U.S. patent application number 13/077866 was filed with the patent office on 2011-07-21 for cylindrical hydrogen fuel generator having tubular cells with microscopic indentations.
Invention is credited to John D. Dupree, Fred E. McConahay, Bjorn Ake Ortenheim, Richard Ortenheim.
Application Number | 20110174242 13/077866 |
Document ID | / |
Family ID | 44276605 |
Filed Date | 2011-07-21 |
United States Patent
Application |
20110174242 |
Kind Code |
A1 |
McConahay; Fred E. ; et
al. |
July 21, 2011 |
CYLINDRICAL HYDROGEN FUEL GENERATOR HAVING TUBULAR CELLS WITH
MICROSCOPIC INDENTATIONS
Abstract
A hydrogen fuel generator having a fuel cell unit having
conductive tubular cells with microscopic indentations on one or
more surfaces is described.
Inventors: |
McConahay; Fred E.; (Ripon,
CA) ; Dupree; John D.; (Tracy, CA) ;
Ortenheim; Richard; (Tracy, CA) ; Ortenheim; Bjorn
Ake; (Muang Phuket, TH) |
Family ID: |
44276605 |
Appl. No.: |
13/077866 |
Filed: |
March 31, 2011 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61322696 |
Apr 9, 2010 |
|
|
|
Current U.S.
Class: |
123/3 ;
204/267 |
Current CPC
Class: |
C25B 11/036 20210101;
F02B 43/08 20130101; F02M 21/0227 20130101; F02B 43/10 20130101;
Y02T 10/30 20130101; F02M 21/0206 20130101; F02B 2043/106 20130101;
F02M 21/0278 20130101 |
Class at
Publication: |
123/3 ;
204/267 |
International
Class: |
F02B 43/10 20060101
F02B043/10; C25B 9/18 20060101 C25B009/18 |
Claims
1. A hydrogen fuel generator, comprising: a cylindrical enclosure
of metal, wherein the cylindrical enclosure is to operate as a
first electrode when coupled to a first terminal of a power source;
and a fuel cell unit disposed within the cylindrical enclosure,
wherein the fuel cell unit comprises: a second electrode coupled to
a second terminal of the power source; and a plurality of
conductive tubular cells disposed in a longitudinal direction of
the cylindrical enclosure, wherein at least one of the plurality of
conductive tubular cells comprises microscopic indentations on one
or more surfaces.
2. The hydrogen fuel generator of claim 1, wherein alternating ones
of the plurality of conductive tubular cells comprise different
metals.
3. The hydrogen fuel generator of claim 2, wherein the different
metals comprise stainless steel and titanium.
4. The hydrogen fuel generator of claim 2, wherein the plurality of
conductive tubular cells are passive conductors and are not coupled
to the first and second terminals.
5. The hydrogen fuel generator of claim 1, wherein every other one
of the plurality of conductive tubular cells is stainless steel and
the others of the plurality of conductive tubular cells are
titanium.
6. The hydrogen fuel generator of claim 1, wherein at least one of
the plurality of conductive tubular cells comprises a plurality of
holes on at least one surface of the respective cell.
7. The hydrogen fuel generator of claim 1, wherein every other one
of the plurality of conductive tubular cells comprises a plurality
of holes on at least one surface of the respective cell.
8. The hydrogen fuel generator of claim 1, further comprising a
polytetrafluoroethylene (PTFE) base insulator disposed within the
cylindrical enclosure to stabilize the plurality of conductive
tubular cells within the cylindrical enclosure and to insulate the
plurality of conductive tubular cells from one another.
9. The hydrogen fuel generator of claim 8, wherein the PTFE base
insulator comprises a plurality of grooves in which the plurality
of conductive tubular cells fit, and wherein the grooves space the
plurality of grooves at a specified distance from one another.
10. The hydrogen fuel generator of claim 1, wherein the second
electrode is a metal rod disposed within the plurality of
conductive tubular cells along a longitudinal axis of the
cylindrical enclosure.
11. The hydrogen fuel generator of claim 10, wherein the metal rod
is a metal bolt disposed within an innermost one of the plurality
of conductive tubular cells.
12. The hydrogen fuel generator of claim 1, wherein the second
electrode is a conductive tubular cell disposed within the
plurality of conductive tubular cells.
13. The hydrogen fuel generator of claim 1, wherein the first
terminal is a negative terminal and the second terminal is a
positive terminal.
14. The hydrogen fuel generator of claim 1, further comprising a
non-metal base coupled to the plurality of conductive tubular
cells, wherein the non-metal base arranges the plurality of
conductive tubular cells to be electrically isolated from one
another and to be spaced apart at specified distances from one
another.
15. The hydrogen fuel generator of claim 14, further comprising: a
non-metal lid coupled to the plurality of conductive tubular cells,
the non-metal lid having a hole through which a metal bolt passes,
wherein the metal bolt operates as the second conductor; a nut
configured to receive the metal bolt to fasten the non-metal lid,
the plurality of conductive tubular cells, and the non-metal base;
and a coupler to couple the second terminal of the power source to
the metal bolt.
16. The hydrogen fuel generator of claim 14, wherein the plurality
of conductive tubular cells are spaced apart by the same
approximate distance by the non-metal base.
17. The hydrogen fuel generator of claim 1, wherein the cylindrical
enclosure is a sump to be filled with the aqueous solution of water
and electrolyte.
18. A hydrogen fuel generator, comprising: a cylindrical enclosure
of metal configured to hold an aqueous solution of water and
electrolyte, wherein the cylindrical enclosure operates as a
cathode when connected to a power source; a metal electrode
disposed along the longitudinal axis of the cylindrical enclosure,
wherein the metal electrode operates as an anode when connected to
the power source; and an electrolysis cell disposed within the
cylindrical enclosure, wherein the electrolysis cell comprises a
plurality of conductive tubular cells disposed in a longitudinal
direction of the cylindrical enclosure, and wherein at least one of
the plurality of conductive tubular cells comprises microscopic
indentations on one or more surfaces.
19. The hydrogen fuel generator of claim 18, wherein alternating
ones of the plurality of conductive tubular cells comprise
different metals.
20. A system, comprising: an engine having an air intake; and an
injector coupled to the air intake to deliver hydrogen gas to the
air intake; and a hydrogen fuel generator coupled to the injector,
wherein the hydrogen fuel generator comprises: a cylindrical
enclosure of metal configured to hold an aqueous solution of water
and electrolyte, wherein the cylindrical enclosure operates as a
cathode when connected to a power source; a metal electrode
disposed along the longitudinal axis of the cylindrical enclosure,
wherein the metal electrode operates as an anode when connected to
the power source; and an electrolysis cell disposed within the
cylindrical enclosure, wherein the electrolysis cell comprises a
plurality of conductive tubular cells disposed in a longitudinal
direction of the cylindrical enclosure, and wherein at least one of
the plurality of conductive tubular cells comprises microscopic
indentations on one or more surfaces.
