HK1193850A - Hydrogen gas generator - Google Patents

Description

Hydrogen generator

Cross reference to related applications

This application claims priority to U.S. application No.13/099,707 filed on 3/5/2011.

Technical Field

The present invention relates to a hydrogen generator for producing hydrogen.

Background

Hydrogen generators typically produce hydrogen (H) in a molar ratio of 2: 1-the same ratio as water₂) And oxygen (O)₂) A mixture of (a).

The hydrogen generator includes four main elements: a cathode, an anode, and a salt or brine solution contained in a cavity (the cavity including the anode and the cathode). The generator typically comprises stainless steel metal plates stacked with spaces between the plates to allow saline solution to flow between them. When a voltage difference is placed between the anode and cathode plates, the alternating cathode and anode plate configuration allows current to flow through the saline solution, creating a chemical reaction.

The metal plate stacked configuration is the most common configuration for hydrogen generators. One problem associated with the plates being stacked is that the fluid between the plates is not readily exchanged with fresh fluid from other parts of the generator, which reduces the efficiency of the generator.

Disclosure of Invention

Accordingly, it is an object of the present invention to provide an apparatus for producing hydrogen in consideration of the problems and efficiencies of the prior art.

It is another object of the present invention to provide a cylindrical hydrogen generator that produces hydrogen gas more efficiently than stacked plate generators.

Other objects and advantages of the invention will in part be obvious and will in part be apparent from the specification.

The above and other objects, which will become apparent to those skilled in the art, are achieved in the present invention, which is directed to a hydrogen generating device comprising an anode, a cathode, a housing having an internal cavity, and a perforated wall in the cavity near an end thereof, the perforated wall being electrically connected to the anode or the cathode and separating an end portion of the cavity from a main portion of the cavity. The device includes water in the housing that extends continuously from a main portion of the cavity through the perforated wall and into an end portion of the cavity.

An anode or cathode electrically connected to the perforated wall may extend from the main portion of the cavity through the perforated wall into the end portion of the cavity and through the housing. The housing may have two ends and a perforated wall in the cavity near each end separating an end portion of the cavity from a main portion of the cavity. The anode or cathode extends through one end of the housing through one perforated wall into the main portion of the cavity, through the other perforated wall into the other end portion of the cavity, and through the other end of the housing. The water in the housing extends continuously from the main portion of the cavity through each perforated wall and into the end portions of the cavity.

The perforated wall may be a metal plate having openings therein, or may be an open-cell metal foam body. The hydrogen generating device may include a cylindrical metal sleeve slidably disposed in the internal cavity, the metal sleeve having an end, and an insulating gasket ring disposed between the end of the metal sleeve and the perforated wall.

The anode may be a hollow metal tube that is helically wound in a cylindrical configuration. The anode may alternatively be a hollow metal cylinder comprising a plurality of anode openings through the cylinder wall, or the anode may be a cylindrical wire mesh.

The hydrogen generating device may include at least one conductive terminal extending outwardly from the cavity through an opening in the housing, wherein the at least one terminal is in electrical contact with the anode.

Another embodiment of the invention is directed to a hydrogen generating device that includes a housing having an internal cavity, an anode in the internal cavity, and a cathode in the internal cavity. The device includes an open-cell metal foam body disposed in the internal cavity in electrical connection with the anode or the cathode. The device includes water in the housing, which extends continuously through the metal foam body. The open cell foam may be an anode having channels therein, the cathode extending through the channels in the foam anode. The channels of the anode may have a length and channel walls, the space between the cathode and the channel walls extending the length of the channel walls, the space being substantially filled with water.

The open cell foam may on the other hand be a cathode having channels therein, the anode extending through the channels in the foam cathode. The hydrogen generating device may include a cylindrical metal sleeve slidably disposed within the internal cavity. The metal sleeve may have an end with an insulating spacer ring disposed between the end of the metal sleeve and the perforated wall.

The metal foam may include a gold (gold) metal coating.

Another embodiment of the invention is directed to a method for using a hydrogen generating device. The method includes providing an anode, a cathode, a housing having an internal cavity, a perforated wall in the cavity near an end thereof, the perforated wall separating an end portion of the cavity from a main portion of the cavity. The anode or cathode extends from the main portion of the cavity through the perforated wall into the end portion of the cavity and through the housing, and water in the housing extends continuously from the main portion of the cavity through the perforated wall and into the end portion of the cavity. The method includes applying a voltage difference between the anode and the cathode sufficient to allow hydrogen gas to be generated.

