the first hydrogen storage unit and the second hydrogen storage unit, respectively, the inlet coupler being connected to a hydrogen fill port and the outlet coupler being connected to the at least one fuel cell.

20. 12. The hydrogen-powered generator of claim 11, wherein the hydrogen storage assembly stores a sufficient amount of hydrogen to output between 250 kilowatt hours and 2 megawatt hours of energy.

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