Hydrogen-powered handheld tool
Patent Information
- Application Number
- PCT/US2026/019643
- Authority / Receiving Office
- WO · WO
- Patent Type
- Applications
- Current Assignee / Owner
- Priority Date
- 2025-03-18
- Filing Date
- 2026-03-17
- Publication Date
- 2026-09-24
Smart Images
Figure US2026019643_24092026_PF_FP_ABST
Abstract
Description
HYDROGEN-POWERED HANDHELD TOOLRELATED APPLICATIONS
[0001] The present application claims priority to U.S. Provisional Patent Application No. 63 / 774,083 filed March 18, 2025, the entire content of which is incorporated herein by reference.TECHNICAL FIELD
[0002] Embodiments of the technology relate generally to a hydrogen-powered handheld tool comprising a hydrogen storage unit coupled to a modular tool.BACKGROUND
[0003] Hydrogen is the object of significant research as an alternate fuel source to fossil fuels. Hydrogen is attractive because (i) it can be produced from many diverse energy sources, (ii) it has a high energy content by weight (about three times more than gasoline) and (iii) it has a zero-carbon emission footprint — the by-products of hydrogen combustion being oxygen and water.
[0004] However, hydrogen has physical characteristics that make it difficult to store in large quantities without taking up a significant amount of space. Despite hydrogen's high energy content by weight, hydrogen has a low energy content by volume. Another major obstacle is hydrogen's flammability and the concomitant safe storage thereof.
[0005] Known hydrogen storage technologies directed to high pressure tanks with compressed hydrogen gas and / or cryogenic liquid hydrogen storage have shortcomings because the risk of explosion still exists. These approaches require pressurized containers that are heavy and also require high energy input — features that detract from commercial viability.
[0006] Metal hydrogen storage is based on metal materials capable of reversibly storing and releasing hydrogen. Metal hydrogen storage provides high energy content by volume, reduces the risk of explosion, and eliminates the need for high pressure tanks andinsulation devices. Metal hydrogen storage, however, struggles with low energy content by weight.
[0007] Examples of hydrogen storage devices using metal are described in U.S. Patent No. 9,841,147 to Kernene. However, further applications that facilitate use of stored hydrogen as a source of power would be useful. Additionally, modular systems for storing hydrogen gas so that the modular systems can be deployed in tools would be desirable. Accordingly, examples of improved hydrogen storage systems and implementations are described herein. While the examples described herein primarily relate to applications for stored hydrogen, it should be understood that the applications disclosed herein can be used to store other gases as well.BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The accompanying drawings illustrate only example embodiments of hydrogen-powered handheld tools and therefore are not to be considered limiting of the scope of this disclosure. The principles illustrated in the example embodiments of the drawings can be applied to alternate methods and apparatus for a hydrogen-powered handheld tool. Additionally, the elements and features shown in the drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the example embodiments. Certain dimensions or positions may be exaggerated to help visually convey such principles. In the drawings, the same reference numerals used in different embodiments designate like or corresponding, but not necessarily identical, elements.
[0009] Figure 1 illustrates a hydrogen-powered handheld tool in accordance with the example embodiments of the disclosure.
[0010] Figure 2A illustrates aspects of a tool head in accordance with the example embodiments of the disclosure.
[0011] Figure 2B illustrates aspects of another tool head in accordance with the example embodiments of the disclosure.
[0012] Figure 3 illustrates a cross-sectional view of a canister of a hydrogen-powered handheld tool in accordance with the example embodiments of the disclosure.
[0013] Figure 4 is an exploded view of aspects of a canister of a hydrogen-WORKAMER\39752966.vl 2powered handheld tool in accordance with the example embodiments of the disclosure.
[0014] Figure 5 is an exploded view of aspects of another canister of a hydrogen-powered handheld tool in accordance with the example embodiments of the disclosure.
[0015] Figure 6 is an exploded view of aspects of yet another canister of a hydrogen-powered handheld tool in accordance with the example embodiments of the disclosure.DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS
[0016] Improvements in rechargeable electric batteries, such as lithium-ion batteries, have led to wider applications for handheld tools. Handheld tools powered by rechargeable electric batteries continue to become more widespread given their advantages with respect to light weight, mobility, power, and ease of recharging and replacing the electric battery. Examples of such handheld tools include drills, cutting tools, pumps, compressors, and luminaires. These handheld tools have a variety of uses, including in industrial, residential, and medical applications.
[0017] As an alternative to electric batteries, hydrogen offers another power source that, relative to electric batteries, can offer advantages with respect to weight, lifecycle, resilience, and recharging. Recent advances in the storage of hydrogen allow for greater amounts of hydrogen to be stored more safely and with greater energy density. For example, U.S. Patent No. 9,841,147 describes an improved storage device for hydrogen. The example embodiments provided herein leverage the improvements in hydrogen storage for use in a variety of hydrogen-powered handheld tools.
