Patent #:
7,700,214
Link to patent on issuing site:
7,700,214
Publishing date:
04/20/2010
Filling date:
11/24/2009 Inventors:
Subramanian Iyer
Vito A. Canuso III
Assignee:
Abstract:
A cartridge comprises a housing that can be easily attached and detached from
an electrolyzer so that the hydrogen generated can be stored within the
cartridge. The housing is further configured to easily attach and detach from
a fuel cell so that the stored hydrogen can be released to the fuel cell for
power generation. In preferred embodiments, the cartridge comprises a cathode
that serves to generate hydrogen when joined to the electrolyzer, as well as
to store hydrogen. With this arrangement, a single device (the fuel cell
cartridge) can function to generate hydrogen when connected to form part of
the electrolyzer, to store hydrogen (whether attached to either the fuel cell
or electrolyzer or neither--in stand alone form), and/or to supply hydrogen
to the fuel cell, when connected thereto.
Claims:
What is claimed is: 1. An electrochemical cartridge comprising an electrode
comprising reactive metal catalytic material within a housing, the cartridge
configured to fluidly connect and disconnect to an electrolyzer in a manner
that the electrode functions as the electrolyzer cathode, the cartridge
further comprising hydrogen storage means and configured to connect and
disconnect to a fuel cell for hydrogen exchange between the cartridge and the
fuel cell. 2. The cartridge of claim 1, wherein the electrode comprises the
hydrogen storage means. 3. The cartridge of claim 2, wherein the electrode
comprises metal hydride. 4. The cartridge of claim 2, wherein the electrode
comprises reactive nano-metal particles. 5. The cartridge of claim 1, wherein
the housing comprises at least one connector for fluidly connecting and
disconnecting the cartridge from either the electrolyzer or the fuel cell. 6.
The cartridge of claim 5, wherein the housing comprises a plurality of
connectors for fluidly connecting and disconnecting the cartridge from either
the electrolyzer or the fuel cell. 7. The cartridge of claim 6, wherein the
plurality of connectors are configured to permit simultaneous connection to
both an electrolyzer and a fuel cell. 8. A system of generating chemical
energy for use in a fuel cell, the system comprising the cartridge of claim 1
and an electrolyzer housing comprising an anode and a supply of electrolyte
to which the cartridge may be sealably connected. 9. The system of claim 8,
further comprising an array of compartments each configured to support a
cartridge such that a single cartridge may be replenished with a supply of
hydrogen by fluidly connecting to the electrolyzer housing. 10. The system of
claim 9, wherein a plurality of cartridges may be replenished at the same
time. 11. A system of powering a fuel cell, the system comprising the
cartridge of claim 1, a fuel cell to which the cartridge may be sealably
connected, and an electrolyzer housing comprising an anode and a supply of
electrolyte to which the cartridge may be sealably connected.
Description:
BACKGROUND 1. Technical Field This disclosure relates to the generation and
storage of hydrogen fuel. 2. Related Art Hydrogen is a renewable fuel that
produces zero emissions when used in a fuel cell. In 2005, the Department of
Energy (DoE) developed a new hydrogen cost goal and methodology, namely to
achieve $2.00-3.00/gasoline U.S. gallon equivalent (gge, delivered, untaxed,
by 2015), independent of the pathway used to produce and deliver hydrogen.
The principal method to produce hydrogen is by stream reformation. Nearly 95%
of the hydrogen currently being produced is made by steam reformation, where
natural gas is reacted on metallic catalyst at high temperature and pressure.
While this process has the lowest cost, four pounds of the greenhouse gasses
carbon monoxide (CO) and carbon dioxide (CO.sub.2) are produced for every one
pound of hydrogen. Without further costly purification to remove CO and
CO.sub.2, the hydrogen fuel cell cannot operate efficiently. Devices that are
configured to electrochemically convert water into hydrogen and oxygen when
energy is applied are generally known as water electrolyzers. Presently,
about five percent of hydrogen production comes from water electrolysis. This
reaction comprises the direct splitting of water molecules to produce
hydrogen and oxygen. Importantly, greenhouse gasses are not produced in these
reactions. In this process, electrodes comprising catalyst particles are
submersed in water, and energy is applied to the electrodes. Using this
energy, the electrodes split water molecules into hydrogen and oxygen.