Drawings

The features of the invention believed to be novel, and the elements characteristic of the invention are set forth with particularity in the appended claims. The figures are for illustration purposes only and are not drawn to scale. The invention itself, however, both as to organization and method of operation, may best be understood by reference to the detailed description which follows taken in conjunction with the accompanying drawings in which:

fig. 1 is an exploded perspective view of a hydrogen generator according to the present invention.

Fig. 2 is a cross-sectional view of an anode terminal and a terminal insulator according to the present invention.

Fig. 3A is an end view of the hydrogen generator of fig. 1 with the end cap removed.

Fig. 3B is an end view showing an alternative configuration of terminals and ports of the hydrogen generator extending through the housing according to the present invention.

Fig. 4 is a perspective view of an anode of the hydrogen generator of fig. 1.

Fig. 5 is a perspective view of a second embodiment of an anode according to the present invention.

Fig. 6 is a perspective view of a third embodiment of an anode according to the present invention.

Fig. 7 is a perspective view of a fourth embodiment of an anode according to the present invention.

Fig. 8 is a sectional view of a hydrogen generator including an anode shown in fig. 7.

Fig. 9 is a side view of the hydrogen generator shown in fig. 8.

Fig. 10 is a cross-sectional end view of the hydrogen generator showing the connection of the anode terminal to the anode shown in fig. 5.

Fig. 11 is a side view of a hydrogen generator according to the present invention, which includes a storage system.

Fig. 12 is a block diagram of a valve system for controlling gas output in accordance with the present invention.

Fig. 13 is a block diagram of a controller for a hydrogen generator according to the present invention.

Detailed Description

In describing the preferred embodiment of the present invention, reference will be made herein to FIGS. 1-13 of the drawings in which corresponding reference numerals refer to corresponding features of the invention.

The hydrogen generator 10 shown in fig. 1 includes a cylindrical ceramic-coated aluminum housing 14, the aluminum housing 14 having a housing opening 16, and a cylindrical metal sleeve 22, the cylindrical metal sleeve 22 being slidably disposed within the housing 14, the metal sleeve 22 being shorter in length than the housing 14. The housing 14 has opposite ends and a cavity between the ends, and the perforated wall 30 is contiguous with the ends of the metal sleeve 22 and is spaced from and adjacent each of the housing ends. The metal sleeve 22 includes a non-insulative sleeve opening 26 and an insulative sleeve opening 28. The non-insulated sleeve openings 26 are used to engage the inlet and outlet ports 12 and 13 for saline solution, the hydrogen gas outlet port 80 and the flush valve port 82. The insulating sleeve opening 28 is for the anode terminal 11, which anode terminal 11 extends from outside the housing 14 to the anode inside the cylindrical metal sleeve 22. A terminal insulator 32 is disposed between the anode terminal 11 and the insulating sleeve opening 28, as shown in the cross-sectional view of fig. 2. The end of the anode terminal 11 protrudes from the terminal insulator 32 so that electrical connections can be made to the anode 18 in the middle of the cavity and to a power source outside the cavity. The openings of the metal sleeve 22 are aligned with the housing openings 16 so that each of the terminal 11 and the discharge port 13, the inlet port 12, the hydrogen gas outlet port 80, and the flush valve port 82 extend through the respective housing opening 16 and sleeve openings 26, 28, sealingly contact the housing 14, and prevent liquid and gas in the cavity from leaking from the cavity through the housing opening 16. The anode of the hydrogen generator may be of any suitable type and configuration, but is shown in fig. 1 as a cylindrical spiral anode 18. The anodes are contacted by terminals 11, these terminals 11 supporting the anodes within the sleeve 22 and being spaced from the sleeve 22 and the cathode structure within the device.

A plurality of cathode rods 20, here shown as a central rod surrounded by four spaced rods, extend from the perforated wall 30 at one end of the housing 14 to the perforated wall 30 at the other end of the housing, each cathode rod 20 making electrical contact with the wall. At each end of the housing 14, a cathode terminal 24 is disposed in the central opening 52 of the perforated wall 30 and extends through an end cap opening 72 in the end cap 70. The cathode terminal 24 may be threaded so that the end cap 70 can be secured against the perforated wall 30 with a terminal nut 74. Cathode terminal 24 provides a common connection to cathode rod 20 by contact with perforated wall 30.

