CA3111016A1 - Hydrogen generator - Google Patents

Abstract

A hydrogen generator including a series of plates positioned in an electrolysis chamber. The plates are configured to generate hydrogen. The chamber has a water inlet configured to receive water from a water source and a hydrogen outlet configured to allow the hydrogen to exit therefrom. The plates include a positive plate, a negative plate, and a neutral plate. Each of the plates has through-holes configured to allow the water and the hydrogen to flow therethrough. The positive and negative plates are configured to be connected to positive and negative terminals, respectively, of an electrical power source. The water inside the chamber forms an electrical connection between the positive and negative plates that splits the water into the hydrogen and oxygen.

Description

HYDROGEN GENERATOR
CROSS REFERENCE TO RELATED APPLICATION
This application claims priority to U.S. Patent Application No. 16/118,265, filed August 30, 2018, and Mexican Patent Application No. MX/a/2018/012133, filed October 4, 2018, the disclosures of which are incorporated herein by reference in their entirety.
BACKGROUND OF THE INVENTION
Field of the Invention The present invention is directed generally to devices configured to generate hydrogen gas and, more particularly, to devices that generate hydrogen gas by performing electrolysis on water.
Description of the Related Art Hydrogen is considered a clean energy source. Unfortunately, many current methods of generating hydrogen for use as a fuel source have not been cost effective. Further, many current methods of generating hydrogen are not capable of generating a sufficient amount of hydrogen at a desired rate.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S) Figure 1 is a block diagram of a system that includes a hydrogen generator.
Figure 2 is an illustration of water being split by electrolysis into hydrogen and oxygen.
Figure 3 is a perspective view of a first embodiment of the hydrogen generator connected to both a water source and a power controller.
Figure 4A is a first partially exploded perspective view of the hydrogen generator of Figure 3.

Figure 4B is a second partially exploded perspective view of the hydrogen generator of Figure 3.
Figure 5 is an enlarged side view of an upper portion of the hydrogen generator of Figure 3 omitting its ties and first and second end caps.
Figure 6 is a view of a first side of a plate of the hydrogen generator of Figure 3.
Figure 7 is a view of a first side of a first embodiment of a positive plate of the hydrogen generator of Figure 3.
Figure 8 is a view of a second side of a first embodiment of a negative plate of the hydrogen generator of Figure 3.
Figure 9 is a view of a first side of a first embodiment of a first neutral plate of the hydrogen generator of Figure 3.
Figure 10 is a view of a second side of a first embodiment of a second neutral plate of the hydrogen generator of Figure 3.
Figure 11 is a back view of a seal of the hydrogen generator of Figure 3.
Figure 12 is a view of a first side of a second embodiment of the positive plate of the hydrogen generator of Figure 3.
Figure 13 is a view of a second side of a second embodiment of the negative plate of the hydrogen generator of Figure 3.
Figure 14 is a view of a first side of a second embodiment of the first neutral plate of the hydrogen generator of Figure 3.
Figure 15 is a view of a second side of a second embodiment of the second neutral plate of the hydrogen generator of Figure 3.
Figure 16 is a perspective view of a second embodiment of the hydrogen generator configured to low-density applications.
Figure 17 is a view of a first side of a positive plate of the hydrogen generator of Figure 16.
Figure 18 is a view of a second side of a negative plate of the hydrogen generator of Figure 16.
Figure 19 is a view of a first side of a first neutral plate of the hydrogen generator of Figure 16.

2 Figure 20 is a view of a second side of a second neutral plate of the hydrogen generator of Figure 16.
Figure 21 is a front view of a seal of the hydrogen generator of Figure 16.
Figure 22 is a front view of a membrane of the hydrogen generator of Figure 16.
Figure 23 is a top view of a slice taken through the hydrogen generator of Figure 16.
Figure 24 is a top view of the slice of Figure 23 illustrated with its first gas chamber shaded.
Figure 25 is a circuit diagram of the power controller configured for use with the hydrogen generators of Figures 3 and 16.
Like reference numerals have been used in the figures to identify like components.
DETAILED DESCRIPTION OF THE INVENTION
Figure 1 is a block diagram of a system 100 that includes a hydrogen generator 106. The hydrogen generator 106 is connected to an electrical power controller 108 by electrical conductors 110 (e.g., wires).
The power controller 108 may be configured to deliver direct current ("DC") to the hydrogen generator 106. As shown in Figure 3, the power controller 108 has a positive terminal T+ and a negative terminal T-. The power controller 108 is configured to determine a voltage of the current delivered to the hydrogen generator 106. Thus, the power controller 108 is configured to deliver current having an adjustable voltage. The power controller 108 is connected to or includes a power source 109 that may be implemented as a battery or a power converter configured to receive alternating current ("AC") from an AC source (e.g., a conventional wall socket) and convert the AC to DC.
The hydrogen generator 106 is connected to a water source 112 (e.g., a water tank) by one or more water lines 114. The hydrogen generator 106 is configured to receive water 116 from the water source 112.
Referring to Figure 2, the hydrogen generator 106 uses electrolysis to split water molecules (H20) 117 (in the water 116) into hydrogen (H) atoms 118 and

3 oxygen (0) atoms 119. Next, two of the hydrogen atoms 118 combine to form hydrogen gas (H2) 120, and two of the oxygen (0) atoms 119 combine to form oxygen gas (02) 121.
Referring to Figure 1, the water 116 may include a catalyst 122, such as potassium hydroxide (KOH). By way of a non-limiting example, the water source 112 may be configured to hold about 5 liters of water. About 600 grams of the catalyst 122 (e.g., KOH) may be added to the 5 liters of water.
In other words, about 120 grams of the catalyst 122 may be added per liter of water.
The hydrogen gas 120 (see Figure 2) produced by the hydrogen generator 106 may be conducted (e.g., by one or more hydrogen gas lines 128) to a hydrogen reservoir 130. In some embodiments, the water source 112 may also function as the hydrogen reservoir 130. The hydrogen gas 120 (see Figure 2) may be conducted (e.g., by one or more gas lines 136) from the hydrogen reservoir 130 to an optional gas control system 132 that is configured to transfer the hydrogen gas 120 to a hydrogen consuming process and/or device 134. If the optional gas control system 132 has been omitted, the gas line(s) 136 may conduct the hydrogen gas 120 (see Figure 2) directly to the hydrogen consuming process and/or device 134. Alternatively, the hydrogen gas 120 (see Figure 2) may remain in the hydrogen reservoir 130 for later use.
The oxygen gas 121 (see Figure 2) produced by the hydrogen generator 106 may be conducted (e.g., by the hydrogen gas line(s) 128 and/or one or more oxygen gas lines 124) to an oxygen reservoir 126. In some embodiments, the hydrogen reservoir 130 and/or the water source 112 may function as the oxygen reservoir 126. The oxygen gas 121 (see Figure 2) may be conducted (e.g., by one or more oxygen gas lines 138) from the oxygen reservoir 126 to the optional gas control system 132 or the hydrogen consuming process and/or device 134. Alternatively, the oxygen gas 121 (see Figure 2) may be vented into the surrounding environment instead of being conducted to the oxygen reservoir 126. By way of yet another non-limiting example, the oxygen gas 121 (see Figure 2) may remain in the oxygen reservoir 126 for later use.

4 The hydrogen generator 106 includes one or more cells 140. In the example illustrated, the hydrogen generator 106 includes cells 140A
and 140B, which are substantially identical to one another. However, the hydrogen generator 106 may include any number of cells each like the cells 140A and 140B. For example, Figure 3 illustrates an implementation in which the hydrogen generator 106 includes only the cell 140A. When the hydrogen generator 106 includes more than one cell, such as the cells 140A
and 140B, the electrical conductors 110 may connect the power controller 108 to the cells in series. The water source 112 may be connected to the cells in parallel.
In the embodiment illustrated in Figure 3, the water source 112 functions as both the hydrogen reservoir 130 and the oxygen reservoir 126.
Thus, the hydrogen gas line(s) 128 connect the hydrogen generator 106 to the water source 112 and conduct both the hydrogen gas 120 (see Figure 2) and the oxygen gas 121 (see Figure 2) into the water source 112. Then, the gas line(s) 136 conduct both the hydrogen gas 120 (see Figure 2) and the oxygen gas 121 (see Figure 2) from the water source 112 to the optional gas control system 132 (see Figure 1) or the hydrogen consuming process and/or device 134 (see Figure 1). In the embodiment illustrated in Figure 3, the cell 140A includes a plurality of plates 142, a plurality of seals 144 (see Figures 4A, 5, and 11), a first end cap 146, a second end cap 148, a plurality of ties 152, and an optional plurality of fasteners 154 (e.g., nuts).
Referring to Figure 6, each of the plates 142 has a generally rectangular outer shape 158 surrounding a body portion 160. The generally rectangular outer shape 158 has a length L1 (e.g., about 10 cm) and a height H1 (e.g., about 15 cm). The generally rectangular outer shape 158 has four corners C1-C4 and four edges E1-E4. The corners C2-C4 are each notched or cutout to define cutouts 161B-161D. The cutouts 161B-161D may each have a quarter-circle shape centered at the corners C2-C4, respectively. By way of a non-limiting example, when the cutouts 161B-161D have a quarter-circle shape, they may each have a radius of about 1.0 cm. In the embodiment illustrated, each of the plates 142 is generally planar.

5 In the embodiment illustrated, the edges El and E3 are shorter than the sides E2 and E4. The edges El -E4 each have cutouts formed therein.
The shorter edges El and E3 each have two cutouts 162A and 162B, and the longer edges E2 and E4 each have three cutouts 163A-163C. Each of the cutouts 162A-163C may have a semicircular shape centered on the edge in which the cutout is formed. By way of a non-limiting example, each of the cutouts 162A-163C may have a radius of about 0.5 cm.
The following are exemplary minimum distances defining positions of the cutouts 162A and 162B formed in each of the edges El and E3.
A minimum distance between the cutout 162A and the cutout 162B may be about 3 cm. A minimum distance between the cutout 162A formed in the edge El and the corner C2 may be about 2.5 cm. Similarly, a minimum distance between the cutout 162A formed in the edge E3 and the corner C3 may be about 2.5 cm. A minimum distance between the cutout 162B formed in the edge El and the corner Cl may be about 2.5 cm. Similarly, a minimum distance between the cutout 162B formed in the edge E3 and the corner C4 may be about 2.5 cm.
The following are exemplary minimum distances defining positions of the cutouts 163A-163C formed in each of the edges E2 and E4. A
minimum distance between the cutout 163A and the cutout 163B may be about 3 cm. A minimum distance between the cutout 163B and the cutout 163C may be about 3.2 cm. A minimum distance between the cutout 163A formed in the edge E2 and the corner C2 may be about 3 cm. Similarly, a minimum distance between the cutout 163A formed in the edge E4 and the corner Cl may be about 3 cm. A minimum distance between the cutout 163C formed in the edge E2 and the corner C3 may be about 2.8 cm. Similarly, a minimum distance between the cutout 163C formed in the edge E4 and the corner C4 may be about 2.8 cm.
The body portion 160 includes a plurality of through-holes 170. A
first embodiment of the plates 142 is illustrated in Figures 3-10. Referring to Figure 6, in the first embodiments, the through-holes 170 include five through-holes 171-175. By way of a non-limiting example, each of the through-holes 171-175 may have a circular shape with a radius of about

