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 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.

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 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 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 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.

Abstract: A hydrogen generator including an initiator assembly having one or more contact members within a compressible member, and a removable fuel unit adjacent a surface of the compressible member. The fuel unit contains a hydrogen containing material that can release hydrogen gas when heated and an exothermic mixture that can react exothermically upon initiation by the initiator assembly. When no fuel unit is in the hydrogen generator, the compressible member is uncompressed and the contact members are at or below its surface, and when a fuel unit is disposed in the hydrogen generator, the compressible member is compressed so the contact members extend beyond the surface to make thermal contact with the fuel unit. Energy from the initiator assembly is conducted by the contact members to corresponding quantities of the exothermic mixture to initiate an exothermic reaction, providing heat for the release of hydrogen gas from the hydrogen containing material.

Abstract: A hydrogen generator including an initiator assembly having one or more contact members within a compressible member, and a removable fuel unit adjacent a surface of the compressible member. The fuel unit contains a hydrogen containing material that can release hydrogen gas when heated and an exothermic mixture that can react exothermically upon initiation by the initiator assembly. When no fuel unit is in the hydrogen generator, the compressible member is uncompressed and the contact members are at or below its surface, and when a fuel unit is disposed in the hydrogen generator, the compressible member is compressed so the contact members extend beyond the surface to make thermal contact with the fuel unit. Energy from the initiator assembly is conducted by the contact members to corresponding quantities of the exothermic mixture to initiate an exothermic reaction, providing heat for the release of hydrogen gas from the hydrogen containing material.

Abstract: A hydrogen generator including an initiator assembly having one or more contact members within a compressible member, and a removable fuel unit adjacent a surface of the compressible member. The fuel unit contains a hydrogen containing material that can release hydrogen gas when heated and an exothermic mixture that can react exothermically upon initiation by the initiator assembly. When no fuel unit is in the hydrogen generator, the compressible member is uncompressed and the contact members are at or below its surface, and when a fuel unit is disposed in the hydrogen generator, the compressible member is compressed so the contact members extend beyond the surface to make thermal contact with the fuel unit. Energy from the initiator assembly is conducted by the contact members to corresponding quantities of the exothermic mixture to initiate an exothermic reaction, providing heat for the release of hydrogen gas from the hydrogen containing material.

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 method of making electrochemical cells with high anode-to-cathode interfacial surface area and improved discharge efficiency at high rate discharge, without sacrificing total capacity involves the use of a separator coated electrode, and a flowable material comprising a second electrode. The first electrode and flowable material comprising the second electrode are disposed in a cell housing. The flowable material surrounds the coated surfaces of the first electrode. The invention also provides simplified methods for making electrochemical cells having a high anode-to-cathode interfacial surface area.

Abstract: A water-soluble binder useful for preparing an electrode for either primary or secondary batteries, having either aqueous or non-aqueous electrolyte, contains polyacrylamide and at least one copolymer selected from carboxylated styrene-butadiene copolymer and styrene-acrylate copolymer. The water-dispersible binder eliminates or reduces the need for organic solvents during preparation of an electrode made of a particulate active electrode material. The binder exhibits good chemical resistance, adhesive properties, flexibility and resilience, making it well suited for use in preparing batteries having a spirally wound electrode assembly.