The hydrogen generator includes an insulating gasket 60 near each end of the housing 14, and the insulating gasket 60 presses against the ends of the sleeve 22 so that the perforated wall 30 can seal the sleeve from electrical contact. The perforated wall includes a plurality of openings or perforations 50, which openings or perforations 50 extend through the perforated wall. Any number of openings or perforations may be employed to allow passage of the saline solution therethrough.

The end cap 70 is slidingly engaged within the end of the housing 14 and contacts the perforated wall 30 to form a seal, thereby preventing gases and liquids from exiting the cavity, along with the seal 60, except through the hydrogen outlet port 80 and the flush valve 82.

In use, the water contained in the cavity of the housing contains sufficient electrolyte, such as salt (Na)⁺Cl^-) Or another electrolyte, to conduct electricity, and may be referred to as a saline solution. When a voltage difference is applied across the anode (+) and cathode (-), an electric current is generated to electrolyze the brine and hydrogen (H) is produced as a gas at the cathode₂) And generating oxygen (O) in the form of a gas at the anode₂). The cathode wall 30 at each end of the sleeve 22 forms a small chamber between the perforated wall 30 and the end cap 70 at each end of the housing 14. Although the exact mechanism is unknown, it is believed that these chambers, which keep the brine in communication with the main cavity, contribute significantly to the production of useful hydrogen gas by the device.

Fig. 3A shows an end view of the hydrogen generator with the end cap 70 removed. Each of the terminal 11 and the discharge port 13, the inlet port 12, the hydrogen gas outlet port 80, and the flush valve port 82 extends in radially opposite directions from the housing 14, as shown in fig. 1. Fig. 3B illustrates an alternative arrangement in which the housing openings are not aligned in a straight line row on the opposite side of the housing. The arrangement may additionally vary depending on the orientation of the hydrogen generator or other factors for the implementation of the hydrogen generator.

Fig. 4-6 illustrate various embodiments of the anode, and fig. 4 is an embodiment of the anode shown in fig. 1, wherein the anode 18 is a hollow metal tube spirally wound in a cylindrical configuration and having a crimped closed end. In another embodiment, the anode 18' shown in FIG. 5 is a hollow metal cylinder that includes a plurality of anode openings 44 through the cylinder wall. The anode 18 "shown in fig. 6 is a cylindrical wire mesh. Anodes 18, 18' and 18 "are supported in the cavity of housing 14 by contact with anode terminal 11.

In another embodiment of the invention shown in fig. 7-9, the hydrogen generator 10' includes a cylindrical open-cell metal foam anode 86, the cylindrical open-cell metal foam anode 86 having bores or channels 88, the bores or channels 88 extending the length of the anode 86. The cathode rods 20 are disposed through the apertures 88 with at least one of the ends of each cathode rod extending beyond a respective end of the cylindrical anode 86. Alternatively, the cathode may be in the form of an open-cell metal foam body and the anode may be in the form of rods extending through openings therein. The bore 88 has a diameter of sufficient size so that the rod 20 does not contact the metal foam body 86. The open cells of the metal foam body allow brine or water 90 to flow freely through the cells from one side of the anode to the other. The cross-sectional view of fig. 8 includes: part a, showing the housing 14; part B with the housing broken away to show the metal sleeve 22; section C, where the metal sleeve is cut away to show the outer surface of the metal foam body 86; and a section D in which the outer surface of the metal foam is cut away to show the inner surface 86' of the metal foam and the cathode rod 20. The metal foam body is preferably an aluminium metal foam body and may comprise a gold metal coating (gold metal coating) to prevent corrosion. The aluminum metal foam may be aluminum throughout the foam or may be a composite foam having an aluminum coating applied to the foam. The anode 18, cathode rod 20 and sleeve 22 may additionally include a gold metal coating to prevent corrosion. An exemplary gold abrasive coating that can be applied to the anode, cathode, and other components of the hydrogen generator of the present invention is the coating sold under the trade name JET-HOT n powered by nCoat LLC of burlington, North Carolina. The coating may be a silica-based nanoceramic based organic mixture applied as a water-based or solvent-based liquid by spraying, dipping, rolling or dip-spin (dip-spin) method and cured at elevated temperatures of 120-180 ℃ for 10 minutes or a time sufficient for bonding and the coating is cured to a desired thickness, e.g. 1-2 microns. One example is Nanomate available from nanomat technology Kaohsiung, Taiwan.

