Patent Publication Number: US-8114545-B2

Title: Water reclamation in a micropower generator

Description:
This application is a continuation of U.S. patent application Ser. No. 11/270,848, filed Nov. 9, 2005, U.S. Pat. No. 7,901,816 issued Mar. 8, 2011 entitled “WATER RECLAMATION IN A MICROPOWER GENERATOR”, which is incorporated herein by reference. 
    
    
     GOVERNMENT RIGHTS 
     This invention was made with government support under Contract No. F33615-01-C-2171 awarded by AFRL Wright Research Lab. The government may have certain rights in the invention. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The invention relates to a waterless power generator. More particularly, the invention pertains to an electrical power generator and process for producing electrical power with a fuel cell. The reaction of oxygen and hydrogen gases in a fuel cell produces electricity and by-product water, which by-product water is reclaimed and used to produce additional hydrogen gas through its reaction with a solid hydrogen producing fuel. 
     2. Description of the Related Art 
     Similar to batteries, fuel cells function to produce electricity through chemical reactions. Rather than storing reactants as batteries do, fuel cells are operated by continuously supplying reactants to the cell. In a typical fuel cell, hydrogen gas acts as one reactant and oxygen as the other, with the two reacting at electrodes to form water molecules and releasing energy in the form of direct current electricity. This direct current electricity may then be converted into an alternating current. The apparatus and process may produce electricity continuously as long as hydrogen and oxygen are provided. While oxygen may either be stored or provided from the air, it is generally necessary to generate hydrogen gas from other compounds through controlled chemical reactions rather than storing hydrogen, because storing hydrogen gas requires that it either be compressed or cryogenically cooled. As fuel cell technology evolves, so do the means by which hydrogen gas is generated for application with fuel cells. 
     Currently, there are various methods which are known and employed for generating hydrogen gas. One method is by a process known as reformation in which fossil fuels are broken down into their hydrogen and carbon products. However, this system is undesirable in the long term because it is dependent upon a non-renewable resource. Another means of generating hydrogen gas is by reversibly adsorbing and releasing hydrogen gas from metal hydrides or alloys through heating. While this method is useful, it is not preferred because the metal hydrides are typically very heavy, expensive and only release small quantities of hydrogen. Yet another means by which hydrogen gas is generated is through reactive chemical hydrides. This process involves chemically generating hydrogen gas from dry, highly reactive solids by reacting them with liquid water or acids. Chemicals especially suitable for this process are lithium hydride, calcium hydride, lithium aluminum hydride, sodium borohydride and combinations thereof, each of which is capable of releasing plentiful quantities of hydrogen. The disadvantages associated with this method is that reaction products from the chemical and liquid water typically form a cake or pasty substance which interferes with further reaction of the reactive chemical with the liquid water or acid. This method is also disadvantageous in that the storage of liquid water fuel consumes additional space and increases the overall weight of the associated power generator. 
     There is currently a need in the art for lighter weight and smaller sized power sources for applications such as portable electronic devices, wireless sensors, battlefield applications, and unmanned air vehicles. Presently, the power source that is most often used for portable applications is the lithium battery, which has a limited energy capacity as a function of volume and especially as a function of weight. It is desirable to increase the energy capacity of current power sources so as to decrease the power supply replacement interval and/or increase operating life, while also reducing the size and weight of the power source. 
     The present invention provides a solution to these problems. The invention provides an electrical power generator and a process for generating hydrogen gas for fueling a fuel cell. The electrical power generator comprises a waterless generator, utilizing only by-product water from a fuel cell as a water vapor fuel source and without the need for externally supplied water. More particularly, the invention provides an electrical power generator that consumes stoichiometric amounts of water vapor and substantially solid, non-liquid chemical hydride. The fuel cell is preferably initially loaded with a hydrogen gas to initiate a reaction at a hydrogen-oxygen Proton Exchange Membrane (PEM) fuel cell between the hydrogen gas and oxygen gas. This reaction produces water molecules which are maintained within the generator housing at a water retention zone that deters the diffusion of generated fuel cell water out of the housing. The water molecules then diffuse back into the power generator in the form of water vapor, which water vapor is then reacted with the chemical hydride to produce more hydrogen gas. This generated hydrogen gas is then used as a fuel which allows the fuel cell to generate additional electrical power and additional water. By reclaiming and recycling this by-product water, the need for stored water is eliminated, thereby reducing the overall size and weight of the system, as well as increasing the energy density, specific energy and current capacity of the system. Further, by reacting water vapor with the aforementioned solid chemical substance, it has been found that the typical problems associated with reactive chemical hydrides are avoided, resulting in a more efficient system than those of the prior art that use liquid water. 
     The electrical power generator of the invention further exemplifies the unique capability of generating electrical power through a passive process, without the need for using pumps or other means of active regulation. It has been unexpected found that the solid chemical fuel inside the power generator creates a region of low humidity hydrogen on the anode side of a PEM fuel cell. The air on the cathode side of the fuel cell is of significantly higher humidity, due to normal ambient air conditions and due to the water produced at the fuel cell cathode by the electrochemical reaction between hydrogen and oxygen. This establishes a concentration gradient which causes water to permeate as water vapor from the more humid cathode side of the fuel cell to the lower humidity hydrogen on the anode side inside the generator cavity to create an equilibrium. Regulation of the hydrogen generation rate is partly self-regulating, because the reaction between hydrogen gas and oxygen gas at the fuel cell produces the required water corresponding to the electrical power generated. A pneumatically controlled valve may further be used to passively adjust the conductance of the water vapor path to the solid fuel. 
     SUMMARY OF THE INVENTION 
     The invention provides an electrical power generator comprising: 
     a) a housing; 
     b) at least one fuel cell mounted within the housing, the fuel cell comprising a cathode, an anode and a water vapor permeable electrolytic membrane positioned between the cathode and the anode; which fuel cell is capable of generating electricity and fuel cell water at the cathode by the reaction of hydrogen gas and oxygen gas;
 