Hydrogen is produced at the cathode electrode, which accepts electrons, and
oxygen is produced at the anode electrode, which liberates electrons. The
amount of hydrogen and oxygen produced by an electrode is dictated by the
current supplied to the electrodes. The efficiency depends upon the voltage
between the two electrodes, and is proportional to the reciprocal of that
voltage. In other words, the efficiency of the system increases as the
voltage decreases. A more catalytic system will have a lower voltage for any
one current, and therefore be more efficient in producing hydrogen and
oxygen. If the catalyst is highly efficient, there will be minimal energy
input to achieve a maximum hydrogen output. While this process is currently
too expensive to compete with steam reformation due low efficiency and the
use of expensive catalysts in the electrodes, emerging technologies show
promise in balancing the economies. For an electrolyzer to operate with high
efficiency, the amount of product produced during reaction should be
maximized relative to the amount of energy input. In many conventional
devices, significant efficiency loss stems from low catalyst utilization in
the electrodes, cell resistance, inefficient movement of electrolyte, and
inefficient collection of reaction products from the electrolyte. In many
cases, low efficiency is compensated for by operating the cell at a low rate
(current). While this strategy increases efficiency, it also lowers the
amount of products that can be produced at a given time. The high-purity
hydrogen produced in any of the above methods can be compressed and stored in
either compressed gas cylinders, liquefied to liquid hydrogen, or adsorbed in
solid state storage systems, such as metal hydride storage systems. The fuel
is then accessible later for power generation. Solid state storage of
hydrogen is widely viewed as a practical strategy for compact hydrogen
storage. The principle is directly used in rechargeable batteries such as
nickel-metal hydride (NiMH) batteries, in which hydrogen is reversibly
absorbed into the anode electrode during battery cycling. Metal hydrides are
also used as a source of hydrogen for supply of the said hydrogen to hydrogen
fuel cells. These metal hydrides are inherently safe, and have good specific
energy (.about.280 Wh/l) and energy density (.about.80 Wh/kg). Hydrogen has
been shown to be a tremendous fuel source for, amongst other energy (power)
generators, fuel cells. A fuel cell is a device that converts chemical energy
directly into electrical energy, via consumption of a fuel, such as hydrogen,
an alcohol, or other hydrocarbons. The fuel cell comprises a negative
terminal (anode), where the hydrogen fuel is consumed, and a positive
terminal (cathode), where oxygen fuel is consumed. This energy generating
device is highly advantageous in that fuel can be resupplied; the device will
operate as long as anode and cathode are supplied with fuel. The anode fuel
is oxidized on a catalyst surface to produce electrons and ions. Ions flow
through an ion exchange membrane, and the electrons flow through an external
circuit, generating electricity. Electrons and ions then recombine at the
cathode catalyst surface with the cathode fuel. At the core of the fuel cell
is the membrane-electrode assembly (MEA). The MEA comprises a membrane
capable of exchanging ions such as H.sup.+ or OH.sup.-, a catalyst layer
applied to each side of the membrane, and an electrically conductive backing
on each catalyst layer. Reliable adhesion and interaction between these
layers are some important factors for a fuel cell to operate at the highest
power. To promote excellent catalyst utilization as well as electronic and
ionic flow within the fuel cell, the composition and interfaces of the
catalyst layer are some important factors to achieving low ohmic resistance
and increased power output. Electrodes for use in fuel cells and/or
electrolyzers can comprise nano-metal particles, or a combination of nano-
and micro-metal particles, that can be either be sintered as a monolithic
structure, or applied as a layer (or embedded into) a supporting substrate
structure, such as is described in Provisional Application Ser. No.
61/109,453, filed on Oct. 29, 2008, Provisional Application Ser. No.
61/046,790, filed on Apr. 21, 2008, U.S. application Ser. No. 11/868,152,
filed on Oct. 5, 2007, U.S. application Ser. No. 12/114,719 filed on May 2,
2008, which has priority to Provisional Application No. 60/915,619, filed on
May 2, 2007, U.S. application Ser. No. 12/053,484, filed on Mar. 21, 2008,
which has priority to Provisional Application Ser. No. 60/896,722, filed on
Mar. 23, 2007, U.S. application Ser. No. 11/781,909, filed on Jul. 27, 2007,
which is a continuation-in-part of and has priority to U.S. application Ser.
