Abstract: Systems and methods for producing a lightweight vacuum insulated vessel are provided herein. An exemplary vessel is of a non-radially symmetric shape and maintains vacuum pressure between two concentric containers (an inner container and outer container). The vacuum insulated vessel is made to withstand high temperatures in a furnace during manufacture. Further, the vessel may contain a fuel cartridge for a fuel cell system and be insulated to retain heat necessary for the fuel cartridge reactions.

Abstract: Systems and methods for producing microcrystalline alpha alane are provided herein. An exemplary process comprises the elimination of the crystallization aid lithium borohydride through the use of excess lithium aluminum hydride or sodium borohydride. Further exemplary processes comprise methods for passivating microcrystalline alpha alane using a weak acid in a nonaqueous solvent solution.

Abstract: Fluidized-bed reactors for producing alane are provided herein. An exemplary process includes inducing an electrical potential difference in an electrolyte solution to produce an anolyte solution that includes an alane adduct, wherein an electrical potential difference is generated between anode aluminum particles and a cathode, the electrolyte solution including an alkali metal hydride dissolved in a solvent, the anode aluminum particles and cathode being separated by a diaphragm.

Abstract: Disclosed herein are systems and methods for heating alane etherate compositions for producing microcrystalline alpha alane. An exemplary heating method comprises introducing a preheated solvent into the alane etherate composition and rapidly stirring to effectuate rapid heating of the composition without the need to heat the reactor walls. In this way, the alane etherate composition can be heated while also reducing the risk of decomposition. In further embodiments, a two-stage reactor can be employed for producing alpha alane, wherein the heating occurs in the second stage.

Abstract: Systems and methods for producing microcrystalline alpha alane are provided herein. An exemplary process for producing microcrystalline alpha alane includes reacting lithium aluminum hydride and aluminum chloride in a solvent to produce alane etherate, filtering alane etherate from the reactant, combining the filtered alane etherate with a lithium borohydride solution to produce solids that include microcrystalline alane etherate, removing remaining solvent from the solids, creating a slurry from the solids and an aromatic solvent, and heating the slurry to convert the microcrystalline alane etherate to microcrystalline alpha alane.

Abstract: Methods for producing aluminum hydride are provided herein. Exemplary methods may include combining an amount of aluminum with an amount of a metal in such a way that a eutectic mixture is formed and treating the eutectic mixture with hydrogen gas to produce aluminum hydride. Various methods and processes are conducted under anhydrous conditions or within anhydrous systems.

Abstract: Fluidized-bed reactors for producing alane are provided herein. An exemplary process includes inducing a negative electrical potential in an electrolyte solution to produce an anolyte solution that includes an alane adduct, wherein the negative electrical potential is generated between anode aluminum particles and cathode aluminum particles, the electrolyte solution including sodium aluminum hydride dissolved in a solvent, the anode aluminum particles and cathode aluminum particles being separated by a diaphragm.

Abstract: A high energy density fuel source that reduces hydride expansion during hydrogen release, including a rigid, thermally insulated container defining an internal volume, a heater mechanism disposed within the internal volume, and a metal hydride rod thermally connected to the heater mechanism, wherein the heater mechanism and metal hydride rod substantially occupying the entirety of the internal volume. The metal hydride rod preferably includes a malleable encapsulation compressed about, thermally coupled to, and substantially encapsulating a volume of compressed metal hydride powder, the malleable encapsulation defined by a first, thermally conductive, malleable cup inverted over a second, thermally conductive, malleable cup, the compressed malleable encapsulation defining a tortuous fluid flow path from the metal hydride to the internal volume of the container.

Abstract: The current invention is a fuel cell controller that includes a first control loop, where the first control loop is disposed to adjust a fuel cell current to regulate a hydrogen output pressure from the fuel cell to a pressure target valve, and further includes a second control loop disposed to adjust a hydrogen flow rate from a hydrogen generator to match a DC/DC power output to a power target value.

Abstract: A fuel cell system for use with an endothermic fuel generator including a fuel cell stack having a primary fuel cell stack having a first thermal mass and a secondary fuel cell stack having a second thermal mass smaller than the first, the fuel cell system further including a first thermal coupling mechanism configured to thermally couple waste heat from the secondary fuel cell stack to the primary fuel cell stack, and a second thermal coupling mechanism configured to thermally couple waste heat from the fuel cell stack to the endothermic fuel generator.

Abstract: A method of controlled fuel release from a fuel storage composition including applying an electric field to a section of the fuel storage composition, supplying a reagent to the section of the fuel storage composition, measuring a system parameter, and adjusting an electric field parameter based on the system parameter measurement.

