U.S. patent application number 12/611727 was filed with the patent office on 2010-11-04 for electrolytic hydrogen generating system.
This patent application is currently assigned to Etorus, Inc.. Invention is credited to Leslie Paul Arnett, Scott Alan DeHart, Robert E. Yelin.
Application Number | 20100276296 12/611727 |
Document ID | / |
Family ID | 43029592 |
Filed Date | 2010-11-04 |
United States Patent
Application |
20100276296 |
Kind Code |
A1 |
Arnett; Leslie Paul ; et
al. |
November 4, 2010 |
ELECTROLYTIC HYDROGEN GENERATING SYSTEM
Abstract
A method of dynamically adding or removing a quantity of active
plates in a plate assembly of a hydrogen generating system, the
plate assembly comprising a plurality of plates. The method
includes receiving a minimum amperage threshold, a maximum amperage
threshold, a maximum temperature threshold, a first actual
amperage, and a first actual temperature of a hydrogen generating
system, selecting a first plurality of plates from the plate
assembly, wherein the selection is based on at least one of the
following: the minimum amperage threshold, the maximum amperage
threshold, the first actual amperage, and the first actual
temperature, and applying a first voltage to the first plurality of
plates.
Inventors: |
Arnett; Leslie Paul; (Eagle,
ID) ; DeHart; Scott Alan; (Eagle, ID) ; Yelin;
Robert E.; (West Hills, CA) |
Correspondence
Address: |
Patent Docket Department;Armstrong Teasdale LLP
7700 Forsyth Boulevard, Suite 1800
St. Louis
MO
63105
US
|
Assignee: |
Etorus, Inc.
Encino
CA
|
Family ID: |
43029592 |
Appl. No.: |
12/611727 |
Filed: |
November 3, 2009 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61115463 |
Nov 17, 2008 |
|
|
|
61117481 |
Nov 24, 2008 |
|
|
|
Current U.S.
Class: |
205/337 |
Current CPC
Class: |
C25B 11/036 20210101;
Y02E 60/36 20130101; F02M 25/12 20130101; C25B 11/03 20130101; C25B
1/04 20130101; Y02T 10/12 20130101; C25B 11/00 20130101 |
Class at
Publication: |
205/337 |
International
Class: |
C25B 15/02 20060101
C25B015/02 |
Claims
1. A method of dynamically adding or removing a quantity of active
plates in a plate assembly of a hydrogen generating system, the
plate assembly comprising a plurality of plates, the method
comprising: receiving a minimum amperage threshold, a maximum
amperage threshold, a maximum temperature threshold, a first actual
amperage, and a first actual temperature of a hydrogen generating
system; selecting a first plurality of plates from the plate
assembly, wherein the selection is based on at least one of the
following: the minimum amperage threshold, the maximum amperage
threshold, the first actual amperage, and the first actual
temperature; and applying a first voltage to the first plurality of
plates.
2. The method of claim 1, further comprising: determining a second
actual amperage and a second actual temperature after applying the
first voltage to the first plurality of plates; comparing the
second actual amperage to the minimum amperage threshold and the
maximum amperage threshold; applying a second voltage to the first
plurality of plates if the first actual amperage is between the
minimum amperage threshold and the maximum amperage threshold;
selecting a second plurality of plates from the plate assembly if
the first actual amperage is not between the minimum amperage
threshold and the maximum amperage threshold; and applying the
second voltage to the second plurality of plates if the first
actual amperage is not between the minimum amperage threshold and
the maximum amperage threshold.
3. The method of claim 2 wherein the second plurality of plates
includes more plates than the first plurality of plates if the
second actual amperage is equal to or exceeds the maximum amperage
threshold.
4. The method of claim 2 wherein the second plurality of plates
includes fewer plates than the first plurality of plates if the
second actual amperage is equal to or below the minimum amperage
threshold.
5. The method of claim 2 further comprising comparing the second
actual temperature to the maximum temperature threshold.
6. The method of claim 5 wherein the second voltage is the same as
the first voltage if the second actual temperature is below the
maximum temperature threshold.
7. The method of claim 5 wherein the second voltage is lower than
the first voltage if the second actual temperature is equal to or
exceeds the maximum temperature threshold.
8. The method of claim 1 wherein the plate assembly comprises a
first fuel cell and a second fuel cell.
9. The method of claim 8 wherein the first fuel cell and the second
fuel cell share a common cathode.
10. The method of claim 8 wherein the first fuel cell and the
second fuel cell share a common anode.
11. The method of claim 8 wherein each of the first fuel cell and
the second fuel cell comprises one or more plates, and wherein at
least one of the one or more plates is configured to be an anode,
and at least one or more of the other plates is configured to be a
cathode.
12. The method of claim 8 wherein the first fuel cell has fewer
plates than the second fuel cell.
13. The method of claim 8 further comprising operating each of the
first fuel cell and the second fuel cell in parallel.
14. The method of claim 8 wherein at least one plate in the first
plurality of plates is in the first fuel cell and wherein at least
one plate in the first plurality of plates is in the second fuel
cell.
15. The method of claim 14 wherein the at least one plate in the
first fuel cell is an anode plate and wherein the at least one
plate in the second fuel cell is an anode plate.
16. A computer readable medium having instructions recorded thereon
that when executed by a processor cause the processor to: receive a
minimum amperage threshold, a maximum amperage threshold, a maximum
temperature threshold, a first actual amperage, and a first actual
temperature of a hydrogen generating system; select a first
plurality of plates from a plate assembly, wherein the selection is
based on at least one of the following: the minimum amperage
threshold, the maximum amperage threshold, the first actual
amperage, and the first actual temperature; and apply a first
voltage to the first plurality of plates.
17. The computer readable media of claim 16 further comprising
instructions recorded thereon that when executed by a processor
cause the processor to: determine a second actual amperage and a
second actual temperature after applying the first voltage to the
first plurality of plates; compare the second actual amperage to
the minimum amperage threshold and the maximum amperage threshold;
apply a second voltage to the first plurality of plates if the
first actual amperage is between the minimum amperage threshold and
the maximum amperage threshold; select a second plurality of plates
from the plate assembly if the first actual amperage is not between
the minimum amperage threshold and the maximum amperage threshold;
and apply the second voltage to the second plurality of plates if
the first actual amperage is not between the minimum amperage
threshold and the maximum amperage threshold.
18. The computer readable media of claim 17 wherein the second
plurality of plates includes more plates than the first plurality
of plates if the second actual amperage is equal to or exceeds the
maximum amperage threshold.
19. The computer readable media of claim 17 wherein the second
plurality of plates includes fewer plates than the first plurality
of plates if the second actual amperage is equal to or below the
minimum amperage threshold.
20. The computer readable media of claim 17 further comprising
instructions recorded thereon that when executed by a processor
cause the processor to compare the second actual temperature to the
maximum temperature threshold.
21. The computer readable media of claim 20 wherein the second
voltage is the same as the first voltage if the second actual
temperature is below the maximum temperature threshold.
22. The computer readable media of claim 20 wherein the second
voltage is lower than the first voltage if the second actual
temperature is equal to or exceeds the maximum temperature
threshold.
23. The computer readable media of claim 16 wherein the plate
assembly comprises a first fuel cell and a second fuel cell.
24. The computer readable media of claim 23 wherein the first fuel
cell and the second fuel cell share a common cathode.
25. The computer readable media of claim 23 wherein the first fuel
cell and the second fuel cell share a common anode.
26. The computer readable media of claim 23 wherein each of the
first fuel cell and the second fuel cell comprises one or more
plates, and wherein at least one of the one or more plates is
configured to be an anode, and at least one or more of the other
plates is configured to be a cathode.
27. The computer readable media of claim 23 wherein the first fuel
cell has fewer plates than the second fuel cell.
28. The computer readable media of claim 23 further comprising
instructions recorded thereon that when executed by a processor
cause the processor to operate each of the first fuel cell and the
second fuel cell in parallel.