[0018] As described and illustrated further below, the example hydrogen-powered handheld tools have a modular configuration that includes a hydrogen storage canister which can be coupled to a tool head that supports a variety of tools. The hydrogen storage canister provides a light weight, portable, and energy dense module that can be held in one or both hands of an adult person while the tool is operated. This modular configuration allows for easy disconnection of the hydrogen storage canister from the tool head so that the hydrogen storage canister can be recharged with hydrogen or replaced with another canister that has been charged with hydrogen. The hydrogen-powered handheld tools described herein also are resilient in that they will continue to operate even when subjected to harsh environmental conditions, including extremeWORKAMER\39752966.vl 3temperatures, pressures, and impacts.
[0019] While the example embodiments described herein utilize hydrogen storage canisters, it is also possible that the storage canisters also can be used to store other types of gases that can be used as a power source. Examples of gases that can be stored in the canisters described herein include hydrogen, methane, ethane, propane, butane, hy thane (hydrogen / methane), and combinations thereof.
[0020] In the following paragraphs, particular embodiments will be 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 feature(s) of the embodiments is not to suggest that all embodiments must include the referenced feature(s).
[0021] Referring now to Figures 1, 2A, and 2B, an example embodiment of a hydrogen-powered handheld tool is illustrated. Figure 1 illustrates a handheld tool 100 comprising a canister 102 and a tool head 140. As referenced above, the canister 102 provides a safe, flexible, portable, and energy dense device for storing hydrogen and making the hydrogen readily available for use as a power source. Examples of the canister 102 will be described in greater detail below in connection with Figures 3-6. Briefly, the canister 102 comprises a metal composition that can store and release hydrogen gas. When charging the canister 102, hydrogen pumped into the canister 102 is adsorbed and / or absorbed by the metal composition producing a metal hydride that can safely store the hydrogen until it is needed to power the tool. In certain embodiments, a vibrating device (or reciprocating element) can be used in conjunction with a pump causing the metal composition to vibrate and thereby increase its capacity for storing hydrogen. For example, vibrating the metal composition at a resonant frequency can significantly increase the hydrogen storage capacity. When discharging the canister 102, the hydrogen can be released from the metal composition by applying heat or negative pressure to the canister 102. The metal hydride stored within the canister 102 is very stable allowing it to be easily transported and stored for several years with very little hydrogen loss. The canister 102 also is optimized to maximize the quantity of hydrogen stored within the volume of the unit.
[0022] Figures 1-2B also illustrate the tool head 140 attached to the canister 102.WORKAMER\39752966.vl 4A canister connector 134 located at one end of the canister 102 provides a connection point to a tool connector 142 of the tool head 140. As illustrated in Figures 1-2B, the canister connector 134 can be a protrusion extending from one endcap of the canister 102 and that fits into a recess that forms the tool connector 142. In alternate embodiments, the canister connector and the tool connector can have other forms. As one example, the canister connector may form a recess into which a protruding portion of the tool connector fits. As another example, the canister connector and the tool connector may each comprise protrusions that may be coupled together.
[0023] The canister connector 134 and the tool connector 142 can be easily coupled or decoupled by features located on the canister connector 13 and the tool connector 142, such features including by not limited to threads, detents, a snap fit, a twist-and-lock arrangement, or a locking ring. When the hydrogen in the canister 102 has been exhausted, the canister 102 can be easily decoupled from the tool head 140 and a replacement canister containing hydrogen and having a similar configuration can be coupled to the tool head 140 at the tool connector 142. The canister connector 134 can include a valve that controls the flow of hydrogen into and out of the canister 102.
[0024] Figure 2A illustrates one example embodiment of a tool head 140. The tool head 140 comprises a housing 147 which may be integrated with the tool connector 142. Within the housing 147 is a fuel cell 144 that receives hydrogen from the canister 102 and converts the hydrogen into electricity. The fuel cell 144 may comprise a stack of multiple individual fuel cells that in combination provide the desired electrical output. As one example, the fuel cell may comprise a stack of proton-exchange membrane (“PEM”) fuel cells. PEM fuel cells perform a two-step reaction that includes splitting electrons from hydrogen to generate a direct current and combining the positive hydrogen ions with oxygen to generate water. A fuel cell vent 143 in the housing 147 can permit oxygen to flow to the fuel cell 144 and can allow water or other byproducts generated by the fuel cell to exit the tool head 140. In other examples, other types of fuel cells can be used with the tool head.
[0025] A controller 145 within the housing 147 can regulate the flow of hydrogen from the canister 102 to the fuel cell 144. As examples, the controller may be a programmable logic controller or an integrated circuit. The controller 145 may operate aWORKAMER\39752966.vl 5shutter or valve of the fuel cell to regulate the flow of hydrogen into the fuel cell. The controller 145 may be powered by a capacitor or small battery. Alternatively, the controller 145 may be powered by a small plunger that extends from the housing 147 and that is manually pumped by a user to generate the electrical power needed for the controller 145.
[0026] As the fuel cell 144 receives hydrogen from the canister 102 and generates a raw direct current, a DC / DC converter can modify the raw direct current into the desired output voltage and output current for operating the handheld tool. The DC / DC converter can be a component integrated with the fuel cell or can be coupled to the fuel cell. The DC / DC converter may be a boost converter circuit or a field effect transistor. Alternatively, the DC / DC converter may use a polymer semiconductor so that it is not susceptible to being compromised by electromagnetic interference or pulses. The DC / DC converter provides the output current and output voltage to an electric motor 146. A power switch 141 can be used to toggle the electric motor and / or the controller between an on state and an off state.
