Abstract: The invention relates to methods of forming an alane-etherate complex and ?-alane from the alane-etherate complex. The methods include reacting an alkyl halide with a metal alanate in a solvent including an ether. A tertiary amine may also be added to the reaction. The alane is collected after removal of the solvent and/or the tertiary amine. An electrospraying process can be used to remove the solvent.

Abstract: A hydrogen generator and a fuel cell system including a fuel cell battery and the hydrogen generator. The hydrogen generator includes a cartridge, a housing with a cavity to removably contain the cartridge, and an initiation system. The cartridge includes a casing; a plurality of pellets including a hydrogen containing material; a plurality of solid heat transfer members in contact with but not penetrating the casing; a hydrogen outlet in the casing; and a hydrogen flow path from each pellet to the hydrogen outlet. A plurality of heating elements is disposed inside the housing. When the cartridge is in the cavity, each heating element is disposed so heat can be conducted from the heating element and through the casing and corresponding heat transfer member to initiate the release of hydrogen gas. The initiation system can selectively heat one or more pellets to release hydrogen gas as needed.

Abstract: A hydrogen generator (30) and fuel cell system are disclosed. The hydrogen generator (30) includes a housing (32) and a flexible feed member (56) including a flexible carrier (64) and a hydrogen-containing reactant (62) disposed on the carrier. The flexible feed member (56) may include a reactant having a braided carrier on the outside or a flexible strip having a carrier with reactant disposed thereon. The hydrogen-containing reactant (62) will release hydrogen gas when heated. The hydrogen generator further includes a heating system including a heater (48) and a pinch roller system (40) for feeding the flexible feed member (56) to position the flexible feed member in proximity to the heater (48), such that the heater is capable of heating the hydrogen-containing reactant to release hydrogen gas. The fuel cell system includes a fuel cell having a hydrogen gas input port and a hydrogen generator.

Abstract: A hydrogen generator and method for generating hydrogen gas for a fuel cell stack. The hydrogen generator includes container, and a first reactant storage area configured to contain a liquid first reactant. The hydrogen generator also includes a reaction area and a solid second reactant within the reaction area, and a hydrogen outlet. The hydrogen generator further includes a flexible liquid delivery member extending into the reaction area and configured to deliver liquid reactant from the first reactant storage area to the reaction area. The flexible liquid delivery member includes a flexible portion that flexes to allow the delivery member to move with the solid second reactant as the second reactant is consumed.

Abstract: A hydrogen generator and a method of producing hydrogen gas using stabilized aluminum hydroxide and water are disclosed. The hydrogen generator contains stabilized aluminum hydride, water, a base, and a reaction chamber within which at least a portion of the stabilized aluminum hydride reacts with at least a portion of the water to produce hydrogen gas. The water that reacts with the stabilized aluminum hydride is contained in a basic aqueous solution including at least a portion of the base. The base can be included with the water in the basic aqueous solution, stored in a reservoir separate from the stabilized aluminum hydroxide, or the base can be a solid contained in a mixture with the stabilized aluminum hydroxide and mix with water when added to the mixture to form the basic aqueous solution.

Abstract: A hydrogen generator and a fuel cell system including the hydrogen generator are disclosed. The hydrogen generator includes a fuel composition including a hydrogen containing material that releases hydrogen gas to produce hydrogen when heated. A biasing member working in cooperation with a heating element and retainer, all of which are disposed within a unitary container, facilitate and control the release of hydrogen gas. The fuel composition can be segregated into individual quantities.

Abstract: A hydrogen generator includes a cartridge including a plurality of thermal conductors each having an outer wall assembled together to form a housing. A plurality of fuel pellets provided on the plurality of thermal conductors. Each fuel pellet has a hydrogen-containing reactant that will react to release hydrogen gas when heated. The hydrogen generator also includes a compartment configured to removably contain the cartridge. The hydrogen generator further includes a plurality of heating elements disposed in the compartment such that each heating element is in thermal communication with one of the thermal conductors when the cartridge is disposed within the compartment to generate heat to selectively heat one or more fuel pellets to initiate a reaction to produce hydrogen gas.