29. The computer readable media of claim 23 wherein at least one
plate in the first plurality of plates is in the first fuel cell
and wherein at least one plate in the first plurality of plates is
in the second fuel cell.
30. The computer readable media of claim 29 wherein the at least
one plate in the first fuel cell is an anode plate and wherein the
at least one plate in the second fuel cell is an anode plate.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional
Patent Application No. 61/115,463 filed on Nov. 17, 2008 and
61/117,481 filed on Nov. 24, 2008, respectively, both of which are
hereby incorporated by reference in their entirety.
BACKGROUND
[0002] The use of hydrogen and oxygen gas to supplement the
conventional fuel in an internal combustion engine in order to
increase the efficiency of the engine is known. For example,
electrolytic hydrogen generating systems are known to produce
hydrogen and oxygen gases for use as fuel additives. However, a
satisfactory hydrogen generating system that efficiently uses the
power supplied to the system and generates a sufficient supply of
gases at acceptable temperatures does not yet exist.
BRIEF DESCRIPTION
[0003] One aspect is directed to a method of dynamically adding or
removing a quantity of active plates in a plate assembly of a
hydrogen generating system, the plate assembly comprising a
plurality of plates. The method includes receiving a minimum
amperage threshold, a maximum amperage threshold, a maximum
temperature threshold, a first actual amperage, and a first actual
temperature of a hydrogen generating system, selecting a first
plurality of plates from the plate assembly, wherein the selection
is based on at least one of the following: the minimum amperage
threshold, the maximum amperage threshold, the first actual
amperage, and the first actual temperature, and applying a first
voltage to the first plurality of plates.
[0004] In another aspect, a computer readable medium has
instructions recorded thereon that when executed by a processor
cause the processor to receive a minimum amperage threshold, a
maximum amperage threshold, a maximum temperature threshold, a
first actual amperage, and a first actual temperature of a hydrogen
generating system, select a first plurality of plates from a plate
assembly, wherein the selection is based on at least one of the
following: the minimum amperage threshold, the maximum amperage
threshold, the first actual amperage, and the first actual
temperature, and apply a first voltage to the first plurality of
plates.
[0005] Various refinements exist of the features noted in relation
to the above-mentioned aspects. Further features may also be
incorporated in the above-mentioned aspects as well. These
refinements and additional features may exist individually or in
any combination. For instance, various features discussed below in
relation to any of the illustrated embodiments may be incorporated
into any of the above-described aspects, alone or in any
combination.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 is a perspective of a hydrogen generating system of
one suitable embodiment;
[0007] FIG. 2 is a perspective of a frame of the device of FIG.
1;
[0008] FIG. 3 is an exploded view of the frame;
[0009] FIG. 4 is a front view of a reservoir of the system of FIG.
1;
[0010] FIG. 5 is an exploded cross-section taken in the plane of
line 5--5 of FIG. 4;
[0011] FIG. 6 is an exploded view of a housing of the system of
FIG. 1;
[0012] FIG. 7 is a top plan view of the housing;
[0013] FIG. 8 is a cross-section taken in the plane of lines 8--8
of FIG. 7;
[0014] FIG. 9 is a bottom perspective of a lid of the housing of
FIG. 1;
[0015] FIG. 10 is a bottom plan view of the lid of FIG. 9;
[0016] FIG. 11 is a front elevation of the lid;
[0017] FIG. 12 is a front elevation of the housing and showing a
heater of the system;
[0018] FIG. 13 is an exploded view of an electrode plate assembly
of the housing of FIG. 6;
[0019] FIGS. 14A-14D are perspectives of plates of the electrode
plate assembly;
[0020] FIGS. 15A-15B are perspectives of connectors of the
electrode plate assembly;
[0021] FIGS. 16A-16C are perspectives of a retention bracket of the
electrode plate assembly;
[0022] FIG. 17 is a perspective of a plate assembly of a second
embodiment;
[0023] FIG. 18 is a block diagram of a vehicle including a hydrogen
generating system;
[0024] FIG. 19 is a block diagram of a hydrogen generating system
including an example electronic controller;
[0025] FIGS. 20 and 21 are flow charts showing an operation of the
electronic controller;
[0026] FIG. 22 is a flow chart showing an operation of the
electronic controller dynamically adding or removing a quantity of
active plates;
[0027] FIG. 23 is a schematic of another embodiment of an electrode
plate assembly;
[0028] FIG. 24 is a graph showing how the electronic controller can
determine which plate set is active;
[0029] FIG. 25 is a graph that illustrates gas production versus
time;
[0030] FIG. 26 is a graph that illustrates temperature versus
time;
[0031] FIG. 27 is a graph that illustrates amperage versus
time;
[0032] FIG. 28 is a graph that illustrates efficiency versus
time;
[0033] FIG. 29 is a graph that illustrates gas production versus
temperature;
[0034] FIG. 30 is a perspective of a hydrogen generating system of
another embodiment;
[0035] FIG. 31 is a front elevation of the system of FIG. 30 with a
housing removed to show a plate assembly;
[0036] FIG. 32 is a cross-section taken in the plane of lines
33--33 of FIG. 30; and
[0037] FIG. 33 is a cross-section taken in the plane of lines
33--33 of FIG. 30.
DETAILED DESCRIPTION
[0038] Referring now to the drawings and particularly to FIG. 1, a
fuel emission device or hydrogen generating system of one suitable
embodiment is generally designated 11. The hydrogen generating
system 11 generally comprises a housing 13 and a frame 15 for
supporting the housing 13. In this embodiment, the hydrogen
generating system 11, and in particular the housing 13 and the
frame 15, are adapted for mounting on a vehicle 19 (see FIG. 18),
such as a diesel tractor of a tractor-trailer combination, and
operably connected to an internal combustion engine 21 (see FIG.
18). A power source of the hydrogen generating system 11 may be,
for example a 12 volt or a 24 volt source, though the hydrogen
generating system 11 may be adapted to multiple voltage sources.
This embodiment also includes a reservoir 25 containing maintenance
solution 27, as shown in FIG. 5, for facilitating continued
operation of the hydrogen generating system 11. The reservoir 25
may, however, be omitted within the scope of this disclosure.
[0039] As shown in FIGS. 2 and 3, the frame 15 includes a floor 31
supporting the housing 13, side walls 33, and a back wall 35 (each
of which are broadly referred to as "frame members") such that the
housing 13 is surrounded on three sides. In other embodiments, the
back wall 35 may be omitted. Upper ends of the side walls 33 have
outwardly extending flanges 37. L-shaped brackets 39 are sized to
engage the flanges 37 and to secure the housing 13 on the frame 15.
The frame members are suitably secured by fasteners 41 (e.g., bolts
and nuts), but may be secured in other ways, and may also be made
as a one-piece unitary frame.
[0040] The frame 15 also includes an upright panel 43 secured to
the back wall 35. The upright panel 43 has side flanges 45 along
both vertical edges that extend forward around the side walls 33.
The side flanges 45 add strength to the upright panel 43. The frame
15 is suitably made of steel, though other materials may be
used.
[0041] Referring to FIGS. 4-5, the reservoir 25 includes a top 51,
a bottom 53, a front wall 55, a right wall 56, a left wall 57, and
a back wall 58. The back wall 58 is generally flat and includes
flanges 61 having holes 63 therein for receiving fasteners (not
shown) therethrough. The fasteners secure the reservoir 25 to the
upright panel 43 of the frame 15.
[0042] The reservoir 25 includes a relatively large opening 64
formed in a neck 65 at the top 51 of the reservoir 25. The opening
64 is closed by a removable cap 67 that is suitably secured to the
neck 65 (e.g., releasably secured by threads, not shown). The
reservoir 25 also includes an outlet port 69 extending from the
bottom 53 of the reservoir 25. A suitable conduit such as a tube 71
(see FIG. 1) connects the outlet port 69 to the housing 13.