[0027] The electric motor 146 drives a tool 148 that is attached to the housing 147. The tool 148 may be removably attached or permanently attached to the housing 147 depending on the desired application. Examples of the tool include but are not limited to a cutting tool such as a rotary saw, a drill chuck that receives a drill bit, a rotary grinding or sanding tool, a pump, or a compressor. In certain embodiments, the tool head 140 may be configured to attach to a variety of different tools that can be interchanged for different applications. For example, a rotary saw can be attached to perform a cutting operation and then removed and replaced with a drill chuck and drill bit for a drilling operation. In certain embodiments, the electric motor 146 can be bypassed by leads that supply the output current and output voltage to other tools such as a multimeter or a luminaire.
[0028] Figure 2B illustrates an alternate embodiment of a tool head that can be attached to the canister 102 and that can use hydrogen as a power source. Specifically, the tool head in Figure 2B is a torch tool 160 that combusts hydrogen and provides a flame for heating, melting, or burning applications. Similar to the tool head of Figure 2A, the torch tool 160 of Figure 2B comprises a housing 167. The housing 167 includesWORKAMER\39752966.vl 6a tool connector 162 for coupling the torch tool 160 to the canister 102 via features, such as threads, detents, a snap fit, a twist-and-lock arrangement, or a locking ring.
[0029] The torch tool 160 differs from the tool head 140 of Figure 2A in that instead of a fuel cell, the torch tool 160 has a combustion unit 164 that ignites the hydrogen received from the canister 102 and generates a flame. The flame generated by the combustion unit 164 can be regulated and directed by a nozzle 166 extending from the exterior of the housing 167. One or more combustion vents 163 on the housing 167 can permit oxygen to flow into the combustion unit 164 to facilitate combustion and can allow exhaust gases generated by the combustion unit to exit the housing 167.
[0030] A controller 165 within the housing 167 can regulate the flow of hydrogen from the canister 102 to the combustion unit 164. As examples, the controller may be a programmable logic controller or an integrated circuit. The controller 165 may operate a shutter or valve of the combustion unit 164 to regulate the flow of hydrogen into the combustion unit 164. The controller 165 may be powered by a capacitor or small battery. Alternatively, the controller 165 may be powered by a small plunger that extends from the housing 167 and that is manually pumped by a user to generate the electrical power needed for the controller 165. A power switch 161 can be used to toggle the controller between an on state and an off state or to extinguish the flame generated by the combustion unit 164.
[0031] Referring now to Figures 3 and 4, an example embodiment of the canister 102 is illustrated in greater detail. Figure 3 provides a cross-sectional view of the canister 102 while Figure 4 provides an exploded view of portions of the canister 102.
[0032] The canister 102 has a length that is greater than its width and is generally rotationally symmetrical about a central longitudinal axis 103. The canister 102 can have a length ranging from 4 to 16 inches and a width (the cross-sectional diameter of the cylinder perpendicular to the longitudinal axis 103) ranging from 1 inch to 4 inches. These dimensions of the canister 102 make it suitable for grasping with one or two hands of an adult person and for use as a handheld tool. The canister 102 comprises an interior cylindrical cavity formed by cylindrical sidewall 104, a first endcap 106, and a second endcap 107. When attached to the cylindrical sidewall 104, the first endcap 106 and second endcap 107 form an enclosure for storing hydrogen or other gases. The cannisterWORKAMER\39752966.vl 7connector 134 can be attached to the first endcap 106 and the canister connector 134 can comprise a valve 133 that regulates the flow of hydrogen into and out of the canister 102. As described previously, the canister connector 134 is configured to couple to a tool head for use with a variety of tools. The canister connector 134 also can be coupled to a pump or compressor so that the canister 102 can be recharged with hydrogen when needed.
[0033] One or both of the endcaps 106, 107 can be removably coupled to the cylindrical sidewall 104 using fasteners such as bolts, screws, clips, detents, or other types of fastening devices. Alternatively, in certain embodiments one of the endcaps may be an integrated portion of the cylindrical sidewall 104 so that only the other endcap is removably coupled to the cylindrical sidewall 104. Additionally, the endcaps 106, 107 also can include bumpers that protect the canister 102 from impacts. Although the canister 102 is cylindrical with a generally circular shape when a cross-section is taken perpendicular to the central longitudinal axis 103 in the example of Figure 3, it should be understood that in alternate embodiments the container can take other shapes such that the cross-section is elliptical or polygonal.