6

7 PCT/IB2019/057170 0.5 cm. The through-holes 171-174 are arranged linearly in a series that is substantially parallel with the edges El and E3. The through-holes 171-174 are positioned nearer the edge E3 than the edge El. The through-holes 171 and 172 are spaced apart by a minimum distance of about 0.8 cm. The through-holes 172 and 173 are spaced apart by a minimum distance of about 0.8 cm. The through-holes 173 and 174 are spaced apart by a minimum distance of about 0.8 cm. The through-holes 171-174 are spaced apart by a minimum distance of about 1.6 cm from the edge E3. The through-hole 171 is spaced apart by a minimum distance of about 2.0 cm from the edge E2. The through-hole 174 is spaced apart by a minimum distance of about 1.6 cm from the edge E4. The through-hole 175 is positioned nearer the edge El than the edge E3. In the embodiment illustrated, the through-hole 175 is spaced apart by a minimum distance of about 2.2 cm from each of the edges El and E4.
The body portion 160 may have an optional through-hole 178 positioned closer to the corner Cl than the through-hole 175. By way of a non-limiting example, the through-hole 178 may have a circular shape with a radius of about 0.2 cm. The through-hole 178 may be spaced apart by a minimum distance of about 0.3 cm from each of the edges El and E4.
While exemplary dimensions are provided above, through application of ordinary skill in the art to the present teachings, the plates may be sized or scaled appropriately for a desired application. For example, smaller plates may be used if less hydrogen is desired. Similarly, larger plates or multiple cells may be used if more hydrogen is desired. Each of the plates 142 is constructed from a substantially electrically conductive material.
By way of a non-limiting example, each of the plates 142 may be constructed from stainless steel and the like.
Referring to Figure 5, the plates 142 are substantially parallel with one another and arranged in a series. The plates 142 include one or more positive plates 101 (see Figure 7), one or more negative plates 102 (see Figure 8), and one or more neutral plates positioned in between each adjacent pair of positive and negative plates. For example, the neutral plate(s) may include a first neutral plate 103 (see Figure 9) and a second neutral plate 104 (see Figure 10), which may alternate inside the cell 140A

(see Figures 1 and 3-46). Referring to Figure 7, the oxygen atoms 119 (see Figure 2) collect along each of the positive plate(s) 101 and a first side 180 or a second side 182 (see Figures 5, 8, 10, 13, 15, 18, and 20) of any of the first and second neutral plates 103 (see Figure 9) and 104 (see Figure 10) facing the positive plate 101. Referring to Figure 8, the hydrogen atoms 118 (see Figure 2) collect along each of the negative plate(s) 102 and the first side 180 (see Figures 5-7, 9, 12, 14, 17, and 19) or the second side 182 of any of the first and second neutral plates 103 (see Figure 9) and 104 (see Figure 10) facing the negative plate 102.
Referring to Figure 5, in the embodiment illustrated, the plates 142 include two positive plates 142-PA and 142-PB (each like the positive plate 101 illustrated in Figure 7), two negative plates 142-NA
and 142-NB (each like the negative plate 102 illustrated in Figure 8), six first neutral plates 142-N1, 142-N3, 142-N5, 142-N7, 142-N9, and 142-N11 (each like the first neutral plate 103 illustrated in Figure 9), and six second neutral plates 142-N2, 142-N4, 142-N6, 142-N8, 142-N10, and 142-N12 (each like the second neutral plate 104 illustrated in Figure 10). Inside the cell 140A (see Figures 1 and 3-46), the plates 142 may be arranged in the following predetermined order from the first end cap 146 (see Figures 3-46, 16, 23, and 24) to the second end cap 148 (see Figures 3-46, 16, 23, and 24):
positive plate 142-PA, first neutral plate 142-N1, second neutral plate 142-N2, first neutral plate 142-N3, second neutral plate 142-N4, negative plate 142-NA, first neutral plate 142-N5, second neutral plate 142-N6, first neutral plate 142-N7, second neutral plate 142-N8, positive plate 142-PB, first neutral plate 142-N9, second neutral plate 142-N10, first neutral plate 142-N11, second neutral plate 142-N12, and negative plate 142-NB.
A pattern may be formed (e.g., etched, scratched, laser cut, embossed, printed, etc.) on the first and/or second sides 180 and 182 of each of the plates 142. The patterns may be configured to help direct water flow and/or gas flow through the cell 140A (see Figures 1 and 3-46). The patterns may be configured to generate a desired volume of hydrogen gas at a desired rate. The patterns may help induce a desired current flow in the water 116 (see Figures 1-3). The patterns may help direct the hydrogen and oxygen

8 gases 120 and 121 (see Figure 2) through the through-holes 171-175 (see Figures 6-10) and toward the second end cap 148 (see Figures 3-4B, 16, 23, and 24).
As mentioned above, each of the positive plates 142-PA
and 142-PB (see Figures 4A and 5) may be implemented as the positive plate 101 (see Figure 7). Referring to Figure 7, the positive plate 101 includes a positive pattern 190 formed on its first side 180. As illustrated in Figure 7, the positive plate 101 is oriented with its corner Cl positioned in an upper left position when the first side 180 is facing forwardly (or toward the first end cap 146 illustrated in Figures 3-4B, 16, 23, and 24). The positive pattern 190 includes four lines 191-194 that extend from the through-holes 171-174, respectively, to the through-hole 175. In the embodiment illustrated, the lines 191-194 intersect at a point on the edge of the through-hole 175. The lines 191-194 induce flow toward the through-hole 175 in a first flow direction identified by an arrow Al. Each of the lines 191-194 may be formed as a continuous line or by a plurality of through-holes arranged in a series to define the line. The plurality of through-holes may each have a diameter of about 1 millimeter ("mm") to about 2 mm.
As mentioned above, each of the negative plates 142-NA
and 142-NB (see Figures 4A and 5) may be implemented as the negative plate 102 (see Figure 8). Referring to Figure 8, the negative plate 102 includes a negative pattern 200 formed on its second side 182. As illustrated in Figure 8, the negative plate 102 is oriented with its corner Cl positioned in an upper right position when the second side 182 is facing forwardly (or toward the first end cap 146 illustrated in Figures 3-4B, 16, 23, and 24). The negative pattern 200 includes four lines 201-204 that extend from the through-holes 171-174, respectively, to the through-hole 175. In the embodiment illustrated, the lines 201-204 intersect at a point on the edge of the through-hole 175.
The lines 201-204 induce flow toward the through-hole 175 in a second flow direction identified by an arrow A2. Each of the lines 201-204 may be formed as a continuous line or by a plurality of through-holes arranged in a series to define the line. The plurality of through-holes may each have a diameter of about 1 mm to about 2 mm. When the plurality of through-holes are used to

9 define the lines 191-194 (see Figure 7) on the first side 180, the plurality of through-holes also define the lines 201-204 on the second side 182. Thus, the positive plate 101 (see Figure 7) and the negative plate 102 may simply be mirror images of one another.
As mentioned above, each of the first neutral plates 142-N1, 142-N3, 142-N5, 142-N7, 142-N9, and 142-N11 may be implemented as the first neutral plate 103 (see Figure 9). Referring to Figure 9, the first neutral plate 103 includes a first neutral pattern 210 formed on its first side 180.
The first neutral plate 103 is oriented with its corner Cl positioned in a lower right position when the first side 180 is facing forwardly (or toward the first end cap 146 illustrated in Figures 3-4B, 16, 23, and 24). The first neutral pattern 210 includes six lines 211-216. The lines 213-216 extend outwardly from a first intersection point 217. By way of non-limiting examples, the first intersection point 217 may be positioned about 2.0 cm above the edge El and about 4.8 cm away from the edge E4. The lines 215 and 216 extend outwardly from the first intersection point 217 and form a V-shape. The line 216 extends from the first intersection point 217 to the through-hole 175. The line 216 may extend through the through-hole 175 and to the edge E4 or may terminate between the through-hole 175 and the edge E4. The lines 213 and 214 extend from the first intersection point 217 to the through-holes 173 and 174, respectively. The line 215 extends from the first intersection point 217 to a termination point 218. By way of non-limiting examples, the termination point 218 may be positioned about 4.5 cm above the edge El and about 1.5 cm away from the edge E2. The lines 211 and 212 extend from the line 215 to the through-holes 171 and 172, respectively. The lines 211 and 212 may each be substantially parallel to the edges E2 and E4. The lines 211-216 induce an upward flow toward the through-holes 171-174 in a third flow direction identified by an arrow A3. The third flow direction may be substantially parallel to the edges E2 and E4. Each of the lines 211-216 may be formed as a continuous line or by a plurality of through-holes arranged in a series to define the line.
The plurality of through-holes may each have a diameter of about 1 mm to about 2 mm.

As mentioned above, each of the second neutral plates 142-N2, 142-N4, 142-N6, 142-N8, 142-N10, and 142-N12 may be implemented as the second neutral plate 104 (see Figure 10). Referring to Figure 10, the second neutral plate 104 includes a second neutral pattern 220 formed on its second side 182. The second neutral plate 104 is oriented with its corner Cl positioned in a lower left position when the second side 182 is facing forwardly (or toward the first end cap 146 illustrated in Figures 3-4B, 16, 23, and 24). The second neutral pattern 220 includes six lines 221-226. The lines 223, 225, and 226 extend outwardly from a second intersection point 227. By way of non-limiting examples, the second intersection point 227 may be positioned about 2.0 cm above the edge El and about 4.8 cm away from the edge E4. The lines 225 and 226 extend outwardly from the second intersection point 227 and form a V-shape. The line 226 extends from the second intersection point 227 to the through-hole 175. The line 226 may extend through the through-hole 175 and to the edge E4 or may terminate between the through-hole 175 and the edge E4. The line 223 extends from the second intersection point 227 to the through-hole 173. The line 225 extends from the second intersection point 227 to the edge E2. The lines 221 and 222 extend from the line 225 to the through-holes 171 and 172, respectively. The lines 221 and 222 may each be substantially parallel to the edges E2 and E4. The line 224 extends from the line 226 to the through-holes 174. The line 224 intersects the line 226 at a location between the second intersection point 227 and the through-hole 175.
The lines 221-226 induce an upward flow toward the through-holes 171-174 in a fourth flow direction identified by an arrow A4. The fourth flow direction may be substantially parallel to the edges E2 and E4. Each of the lines 221-226 may be formed as a continuous line or by a plurality of through-holes arranged in a series to define the line. The plurality of through-holes may each have a diameter of about 1 mm to about 2 mm. When the plurality of through-holes are used to define the lines 211-216 (see Figure 7) on the first side 180, the plurality of through-holes also define the lines 221-226 on the second side 182.
Thus, the first neutral plate 103 (see Figure 9) and the second neutral plate may simply be mirror images of one another.