[0043] Referring to FIGS. 6-8, the housing 13 defines an interior
chamber 75 containing an electrolyte solution 77, an electrode
plate assembly 79, a gasket 81 and a lid 83. The electrode plate
assembly 79 is generally received in the chamber 75, and at least
partially submersed, and more suitably fully submersed in the
electrolyte solution 77. The gasket 81 of this embodiment is an
O-ring made of a material capable of withstanding high
temperatures, such as 250.degree. F. and is generally adapted to
facilitate sealing the housing 13. The lid 83 of this embodiment is
also generally rectangular and is configured to cover the chamber
75. The gasket 81 and the lid 83 are adapted to seal the housing
13.
[0044] Referring to FIGS. 9-11, the lid 83 includes a set of
channels 87 formed in an inner surface 89 of the lid 83 for
channeling gas generated within the chamber 75 to a dome portion
(e.g., collector 91) of the lid 83. In this embodiment, the
channels 87 are V-shaped in cross-section and an end of each of the
channels 87 are adjacent to an end of the lid 83. Each of the
channels 87 extend generally from the end adjacent to the lid 83 to
the collector 91. An outlet 93 is disposed at an apex of the
collector 91. A suitable delivery system, such as conduit 95 (see
FIG. 1) connects the outlet 93 to the engine 21 of the vehicle 19
(see FIG. 18). The lid 83 has holes 96 around the periphery 97 for
receiving fasteners that secure the lid 83 to the housing 13. The
lid 83 has a square recess 99 for receiving a temperature sensor
101 (e.g., a thermistor) to sense the temperature of the hydrogen
generating system 11. The sensor 101 may be disposed inside or
outside the chamber 75, and may be disposed anywhere on the housing
13.
[0045] The delivery system may also include a condenser 100
disposed along the conduit 95 for inhibiting water vapor from
entering the engine 21. The condenser may suitably be a
bubbler-type condenser, though other types are contemplated.
[0046] Referring to FIGS. 6 and 12, the housing 13 has a generally
rectangular opening for receiving the electrode plate assembly 79
when the lid 83 is removed. The housing 13 also has four generally
upright sides 103 and a bottom 105. Ribs 106 on the sides 103
strengthen the housing 13. The housing 13 includes a flange 107
along an upper edge that mates with the lid 83. Fasteners 98 extend
through the lid 83 and the flange 107 of the housing 13.
[0047] The housing 13 of this embodiment is of unitary, one-piece
construction. The housing 13 is made of a crack and corrosion
resistant material. Also, the material may be non-insulating so
that thermal energy (e.g., heat) can be more easily transmitted
through the housing 13. One suitable material for the housing 13 is
high-density polyethylene which can be molded to form the housing
13. Other materials may be used without departing from the scope of
this disclosure.
[0048] As shown in FIG. 12, an exterior of the bottom 105 of the
housing 13 includes a central recess 109. The recess 109 spaces a
portion of the housing 13 above the frame 15, and is suitably
configured to accommodate a heater 110 in abutting, thermal
communication with the exterior of the bottom 105 (or generally the
underside) of the housing 13. The heater 110 may be any suitable
type of heater, including for example a radiant heater. The heater
110 may be used to warm the housing 13 and the solution 77 therein
to an operating temperature more quickly.
[0049] Referring to FIG. 13, the electrode plate assembly 79
generally includes electrode plates, suitable brackets 121 (e.g.,
retention brackets), and connection posts 141. The electrode plates
in this embodiment may be generally characterized as one of a
neutral plate 125N (FIG. 14A), an anode plate 125A (FIG. 14B), or a
cathode plate 125C (FIG. 14C). Each electrode plate is generally
rectangular and may include notches 129 along each edge. For
example, as shown in FIG. 14A, the neutral plate 125N includes one
notch 129 on a top edge 136, one notch 129 on each side edge 137,
and two notches 129 along a bottom edge 138 to accommodate
retention brackets 121. Each electrode plate may have fastener
holes 131 in a periphery of each electrode plate for receiving
fasteners 122 therethrough for use in securing the retention
brackets 121 on the electrode plate assembly 79.
[0050] One or more of the electrode plates may include surface
features, such as openings or holes, that are sized and shaped to
increase a surface area and "active sites" of the one or more
electrode plates. As shown in FIG. 14A, suitable surface features
include a plurality of holes in the form of slots 133 formed in a
central section of the neutral plate 125N. Other shapes of openings
are contemplated within the scope of the disclosure. The slots 133
provide an increase in surface area of at least about 0.3%, and in
some embodiments at least about 0.5%, when compared to a
hypothetical plate of the same dimensions but without surface
features. A ratio of surface area of each electrode plate having
surface features as compared to the hypothetical electrode plate
without such features is at least 1.03, and in some embodiments at
least about 1.05.
[0051] In one example (further described below in the Example
surface area section) each electrode plate is
0.40005.times.0.17780.times.0.00160 meters (16 gauge) and includes
200 slots 133. Each slot 133 has a radius of 0.00117 meters. This
configuration results in an increase in surface area of about 0.5%
(with a ratio of 1.005) when the surface area of an electrode plate
includes openings as compared to the hypothetical plate without
such openings. In this embodiment, the cathode plate 125C and the
anode plate 124A do not include slots 133, but only holes 131 for
receiving the fasteners 122 therethrough. However, other
embodiments have small slots 133 in the anode plate 125A and/or the
cathode plate 125C. The electrode plates may have other surface
features for increasing surface area (e.g., additional surfaces,
slits, holes, bumps, projections, or a rough or an abraded
surface). For example, the plate 125D of FIG. 14D includes
projections 134 extending outward from a surface or face of the
plate 125D, and dimples or impressions 135 extending inward into
the surface.
[0052] In one suitable plate assembly shown in FIG. 13, cathode
plates 125C (first and second cathode plates) are disposed at each
end of the electrode plate assembly 79 so that the plates are in
spaced apart relationship. An anode plate 125A is separate from the
cathode plates 125C and disposed in a center of the electrode plate
assembly 79 intermediate the cathode plates in spaced apart
relationship therewith. A plurality of neutral plates 125N are
disposed between each cathode plate 125C and the anode plate 125A,
each neutral plate in spaced relationship with the anode plate and
the cathode plates.
[0053] The cathode plates 125C and the anode plate 125A may be
swapped such that one anode plate 125A is at each end of the
electrode plate assembly 79 and one cathode plate 125C is in the
center of the electrode plate assembly 79. The number of neutral
plates 125N may also vary. In embodiments, for example, there may
be 18 neutral plates 125N, 16 neutral plates 125N, 14 neutral
plates 125N, 12 neutral plates 125N, 10 neutral plates 125N, or 8
neutral plates 125N. In the latter embodiment (8 neutral plates
125N), there are a total of 11 electrode plates (8 neutral plates
125N, one anode plate 125A, and two cathode plates or end plates
125C).
[0054] One advantage of using more electrode plates is that using
more electrode plates enables the hydrogen generating system 11 to
operate at a lower temperature. For example, in embodiments where
the anode plate 125A is in the center of the electrode plate
assembly 79, the number of neutral plates 125N on either side of
the anode plate 125A may be equal. However, other numbers and
configurations of the electrode plates are contemplated.
[0055] Two cathode plates 125C may be electrically connected by
suitable connectors, such as by a U-shaped connector 139 shown in
FIG. 15A or by other suitable connector(s). A post 141 extends
upward from the U-shaped connector 139. In this embodiment, the
post 141 is suitably a "clench" or threaded fastener that is joined
to the U-shaped connector 139 by a nut 143. The post 141 may be
joined to the U-shaped connector 139 by a separate fastener, by
welding, or the like. The post 141 may also be formed as one-piece
with the U-shaped connector 139. Likewise, the U-shaped connector
139 is suitably joined to the cathode plates 125C by a fastener,
but may be joined in other suitable ways. For example, the U-shaped
connector 139 and the post 141 may also both be formed as one-piece
with one or both of the cathode plates 125C.