[0034] As illustrated in Figures 3 and 4, the canister 102 comprises an interior chamber that is divided by a diaphragm 114. The diaphragm 114 extends from the first endcap 106 at one end of the canister’s interior chamber to the second endcap 107 at the other end of the canister’s interior chamber. In the example illustrated in the figures, the diaphragm has a generally cylindrical shape with open ends and a longitudinal axis that is co-axial with the longitudinal axis 103 of the canister 102. An inner portion of the canister’s interior chamber, referred to as the diaphragm chamber 113, is defined by a cylindrical inner surface of the diaphragm 114 and the endcaps 106, 107 located at opposing ends of the diaphragm 114. An outer portion of the canister’s interior chamber, referred to as the metal chamber 109, is in the shape of an annulus and is defined by a cylindrical outer surface of the diaphragm 114, an inner surface of the cylindrical sidewall 104, and the endcaps 106, 107 located at opposing ends of the canister 102. A metal composition 110 is positioned in the metal chamber 109 between the outer surface of the diaphragm 114 and the inner surface of the cylindrical sidewall 104. In this arrangement, the diaphragm 114 and endcaps 106, 107 hold the metal composition in place within the canister 102.WORKAMER\39752966.vl 8
[0035] The metal composition 110 is of a type that can absorb hydrogen gas to form a metallic hydride. The metal composition can comprise any one or 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 composition is typically a granular material that forms a porous composition and may include a binding agent. The metal granules can have a D50 particle size from 1.0 microns, or 1.5 microns, or 2.0 microns to 2.5 microns, or 3.0 microns, or 4.0 microns, or 5.0 microns. In one example, the D50 particle size of the metal granules ranges from 1.5 microns to 2.0 microns. The term “D50” refers to the median diameter of the metal granules such that 50% of the sample weight is above the stated particle diameter.
[0036] With each charging and discharging of the canister 102, hydrogen can flow between the valve 133 and the metal composition 110. The flow of hydrogen between the diaphragm chamber 113 and the metal composition 110 can take one or more paths depending upon the particular embodiment of the canister 102.
[0037] Figure 4 illustrates one embodiment in which the hydrogen passes through vents in the diaphragm 114. Specifically, the diaphragm 114 includes a top flange 116 and a bottom flange 117 which have the general shape of disks extending radially from each end of the diaphragm 114. The top flange 116 comprises one or more hydrogen vents 118 and the bottom flange 117 comprises one or more hydrogen vents 119. The number of hydrogen vents and the placement of the hydrogen vents can be varied to suit different applications or different dimensions of the canister 102. In certain embodiments, the vents also can be placed on the cylindrical portion of the diaphragm 114. The hydrogen vents can include a filter that prevents the granules of the metal composition 110 from leaking through the hydrogen vents, but that permits hydrogen to flow through the filter of each hydrogen vent.
[0038] When charging the canister 102, the hydrogen gas can enter the canister 102 through valve 133, pass through the open end of the diaphragm 114 and into the diaphragm chamber 113. From the diaphragm chamber 113, the hydrogen gas can pass through a gap between the inner surface of the first endcap 106 and an outer surface of the top flange 116 and then pass through the hydrogen vents 118 and into the metalWORKAMER\39752966.vl 9chamber 109 where the metal composition 110 can store the hydrogen gas in a stable and secure state as a metal hydride. Similarly, the hydrogen gas also can flow through the diaphragm chamber 113 toward the bottom flange 117 where it passes through a gap between the inner surface of the second endcap 107 and an outer surface of the bottom flange 117 and then pass through the hydrogen vents 119 and into the metal chamber 109 where the metal composition stores the hydrogen gas as a metal hydride. Locating the vents at the top flange 116 and the bottom flange 117 can promote the flow of hydrogen within the metal composition in a vertical direction parallel to the longitudinal axis 103, which can be advantageous with respect to the transfer of heat through the cylindrical sidewall 104. When discharging hydrogen from the canister 102, the hydrogen gas can follow the foregoing paths in reverse by flowing from the metal composition 110, through the hydrogen vents 118 and 119, into the diaphragm chamber 113, and exiting through the valve 113. As described further below, Figures 5 and 6 illustrate alternate embodiments of the canister in which the hydrogen gas flows differently within the canister.
[0039] Examples of suitable materials for the cylindrical sidewall 104 and the endcaps 106, 107 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 material include carbon fiber, polyolefin, polycarbonate, acrylate, fiberglass, Ultem, and combinations thereof. The cylindrical container and its components may be a combination of metal and polymeric material such as a metal liner thermoset in a polymeric resin, for example.
[0040] In an embodiment, the cylindrical sidewall 104 and endcaps 106, 107 are composed of a heat conductive material. The metal composition 110 is packed against the inner surfaces of the cylindrical sidewall 104 to facilitate the exchange of heat. The heat conductive material promotes heat dissipation (cooling) during charging of the canister with hydrogen and promotes warming during discharging of hydrogen from the canister. In this way, the cylindrical container functions as a heat exchanger and the canister eliminates the need for a separate heat exchanger and / or a separate coolant system as is often used in prior art approaches to hydrogen storage. The structure and composition of the canister advantageously promotes energy efficiency, ease-of-use,WORKAMER\39752966.vl 10ease-of-production, and reduction in weight.