c) at least one fuel chamber mounted within the housing, which fuel chamber contains a fuel substance which reacts with water vapor to generate hydrogen gas;
 
d) at least one air inlet for admitting atmospheric air into the housing;
 
e) a water retention zone within the housing extending from the air inlet to the fuel cell cathode, which water retention zone deters the diffusion of generated fuel cell water out of the air inlet; and
 
f) a cavity within the housing extending from the fuel cell to the fuel chamber, which admits a flow of hydrogen gas from the fuel chamber to the fuel cell, and which admits a flow of water vapor from the fuel cell to the fuel chamber.
 
     The invention also provides an electrical power generator comprising: 
     a) a housing; 
     b) at least one fuel cell mounted within the housing, the fuel cell comprising a cathode, an anode and a water vapor permeable electrolytic membrane positioned between the cathode and the anode; which fuel cell is capable of generating electricity and fuel cell water at the cathode by the reaction of hydrogen gas and oxygen gas;
 
c) at least one fuel chamber mounted within the housing, which fuel chamber contains a fuel substance which reacts with water vapor to generate hydrogen gas;
 
d) at least one air inlet for admitting atmospheric air into the housing;
 
e) a water retention zone within the housing extending from the air inlet to the fuel cell cathode, which water retention zone deters the diffusion of generated fuel cell water out of the air inlet;
 
f) a cavity within the housing extending from the fuel cell to the fuel chamber, which admits a flow of hydrogen gas from the fuel chamber to the fuel cell, and which admits a flow of water vapor from the fuel cell to the fuel chamber;
 
g) at least one valve positioned within said cavity for regulating the passage of hydrogen gas from the fuel chamber to the fuel cell, and for regulating the passage of water vapor from the fuel cell to the fuel chamber;
 
h) an oxygen permeable, water vapor impermeable membrane united with the air inlet, which membrane deters the flow of fuel cell water into the atmosphere; and
 
i) a water permeable, hydrogen impermeable membrane within the cavity and juxtaposed with said valve, which water permeable, hydrogen impermeable membrane allows the diffusion of water vapor to said fuel chamber without passing the water vapor through said electrolytic membrane.
 
     The invention further provides a process for producing electrical power comprising: 
     I) providing an electrical power generator which comprises: 
     
         
         
           
             a) a housing; 
             b) at least one fuel cell mounted within the housing, the fuel cell comprising a cathode, an anode and a water vapor permeable electrolytic membrane positioned between the cathode and the anode; which fuel cell is capable of generating electricity and fuel cell water at the cathode by the reaction of hydrogen gas and oxygen gas; 
             c) at least one fuel chamber mounted within the housing, which fuel chamber contains a fuel substance which reacts with water vapor to generate hydrogen gas; 
             d) at least one air inlet for admitting atmospheric air into the housing; 
             e) a water retention zone within the housing extending from the air inlet to the fuel cell cathode, which water retention zone deters the diffusion of generated fuel cell water out of the air inlet; and 
             f) a cavity within the housing extending from the fuel cell to the fuel chamber, which admits a flow of hydrogen gas from the fuel chamber to the fuel cell, and which admits a flow of water vapor from the fuel cell to the fuel chamber; and
 
II) operating said power generator to generate electricity by:
 
             a) reacting hydrogen gas and atmospheric oxygen gas in the fuel cell, thereby generating fuel cell water and electricity, which fuel cell water is retained in the water retention zone; 
             b) diffusing said fuel cell water from the water retention zone, through the electrolytic membrane, into the cavity and to the at least one fuel chamber; 
             c) reacting the water vapor with the fuel substance to generate hydrogen gas; and 
             d) diffusing the generated hydrogen gas through the cavity and to the fuel cell. 
           