[0056] An L-shaped connector 147 (FIG. 15B) has the post 141
extending upward from a main surface of the L-shaped connector 147.
The L-shaped connector 147 is suitably joined to the anode plate
125A at a top edge of the anode plate 125A by threads as described
above. Like the U-shaped connector 139 of FIG. 15A, the post 141
may be made as one-piece with the L-shaped connector 147 and the
anode plate 125A. The posts 141 are suitably connected to the power
source by wires (not shown).
[0057] In the embodiment shown in FIG. 13, the electrode plate
assembly 79 may alternatively be referred to as a "cell." In
further embodiments, more than one electrode plate assembly 79, or
cell, may be used. For example, a second electrode plate assembly,
or cell, may be added to the electrode plate assembly 79, described
above, and more suitably a non-conductive barrier may be disposed
between each of the electrode plate assemblies.
[0058] Each electrode plate is made of a suitable material that is
resistant to reactivity with the solution 77 or amperage applied.
In one embodiment, the electrode plates are made of a 316L
stainless steel. The material of an electrode plate is chosen to
have an appropriate resistance. Each electrode plate should be
sufficiently thick to reduce electrical resistance and to inhibit
significant flexing of the electrode plates. In some embodiments,
each electrode plate is between 16 gauge and 20 gauge, and in one
embodiment each electrode plate is 20 gauge. Note that a resistance
of a wire (and by analogy an electrode plate) is generally affected
by four factors: (1) material (for example, gold and silver have
relatively low resistance), (2) a thickness of the wire or the
electrode plate, (3) a temperature of the wire or the electrode
plate, and (4) a length of the wire (but a length of an electrode
plate is not an applicable factor). The thicker an electrode plate,
the more space exists for a current to flow. As an electrode plate
warms up, there is more energy therein and a resistance to a
current and an electron flow decreases.
[0059] Referring to FIGS. 16A-C, each retention bracket 121 is
generally U-shaped. Each bracket 121 is generally "combed", meaning
that each bracket 121 includes a bridge 148 and a plurality of
spacers 149 (or teeth) spaced apart such that one electrode plate
fits between two adjacent spacers 149. Spacing between spacers 149
is uniform so that a spacing between each electrode plate is equal.
In one embodiment, for example, the spacing between each electrode
plate is suitably between about 2.0 mm and about 6.5 mm. Fasteners
(for example, the fasteners 122) extend through the brackets 121
and through the electrode plates to secure the stack (e.g., the
electrode plate assembly), together. Each bracket is suitably made
of an electrically non-conductive material.
[0060] Referring to FIG. 17, in this embodiment, there are 12
interleaved electrode plates 151. The electrode plates 151 may be
formed as described above (e.g., of low carbon stainless steel).
Each electrode plate 151 is configured for an electrical connection
point 153 at one end of each electrode plate 151, for a total of 12
connection points. The plates are interleaved such that connection
points of adjacent plates 151 are opposite one another. A first set
of electrical connections 153 are attached (e.g., by jumper wires)
to connector blocks 156, with a corresponding second set of
electrical connections 153 being attached to a respective wire
harnesses (not shown) and connected to an electrical controller 202
(see FIG. 19). Generally, the controller 202 switches an electrical
current to various combinations of electrode plate sets to develop
a best use of current in the hydrogen generating system 11, such as
by the method described below.
[0061] Generating system 11' of another embodiment shown in FIG. 23
and FIGS. 30-32 is similar to the system 11 of FIGS. 1-12. The
positioning of the electrode plates in generating system 11' is
shown schematically in FIG. 23 and described in more detail in the
Example System below. In this embodiment, plate assembly 502
includes 22 electrode plates (six anode plates 510, 512, 514, 516,
518, 520, one cathode plate 508, and 15 neutral plates 524).
Alternatively, the anode plates may instead be cathode plates, and
the cathode plate may be an anode plate. Also, if not energized,
the anode plates 510, 512, 514, 516, 518, 520 serve as neutral
plates. As shown, the cathode plate 508 includes a post 509 that
extends through the lid 83, and each anode plate 125A includes a
similar post 511 that extends through the lid 83 at an opposite end
of the lid 83.
[0062] The brackets 121' of this embodiment include spacers 122'
that extend upward about 1.5 inches. The brackets 121 are sized
such that there is about 0.25 inches clearance between a bottom of
the electrode plates and the housing 13. The brackets 121 may also
be beveled to provide clearance of the electrode plates relative to
the housing 13.
[0063] Referring to FIG. 32, a float mechanism 124 extends from a
port in the lid 83. The float mechanism 124 serves to ensure that
the solution 77' is at a level above a top of the electrode plate
assembly 502. The float mechanism 124 is suitably a conventional
float 126 similar to a type used in a home toilet tank. The
mechanism 124 is in fluid communication with the solution 77' in
the chamber 75' and with the reservoir 25 via tube 71'. When the
level of the solution 77' begins to fall, the float 126 pivots
downward, opening a valve that allows maintenance solution (e.g.,
solution 27) from the reservoir 25 to enter the chamber 75'. As the
level of the solution 77' rises, the float 126 moves upward and
closes the valve. Note that the reservoir 25 is suitably disposed
above the housing 13' for gravity flow of the maintenance solution
to the chamber.
[0064] One advantage of some embodiments of this disclosure is that
each electrode plate can be monitored to control an amperage level
generated. As described in detail below, power can be channeled to
each electrode plate as needed to increase hydrogen production for
a given amperage. This can increase the generation of hydrogen and
oxygen available at start-up and significantly reduce a usual
warm-up period required to get the hydrogen generating system 11 to
full production at optimum temperature.
Starter and Maintenance Solutions:
[0065] The housing 13 or 13' has sufficient fluid (e.g.,
electrolyte solution 77) therein so that the electrode plates are
submersed in the fluid. Opposite faces (both faces) of the
electrode plates (any of the plates described herein) are exposed
to the electrolyte solution. Also, the surface features as
described herein are exposed to the solution. The fluid of one
embodiment is a solution having 20-320 mL of 2.14 molar potassium
hydroxide diluted to 11.353 liters. In this embodiment, the
electrolyte suitably contains color and buffers.
[0066] In the above embodiment, 200 mL of 2.14 molar solution is
added to the chamber 75 or 75' and diluted with distilled water to
a capacity of the chamber, for example 11.353 liters. A
concentration of electrolyte facilitates the electrical current
through the aqueous solution.
[0067] The reservoir 25 holds a maintenance solution (e.g.,
solution 27). In one embodiment, the maintenance solution includes
two buffer solutions and distilled water, though it is contemplated
to use only distilled water. The first buffer is alkaline, and
includes boric acid (H.sub.2B.sub.4O.sub.7) and Sodium hydroxide,
N.sub.aOH. The solution has a pH of about 12.7. In one embodiment,
there is between 25 grams and 35 grams of boric acid and between
about 9 grams and 15 grams of sodium hydroxide, in another
embodiment between about 30 and 32 grams of boric acid and between
11 grams and 13 grams of sodium hydroxide, and in one embodiment
about 31.4 grams of boric acid and about 12 grams of sodium
hydroxide. In one embodiment, the solution is made by dissolving
the boric acid and sodium hydroxide in 1 liter of distilled water.
This yields 0.1 M concentrations of each species. Then 10 mL of the
solution is added to 3.7843 liters of distilled water. A suitable
dye, such as bromothymol blue, may then be added.