No. 11/394,456, filed on Mar. 31, 2005, U.S. Ser. No. 11/482,290, filed on
Jul. 7, 2006, and U.S. Ser. No. 11/525,469, filed on Sep. 22, 2006, the
entire contents of all of which are expressly incorporated herein by
reference. The composition of the metal nanoparticles can be a pure metal, an
oxide of a metal, or an alloy of two or more metals. Preferably, the metal
composition is selected from groups IIA, IB, and IIIB-VIIIB of the periodic
table, most preferably nickel, manganese, aluminum, cobalt, copper, tin,
palladium, silver, gold, lanthanum, and alloys thereof. Other metals have
been shown to prove useful as a catalyst in an electrochemical context. The
nano-metal particles can be made from one of a number of manufacturing
process, such as the ones described in U.S. Pat. No. 7,282,167 to Carpenter
issued on Oct. 16, 2007, and U.S. Ser. No. 11/591,787, filed on Nov. 2, 2006,
the entire contents of both of which is hereby expressly incorporated by
reference. In the '167 patent and '787 application, processes for making
nano-metal particles more uniformly are described. Portable power generation
has increased significantly in demand as portable consumer electronics become
personal assistants for most forms of entertainment and information. Powering
these portable consumer electronics for long term use presents challenges,
most of which are being addressed as part of battery technology. Batteries
can comprise single use configurations or rechargeable configurations. While
battery technology has proven to be quite successful, alternative sources of
energy are also being considered. Indeed, technology has emerged that permits
electrochemical systems to be scaled down to address desires of greater
portability that eliminate the need for a traditional battery. Others have
suggested powering portable consumer electronics with a fuel cell supplied
with a continual source of chemical energy to power the fuel cell. The fuel
cell works in place of a battery by providing an efficient supply of electric
power to the consumer electronic device. Like a battery, however, a supply of
chemical energy is necessary. Therefore, a solution is desired to effectively
provide a portable source of chemical energy to more easily and readily
generate electric power for portable consumer electronics. SUMMARY In various
embodiments, an electrochemical system is disclosed that is configured to
generate hydrogen by, for example, water electrolysis wherein the catalyst
comprises a material that is catalytic for hydrogen generation and/or is
configured to store hydrogen for discharge to a fuel cell. Relying in part
upon technology developed at Quantumsphere, Inc. in Santa Ana, Calif., (see
above), solutions are disclosed that effectively provide a portable source of
chemical energy to more easily and readily generate electric power for
portable consumer electronics. In one embodiment contemplated, a fuel cell
cartridge comprises means for storing hydrogen that is produced in an
electrolyzer, where the cartridge also functions as the anode for the
electrolyzer. The storage means comprises, in one embodiment, metal hydride
positioned within the cartridge. Advantageously, the cartridge comprises a
housing that can be easily attached and detached from the electrolyzer so
that the hydrogen generated can be stored within the cartridge. The housing
is further configured to easily attach and detach from a fuel cell so that
the stored hydrogen can be released to the fuel cell for power generation.
