Abstract:
A simple hydrogen generator system for maintaining zero PSI across the proton exchange membrane while generating ultra pure hydrogen gas at high pressure from water. The system includes a proton exchange membrane across which an electrolysis reaction is induced, thereby producing hydrogen gas on a first side of the proton exchange membrane and oxygen gas on a second side of the proton exchange membrane. The current source used to induce the electrolysis reaction is computer controlled so as to maintain a near constant pressure of hydrogen, even as hydrogen is drawn from the assembly. By minimizing the pressure differential across the proton exchange membrane, a more durable and efficient hydrogen generator is produced.

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to systems and methods of generating hydrogen gas from water using an electrolysis reaction. More particularly, the present invention is related to systems and methods of generating hydrogen gas where an electrolysis reaction is induced across a proton exchange membrane. 
     2. Description of the Prior Art 
     For many years, it has been known that water can be separated into hydrogen gas and oxygen gas using an electrolysis reaction. Over the years there have been many production of hydrogen gas, such devices are commonly known as hydrogen generators. 
     In some of the more efficient prior art hydrogen generators, an electrolysis reaction is induced across a proton exchange membrane. To increase the output pressure of hydrogen, a pressure differential is commonly produced across the proton exchange membrane. However, proton exchange membranes are thin and are easily damaged. Proton exchange membranes by themselves cannot withstand any significant pressure differential without rupturing. Accordingly, the proton exchange membranes in many prior art devices are reinforced with wire mesh screens that support the proton exchange membranes. During the operation of such prior art hydrogen generators, the proton exchange membrane is biased against a wire mesh screen by a pressure on the hydrogen side of the membrane. The pressure on the membrane is greater on the hydrogen side than it is on the oxygen side, which is usually at atmospheric pressure. The output pressure of the hydrogen gas is equal to the pressure that is being applied to hydrogen side of the proton exchange membrane. The wire mesh screen typically has a 70% to 80% opening this results in the pressure on the screen to be 3.3 to 5 times higher than the output pressure of the hydrogen gas. This causes the proton exchange membrane to wear rapidly. This is due to the large forces developed at the points of contact with the screen and the openings in the screen, where the proton exchange membrane is being stretched between the supporting elements of the screen. After a relatively short operational life, holes begin to appear in the proton exchange membrane at points where the membrane contacts the wire mesh screen. Once the holes add up to a predetermined minimum area, for a given size hydrogen generator, the proton exchange membrane is incapable of producing the hydrogen required and the hydrogen generator ceases to function adequately. 
     In prior art designs, a single hydrogen electrolysis cell typically has more than 15 separate parts not counting nuts, bolts and washers. These parts include as many as eight titanium screens, titanium supporting plates and rubber like sections that must be glued together. The net result is that the hydrogen generating devices using proton exchange membranes are expensive, complex, difficult to assembly and unreliable. These designs also have significant pressure variations across the proton exchange membrane causing accelerated wear and decreased performance of the hydrogen generator. 
     In prior art hydrogen generators, certain manufacturers developed designs that stack multiple proton exchange membranes atop one another. In such designs, each of the proton exchange membranes is supported by its own set of wire mesh screens. Although holes do develop in each of the proton exchange membranes, the life of the hydrogen generator is prolonged by the redundant positioning of the proton exchange membranes and therefore the increased capacity of the initial hydrogen generator. Hydrogen generators that use multiple proton exchange membranes, however, are significantly more expensive due to the cost of the multiple proton exchange membranes and the complexity of the design. This stacking of proton exchange membranes significantly reduces the manufacturability and reliability of such hydrogen generating devices. 