Fig. 8 and 9 include a cylindrical ceramic coated aluminum housing 14, the housing 14 having a housing opening 16, and a metal sleeve 22, the metal sleeve 22 being slidably disposed within the housing 14. The housing 14 has opposite ends and a cavity between the ends, and a perforated wall 30' is disposed adjacent each housing end. The illustrated perforated wall 30' is a plate made of an open-cell metal foam body. The terminal insulator 32 is disposed between the anode terminal 11 and the metal sleeve 22. The end of the anode terminal 11 projects inwardly from the terminal insulator 32 so as to be mechanically and electrically connectable to the anode 18 in the middle of the cavity and outwardly for connection to a power source outside the cavity. The hydrogen generator 10' includes an end cap 70, at least a portion of which is slidably disposed inside an end of the housing 14, and the cathode terminal 24 is disposed through an end cap opening 72 in the end cap 70. The cathode terminal 24 electrically contacts the metal foam perforated wall 30' inside the housing and the voltage source outside the housing.

Fig. 9 is an assembled hydrogen generator 10' that includes a fixed end cap 70 so that the brine or water 90 in the cavity can flow freely in the cavity without leaking out. The drain port 13 allows brine or water to exit the housing cavity when the port is in the open position and prevents flow when in the closed position. The inlet port 12 allows saline or water to flow into the housing cavity when the port is in the open position and prevents flow when in the closed position.

Fig. 10 shows anode 18 ', which anode 18' is supported in the housing cavity by anode terminal 11 and anode gasket 34. Gasket 34 is coupled to anode terminal 11 and contacts the outer wall of anode 18 'preventing anode 18' from moving relative to housing 14. Anode terminal 11 is secured to housing 14 with an insulating O-ring 32'.

Fig. 11 shows the hydrogen generator 10 connected to a storage system for flushing the brine solution in the housing cavity. The housing may include a transparent window 46, the transparent window 46 being used to visually inspect the internal activity of the generator. The storage system includes a storage tank 58, a feed line 62, the feed line 62 for flowing solution 59 from the tank 58 to the generator through a valve 67. The system also includes a return line 64, a return valve 68, and a pump 66, the pump 66 being used to pump the brine solution 59 through the generator and tank. Fig. 12 shows some of the elements attached to the hydrogen generator that are used to control and sense the gas output from the generator outlet 80 (fig. 1). The elements include a valve 124, the valve 124 being used to control the flow of hydrogen from the outlet 80 to the caustic bubbler 38. The outlet of the bubbler 38 includes a bleed valve 126, a hydrogen outlet valve 122 and a Hobb switch 128. The Hobb switch 128 is a pressure detection switch that includes a relay that engages when the pressure exceeds a given value. If the hydrogen pressure exceeds a safe value, the Hobb switch can be used to close the safety circuit and shut down the operation of the hydrogen generator.

Fig. 13 shows a block diagram of a controller for the hydrogen generator. The controller includes a central processing unit 100 and inputs from the hydrogen generator or from control elements shown in fig. 12, including input 102 from the Hobb switch 128 and input 104 from a pressure gauge on the gas generator housing. The controller outputs include output 110, output 112, output 116, and output 118, the output 110 sending an electrical output for controlling the exhaust port, the output 112 for controlling power to the anode and cathode terminals, the output 116 for controlling the pump 66, and the output 118 for controlling the flush valves 67, 68. The controller outputs may also include a safety trip output 114, and a hydrogen control output 120 for controlling a valve 124.

The anode is preferably aluminum, although other metals may be used. The cathode rods are preferably stainless steel, although other metals may be used. The anode and cathode configurations may be interchanged and/or reversed in the hydrogen generator of the present invention.

In operation, brine or water 90 is injected into the cavity of the hydrogen generator 10 and a voltage differential is applied between the anode and cathode, decomposing and electrolyzing the water inside the cylinder. The chemical reaction produces hydrogen and oxygen, and may produce other by-products including hydroxides, chlorine, and caustic soda. The generated hydrogen gas is allowed to exit the hydrogen gas outlet 80 while a flush valve 82 is provided for flushing other gases or water from the cavity of the housing 14.