A first embodiment of the seals 144 is illustrated in Figures 4A, 5, and 11. In the embodiment illustrated, each of the seals 144 is generally planar. Referring to Figure 4A, the seals 144 help define a sealed internal chamber 228 inside the cell 140A. The sealed internal chamber 228 may be characterized as being an electrolysis chamber because the plates 142 split the water (see Figures 1-3) inside the sealed internal chamber 228. Referring to Figure 11, each of the seals 144 has a peripheral portion 229 that defines an interior shape 230, which is closed along the peripheral portion 229 of the seal.
Referring to Figure 5, each of the seals 144 has a front side 231 opposite a back side 232. The interior shape 230 (see Figures 11 and 21) is open along both the front and back sides 231 and 232. Referring to Figure 4A, an interstitial space 234 is defined between each adjacent pair of plates within the series of plates 142. One of the seals 144 is positioned within each of the interstitial spaces 234. For example, one of the seals 144 is positioned in the interstitial space 234 defined between the plates 142-PA and 142-N1. The seals 144 are configured such that the through-holes 171 -1 75 (see Figures 6-10) of each of the plates 142 are positioned within the interior shape 230 (see Figures 11 and 21) of any of the seals 144 positioned alongside the plate. Thus, the interior shapes 230 (see Figures 11 and 21) of the seals 144 are interconnected inside the cell 140A by one or more of the through-holes 170 (see Figures 6-10, 12-15, and 17-20) and define the sealed internal chamber 228.
Referring to Figure 4B, an interstitial space 236 may be defined between the first end cap 146 and the positive plate 142-PA. One of the seals 144, identified with reference numeral 144A, may be positioned in the interstitial space 236. The seal 144A is positioned such that the through-holes 171-175 (see Figures 6-10) of the positive plate 142-PA are positioned within the interior shape 230 (see Figures 11 and 21) of the seal 144A. Thus, the interior shape 230 (see Figures 11 and 21) of the seal 144A may be considered to be part of the sealed internal chamber 228.
Similarly, an interstitial space 238 may be defined between the second end cap 148 and the negative plate 142-NB. One of the seals 144, identified with reference numeral 144B in Figure 5, may be positioned in the interstitial space 238. The seal 144B (see Figure 5) is positioned such that the through-holes 171-175 (see Figures 6-10) of the negative plate 142-NB are positioned within the interior shape 230 (see Figures 11 and 21) of the seal 144B. Thus, the interior shape 230 (see Figures 11 and 21) of the seal 144B (see Figure 5) may be considered to be part of the sealed internal chamber 228.
Referring to Figure 4A, the seals 144 are substantially electrically non-conductive, and electrically isolate the plates 142 from one another.
Thus, within the cell 140A, current flows between the plates 142 through the water 116 (see Figures 1-3). By way of a non-limiting example, the seals 144 may each be constructed from styrene-butadiene rubber ("SBR"), silicone, and the like.
As is apparent to those of ordinary skill in the art, the hydrogen gas 120 (see Figure 2) will collect along the negative plates 142-NA and 142-NB and the oxygen gas 121 (see Figure 2) will collect along the positive plates 142-PA and 142-PB. Referring to Figure 3, the hydrogen and oxygen gases 120 and 121 (see Figure 2) are both lighter than the water 116 and collect near the top of the sealed internal chamber 228 (see Figures 4A
and 4B). Additionally, the hydrogen gas 120 (see Figure 2) is lighter than the oxygen gas 121 (see Figure 2). Thus, the hydrogen gas 120 (see Figure 2) may collect nearer the top of the sealed internal chamber 228 (see Figures 4A
and 4B) than the oxygen gas 121 (see Figure 2). Each of the flows identified by the arrows A1-A4 in Figures 7-10, respectively, may be directed toward the near the top of the sealed internal chamber 228 (see Figures 4A and 4B).
Referring to Figure 4A, the cell 140A has at least one water inlet, such as a water inlet 240, through which the water 116 (see Figures 1-3) enters the sealed internal chamber 228 of the cell 140A. In the embodiment illustrated, the water inlet 240 is formed in the first end cap 146. Thus, the water inlet 240 is in fluid communication with the sealed internal chamber 228.
The water 116 (see Figures 1-3) flows from the water inlet 240 toward the second end cap 148. The water 116 (see Figures 1-3) flows through the through-holes 170 (see Figures 6-10, 12-15, and 17-20) in the plates 142 and into the interior shapes 230 (see Figures 11 and 21) of the seals 144 (see Figures 4A, 5, and 11) positioned between each adjacent pair of plates. The first end cap 146 includes a plurality of through-holes 242 (see Figure 4B) through which the ties 152 may extend.
The cell 140A has at least one hydrogen outlet, such as a hydrogen outlet 244, through which the hydrogen gas 120 (see Figure 2) exits the sealed internal chamber 228 of the cell 140A (e.g., and enters the hydrogen gas line(s) 128 illustrated in Figures 1 and 3). In the embodiment illustrated, the hydrogen outlet 244 is formed in second end cap 148. Thus, the hydrogen outlet 244 is in fluid communication with the sealed internal chamber 228. The hydrogen gas 120 (see Figure 2) flows from the negative plates 142-NA
and 142-NB toward the second end cap 148. Like the water 116 (see Figures 1-3), the hydrogen gas 120 (see Figure 2) flows through the through-holes 170 (see Figures 6-10, 12-15, and 17-20) in the plates 142 and into the interior shapes 230 (see Figures 11 and 21) of the seals 144 positioned .. between each adjacent pair of plates. By way of a non-limiting example, the hydrogen outlet 244 may be threaded with 1/4 National Pipe Thread Taper ("NPT") threads configured to receive a 10 mm quick connector. The oxygen gas 121 (see Figure 2) may exit through the hydrogen outlet 244 or be vented into the surrounding environment via one or more check valves (not shown) formed in the second end cap 148. The second end cap 148 includes a plurality of through-holes 246 (see Figure 4B) through which the ties 152 may extend. The first and second end caps 146 and 148 are each constructed from a substantially electrically non-conductive material. By way of a non-limiting example, the first and second end caps 146 and 148 may be constructed from plastic (e.g., nylon, acrylonitrile Butadiene Styrene ("ABS"), etc.) and the like.
Referring to Figure 3, the positive terminal T+ of the power controller 108 is connected (e.g., by one of the conductors 110) to the positive plates 142-PA and 142-PB (see Figures 4A-5). Referring to Figure 4B, in the embodiment illustrated, an optional positive conductor 250 (e.g., a bolt) is inserted through the optional through-hole 178 (see Figures 6-10, 12-15, and 17-20) of the positive plates 142-PA and 142-PB. Referring to Figure 3, the positive terminal T+ of the power controller 108 is connected (e.g., by one of the conductors 110) to the positive conductor 250. Referring to Figure 4A, the cutout 161B (see Figure 6) of the negative plates 142-NA and 142-NB prevents the positive conductor 250 from contacting the negative plates 142-NA
and 142-NB. Similarly, referring to Figure 5, the cutout 161C (see Figure 6) of the neutral plates 142-N1, 142-N3, 142-N5, 142-N7, 142-N9, and 142-N11 .. prevents the positive conductor 250 (see Figures 3-4B) from contacting the neutral plates 142-N1, 142-N3, 142-N5, 142-N7, 142-N9, and 142-N11.
Additionally, the cutout 161D (see Figure 6) of the neutral plates 142-N2, 142-N4, 142-N6, 142-N8, 142-N10, and 142-N12 prevents the positive conductor 250 (see Figures 3-4B) from contacting the neutral plates 142-N2, 142-N4, 142-N6, 142-N8, 142-N10, and 142-N12.
Referring to Figure 3, the negative terminal T- of the power controller 108 is connected to the negative plates 142-NA and 142-NB
(see Figures 4A-5). Referring to Figure 4A, in the embodiment illustrated, an optional negative conductor 252 (e.g., a bolt) is inserted through the .. through-hole 178 (see Figures 6-10, 12-15, and 17-20) of the negative plates 142-NA and 142-NB. Referring to Figure 3, the negative terminal T- of the power controller 108 is connected to the negative conductor 252 (e.g., by one of the conductors 110). Referring to Figure 4A, the cutout 161B (see Figure 6) of the positive plates 142-PA and 142-PB prevents the negative .. conductor 252 from contacting the positive plates 142-PA and 142-PB.
Similarly, referring to Figure 5, the cutout 161D (see Figure 6) of the neutral plates 142-N1, 142-N3, 142-N5, 142-N7, 142-N9, and 142-N11 prevents the negative conductor 252 from contacting the neutral plates 142-N1, 142-N3, 142-N5, 142-N7, 142-N9, and 142-N11. Additionally, the cutout 161C
(see Figure 6) of the neutral plates 142-N2, 142-N4, 142-N6, 142-N8, 142-N10, and 142-N12 prevents the negative conductor 252 from contacting the neutral plates 142-N2, 142-N4, 142-N6, 142-N8, 142-N10, and 142-N12.
Referring to Figure 4A, the water 116 (see Figures 1-3) inside the cell 140A connects the positive plates 142-PA and 142-PB and the negative plates 142-NA and 142-NB to form a circuit. Referring to Figure 3, the flow of current through the water 116 causes the water molecules 117 (see Figure 2) to split into the hydrogen atoms 118 (see Figure 2) and the oxygen atoms 119 (see Figure 2). In other words, the electrolysis performed by the cell 140A is powered by the power controller 108.
Referring to Figure 5, optionally, a first ground conductor (not shown) may be inserted through the through-hole 178 (see Figures 6-10, 12-15, and 17-20) of the first neutral plates 142-N1, 142-N3, 142-N5, 142-N7, 142-N9, and 142-N11. Similarly, a second ground conductor (not shown) may be inserted through the through-hole 178 (see Figures 6-10, 12-15, and 17-20) of the second neutral plates 142-N2, 142-N4, 142-N6, 142-N8, 142-N10, and 142-N12. The first and second ground conductors (not shown) may each be connected to ground and do not contact either the positive plates 142-PA
and 142-PB or the negative plates 142-NA and 142-NB.
Thus, the cell 140A (see Figures 1 and 3-4B) may be configured as follows:
1. the positive plate 142-PA oriented with its through-hole 178 (see Figures 6-10, 12-15, and 17-20) positioned top left and connected to the positive conductor 250 (see Figure 3-4B);
2. the neutral plates 142-N1 to 142-N4 (optionally, the first neutral plates 142-N1 and 142-N3 may be connected to the first ground conductor (not shown) and the second neutral plates 142-N2 and 142-N4 may be connected to the second ground conductor (not shown));
3. the negative plate 142-NA oriented with its through-hole 178 positioned top right and connected to the negative conductor 252;
4. the neutral plates 142-N5 to 142-N8 (optionally, the first neutral plates 142-N5 and 142-N7 may be connected to the first ground conductor (not shown) and the second neutral plates 142-N6 and 142-N8 may be connected to the second ground conductor (not shown));
5. the positive plate 142-PB oriented with its through-hole 178 positioned top left and connected to the positive conductor 250;