         
       
    
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a cross-sectional schematic representation of a power generator of the invention without an oxygen permeable, water vapor impermeable membrane united with an air inlet of the generator. 
         FIG. 2  is a cross-sectional schematic representation of a power generator of the invention having an oxygen permeable, water vapor impermeable membrane united with an air inlet of the generator. 
         FIG. 3A  is a cross-sectional schematic representation of a corner of the power generator illustrated in  FIG. 1  illustrating a water retention zone between the air inlet and the fuel cell cathode. 
         FIG. 3B  is a cross-sectional schematic representation of a corner of the power generator illustrated in  FIG. 2  illustrating a water retention zone between the air inlet and the fuel cell cathode. 
         FIG. 4  is a schematic representation of a fuel cell. 
         FIG. 5  is a plot of power output versus time for a power generator of the invention. 
         FIG. 6  is a schematic representation of the molar flux of water vapor from one location to another. 
         FIG. 7  is a top-view of a cylindrical power generator of the invention incorporating a plurality of fuel cells. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     An electrical power generator is provided which generates hydrogen gas internally through the reaction of water vapor with a moisture absorbing, solid fuel substance, which hydrogen gas is reacted with atmospheric oxygen from the air at a fuel cell to generate electrical energy. The reaction of hydrogen and oxygen also produces water molecules as a byproduct at the fuel cell. This generated water is passively diffused from the fuel cell as water vapor to a fuel chamber that contains the solid fuel substance, where it reacts with the fuel substance to generate hydrogen gas. The electrical energy generated may be used to power large or small devices that are connected to the power generator, depending on the size of the power generator. The power generator of the invention is particularly useful for powering miniature devices such as wireless sensors, cellular phones or other hand held electronic devices that are electrically connected to the anode and cathode of the one or more fuel cells of the power generator. 
       FIGS. 1 and 2  illustrate cross-sectional views of alternate power generator apparatuses for carrying out the process of the invention. As seen in  FIG. 1  and  FIG. 2 , an electrical power generator  10  comprises a housing  36 , at least one fuel cell  14  mounted within the housing  36 , at least one fuel chamber  12  for storing a fuel substance  44  mounted with the housing  36 , and a cavity  24  within the housing  36  extending from the at least one fuel cell  14  to the fuel chamber  12 . Cavity  24  admits a flow of hydrogen gas from the fuel chamber  12  to the fuel cell  14 , and admits a flow of water vapor from the fuel cell  14  to the fuel chamber  12 . Fuel cell  14  generates electricity and fuel cell water from the reaction of hydrogen gas and oxygen gas from the air. Atmospheric oxygen enters into the housing  36  through at least one air inlet  20 . The oxygen gas then travels to the fuel cell  14  where it reacts with hydrogen gas, generating electricity and water molecules. The type of fuel cell used herein is well known in the art and is referred to in the art as a Proton Exchange Membrane (PEM) fuel cell, also known as a Polymer Electrolyte Membrane. 
     As seen in  FIG. 4 , a typical PEM fuel cell comprises an electrolytic membrane  42  positioned between a negatively charged electrode, or cathode  16 , on one side of the membrane, and a positively charged electrode, or anode  18 , on the other side of the membrane. In typical hydrogen-oxygen PEM fuel cell behavior, a hydrogen fuel (e.g. hydrogen gas) is channeled through flow field plates to the anode, while oxygen is channeled to the cathode of the fuel cell. At the anode, the hydrogen is split into positive hydrogen ions (protons) and negatively charged electrons. The electrolytic membrane allows only the positively charged ions to pass through it to the cathode. The negatively charged electrons must instead travel along an external circuit to the cathode, creating an electrical current. At the cathode, the electrons and positively charged hydrogen ions combine with oxygen to form water molecules. 
     Inside the generator, on the anode  18  side of the fuel cell, an initial flush of hydrogen gas is preferably provided to remove residual air from within the power generator. This initial flush of hydrogen gas serves a dual purpose, as it will also react with atmospheric oxygen at the fuel cell, generating an initial amount of electrical energy and generating an initial amount of fuel cell water at the fuel cell cathode  16 . This initial amount of fuel cell water is then reclaimed and reacted with the fuel substance  44 . Alternately, the process of the invention may be initiated by the permeation of water molecules from the humidity of the atmosphere outside the power generator, through the air inlet  20 , and into the power generator. Although less preferred, it is also possible to add an initial amount of non-fuel cell water to the generator, in an amount substantially less than the amount of fuel cell water generated by the fuel cell, to react with the fuel substance  44  and initiate hydrogen gas generation. Such start-up water may be added to the generator, for example, through an opening in the fuel chamber  12 , such as entry  46 , or through another suitable means, such as through air inlet  20 . However, the process and apparatus of the invention are designed to operate without an externally provided water supply, i.e. the system is water-less except for water that is generated by the fuel cell and water molecules present in the atmosphere outside of the power generator. There is no incorporated or connected water supply, such as a water chamber or water reservoir, to provide water for reaction with the hydrogen fuel substance. This results in a significant improvement in the energy density and specific energy of the power generator compared to conventional systems. Accordingly, the present invention provides a continuous, self-regulating process since the hydrogen-oxygen reaction produces exactly the required water corresponding to the electrical power generated, wherein stoichiometric amounts of recycled water and solid fuel are used. 
     The process of the invention is also preferably passive, running without actively controlled valves or pumps. More particularly, once water is formed as a by-product of the oxygen-hydrogen reaction at the fuel cell  14 , the produced water passively diffuses back through the fuel cell  14 , into the cavity  24  and to the fuel chamber  12 . This passive diffusion is enabled in part due to one or more water retention zones  22 , and in part due to the low humidity inside the cavity  24 . Water retention zone  22  is highlighted by  FIGS. 3A and 3B  which offer corner views of the power generators illustrated in  FIGS. 1 and 2 . As used herein, and as shown in  FIGS. 3A and 3B , a water retention zone  22  comprises the channel extending from the air inlet  20  to each the fuel cell cathode  16 . A water retention zone  22  is present at each fuel cell  14  which generates fuel cell water. Due to the geometry of the water retention zone  22 , diffusive water loss of fuel cell generated water molecules out of the air inlet is deterred, thereby maintaining a high concentration of water vapor at the fuel cell cathode  16 . Instead of losing water molecules to the ambient air, water retention zone  22  causes generated water molecules to accumulate at the cathode  16 , creating a region of high humidity between the cathode  16  and air inlet  20 . This molar flow rate can be described with more specificity via the equation below with reference to  FIG. 6 : 
     