[0068] The second buffer solution for the maintenance solution is
also alkaline and includes dipotassium phosphate (K.sub.2HPO.sub.4)
and tripotassium phosphate K.sub.3PO.sub.4. The solution has a pH
in a range of 10-14, or in some embodiments between 11 and 13, and
in some embodiments about 12.7. In one embodiment, there is between
10 grams and 20 grams of dipotassium phosphate and between about 9
grams and 15 grams of tripotassium phosphate, in another embodiment
between about 30 grams and 32 grams of dipotassium phosphate and
between 11 grams and 13 grams of tripotassium phosphate, and in one
embodiment about 15.8 grams of dipotassium phosphate and about 19.6
grams of tripotassium phosphate. In one embodiment, the solution is
made by dissolving the dipotassium phosphate and tripotassium
phosphate in 1 liter of distilled water. This yields 0.1 M
concentrations of each species. Then 10 mL of the solution is added
to 3.7843 liters of distilled water. A suitable dye, such as
bromothymol blue, may then be added.
Example System:
[0069] Referring to FIG. 18, an exemplary block diagram of the
vehicle 19 (e.g., a truck) including the hydrogen generating system
11 in communication with the engine 21 of the vehicle is shown.
Note that system 11' can be used instead. Embodiments of the
disclosure enable the hydrogen generating system 11 to generate a
sufficient amount hydrogen gas per minute (e.g., 6 liters of
hydrogen gas per minute) at a very low temperature (e.g.,
40.degree. F.) immediately upon start-up. Further, embodiments of
the present disclosure enable the hydrogen generating system to
manage heat at high temperatures (e.g., 140-180.degree. F.) while
producing acceptable quantities of hydrogen gas (e.g., over 2
liters per minute).
[0070] Referring to FIG. 19, an exemplary block diagram of the
hydrogen generating system 11 including an electronic controller
202 is shown. Embodiments of the disclosure enable the electronic
controller 202 to monitor an actual amperage and an actual
temperature of the hydrogen generating system 11. Further, the
embodiments described herein enable the hydrogen generating system
11 to achieve increased amperage between electrode plates of a cell
substantially immediately upon a start-up of the hydrogen
generating system 11 by effectively omitting a quantity of
electrode plates over which a voltage is applied.
[0071] The electronic controller 202 as described herein has one or
more processors 204 or processing units, a memory area 206, and
some form of computer readable media. By way of example and not
limitation, computer readable media comprise computer storage media
and communication media. Computer storage media include volatile
and nonvolatile, removable and non-removable media implemented in
any method or technology for storage of information such as
computer readable instructions, data structures, program modules or
other data. Communication media typically embody computer readable
instructions, data structures, program modules, or other data in a
modulated data signal such as a carrier wave or other transport
mechanism and include any information delivery media. Combinations
of any of the above are also included within the scope of computer
readable media.
[0072] Although the processor(s) 204 is shown separate from the
memory area 206, embodiments of the disclosure contemplate that the
memory area 206 may be onboard the processor(s) 204 such as in some
embedded systems. The processor(s) 204 executes computer-executable
instructions for implementing aspects of the disclosure. For
example, the processor(s) 204 is programmed with instructions such
as illustrated in FIGS. 20-22. The computer-executable instructions
may be organized into one or more computer-executable components or
modules. Generally, program modules include, but are not limited
to, routines, programs, objects, components, and data structures
that perform particular tasks or implement particular abstract data
types. Aspects of the present disclosure may be implemented with
any number and organization of such components or modules. For
example, aspects of the invention are not limited to the specific
computer-executable instructions illustrated in the figures and
described herein. Other embodiments of the invention may include
different computer-executable instructions. Aspects of the
disclosure may also be practiced in distributed computing
environments where tasks are performed by remote processing devices
that are linked through a communications network. The processor(s)
204 is transformed into a special purpose microprocessor by
executing computer-executable instructions or by otherwise being
programmed.
[0073] The electronic controller 202 may be in communication with a
display device (not shown) separate from or physically coupled to
the hydrogen generating system 11. The display device may be a
capacitive touch screen display, or a non-capacitive display. User
input functionality may also be provided in the display, where the
display acts as a user input selection device such as in a touch
screen. The display device may provide a user with information
regarding the hydrogen generating system 11, such as, temperature,
measured amperage, error messages, and the like.
[0074] In this embodiment, the hydrogen generating system 11
includes a temperature sensor (e.g., temperature sensor 101)
configured to measure an actual temperature of the hydrogen
generating system 11. The temperature sensor 101 may be disposed on
the outside of the housing 13. Due to the thermal properties of the
housing 13, a temperature drop across a wall of the housing 13 is
minimal so that the sensed/measured temperature is relatively close
to the temperature inside the housing 13. However, the temperature
sensor 101 may alternatively be disposed inside the housing 13.
[0075] A time from a start-up to optimum operating temperature
(e.g., about 140.degree. F. to about 160.degree. F.) of the
hydrogen generating system 11 is a function of an amount of
amperage generated by electrolysis. Therefore, as temperature
increases, amperage increases, and an efficiency for producing
hydrogen gas increases. An amperage sensor (not shown) may be used
to measure an actual amperage of the hydrogen generating system 11.
In a further embodiment, the hydrogen generating system 11 includes
resistors configured to measure an actual amperage.
[0076] Referring next to FIG. 20, a flow chart showing an operation
of the electronic controller 202 is shown. Upon a start-up of the
hydrogen generating system 11, at 208 a target amperage (e.g.,
about 20 amps to about 30 amps) and a maximum threshold temperature
(e.g., about 180.degree. F.) is received. The target amperage and
the maximum threshold temperature may be automatically set by a
manufacturer and/or manually selected by a user via the display
device.
[0077] To control amperage, the electronic controller 202 enables
each electrode plate in the electrode plate assembly 79 to be
individually monitored and controlled. At 210, a quantity of
electrode plates less than a total quantity of the electrode plates
in the electrode plate assembly 79 to apply a voltage to is
selected. Choosing to apply a voltage across a selected quantity of
electrode plates less than a total quantity of the electrode plates
in the electrode plate assembly 79 can result in higher currents
dissipating more power. This causes a faster rise in a temperature
of an electrolyte between the electrode plates to which the voltage
is applied (e.g., the active electrode plate set), thereby
increasing production of hydrogen gas that is being produced by the
active electrode plates. For example, as temperature increases, the
electrolyte becomes more conductive, enabling an inclusion of
additional electrode plates in the active electrode plate set and
thus increasing the efficiency of hydrogen gas produced by the
hydrogen generating system 11. Applying a voltage across a quantity
of electrode plates less than a total quantity of electrode plates
in the electrode plate assembly enables the hydrogen generating
system to generate at least 2 liters of hydrogen gas per minute at
a very low temperature (e.g., 40.degree. F.) substantially
immediately upon start-up. In one embodiment, only the electrode
plates required to achieve the target amperage receive an applied
voltage. The quantity of the plurality of electrode plates that
receive the applied voltage may be based on at least one of the
following: a temperature of an electrolytic solution, an amount of
voltage applied, a distance between each of the plurality of
electrode plates (e.g., about 3 mm), and a type and concentration
of electrolytic solution used. This can increase generation of
hydrogen and oxygen available at start-up and significantly reduce
a warm-up period required to get the hydrogen generating system 11
to full production at optimum temperature, the process of which is
described in detail below.
[0078] The electronic controller 202 provides a pulse of
electricity at a particular voltage for a duty cycle of, for
example, 4 ms (four milliseconds). The length of the duty cycle
(i.e., 4 ms) is merely exemplary and is not intended to limit the
scope of the present disclosure. One of ordinary skill in the art
will appreciate that various lengths of time may be used, for
example, 8 ms, 12 ms, and 14 ms may be used. A duty cycle may be
limited by applying the pulse for a fraction of the duty cycle. For
example, with a duty cycle of 4 ms, a pulse may be applied for only
3 ms of the 4 ms duty cycle, 2 ms of the 4 ms duty cycle, or even 1
ms of the 4 ms duty cycle. In further embodiments, the pulse
applied during the 4 ms duty cycle can be divided even further, for
example, to 1/16 or 1/32 of the 4 ms duty cycle.