6. the neutral plates 142-N9 to 142-N12 (optionally, the first neutral plates 142-N9 and 142-N11 may be connected to the first ground conductor (not shown) and the second neutral plates 142-N10 and 142-N12 may be connected to the second ground conductor (not shown)); and 7. the negative plate 142-NB oriented with its through-hole 178 positioned top right and connected to the negative conductor 252.
The positive plates 142-PA and 142-PB create an electric arc with the negative plates 142-NA and 142-NB that is driven by the water 116 (see Figures 1-3). The neutral plates 142-N1 to 142-N12 create resistance between the positive plates 142-PA and 142-PB and the negative plates 142-NA
and 142-NB and increase the flow of current (e.g., measured in amperes).
Referring to Figure 4A, in the embodiment illustrated, the ties 152 (e.g., threaded rods) are configured to connect the first and second end caps 146 and 148 together with the plates 142 and seals 144 positioned therebetween. The ties 152 extend alongside and substantially perpendicular to the edges El -E4 (see Figure 6) of the plates 142. Referring to Figure 6, the cutouts 162A and 1626 on the edges El and E3 and the cutouts 163A-163C on the edges E2 and E4 are each configured to receive a portion of a different one of the ties 152 (see Figures 3-46). Referring to Figure 4A, the ties 152 may be constructed from a substantially electrically non-conductive material or may be wrapped in a substantially electrically non-conductive material 153. Thus, the ties 152 do not conduct electricity between the plates 142. The ties 152 help prevent the plates 142 from moving inside the cell 140A and help maintain their positioning inside the cell 140A. The seals 144 are each positioned inwardly of the ties 152, which do not extend through the closed interior shapes 230 (see Figures 11 and 21) of the seals 144.
The ties 152 are configured to compress the seals 144 inside the cell 140A to help ensure that the water 116 (see Figures 1-3) and/or the hydrogen gas 120 (see Figure 2) does not leak from the cell 140A. In the embodiment illustrated, the ties 152 have been implemented as threaded rods surrounded by the substantially electrically non-conductive material 153. The fasteners 154 (e.g., nuts) are threaded onto the ends of the threaded rods alongside each of the first and second end caps 146 and 148. By tightening the fasteners 154, sufficient pressure may be applied to the first and second end caps 146 and 148 to compress the seals 144 and prevent leakage.
As mentioned above, referring to Figure 1, the water 116 may include the catalyst 122 (e.g., potassium hydroxide), which reacts with the electricity and increases the flow of current (e.g., measured in amperes).
Referring to Figure 2, increasing the current splits more of the water molecules 117 into the hydrogen and oxygen atoms 118 and 119. Referring to Figure 3, by way of a non-limiting example, the cell 140A may be configured to generate about 1.3 liters per minute of hydrogen gas. Referring to Figure 1, if the hydrogen consuming process and/or device 134 requires less hydrogen, the excess hydrogen may simply be vented to the outside environment. By not storing the excess hydrogen, the system 100 avoids potential explosion risks associated with storing hydrogen.
Referring to Figure 4A, in alternate embodiments, different numbers of neutral plates may be positioned between the positive and negative plates 101 (see Figure 7) and 102 (see Figure 8) of the cell 140A. For example, the cell 140A may include fifteen neutral plates and be configured as follows:
1. a first positive plate (like the positive plate 101 illustrated in Figure 7);
2. a first neutral plate (like the first neutral plate 103 illustrated in Figure 9);
3. a second neutral plate (like the second neutral plate 104 illustrated in Figure 10);
4. a third neutral plate (like the first neutral plate 103 illustrated in Figure 9);
5. a fourth neutral plate (like the second neutral plate 104 illustrated in Figure 10);
6. a fifth neutral plate (like the first neutral plate 103 illustrated in Figure 9);

7. a first negative plate (like the negative plate 102 illustrated in Figure 8);
8. a sixth neutral plate (like the first neutral plate 103 illustrated in Figure 9);
9. a seventh neutral plate (like the second neutral plate 104 illustrated in Figure 10);

10. an eighth neutral plate (like the first neutral plate 103 illustrated in Figure 9);

11. a ninth neutral plate (like the second neutral plate 104 illustrated in Figure 10);

12. a tenth neutral plate (like the first neutral plate 103 illustrated in Figure 9);

13. a second positive plate (like the positive plate 101 illustrated in Figure 7);

14. an eleventh neutral plate (like the first neutral plate 103 illustrated in Figure 9);

15. a twelfth neutral plate (like the second neutral plate 104 illustrated in Figure 10);

16. a thirteenth neutral plate (like the first neutral plate 103 illustrated in Figure 9);

17. a fourteenth neutral plate (like the second neutral plate 104 illustrated in Figure 10);

18. a fifteenth neutral plate (like the first neutral plate 103 illustrated in Figure 9);

19. a second negative plate (like the negative plate 102 illustrated in Figure 8).
Again, the two positive plates (each like the positive plate 101 illustrated in Figure 7) create electric arcs with the two negative plates (each like the negative plate 102 illustrated in Figure 8) that is driven by the water 116 .. (see Figures 1-3). The fifteen neutral plates create resistance between the positive plates and the negative plates and increase the flow of current.

HIGH-DENSITY EMBODIMENT
Figures 12-15 illustrate second embodiments of the plates 142 (see Figures 3-6, 16, and 23) that may be used to construct a high-density version of the cell 140A (see Figures 1 and 3-46). The high-density version may be used to supply hydrogen to a flame consuming a very high number of calories (e.g., a furnace, an industrial oven, and the like). Oxygen produced by the high-density version may be combined with the hydrogen to increase the heat output of the flame.
In Figures 12-15, the through-holes 170 include only the through-holes 171 and 175. In other words, the through-holes 172-174 are omitted.
Figures 12-15 illustrate plates 301-304, respectively.
Referring to Figure 12, the positive plate 301 may be used to construct the cell 140A (see Figures 1 and 3-46) instead and in place of the positive plate 101 (see Figure 7). The positive plate 301 includes a positive pattern 310 instead of the positive pattern 190 (see Figure 7). The positive pattern 310 is formed on the first side 180 of the positive plate 301. The positive plate 301 is oriented with the corner Cl positioned in the upper left position when the first side 180 is facing forwardly (or toward the first end cap 146 illustrated in Figures 3-46, 16, 23, and 24). The positive pattern 310 includes five lines 311-315. The line 311 extends from the through-hole 171 to the through-hole 175 and the line 312 extends from the through-hole 171 to a first location near the through-hole 175. The line 315 extends outwardly from the through-hole 171 in a direction substantially parallel with the edge E3.
The line 313 extends from the line 315 to a second location near the through-hole 175 and spaced apart from the first location. The line 314 extends from the line 315 to the edge E4. The lines 311-315 are configured to induce flow toward the through-hole 175 in a fifth flow direction identified by an arrow AS.
Each of the lines 311-315 may be formed as a continuous line or by a plurality of through-holes arranged in a series to define the line. The plurality of through-holes may each have a diameter of about 1 mm to about 2 mm.
Referring to Figure 13, the negative plate 302 may be used to construct the cell 140A (see Figures 1 and 3-46) instead and in place of the negative plate 102 (see Figure 8). The negative plate 302 includes a negative pattern 320 instead of the negative pattern 200 (see Figure 8). The negative pattern 320 is formed on the second side 182 of the negative plate 302. The negative pattern 320 is oriented with the corner Cl positioned in the upper right position when the second side 182 is facing forwardly (or toward the first end cap 146 illustrated in Figures 3-4B, 16, 23, and 24). The negative pattern 320 includes five lines 321-325. The line 321 extends from the through-hole 171 to the through-hole 175 and the line 322 extends from the through-hole 171 to a first location near the through-hole 175. The line 325 extends outwardly from the through-hole 171 in a direction substantially parallel with the edge E3.
The line 323 extends from the line 325 to a second location near the through-hole 175 and spaced apart from the first location. The line 324 extends from the line 325 to the edge E4. Each of the lines 321-325 may be formed as a continuous line or by a plurality of through-holes arranged in a series to define the line. The plurality of through-holes may each have a diameter of about 1 mm to about 2 mm. The lines 321-325 are configured to induce flow toward the through-hole 175 in a sixth flow direction identified by an arrow A6. When the plurality of through-holes are used to define the lines 311-315 (see Figure 12) on the first side 180, the plurality of through-holes also define the lines on the second side 182. Thus, the positive plate 301 (see Figure 12) and the negative plate 302 may simply be mirror images of one another.
Referring to Figure 14, the first neutral plate 303 may be used to construct the cell 140A (see Figures 1 and 3-4B) instead and in place of the first neutral plate 103 (see Figure 9). The first neutral plate 303 includes a first neutral pattern 330 instead of the first neutral pattern 210 (see Figure 9).
The first neutral pattern 330 is formed on the first side 180 of the first neutral plate 303. The first neutral plate 303 is oriented with the corner Cl positioned in the lower right position when the first side 180 is facing forwardly (or toward the first end cap 146 illustrated in Figures 3-4B, 16, 23, and 24). The first neutral pattern 330 includes three lines 331-333. The line 331 extends from the through-hole 171 to the through-hole 175. The line 333 extends inwardly from the edge E4 in a direction substantially parallel with the edge El. The line terminates near the through-hole 175. The line 332 extends from the line 333 to the edge E2 or to a location near the through-hole 175. The lines 331-333 are configured to induce flow toward the through-hole 171 in a seventh flow direction identified by an arrow A7. Each of the lines 331-333 may be formed as a continuous line or by a plurality of through-holes arranged in a series to define the line. The plurality of through-holes may each have a diameter of about 1 mm to about 2 mm.
Referring to Figure 15, the second neutral plate 304 may be used to construct the cell 140A (see Figures 1 and 3-4B) instead and in place of the second neutral plate 104 (see Figure 10). The second neutral plate 304 includes a second neutral pattern 340 instead of the second neutral pattern (see Figure 10). The second neutral pattern 340 is formed on the second side 182 of the second neutral plate 304. The second neutral plate 304 is oriented with the corner Cl positioned in the lower left position when the second side 182 is facing forwardly (or toward the first end cap 146 illustrated in Figures 3-4B, 16, 23, and 24). The second neutral pattern 340 includes three lines 341-343. The line 341 extends from the through-hole 171 to the through-hole 175. The line 343 extends inwardly from the edge E4 in a direction substantially parallel with the edge El. The line 343 terminates near the through-hole 175. The line 342 extends from the line 343 to the edge E2 or to a location near the through-hole 171. The lines 341-343 are configured to induce flow toward the through-hole 171 in an eighth flow direction identified by an arrow A8. Each of the lines 341-343 may be formed as a continuous line or by a plurality of through-holes arranged in a series to define the line. The plurality of through-holes may each have a diameter of about 1 mm to about 2 mm.
When the plurality of through-holes are used to define the lines 331-333 (see Figure 14) on the first side 180, the plurality of through-holes also define the lines 341-343 on the second side 182. Thus, the first neutral plate 303 (see Figure 9) and the second neutral plate 304 may simply be mirror images of one another.
Each of the flows identified by the arrows A5-A8 in Figures 12-15, respectively, may be directed toward the near the top of the sealed internal chamber 228 (see Figures 4A and 4B). In the positive and negative plates 301 and 302, the through-hole 171 may be characterized as being an entrance or inlet and the through-hole 175 may be characterized as being an exit or outlet.