The cartridge housing can vary in configuration as necessary to accommodate
fuel cells having particular dimension and form factors, as well as
electrolyzers having particular dimension and form factors. Depending upon
the uniformity of such form factors, adapters can be included to permit
interchange of a single cartridge between fuel cells and electrolyzers having
non-uniform configurations. Each cartridge comprises a metal hydride
electrode. In preferred embodiments, the metal hydride electrode comprises a
cathode, whereby the cathode serves to generate hydrogen when joined to the
electrolyzer and whereby the cathode serves to store hydrogen. Given the
differing chemical environments present in an electrolyzer and in a fuel
cell, the cartridge comprises membranes and fluid control for controlling the
influx and expulsion of water to and from the cartridge so that the water
does not interfere with the controlled flow of hydrogen in and out of the
metal hydride structure. The system can comprise electronic controls, voltage
and/or power regulators in a parallel circuitry. In preferred embodiments,
oxygen is generated at the anode, while the atomic hydrogen produced at the
metal hydride cathode is preferentially adsorbed into the lattice structure
of the metal hydride. With this arrangement, a single device (the fuel cell
cartridge) can function to generate hydrogen when connected to form part of
the electrolyzer, to store hydrogen (whether attached to either the fuel cell
or electrolyzer or neither--in stand alone form), and/or to supply hydrogen
to the fuel cell, when connected thereto. It is further contemplated that
efficiency can be derived from providing a carousel arrangement of
compartments for storing individual cartridges where charged cartridges can
reside or can be moved to a charging station adjacent the carousel. For
example, an arrangement of twelve compartments can be arranged in a generally
circular configuration so that they can be moved to a charging station by
rotating the carousel. One or more cartridges can be charged at a time,
depending upon the number of adjacent charging stations provided. In one
embodiment, the charging station comprises the portion of the electrolyzer to
which the cartridge can be connected fluidly and electrically to electrolyze
water. Other arrangements are contemplated, as described below and as covered
by the claims. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a schematic
showing one embodiment of an arrangement of cartridge compartments and a
charging station. FIG. 2 is a schematic showing an electrolyzer comprising a
metal hydride cathode that is configured to be housed within or without a
cartridge housing for quick connection to portions of an electrolyzer to
which the cathode functions. FIG. 3 is a schematic showing one embodiment of
a system comprising a fuel cell cartridge with metal hydride cathode and
mating electrolyzer housing. FIG. 4 is a schematic showing the system of FIG.
3 where the fuel cell cartridge with metal hydride cathode and mating
electrolyzer housing are joined via a set of quick disconnect couplings. FIG.
5 is a schematic showing one face of the housing for the fuel cell cartridge
of FIGS. 3 and 4 showing two sets of quick disconnect couplings, one set
dedicated to fluid communication with a corresponding set of quick disconnect
couplings on an electrolyzer ("QD H"), and another set dedicated to fluid
communication with a corresponding set of quick disconnect couplings on a
fuel cell ("QD F"). FIG. 6 is a schematic showing the fuel cell cartridge
system of FIG. 5 where the cartridge and fuel cell are joined via a set of
quick disconnect couplings. FIG. 7 is a schematic showing, on the left, a
face of the electrolyzer housing with the corresponding set of quick
disconnect couplings and, on the right, a face of the fuel cell housing with
the corresponding set of quick disconnect couplings. DETAILED DESCRIPTION At
least some of the embodiments contemplated herein comprise a compact system
for the generation and solid storage of hydrogen. Hydrogen stored in the
solid state within a cartridge can be useful in a number of electrochemical
applications, for example as the hydrogen supply to a fuel cell anode
electrode. This is accomplished without the need for additional compression,
cooling or heating steps as would be needed in a conventional hydrogen
storage system in gaseous cylinders. In a first aspect, a composition is
provided that serves as both the cathode electrode in an alkaline water
electrolyzer and a hydrogen storage material. During electrolysis, atomic
hydrogen produced during the cathodic reaction is immediately absorbed and
stored as a hydride, as reflected in the example of reaction below, where
M=metal: M.sub.(alloy)+H.sub.2O+e.sup.-.fwdarw.MH.sub.x+OH.sup.- Preferably,
the composition is a metal hydride, more preferably a mischmetal (Mm), and
most preferably a multi-component alloy with a Ni or Ni alloy/oxide enriched
surface coating. The metal hydride can be encapsulated in a cartridge system
for easy installation or removal from the water electrolyzer system, and
installation onto the anode area of a fuel cell for supply of hydrogen fuel
to the fuel cell. It is contemplated that the metal or metal alloy would
comprise nano-particles, either sintered together or coating (or embedded in)
a support substrate. The nano-metal particles preferably comprise pure metal
or an alloy of two or more metals selected from groups IIA, IB, and
IIIB-VIIIB of the periodic table, most preferably nickel, manganese,
aluminum, cobalt, copper, tin, palladium, silver, gold, lanthanum, and alloys
thereof. The nano-metal particles can be made from one of a number of
manufacturing process, such as the ones described in U.S. Pat. No. 7,282,167
to Carpenter, issued on Oct. 16, 2007, and/or those made by Quantumsphere,
Inc. of California. The fuel cell cartridge comprises an electrode that is
configured to function effectively as the cathode of a water electrolysis
system for generating hydrogen, where the electrode can be made as is
described in one or more of the patent applications and patents identified
above. In a preferred embodiment, a system useful as a compact device to
provide hydrogen fuel to a fuel cell is contemplated, where the cathode
electrode comprises a metal hydride hydrogen storage cartridge that can be
removed from the system, or remain within the cartridge, and docked to the
anode of a fuel cell, and then docked back to the system and refueled when
the cartridge is depleted of hydrogen. In one embodiment, the system
comprises a water supply container, and alkaline electrolyzer with
cathode-metal hydride docking system, and related electronics and controls
such that the system can sense and control water levels, hydrogen content,
temperature, and pressure. The cartridge comprises a housing that sealably
houses a metal hydride cathode that can be placed in fluid communication
interchangeably with both an electrolyzer and a fuel cell. The housing
comprises at least two one coupling configured to relatively quickly connect
and disconnect the housing from a corresponding electrolyzer and fuel cell.