Description
RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional
Application No. 61/322,696, filed Apr. 9, 2010, the entire contents
of which are incorporated herein by reference. This application is
related to co-pending U.S. Application No. not yet assigned,
Attorney Docket No. 8749P001, entitled "Supplementary Fuel System
for Delivery of Hydrogen Gas to an Engine," filed herewith, and
co-pending U.S. Application No. not yet assigned, Attorney Docket
No. 8749P002, entitled "A Cylindrical Hydrogen Fuel Generator
Having Passive Tubular Cells," filed herewith, the contents of both
are incorporated herein by reference.
TECHNICAL FIELD
[0002] Embodiments of the present invention relate to fuel systems,
and more specifically, to a supplementary hydrogen fuel generator
and a computerized injection controller to supplement an existing
fuel system.
BACKGROUND
[0003] Using hydrogen as a supplemental fuel in motor vehicle
engines has been proposed to increase the performance of the
engine. When using hydrogen and oxygen as part of the air-fuel
mixture for the engine, the performance of the engine increases,
including increasing the mileage (e.g., miles per gallon (MPG))
and/or reducing the emissions of the engine. The hydrogen gas may
be generated through electrolysis of an aqueous solution. The
hydrogen gas may be referred to as monatomic hydrogen (HHO) gas, or
"Brown Gas," which is created by electrolysis by separating H2O
into molecules by passing an electrical current through water or an
aqueous solution. Electrolysis is a method of using an electric
current to drive an otherwise non-spontaneous chemical reaction.
Electrolysis is commercially highly important as a stage in the
separation of elements from naturally occurring sources such as
ores using an electrolytic cell. The three main components required
to achieve electrolysis are 1) a liquid containing mobile ions,
also referred to as an electrolyte; 2) an external power source of
direct electric current; and 3) two electrodes.
[0004] One conventional system, described in U.S. Pat. No.
5,231,954, filed Jan. 18, 2005, describes an electrolyzer having an
electrolysis chamber and a rack with an anode and a cathode and
alternating supplemental electrodes.
[0005] Another conventional hydrogen generating system is described
in U.S. Pat. No. 6,336,430, filed Jun. 29, 1998. This conventional
hydrogen generating system includes an electrolysis cell for
generating hydrogen and oxygen gases by electrolysis of an aqueous
solution, a power source for providing electrical power to the
electrolysis cell, and an outlet flow means for introducing the
generated gases into the intake manifold system of an internal
combustion engine. The electrolysis cell has a cylindrical shaped
case of polyvinyl chloride and an electrode assembly having a
series of bipolar electrode plates between an anode and a cathode,
held together by polypropylene bolts and nuts. The electrode plates
are a series of alternating parallel anodes and cathodes joined
together by means of bridging straps, and the outside cathode and
anode electrode plates are connected to the positive and negative
supply from the motor vehicle system via an adapter. The U.S. Pat.
No. 6,336,430 also describes that the series of bi-polar electrodes
could be concentric circular electrodes.
[0006] The conventional system described in U.S. Pat. No. 6,336,430
also includes a controller for monitoring the operating conditions
of the hydrogen generating system and for controlling parameters of
the hydrogen generating system to control its operation in response
to the monitoring. U.S. Pat. No. 6,336,430 describes the controller
monitoring parameters of the hydrogen generating system, including
the level of aqueous solution, temperature of the solution, engine
vacuum, and pressure in the gas supply line. In response to
negative inputs for these parameters, the controller turns off the
hydrogen generating system. The controller can also regulate the
electrical power provided to the electrolysis cell, controlling the
amount of hydrogen to be generated, as well as the power provided
to a pump to control the flow rate of the pump, if the pump is
included as part of the system.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] The present invention will be understood more fully from the
detailed description given below and from the accompanying drawings
of various embodiments of the invention, which, however, should not
be taken to limit the invention to the specific embodiments, but
are for explanation and understanding only.
[0008] FIG. 1 is a diagram of a supplementary fuel system having a
hydrogen fuel generator and a computerized injection controller
according to one embodiment.
[0009] FIG. 2 is a side-view diagram of the hydrogen fuel generator
of FIG. 1, including a fuel cell unit, according to one
embodiment.
[0010] FIG. 3A is a diagram illustrating a side-view and a
cross-section view of the fuel cell unit of FIG. 2 according to one
embodiment.
[0011] FIG. 3B is a diagram illustrating a side-view and a
cross-section view of the fuel cell unit of FIG. 2 according to
another embodiment.
[0012] FIG. 4A illustrates another embodiment of the hydrogen fuel
generator of FIG. 1.
[0013] FIG. 4B is a top-view of the hydrogen fuel generator of FIG.
4A.
[0014] FIG. 4C illustrates another embodiment of the hydrogen fuel
generator of FIG. 1.
[0015] FIG. 5A is a block diagram of one embodiment of the
injection control system 120 of FIG. 1.
[0016] FIG. 5B is a flow diagram of one embodiment of a method of
injection control for delivery of hydrogen to an engine.
[0017] FIG. 6 illustrates a diagrammatic representation of a
machine in the exemplary form of a computer system for injection
control of hydrogen gas into an engine.
DETAILED DESCRIPTION
[0018] A method and system of a supplementary fuel system for
delivering hydrogen to an engine is described. The embodiments
described herein include hydrogen fuel generator, also referred to
as an electrolyzer that is designed to be simple, compact and to
produce HHO gas. HHO gas is being produced in order to "boost" the
vehicle or generator by improving miles per gallon (MPG)
performance, improving the burn quality of the fuel, thus reducing
any unwanted emissions, and producing more power and to clean out
old carbon deposits inside the engine. The supplementary fuel
system adds the HHO gas to the air entering the engine. In one
embodiment, the supplementary fuel system can be integrated to work
with existing engines, and may leverage some of the existing
components associated with the engine. In another embodiment, the
supplement fuel system can be integrated along with another type of
fuel system when initially manufactured or assembled. In addition,
the embodiments describe an on-demand system that generates
hydrogen gas on demand, instead of storing the hydrogen gas.
[0019] The embodiments described herein can be used to provide an
improved fuel system for an engine. The embodiments described
herein can be used to address the need for drastic emission
reductions and improved fuel economy in all engines. The term
"engine" as used herein refers to any engine that consumes a
fuel-air mixture within the engine itself so that the host gaseous
produces of the combustion act directly on the surfaces of engine's
moving parts. Such moving parts may include pistons, turbine rotor
blades, or the like. The engine may be an internal combustion
engine, including gasoline engines, diesel engines, Liquefied
petroleum gas (LPG) engines, Bio Diesel engines, gas turbine
engines, jet engines, rocket engines, or the like. The embodiments
described herein can be utilized with any engine, regardless of
fuel type currently being utilized. The embodiments described
herein can work along with an existing fuel source to compliment
the efficiency of fuel burn within the combustion chamber, thus
reducing emissions and increasing fuel economy. The embodiments
described herein generate hydrogen gas from an aqueous electrolyte
solution utilizing electrolysis to achieve this process.