       
         
           
             
               J 
               A 
             
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                   D 
                   AB 
                 
                 * 
                 
                   ( 
                   
                     
                       P 
                       
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                         1 
                       
                     
                     - 
                     
                       P 
                       
                         A 
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                         2 
                       
                     
                   
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                 R 
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                 T 
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                   ( 
                   
                     
                       Z 
                       2 
                     
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                       Z 
                       1 
                     
                   
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     The transport of water vapor from the cathode  16  to the ambient air, and the transport of oxygen from the ambient air to the cathode  16  are both diffusion controlled processes. The molar flux, or molar flow rate, of A is J A , where A is the desired species, i.e. either water or oxygen. The molar flux of water or oxygen is a function of the diffusivity D AB , the partial pressure difference between point  1  and point  2  (P A1 −P A2 ), the gas constant R, the temperature T in Kelvin, and the distance between points  1  and  2  (Z 2 −Z 1 ). Additionally, flux is defined as per area, with units of 
             kgA       m   2     ⁢   sec           
(kilograms of A, per m 2  second).
 
     The diffusion coefficient is the proportionality constant between the flux of a species to its concentration gradient. The diffusion coefficient D AB  refers to the diffusion coefficient of species A in species B. In the present case, it refers to the diffusion coefficient of water vapor in air, or the diffusion coefficient of oxygen in air. A large diffusion coefficient will yield a large flux value, and a small diffusion coefficient will yield a small flux value. The diffusion coefficient for oxygen in air is about 0.21 cm 2 /sec at room temperature and normal room humidity, while the diffusion coefficient for water vapor in air at room temperature and humidity is about 0.24 cm 2 /sec. 
     Partial pressure is the fraction of the total pressure of a mixture of gases that is due to one component of the mixture. A large partial pressure difference will generate a relatively large flux of the species, while a small partial pressure difference will generate a relatively small flux. The water retention zone is designed to give a small partial pressure difference, e.g. about 10% to about 20% of atmospheric oxygen partial pressure, to obtain the oxygen flux required for the desired power level. 
     The gas constant is a product of Boltzmann&#39;s constant and Avogadro&#39;s number. The temperature in Kelvin affects the flux of the species of interest. Higher temperatures tend to reduce flux, while lower temperatures tend to increase flux. Thus, the diffusion of gases, and by extension, their partial pressure differences, can be controlled by adjusting the channel geometry. 
     With reference to  FIG. 6 , to control the diffusion of a gas between point  1  and point  2 , the geometry of the channel which separates the two points can be changed. For example, if the area of the channel which separates point  1  and point  2  is increased, diffusion between points  1  and  2  is increased, and conversely if the area is decreased, diffusion is reduced. The opposite applies to the distance between point  1  and point  2 , whereby increasing the distance between points  1  and  2  results in reduced diffusion, and decreasing the distance between points  1  and  2  results in greater diffusion out of air inlet  20 . 
     The power generators of the invention as seen in  FIGS. 1 and 2  are designed to allow enough oxygen to diffuse from the ambient air, through the air inlet  20  and to the cathode  16  with only a small pressure drop, e.g. 10% to 20% of the atmospheric oxygen pressure. The power generator will have high hydrogen permeation losses and thus reduced lifetime if operated at high pressures. 
     The chemical reaction that converts hydrogen and oxygen to water (2H 2 +O 2 →2H 2 O) creates two moles of water for every mole of oxygen it consumes. Further, the diffusivity of water vapor in air and the diffusivity of oxygen in air are similar. Accordingly, the partial pressure difference of water vapor must be roughly twice that of oxygen to maintain equilibrium. Therefore, the power generator of the invention having the above proportions maintains a humidified environment instead of losing the generated water molecules to the atmosphere outside the generator. 
     Within the cavity  24 , on the anode  18  side of the fuel cell  14 , a comparatively low humidity region exists due to the moisture absorbing, hygroscopic nature of the fuel substance  44 . Accordingly, the water generation and retention at the cathode  16  generates a moisture concentration gradient and a gas pressure differential which causes water molecules to diffuse back through the fuel cell  14 , into the cavity  24  and to the fuel chamber  12  in the form of water vapor. This water vapor then reacts with fuel substance  44 , generating hydrogen gas. The generated hydrogen gas will then pass through cavity  24  and to the fuel cell anode  18  where it will react with oxygen to once again generate water molecules. This cycle may optionally continue until all of the fuel substance  44  is consumed. 