     Another problem associated with prior art hydrogen generators is that the electrolysis reaction tends to warm the water being used in the electrolysis reaction. This in part is due to the oxidation of the titanium that is used in the electrolysis chamber, which increases the resistance in the current path. The excess heat generated is in close proximity to the proton exchange membrane. As the water warms, the vapor pressure of the water increases. The water vapor contaminates the hydrogen gas being produced. The hydrogen gas in many cases must therefore be processed through a separate purification procedure before the hydrogen gas can be used. The problem of heated water is particularly prevalent in hydrogen generator designs that use multiple proton exchange membranes. In such prior art hydrogen generators, each proton exchange membrane chamber tends to be thermally isolated. It is therefore difficult to remove heat from the internal chambers and reduce the water vapor pressure to acceptable levels. The proton exchange membrane also degrades more rapidly at higher temperatures thereby further reducing the useful life of the hydrogen generator. 
     A need therefore exists in the art for a hydrogen generator that operates with a proton exchange membrane that does not have a pressure differential across the proton exchange membrane, thereby eliminating the production of wear abrasions in the membrane. A need also exists for a hydrogen generator that is capable of using only a single high efficiency proton exchange membrane and that operates at reduced water temperatures and can be actively cooled if necessary and at the same time have a high output gas pressure with little differential strain on the proton exchange membrane. These types of cells can then be stacked, connecting the gas outputs of each cell in parallel to achieve the desired hydrogen flow. These needs are met by the present invention system and method as is described and claimed below. 
     SUMMARY OF THE INVENTION 
     The present invention is a hydrogen generator system for generating hydrogen gas from water. The system includes a proton exchange membrane across which an electrolysis reaction is induced, thereby producing hydrogen gas on a first side of the proton exchange membrane and oxygen gas on a second side of the proton exchange membrane. The gas produced by the system is regulated by a unique high efficiency, high speed constant current power supply that controls the flow of current across the proton exchange membrane. This power supply both monitors and controls the current through the proton exchange membrane. In addition the voltage drop across the proton exchange membrane or membranes are also monitored if more than one membrane is placed in series. 
     A hydrogen gas chamber receives the hydrogen gas produced on the first side of the proton exchange membrane. Similarly, an oxygen gas chamber receives the oxygen gas produced on the second side of the proton exchange membrane. The proton exchange membrane is uniquely mounted so that there is a notable increase in gas produced per unit area, as compared to prior art systems. 
     A pressure regulator mechanism is provided for maintaining a predetermined pressure differential between the hydrogen gas chamber and the oxygen gas chamber. By maintaining a pressure differential of near zero between the gas chambers, the proton exchange membrane is not differentially stressed and both the life and performance of the hydrogen generator are significantly improved. In addition, because of the good thermal connection to the anode and cathode in the proton exchange membrane the operating temperature of the membrane is kept cool. This also increases the reliability and life of the hydrogen generator. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     For a better understanding of the present invention, reference is made to the following description of an exemplary embodiment thereof, considered in conjunction with the accompanying drawings, in which: 
     FIG. 1 is a schematic of an exemplary embodiment of a hydrogen generator system in accordance with the present invention. 
     FIG. 2 is another exemplary embodiment of the present invention. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring to FIG. 1, a schematic of an exemplary embodiment of a hydrogen generating system  10  is shown. The hydrogen generating system  10  includes a water tank  12  that contains the water that is to be turned into hydrogen gas and oxygen gas by electrolysis. The water from the water tank  12  is pumped out of the tank  12  by a variable speed pump  14 . The variable speed pump  14  is electronically controlled by a central systems controller  16 . The variable speed pump  14  pumps water into the anode side of an electrolysis cell  20 . This pump may be driven using various electric motors or a gas power pump driven by the oxygen produced at pressure, as a byproduct of the hydrogen generating system  10 . 
     The electrolysis cell  20  contains an anode terminal  22 , where the oxygen is formed and a cathode terminal  24 , where the hydrogen is formed. A single proton exchange membrane  26  is disposed between the anode terminal  22  and the cathode terminal  24 . Water enters the proton exchange membrane  26  from the anode side of the cell and fills the area between the anode terminal  22  and the proton exchange membrane  26 . Water then permeates (this is a first order chemical reaction) into the proton exchange membrane  26  and fills the area between the cathode terminal  24  and the proton exchange membrane  26 . 