The fifth and sixth flow directions (identified by the arrows A5 and A6) each flow from the inlet (the through-hole 171) toward the outlet (the through-hole 175).
In the first and second neutral plates 303 and 304, the through-hole 175 may be characterized as being an entrance or inlet and the through-hole 171 may be characterized as being an exit or outlet. The seventh and eighth flow directions (identified by the arrows A7 and A8) each flow from the inlet (the through-hole 175) toward the outlet (the through-hole 171). Referring to Figures 12-15, when the plates 301-304 are used to construct the cell 140A
(see Figures 1 and 3-46), the flows induced by the fifth, sixth, seventh, and eighth flow directions cause the water 116 (see Figures 1-3), the hydrogen gas 120 (see Figure 2), and/or the oxygen gas 121 (see Figure 2) to zig-zag through the cell 140A. Thus, fewer ones of the through-holes 170 are needed to create the desired flows.
LOW-DENSITY EMBODIMENT
Figure 16 is a perspective view of a cell 350 that is a low-density version of the cell 140A (see Figures 1 and 3-46). The cell 350 may be used to supply hydrogen to a low-density application, such as a flame consuming a low number of calories (e.g., a residential oven, a lamp, and the like). Oxygen produced by the low-density version may be vented to the atmosphere. Like the cell 140A (see Figures 1 and 3-46), the cell 350 includes the plates 142 but the seals 144 are replaced with seals 352 (see Figures 21 and 23) and membranes 354 (see Figure 22). In the embodiment illustrated, the water inlet 240 (see Figures 4A and 46), the hydrogen outlet 244 (see Figures 4A, 46, 23, and 24), and a separate oxygen outlet 362 (see Figures 23 and 24) are formed in the second end cap 148. In alternate embodiments, the second end cap 148 may include two or more separate water inlets that are each like the water inlet 240 (see Figures 4A and 46) and connected to the water source 112 (see Figures 1 and 3) by the water line(s) 114 (see Figures 1 and 3). In alternate embodiments, the first end cap 146 may include the water inlet 240 (see Figures 4A and 46) or two or more separate water inlets that are each like the water inlet 240 and connected to the water source 112 (see Figures 1 and 3) by the water line(s) 114 (see Figures 1 and 3). Optionally, referring to Figure 23, the hydrogen outlet 244 may be positioned above the oxygen outlet 362. In the embodiment illustrated, the hydrogen outlet 244 and the oxygen outlet 362 are spaced apart from one another and arranged side-by-side.
Referring to Figure 16, fittings 364-368 may be connected to the water inlet 240 (see Figures 4A and 4B), the hydrogen outlet 244 (see Figures 4A, 4B, 23, and 24), and the oxygen outlet 362 (see Figures 23 and 24), respectively. The fitting 364 is configured to be coupled to the water line(s) 114 (see Figures 1 and 3) and to supply the water 116 (see Figures 1-3) received therethrough from the water source 112 (see Figures 1 and 3) to a sealed interior 370 (see Figures 23 and 24) of the cell 350. The fitting 366 is configured to be coupled to the hydrogen gas line(s) 128 (see Figures 1 and 3) and to conduct the hydrogen gas 120 (see Figure 2) produced by the cell 350 to the hydrogen reservoir 130 (see Figure 1). The fitting 368 is configured to be coupled to the oxygen gas line(s) 138 (see Figure 1) and to vent the oxygen gas 121 (see Figure 2) produced by the cell 350 to the atmosphere.
Figures 17-20 illustrate plates 401-404, respectively, that together are a third embodiment of the plates 142 (see Figures 3-6, 16, and 23) and may be used to construct the cell 350 (see Figures 16, 23, and 24). As shown in Figures 17-20, none of the plates 401-404 includes a pattern of lines.
In Figures 17-20, the through-holes 170 include only the through-holes 171, 174, 175, and 176. In other words, the through-holes 172 and 173 are omitted. The through-hole 171 may be positioned directly below the through-hole 176 and directly across from the through-hole 174. The through-hole 175 may be positioned directly above the through-hole 174 and directly across from the through-hole 176. Thus, the through-holes 171, 174, 175, and 176 may be positioned at corners of rectangular shape.
Referring to Figure 17, the positive plate 401 is oriented with its corner Cl positioned in the upper left position when the first side 180 is facing forwardly (or toward the first end cap 146 illustrated in Figures 3-4B, 16, 23, and 24). A flow may be induced along the first side 180 toward the through-hole 175 in a ninth flow direction identified by an arrow A9. Referring to Figure 3, the positive conductor 250 (e.g., a bolt) may be inserted through the through-hole 178 of the positive plate 401 (see Figure 17) and connected (e.g., by one of the conductors 110) to the positive terminal T+ of the power controller 108. In this manner, the positive plate 401 (see Figure 17) may be charged. Alternatively, one of the conductors 110 may direct couple the positive plate 401 (see Figure 17) to the positive terminal T+ of the power controller 108.
Referring to Figure 18, the negative plate 402 is oriented with the corner Cl positioned in the upper right position when the second side 182 is facing forwardly (or toward the first end cap 146 illustrated in Figures 3-4B, 16, 23, and 24). A flow may be induced along the second side 182 toward the through-hole 175 in a tenth flow direction identified by an arrow A10.
Referring to Figure 3, the negative conductor 252 (e.g., a bolt) may be inserted through the through-hole 178 of the negative plate 402 (see Figure 18 and 23) and connected (e.g., by one of the conductors 110) to the negative terminal T- of the power controller 108. In this manner, the negative plate 402 (see Figure and 23) may be charged. Alternatively, one of the conductors 110 may direct couple the negative plate 402 (see Figure 18 and 23) to the negative terminal T- of the power controller 108.
Referring to Figure 19, the first neutral plate 403 is oriented with the corner Cl positioned in the lower right position when the first side 180 is facing forwardly (or toward the first end cap 146 illustrated in Figures 3-4B, 16, 23, and 24). A flow may be induced along the first side 180 toward the through-hole 171 in an eleventh flow direction identified by an arrow A11.
Referring to Figure 20, the second neutral plate 404 is oriented with the corner Cl positioned in the lower left position when the second side 182 is facing forwardly (or toward the first end cap 146 illustrated in Figures 3-4B, 16, 23, and 24). A flow may be induced along the second side 182 toward the through-hole 171 in a twelfth flow direction identified by an arrow Al2.
Referring to Figure 21, the seals 352 are substantially similar to the seals 144 (see Figures 4A, 5, and 11). Thus, each of the seals 352 includes the peripheral portion 229 that defines the interior shape 230, which is closed along the peripheral portion 229 of the seal. Each of the seals 352 also has the front side 231 opposite the back side 232 (see Figures 5, 11, and 24).

Further, each of the seals 352 may be generally planar. However, the seals 352 differ from the seals 144 (see Figures 4A, 5, and 11) because each of the seals 352 include first and second barriers 410 and 412 that define first and second sealed regions 420 and 422, respectively, within the interior shape 230.
The first sealed region 420 is sealed by the first barrier 410 and the peripheral portion 229. The second sealed region 422 is sealed by the second barrier 412 and the peripheral portion 229. The first and second sealed regions 420 and 422 are positioned to isolate two of the through-holes 170 (see Figures 6-10, 12-15, and 17-20) of each of the plates 401-404 (see Figures 17-20, respectively) from a remainder 424 of the interior shape 230.
Figure 22 illustrates one of the membranes 354. Each of the membranes 354 may be generally planar. As shown in Figure 22, the membrane 354 may have the same general outer shape as the plates 142 (see Figures 3-6, 16, and 23). The membranes 354 each include through-holes 470 that correspond to the through-holes 170 (see Figures 6-10, 12-15, and 17-20) of the plates 401-404 illustrated in Figures 17-20, respectively. Thus, referring to Figure 17, the through-holes 470 (see Figure 22) each include through-holes 471 and 474-476 (see Figure 22) that correspond to the through-holes 171 and 174-176, respectively. The through-holes 470 are configured to allow the water 116 (see Figures 1-3), the hydrogen gas 120 (see Figure 2), and the oxygen gas 121 (see Figure 2) to flow therethrough.
Each of the membranes 354 is configured to be sandwiched between a pair of the seals 352 (see Figures 21 and 23) and to permit flow between the pair of seals only through the through-holes 470. By way of a non-limiting example, the membranes 354 (see Figure 22) may each be constructed from vinyl or a similar material configured to block oxygen and hydrogen from flowing through the material.
Figure 21 illustrates the seal 352 in a first orientation with its first and second sealed regions 420 and 422 positioned in the upper right hand and lower left hand corners, respectively. In this orientation, the front side 231 faces toward the first end cap 146 (see Figures 3-4B, 16, 23, and 24). The seal 352 may be positioned in a second orientation in which the front side 231 faces toward the second end cap 148 (see Figures 3-4B, 16, 23, and 24). In the second orientation, the first and second sealed regions 420 and 422 are positioned in the upper left hand and lower right hand corners, respectively.
Table A below lists which of the through-holes 170 (see Figures 6-10, 12-15, and 17-20) of each of the plates 401-404 (see Figures 17-20, respectively) is positioned inside each of the first and second sealed regions 420 and 422 when the seal 352 is positioned alongside the plate in the first and second orientations. For example, when the seal 352 is positioned alongside the positive plate 401 (see Figure 17) in the first orientation, the through-holes and 174 are positioned inside the first and second sealed regions 420 and 422, respectively. On the other hand, when the seal 352 is positioned alongside the positive plate 401 (see Figure 17) in the second orientation, the through-holes 175 and 171 are positioned inside the first and second sealed regions 420 and 422, respectively.
Orientation of Seal 352 First Orientation Second Orientation (Shown in Figure 21) First sealed Second First sealed Second region 420 sealed region region 420 sealed region Positive plate through-hole through-hole through-hole through-hole Negative plate through-hole through-hole through-hole through-hole First neutral through-hole through-hole through-hole through-hole plate 403 174 176 171 175 Second neutral through-hole through-hole through-hole through-hole plate 404 171 175 174 176 Membrane 354 through-hole through-hole through-hole through-hole Table A
Table A above also lists which of the through-holes 470 (see Figure 22) of the membrane 354 (see Figure 22) is positioned inside each of the first and second sealed regions 420 and 422 when the seal 352 is positioned alongside the membrane 354 in the first and second orientations.
For example, when the seal 352 is positioned alongside the membrane 354 (see Figure 22) in the first orientation, the through-holes 476 and 474 are positioned inside the first and second sealed regions 420 and 422, respectively.
On the other hand, when the seal 352 is positioned alongside the membrane 354 (see Figure 22) in the second orientation, the through-holes 475 and 471 are positioned inside the first and second sealed regions 420 and 422, respectively.
Figure 23 illustrates an exemplary slice 430 through the cell 350, which is also illustrated in Figures 16 and 24. Referring to Figure 23, the slice 430 includes the first end cap 146, the second end cap 148, the plates 142, the seals 352, and the membranes 354 (see Figure 22). In this embodiment, the plates 142 include positive plates 401A and 401B, the negative plate 402, first neutral plates 403A-403D, second neutral plates 404A-404C. The positive plates 401A and 401B are each like the positive plate 401 (see Figure 17). The first neutral plates 403A-403D are each like the first neutral plate 403 (see Figure 19). The second neutral plates 404A-404C are each like the second neutral plate 404 (see Figure 20).
The seals 352 include seals 352A-352Q and the membranes 354 (see Figure 22) include membranes 354A-354F. In the embodiment illustrated, the first end cap 146, the second end cap 148, the plates 142, the seals 352, and the membranes 354 (see Figure 22) are arranged in the following order:
1. the first end cap 146;
2. the seal 352A (in the first orientation);
3. the positive plate 401A;
4. the seal 352B (in the first orientation);
5. the second neutral plate 404A;
6. the seal 352C (in the second orientation);

7. the membrane 354A;
8. the seal 352D (in the first orientation);
9. the first neutral plate 403A;
10. the seal 352E (in the second orientation);
11. the membrane 354B;
12. the seal 352F (in the first orientation);
13. the second neutral plate 404B;
14. the seal 352G (in the second orientation);
15. the membrane 354C;
16. the seal 352H (in the first orientation);
17. the first neutral plate 403B;
18. the seal 3521 (in the second orientation);
19. the negative plate 402;

20. the seal 352J (in the first orientation);

21. the membrane 354D;

22. the seal 352K (in the second orientation);

23. the first neutral plate 403C;

24. the seal 352L (in the first orientation);

25. the membrane 354E;