[0041] As illustrated in Figure 4, the inner surface of the cylindrical sidewall 104 can have a non-smooth surface that increases surface area to promote heat exchange during charging or discharging of the canister with hydrogen. The non-smooth character of the inner surface of the cylindrical sidewall 104 can have a variety of configurations. In the example illustrated in Figure 4, the inner surface 105 of the cylindrical sidewall 104 is contoured with channels, also called fluting, oriented with longitudinal axes parallel to the longitudinal axis 103. The channels, or fluting, run continuously along the length of the inner surface 105 of the cylindrical sidewall 104 to maximize the surface area of the inner surface 105, thereby enhancing the exchange of heat through the cylindrical sidewall 104 during charging and discharging of the gas storage unit. The trough and peak of each flute of the fluting can be curved or pointed and can have a variety of dimensions. In a particular gas storage unit, the dimensions of each flute will typically be consistent throughout the circumference of the inner surface 105 of the cylindrical sidewall 104. For example, in the case of curved flutes, each flute can have a radius of curvature in a range from 0.1 mm to 200 mm.
[0042] Another advantage of the fluting along the inner surface 105 of the cylindrical sidewall 104 is that it forms semicylindrical shapes along the outer surface of the metal composition 110 where the metal composition contacts the inner surface 105. The semi -cylindrical shapes along the outer surface of the metal composition 110 foster a helical flow path for the hydrogen as it moves through the metal composition in a direction parallel to the longitudinal axis 103. A helical flow path can be beneficial because it can encourage more absorption of hydrogen as it spends more time circulating through the metal composition 110.
[0043] Lastly, yet another advantage of the fluting extending along the length of the inner surface 105 is that it maintains symmetry about the central longitudinal axis 103. 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 canister 102. The reciprocating element can be a solenoid, a vibration motor, a linear actuator, a piezoelectric drive, or a similar component. When the reciprocating element vibrates at a resonant frequency ofWORKAMER\39752966.vl 11the metal composition 110 while hydrogen is being pumped into the canister 102, the reciprocating element can impart a vibrating or percussive force on the hydrogen and the metal composition causing an expansion of the interstitial spaces in the metal composition lattice structure and causing the metal composition to achieve a supersaturated state storing additional hydrogen.
[0044] As illustrated in Figures 3 and 4, the cylindrical wall of the diaphragm 114 can have a ribbed configuration that forms flutes or channels along the cylindrical wall of the diaphragm 114. The fluting of the diaphragm is optional, but provides certain advantages. First, the diaphragm is typically constructed of a flexible and resilient material that can flex permitting the volume of the metal composition 110 to expand as it absorbs hydrogen. Providing fluting in the flexible material of the diaphragm gives the diaphragm greater rigidity and strength. Second, the fluting of the diaphragm forms a semi-cylindrical pattern on the inner surface of the metal composition similar to the effect described above of the fluted inner surface 105 of the cylindrical sidewall 104 on the outer surface of the metal composition 110. As explained previously, this semi-cylindrical pattern on the inner and outer surface of the metal composition 110 can promote a helical flow pattern as the hydrogen passes through the metal composition 110 in a direction generally parallel to the longitudinal axis 103 of the canister 102 thereby encouraging greater absorption of hydrogen by the metal composition 110. In some example embodiments, the fluting of the diaphragm 114 can have a similar shape as and can align with the fluting along the inner surface 105 of the cylindrical sidewall 104 so that the metal composition 110 has a shape generally similar to a collection of joined cylinders that surround the diaphragm 114.
[0045] Regardless of whether the diaphragm is ribbed with fluting, using a flexible and resilient material for the diaphragm provides another advantage. As referenced above, during charging with hydrogen, the flexible diaphragm allows the metal composition 110 to expand as it stores hydrogen. When the metal composition is in an expanded state, the flexible and resilient diaphragm can apply a “back pressure” pushing back against the expanded metal composition 110. This back pressure of the diaphragm pushing against the metal composition 110 can be beneficial when the canister is discharging hydrogen as the back pressure can facilitate pushing the hydrogen out ofWORKAMER\39752966.vl 12the interstitial spaces in the metal composition 110. As examples, the flexible and resilient material of the diaphragm can be a natural or synthetic rubber, an elastic polymer, or a composite.
[0046] Referring now to Figure 5, another example embodiment of a canister for a hydrogen-powered tool is illustrated in an exploded view. The canister 202 of Figure 5 is similar to the canister 102 of Figures 3 and 4. The features of the canister 202 can have the same attributes, options, and alternatives as the features of the canister 102 described above unless otherwise noted. The canister 202 comprises a cylindrical sidewall 204. Although not illustrated in Figure 5, the cylindrical sidewall 204 is bounded by a first endcap having a cannister connector and a second endcap in a manner similar to that illustrated in Figures 3 and 4. The inner surface of the cylindrical sidewall 204 may be smooth or non-smooth as with the example of Figures 3 and 4.