The coupling is configured to permit the controlled flow therethrough of
either water, hydrogen or both. Depending upon the desired design and size,
the means for fluid connection and disconnection can comprise a plurality of
connectors on the housing, each functioning similarly to permit the
controlled flow therethrough of either water, hydrogen or both. In one
embodiment, the connection means comprises two sets of quick disconnect
couplings, an example of which is described in U.S. Pat. No. 5,253,842 to
Huebscher et al., although other quick disconnect configurations would also
be effective in sealably and fluidly connecting the cartridge to either an
electrolyzer or a fuel cell. One set of quick disconnect couplings would be
configured to connect to corresponding quick disconnect couplings on the
electrolyzer housing, while another set quick disconnect couplings would be
configured to connect to corresponding quick disconnect couplings on the fuel
cell housing. Although the embodiments described herein configure the
cartridge to be interchangeable with an electrolyzer and fuel cell at
separate times, it is also contemplated that a housing would comprise
opposing sets of quick disconnect couplings (e.g., on different sides of the
cartridge housing) that would enable simultaneous connection of the cartridge
to both the electrolyzer and the fuel cell, if so desired. Referring to FIG.
1, it is contemplated that efficiency can be derived from providing a
carousel arrangement of compartments for storing individual cartridges where
charged cartridges can reside or can be moved to a charging station adjacent
the carousel. For example, an arrangement of twelve compartments can be
arranged in a generally circular configuration so that they can be moved to a
charging station by rotating the carousel. One or more cartridges can be
charged at a time, depending upon the number of adjacent charging stations
provided. In one embodiment, the charging station comprises the portion of
the electrolyzer to which the cartridge can be connected fluidly and
electrically to electrolyze water. EXAMPLE 1 Description of a Hydrogen
Refueling System for Fuel Cells Referring to FIG. 1, one example
configuration has one or more of the following features: a Docking/recharging
station, capable of simultaneously charging 12 cathode/metal hydride (MH)
cartridges to 12 Whr each per day at the cathode of each of the electrolyzer
cells, arranged in a circular array, with easy access to the MH cartridges
for installation or removal; all individual electrolyzer cells in a parallel
circuit to enable continuous operation of individual cells even when some
cells have the MH cartridges removed after charging; MH cartridge port at
cathode of each cell; smart sensors to assess completion of hydrogen charging
and shut-off of power supply to cell; MH capable of electrochemical hydrogen
charging with 3-5 wt % H.sub.2 capacity and fast charging/discharging
kinetics via addition of metal nanoparticles; Metal hydride system capable of
direct hydrogen absorption from alkaline electrolyzer cathode to charge metal
hydrides at operational pressure and low temperature; MH cartridge, capable
of 150 cycles of charge/discharge per cartridge; MH cartridge, capable of
hydrogen desorption to fuel cell at less than 150.degree. C., and as close to
ambient temperature as possible; Electrolyzer hydrogen production=100
standard liters per day in a 12-cell circular system, absorbed in situ into
MH cartridges; 12-cell circular electrolyzer system, each cell with 8.40
cm.sup.2 active area of electrode; system integration with water supply,
process control electronics, voltage and current regulation for 12 parallel
circuit cells, enabling individual cartridges to be removed upon completion
of charging; oxygen venting to atmosphere or collection system.
Attorney, Agent or Firm:
References:
Comments
There are no posts on the Testimonials yet.
Login to post a Testimonials