     The volume of hydrogen gas and oxygen gas produced in a given period of time is controlled by the flow of current supplied to the proton exchange membrane  26 . A power supply  27  is provided. The power supply produces a current output that is programmable. The output of the power supply  27  is coupled to the proton exchange membrane  26 . The programmable power supply&#39;s  27  current output across the proton exchange membrane  26  is programmed by the central systems controller  16  to maintain the pressure differential across the proton exchange membrane  26  at an appropriate value. 
     A heat exchanger  28  is connected to the cathode terminal  24 . Similarly, an additional heat exchanger  30  can also be connected to the anode terminal  22 . The heat exchangers  28 ,  30  can be cooled by convection, forced air, water, or actively cooled with Peltier devices. 
     The area between the cathode terminal  24  and the proton exchange membrane  26  defines a first water pathway  17 . The area between the anode terminal  22  and the proton exchange membrane  26  defines a second water pathway  18 . Water flowing through the first water pathway  17  enters a first chamber  32  positioned above the electrolysis cell  20 . Similarly, water passing through the second water pathway  18  enters a second chamber  34  positioned above the electrolysis cell  20 . A first water level sensor  36  is disposed in the first chamber  32 . A second water level sensor  38  is disposed in the second chamber  34 . Both water level sensors  36 ,  38  sense when the level of water is within an acceptable operational range. The output of both water level sensors  36 ,  38  is connected to the central systems controller  16 . 
     A first variable water flow restrictor  40  is connected to the first chamber  32 . The first variable water flow restrictor  40  is controlled by the central systems controller  16 . When the first water level sensor  36  detects that the level of water is too high, the flow of water through the first variable water flow restrictor  40  is increased and the level of water in the first chamber  32  is lowered to an acceptable level. If the water level in the first chamber  32  is too low, the flow of water through the first variable water flow restrictor  40  is reduced until the water level rises to an acceptable level. 
     The level of water in the second chamber  34  is controlled in the same manner as described above, using the second water level sensor  38  and a second variable water flow restrictor  42 . 
     The water passing through either variable flow water restrictor  40  or  42  passes through de-bubblers  44  and  46  respectively where excess gas dissolved in the water escapes before entering the water tank  12 . 
     Hydrogen gas produced by electrolysis in the electrolysis cell  20  rises up through the first chamber  32 . Similarly, oxygen gas produced in the electrolysis cell  20  rises up through the second chamber  34 . The hydrogen gas contained in the first chamber  32  and the oxygen gas contained in the second chamber  34  are both contaminated with water vapor. The level of water vapor is reduced in three ways. First, the operating temperature of the electrolysis cell  20  is kept at a predetermined temperature by the heat exchanger  28 ,  30  that attach to he electrolysis cell  20 . The lower operating temperature of the electrolysis cell  20  directly correlates to lower vapor contamination. For example, if the water in the electrolysis cell  20  is kept at 5° Celsius, the water vapor is 6.5 mm of Hg. If the temperature is increased ten fold to 50° Celsius, the vapor pressure increases to 92.5 mm of Hg, which is an increase of eighteen fold. Accordingly, it is preferred that the operating temperature of the electrolysis cell  20  be maintained under 10° Celsius. 
     A second procedure used to reduce water vapor contamination is to position a condenser coil  46  in both the first chamber  32  and the second chamber  34 . Water vapor condenses on the condenser coil  46  and falls back into the first and second chambers  32 ,  34 , respectively. Water flow restrictors  48  are positioned in the first and second chambers, respectively, just above the condenser coil  46 . The presence of the water flow restrictors  48  prevents water bubbles from percolating further up within the first and second chambers,  32 , and  34 . 
     A first pressure sensor  56  detects the pressure of hydrogen gas in the first chamber  32 . A second pressure sensor  54  detects the pressure of oxygen gas in the second chamber  34 . A third pressure sensor  59  detects the pressure of pure hydrogen gas  58 . These pressure reading are forwarded to the central controller  16 . To the user the important parameter is the output pressure read by sensor  59 . The user of the hydrogen generator  10  inputs the required pressure of the pure hydrogen gas output  58  and the hydrogen generator  10  dynamically sets both the current through the proton exchange membrane and the relief pressure on the pressure relief valve  52  so that the pressure of the pure hydrogen output  58  is at the correct value. 