     During operation of the power generator, more generated water vapor will diffuse back into the cavity than is lost out of the air inlet. Furthermore, fuel cell output is directly dependent on the flow of oxygen and hydrogen reactants to the fuel cells, and hence the flow of water vapor the fuel chamber. Accordingly, fuel cell output is proportional to the ratio of the area of the water retention zone to its length. In the preferred embodiment of the invention, the ratio of zone area to zone length per unit of power is preferably from about 0.01 cm/mW to about 0.05 cm/mW of power output for a single fuel cell. If multiple fuel cells are incorporated, this ratio of zone area to zone length per unit of power is divided by the number of fuel cells which share the reactants. 
     The generator will operate at reduced power if the geometry of the water retention zone  22  is too restrictive to allow sufficient oxygen to diffuse to the fuel cells  14 . Particularly, at a zone area to length ratio of greater than 0.05 cm 2  area/1 cm length, excess water vapor will diffuse out of the air inlet, and at a zone area to length ratio of less than 0.01 cm 2  area/1 cm length, not enough oxygen will reach the fuel cells to operate at a high efficiency. The same is true for the geometry of the cavity within the housing extending from the fuel cell to the fuel chamber, which admits a flow of hydrogen gas from the fuel chamber to the fuel cell, and which admits a flow of water vapor from the fuel cell to the fuel chamber. 
     In another embodiment, the power generator  10  may further include at least one valve  26  for regulating the flow hydrogen gas from the fuel chamber  12  to the fuel cell  14 , and for regulating the passage of water vapor from the fuel cell  14  to the fuel chamber  12 . As shown in  FIGS. 1 and 2 , valve  26  is positioned within the cavity  24  between fuel chamber  12  and the fuel cell  14 . In the preferred embodiment of the invention, valve  26  comprises a pneumatic valve that is controlled by gas pressure within said cavity  24 , pneumatically adjusting the conductance of water vapor to the fuel chamber  12 . Valve  26  preferably comprises a pneumatically actuated flexible diaphragm  30  having a periphery that is preferably fixed to the power generator housing  36  at a support  50 ; a valve disc  28  positioned opposite the diaphragm  30 ; and a rod connector joins the valve disc  28  and diaphragm  30 . The valve  26  is in a closed position when the valve disc  28  is in contact with a seal  38 , preventing water vapor from reaching the fuel chamber  12 . Alternately, the valve is in an open position when the valve disc is separated from seal  38 , allowing water vapor to reach the fuel chamber  12  and allowing generated hydrogen gas to reach the fuel cells  14 . Preferably, seal  38  comprises a portion of housing  36 . Support  50  also preferably comprises part of housing  36 . As seen in  FIGS. 1 and 2 , the fuel cell or fuel cells  14  are also preferably mounted inside the housing by support  50 . 
     The dimensions of the component parts of the valve are preferably very small in scale but may vary with respect to the particular application of the valve. The diaphragm thickness and diameter should be within a certain range depending on the desired power output. In the preferred embodiment of the invention, the diaphragm  30  is either tensile or non-tensile and preferably comprises a thin circular plate preferably having a diameter of from about 1 cm to about 3 cm, more preferably from about 1 cm to about 2 cm. The valve disc  28  preferably has a diameter of from about 0.2 to about 1 cm, more preferably from about 0.2 cm to about 0.5 cm. In the preferred embodiment of the invention, the rod connector may comprise a screw or a bolt, but any other means of connecting the diaphragm  30  to the valve disc  28  is suitable such that the valve can alternate between the open and closed positions. 
     The actuation of the valve is preferably controlled by the internal gas pressure exerted on the diaphragm  30 . As the internal gas pressure of the apparatus rises due to the generation of hydrogen gas, the diaphragm  30  will bend or push outward slightly. This causes the connector to pull the valve disc  28  against the seal  38 , closing the valve and preventing the flow of additional water vapor to the fuel chamber  12 . With the valve closed, hydrogen production ceases. This also prevents the internal gas pressure from rising further. As hydrogen is consumed, such as by fuel cells  14 , the internal gas pressure drops, allowing the valve disc  28  to disengage the seal  38  and opening the valve. Accordingly, hydrogen gas is automatically produced at the rate at which it is consumed. 
