US Patent 9169976 Method of manufacture of a metal hydride fuel supply

A high energy density fuel source that reduces hydride expansion during hydrogen release, including a rigid, thermally insulated container defining an internal volume, a heater mechanism disposed within the internal volume, and a metal hydride rod thermally connected to the heater mechanism, wherein the heater mechanism and metal hydride rod substantially occupying the entirety of the internal volume. The metal hydride rod preferably includes a malleable encapsulation compressed about, thermally coupled to, and substantially encapsulating a volume of compressed metal hydride powder, the malleable encapsulation defined by a first, thermally conductive, malleable cup inverted over a second, thermally conductive, malleable cup, the compressed malleable encapsulation defining a tortuous fluid flow path from the metal hydride to the internal volume of the container.