[0020] By including HHO gas in your combustion chamber, the
temperatures may decrease slightly, and may be a helpful additive
or fuel because the hydrogen first burns inside the engine and the
byproduct is stream, which becomes water as it condenses. The
condensation may possibly cool the outside of the engine's exhaust.
The embodiments described herein may result in approximately 20% to
70% improvement of gas mileage. Alternatively, other percentages
may be achieved. However, it should also be noted that the overall
mileage increase in vehicles may be determined by several factors,
such as driving habits, the condition of your vehicle, tire
inflation, driving conditions and more. In addition, because
hydrogen gas burns at a cooler temperature than diesel, the
viscosity of the engine's oil may not break down as quickly. This
may lead to longer periods between oil changes and less wear to the
cylinders, hence reducing your overall maintenance costs of the
engine.
[0021] The embodiments described herein may also reduce engine
emissions. In some cases, the embodiments have been shown to
significantly reduce the noxious and toxic engine emissions,
thereby reducing greenhouse gas emissions and providing cleaner air
than vehicles without these embodiments. In addition, hydrogen and
oxygen are two of the most abundant elements available on earth.
The hydrogen-per-unit is three times more powerful in energy
produced than gasoline and almost four times that of ethanol. No
only will emissions decrease to lower levels, the fuel (e.g.,
gasoline, diesel, or the like) may combust more efficiently with
fewer pollutants in the exhaust. The oil may stay cleaner, the
plugs may last longer, the engine may stay cleaner internally, and
the engine temperature may drop by several degrees Fahrenheit.
Alternatively, these embodiments may provide other benefits as
would be appreciated by those of ordinary skill in the art having
the benefit of this disclosure.
[0022] In the following description, numerous details are set
forth. It will be apparent, however, to one of ordinary skill in
the art having the benefit of this disclosure, that embodiments of
the present invention may be practiced without these specific
details. In some instances, well-known structures and devices are
shown in block diagram form, rather than in detail, in order to
avoid obscuring the embodiments of the present invention.
[0023] Some portions of the detailed description that follow are
presented in terms of algorithms and symbolic representations of
operations on data bits within a computer memory. These algorithmic
descriptions and representations are the means used by those
skilled in the data processing arts to most effectively convey the
substance of their work to others skilled in the art. An algorithm
is here, and generally, conceived to be a self-consistent sequence
of steps leading to a desired result. The steps are those requiring
physical manipulations of physical quantities. Usually, though not
necessarily, these quantities take the form of electrical or
magnetic signals capable of being stored, transferred, combined,
compared, and otherwise manipulated. It has proven convenient at
times, principally for reasons of common usage, to refer to these
signals as bits, values, elements, symbols, characters, terms,
numbers, or the like.
[0024] It should be borne in mind, however, that all of these and
similar terms are to be associated with the appropriate physical
quantities and are merely convenient labels applied to these
quantities. Unless specifically stated otherwise as apparent from
the following discussion, it is appreciated that throughout the
description, discussions utilizing terms such as "receiving,"
"monitoring," "processing," "providing," "computing,"
"calculating," "determining," "displaying," or the like, refer to
the actions and processes of a computer system, or similar
electronic computing systems, that manipulates and transforms data
represented as physical (e.g., electronic) quantities within the
computer system's registers and memories into other data similarly
represented as physical quantities within the computer system
memories or registers or other such information storage,
transmission or display devices.
[0025] Embodiments of the present invention also relate to an
apparatus for performing the operations herein. This apparatus may
be specially constructed for the required purposes, or it may
comprise a general-purpose computer system specifically programmed
by a computer program stored in the computer system. Such a
computer program may be stored in a computer-readable storage
medium, such as, but not limited to, any type of disk including
floppy disks, optical disks, CD-ROMs, and magnetic-optical disks,
read-only memories (ROMs), random access memories (RAMs), EPROMs,
EEPROMs, magnetic or optical cards, or any type of media suitable
for storing electronic instructions.
[0026] FIG. 1 is a diagram of a supplementary fuel system 100
having a hydrogen fuel generator 110 and a computerized injection
controller 120 according to one embodiment. The supplementary fuel
system 100 includes a hydrogen fuel generator 110 to generate
hydrogen gas using electrolysis. The hydrogen fuel generator 110
delivers hydrogen gas through the check valve 113 to the hydrogen
supply line 127. The check valve 113 may be used to prevent the
back flow of fluids into the hydrogen fuel generator 110. As the
flow of hydrogen gas leaves the hydrogen fuel generator 110, the
supply line 13 routes the hydrogen gas through a receiver/dryer 130
to ensure no moisture is passed through to the engine 150. From the
receiver/dryer 130, the hydrogen gas passes through the induction
line 123 to an injection control system 120, including a
computerized injection controller 122 and an injector 124. The
injection control system 120 regulates the flow of hydrogen gas to
the engine 150 on the induction line 125. The injection control
system 120 can regulate the amount of hydrogen gas that is induced
into the engine at any given time. Unlike the conventional system
described in U.S. Pat. No. 6,336,430, which uses a flow control
valve and a pump to regulate the flow of gas, the injection control
system 120 can electronically regulate the injector 124 to inject a
specified amount of hydrogen gas into the engine 150 via the
induction line 125. The injection control system 120 does not
regulate how much hydrogen gas is being generated by the hydrogen
fuel generator 110, rather how much hydrogen gas is delivered to
the engine 150 at any given point in time. For example, the
injection control system 120 controls the appropriate amount of
hydrogen to be injected into an air intake of the engine. The
injection controller 122 may be programmed for each individual
engine at any given time. In one embodiment, the injection control
system 120 is programmed for each specific engine to optimize the
amount of hydrogen gas injected into the engine 150 to increase
emission reduction and reduce fuel economy. In some cases, the
injection control system 120 is programmed to achieve the highest
emission reduction and highest fuel economy obtainable for a given
engine.
[0027] In one embodiment, the induction lines 123 and 125 are
stainless steel tubing, such as stainless steel aircraft tubing. In
another embodiment, the induction lines 123 and 125 are
polytetrafluoroethylene (PTFE) tubing (also commonly referred to
DuPont.RTM. brand name "Teflon.RTM." tubes). PTFE is a synthetic
fluoropolymer or tetrafluoroethylene. Alternatively, other types of
lines may be used as would be appreciated by those of ordinary
skill in the art having the benefit of this disclosure. The supply
line 127 (also referred to as a fuel line) may be stainless steel
fuel line, as well as other types of supply lines.