[0079] After a voltage is applied to the selected quantity of
plates, at 212, an actual amperage and an actual temperature of the
hydrogen generating system 11 are measured. To compensate for an
increased temperature as the process of electrolysis occurs, the
electronic controller 202 can effectively lower the voltage applied
to the selected number of the plurality of plates (e.g., by
decreasing the time a pulse is applied in the duty cycle) to
maintain the amperage at a desired level during operation. For
example, at 214, the electronic controller 202 is configured to
compare the actual amperage to an amperage threshold (e.g., 25
amps), compare the actual temperature to a maximum threshold
temperature (e.g., 160.degree. F.), and at 216, adjust at least one
of a duty cycle and/or the applied voltage based on the comparisons
in order to regulate the actual temperature and the actual
amperage. For example, if it is determined that an actual amperage
exceeds a maximum amperage threshold (e.g., 30 amps) and/or the
actual temperature is greater than the optimal temperature, the
duty cycle may be adjusted to enable an average of an actual
amperage to substantially equal the target amperage. In contrast,
if it is determined that the actual amperage is equal to or less
than the maximum amperage threshold, and the actual temperature is
less than or equal to the optimal temperature, at 218, the duty
cycle may be increased. For example, a maximum voltage may be
applied to the selected quantity of plates for at least one duty
cycle. Next, the actual amperage and the actual temperature of the
hydrogen generating system are measured again, and the process is
repeated.
[0080] Referring next to FIG. 21, an additional flow chart showing
an operation of the electronic controller 202 is shown. At 302,
upon an initialization of the processor(s) 204 and other hardware
associated with the hydrogen generating system 11, a target
amperage (e.g., about 20 amps and about 30 amps), an optimal
temperature (e.g., about 160.degree. F.), and a maximum threshold
temperature (e.g., 180.degree. F.) are determined/received at 304.
In one embodiment, the optimal temperature is a range of
temperatures, for example, the optimal temperature may be a
temperature between 140.degree. F. and 160.degree. F. After the
target amperage, the optimal temperature, and the maximum threshold
temperature are determined/received, a voltage is applied to at
least some (e.g., a selected quantity) of the plurality of plates
in the hydrogen generating system.
[0081] Using the amperage sensor (not shown) and the temperature
sensor 101, at 306, an actual amperage and an actual temperature of
the hydrogen generating system 11 are determined/obtained, and
thereafter, compared to the target amperage and the optimal
temperature, respectively. At 308, if the actual amperage is below
the maximum amperage threshold (e.g., an amperage that does not
overburden a battery of the vehicle 19), and if the actual
temperature is below the optimal temperature, at 310, full voltage
is applied for at least one duty cycle.
[0082] At 312, if the actual amperage exceeds the maximum amperage
threshold, i.e., the current reaches a level where components may
be damaged, and if the actual temperature is below the optimal
temperature, at 314, a duty cycle is computed resulting in an
increased temperature. As one example, the maximum amperage
threshold may be 50 amps. However, at 316, if the actual
temperature equals the optimal temperature, at 318, a duty cycle is
computed and a rated amount of hydrogen gas is produced.
[0083] If however, at 316, the actual temperature exceeds the
optimal temperature, at 320, a duty cycle is reduced to maintain
the temperature. After the duty cycle is reduced, the actual
amperage is compared to the maximum safe amperage. If, at 322, the
actual amperage is less than or equal to a maximum safe amperage
threshold, the actual temperature is compared to the maximum
threshold temperature. At 328, if the actual temperature exceeds
the maximum temperature threshold, at 330, a current of the
hydrogen generating system 11 is turned off, an actual temperature
(e.g., a second actual temperature) is measured, and the current of
the hydrogen generating system 11 is turned on when it is
determined that the second actual temperature is below the maximum
temperature threshold.
[0084] If however, at 322, after the duty cycle has been reduced
and the actual amperage exceeds a maximum safe amperage threshold
(to prevent damage to the system), at 324, the current of the
hydrogen generating system 11 is turned off for a predefined period
of time (e.g., three minutes). At 326, after the predefined period
of time, the current is turned back on. Thereafter, an actual
amperage (e.g., a second actual amperage) is determined and
compared to the maximum safe amperage, and the process is
repeated.
[0085] In addition to the above advantages, using interchangeable
electrode plates as anodes and cathodes also maximizes gas
production by optimizing the quantity of energized (e.g., active)
electrode plates based on a target amperage. As more electrode
plates are energized, the quantity of electrolyte to electrode
plate transitions is increased which increases the gas production
per amp.
[0086] A transition occurs where electricity passes from the liquid
electrolyte to the metal of an electrode plate (the
electrolyte/plate interface). Hydrogen gas is formed at this
electrolyte/plate interface. Hence, if an electric current makes
the same amount of hydrogen gas for each transition from liquid to
metal, the more times a current is forced to make the transition,
the more hydrogen gas is produced per amp and the more efficient
the hydrogen generating system becomes.
[0087] For example, when anodes 514 and 516 in the embodiment shown
in FIG. 23 are energized, the electrolyte increases in temperature,
becomes more conductive, and the current increases. When the
current reaches 30 amps, anodes 512 and 516 are energized. The
current now drops because the additional transitions limit the
current. This process continues as anodes 512 and 518, then anodes
510 and 518, and then anodes 510 and 520 are sequentially
energized. After anodes 510 and 520 have been energized, individual
anodes are energized, starting with anode 514 followed in turn by
anode 516, anode 512, anode 518, anode 510, and finally anode 520.
In practice, it is not necessary to perform all the steps just
described. Some steps may not be reached while others may be
skipped. As further described below, any single anode, as opposed
to multiple anodes, may be selected to be energized based, for
example, on amperage and/or temperature. The electrolyte
concentration is set to allow sufficient current to flow at the
largest plate set contemplated to produce the desired gas. As
explained above, when an amperage threshold is detected, additional
plates may be energized to enable the hydrogen generating system 11
operate at optimal production. The conversion to an optimal
operating electrode plate configuration is a factor in the
increased efficiency of the electrolysis process.
[0088] Further, as a temperature of an aqueous solution increases,
an amperage of the hydrogen generating system 11 also increases.
Therefore, with 200 mL of electrolytic solution using multiple
anodes and cathodes, an actual amperage may become excessive. The
methods of controlling and/or limiting the actual amperage while
allowing a use of multiple anodes and cathodes described above
enable a use of the multiple anodes and cathodes to provide
constant amperage from a start-up of the electrolytic generating
system 11 until it is turned off.
[0089] Although described in connection with an exemplary computing
system environment, embodiments of the disclosure are operational
with numerous other general purpose or special purpose computing
system environments or configurations. Examples of well known
computing systems, environments, and/or configurations that may be
suitable for use with aspects of the disclosure include, but are
not limited to, mobile computing devices, personal computers,
server computers, hand-held or laptop devices, multiprocessor
systems, microprocessor-based systems, programmable consumer
electronics, mobile telephones, network PCs, minicomputers,
mainframe computers, distributed computing environments that
include any of the above systems or devices, and the like.
[0090] A method for dynamically adding or removing a quantity of
active electrode plates based on actual amperage will now be
described with reference to FIGS. 22-28.
[0091] FIG. 22 is a flow chart showing an operation of the
electronic controller 202 dynamically adding or removing a quantity
of active electrode plates from an electrode plate assembly (e.g.,
electrode plate assembly 502 in FIG. 23) based on at least one of
an actual amperage and an actual temperature.
[0092] At 402, upon receiving a minimum amperage threshold, a
maximum amperage threshold, a maximum temperature threshold, and an
actual temperature (e.g., first actual temperature of the hydrogen
generating system 11), at 404, the electronic controller 202
selects a first plurality of plates (e.g., an initial plurality of
plates) from the electrode plate assembly 502. The selection of the
first plurality of plates is based on at least one of the
following: the minimum amperage threshold, the maximum amperage
threshold, and the first actual temperature of a hydrogen
generating system. The first actual temperature may be the
temperature of the hydrogen generating system 11 upon start-up.
