Method of fabricating a reaction chamber for a fuel storage assembly

Abstract

A method for manufacturing a reaction chamber comprising a fuel insert and an elastic enclosure with a body and an opening, the method including the steps of stretching the body of the elastic enclosure to define a working lumen, orienting the metal hydride insert within the working lumen, and restituting the elastic enclosure over the insert.

1 . A method for manufacturing a reaction chamber, the reaction chamber having a fuel insert and an elastic enclosure, the elastic enclosure having a body and an opening portion that defines an opening in the elastic enclosure, the method comprising the steps of:
 a) stretching the body of the elastic enclosure to define a working lumen;   b) orienting the fuel insert within the working lumen; and   c) restituting the elastic enclosure over the insert.   
     
     
         2 . The method of  claim 1 , wherein step (a) further includes the steps of:
 placing the body of the elastic enclosure within a vacuum tube, wherein the opening of the elastic enclosure is disposed outside the vacuum tube;   securing the elastic enclosure opening portion to the vacuum tube opening, thereby sealing the vacuum tube opening; and   defining a working lumen in the elastic enclosure by pulling a suction within the vacuum tube to expand the elastic enclosure body.   
     
     
         3 . The method of  claim 2 , wherein step (a) further includes the step of sealing the elastic enclosure to leave one opening. 
     
     
         4 . The method of  claim 3 , wherein the elastic enclosure is a tube, and the end opposing the opening is sealed. 
     
     
         5 . The method of  claim 2 , wherein step (c) includes the step of releasing the suction within the vacuum tube. 
     
     
         6 . The method of  claim 2 , wherein the step of securing the elastic enclosure opening portion to the vacuum tube opening includes disposing the elastic enclosure opening portion in a fold over the vacuum tube opening, such that the body of the elastic enclosure is encapsulated within the vacuum tube lumen and the elastic enclosure opening portion is disposed outside the vacuum tube. 
     
     
         7 . The method of  claim 6 , wherein disposing the elastic enclosure opening portion in a fold over the vacuum tube opening comprises the steps of:
 folding the elastic enclosure opening portion over a stretching apparatus;   stretching the elastic enclosure opening portion radially to a diameter larger than the vacuum tube diameter;   sliding the vacuum tube into the fold between the elastic enclosure opening portion and the elastic enclosure body; and   transferring the folded elastic enclosure to the vacuum tube.   
     
     
         8 . The method of  claim 6 , wherein the elastic enclosure opening portion has substantially the same diameter as the body. 
     
     
         9 . The method of  claim 6 , wherein the elastic enclosure is stretched prior to disposing the elastic enclosure opening portion in a fold over the vacuum tube opening. 
     
     
         10 . The method of  claim 6 , wherein the elastic enclosure opening portion is flared outward from the body. 
     
     
         11 . The method of  claim 10 , wherein a portion of the flared opening has a diameter larger than the vacuum tube diameter. 
     
     
         12 . The method of  claim 10 , wherein the method further includes the step of flaring the elastic enclosure opening portion, which includes the steps of:
 placing a portion of the elastic enclosure body within the vacuum tube lumen while leaving a second portion of the elastic enclosure outside the vacuum tube, wherein the second portion is proximal to the elastic enclosure opening portion;   coupling the elastic enclosure opening to a pressure source; and   pressurizing the elastic enclosure such that a section of the second portion is flared to a diameter larger than the vacuum tube diameter.   
     
     
         13 . The method of  claim 12 , wherein the step of disposing the elastic enclosure opening portion in a fold over the vacuum tube opening includes the step of pushing the flared portion of the elastic enclosure over the exterior of the vacuum tube. 
     
     
         14 . The method of  claim 2 , wherein step (a) further includes the step of lubricating the vacuum tube. 
     
     
         15 . The method of  claim 1 , wherein step (b) further includes the steps of:
 positioning the fuel insert relative to the working lumen opening; and   inserting a portion of the fuel insert into the working lumen.   
     
     
         16 . The method of  claim 15 , wherein the step of positioning the fuel insert includes using a guide. 
     
     
         17 . The method of  claim 16 , wherein the fuel insert includes multiple pieces, and the guide retains the relative positions of the multiple pieces. 
     
     
         18 . The method of  claim 15 , wherein the fuel insert is fully inserted into the working lumen. 
     