[0047] The canister 202 comprises an interior chamber that is divided by an inner cylinder 214. The inner cylinder 214 may be a diaphragm having flexibility similar to that described in association with Figures 3 and 4 or the inner cylinder 214 may be constructed of a more rigid material. The inner cylinder 214 extends from the first endcap at one end of the canister’s interior chamber to the second endcap at the other end of the canister’s interior chamber. As shown in Figure 5, the inner cylinder 214 has a generally cylindrical shape with open ends and a longitudinal axis that is co-axial with a central longitudinal axis 203 of the canister 202. An inner portion of the canister’s interior chamber, referred to as the inner chamber 213, is defined by a cylindrical inner surface of the inner cylinder 214 and the endcaps located at opposing ends of the inner cylinder 214. An outer portion of the canister’s interior chamber, referred to as the metal chamber 209, is in the shape of an annulus and is defined by a cylindrical outer surface of the inner cylinder 214, an inner surface of the cylindrical sidewall 204, a top flange 216, a bottom flange 217, and the endcaps located at opposing ends of the canister 202. The top flange 216 and the bottom flange 217 each have the general shape of a disk and extend radially outward from the top and bottom ends of the inner cylinder 214. Similar to Figure 3, a metal composition is positioned in the metal chamber 209 between the outer surface of the inner cylinder 214 and the inner surface of the cylindrical sidewall 204. In this arrangement, the inner cylinder 214, the top flange 216, the bottom flangeWORKAMER\39752966.vl 13217, the endcaps, and the inner surface of the cylindrical sidewall 204 hold the metal composition in place within the canister 202.
[0048] The inner cylinder 214 also comprises an etched portion 215 that comprises perforations through which hydrogen can pass. The perforations in the etched portion 215 may be formed by a laser or another puncturing device. The perforations are of a size that permits hydrogen to flow through the perforations, but are small enough that the perforations do not permit the granules of the metal composition to leak through the perforations. In one example, the inner cylinder 214 may be a diaphragm in which the perforations are formed in the etched portion 215 at the middle section of the inner cylinder 214, whereas the top and bottom portions of the cylindrical portion of the diaphragm are more rigid due to the absence of perforations and thereby supplying back pressure to the metal composition as described previously. As an alternative to a diaphragm, the inner cylinder 214 may be a composite having a more rigid structure at the top and bottom portions of the cylinder and a more flexible structure at the etched portion 215 located at the middle section of the inner cylinder 214.
[0049] With the example canister 202 of Figure 5, hydrogen flows in and out of the canister 202 through a valve in the endcap in a manner similar to the canister 102 of Figures 3 and 4. When charging the canister 202, hydrogen flows from the valve into the inner chamber 213, it passes through the perforations of the etched portion 215 and into the metal composition stored in the metal chamber 209. When discharging the canister 202, the hydrogen flows from the metal composition in the metal chamber 209, through the perforations of the etched portion 215, into the inner chamber 213 of the inner cylinder 214, and through a valve in the endcap.
[0050] Referring now to Figure 6, another example embodiment of a canister for a hydrogen-powered tool is illustrated in an exploded view. The canister 302 of Figure 6 is similar to the canister 102 of Figures 3 and 4. The features of the canister 302 can have the same attributes, options, and alternatives as the features of the canister 102 described above unless otherwise noted. The canister 302 comprises a cylindrical sidewall 304. Although not illustrated in Figure 6, the cylindrical sidewall 304 is bounded by a first endcap having a cannister connector and a second endcap in a manner similar to thatWORKAMER\39752966.vl 14illustrated in Figures 3 and 4. The inner surface of the cylindrical sidewall 304 may be smooth or non-smooth as with the example of Figures 3 and 4.
[0051] The canister 302 comprises an interior chamber that is divided by a diaphragm 314. The diaphragm 314 may be flexible similar to the diaphragm described in association with Figures 3 and 4. The diaphragm 314 extends from the first endcap at one end of the canister’s interior chamber to the second endcap at the other end of the canister’s interior chamber. As shown in Figure 6, the diaphragm 314 has a generally cylindrical shape with open ends and a longitudinal axis that is co-axial with a central longitudinal axis 303 of the canister 302. An inner portion of the canister’s interior chamber, referred to as the diaphragm chamber 313, is defined by a cylindrical inner surface of the diaphragm 314 and the endcaps located at opposing ends of the diaphragm 314. An outer portion of the canister’s interior chamber, referred to as the metal chamber 309, is in the shape of an annulus and is defined by a cylindrical outer surface of the diaphragm 314, an inner surface of the cylindrical sidewall 304, a top flange 316, a bottom flange 317, and the endcaps located at opposing ends of the canister 302. The top flange 316 and the bottom flange 317 each have the general shape of a disk and extend radially outward from the top and bottom ends of the diaphragm 314. Similar to Figure 3, a metal composition is positioned in the metal chamber 309 between the outer surface of the diaphragm 314 and the inner surface of the cylindrical sidewall 304. In this arrangement, the diaphragm 314, the top flange 316, the bottom flange 317, the endcaps, and the inner surface of the cylindrical sidewall 304 hold the metal composition in place within the canister 302.
[0052] The diaphragm 314 comprises a semi-permeable material that retains the granules of the metal composition in the metal chamber 309 while permitting gaseous hydrogen to pass through the diaphragm and back and forth between the diaphragm chamber 313 and the metal chamber 309 during charging and discharging of the canister 302. During charging of the canister 302, hydrogen gas passes through a valve in an endcap, into the diaphragm chamber 313, through the semi-permeable material of the diaphragm 314, and is stored in the metal composition in the metal chamber 309. During discharging of the canister 302, hydrogen gas passes from the metal composition in the metal chamber 309, through the semi-permeable material of the diaphragm 314, into theWORKAMER\39752966.vl 15diaphragm chamber 313, and through a valve in an endcap. Examples of the semi-permeable material of the diaphragm include, but are not limited to, polymeric materials such as polyethylene and polypropylene, as well as composite materials. Optionally, the diaphragm chamber 313 also can include a cylindrical fdter 317 that inhibits the flow of granules of the metal composition that may have leaked from the metal chamber 309.