26. the seal 352M (in the second orientation);

27. the second neutral plate 404C;

28. the seal 352N (in the first orientation);

29. the membrane 354F;

30. the seal 3520 (in the second orientation);

31. the first neutral plate 403D;

32. the seal 352P (in the first orientation);

33. the positive plate 401B;

34. the seal 352Q (in the first orientation); and

35. the second end cap 148 As shown in Figure 24, the seals 352A-352Q define a first gas chamber 432 (shown using hash marks) and a second gas chamber 434 in the cell 350. The first and second gas chambers 432 and 434 are isolated from one another. The first gas chamber 432 (shown using hash marks) may temporarily house the oxygen gas 121 (see Figure 2) and conduct it to the oxygen outlet 362. The second gas chamber 434 may temporarily house the hydrogen gas 120 (see Figure 2) and conduct it to the hydrogen outlet 244. As shown in Figure 23, one side of each of the negative plate 402, the first neutral plates 403A-403D, the second neutral plates 404A-404C, and the membranes 354A-354F is positioned in the first gas chamber 432 (see Figure 24) and the other side of each of these structures is positioned in the second gas chamber 434 (see Figure 24).
As explained above and shown in Figure 24, the seals 352A-352Q cause the water 116 (see Figures 1-3) and the oxygen gas 121 (see Figure 2) to zigzag through the first gas chamber 432 and the water 116 and the hydrogen gas 120 (see Figure 2) to zig-zag through the second gas chamber 434. Thus, fewer ones of the through-holes 170 (see Figures 6-10, 12-15, and 17-20) are needed to create the desired flows. As mentioned above, the cell 350 may include more than one water inlet like the water inlet 240 (see Figures 4A and 4B). In such embodiments, at least one of the water inlets may open into the first gas chamber 432 and at least one of the water inlets may open into the second gas chamber 434.
Referring to Figure 21, the seals 352 may be constructed from any material suitable for constructing the seals 144 (see Figures 4A, 5, and 11).
In alternate embodiments, the seals 144 may be used with the plates 401-404.
In such embodiments, additional seals (e.g., 0-rings) may be used to block or isolate at least two of the through-holes 170 of the plates 401-404 as described above.
POWER CONTROLLER
Figure 25 illustrates an exemplary implementation of the power controller 108 connected to the hydrogen generator 106 by the electrical conductors 110. As mentioned above, the power controller 108 may be connected to the power source 109 (see Figure 1), which may be implemented as an AC source (e.g., a conventional wall socket). Thus, the power controller 108 has positive and negative contacts 502 and 504 configured to be connected to the power source 109 (see Figure 1). By way of a non-limiting example, the positive and negative contacts 502 and 504 may be components of a conventional plug configured to plug into a conventional (110 V) AC wall outlet. The AC is conducted to a rectifier 510 that converts the AC to DC.
Conductors 512 and 514 conduct the DC to the positive and negative terminals T+ and T-, respectively.
In the embodiment illustrated, the negative contact 504 is connected to the rectifier 510 by a conductor 516. The positive contact 502 is connected by a conductor 518 to a solid-state relay 520. The solid-state relay 520 is connected to the rectifier 510 by a conductor 522. The solid-state relay 520 includes a potentiometer 530 that is used to determine the voltage of the AC input into the rectifier 510. The potentiometer 530 is connected to an interface 532 that may be operated manually (e.g., a dial) or by a computing device (not shown). The interface 532 controls the potentiometer 530 and determines the voltage of the AC input into the rectifier 510. The voltage of the DC output by the rectifier 510 depends upon the voltage of the AC input into the rectifier 510. Thus, by controlling the voltage of the AC input into the rectifier 510, the potentiometer 530 determines the voltage of the DC output by the rectifier 510.
The voltage of the DC output by the rectifier 510 determines at least in part the amount of hydrogen gas output by the hydrogen generator 106.
HYDROGEN CONSUMING PROCESS AND/OR DEVICE
Referring to Figure 1, the hydrogen consuming process and/or device 134 may be any process or device configured to use or consume the hydrogen gas 120 (see Figure 2). Optionally, the hydrogen consuming process and/or device 134 may use or consume the oxygen gas 121 (see Figure 2) with the hydrogen gas 120 (see Figure 2).
The hydrogen consuming process and/or device 134 may be implemented as a hydrogenation process. By way of another non-limiting example, the hydrogen consuming process and/or device 134 may be any device configured to produce an explosion. For example, the hydrogen consuming process and/or device 134 may be implemented as an internal combustion engine (e.g., a diesel engine or a gasoline engine). Such an internal combustion engine may be incorporated into a vehicle (e.g., a car, a truck, a motorcycle, a tractor, a bus, a semi-trailer truck, a boat, an airplane, a train, etc.). By way of yet another non-limiting example, the hydrogen consuming process and/or device 134 may be any device configured to produce a flame used to produce heat and/or light. For example, the hydrogen consuming process and/or device 134 may be implemented as an oven, an industrial oven (e.g., configured to melt steel, glass, aluminum, etc.), an electric generator, a heating unit (e.g., used for residential and/or commercial heating), a stove, and the like.
Embodiments of the present disclosure can be described in view of the following clauses:
1. A
hydrogen generator for use with a water source and an electrical power source, the hydrogen generator comprising:
a plurality of plates each having a plurality of through-holes formed therein, each of the plurality of plates being electrically conductive, the plurality of plates comprising a first positive plate, a first negative plate, and a first neutral plate, the first positive plate being configured to be connected to a positive terminal of the electrical power source, the first negative plate being configured to be connected to a negative terminal of the electrical power source, the plurality of plates being arranged in a series with the first neutral plate being positioned between the first positive plate and the first negative plate, interstitial spaces being defined between adjacent ones of the plurality of plates in the series;
a plurality of seals each being positioned within a corresponding one of the interstitial spaces, each of the plurality of seals defining an interior shape that is closed along a peripheral portion of the seal within the corresponding interstitial space and open along the adjacent plates defining the corresponding interstitial space, the peripheral portion of each of the plurality of seals being configured to position the plurality of through-holes formed in each of the adjacent plates defining the interstitial space corresponding to the seal in communication with the interior shape defined by the seal to thereby form a sealed chamber that extends through the series, each of the plurality of seals being electrically non-conductive;
a water inlet configured to allow water from the water source into the sealed chamber, the water electrically connecting the first positive plate to the first negative plate, which causes the water to split into oxygen and hydrogen; and a hydrogen outlet configured to allow the hydrogen to exit from the sealed chamber.
2. The hydrogen generator of clause 1, wherein the plurality of through-holes formed in each of the plurality of plates comprise first, second, third, fourth, and fifth through-holes, each of the plurality of plates has first, second, third, and fourth edges, the first and third edges are parallel with one another, the second and fourth edges are parallel with one another, the first, second, third, and fourth through-holes are arranged in a linear series positioned closer to the third edge than the first edge, the linear series is parallel with the third edge, the fifth through-hole is positioned closer to the first edge than the third edge, and the fifth through-hole is positioned closer to the fourth edge than the second edge.
3. The hydrogen generator of claim 2, wherein the plurality of plates comprises a second neutral plate, the second neutral plate is positioned between the first neutral plate and the first negative plate, the plurality of plates each have a plurality of lines formed thereupon, the plurality of lines formed on the first positive plate defines a positive pattern, the plurality of lines formed on the first negative plate defines a negative pattern, the plurality of lines formed on the first neutral plate defines a first neutral pattern, the plurality of lines formed on the second neutral plate defines a second neutral pattern, and the positive pattern, the negative pattern, the first neutral pattern, and the second neutral pattern are different from one another.
4. The hydrogen generator of clause 3, wherein each of the plurality of plates has a first side opposite a second side, the positive pattern is formed on the first side of the first positive plate, the negative pattern is formed on the second side of the first negative plate, the first neutral pattern is formed on the first side of the first neutral plate, the second neutral pattern is formed on the second side of the second neutral plate, and the positive pattern, the negative pattern, the first neutral pattern, and the second neutral pattern all face in a common direction.
5. The hydrogen generator of clause 4, wherein a corner is defined at an intersection of the first and fourth edges, the corner of the first positive plate is positioned in a first upper position, the corner of the first negative plate is positioned in a second upper position, the corner of the first neutral plate is positioned in a first lower position, and the corner of the second neutral plate is positioned in a second lower position.
6. The hydrogen generator of clause 5, wherein the positive and negative patterns encourage flow toward the fifth through-hole, and the first and second neutral patterns encourage flow toward the first, second, third, and fourth through-holes.
7. The hydrogen generator of clause 6, wherein the positive and negative patterns each include first, second, third, fourth lines that extend from the first, second, third, and fourth through-holes, respectively, to the fifth through-hole, and the first and second neutral patterns each include fifth, sixth, seventh, eighth, ninth, and tenth lines, the ninth and tenth lines are connected together at an intersection point, the tenth line extends from the intersection point to the fifth through-hole, the fifth, sixth, seventh, and eighth lines extend from the first, second, third, and fourth through-holes, respectively, to at least one of the ninth or tenth lines.
8. The hydrogen generator of any one of clauses 1-7, wherein the plurality of plates comprises a second, third, and fourth neutral plates the plurality of plates each have a plurality of lines formed thereupon, the plurality of lines formed on the first positive plate defines a positive pattern, the plurality of lines formed on the first negative plate defines a negative pattern, the plurality of lines formed on the first neutral plate defines a first neutral pattern, the plurality of lines formed on the second neutral plate defines a second neutral pattern, the positive pattern, the negative pattern, the first neutral pattern, and the second neutral pattern are different from one another, the first neutral plate is positioned between the first positive plate and the second neutral plate, the third neutral plate is positioned between the second neutral plate and the fourth neutral plate, the fourth neutral plate is positioned between the third neutral plate and the first negative plate, the plurality of lines formed on the third neutral plate define the first neutral pattern, the plurality of lines formed on the fourth neutral plate define the second neutral pattern, and together, the first, second, third, and fourth neutral plates are a first series of neutral plates.
9. The hydrogen generator of clause 8, wherein the plurality of plates comprise a second positive plate, a second negative plate, a second series of neutral plates like the first series of neutral plates, and a third series of neutral plates like the first series of neutral plates, the second series of neutral plates is positioned between the first negative plate and the second positive plate, and the third series of neutral plates is positioned between the second positive plate and the second negative plate.
10. The hydrogen generator of clause 9, further comprising:
a positive conductor connected to the positive terminal, the first positive plate, and the second positive plate; and a negative conductor connected to the negative terminal, the first negative plate, and the second negative plate.
11. The hydrogen generator of clause 9 or 10, further comprising:
a first end cap comprising the water inlet;
first and second end seals each like one of the plurality of seals comprising, the first end seal being positioned between the first end cap and the first positive plate; and a second end cap comprising the hydrogen outlet, the second end seal being positioned between the second end cap and the second negative plate.
12. The hydrogen generator of clause 11, further comprising:

36 a plurality of ties connecting the first and second end caps together, the plurality of ties passing alongside the series of the plurality of plates, each of the plurality of plates comprises at least one edge with cutouts formed therein, each of the cutouts being configured to receive a portion of one of the plurality of ties.
13. The hydrogen generator of any of clauses 1-12, wherein the water comprises a catalyst.
14. The hydrogen generator of clause 13, wherein the catalyst is potassium hydroxide.
15. The hydrogen generator of any of clauses 1-14, wherein the plurality of plates comprises a second neutral plate, the second neutral plate is positioned between the first neutral plate and the first negative plate, the first positive plate has a first pattern of through-holes formed therein that define a positive pattern of lines, the first negative plate has a second pattern of through-holes formed therein that define a negative pattern of lines, the first neutral plate has a third pattern of through-holes formed therein that define a first neutral pattern of lines, the second neutral plate has a fourth pattern of through-holes formed therein that define a second neutral pattern of lines, the positive and negative patterns are mirror images of one another; and the first and second neutral patterns are mirror images of one another.
16. The hydrogen generator of clause 15, wherein the through-holes of the first, second, third, and fourth patterns each have a diameter from 1 millimeter to 2 millimeters.
17. A hydrogen generator for use with a water source and an electrical power source, the hydrogen generator comprising:

37 an electrolysis chamber having a water inlet and a hydrogen outlet, the water inlet being configured to receive water from the water source, the hydrogen outlet being configured to allow hydrogen generated inside the electrolysis chamber to exit therefrom; and a series of parallel plates positioned in the electrolysis chamber and configured to generate the hydrogen, the series of parallel plates comprising at least one positive plate, at least one negative plate, and at least one neutral plate, each of the series of parallel plates comprising through-holes configured to allow the water and the hydrogen to flow therethrough, the at least one positive plate being configured to be connected to a positive terminal of the electrical power source, the at least one negative plate being configured to be connected to a negative terminal of the electrical power source, the water inside the electrolysis chamber forming an electrical connection between the at least one positive plate and the at least one negative plate that splits the water into the hydrogen and oxygen.
18. The hydrogen generator of clause 17, wherein the electrolysis chamber is at least partially defined within a plurality of seals positioned one each between each adjacent pair of plates within the series of parallel plates.
19. The hydrogen generator of clause 18, further comprising:
first and second end caps flanking the series of parallel plates;
a first end cap seal positioned between the first end cap and the series of parallel plates; and a second end cap seal positioned between the second end cap and the series of parallel plates, the electrolysis chamber extending from the first end cap to the second end cap.
20. The hydrogen generator of clause 19, wherein the water inlet is formed in the first end cap, and the hydrogen outlet is formed in the second end cap.

38 21. The hydrogen generator of any of clauses 17-20, wherein the at least one neutral plate comprises a plurality of neutral plates configured to provide a desired amount of electrical resistance between the at least one positive plate and the at least one negative plate.
22. The hydrogen generator of any of clauses 17-21, wherein the water comprises a catalyst.
23. The hydrogen generator of clause 22, wherein the catalyst is potassium hydroxide.
24. The hydrogen generator of any of clauses 17-23, wherein the at least one neutral plate comprises a plurality of neutral plates, each of the at least one positive plate has a positive pattern of lines formed thereon, each of the at least one negative plate has a negative pattern of lines formed thereon, a first portion of the plurality of neutral plates each has a first neutral pattern of lines formed thereon, a second portion of the plurality of neutral plates each has a second neutral pattern of lines formed thereon, and the positive pattern of lines, the negative pattern of lines, the first neutral pattern of lines, and the second neutral pattern of lines being different from one another.
25. The hydrogen generator of any of clauses 17-24, wherein the at least one neutral plate comprises a plurality of neutral plates, each of the at least one positive plate has a first pattern of through-holes formed therein that define a positive pattern of lines, each of the at least one negative plate has a second pattern of through-holes formed therein that define a negative pattern of lines, a first portion of the plurality of neutral plates each has a third pattern of through-holes formed therein that define a first neutral pattern of lines,

39 a second portion of the plurality of neutral plates each has a fourth pattern of through-holes formed therein that define a second neutral pattern of lines, the positive and negative patterns are mirror images of one another; and the first and second neutral patterns are mirror images of one another.
26. The hydrogen generator of clause 25, wherein the through-holes of the first, second, third, and fourth patterns each have a diameter from 1 millimeter to 2 millimeters.
27. A hydrogen generator for use with a water source and an electrical power source, the hydrogen generator comprising:
an electrolysis chamber divided into an oxygen chamber and a hydrogen chamber;
at least one water inlet in communication with the electrolysis chamber, each of the at least one water inlet being configured to receive water from the water source;
a hydrogen outlet in communication with the hydrogen chamber, the hydrogen outlet being configured to allow hydrogen generated inside the electrolysis chamber to exit therefrom;
an oxygen outlet in communication with the oxygen chamber, the oxygen outlet being configured to allow oxygen generated inside the electrolysis chamber to exit therefrom; and a series of parallel plates positioned in the electrolysis chamber and configured to generate the hydrogen, the series of parallel plates comprising at least one positive plate, at least one negative plate, and at least one neutral plate, each of the series of parallel plates comprising through-holes configured to allow the water, the oxygen, and the hydrogen to flow therethrough, the at least one positive plate being configured to be connected to a positive terminal of the electrical power source, the at least one negative plate being configured to be connected to a negative terminal of the electrical power source, the water inside the electrolysis chamber forming an electrical connection between the at least one positive plate and the at least one negative plate that splits the water into the hydrogen and the oxygen.
28. The hydrogen generator of clause 27, further comprising:
a plurality of membranes each comprising through-holes configured to allow the water, the oxygen, and the hydrogen to flow therethrough, each of the plurality of membranes being positioned at a different location within the series of parallel plates; and a plurality of seals each positioned in between a different first one of the series of parallel plates and either a different second one of the series of parallel plates or a different one of the plurality of membranes, the electrolysis chamber being at least partially defined within the plurality of seals, the plurality of seals dividing the electrolysis chamber into the hydrogen chamber and the oxygen chamber.
29. The hydrogen generator of clause 28, further comprising:
first and second end caps flanking the series of parallel plates;
a first end cap seal positioned between the first end cap and the series of parallel plates; and a second end cap seal positioned between the second end cap and the series of parallel plates, the electrolysis chamber extending from the first end cap to the second end cap.
30. The hydrogen generator of clause 29, wherein the each of the at least one water inlet is formed in the second end cap, the hydrogen outlet is formed in the second end cap, and the oxygen outlet is formed in the second end cap.
31. The hydrogen generator of clause 29 or 30, wherein the at least one water inlet comprises a first water inlet and a second water inlet, the first water inlet is in communication with the hydrogen chamber, and the second water inlet is in communication with the oxygen chamber.

32. The hydrogen generator of any of clauses 27-31, wherein the at least one neutral plate comprises a plurality of neutral plates configured to provide a desired amount of electrical resistance between the at least one positive plate and the at least one negative plate.
33. The hydrogen generator of any of clauses 27-32, wherein the water comprises a catalyst.
34. The hydrogen generator of clause 33, wherein the catalyst is potassium hydroxide.
The foregoing described embodiments depict different components contained within, or connected with, different other components. It is to be understood that such depicted architectures are merely exemplary, and that in fact many other architectures can be implemented which achieve the same functionality. In a conceptual sense, any arrangement of components to achieve the same functionality is effectively "associated" such that the desired functionality is achieved. Hence, any two components herein combined to achieve a particular functionality can be seen as "associated with" each other such that the desired functionality is achieved, irrespective of architectures or intermedial components. Likewise, any two components so associated can also be viewed as being "operably connected," or "operably coupled," to each other to achieve the desired functionality.
While particular embodiments of the present invention have been shown and described, it will be obvious to those skilled in the art that, based upon the teachings herein, changes and modifications may be made without departing from this invention and its broader aspects and, therefore, the .. appended claims are to encompass within their scope all such changes and modifications as are within the true spirit and scope of this invention.
Furthermore, it is to be understood that the invention is solely defined by the appended claims. It will be understood by those within the art that, in general, terms used herein, and especially in the appended claims (e.g., bodies of the appended claims) are generally intended as "open" terms (e.g., the term "including" should be interpreted as "including but not limited to," the term "having" should be interpreted as "having at least," the term "includes"
should be interpreted as "includes but is not limited to," etc.). It will be further understood by those within the art that if a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation no such intent is present. For example, as an aid to understanding, the following appended claims may contain usage of the introductory phrases at least one" and one or more" to introduce claim recitations. However, the use of such phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles "a" or "an"
limits any particular claim containing such introduced claim recitation to inventions containing only one such recitation, even when the same claim includes the introductory phrases one or more" or at least one" and indefinite articles such as "a" or "an" (e.g., "a" and/or "an" should typically be interpreted to mean at least one" or one or more"); the same holds true for the use of definite articles used to introduce claim recitations. In addition, even if a specific number of an introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should typically be interpreted to mean at least the recited number (e.g., the bare recitation of two recitations," without other modifiers, typically means at least two recitations, or two or more recitations).
Conjunctive language, such as phrases of the form at least one of A, B, and C," or at least one of A, B and C," (i.e., the same phrase with or without the Oxford comma) unless specifically stated otherwise or otherwise clearly contradicted by context, is otherwise understood with the context as used in general to present that an item, term, etc., may be either A or B or C, any nonempty subset of the set of A and B and C, or any set not contradicted by context or otherwise excluded that contains at least one A, at least one B, or at least one C. For instance, in the illustrative example of a set having three members, the conjunctive phrases at least one of A, B, and C" and at least one of A, B and C" refer to any of the following sets: {A}, {B}, {C}, {A, B}, {A, C}, {B, C}, {A, B, C}, and, if not contradicted explicitly or by context, any set having {A}, {B}, and/or {C} as a subset (e.g., sets with multiple "A"). Thus, such conjunctive language is not generally intended to imply that certain embodiments require at least one of A, at least one of B, and at least one of C

each to be present. Similarly, phrases such as at least one of A, B, or C" and at least one of A, B or C" refer to the same as at least one of A, B, and C"
and at least one of A, B and C" refer to any of the following sets: {A}, {B}, {C}, {A, B}, {A, C}, {B, C}, {A, B, C}, unless differing meaning is explicitly stated or clear from context.
Accordingly, the invention is not limited except as by the appended claims.

Claims (34)

WO 2020/044207 PCT/IB2019/057170The invention claimed is:

1. A hydrogen generator for use with a water source and an electrical power source, the hydrogen generator comprising:
a plurality of plates each having a plurality of through-holes formed therein, each of the plurality of plates being electrically conductive, the plurality of plates comprising a first positive plate, a first negative plate, and a first neutral plate, the first positive plate being configured to be connected to a positive terminal of the electrical power source, the first negative plate being configured to be connected to a negative terminal of the electrical power source, the plurality of plates being arranged in a series with the first neutral plate being positioned between the first positive plate and the first negative plate, interstitial spaces being defined between adjacent ones of the plurality of plates in the series;
a plurality of seals each being positioned within a corresponding one of the interstitial spaces, each of the plurality of seals defining an interior shape that is closed along a peripheral portion of the seal within the corresponding interstitial space and open along the adjacent plates defining the corresponding interstitial space, the peripheral portion of each of the plurality of seals being configured to position the plurality of through-holes formed in each of the adjacent plates defining the interstitial space corresponding to the seal in communication with the interior shape defined by the seal to thereby form a sealed chamber that extends through the series, each of the plurality of seals being electrically non-conductive;
a water inlet configured to allow water from the water source into the sealed chamber, the water electrically connecting the first positive plate to the first negative plate, which causes the water to split into oxygen and hydrogen; and a hydrogen outlet configured to allow the hydrogen to exit from the sealed chamber.