After the first plurality of plates is selected, at 406, a voltage
is applied to the first plurality of plates.
[0093] After the voltage is applied to the first plurality of
plates, at 408, an actual amperage (e.g., a first actual amperage)
and an actual temperature (e.g., a second actual temperature) of
the hydrogen generating system 11 is determined. At 410, the first
actual amperage is compared to the minimum amperage threshold and
the maximum amperage threshold. At 412, if it is determined, based
on the comparison, that the first actual amperage is between the
minimum amperage threshold and the maximum amperage threshold, at
414, a voltage is again applied to the first plurality of electrode
plates. If however, at 412, it is determined that the first actual
amperage is not between the minimum amperage threshold and the
maximum amperage threshold, and, at 416, the first actual amperage
is greater than or equal to the maximum amperage threshold, at 418,
a second plurality of electrode plates is selected from the
electrode plate assembly 502 whereafter a voltage is applied to the
second plurality of electrode plates.
[0094] If however, at 412, it is determined that the first actual
amperage is not between the minimum amperage threshold and the
maximum amperage threshold, and, at 416, the first actual amperage
is not greater than or equal to the maximum amperage threshold, at
420, it is determined if the first actual amperage is less than or
equal to the minimum amperage threshold. If, at 420, the first
actual amperage is less than or equal to the minimum amperage
threshold, the second plurality of plates selected includes more
plates than the first plurality of plates. However, if the second
actual amperage is equal to the minimum amperage threshold or if
the second actual amperage is below the minimum amperage threshold,
at 422, a second plurality of electrode plates that includes fewer
plates than the first plurality of plates is selected from the
electrode plate assembly 502.
[0095] FIG. 23 is a further example of an electrode plate assembly
(e.g., the electrode plate assembly 502 described above). The
electrode plate assembly 502 can be used in place of the assembly
shown above in FIGS. 6-8 in a housing, such as housing 13', sized
accordingly.
[0096] The electrode plate assembly 502 includes two cells (e.g.,
cell 504 and cell 506) that share a common cathode 506. The present
disclosure enables the cells 504 and 506 to operate (or run) in
parallel to achieve a sufficient amount of hydrogen gas production
(e.g., about 2 liters of hydrogen gas per minute) at low
temperatures (e.g., about 40.degree. F.). The cell 504 includes 11
electrode plates, three of which are anodes (e.g., anode 510, anode
512, and anode 514) and one of which is the cathode 508. The cell
506 includes 12 electrode plates, three of which are anodes (e.g.,
anode 516, anode 518, and anode 520) and one of which is the
cathode 508. By providing two cells that are asymmetrical (cell 504
including 11 electrode plates, and the cell 506 including 12
electrode plates), increased control and increased resolution is
obtained. That is, with the cells operating in parallel, the
electronic controller 202 is able to increase and decrease a
quantity of active electrode plates in smaller amounts, described
below.
[0097] In this embodiment, a distance between each electrode plate
in the electrode plate assembly 502 is suitably about 3 mm, and a
thickness of each electrode plate is suitably about 20 gauge. One
of ordinary skill in the art will appreciate that a quantity of
electrode plates, a distance between each electrode plate, and a
thickness of each electrode plate are merely exemplary and are not
intended to limit the scope of the present disclosure.
[0098] The electrode plate assembly 502 is configured to have a
voltage applied to a quantity of electrode plates less than the
total quantity of electrode plates in each cell 504 and 506. To
achieve this, the total quantity of electrode plates (e.g., 22
plates with the cells 504 and 506 operating in parallel) are
separated into electrode plate sets (e.g., electrode plate set 1,
electrode plate set 2, electrode plate set 3, electrode plate set
4, and electrode plate set 5). Each electrode plate set has a
different quantity of electrode plates. In this embodiment, a
quantity of electrode plates in each electrode plate set increases
from electrode plate set 1 to electrode plate set 5. For example,
electrode plate set 1 includes 14 electrode plates, electrode plate
set 2 includes electrode 16 plates, electrode plate set 3 includes
18 electrode plates, electrode plate set 4 includes 20 electrode
plates, and electrode plate set 5 includes 22 electrode plates.
Each of the electrode plate sets are defined by anode plates at
opposing ends of each electrode plate set. For example, electrode
plate set 1 has anode 514 and anode 516 at opposing ends, electrode
plate set 2 has anode 512 and anode 516 at opposing ends, electrode
plate set 3 has anode 512 and anode 518 at opposing ends, electrode
plate set 4 has anode 510 and anode 518 at opposing ends, and
electrode plate set 5 has anode 510 and anode 520 at opposing
ends.
[0099] FIG. 24 is a graph that includes data that further
illustrates how the electronic controller 202 determines which
electrode plate set is active (e.g., which electrode plate set
receives a voltage). In this embodiment, the determination is based
on a target amperage, and more specifically, a target amperage
range bound by a minimum amperage threshold and maximum amperage
threshold. In this example, the minimum amperage threshold is 20
amps and the maximum amperage threshold is 30 amps. The minimum
amperage threshold and the maximum amperage threshold may be
automatically set and/or manually selected by a user via the
display device. Furthermore, the minimum amperage threshold of 20
amps and the maximum amperage threshold of 30 amps are merely
exemplary are not intended to limit the scope of the present
disclosure.
[0100] Generally speaking, at any given temperature, amperage
decreases as a quantity of active electrode plates increase. In
addition, at any given quantity of active electrode plates,
amperage increases as temperature increases. Based on this
understanding, at a given temperature, applying a voltage to an
electrode plate set with a lesser quantity of electrode plates will
return a higher amperage compared to applying a voltage to an
electrode plate set with a greater quantity of electrode plates at
the same temperature. Therefore, when a voltage is applied to a
particular electrode plate set and an actual amperage reaches the
maximum amperage threshold, the electronic controller 202 activates
an electrode plate set that has a greater quantity of electrode
plates than the presently active electrode plate set, thereby
decreasing the amperage. In contrast, when a voltage is applied to
a particular electrode plate set, and an actual amperage reaches
the minimum amperage threshold, the electronic controller 202
activates an electrode plate set that has a lesser quantity of
electrode plates than the presently active electrode plate set,
thereby increasing the amperage.
[0101] Thus, at a given temperature, applying a voltage to an
electrode plate set that includes the least quantity of electrode
plates (e.g., plate set 1 if the cells 504 and 506 are operating in
parallel) returns the highest amperage. Therefore, in the example
shown in FIG. 24, because the temperature of the hydrogen
generating system 11 is only at 60.degree. F., the electronic
controller 202 initially activates electrode plate set 1, which
returns an actual amperage of 34.8 amps. However, 34.8 amps is
above the maximum amperage threshold of 30 amps. Therefore, the
electronic controller 202 increases a quantity of active electrode
plates by activating electrode plate set 2. Activating electrode
plate set 2 returns an actual amperage of 30.5 amps. However, 30.5
amps is still above the maximum amperage threshold of 30 amps.
Therefore, the electronic controller 202 increases a quantity of
active electrode plates by activating electrode plate set 3.
Activating electrode plate set 3 returns an actual amperage of 28
amps.
[0102] As shown in FIG. 24, the temperature of the hydrogen
generating system increases with time. As mentioned above, as the
temperature of the hydrogen generating system 11 increases,
amperage increases. Therefore, while the electrode plate set 3
initially returns an actual amperage of 28 amps, as time elapses,
the temperature of the hydrogen generating system 11 increases from
69.degree. F. to 78.degree. F. However, once the temperature of the
hydrogen generating system 11 reaches 78.degree. F., the electrode
plate set 3 returns an actual amperage of 30.30 amps, which is
above the maximum amperage threshold of 30 amps. Therefore, the
electronic controller 202 increases a quantity of active electrode
plates by activating electrode plate set 4, and at 78.degree. F.,
the electrode plate set 4 returns an actual amperage of 23.7 amps.