[0053] Other example embodiments can include canisters that combine aspects of the embodiments in Figures 3-6. For example, in certain embodiments, hydrogen gas may flow through a variety of paths when charging and discharging the canister. Such an embodiment may include both a hydrogen permeable diaphragm as well as hydrogen vents in top and bottom flanges of the diaphragm so that there is more than one path for the hydrogen to flow in and out of the metal composition within the canister.
[0054] The example hydrogen-powered handheld tools described in connection with Figures 1-6 have a variety of advantages. The canisters may be charged with hydrogen using a wide range of pressures. For example, the canisters may be charged with hydrogen at pressures ranging from 55 kPa (8 psi) to 2758 kPa (400 psi). Once charged, the canisters store hydrogen and subsequently discharge the hydrogen at near atmospheric pressure. Given the stability of the canisters, their operation is quiet (under 55 dB) and their only emission is water allowing them to be used either indoors or outdoors. Furthermore, the canisters have a lifecycle of approximately 20,000 respirations (cycles of charging and discharging hydrogen) and can safely store hydrogen for several years with very little loss of hydrogen. The size of the canisters used for handheld tools can store in the range of 1 to 20 grams of hydrogen and, assuming a fuel cell efficiency of 50%, provide an output power of 15 to 330 Watt-hours. In certain embodiments, the canisters may have a storage density of approximately 126.4 grams of hydrogen per liter.
[0055] For any apparatus shown and described herein, one or more of the components may be omitted, added, repeated, and / or substituted. Accordingly, embodiments shown in a particular figure should not be considered limited to the specific arrangements of components shown in such figure. Further, if a component of a figure is described but not expressly shown or labeled in that figure, the label used for a corresponding component in another figure can be inferred to that component.WORKAMER\39752966.vl 16Conversely, if a component in a figure is labeled but not described, the description for such component can be substantially the same as the description for the corresponding component in another figure.
[0056] Referring generally to the examples herein, any components of the apparatus (e.g., the canister, the tool head), described herein can be made from a single piece (e.g., as from a mold, injection mold, die cast, 3-D printing process, extrusion process, stamping process, or other prototype methods). In addition, or in the alternative, a component of the apparatus can be made from multiple pieces that are mechanically coupled to each other. In such a case, the multiple pieces can be mechanically coupled to each other using one or more of a number of coupling methods, including but not limited to epoxy, welding, fastening devices, compression fittings, mating threads, and slotted fittings. One or more pieces that are mechanically coupled to each other can be coupled to each other in one or more of a number of ways, including but not limited to couplings that are fixed, hinged, removeable, slidable, and threaded.
[0057] Terms such as “first”, “second”, “top”, “bottom”, “side”, “distal”, “proximal”, and “within” are used merely to distinguish one component (or part of a component or state of a component) from another. Such terms are not meant to denote a preference or a particular orientation, and are not meant to limit the embodiments described herein. In the example embodiments described herein, numerous specific details are set forth in order to provide a more thorough understanding of the invention. However, it will be apparent to one of ordinary skill 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.
[0058] Although example embodiments are described herein, it should be appreciated by those skilled in the art that various modifications are well within the scope of this disclosure. Those skilled in the art will appreciate that the example embodiments described herein are not limited to any specifically discussed application and that the embodiments described herein are illustrative and not restrictive. From the description of the example embodiments, equivalents of the elements shown therein will suggest themselves to those skilled in the art, and ways of constructing other embodiments usingWORKAMER\39752966.vl 17the present disclosure will suggest themselves to practitioners of the art. Therefore, the scope of the example embodiments is not limited herein.WORKAMER\39752966.vl 18
Claims
CLAIMSWhat is claimed is:
1. A hydrogen-powered handheld tool comprising:a canister, the canister comprising:a cylindrical sidewall, a first endcap, and a second endcap opposite the first endcap;a canister connector coupled to the first endcap;a cylindrical diaphragm disposed within the canister in a longitudinal coaxial position; anda metal chamber disposed between an outer surface of the cylindrical diaphragm and an inner surface of the cylindrical sidewall, the metal chamber configured to contain a metal composition that stores hydrogen; anda tool head, the tool head comprising:a tool head connector removably couplable to the canister connector; a fuel cell having a direct current output, the fuel cell configured to receive from the canister the hydrogen stored in the metal composition and to output a direct current at the direct current output; andan electric motor connected to the direct current output.
2. The hydrogen-powered handheld tool of claim 1, further comprising a tool coupled to the electric motor, wherein the tool is selected from a drill, a rotary saw, a compressor, and a pump.
3. The hydrogen-powered handheld tool of any one of the previous claims, wherein the tool head further comprises a converter that modifies the direct current that is output from the fuel cell.
4. The hydrogen-powered handheld tool of claim 3, wherein the converter is a direct current to direct current converter comprising a semiconducting polymer.
5. The hydrogen-powered handheld tool of any one of the previous claims, wherein the tool head further comprises a controller that controls the flow of hydrogen from the canister to the tool head.