     
         19 . The method of  claim 15 , wherein the step of inserting a portion of the fuel insert into the working lumen includes the step of inverting the working lumen over the fuel insert. 
     
     
         20 . The method of  claim 1 , wherein step (c) includes the step of maintaining the fuel insert position within the working lumen. 
     
     
         21 . The method of  claim 1 , further comprising the step of inserting a liquid delivery mechanism between the fuel insert and the elastic enclosure. 
     
     
         22 . The method of  claim 21 , wherein the step of inserting a liquid delivery mechanism occurs before the step of restituting the elastic enclosure over the fuel insert, wherein the step of inserting a liquid delivery mechanism includes the steps of:
 positioning the liquid delivery mechanism within the working lumen; and   maintaining the liquid delivery mechanism position during restitution.   
     
     
         23 . The method of  claim 21 , wherein the step of inserting a nozzle occurs after the step of restituting the elastic enclosure over the insert, wherein the step of inserting a liquid delivery mechanism includes the steps of:
 stretching a portion of the elastic enclosure away from the insert;   positioning the liquid delivery mechanism between the insert and the elastic enclosure; and   releasing the portion of the elastic enclosure.   
     
     
         24 . The method of  claim 1 , further comprising the step of trimming the excess restituted elastic enclosure from the reaction chamber. 
     
     
         25 . The method of  claim 1 , wherein steps (a), (b) and (c) are repeated for a second elastic enclosure, wherein the fuel insert is encapsulated in a first elastic enclosure. 
     
     
         26 . A method for manufacturing a reaction chamber, the reaction chamber comprising a metal hydride insert and an elastic enclosure, the elastic enclosure including a body and an opening portion that defines an opening in the elastic enclosure, the method comprising:
 placing the body of the elastic enclosure within a vacuum tube, wherein the opening portion of the elastic enclosure is disposed outside the vacuum tube;   securing the elastic enclosure opening portion to the vacuum tube opening, thereby sealing the vacuum tube opening;   defining a working lumen in the elastic enclosure by reducing air pressure within the vacuum tube to expand the elastic enclosure body;   maintaining constant vacuum tube pressure when the elastic enclosure is stretched to a desired working lumen size;   orienting the metal hydride insert within the working lumen;   maintaining the insert orientation; and   allowing pressure increase within the vacuum tube to allow restitution of the elastic enclosure about the insert.   
     
     
         27 . The method of  claim 26 , further comprising the step of inserting a liquid delivery mechanism between the insert and the elastic enclosure. 
     
     
         28 . The method of  claim 26 , wherein the step of securing the elastic enclosure opening to the vacuum tube opening includes disposing the elastic enclosure opening in a fold over the vacuum tube opening edge, such that the body of the elastic enclosure is enclosed within the vacuum tube lumen and the elastic enclosure opening is disposed on the vacuum tube exterior. 
     
     
         29 . The method of  claim 28 , wherein the step of disposing the elastic enclosure opening in a fold over the vacuum tube opening includes the steps of:
 folding the elastic enclosure opening portion over a stretching apparatus;   stretching the elastic enclosure opening portion radially to a diameter larger than the vacuum tube opening diameter;   sliding the vacuum tube into the fold between the elastic enclosure opening portion and the elastic enclosure body; and   transferring the folded elastic enclosure to the vacuum tube.   
     
     
         30 . The method of  claim 28 , wherein the elastic enclosure opening portion is flared outward from the body, and the step of disposing the elastic enclosure opening in a fold over the vacuum tube opening includes the step of stretching the flared opening over the vacuum tube opening. 
     
     
         31 . The method of  claim 30 , further comprising the step of flaring the opening, which includes the steps of:
 placing a portion of the elastic enclosure body within the vacuum tube lumen while leaving a second portion of the elastic enclosure outside the vacuum tube, wherein the second portion includes the elastic enclosure opening portion;   coupling the elastic enclosure opening to a pressure source; and   pressurizing the elastic enclosure such that the second portion of the elastic enclosure is flared to a diameter larger than the vacuum tube diameter;   
       wherein the step of disposing the elastic enclosure opening in a fold over the vacuum tube opening includes the step of pushing the flared portion of the elastic enclosure over the exterior of the vacuum tube.