[0028] In one embodiment, the injection control system is a
stand-alone injection controller 122, which provides a map having
multiple cell elements that contain a number that indicates the
amount of hydrogen that is to be delivered to the engine. In one
embodiment, the map is a three-dimensional mapping of the flow of
hydrogen gas to be injected. In one embodiment, a three-dimensional
map is used that includes multiple cell locations (also referred to
as "cells"), where each cell locations contains a value that
corresponds to an injector pulse width (e.g., the amount of time
the injector is active (e.g., on-time) or the amount of time the
injector is pulsed) based on multiple factors, such as manifold
pressure and RPMS. In this embodiment, the injection controller 122
programs the injector pulse width directly into cell locations of
the map according to the boost pressure and revolutions per minute.
In one embodiment, the injection controller 122 includes an
interface, such as a serial port to program and calibrate the
injection controller 122. In one embodiment, the injection
controller 122 receives various inputs through the interface. For
example, the injection controller 122 can monitor the engine's
tachometer signal, injector loom, and/or vacuum/boost line. The
injection controller 122 computes the output pulse width according
to the desired parameters defined during programming and outputs
the pulse width to the injector 124, which injects the desired
amount of hydrogen gas received on the induction line 123 into the
induction line 125. In one embodiment, the injector 124 injects the
hydrogen gas directly into an intake manifold of the engine 150.
This may vary based on the type of engine. For example, there may
be other intervening components of the fuel system. For example,
the injector 124 may inject the hydrogen gas into a dryer before
the intake manifold. Most diesel engines, for example, are induced
on the return side of the air-to-air cooler nearest the intake
manifold. Most gasoline engines are induced into a spacer plate,
which is installed directly on top of the manifold. In most cases,
these types of engines utilize a threaded fitting to which the
induction line 125 (e.g., stainless steel line) can couple.
[0029] The hydrogen fuel generator 110 is coupled to a power
source, such as the existing engine battery 160 or the alternator
power supply. Alternatively, other types of power sources may be
used as would be appreciated by those of ordinary skill in the art
having the benefit of this disclosure. The main power from the
battery 160 may be routed through an automatic re-settable circuit
breaker 161 and a control relay 162 for operation and protection.
The positive terminal of the battery 160 can be coupled to the
control relay 162 using a wire (e.g., 8-gauge), and the load side
of the control relay 162 can be coupled to the positive terminal of
the hydrogen fuel generator 110 (e.g., coupler coupled to the
anode). The negative terminal of the battery 160 can be coupled to
a mounting bolt of the hydrogen fuel generator 110. The negative
control terminal of the relay 162 is connected to the positive
terminal of the cycle switch 140 using a wire, while the negative
terminal of the cycle switch 140 is coupled to the mounting bolt of
the hydrogen fuel generator 110, which is coupled to the negative
terminal of the battery 160. The relay 162 may also receive power
from a positive ignition source, as well as an optional oil
pressure control from a cycle switch (not illustrated). In the case
of the positive ignition source, a wire (e.g., 14-gauge) can couple
the keyed ignition power source to the positive control terminal of
the relay 162. Alternatively, other power configurations are
possible based on the engine's existing electrical configuration as
would be appreciated by one of ordinary skill in the art having the
benefit of this disclosure. The control side of the relay's
circuitry may be activated by a switched ignition power source to
ensure the hydrogen fuel generator 110 is only active during
operation of the engine. It should be noted that the hydrogen fuel
generator 110 can be wired in other configurations as would be
appreciated by those of ordinary skill in the art having the
benefit of this disclosure.
[0030] As depicted in FIG. 1, the injection control system 120 may
also be powered by the engine's battery 160 and may be
independently fused to ensure over current protection.
Alternatively, the injection control system 120 can be powered
using other configurations as would be appreciated by one of
ordinary skill in the art having the benefit of this
disclosure.
[0031] In one embodiment, the hydrogen fuel generator 110 includes
an adjustable pressure cycle switch 140, which is utilized to
precisely regulate the pressure within the hydrogen fuel generator
110 that is produced during the hydrogen manufacturing process. In
another embodiment, the entire outer housing is equipped with an
atmospheric discharge valve 111 (labeled as safety valve) as a
secondary safety measure to prevent over pressurization of the
hydrogen fuel generator 110. Alternatively, other safety mechanisms
can be used in connection with the hydrogen fuel generator 110.
[0032] Additional details regarding the hydrogen fuel generator 110
are described below with respect to FIGS. 2, 3A, 3B, 4A, 4B, and
4C. Additional details regarding the injection control system 120
are described below with respect to FIGS. 5A, 5B, and 6.
[0033] FIG. 2 is a side-view diagram of the hydrogen fuel generator
110 of FIG. 1, including a fuel cell unit 220, according to one
embodiment. The hydrogen fuel generator 110 includes a head 210,
the fuel cell unit 220, a housing unit 230, and a ring nut 240.
[0034] The head 210 includes an opening (and corresponding cap and
fitting) for filling the hydrogen fuel generator 110 with the
aqueous electrolyte solution. The solution may be water or may be a
water solution having electrolyte. Electrolyte is a substance that
when dissolved in a suitable solvent, such as water, or when fused
becomes an ionic conductor. Electrolytes are used in the hydrogen
fuel generator 110 to conduct electricity between the anode and
cathode. The electrolyte may be used to provide increased
efficiency of the electrolysis reaction. The solution may be
adjusted to remain in a liquid solution form and not freeze at
extremely low temperatures as would be appreciated by one of
ordinary skill in the art having the benefit of this disclosure.
The head 210 may be threaded to allow coupling with the ring nut
240 in order to fasten the head 210 to the housing unit 230. The
head 210 includes another opening in which the check valve 113 may
be disposed. Alternatively, the check valve 113 may be disposed in
other locations. The check valve 113 (illustrated in FIG. 1) can be
adjusted to release the hydrogen gas generated by the fuel cell
unit 220 when a specified pressure has been reached. In one
embodiment, the check valve 113 is adjusted to 20 pounds per square
inch (psi). In other embodiments, the check value 113 may be set to
other pressure levels. In one embodiment, the check valve 113 and
the outer housing of the hydrogen fuel generator 110 is tested and
rated to ensure 300% safety margin over the maximum operating
pressures, such as between 20 to 100 psi. In one embodiment, by
setting the check valve 113 to be set at 20 psi on the lower end of
the range, the hydrogen fuel generator 110 does not go all the way
down to zero psi. This may allow faster delivery of the hydrogen
gas to the engine 140. The check valve's purpose may include
maintaining a minimum pressure level when the system is not in use.
This in-turn assists in the production of hydrogen gas returning to
optimum pressure at a faster rate. The check valve 113 may also aid
in the elimination of water/electrolyte solution traveling through
the supply line 127 to the receiver/dryer 130. The head 210 may
also include the adjustable pressure cycle switch 140, which is
utilized to precisely regulate the pressure within the hydrogen
fuel generator 110 that is produced during the hydrogen
manufacturing process. Alternatively, the adjustable pressure cycle
switch 140 may be disposed in other locations on the hydrogen fuel
generator 110, or elsewhere in the fuel system. In another
embodiment, the head 210 is equipped with an atmospheric discharge
valve (e.g., safety valve 111) as a secondary safety measure to
prevent over pressurization of the hydrogen fuel generator 110. The
head 210 may also include a terminal to be coupled to a negative
terminal of the battery 160, as illustrated in FIG. 1.