6. The hydrogen-powered handheld tool of claim 5, wherein the controller further comprises a capacitor that provides power to the controller.WORKAMER\39752966.vl 197. The hydrogen-powered handheld tool of claim 5, wherein the controller further comprises a plunger, wherein pumping the plunger provides power to the controller.
8. The hydrogen-powered handheld tool of any one of the previous claims, wherein the cylindrical sidewall of the canister is fluted and the cylindrical diaphragm is fluted.
9. The hydrogen-powered handheld tool of any one of the previous claims, wherein the cylindrical diaphragm is permeable to the hydrogen stored in the metal alloy.
10. The hydrogen-powered handheld tool of any one of the previous claims, wherein the cylindrical diaphragm comprises an etched portion that permits the hydrogen to permeate through the cylindrical diaphragm.
11. The hydrogen-powered handheld tool of claim 10, wherein the etched portion is located at a middle section of the cylindrical diaphragm between a top portion and a bottom portion of the cylindrical diaphragm.
12. The hydrogen-powered handheld tool of any one of the previous claims, wherein the cylindrical diaphragm comprises fdtered vents that permit the hydrogen to permeate through the cylindrical diaphragm.
13. The hydrogen-powered handheld tool of any one of the previous claims, wherein the canister has a capacity to store 1 to 20 grams of hydrogen.
14. The hydrogen-powered handheld tool of any one of the previous claims, wherein the hydrogen-powered handheld tool has an output power of 15 to 330 Watt-hours.
15. The hydrogen-powered handheld tool of any one of the previous claims, wherein the canister connector and the tool head connector are joined by threads.
16. The hydrogen-powered handheld tool of any one of the previous claims, wherein the canister connector and the tool head connector are joined by a detent.
17. The hydrogen-powered handheld tool of any one of the previous claims, wherein the canister connector and the tool head connector are joined by a locking ring.
18. The hydrogen-powered handheld tool of any one of the previous claims, wherein the canister connector and the tool head connector are joined by a twist and lock feature.
19. The hydrogen-powered handheld tool of any one of the previous claims, wherein the canister connector and the tool head connector are joined by a snap fit.WORKAMER\39752966.vl 2020. A hydrogen-powered handheld torch comprising:a canister, the canister comprising:a cylindrical sidewall, a first endcap, and a second endcap opposite the first endcap;a canister connector coupled to the first endcap;a cylindrical diaphragm disposed within the canister in a longitudinal coaxial position; anda metal chamber disposed between an outer surface of the cylindrical diaphragm and an inner surface of the cylindrical sidewall, the metal chamber configured to contain a metal composition that stores hydrogen; anda tool head, the tool head comprising:a tool head connector removably couplable to the canister connector; a combustion unit configured to receive from the canister the hydrogen stored in the metal composition and to ignite the hydrogen to generate a flame; and a nozzle that outputs the flame from the tool head.
21. The hydrogen-powered handheld torch of claim 20, wherein the tool head further comprises a controller that controls the flow of hydrogen from the canister to the tool head.
22. The hydrogen-powered handheld torch of claim 21, wherein the controller further comprises a capacitor that provides power to the controller.
23. The hydrogen-powered handheld torch of claim 21, wherein the controller further comprises a plunger, wherein pumping the plunger provides power to the controller.
24. The hydrogen-powered handheld torch of any one of the previous claims, wherein the cylindrical sidewall of the canister is fluted and the cylindrical diaphragm is fluted.
25. The hydrogen-powered handheld torch of any one of the previous claims, wherein the cylindrical diaphragm is permeable to the hydrogen stored in the metal composition.
26. The hydrogen-powered handheld torch of any one of the previous claims, wherein the cylindrical diaphragm comprises an etched portion that permits the hydrogen to permeate through the cylindrical diaphragm.WORKAMER\39752966.vl 2127. The hydrogen-powered handheld torch of claim 26, wherein the etched portion is located in a middle section of the cylindrical diaphragm between a top portion and a bottom portion of the cylindrical diaphragm.
28. The hydrogen-powered handheld torch of any one of the previous claims, wherein the cylindrical diaphragm comprises fdtered vents that permit the hydrogen to permeate through the cylindrical diaphragm.
29. The hydrogen-powered handheld torch of any one of the previous claims, wherein the the canister has a capacity to store 1 to 20 grams of hydrogen.
30. The hydrogen-powered handheld torch of any one of the previous claims, wherein the hydrogen-powered handheld torch has an output power of 15 to 330 Watt-hours.
31. The hydrogen-powered handheld torch of any one of the previous claims, wherein the canister connector and the tool head connector are joined by threads.
32. The hydrogen-powered handheld torch of any one of the previous claims, wherein the canister connector and the tool head connector are joined by a detent.
33. The hydrogen-powered handheld torch of any one of the previous claims, wherein the canister connector and the tool head connector are joined by a locking ring.
34. The hydrogen-powered handheld torch of any one of the previous claims, wherein the canister connector and the tool head connector are joined by a twist and lock feature.
35. The hydrogen-powered handheld torch of any one of the previous claims, wherein the canister connector and the tool head connector are joined by a snap fit.WORKAMER\39752966.vl 22