The hydrogen generator of the present invention has overcome the deficiencies of the prior art by implementing a perforated wall that adequately separates the main housing cavity from the end chamber, but allows brine to flow from the cavity to the end chamber and from the end chamber to the cavity.

While the present invention has been particularly described, in conjunction with a specific preferred embodiment, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art in light of the foregoing description. It is therefore contemplated that the appended claims will embrace any such alternatives, modifications and variations as falling within the true scope and spirit of the present invention.

Claims (20)

1. A hydrogen generating apparatus comprising:

an anode;

a cathode;

a housing having an interior cavity;

a perforated wall in the cavity near an end thereof, electrically connected to the anode or cathode, and separating an end portion of the cavity from a main portion of the cavity; and

water extending continuously within the housing from a main portion of the cavity through the perforated wall and into an end portion of the cavity.

2. The hydrogen generating device according to claim 1, wherein the anode or the cathode electrically connected to the perforated wall extends from the main portion of the cavity through the perforated wall into the end portion of the cavity and through the housing.

3. The hydrogen generating device according to claim 1, wherein the housing has two ends and a perforated wall in the cavity near each end separating an end portion of the cavity from a main portion of the cavity, the anode or the cathode extends through one end of the housing, through one perforated wall into the main portion of the cavity, through the other perforated wall into the other end portion of the cavity, and through the other end of the housing, the water in the housing extending continuously from the main portion of the cavity through each perforated wall and into the end portion of the cavity.

4. The hydrogen generating apparatus according to claim 1, wherein the perforated wall is a metal plate having openings therein.

5. The hydrogen generating device according to claim 1, wherein the perforated wall is an open-cell metal foam.

6. The hydrogen generation device according to claim 1, comprising: a cylindrical metal sleeve slidably disposed in the internal cavity, the metal sleeve having an end; and an insulating spacer ring is disposed between an end of the metal sleeve and the perforated wall.

7. The hydrogen generating apparatus according to claim 1, wherein the anode is a hollow metal tube that is spirally wound in a cylindrical configuration.

8. The hydrogen generation device of claim 1, wherein the anode is a hollow metal cylinder comprising a plurality of anode openings through a cylinder wall.

9. The hydrogen generation device of claim 1, wherein the anode is a cylindrical wire mesh.

10. The hydrogen generating device according to claim 1, comprising at least one electrically conductive terminal extending outwardly from the cavity through an opening in the housing, wherein the at least one terminal is in electrical contact with the anode.

11. A hydrogen generating apparatus comprising:

a housing having an interior cavity;

an anode in the internal cavity;

a cathode in the internal cavity;

an open-cell metal foam body disposed in the internal cavity in electrical connection with the anode or the cathode;

water extending continuously through the metal foam body in the housing.

12. The hydrogen generation device of claim 11, wherein the open cell foam is an anode.

13. A hydrogen generation device in accordance with claim 11, wherein the open cell foam is an anode and has channels therein, and the cathode extends through the channels in the foam anode.

14. A hydrogen generation device in accordance with claim 13, wherein the channels of the anode have a length and comprise channel walls, the space between the cathode and the channel walls extending the length of the channel walls, the space being substantially filled with water.

15. The hydrogen generation device of claim 11, wherein the open cell foam is a cathode.

16. A hydrogen generation device in accordance with claim 11, wherein the open cell foam is a cathode and has channels therein, and the anode extends through the channels in the foam cathode.

17. The hydrogen generation device of claim 11, comprising a cylindrical metal sleeve slidably disposed in the internal cavity.

18. The hydrogen generation device of claim 17, wherein the metal sleeve has an end, and wherein an insulating spacer ring is disposed between the end of the metal sleeve and the perforated wall.

19. The hydrogen generating device according to claim 11, wherein the metal foam body comprises a gold metal coating.

20. A method for using a hydrogen generating device, comprising:

providing an anode, a cathode, a casing having an internal cavity, a perforated wall in the cavity near an end thereof, the perforated wall separating an end portion of the cavity from a main portion of the cavity, the anode or the cathode extending from the main portion of the cavity through the perforated wall into the end portion of the cavity and through the casing, and water extending continuously in the casing from the main portion of the cavity through the perforated wall and into the end portion of the cavity; and

a voltage difference is applied between the anode and the cathode sufficient to allow hydrogen gas to be generated.