     At the top of the first chamber  32  there can be disposed a palladium purifier  50  mentioned above. The pure hydrogen output  58  of this purifier may have a pressure sensor  59 . The output of the pressure sensor  59  can be used by the system controller to control the current output of the high speed constant current source. The output pressure of the pure hydrogen can be to within 0.1% when the flow of hydrogen gas required does not exceed the capacity of the hydrogen generator  10 . A check valve  61  may be used on the pure hydrogen output to prevent contamination from entering the palladium purifier when the generator is turned off. A check valve  53  can also place in series in the bleed line to prevent contamination from entering the palladium purifier when the generator is turned off. 
     At the top of the second chamber  34  is disposed a variable gas pressure relief valve  52 . The output flow of hydrogen gas from the first chamber  32  is determined by the demand of the user. The output flow of oxygen gas from the second chamber  34 , is determined by the requirement that the oxygen pressure be kept at a value that minimizes the pressure gradient across the proton exchange membrane. This is accomplished by adjusting the pressure relief valve  52 , above the second chamber  34 , to a value that is large enough so that when the hydrogen in the first chamber  32  reaches this pressure the user can obtain the flow required. The pressure differential across the proton exchange membrane  26  is kept at the desired value usually near zero PSI when measured differentially. The pressure in the second chamber  34  is determined by adjusting the variable gas pressure relief valve  52  so that the pressure in the first chamber  32  and the second chamber  34  are equal. The pressure in the first chamber  32  is higher than the output pressure measured by sensor  59  of the hydrogen gas required because of the pressure drop in the palladium diffusion cell. The pressure in the first chamber  32  and the second chamber  34  are maintained at equal values under the various hydrogen flow conditions that may be required by the user as described below. 
     When the user demand for hydrogen gas changes, the pressure measured by pressure sensor  59  will tend to either increase or decrease depending on whether the user demand decreased or increased respectively. In order to maintain a steady pressure reading on sensor  59  the pressure in the first chamber  32  must change. The central systems controller  16  decreases or increases the current to the proton exchange membrane  26  as necessary to maintain the pressure measured by sensor  59  at the desired pressure value. The pressure in the second chamber  34  will change to hold the differential pressure across the proton exchange membrane near zero as the user hydrogen flow requirement changes. As the pressure in the first chamber  32  changes the central systems controller  16  decreases or increases the pressure in the second chamber  34  by adjusting the relief pressure valve  52 . The variable pressure relief valve  52  on the second chamber  34  regulates the pressure in the second chamber  34  so that the pressure in the second chamber  34  is equal to the pressure in the first chamber  32 . Oxygen is vented when the pressure in the second chamber  34  exceeds the relief pressure set by the pressure relief valve  52 . The result is an equilibrium that results in equal pressures in both the first chamber  32  and the second chamber  34  while maintaining a constant pressure on the pure hydrogen output gas  58  up to the generating capacity of generator. 
     Preferably, the relative pressure between the first chamber  32  and the second chamber  34  is maintained at zero pounds per square inch. However, the pressure differential across the proton exchange membrane  26  can be held at other pressures, for the particular cell configuration or application. 
     The shown first and second pressure sensor  54 ,  56  can be replaced by a single differential pressure sensor that is disposed between the first chamber  32  and the second chamber  34 . Two separate pressure sensors  54 ,  56  may be preferred to prevent any possible cross contamination of gasses, should the differential pressure sensor fail. 
     Above the first pressure chamber  32  can be disposed a palladium purifier  50 . The palladium purifier  50  purifies the output hydrogen so that it typically contains less than 1 part per billion of impurities. The bleed line  55  allows water vapor and other impurities to continually be purged from the palladium purifier  55 . The ultra pure hydrogen output is now available to the user. 
