Metal hydride fuel storage and method thereof

1. An apparatus comprising: a first substrate having (1) a cavity, (2) one or more resistive heaters, and (3) one or more coatings forming a diffusion barrier to hydrogen; a second substrate having (1) an outlet valve comprising a pressure relief structure and (2) one or more coatings forming a diffusion barrier to hydrogen, wherein said second substrate is coupled to said first substrate forming a sealed volume in said cavity; a metal hydride material contained within said cavity; and a gas distribution system formed by coupling a microfluidic interconnect to said pressure relief structure.

2. The apparatus recited in claim 1 , wherein said first substrate comprises at least one of silicon, glass, plastic and ceramic.

3. The apparatus recited in claim 1 , wherein said second substrate comprises at least one of silicon, glass, plastic and ceramic.

4. The apparatus recited in claim 1 , wherein said cavity has enough strength to withstand 20-50 psi pressure as the hydride is heated.

5. The apparatus recited in claim 1 , wherein the volume of said cavity is predetermined based on the power requirement to heat the metal hydride with said resistive heaters and outgas the hydrogen through said outlet valve.

6. The apparatus recited in claim 1 , wherein said coatings comprises silicon dioxide, polymers, metals, or mixtures thereof.

7. The apparatus recited in claim 1 , wherein the pressure relief structure comprises a hydrogen permaselective membrane, wherein said hydrogen permaselective membrane comprises a polymer and/or metal alloy material that enables selective gas permeation through the membrane as a function of temperature.

8. The apparatus recited in claim 1 , wherein the pressure relief structure comprises a porous material, wherein said porous material is selected from a group consisting of nickel, silicon, silicon dioxide, silicon nitride, aluminum, alumina, polyimide, palladium, titanium, or alloys thereof.

9. The apparatus recited in claim 1 , wherein the pressure relief structure comprises a porous material, wherein a thickness and porosity of said porous material is tailored to provide a pressure gradient such that a hydrogen flow at the outlet valve is at ambient pressure.

10. The apparatus recited in claim 1 , wherein the pressure relief structure comprises a porous material, wherein said coupling is accomplished by placing an O-ring around said porous material.

11. The apparatus recited in claim 10 , wherein said O-ring is a ceramic material.

12. The apparatus recited in claim 1 , wherein said coupling comprises a seal.

13. An apparatus comprising: a first substrate having an array of cavities containing (1) one or more resistive heaters, and (2) one or more electrically isolating, heat conducting coatings; a second substrate having (1) an array of outlets each comprising a pressure relief structure and (2) one or more electrically isolating, heat conducting coatings, wherein said second substrate is coupled to said first substrate forming a sealed volume in said array of cavities; and a metal hydride material contained in said array of cavities; and a gas distribution system formed by coupling a microfluidic interconnect to said pressure relief structure.

14. The apparatus recited in claim 13 , wherein each pressure relief structure comprises a porous material and a hydrogen permaselective membrane.

15. The apparatus recited in claim 13 , wherein at least one of the substrates comprises at least one of silicon, glass, plastic and ceramic.

16. The apparatus recited in claim 13 , wherein said cavity has enough strength to withstand 20-50 psi pressure as the hydride is heated.

17. The apparatus recited in claim 13 , wherein said coatings comprise silicon dioxide, polymers, metals, or mixtures thereof.

18. The apparatus recited in claim 13 , wherein the pressure relief structure comprises a hydrogen permaselective membrane, wherein said hydrogen permaselective membrane comprises a polymer and/or metal alloy material that enables selective gas permeation through the membrane as a function of temperature.

19. The apparatus recited in claim 13 , wherein the pressure relief structure comprises a porous material, wherein said porous material is selected from a group consisting of nickel, silicon, silicon dioxide, silicon nitride, aluminum, alumina, polyimide, palladium, titanium, or alloys thereof.

20. The apparatus recited in claim 13 , wherein the pressure relief structure comprises a porous material, wherein a thickness and porosity of said porous material is tailored to provide a pressure gradient such that a hydrogen flow at the outlet valve is at ambient pressure.

21. The apparatus recited in claim 13 , wherein the pressure relief structure comprises a porous material, wherein said coupling is accomplished by placing an O-ring around said porous material.

22. An apparatus comprising: a first substrate having an array of cavities containing (1) one or more resistive heaters, and (2) one or more coatings forming a diffusion barrier to hydrogen; a second substrate having (1) an array of outlets each comprising a pressure relief structure and (2) one or more coatings forming a diffusion barrier to hydrogen, wherein said second substrate is coupled to said first substrate forming a sealed volume in said array of cavities; and a metal hydride material contained in said array of cavities; and a gas distribution system formed by coupling a microfluidic interconnect to said pressure relief structure.

23. A method comprising:

forming a first substrate having a cavity;

positioning one or more resistive heaters in said cavity;

coating said cavity and said resistive heaters with one or more materials that are capable of (1) electrically isolating said one or more resistive heaters and (2) conducting heat; and

adding a metal hydride material to said cavity.

24. The method recited in claim 23 , further comprising bonding a cap to the first substrate for sealing said cavity.