Abstract: A hydrogen generator having one or more actuators coupled to one or more heating elements in which the actuator(s) are used to improve the transfer of thermal energy from heating element(s) to one or more fuel units contained within the generator. In one embodiment, an actuator allows insertion and/or removal of packaged fuel units without the need of removing the heating element(s) and/or the actuator(s). When the actuator is in a retracted state (e.g., a low temperature state), the packaged fuel unit may be inserted and/or removed from a cavity of the hydrogen generator. When the actuator is in an extended state (e.g., a higher temperature state), the actuator forces contact between itself or the heating element and the fuel unit when a prescribed operating temperature is reached.

Abstract: A packaged fuel unit and a refillable hydrogen generator that uses the fuel unit to produce hydrogen gas are disclosed. The fuel unit includes a reactant that can undergo a thermal decomposition reaction that produces hydrogen gas when heated to at least a minimum initiation temperature. The reactant is contained within a package that includes a poor thermal conductor with one or more thermal conductor sections for conducting heat from outside the package to the reactant. The hydrogen generator includes a holder with a cavity in which the fuel unit can be removably disposed and a heating system for heating the fuel unit when disposed therein. The hydrogen generator can be part of a fuel cell system including a fuel cell battery that is provided with hydrogen gas from the hydrogen generator.

Abstract: A hydrogen generator and a fuel cell system including a fuel cell battery and the hydrogen generator. The hydrogen generator includes a cartridge, a housing with a cavity to removably contain the cartridge, and an initiation system. The cartridge includes a casing; a plurality of pellets including a hydrogen containing material; a plurality of solid heat transfer members in contact with but not penetrating the casing; a hydrogen outlet in the casing; and a hydrogen flow path from each pellet to the hydrogen outlet. A plurality of heating elements is disposed inside the housing. When the cartridge is in the cavity, each heating element is disposed so heat can be conducted from the heating element and through the casing and corresponding heat transfer member to initiate the release of hydrogen gas. The initiation system can selectively heat one or more pellets to release hydrogen gas as needed.

Abstract: A packaged fuel unit and a refillable hydrogen generator that uses the fuel unit to produce hydrogen gas are disclosed. The fuel unit includes a reactant that can undergo a thermal decomposition reaction that produces hydrogen gas when heated to at least a minimum initiation temperature. The reactant is contained within a package that includes a poor thermal conductor with one or more thermal conductor sections for conducting heat from outside the package to the reactant. The hydrogen generator includes a holder with a cavity in which the fuel unit can be removably disposed and a heating system for heating the fuel unit when disposed therein. The hydrogen generator can be part of a fuel cell system including a fuel cell battery that is provided with hydrogen gas from the hydrogen generator.

Abstract: A hydrogen generator having one or more actuators coupled to one or more heating elements in which the actuator(s) are used to improve the transfer of thermal energy from heating element(s) to one or more fuel units contained within the generator. In one embodiment, an actuator allows insertion and/or removal of packaged fuel units without the need of removing the heating element(s) and/or the actuator(s). When the actuator is in a retracted state (e.g., a low temperature state), the packaged fuel unit may be inserted and/or removed from a cavity of the hydrogen generator. When the actuator is in an extended state (e.g., a higher temperature state), the actuator forces contact between itself or the heating element and the fuel unit when a prescribed operating temperature is reached.

Abstract: A hydrogen generator and method for generating hydrogen gas for a fuel cell stack. The hydrogen generator includes container, and a first reactant storage area configured to contain a liquid first reactant. The hydrogen generator also includes a reaction area and a solid second reactant within the reaction area, and a hydrogen outlet. The hydrogen generator further includes a flexible liquid delivery member extending into the reaction area and configured to deliver liquid reactant from the first reactant storage area to the reaction area. The flexible liquid delivery member includes a flexible portion that flexes to allow the delivery member to move with the solid second reactant as the second reactant is consumed.

Abstract: A hydrogen generator and a fuel cell system including a fuel cell battery and the hydrogen generator. The hydrogen generator includes a cartridge, a housing with a cavity to removably contain the cartridge, and an initiation system. The cartridge includes a casing; a plurality of pellets including a hydrogen containing material; a plurality of solid heat transfer members in contact with but not penetrating the casing; a hydrogen outlet in the casing; and a hydrogen flow path from each pellet to the hydrogen outlet. A plurality of heating elements is disposed inside the housing. When the cartridge is in the cavity, each heating element is disposed so heat can be conducted from the heating element and through the casing and corresponding heat transfer member to initiate the release of hydrogen gas. The initiation system can selectively heat one or more pellets to release hydrogen gas as needed.

