Thermal enclosure

1. An enclosure for a fuel cell-based power generator comprising:

a first partial enclosure comprising:

a first set of plates comprising:

a first plate; and

a second plate formed to nest adjacent the first plate with a gap between the first and second plates;

a first porous material arranged in the gap between the first and second plates; and

a first sealing layer and a second sealing layer, wherein the first sealing layer and the second sealing layer are disposed between the first and second plates such that the first porous material is sealed from ambient at a pressure less than ambient, and wherein the first sealing layer and the second sealing layer are each separate from the first porous material;

wherein the first and second plates comprise a substantially planar portion and sides, and wherein the sealing layer is arranged between sides of the first and second plates;

a second partial enclosure comprising:

a second set of plates comprising:

a third plate; and

a fourth plate formed to nest adjacent the third plate with a gap between the first and second plates;

a second porous material arranged in the gap between the third and fourth plates; and

a third sealing layer and a fourth sealing layer, wherein the third sealing layer and the fourth sealing layer are disposed between the third and fourth plates such that the second porous material is sealed from ambient at a pressure less than ambient, and wherein the third sealing layer and the fourth sealing layer are each separate from the first porous material;

wherein the first set of plates comprises a first substantially planar portion, a first side extending from the first substantially planar portion, and a second side extending from the first substantially planar portion, and wherein the second set of plates comprises a second substantially planar portion, a third side extending from the second substantially planar portion, and a fourth side extending from the second substantially planar portion;

wherein the first sealing layer is disposed at the first side, the second sealing layer is disposed at the second side, the third sealing layer is disposed at the third side, and the fourth sealing layer is disposed at the fourth side, and

wherein the first and second enclosures are separated from one another at the first and second sides, with one of the first and second sides allowing at least oxygen from ambient to reach a fuel cell-based power generator therein.

2. The enclosure for a fuel cell-based power generator of claim 1 wherein the porous material is a nano-porous material comprising an open cell material.

3. The enclosure for a fuel cell-based power generator of claim 1 wherein the porous material is a nano-porous material comprising a low-density mixture of fumed silica, fiberglass, and silicon carbide.

4. The enclosure for a fuel cell-based power generator of claim 1 wherein the porous material comprises a getter material.

5. The enclosure for a fuel cell-based power generator of claim 1 wherein the pressure is between approximately 0 and 1000 Pa (Pascal-Newtons/Meter 2 ).

6. The enclosure of claim 1 , wherein at least one of the first sealing layer, the second sealing layer, the third sealing layer, and the fourth sealing layer further comprises:

a polymer; and

a metal layer that covers the polymer.

7. The enclosure of claim 1 , wherein the first sealing layer comprises:

a polymer; and

a metal layer that covers, and is in contact with, the polymer, wherein the metal layer is limited to a location at the first side between the first plate and the second plate.

8. A method of forming an interior pocket of ambient environment enclosure for a fuel cell-based power generator, the method comprising:

forming a first partial enclosure by:

pressing a first porous material between a first set of plates comprising a first plate and a second plate such that the first plate and the second plate are separated from each other by a gap defined by the porous material, wherein the first set of plates comprise comprises a first substantially planar portion, a first side extending from the first substantially planar portion, and a second side extending from the first substantially planar portion;

forming a second partial enclosure by:

pressing a porous material between a second set of plates comprising a third plate and a fourth plate such that the-third plate and the fourth plate are separated from each other by a gap defined by the porous material, wherein the second set of plates comprises a second substantially planar portion, a third side extending from the second substantially planar portion, and a fourth side extending from the second substantially planar portion; and

in a partial vacuum,

depositing a first conformal sealing layer on a surface of the porous material in the gap to form a first gas seal between the first and second plates at the first side,

depositing a second conformal sealing layer on a surface of the porous material in the gap to form a second gas seal between the first and second plates at the second side;

depositing a third conformal sealing layer on a surface of the porous material in the gap to form a third gas seal between the third and fourth plates at the third side; and

depositing a fourth conformal sealing layer on a surface of the porous material in the gap to form a fourth gas seal between the third and fourth plates at the fourth side;

physically separating the first and second partial enclosures from one another to form an interior pocket of ambient environment;

pocket; and

placing a fuel cell-based power generator within the pocket such that the fuel cell-based power generator is partially thermally insulated from ambient; and,

wherein the first and second enclosures are separated from each other to allow at least oxygen from ambient to reach the fuel cell-based power generator.

9. The method of forming an interior pocket of ambient environment enclosure for a fuel cell-based power generator of claim 8 , wherein the first and second partial enclosures are completely physically separated from one another.

10. The method of forming an interior pocket of ambient environment enclosure for a fuel cell-based power generator of claim 9 , wherein based on dimensions of the first set of plates and the second set of plates, the fuel cell-based power generator is positioned between i) the first and second sides and ii) the third and fourth sides.

11. The method of forming an interior pocket of ambient environment enclosure for a fuel cell-based power generator of claim 8 , wherein at least one of the first conformal sealing layer, the second conformal sealing layer, the third conformal sealing layer, and the fourth conformal sealing layer further comprises:

a polymer; and

a metal layer that covers the polymer.