     In the preferred embodiment of the invention, the power generator  10  operates by maintaining a fixed pressure, via the pneumatic valve  26 . The power generator  10  should be able to operate down to low ambient pressures at reduced power output, and up to theoretically unlimited ambient pressures at full power output. In the preferred embodiment of the invention, the internal H 2  pressure of the apparatus when in the closed position is from about 0 kPa to about 1000 kPa. The valve will be fully shut when no hydrogen gas is used by the fuel cell, and will open the amount required to meet consumption rate of the hydrogen gas. In the most preferred embodiment of the invention, the internal pressure of the power generator is maintained at about 100 kPa at all times, wherein when the pressure drops below about 10 kPa, the valve will open slightly until the internal pressure raises to at or above about 500 kPa, causing the valve to close. The most preferred operating pressures are preferably from about 0.5 atm (about 50 kPa) to about 2 atm (about 202 kPa) for small scale applications such as portable electronic devices or wireless sensors. 
     In general, the power generator  10  operates by maintaining a fixed pressure, usually a few psi over ambient, using the pneumatic valve  26 . Preferably, generator  10  is able to operate down to low ambient pressures at reduced power output, and up to theoretically unlimited ambient pressures at full power output. 
     The power generator  10  is preferably maintained at an operating temperature of from about −40° C. to about 85° C., more preferably from about −20° C. to about 50° C., more preferably from about 0° C. to about 50° C. and most preferably from about 20° C. to about 50° C. while in use. 
     For the purposes of this invention, the term “water vapor” does not include steam. While “water vapor” and “steam” are both forms of water, each has very different properties and uses. For example, a locomotive can be driven by steam, but will not operate on the water vapor present in humid air, as does the present invention. In and of itself, “water vapor” is the gas of individual water molecules that may form naturally over a body of water at any temperature, including ice, or that may be naturally present in ambient air. It has a low partial pressure, so it contains relatively few water molecules unless the water that forms it is heated. On the other hand, “steam” is made up of tiny hot water droplets produced by heating water to boiling. 
     Steam contains about 100× more water molecules than does water vapor at 15° C., naturally expands with high force and velocity, and large amounts of water can be boiled and transported off as steam. Water vapor is present in everyday air and contains a much smaller number of water molecules than steam or liquid water, and moves very slowly by natural diffusion. Only very small amounts of water can be transported in the form of water vapor. To illustrate, a single drop of water takes typically one hour to evaporate at room temperature, while an entire kettle of water can be boiled into steam in about twenty minutes. Further, a steam powered generator would require a water supply or water source from which steam may be generated. In contrast, the present invention provides an improvement upon the related art by eliminating such a water source. Accordingly, the apparatus and process of the present invention are designed to function at low operating temperatures using water vapor, not at high operation temperatures using steam. 
     As seen in  FIGS. 1 and 2 , the power generator  10  may further include a restriction  32  united with the air inlet  20 , regulating the diffusion of atmospheric oxygen and atmospheric water molecules into the power generator. This restriction also aids in raising the humidity at the fuel cell cathode  16  due to impedance presented to outward diffusion of water vapor produced at the cathode  16 . This increased humidity improves the operation of the fuel cell. The restriction preferably comprises a hydrophobic membrane that is substantially permeable to atmospheric oxygen gas, but substantially impermeable to water vapor, which membrane substantially obstructs the flow of fuel cell water into the atmosphere. Suitable materials for this oxygen permeable, water vapor impermeable membrane having the desired properties include fluoropolymer containing materials such as fluorinated ethylene propylene (FEP), perfluoroalkoxy, and non-fluoropolymer containing materials such as oriented polypropylene (OPP), low density polyethylene (LDPE), high density polyethylene (HDPE) and cyclic olefin copolymers (COCs). The most preferred oxygen permeable, water vapor impermeable membrane material comprises fluorinated ethylene propylene. In addition, for some embodiments, the membrane alone may not allow sufficient oxygen permeation to the cathode. Accordingly, a small opening  48  (see  FIG. 2 ) in the restriction  32  may be provided to allow the ingress of extra atmospheric oxygen and atmospheric water molecules into the cavity to diffuse to the fuel cell cathode or cathodes. However, this opening may also cause some of the water vapor to diffuse out of the power generator  10 . The required opening size is a function of the power level, the diffusion path length, and the desired partial pressure drop. The size of this opening is preferably very small in size and may preferably comprise from about 0.001% to about 1% of the entire surface area of the membrane. 
     The substantially non-fluid substance within the fuel chamber  12  preferably comprises a material in powder, granule or pellet form and is preferably an alkali metal, calcium hydride, lithium hydride, lithium aluminum hydride, lithium borohydride, sodium borohydride and combinations thereof. Suitable alkali metals non-exclusively include lithium, sodium and potassium. The preferred material for the non-fluid substance is lithium aluminum hydride. The fuel substance is preferably a solid, porous material that allows for the diffusion of gases and vapors. Further, the non-fluid substance is also preferably combined with a hydrogen generation catalyst to catalyze the reaction of the water vapor and the non-fluid substance. Suitable catalysts include non-exclusively include cobalt, nickel, ruthenium, magnesium and alloys and combinations thereof. 