Abstract: Disclosed are a hydrogen generator and a method of producing hydrogen gas therefrom. A fuel unit containing a fuel that releases hydrogen gas when heated is removably disposed in a cavity within a housing having a door. A heater assembly for heating the fuel unit is disposed in the hydrogen generator. A mechanism retracts the heater assembly from the fuel unit when the door is opened and extends the heater assembly to contact the fuel unit when the door is closed. When the heater assembly is retracted, more space is available into which the fuel unit can be inserted to prevent damage to the heater assembly and the fuel unit, and when the heater assembly is extended, good contact is provided between the heater assembly and the fuel unit for efficient heating. A cam bar can move the heater assembly normal to the lateral motion of the cam bar.

Abstract: Disclosed is a hydrogen generator with a door that can be opened to replace a fuel unit and closed to seal the door. A lock responds directly to pressure within the chamber to prevent opening when the pressure exceeds a threshold value. The lock includes a locking member with a lug that engages a retainer to seal the door when the door is locked and is disengaged from the retainer when the door is unlocked. An opening mechanism moves the locking member to lock and unlock the door. A movable key is engaged with the opening mechanism and the locking member when the pressure in the chamber is at or below the threshold value and disengaged from one of the opening mechanism and the locking member by an actuator (e.g., a flexible diaphragm) so the door cannot be unlocked and opened when the pressure is above the threshold value.

Abstract: The invention is a hydrogen generator with a fuel gauge and a method of fuel gauging. The hydrogen generator includes a replaceable fuel unit, containing a hydrogen-containing material (fuel) that can release hydrogen gas when heated and whose thermal conductivity is related to a quantity of releasable hydrogen contained therein, and a fuel gauge including a heat source and a temperature sensor adjacent to the fuel unit and a controller for determining a fuel level value based on a measured temperature. The temperature is measured at a pre-established time after activating the heat source, and the measured temperature is compared to a predetermined relationship between the measured temperature and a releasable hydrogen content in the fuel at the pre-established time. An output signal is provided (e.g., to a visible display, an audible signal or a controller).

Abstract: A valve assembly is provided with concentric fluid paths and may be used on a hydrogen generator to transport liquid reactant to the hydrogen generator and hydrogen gas. The valve assembly includes a housing defining first and second fluid paths, a first valve member disposed in the first fluid path, and a second valve member disposed in the second fluid path. The assembly includes a connector including a first elongated member configured to engage the first valve member to open the first valve member to allow a first fluid to flow through the first fluid path, and a second fluid port including a second elongated member configured to allow fluid to flow through the second fluid path. The valve assembly is concentric in that the second fluid path surrounds at least a portion of the first fluid path.

Abstract: A hydrogen generator is provided for generating hydrogen gas for a fuel cell stack. The hydrogen generator includes container, and a first reactant storage area configured to contain a liquid first reactant. The hydrogen generator also includes a reaction area and a solid second reactant within the reaction area, and a hydrogen outlet. The hydrogen generator further includes a flexible liquid delivery member extending into the reaction area and configured to deliver liquid reactant from the first reactant storage area to the reaction area. The flexible liquid delivery member includes a flexible portion that flexes to allow the delivery member to move with the solid second reactant as the second reactant is consumed.

Abstract: A heater assembly for use in a hydrogen generator can be retracted to facilitate insertion and removal of a replaceable fuel unit without damaging the heater assembly or the fuel unit and extended to provide good thermal contact with the fuel unit during use of the hydrogen generator. The heater assembly includes a support member, a heater, and an actuator for extending and retracting the heater assembly. When the heater is energized it heats the actuator, thereby extending the heater assembly to contact the adjacent fuel unit, and when the heater is deenergized the actuator cools to retract the heater assembly and provide a gap between the heater assembly and the adjacent fuel unit. The actuator is movably secured to the heater or the support member by a retainer such that an end of the actuator is movable within the retainer as the actuator changes shape during heating and cooling.