2. The hydrogen generator of claim 1, wherein the plurality of through-holes formed in each of the plurality of plates comprise first, second, third, fourth, and fifth through-holes, each of the plurality of plates has first, second, third, and fourth edges, the first and third edges are parallel with one another, the second and fourth edges are parallel with one another, the first, second, third, and fourth through-holes are arranged in a linear series positioned closer to the third edge than the first edge, the linear series is parallel with the third edge, the fifth through-hole is positioned closer to the first edge than the third edge, and the fifth through-hole is positioned closer to the fourth edge than the second edge.

3. The hydrogen generator of claim 2, wherein the plurality of plates comprises a second neutral plate, the second neutral plate is positioned between the first neutral plate and the first negative plate, the plurality of plates each have a plurality of lines formed thereupon, the plurality of lines formed on the first positive plate defines a positive pattern, the plurality of lines formed on the first negative plate defines a negative pattern, the plurality of lines formed on the first neutral plate defines a first neutral pattern, the plurality of lines formed on the second neutral plate defines a second neutral pattern, and the positive pattern, the negative pattern, the first neutral pattern, and the second neutral pattern are different from one another.

4. The hydrogen generator of claim 3, wherein each of the plurality of plates has a first side opposite a second side, the positive pattern is formed on the first side of the first positive plate, the negative pattern is formed on the second side of the first negative plate, the first neutral pattern is formed on the first side of the first neutral plate, the second neutral pattern is formed on the second side of the second neutral plate, and the positive pattern, the negative pattern, the first neutral pattern, and the second neutral pattern all face in a common direction.

5. The hydrogen generator of claim 4, wherein a corner is defined at an intersection of the first and fourth edges, the corner of the first positive plate is positioned in a first upper position, the corner of the first negative plate is positioned in a second upper position, the corner of the first neutral plate is positioned in a first lower position, and the corner of the second neutral plate is positioned in a second lower position.

6. The hydrogen generator of claim 5, wherein the positive and negative patterns encourage flow toward the fifth through-hole, and the first and second neutral patterns encourage flow toward the first, second, third, and fourth through-holes.

7. The hydrogen generator of claim 6, wherein the positive and negative patterns each include first, second, third, fourth lines that extend from the first, second, third, and fourth through-holes, respectively, to the fifth through-hole, and the first and second neutral patterns each include fifth, sixth, seventh, eighth, ninth, and tenth lines, the ninth and tenth lines are connected together at an intersection point, the tenth line extends from the intersection point to the fifth through-hole, the fifth, sixth, seventh, and eighth lines extend from the first, second, third, and fourth through-holes, respectively, to at least one of the ninth or tenth lines.

8. The hydrogen generator of claim 1, wherein the plurality of plates comprises a second, third, and fourth neutral plates the plurality of plates each have a plurality of lines formed thereupon, the plurality of lines formed on the first positive plate defines a positive pattern, the plurality of lines formed on the first negative plate defines a negative pattern, the plurality of lines formed on the first neutral plate defines a first neutral pattern, the plurality of lines formed on the second neutral plate defines a second neutral pattern, the positive pattern, the negative pattern, the first neutral pattern, and the second neutral pattern are different from one another, the first neutral plate is positioned between the first positive plate and the second neutral plate, the third neutral plate is positioned between the second neutral plate and the fourth neutral plate, the fourth neutral plate is positioned between the third neutral plate and the first negative plate, the plurality of lines formed on the third neutral plate define the first neutral pattern, the plurality of lines formed on the fourth neutral plate define the second neutral pattern, and together, the first, second, third, and fourth neutral plates are a first series of neutral plates.

9. The hydrogen generator of claim 8, wherein the plurality of plates comprise a second positive plate, a second negative plate, a second series of neutral plates like the first series of neutral plates, and a third series of neutral plates like the first series of neutral plates, the second series of neutral plates is positioned between the first negative plate and the second positive plate, and the third series of neutral plates is positioned between the second positive plate and the second negative plate.

10. The hydrogen generator of claim 9, further comprising:
a positive conductor connected to the positive terminal, the first positive plate, and the second positive plate; and a negative conductor connected to the negative terminal, the first negative plate, and the second negative plate.

11. The hydrogen generator of claim 9, further comprising:
a first end cap comprising the water inlet;
first and second end seals each like one of the plurality of seals comprising, the first end seal being positioned between the first end cap and the first positive plate; and a second end cap comprising the hydrogen outlet, the second end seal being positioned between the second end cap and the second negative plate.

12. The hydrogen generator of claim 11, further comprising:
a plurality of ties connecting the first and second end caps together, the plurality of ties passing alongside the series of the plurality of plates, each of the plurality of plates comprises at least one edge with cutouts formed therein, each of the cutouts being configured to receive a portion of one of the plurality of ties.

13. The hydrogen generator of claim 1, wherein the water comprises a catalyst.

14. The hydrogen generator of claim 13, wherein the catalyst is potassium hydroxide.

15. The hydrogen generator of claim 1, wherein the plurality of plates comprises a second neutral plate, the second neutral plate is positioned between the first neutral plate and the first negative plate, the first positive plate has a first pattern of through-holes formed therein that define a positive pattern of lines, the first negative plate has a second pattern of through-holes formed therein that define a negative pattern of lines, the first neutral plate has a third pattern of through-holes formed therein that define a first neutral pattern of lines, the second neutral plate has a fourth pattern of through-holes formed therein that define a second neutral pattern of lines, the positive and negative patterns are mirror images of one another;
and the first and second neutral patterns are mirror images of one another.

16. The hydrogen generator of claim 15, wherein the through-holes of the first, second, third, and fourth patterns each have a diameter from 1 millimeter to 2 millimeters.

17. A hydrogen generator for use with a water source and an electrical power source, the hydrogen generator comprising:
an electrolysis chamber having a water inlet and a hydrogen outlet, the water inlet being configured to receive water from the water source, the hydrogen outlet being configured to allow hydrogen generated inside the electrolysis chamber to exit therefrom; and a series of parallel plates positioned in the electrolysis chamber and configured to generate the hydrogen, the series of parallel plates comprising at least one positive plate, at least one negative plate, and at least one neutral plate, each of the series of parallel plates comprising through-holes configured to allow the water and the hydrogen to flow therethrough, the at least one positive plate being configured to be connected to a positive terminal of the electrical power source, the at least one negative plate being configured to be connected to a negative terminal of the electrical power source, the water inside the electrolysis chamber forming an electrical connection between the at least one positive plate and the at least one negative plate that splits the water into the hydrogen and oxygen.

18. The hydrogen generator of claim 17, wherein the electrolysis chamber is at least partially defined within a plurality of seals positioned one each between each adjacent pair of plates within the series of parallel plates.

19. The hydrogen generator of claim 18, further comprising:
first and second end caps flanking the series of parallel plates;
a first end cap seal positioned between the first end cap and the series of parallel plates; and a second end cap seal positioned between the second end cap and the series of parallel plates, the electrolysis chamber extending from the first end cap to the second end cap.

20. The hydrogen generator of claim 19, wherein the water inlet is formed in the first end cap, and the hydrogen outlet is formed in the second end cap.

21. The hydrogen generator of claim 17, wherein the at least one neutral plate comprises a plurality of neutral plates configured to provide a desired amount of electrical resistance between the at least one positive plate and the at least one negative plate.

22. The hydrogen generator of claim 17, wherein the water comprises a catalyst.

23. The hydrogen generator of claim 22, wherein the catalyst is potassium hydroxide.

24. The hydrogen generator of claim 17, wherein the at least one neutral plate comprises a plurality of neutral plates, each of the at least one positive plate has a positive pattern of lines formed thereon, each of the at least one negative plate has a negative pattern of lines formed thereon, a first portion of the plurality of neutral plates each has a first neutral pattern of lines formed thereon, a second portion of the plurality of neutral plates each has a second neutral pattern of lines formed thereon, and the positive pattern of lines, the negative pattern of lines, the first neutral pattern of lines, and the second neutral pattern of lines being different from one another.

25. The hydrogen generator of claim 17, wherein the at least one neutral plate comprises a plurality of neutral plates, each of the at least one positive plate has a first pattern of through-holes formed therein that define a positive pattern of lines, each of the at least one negative plate has a second pattern of through-holes formed therein that define a negative pattern of lines, a first portion of the plurality of neutral plates each has a third pattern of through-holes formed therein that define a first neutral pattern of lines, a second portion of the plurality of neutral plates each has a fourth pattern of through-holes formed therein that define a second neutral pattern of lines, the positive and negative patterns are mirror images of one another;
and the first and second neutral patterns are mirror images of one another.

26. The hydrogen generator of claim 25, wherein the through-holes of the first, second, third, and fourth patterns each have a diameter from 1 millimeter to 2 millimeters.

27. A hydrogen generator for use with a water source and an electrical power source, the hydrogen generator comprising:
an electrolysis chamber divided into an oxygen chamber and a hydrogen chamber;
at least one water inlet in communication with the electrolysis chamber, each of the at least one water inlet being configured to receive water from the water source;
a hydrogen outlet in communication with the hydrogen chamber, the hydrogen outlet being configured to allow hydrogen generated inside the electrolysis chamber to exit therefrom;
an oxygen outlet in communication with the oxygen chamber, the oxygen outlet being configured to allow oxygen generated inside the electrolysis chamber to exit therefrom; and a series of parallel plates positioned in the electrolysis chamber and configured to generate the hydrogen, the series of parallel plates comprising at least one positive plate, at least one negative plate, and at least one neutral plate, each of the series of parallel plates comprising through-holes configured to allow the water, the oxygen, and the hydrogen to flow therethrough, the at least one positive plate being configured to be connected to a positive terminal of the electrical power source, the at least one negative plate being configured to be connected to a negative terminal of the electrical power source, the water inside the electrolysis chamber forming an electrical connection between the at least one positive plate and the at least one negative plate that splits the water into the hydrogen and the oxygen.

28. The hydrogen generator of claim 27, further comprising:
a plurality of membranes each comprising through-holes configured to allow the water, the oxygen, and the hydrogen to flow therethrough, each of the plurality of membranes being positioned at a different location within the series of parallel plates; and a plurality of seals each positioned in between a different first one of the series of parallel plates and either a different second one of the series of parallel plates or a different one of the plurality of membranes, the electrolysis chamber being at least partially defined within the plurality of seals, the plurality of seals dividing the electrolysis chamber into the hydrogen chamber and the oxygen chamber.

29. The hydrogen generator of claim 28, further comprising:
first and second end caps flanking the series of parallel plates;
a first end cap seal positioned between the first end cap and the series of parallel plates; and a second end cap seal positioned between the second end cap and the series of parallel plates, the electrolysis chamber extending from the first end cap to the second end cap.

30. The hydrogen generator of claim 29, wherein the each of the at least one water inlet is formed in the second end cap, the hydrogen outlet is formed in the second end cap, and the oxygen outlet is formed in the second end cap.

31. The hydrogen generator of claim 29, wherein the at least one water inlet comprises a first water inlet and a second water inlet, the first water inlet is in communication with the hydrogen chamber, and the second water inlet is in communication with the oxygen chamber.

32. The hydrogen generator of claim 27, wherein the at least one neutral plate comprises a plurality of neutral plates configured to provide a desired amount of electrical resistance between the at least one positive plate and the at least one negative plate.

33. The hydrogen generator of claim 27, wherein the water comprises a catalyst.

34. The hydrogen generator of claim 33, wherein the catalyst is potassium hydroxide.