     As seen in  FIGS. 1 and 2 , fuel chamber  12  is preferably bordered by porous vapor membrane  34 . This membrane  34 , attached to the housing  36  and juxtaposed with the fuel chamber  12 , is necessarily permeable to water vapor, so as to allow water vapor to pass into the fuel chamber  12  and react with the solid fuel substance, thereby generating hydrogen gas. It is also necessarily permeable to hydrogen gas, so as to allow generated hydrogen gas to pass into the cavity  24  and back to the fuel cell  14 . Suitable materials for this vapor membrane  34  having such dual properties non-exclusively include porous polymers including fluoropolymers, including expanded-polytetrafluoroethylene (ePTFE) laminates such as expanded Teflon®. Particularly preferred ePTFE laminates are GORE-TEX® manufactured by W. L. Gore &amp; Associates, Inc. of Delaware, and eVENT®, manufactured by BHA technologies of Delaware. 
     Referring to  FIG. 2 , in particular, is a cross-sectional schematic representation of an alternate power generator of the invention having an air inlet with a larger surface area compared to the generator of  FIG. 1 . Similarly, in this embodiment, a hydrophobic membrane  32  that is substantially permeable to atmospheric oxygen gas, but substantially impermeable to water vapor, is preferably placed at air inlet  20 . However, in order to allow for the intake of water molecules from natural air humidity in the atmosphere, a small opening  48  (e.g. about 0.008 cm 2 ) opening is preferably cut into the membrane  32 . This opening  48  will also allow extra oxygen to diffuse to the fuel cell cathodes. In the preferred embodiment of the invention, the power generators of the invention will perform best when in an environment having a relative humidity of at least about 5%, wherein the performance will improve with increasing humidity. 
     The embodiment of  FIG. 2  also preferably includes a pneumatic valve  26  which preferably includes a mesh diaphragm  30  and a water permeable, hydrogen impermeable membrane  40  in juxtaposition with the mesh diaphragm  30  of the valve  26 . The mesh diaphragm  30  is preferably permeable to water vapor and is preferably formed from a polymeric material, such as polyethylene terephthalate or a metal such as stainless steel. Suitable water permeable materials for this water permeable membrane  40  include perfluorinated polymers such as perfluorosulfonate ionomers. Also suitable are epoxides and chloroprene rubber. Most preferably, the water permeable membrane comprises a perfluorosulfonate ionomer membrane commercially available under the trademark Nafion® from EI DuPont de Nemours &amp; Co. of Delaware. Nafion® is preferred because it has a fluorinated backbone that makes it very stable, with sulfonic acid side chains to support high ionic conductivity. The water permeable, hydrogen impermeable membrane  40  allows the diffusion of water vapor to the fuel chamber  12  without passing the water vapor through the electrolytic membrane  42 . It provides a large area path for water vapor to permeate into the fuel chamber and may allow the fuel cells  14  to operate at higher current densities than if the water is recovered solely though the fuel cells themselves. A similar material forms the electrolytic membrane  42  of the at least one fuel cell  14 . 
     Accordingly, as can from  FIG. 2 , this power generator  10  provides dual avenues for the transport of fuel cell generated water molecules from the fuel cell cathode  16  to the fuel chamber  12 . Specifically, in the embodiment of  FIG. 2 , the reaction of hydrogen gas and atmospheric oxygen in the fuel cell  14  results in the generation of fuel cell water at the fuel cell cathode  16 , and thereby generates electricity. This generated fuel cell water is retained in the water retention zone  22  and may re-enter cavity  24  by either diffusing back through the fuel cell  14 , or by diffusing from the water retention zone  22  and permeating through the mesh diaphragm  30  and water permeable membrane  40 . 
     Illustrated in  FIG. 7  is a top view of a cylindrical power generator  10  of the invention having a plurality of fuel cells. As seen in  FIG. 7 , in a preferred embodiment, a plurality of fuel cells  14  are positioned around a circumference of the power generator  10 . A power generator  10  of the invention may also include an entry  46 , through which fuel substance  44  may optionally be replenished. Alternately, when fuel substance  44  is consumed, the power generator may be disposed, similar to a battery. Each of the assembled component parts of the power generator  10  may further be enclosed in a suitable hollow structure such as a tube formed from a suitable material, such as polyethylene terephthalate (not shown), which enclosure may also be capped on the top and/or bottom surfaces with a suitable cap (not shown), which cap may be removable and is preferably formed of a similar or different material as the enclosure. The power generator  10  also further preferably includes at least one electrical connector through which a device may be electrically connected to the power generator  10 . As illustrated in  FIG. 1 , in the preferred embodiment of the invention, a device  52  (schematically represented, not drawn to scale) is preferably electrically connected to the power generator  10  through electrical connectors  54  and  56 , which electrical connectors  54  and  56  are preferably connected to the cathode(s) and anode(s) of the fuel cell(s). Electrical connectors  54  and  56  are also illustrated in  FIG. 7 . In embodiments incorporating a plurality of fuel cells, the plurality of fuel cells are preferably connected in series, and are preferably connected to a single set of electrical connectors  54  and  56  protruding from the generator housing  36 . In a preferred embodiment of the invention, the power generator  10  includes eight interconnected fuel cells. 
