Abstract: Provided is an improved thermal processing apparatus. The thermal processing apparatus comprises a shell and an insulator on the interior of the shell. A liner is on the interior of the insulator wherein the liner forms an inner cavity. A heater is in the inner cavity.

Abstract: A method of forming an improved calcined lithium metal oxide is provided wherein the metal comprises at least one of nickel, manganese and cobalt. The method comprises forming a first solution in a first reactor wherein the first solution comprises at least one first salt of at least one of lithium, nickel, manganese or cobalt in a first solvent. A second solution is formed wherein the second solution comprises a second salt of at least one of lithium, nickel, manganese or cobalt in a second solvent wherein the second salt is not present in the first solution. A gas in introduced into said first solution to form a gas saturated first solution. A second solution is added to the gas saturated first solution without bubbling to form a lithium metal salt. The lithium metal salt dried and calcined to form the calcined lithium metal oxide.

Abstract: A method of forming an improved calcined lithium metal oxide is provided wherein the metal comprises at least one of nickel, manganese and cobalt. The method comprises forming a first solution in a first reactor wherein the first solution comprises at least one first salt of at least one of lithium, nickel, manganese or cobalt in a first solvent. A second solution is formed wherein the second solution comprises a second salt of at least one of lithium, nickel, manganese or cobalt in a second solvent wherein the second salt is not present in the first solution. A gas in introduced into said first solution to form a gas saturated first solution. A second solution is added to the gas saturated first solution without bubbling to form a lithium metal salt. The lithium metal salt dried and calcined to form the calcined lithium metal oxide.

Abstract: A method of forming an improved calcined lithium metal oxide is provided wherein the metal comprises at least one of nickel, manganese and cobalt. The method comprises forming a first solution in a first reactor wherein the first solution comprises at least one first salt of at least one of lithium, nickel, manganese or cobalt in a first solvent. A second solution is formed wherein the second solution comprises a second salt of at least one of lithium, nickel, manganese or cobalt in a second solvent wherein the second salt is not present in the first solution. A gas in introduced into said first solution to form a gas saturated first solution. A second solution is added to the gas saturated first solution without bubbling to form a lithium metal salt. The lithium metal salt dried and calcined to form the calcined lithium metal oxide.

Abstract: A method of forming an improved calcined lithium metal oxide is provided wherein the metal comprises at least one of nickel, manganese and cobalt. The method comprises forming a first solution in a first reactor wherein the first solution comprises at least one first salt of at least one of lithium, nickel, manganese or cobalt in a first solvent. A second solution is formed wherein the second solution comprises a second salt of at least one of lithium, nickel, manganese or cobalt in a second solvent wherein the second salt is not present in the first solution. A gas in introduced into said first solution to form a gas saturated first solution. A second solution is added to the gas saturated first solution without bubbling to form a lithium metal salt. The lithium metal salt dried and calcined to form the calcined lithium metal oxide.

Abstract: A hydrogen generator, a fuel pellet assembly for use in the hydrogen generator and a fuel cell system are disclosed. The hydrogen generator includes a housing having a lid pivotally connected to a base and a strip having a plurality of heaters on one side and a second plurality of heaters on the opposite side. A first cartridge is disposed on one side of the strip and a second cartridge is disposed on the opposite side. Each of the first and second cartridges has a plurality of fuel pellets, each including a hydrogen-containing material that will release hydrogen gas when heated. The heaters are selectively activated to heat one or more fuel pellets to initiate the release of hydrogen gas.

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: 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 fuel unit for a gas generator such as a hydrogen gas generator that can supply gas to a gas consuming system such as a fuel cell system. The fuel unit includes a housing containing a solid fuel composition and a heat producing material. The fuel composition contains gas releasing solid material that reacts to release gas when heated. The heat producing material reacts exothermically to produce heat. A plurality of quantities of the heat producing material are in thermal communication with corresponding portions of an unsegregated quantity the fuel composition such that, following initiation of a reaction of each quantity of the heat producing material, the quantity of heat producing material will heat the corresponding portion of the unsegregated quantity of the fuel composition, and the corresponding portion of the unsegregated quantity of the fuel composition will react to release a quantity of the gas.

Abstract: A gas generator includes a reactant capable of producing a gas and a gas outlet valve that can function as both a gas flow valve and a pressure relief vent, using the same gas flow path through the valve. When the valve is closed and the pressure within the gas generator is below a threshold pressure, a moveable valve member is biased against a valve seat to block the outlet port. When gas generator is coupled to the apparatus, an actuator is inserted into the valve, displacing the moveable valve member and separating it from the valve seat to open the valve. When the gas generator is uncoupled, pressure at or above a threshold displaces the moveable member, separating it from the valve seat to open the outlet port so pressure can be released to the external environment.

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: The invention is a hydrogen generator including a housing, a reaction area, a fluid reservoir, a pellet comprising a first reactant within the reaction area, a fluid comprising a second reactant within the fluid reservoir, a fluid flow path between the fluid reservoir and the reaction area, and a hydrogen outlet. The fluid flow path comprises a follower assembly biased toward the pellet, the follower assembly includes an articulated joint and a follower, and the second reactant can react with the first reactant in the reaction area to produce hydrogen gas and byproducts.

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 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 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 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 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: 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: 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 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.