[0035] When coupled to the negative terminal of the battery 160,
the entire outer housing of the hydrogen fuel generator 110,
including the head 210, housing unit 230, and ring nut 240,
operates as a first electrode, specifically the cathode for
electrolysis. In one embodiment, the housing unit 230 is a
cylindrical enclosure of metal. In one embodiment, the housing unit
230 is stainless steel. In one exemplary embodiment, the stainless
steel 316 grade is used. The head 210, housing unit 230, and the
ring nut 240 may be stainless steel. Alternatively, other grades of
stainless steel or different metals may be used for the different
parts of the hydrogen fuel generator 110. The outer housing 230 may
include an opening at the bottom to allow the aqueous solution to
be drained from the housing unit 230. In one embodiment, the
housing unit 230 includes a female national pipe thread (FNPT)
(e.g., 1/4'' FNPT) to allow a drain valve to be screwed into the
bottom of the housing unit. In one embodiment, the housing unit 230
is approximately 10.375 inches in height (H), 3.375 inches in width
(W) (diameter), and the overall height (H) of the hydrogen fuel
generator 110 is approximately 12 inches. In one embodiment, the
diameters (D) of the cylindrical tubular cells 310 and 320 are 1.0
inches, 1.5 inches, 2.0 inches, 2.5 inches, and 3.0 inches,
respectively from the innermost tube 320 to the outer tube 310. In
other embodiments, other diameters (D) may be used. In one
embodiment, each of the outer tube 310 and inner tubes 320 has a
thickness of 0.060 inches. Alternatively, other thicknesses may be
used. In another embodiment, the housing unit 230 is approximately
20 inches in height (H), 3.375 inches in width (W) (diameter), and
the overall height (H) of the hydrogen fuel generator 110 is
approximately 22 inches. In another embodiment, the overall height
(H) of the hydrogen fuel generator 110 is between approximately 10
inches to 36 inches, and the overall width (W) is between
approximately 3 inches to 8 inches. Alternatively, other dimensions
may be used based on various factors, such as the size of the
engine, the space available for installing the hydrogen fuel
generator 110, amount of hydrogen gas needed, etc, the amount of
voltage of the power source (e.g., 12V, 24V, or the like) as would
be appreciated by one of ordinary skill in the art having the
benefit of this disclosure.
[0036] The fuel cell unit 220 is disposed within the cylindrical
enclosure 230, and includes multiple conductive tubular cells
disposed in a longitudinal direction of the cylindrical enclosure
230 and a metal rod disposed within the conductive tubular cells
along a longitudinal axis of the cylindrical enclosure 230. When
coupled to the positive terminal of a power source (e.g., the
battery 160), the metal rod operates as a second electrode,
specifically the anode for electrolysis. Unlike the alternating
bi-polar plates described in the conventional systems, the
conductive tubular cells of the embodiments described herein are
passive conductors and are not coupled to the negative and positive
terminals. In one embodiment, the fuel cell unit 220 includes one
outer tube and one or more inner tubes, for example, three inner
tubes, or four inner tubes. In another embodiment, the metal rod is
a metal bolt, such as a stainless steel bolt, disposed within the
innermost tube of the one or more inner tubes. The metal bolt may
be used to fasten the fuel cell unit 220 together as described in
more detail below. Alternatively, the metal rod may be other types
of metal and may or may not be used to fasten the fuel cell unit
220 together. In another embodiment, the innermost tube is
connected to the positive terminal and operates as the anode. For
example, the innermost tube may have threads to fasten to the lid
and base.
[0037] In one embodiment, the power source is approximately 12
volts. In another embodiment, the power source is approximately
24V. When using 24 volts, the dimensions of the fuel cell unit 220
may be changed. For example, the height (H) dimensions of the fuel
cell unit 220 (e.g., height (H) of the conductive tubular cells)
may be twice as big as the dimensions for the fuel cell unit 220
that operates at 12 volts, while the diameters and placement of the
conductive tubular cells may remain substantially unchanged. The
dimensions of the fuel cell unit 220 may also be affected based on
the total surface area of the conductive tubular cells. For
example, in some embodiments, the conductive tubular cells may have
holes to have approximately 52% to 65% total surface area, leaving
between approximately 35% to 48% open surface area on the
conductive tubular cells. In one exemplary embodiment, the
conductive tubular cells have 40% open surface area. When the
dimensions of the conductive tubular cells change, the appropriate
amount of holes may be made in the fuel cells to provide
approximately 40% of the open surface area. Alternatively, when
other voltages are used, the dimensions of the fuel cell units may
vary accordingly in order to generate and maintain the appropriate
currents for proper operation.
[0038] FIG. 3A is a diagram illustrating a side-view and a
cross-section view of the fuel cell unit 220 of FIG. 2 according to
one embodiment. The fuel cell unit 220 includes one outer tube 310
and four inner tubes 320. In another embodiment, the fuel cell unit
220 includes one outer tube 310 and the innermost tube of the four
inner tubes 320 is optional, totaling four tubes, one outer tube
and three inner tubes. In one embodiment, the outer and inner tubes
310 and 320 are stainless steel. Alternatively, other types of
metal may be used as described herein.
[0039] The outer and inner tubes 310 and 320 are coupled to a
non-metal base 330, which arranges the inner tubes 310 and 320 to
be electrically isolated from one another. In another embodiment,
the non-metal base 330 are configured to space the tubes 310 and
320 at specified distances from one another, such as at approximate
fixed distances or the same approximate distances from one another.
In one exemplary embodiment, as shown in the cross-section view,
the outer tube 310 is approximately 3 inches, and the inner tubes
320 are approximately 2.5'', 2.0'', 1.5'', and 1'', respectively.
