Gas-Loading and Packaging Method and Apparatus

Abstract

A gas-loading and packaging system is provided for loading a solid material used in a hydrogen fuel cell with gas and packaging the solid material in a sealed container. The gas may comprise a hydrogen gas or other gas. The solid material may, for example, comprise palladium, a nickel alloy, platinum, or other metal. The solid material is loaded with gas by exposing the solid material to the gas under high pressure. When the solid material is exposed to gas under pressure, the gas absorbs into or adsorbs onto the solid material. The mass of the solid material is continuously monitored and used to determine when the solid material is loaded with the desired amount of gas. After the solid material is loaded with gas, high pressure is maintained while the solid material is packaged in a sealed container that is capable of retaining the high pressure gas.

What is claimed is: 
     
         1 . A gas-loading and packaging apparatus comprising:
 a process chamber configured to receive a solid material to be loaded with hydrogen gas;   a scale disposed inside the process chamber for measuring a mass of the solid material while the solid material is loaded with the hydrogen gas;   a packaging chamber connected by a first passageway to the process chamber and configured to receive the solid material from the process chamber through said first passageway;   a gas supply system including a gas source for supplying hydrogen gas under pressure to the process chamber and the packaging chamber, said gas supply system configured to:
 in a loading mode, supply hydrogen gas to the process chamber to increase the process chamber pressure to a first pressure level sufficient to effect the loading of solid material with hydrogen gas while the solid material is disposed within the process chamber; and 
 in a first transfer mode, supply hydrogen gas to the packaging chamber to increase the packaging chamber pressure to a second pressure level lower than the first pressure level to enable transfer of the solid material from the process chamber to the packaging chamber. 
   
     
     
         2 . The gas-loading and packaging apparatus of  claim 1  further comprising:
 a loading chamber connected by a second passageway to the process chamber and configured to receive the solid material prior to it being placed into the process chamber; and 
 a vacuum pump for evacuating the loading chamber prior to transfer of the solid material to the process chamber. 
 
     
     
         3 . The gas-loading and packaging apparatus of  claim 2  wherein the gas supply system is further configured to, in a second transfer mode during which the solid material is transferred via the second passageway from the loading chamber to the process chamber, increase the pressure level in the process chamber sufficient to prevent the flow of contaminants from the loading chamber into the process chamber. 
     
     
         4 . The gas-loading and packaging apparatus of  claim 3  wherein the gas supply system is further configured to, in the second transfer mode, increase the process chamber pressure to at least about 10 Torr above the loading chamber pressure. 
     
     
         5 . The gas-loading and packaging apparatus of  claim 3  wherein the gas supply system is further configured to, in the second transfer mode, increase the process chamber pressure to the range of about 10 Torr to about 50 Torr above the loading chamber pressure. 
     
     
         6 . The gas-loading and packaging apparatus of  claim 2  further comprising a linear transfer apparatus disposed in the loading chamber for transferring the solid material from the loading chamber to the process chamber. 
     
     
         7 . The gas-loading and packaging apparatus of  claim 1  wherein the first pressure level comprises a pressure level of at least about 3800 Torr. 
     
     
         8 . The gas-loading and packaging apparatus of  claim 1  wherein the first pressure level comprises a pressure level in the range of about 3800 Torr to about 7600 Torr. 
     
     
         9 . The gas-loading and packaging apparatus of  claim 1  further comprising a process control circuit configured to:
 receive mass measurements from the scale in the process chambers obtained while the solid material is being loaded with hydrogen gas; 
 calculate a change of mass of the solid material based on the measurements; and 
 determine when the solid material is loaded with a predetermined amount of hydrogen gas based on the change in mass of the solid material. 
 
     
     
         10 . The gas-loading and packaging apparatus of  claim 9  wherein, to determine when the solid material is loaded with the predetermined amount of hydrogen gas, the process control circuit is further configured to compare the change of mass of the solid material to a threshold. 
     
     
         11 . The gas-loading and packaging apparatus of  claim 9  wherein, to determine when the solid material is loaded with the predetermined amount of hydrogen gas, the process control circuit is further configured to calculate the amount of hydrogen loaded onto the solid material based on the mass change. 
     
     
         12 . The gas-loading and packaging apparatus of  claim 1  wherein second pressure level is sufficiently below the process chamber pressure to prevent the flow of contaminants from the packaging chamber into the process chamber while the solid material is being transferred into the packaging chamber. 
     
     
         13 . The gas-loading and packaging apparatus of  claim 12  wherein the second pressure level comprises a pressure level at least 10 Torr below the loading chamber pressure. 
     
     
         14 . The gas-loading and packaging apparatus of  claim 12  wherein the second pressure level comprises a pressure level in the range of about 10 Torr to about 50 Torr below the loading chamber pressure. 
     
     
         15 . The gas-loading and packaging apparatus of  claim 1  further comprising a second a linear transfer apparatus disposed in said packaging chamber for transferring the solid material loaded with hydrogen gas to the packaging chamber. 
     
     
         16 . The gas-loading and packaging apparatus of  claim 1  wherein the gas supply system is further configured to, after the solid material is transferred to the packaging chamber, increase the packaging chamber pressure to a third pressure level greater than the first pressure level; and maintain the packaging chamber pressure at or above the third pressure level in a packaging mode during which the solid material is packaged. 
     
     
         17 . The gas-loading and packaging apparatus of  claim 1  further comprising automated packaging equipment in said packaging chamber for packaging the solid material.