Abstract: A fuel cell gas purge system is provided that includes at least one fuel cell, such as a fuel cell stack or a fuel cell array, a fuel supply, and an adjustable fuel cell current load. The system further includes at least one passive purge valve disposed to purge accumulated non-fuel matter in the fuel cell, and operates according to a pressure differential across the valve. The valve can be a passive bi-directional valve, such as a dome valve, or a passive unidirectional valve. Further included is a purge management module that has a purge request module to determine when to increase the pressure of the hydrogen fuel to initiate the purge, and a purge complete module to determine when to adjust the pressure of the hydrogen fuel to complete the purge. The non-fuel matter can include non-fuel gases or condensed water.

Abstract: A method for controlling fuel cartridge supply for a device powered by a fuel cell system, the fuel cell system including a fuel cell stack that converts fuel from the fuel cartridge into electrical power, the method including receiving operation data from each of a plurality of devices at a first time period, calculating a future fuel cartridge demand from the operation data, the future fuel cartridge demand associated with a second time period after the first time period, calculating a target fuel cartridge manufacturing volume from the future hydrogen cartridge demand, and sending the target fuel cartridge manufacturing volume to a manufacturing facility.

Abstract: A method of operating a power adapter that includes an energy storage device and a fuel cell system including a fuel supply and a fuel cell stack, the method including determining a connectivity state of an auxiliary power source and a load with the power adapter, and selecting a power adapter operation mode based on the connection states of the auxiliary power source and the load. The operation modes of the power adapter include at least an auxiliary mode when the auxiliary power source and the load are connected to the power adapter, and a fuel cell mode when the auxiliary power source is disconnected from the power adapter and the load is connected to the power adapter. The auxiliary mode includes providing power from the auxiliary power source to the load, and the fuel cell mode includes providing fuel cell power to the load.

Abstract: A method for purging non-fuel gasses from a fuel supply of a fuel cell system, including measuring a first parameter indicative of fuel concentration within the fuel supply, in response to the first parameter measurement satisfying a purge condition, wherein the purge condition is satisfied when the first parameter measurement is indicative of the fuel concentration below a predetermined concentration threshold, opening a purge valve fluidly coupled to the fuel supply and generating a purging pressure within the fuel supply to purge the fuel supply, measuring a second parameter indicative of purge completion, and in response to the second parameter measurement satisfying a purge completion condition, closing the purge valve.

Abstract: A high energy density fuel source that reduces hydride expansion during hydrogen release, including a rigid, thermally insulated container defining an internal volume, a heater mechanism disposed within the internal volume, and a metal hydride rod thermally connected to the heater mechanism, wherein the heater mechanism and metal hydride rod substantially occupying the entirety of the internal volume. The metal hydride rod preferably includes a malleable encapsulation compressed about, thermally coupled to, and substantially encapsulating a volume of compressed metal hydride powder, the malleable encapsulation defined by a first, thermally conductive, malleable cup inverted over a second, thermally conductive, malleable cup, the compressed malleable encapsulation defining a tortuous fluid flow path from the metal hydride to the internal volume of the container.

Abstract: A fuel cell system for providing power to and leveraging waste heat from a consumer device, including a fuel cell stack that converts fuel to power at an operational temperature; a fuel source compartment that receives a fuel source that provides fuel to the fuel cell stack; an energy storage device; electrically connected to the fuel cell stack, that heats the fuel cell stack, receives power from the fuel cell stack, provides power to the device, and stores power from the fuel cell stack; and a thermal connection that directs waste heat from the device preferentially from the device to the fuel cell stack.

Abstract: A fuel cell purge system including a fuel cell assembly, a fuel supply that supplies fuel to the fuel cell assembly at a first flow rate, an adjustable load that applies a load on the fuel cell assembly, and a purge valve coupled to the fuel cell assembly, and a purge management module. The fuel cell purge system purges the fuel cell assembly by detecting a purge initiation event, adjusting a system parameter to initiate a purge, detecting a purge completion event, and adjusting a system parameter to cease the purge.

Abstract: A pump assembly including a first subassembly and a second subassembly. The first subassembly includes a fluid conduit; an inlet fluidly coupled to the liquid reactant dispenser and the fluid conduit; an outlet fluidly coupled to a reaction chamber and the fluid conduit; and a diaphragm, defining a portion of the fluid conduit, that flexes to pump the liquid reactant from the inlet to the outlet. The diaphragm preferably includes an actuation point coupled to the diaphragm, wherein the liquid reactant is substantially contained within the first subassembly during pumping. The second subassembly is couplable to the first subassembly, and is fluidly isolated from the liquid reactant. The second subassembly includes an actuator that couples to the actuation point, wherein operation of the actuator causes pumping action.

Abstract: A fuel cell air exchanger is provided. The fuel cell air exchanger includes a platform having at least one throughput opening and at least one holding post, where the holding post fixedly holds a fuel cell offset from the platform and proximal to the opening, where the opening can have many shapes. The fuel cell air exchanger provides an unimpeded air exchange through the openings to the fuel cell and can be flexible, semi-flexible or rigid. The fuel cell air exchanger can hold an array of fuel cells and fuel cell electronics. A chimney feature provides enhanced airflow when the air exchanger is disposed in a vertical position.