As stated above, the innermost tube 320 of approximately 1'' may be
optional. Alternatively, other dimensions may be used based on
various factors, such as the size of the engine, the space
available for installing the hydrogen fuel generator 110, amount of
hydrogen gas needed, etc, as would be appreciated by one of
ordinary skill in the art having the benefit of this disclosure. In
one embodiment, the outer and inner tubes 310 and 320 are 0.075
gauge tubes. In another embodiment, the outer and inner tubes 310
and 320 have a height between approximately 4 inches and 30 inches,
and a width between approximately 1 inch and 71/2 inches. The
non-metal base 330 and a non-metal lid 350 may be PTFE isolators at
the top and bottom to support and stabilize the outer and inner
tubes 310 and 320. In one embodiment, the non-metal base 330 and
non-metal lid 350 have a thickness between approximately 1/2 inch
and 3 inches, and the diameter is approximately 1/2 inch less than
the respective housing dimensions in FIG. 2. Alternatively, other
dimensions may be used. In one embodiment, the non-metal base 330
and lid 350 have circular groves in which the tubes fit to support
the tubes at the specified distances. These circular tubes isolate
the tubes from one another and the spacing between the tubes
affects the current generated by electrolysis. The non-metal base
330 and lid 350 may each have a hole through which a metal bolt 340
(e.g., stainless steel bolt) passes to secure the entire inner
assembly. The metal bolt 340 passes through the base 330, innermost
tube, and lid 350 to be secured to a nut 360 (with or without the
washer 361). In another embodiment, the metal bolt 340 bonds to the
inner most tube, thus creating a larger anode surface area. For
example, the top of the innermost tube may include a surface having
a threaded hole to which the metal bolt 340 bonds disposed within
the innermost tube. The remaining tubes (e.g., 3 of 4 tubes) are
passive conductors that are neutral and have no physical bond to
the anode or the cathode (e.g., the entire outer housing).
[0040] In one embodiment, the metal rod 340 and nut 360 are coupled
to a coupler 370, which is coupled to the positive terminal of the
power source. In one embodiment, the coupler 370 passes through the
opening of the head 210 to be coupled to the positive terminal. In
another embodiment, the coupler 370 is coupled to a threaded stud
that passes through the opening. The threaded stud is secured to
the head 210 with PTFE insulator and corresponding nut.
Alternatively, other types of coupling between the positive
terminal of the power source and the metal bolt 340 may be
used.
[0041] FIG. 3B is a diagram illustrating a side-view and a
cross-section view of the fuel cell unit 320 of FIG. 2 according to
another embodiment. The fuel cell unit 320 is similar to the fuel
cell unit 220 of FIG. 3A as noted by similar reference labels. As
described above, the fuel cell unit 220 includes the metal bolt 340
that passes through a hole in the base 330 up through the innermost
tube 320, through a hole in the lid 350 to be secured by the nut
360 and coupler 370. This design is used to secure the cylindrical
tubular cells between the lid 350 and the base 330, and uses the
bolt 340 as an anode disposed within the cylindrical tubular
cells.
[0042] Referring to FIG. 3B, instead of using the metal bolt 340,
the fuel cell unit 320 uses a threaded rod 372 to be secured to the
innermost tubular cell (innermost one of the tubes 320) at the top
and a threaded rod 373 to be secured to the innermost tubular cell
at the bottom. In particular, a threaded washer 362 is secured
(e.g., welded) to the top of the innermost tube 320, and a threaded
washer 344 is secured (e.g., welded) to the bottom. The threaded
washers 362 and 344 have a hole through which the threaded rods 372
and 373 can be threaded. The threaded rods 372 and 373 can be
threaded into the innermost tube 320 by a specified amount to
secure the respective rode to the innermost tube 320. This allows
the innermost tube 320 to be open (or hollow) throughout most of
the height (H) of the innermost tube 320. The threaded rod 373 is
secured to the nut 342 at the bottom, and the nut 342 can be
semi-permanently or permanently secured to the bottom of the base
330 or to the threaded rod 473, such as by welding. The innermost
tube 320 and threaded rods 372 and 373 become a single component
that is secured to the base 330 and the lid 350, and can be used as
the anode, instead of the bolt 330. The threaded rod 372 is secured
to the lid 350 using two nuts 363 and a washer 361. Since the lid
350 may be made of softer material than metal, two nuts 363 can be
used to provide additional stability to the threaded rod 372 and
the innermost tube 320 within the fuel cell unit. The threaded rod
372 is secured to the head 210, such as by being welded. The
threaded rod 372 can be secured to the head 210 before or after
being secured to the innermost tube. In one embodiment, the
threaded rod 372 is between approximately 5 inches and 11 inches,
based on the size of the fuel cell unit. The threaded rod 373 may
be between 1/2 and 3/4 inch depending on the height of the base
330. The threaded rods 372 and 373 may be stainless steel, such as
316 grade. In one embodiment, the threaded rods 372 and 373 are
1/4-20 rods. Alternatively, other dimensions and other types of
metals may be used for the threaded rod 372 and for the threaded
rod 373 as would be appreciated by one of ordinary skill in the art
having the benefit of this disclosure.
[0043] At the top of the fuel cell unit 320, a PTFE insulator 374
can be disposed above the lid 350 can insulate the threaded rod
372. The PTFE insulator 374 prevents exposure of the metal to
reduce or eliminate arcs caused from being exposed. In one
embodiment, the PTFE insulator 374 may be between approximately 5
inches and 11 inches in height (H) and is disposed to cover the
threaded rod 372. Of course, the height of the PTFE insulator 374
may vary based on the height of the threaded rod 372. It should be
noted that although the depicted insulator 374 is PTFE, other types
of materials may be used. This embodiment removes the coupler 370
and the metal bolt 340.
[0044] FIG. 4A illustrates another embodiment of the hydrogen fuel
generator 110 of FIG. 1. In this embodiment, the hydrogen fuel
generator 110 includes a fuel cell unit 420. The fuel cell unit 420
has an inner core 410 having four tubes 411-414. Within the outer
tube 411 are disposed three inner tubes 412-414, each opposing tube
has holes in the outer cylindrical surfaces, beginning with the
anode bolt 440, which is bonded with the innermost tube 414. In one
embodiment, the holes are equally spaced. Alternatively, other
patterns may be used for the holes. The holes increase the surface
area of metal exposed to the aqueous solution. In one embodiment,
the holes are drilled to optimize the reactive surface. In one
exemplary embodiment, the holes are 1/8'' holes drilled on 3/16''
staggered centers. This configuration may be modified to increase
or decrease the reactive surface, which affects the current draw of
the core design. In this embodiment, the innermost tube 414 and the
inner tube 412 have holes. Alternatively, other patterns can be
used, such as all of the tubes have holes, or all of the tubes
except the outer tube 411.
[0045] In another embodiment, the inner core tubes 411-414 include
microscopic indentations on its surfaces. In one embodiment, all
surfaces of the inner core tubes 411-414 include microscopic
indentations. In another embodiment, less than all surfaces of the
inner core tubes 411-414 include microscopic indentations. In one
embodiment, the microscopic indentations are manufactured using
abrasive blasting. Abrasive blasting is the operation of forcibly
propelling a stream of abrasive material against the surface under
high pressure to make the microscopic indentations on the surfaces
of the inner core tubes 411-414. There are several variations of
abrasive blasting, such as, for example, sand blasting, bead
blasting, shot blasting, and sodablasting. In another embodiment,
the microscopic indentations may be made using other techniques as
would be appreciated by one of ordinary skill in the art having the
benefit of this disclosure.