Once the temperature of the hydrogen generating system 11 reaches
118.degree. F., the electrode plate set 4 returns an actual
amperage of 31.50 amps, which is above the maximum amperage
threshold of 30 amps. Therefore, the electronic controller 202
increases a quantity of active electrode plates by activating
electrode plate set 5, and at 118.degree. F., the electrode plate
set 5 returns an actual amperage of 26.2 amps.
[0103] As mentioned above, using two cells (e.g., cells 504 and
506) that are asymmetrical increases control and resolution. For
example, once the hydrogen generating system 11 reaches an optimal
temperature, the electronic controller 202 may stop operating each
of the cells 504 and 506 in parallel. In this embodiment, operating
only one cell, three electrode plate sets are left available:
[0104] (1) electrode plate set 6, which is in the cell 506, and
includes all of the electrode plates from anode 518 to the cathode
508, totaling 10 electrode plates; [0105] (2) electrode plate set
7, which is in the cell 504, and includes all of the electrode
plates from anode 510 to the cathode 508, totaling 11 electrode
plates; and [0106] (3) electrode plate set 8, which is in the cell
506 and includes all of the electrode plates from anode 520 to the
cathode 508, totaling 12 electrode plates.
[0107] Thus, because the cell 506 has one more electrode plate than
the cell 504 (making the two cells asymmetrical), electrode plate
sets 6, 7, and 8 increase in total electrode plates by only 1
electrode plate, increasing the control and resolution.
[0108] In addition to adding and removing a quantity of active
electrode plates to maintain an amperage between a minimum amperage
threshold and maximum amperage threshold, if a temperature of the
hydrogen generating system 11 exceeds a maximum temperature
threshold, the electronic controller 202 may also adjust the duty
cycle.
[0109] FIG. 25 is a graph that illustrates gas production versus
time. The graph represents the results achieved by implementing
what is shown in FIG. 22, where the electronic controller 202
dynamically added/removed a quantity of electrode plates and/or at
least one of the applied voltage and a duty cycle based on amperage
and temperature. As shown in the graph, about 2.8 liters of
hydrogen gas are produced per minute upon initial start-up. The
last two points on the graph (points 602 and 604) represent where a
current was limited in order to prevent an increase in
temperature.
[0110] FIG. 26 is a graph that illustrates temperature versus time.
As expected, the temperature rises faster in the beginning when
fewer electrode plates are active, and as more electrode plates are
added, the rate of increase in the temperature is reduced.
[0111] FIG. 27 is a graph that illustrates current/amperage versus
time. As shown in the graph, the actual amperage decreases with
time because, as time elapses, temperature increases and a quantity
of active electrode plates operated is increased to decrease the
amperage (see FIG. 22). Further, power dissipated is equal to a
voltage applied across a cell multiplied by the amps passing
through the cell. As amperage drops at higher temperatures, the
power flowing to the hydrogen generating system 11 drops and a rate
of temperature rise slows down.
[0112] FIG. 28 is a graph that illustrates efficiency versus time,
where efficiency is an amount of hydrogen gas produced per amperage
of electricity. As shown in the graph, efficiency generally
improves as temperature increases and the quantity of active
electrode plates increases.
[0113] With reference back to FIG. 27, as shown in the graph, the
actual amperage decreases with time. The efficiency achieved in
each plate set is as follows: electrode plate set 1 (0.083),
electrode plate set 2 (0.092), electrode plate set 3 (0.094),
electrode plate set 4 (0.104), and electrode plate set 5 (0.110).
As shown here, increasing a quantity of active electrode plates
between an anode and a cathode increases efficiency.
[0114] FIG. 29 is a graph that illustrates gas production versus
temperature. As shown in the graph, about 2.7 liters of gas per
minute is achievable at 60.degree. F. These numbers are merely
exemplary and are not intended to limit the scope of the present
disclosure. For example, further tests have shown that 2 liters of
hydrogen gas per minute can be achieved at only 40.degree. F.,
without going over 30 amps.
Operating Environment
[0115] In one embodiment shown in FIG. 18, the hydrogen generating
system 11 is mounted in the vehicle 19, such as a truck, and is
mounted outside the engine 21, for example, behind a cab of the
truck. Other mounting arrangements are contemplated.
[0116] In this embodiment, the hydrogen output from the hydrogen
generating system 11 is directed to the engine 21 of the truck. The
hydrogen gas is a supplement to the conventional fuel of such an
engine (e.g., a petroleum-based fuel or "fossil fuel" such as
unleaded gasoline, diesel, natural gas or propane). The hydrogen
gas can improve fuel efficiency of the engine 21. The hydrogen gas
may enable the engine 21 to meet stringent emission standards while
also increasing fuel economy and/or power output.
Example Surface Area Increase Due to Holes in the Plate
Plate Parameters
[0117] Hole radius=0.00117 meters [0118] Length of plate=0.40005
meters [0119] Width of plate=0.17780 meters [0120] Thickness of
plate=16 gauge=0.00160 meters [0121] Number of holes=200 Surface
Area of Plate with no Holes [0122] Top & Bottom [0123] 0.40005
meters.times.0.17780 meters=2.80035 meters.sup.2 (L.times.W)
2.80035.times.2=5.6007 meters.sup.2 (top and bottom) [0124] Sides
[0125] 0.00160 meters.times.0.17780 meters.times.2=0.02235
meters.sup.2 (short sides) [0126] 0.00160 meters.times.0.40005
meters.times.2=0.05029 meters.sup.2 (long sides)
Total Surface Area of Plate
[0126] [0127] 5.6007 meters.sup.2+0.02235 meters.sup.2+0.05029
meters.sup.2=5.67258 meters.sup.2 Surface Area Removed from Holes
Being Added [0128]
200.times.pi.times.r.sup.2.times.2=200.times.0.07976.times.0.00117.times.-
0.00117.times.2 =0.06756 in.sup.t Surface Area Gained from
Cylinders Being Formed at Each Hole Made [0129]
200{(2.times.pi.times.r.times.r)+(2.times.pi.times.r.times.h)-(2.times.pi-
.times.r.times.r)} Note accounts for the top/bottom circles
removed. [0130] 200{(2.times.0.07976 meters.times.0.00117
meters.times.0.00117 meters)+(2.times.0.07976 meters.times.0.00117
meters.times.0.00160 meters)-(2.times.0.07976 meters.times.0.00117
meters.times.0.00117 meters)}=200.times.(2.times.0.07976
meters.times.0.00117 meters.times.0.00160 meters)=0.09446
meters.sup.2 Surface Area of Plates with Holes [0131] Surface Area
of Plates with Holes={Surface area of Solid Plate-Surface area of
plate removed to form holes +Surface Area Gained from Formation of
Cylinders where holes are made} [0132] Surface Area of Plates with
Holes=(5.67258 meters.sup.2-0.06756 meters.sup.2+0.09627
meters.sup.2)=5.69620 meters.sup.2 Ratio of Surface Area of Plates
with Holes vs. Solid Plate--16 Gauge [0133] Plate with Holes/Solid
Plate=5.69620/5.67258=0.02553 or 0.51% more surface area
[0134] When introducing elements of the present invention or the
embodiment(s) thereof, the articles "a", "an", "the" and "said" are
intended to mean that there are one or more of the elements. The
terms "comprising", "including" and "having" are intended to be
inclusive and mean that there may be additional elements other than
the listed elements.
[0135] As various changes could be made in the above constructions
without departing from the scope of the invention, it is intended
that all matter contained in the above description and shown in the
accompanying drawing[s] shall be interpreted as illustrative and
not in a limiting sense.
* * * * *