     Each of the parts of the power generator  10  and the valve  26  may be fabricated of a suitable polymeric material, a metal or other material as determined by the requirements of the intended use of the generator and valve. A preferred material non-exclusively includes polyethylene terephthalate. The preferred dimensions of the component parts of the power generator  10  are preferably very small in scale, but may also vary with respect to the use of the power generator  10 . The preferred outer dimensions of such a waterless, micro-power generator are from about 1 mm to about 100 mm in length, from about 1 mm to about 100 mm in width, and from about 1 to about 100 mm in depth, more preferably from about 1 mm to about 25 mm in length, from about 1 mm to about 25 mm in width, and from about 1 to about 25 mm in depth. Such a waterless, micro-power generator is capable of incorporating one or more fuel cells  14  which fuel cells may range in size from about 0.1 mm 2  to about 5,000 mm 2 . A waterless, micro-power generator of the invention is also preferably capable of containing a volume capacity of from about 0.1 mm 3  to about 15,625 cm 3 . A larger power generator may preferably have dimensions of up to at least about 50 cm or more in length, width and depth, up to at least about 5000 cm 2  or more in fuel cell area and up to at least about 0.125 m 3  or more in power generator volume. While these dimensions are preferred, they may vary widely and are not intended to be limiting. The dimensions of each of the component parts of the power generator may similarly vary as could be determined by one skilled in the art in such a manner that the power generator of the invention will operate as intended. 
     Each of the embodiments illustrated in  FIGS. 1 and 2  have been found to exhibit electrical conductivity in the absence of a provided, non-fuel cell water source.  FIG. 5  and Example 1 below offer an example of the power output vs. time plot for a small-scale, micro-power generator of the invention. A micro-power generator of the invention preferably produces a power output of from about 1 micro Watt to about 100 milli Watts, more preferably from about 1 micro Watt to about 1000 milli Watts, and energy densities of from about 0.1 W-hr/cc to about 10 W-hr/cc. Larger power generators of the invention may produce power output levels of from about 0.1 W to about 100 W and energy densities of from about 0.1 W-hr/cc to about 10 W-hr/cc. 
     It should be further understood that while the exemplified embodiments of  FIGS. 1 and 2  represent preferred power generator apparatuses of the invention, such structures are not intended to be limiting. Other design variations that perform in a substantially similar manner, i.e. waterless power generators capable of producing useful levels of electricity with hydrogen-oxygen fuel cells including a solid fuel substance, are incorporated within the scope of the invention. 
     The following examples serve to illustrate the invention: 
     EXAMPLE 1 
     A power generator as seen in  FIG. 1  was provided and given an initial flush of hydrogen gas. The initial flush evacuated air from the generator cavity, and was thereafter consumed by the fuel cell, producing electricity and byproduct water. Following consumption of this initial hydrogen flush, hydrogen gas was continuously generated internally, as well as electricity. The power output of the generator was measured over time. The results are shown in  FIG. 5 , which is a plot of the power output of the power generator versus time. Power output was initially set at 50 microWatts, but was later increased to 170 and then to 210 microWatts, where it was maintained for the duration of a 30 day test. During the first 20 days of the test, ambient laboratory air relative humidity varied between about 10 to 20 percent. Laboratory air temperature was about 23° C. The initial flush of hydrogen was estimated to have been consumed in about the first day of operation. For this waterless operation, the required water is back-permeating through the fuel cells themselves. Internal gas pressure was stable over a range of operating power levels, and the amount of cathodic water was exactly the right amount at any power level. The possible net gains from water recycling are an approximate 2× reduction in system volume and weight, reduced cost and complexity, and greater safety, due to the elimination of liquid water that must be loaded. Better hydration of the PEM is also achieved due to the humidity of the air over the cathodes. 
     While the present invention has been particularly shown and described with reference to preferred embodiments, it will be readily appreciated by those of ordinary skill in the art that various changes and modifications may be made without departing from the spirit and scope of the invention. It is intended that the claims be interpreted to cover the disclosed embodiment, those alternatives which have been discussed above and all equivalents thereto.