[0046] In another embodiment, the inner core tubes 411-414 include
microscopic indentations and holes as depicted in FIG. 4A. The
microscopic indentations, like the holes, increase the amount of
reactive surface exposed to the aqueous solution, which further
increases the excitation of hydrogen molecules, which consequently
increases the efficiency of the electrolysis towards optimal
hydrogen gas production.
[0047] In another embodiment, the inner core tubes 411-414 can be
disparate materials. For example, the outer tube 411 and the inner
tube 413 may be stainless steel and the inner tubes 412 and 414 may
be titanium. The disparate metals may also increase the excitation
of hydrogen molecules, increasing the efficiency of the
electrolysis. In other embodiments, other combinations of different
metal types may be used, such as stainless steel and other metals
with similar characteristics as titanium. In one embodiment,
embodiment, the inner core tubes 411-414 includes holes,
microscopic indentations, and alternating metals. Alternatively,
the inner core tubes 411-414 may include any combination
thereof.
[0048] The inner core 410 also includes PTFE pucks 430 and 450 as
the base and lid of the inner core 410. The PTFE pucks 430 and 450
include groves in which the tubes 411-414 fit to support and
maintain the tubes 411-414 in their respective positions, such as
at fixed distances from one another. The PTFE puck 430 includes a
hole through which the bolt 440 may be disposed. The bolt 440
passes through the PTFE puck 430, the innermost tube 414 and
through a hole of the PTFE puck 450 to be secured by the washer 461
and nut 460. In another embodiment, the pucks 430 and 450 are
high-density polyethylene (HDPE) pucks. Alternatively, other
polyethylene thermoplastics may be used.
[0049] In one embodiment, the inner core 410 is coupled to a head
411 of the hydrogen fuel generator 110 via a rod coupling 470. A
rubber insulator 471 may be placed around the rod coupling 470 and
the nut 460 to insulate the anode connection. Alternatively, other
types of insulators may be used. The rod coupling 470 is coupled to
the stud 462, such as a continuous-thread stud (e.g., 1/4''-20).
The nut 463 secures the stud 462 on the one side of the head 411
and the nut(s) 468 secure the stud 462 on the other side of the
head 411. The nuts 468 can be insulated with PTFE insulators 464
and 466, respectively. The PTFE insulator 466 and stud 426 are also
illustrated in the top-view of FIG. 4B. An o-ring 465 can be
disposed on the head 411 to help provide a seal between the head
and the lock ring 442, which is secured to the sump 432. The sump
432 can be filled with the aqueous solution through the fill cap
467. In one embodiment, the sump 432 is implemented as a wet sump,
which has the sump 432 as the only reservoir to be filled with the
aqueous solution (e.g., water and electrolyte). In another
embodiment, the sump 432 is implemented as a dry sump having an
external reservoir that is filled with the aqueous solution and a
pressure pump is used to pump the solution into the sump 432.
[0050] In another embodiment, such as depicted in FIGS. 4A and 4B,
the head 411 also includes a pressure pop off valve 480, such as an
atmospheric discharge valve that can be adjusted, for example, to
the maximum operating pressure of the hydrogen fuel generator 110
(e.g., 200 psi). The head 411 also includes an adjustable pressure
cycle switch 490, which is utilized to precisely regulate the
pressure within the hydrogen fuel generator 110 that is produced
during the hydrogen manufacturing process. In one embodiment, the
cycle switch 490 is adjusted to operate at approximately 90 psi
with a 3-psi variance. Alternatively, the cycle switch 490 can be
set to other pressure levels based on the design. In other
embodiments, the adjustable pressure cycle switch 490 may be
disposed in other locations on the hydrogen fuel generator 110.
Also, the adjustable pressure cycle switch 490 may be disposed in
other locations in the fuel system. For example, a fuel system that
includes multiple hydrogen fuel generators, a single adjustable
pressure cycle switch 490 can be disposed, for example, a dryer, or
at another location and control each of the multiple fuel
generators.
[0051] In one embodiment, the head 411 also includes a fill cap and
fitting 467, through which the sump 432 can be filled with the
aqueous solution. In addition, the sump 432 may include a drain
valve 491, through which the aqueous solution can be drained from
the sump 432. Alternatively, the hydrogen fuel generator may
include more or less components in order to supply the aqueous
solution to the hydrogen fuel generator.
[0052] In the depicted embodiment, the head 411 also includes the
check valve 490 that allows the hydrogen gas to be delivered to the
receiver/dryer 130 via the supply line 127. Like the check valve
113, the check valve 490 prevents back flow of fluids into the
hydrogen fuel generator 110. As described herein, the check valve
490 may operate as a safety mechanism, and other safety mechanisms
may be used.
[0053] As depicted in FIG. 4B, the head 411 includes at least one
terminal 499 (e.g., one of the four mounting bolts depicted as
circles in FIG. 4B) at which the entire outer housing of the
hydrogen fuel generator 110 can be connected to a negative terminal
of the power source, such as the battery 160. In another
embodiment, the terminal on the head 411 can be coupled via a wire
to the metal chassis or the engine ground, which is connected to
the negative supply terminal of the battery 160.
[0054] FIG. 4C illustrates another embodiment of the hydrogen fuel
generator of FIG. 1. The fuel cell unit 480 is similar to the fuel
cell unit 420 of FIG. 4A as noted by similar reference labels. As
described above, the fuel cell unit 420 includes the metal bolt 440
that passes through a hole in the PTFE puck 340 up through the
innermost tube 414, through a hole in the PTFE puck 450, washer
461, and is secured by the nut 460. Also, the fuel cell unit 420
includes a rubber insulator 471 and rod coupling 470 to secure and
electrically couple the bolt 440 (and nut 46) to the stud 462 of
the head 411. This design is used to secure the cylindrical tubular
cells between the pucks 430 and 450, and uses the bolt 440 as an
anode disposed within the cylindrical tubular cells.
[0055] Referring to FIG. 4C, instead of using the metal bolt 340,
the fuel cell unit 480 uses a threaded rod 472 to be secured to the
innermost tubular cell (innermost one of the tubes 414) at the top
and a threaded rod 473 to be secured to the innermost tubular cell
at the bottom. In particular, a threaded washer 462 is secured
(e.g., welded) to the top of the innermost tube 414, and a threaded
washer (not illustrated) is secured (e.g., welded) to the bottom.
The threaded washers have a hole through which the threaded rods
472 and 473 can be threaded. The threaded rods 472 and 473 can be
threaded into the innermost tube 414 by a specified amount to
secure the respective rode to the innermost tube 414. This allows
the innermost tube 414 to be open (or hollow) throughout most of
the height (H) of the innermost tube 414. The threaded rod 473 is
secured to the nut 474 at the bottom, and the nut 474 can be
semi-permanently or permanently secured to the threaded rod 473,
such as by welding. The innermost tube 414 and threaded rods 472
and 473 become a single component that is secured to the pucks 430
and 450, and can be used as the anode, instead of the bolt 440. The
threaded rod 472 is secured to the puck 450 using two nuts 460 and
a washer 461. The two nuts 460 can provide stability to the
innermost tub and threaded rods. The threaded rod 472 is secured to
the head 411, such as by being welded before or after being secured
to the innermost tube 411. Like above, the threaded rod 472 may be
between approximately 5 inches and 11 inches, based on the size of
the fuel cell unit. The threaded rod 473 may be between 1/2 and 3/4
inch depending on the height of the puck 430. The threaded rods 472
and 473 may be stainless steel, such as 316 grade. In one
embodiment, the threaded rods 472 and 473 are 1/4-20 rods.