     The palladium purifier  50  is not required if it is not necessary to remove all the water vapor present in the output hydrogen gas. When the palladium purifier is not used it can be replaced by a flow restrictor that limits the rate of pressure change in the first chamber  32 . The current output from the high speed constant current source is adjusted so that the rate of hydrogen produced meets the demand required by the user. 
     The actual volume of the first chamber  32  and the second chamber  34  is relatively small. Accordingly, sudden changes in gas flow requirements from the first chamber  32  has a tendency to cause the pressure to fluctuate in the first chamber  32  because of the finite response time of the system. To make the overall system  10  more capable of responding to changing demands, with only a very small pressure fluctuate on the proton exchange membrane  26 , a ballast chamber  60  for hydrogen can be attached to the first chamber  32 . Similarly and a ballast chamber  64  for oxygen can be attached to the second chamber  34 , if there were demands on the oxygen gas. An example would be if the oxygen output were also being used and the requirements were fluctuating or if the high-pressure oxygen were being used as the driving force for the water pump  14 . The added ballast chambers  60 ,  62  increase the volume of hydrogen gas and oxygen gas stored in the first and second chambers  32 ,  34 , respectively. The total volumes are still small typically less than 50 cc. However, this small amount of volume increases the time constant associated with the pressure changes to ten or more milliseconds and eases the demand on the central systems controller  16 . The system  10  can therefore more readily respond to changing supply demands while minimizing the pressure fluctuate. Under various conditions the additional ballast chambers  60 ,  62  are not needed. 
     Temperature sensor  64  is disposed in the first chamber  32 . The temperature sensor  64  detects the temperature of the water above the electrolysis cell  20 . By measuring the temperature of the water with temperature sensor  64 , the degree of water vapor in the generated hydrogen gas can be calculated by the central systems controller  16 . A second temperature sensor  66  may be disposed in the first chamber  32 . The temperature sensor  66  detects the temperature of the gas above the condensing coils  46 . A third temperature sensor  68  can be use to measure the ambient temperature. The temperature sensors can be used by the central systems controller  16  to determine the effectiveness of the condensing coils  46 , the proton exchange heat sinks and the general condition of the hydrogen generating cell  20 . 
     In the hydrogen generator system  10  described, the pressure within the electrolysis cell  20 , on one side of the proton exchange membrane  26  is regulated with respect to the pressure on the opposite side of that membrane  26 , such that the hydrogen flow required by the user is dynamically met. In many cases the user needs a reliable source of high pressure pure hydrogen were the demand varies slowly or is constant. In this case the ballast  60  and  62  are not needed to keep the differential pressure across the proton exchange membrane close to zero. If the pressure differential is kept at zero, there are no differential pressure forces acting on the proton exchange membrane  26 . Accordingly, the proton exchange membrane  26  is not differentially stressed. Accordingly, there are no forces that cause the proton exchange membrane  26  to tear or wear. The life of the proton exchange membrane  26  is therefore significantly longer than prior art systems here the proton exchange membrane is differentially stressed and these differential forces can exceed 400 PSI considerably reducing the life of the membrane. In the prior art systems the differential forces are placed on the proton exchange membrane and cause excessive wear and tear. 
     It will be understood that the specifics of the hydrogen generator described above illustrates only one exemplary embodiment of the present invention. Other embodiments of the present invention can be made. For example, the temperature sensors can be removed if it is not necessary to monitor the temperature of the cell, the ambient or the gas produced. These measurements are used primarily for measuring the condition of the hydrogen generator and the temperature of the environment. 
     Another modification that can be easily introduced is to place multiple generator cells in series so that the electrical current flows through each of them serially but the gas output is taken out in a parallel mode for both gas outputs. For two generator cells this would double the gas generating capability while at the same time keeping the differential pressure across each cell near zero, without increasing the number of pressure sensors. Any number of cells can be put in series with the appropriate programmable current supply. 
     It will therefore be understood that a person skilled in the art can therefore make numerous alterations and modifications to the shown embodiment utilizing functionally equivalent components to those shown and described. All such modifications are intended to be included within the scope of the present invention as defined by the appended claims.