Alternatively, other dimensions and other types of metals may be
used for the threaded rod 472 and for the threaded rod 473 as would
be appreciated by one of ordinary skill in the art having the
benefit of this disclosure.
[0056] At the top of the fuel cell unit 480, a PTFE insulator 475
can be disposed above the PTFE puck 450 can insulate the threaded
rod 472. The PTFE insulator 475 prevents exposure of the metal to
reduce or eliminate arcs caused from being exposed. In one
embodiment, the PTFE insulator 475 may be between 5 inches and 11
inches in height (H) and is disposed to cover the threaded rod 472.
Of course, the height of the PTFE insulator 475 may vary based on
the height of the threaded rod 472. It should be noted that
although the depicted insulator 475 is PTFE, other types of
materials may be used. This embodiment removes the rod coupling
470, and rubber insulator 471, as used in the fuel cell unit 410.
In some cases, the rubber insulator 471 may melt or change shape
due to temperatures within the fuel cell unit. The melted or
changed shape of the rubber insulator 471 may cause arcing by
exposing portions of the metal. The embodiments that use the
innermost tube as the anode may avoid this problem.
[0057] FIG. 5A is a block diagram of one embodiment of the
injection control system 120 of FIG. 1. The injection control
system 120 includes the computerized injection controller 122 and
one or more injectors 124 as depicted in FIG. 1. The one or more
injectors 124 can be high-impedance injections or low-impedance
injectors. The injection control system 120 regulates the flow of
hydrogen gas from the induction line 123 from the receiver/dryer
130 to the induction line 125 to the engine 150. The injection
control system 120 may be programmable for each specific engine to
calculate and deliver the desired amount of hydrogen gas to the
engine to reduce emissions and increase fuel efficiency.
[0058] The injection controller 122 may be a stand-alone injection
controller, which provides three-dimensional mappings of the flow
of hydrogen induced, which is described in more detail below. In
another embodiment, the injection controller 122 may be a component
or a module of an engine management controller or other computing
device associated with the engine 150, such as an on-board computer
of a vehicle or of a machine using the engine 150. In one
embodiment, the injection controller 122 is programmable, and may
be programmed for the particular engine being used.
[0059] In one embodiment, the injection controller 122 provides
precise hydrogen gas delivery to an internal combustion engine. A
user can program the injection controller 122, providing the user a
convenient way to set the mixture of hydrogen gas, air, and fuel
injected into the combustion engine. The injection controller 122
can be programmed to deliver the desired amount of hydrogen gas to
the engine to achieve a desired air/fuel ratio, to reduce
emissions, and/or to increase mileage. In one embodiment, the user
can access the injection controller 122 via an interface, such as a
serial port or a USB port. The user can create a file, such as a
configuration file that contains a three-dimensional map that
includes multiple cell locations containing a value corresponding
to the amount of hydrogen gas to deliver to the engine based on one
or more factors as described herein. The configuration file may
also include other settings that are used to control the injector
124. The file may also contain other settings that are used to
control fuel delivery, ignition timing, Exhaust Gas Oxygen (EGO)
sensor offset, and a variety of other engine parameters as would be
appreciated by those of ordinary skill in the art having the
benefit of this disclosure.
[0060] In one embodiment, the injection controller 122 receives one
or more engine parameters 521, and can monitor one or more input
connections that receive monitored operational parameters 523 from
other components of the system, such as the tachometer, the
injector loom, the vacuum/boost line, or the like. The engine
parameters 521 may include boost pressure, vacuum pressure, or
voltage from the engine's injector loom and vacuum/boost lines. The
engine parameters 521 may also include revolutions per minute
(RPM), such as from the engine's tachometer signal, respectively.
In the depicted embodiment, the injection controller 122, via input
connections, monitors the engine's tachometer signal, injector loom
510, the vacuum/boost line 520, the injector's pulse width or duty
cycle, or the like, as the monitored operating parameters 423. The
injector controller 122 varies the output pulse width of the
injector 524 according to the desired parameters defined during the
programming based on the monitored operational parameters 523. In
another embodiment, the induction control system 120 can measure
the engines cam-positioning sensor and throttle positioning sensor
and varies the flow of hydrogen accordingly.
[0061] In one embodiment, the injection controller 122 uses the
three-dimensional map, which includes cell locations that each
contains a value that represents the injector's on-time or how much
the injectors are pulsed. This value may represent the amount of
time, for example, in milliseconds. For example, if one of the cell
locations is filled with a value of 10, whenever the manifold boost
pressure and RPM match one of those cell locations, the injectors
will be pulsed for 10 milliseconds. In one embodiment, the
injection controller 122 programs the injector pulse width directly
into cell locations on a map defined by boost pressure and
revolutions per minute. The three-dimensional map may be stored in
memory, such as a non-volatile memory, or other types of memory or
storage devices that are internal or external to the injection
controller 122. Programming and calibration of the interrupt
controller 122 may be achieved through a serial interface, which is
active during engine operation. Alternatively, the injection
controller 122 can use other techniques to control the injector
124, such as a look-up table (LUT), an algorithm, or dedicated
hardware or software logic to compute the desired output to the
injector 124 based on the engine parameters 521 and monitored
operating parameters 523. It should also be noted that the
three-dimensional map, LUT, algorithm or dedicated logic can be
calibrated to adjust the injection controller's response to the
engine parameters being monitored as would be appreciated by those
of ordinary skill in the art having the benefit of this
disclosure.
[0062] In the depicted embodiment, the injectors 124 receive the
hydrogen gas from the induction line 123 from the receiver/dryer
130. The intake pressure tube 521 receives the airflow 524 and the
injectors 124 inject the hydrogen gas into the airflow 524 as
described above. The airflow with the hydrogen passes the throttle
body 522 to the induction line 125 to the engine 150.
[0063] In the depicted embodiment, the injection controller 122
provides one or more outputs 522 to one or more user interface
devices 560. The user interface device 560 may be a digital
display, a meter, a graphical user interface on a display, or other
types of user interface devices, such as those present on a
dashboard or console of the vehicle or on a control panel
associated with an engine used in another type of machine. The user
interface device 560 may be a meter or digital display, indicating
the performance of the supplementary fuel system, or specific
aspects of the supplementary fuel system. The meter, for example,
may indicate that supplementary fuel system is injecting hydrogen
gas into the air-fuel mixture, the rate at which hydrogen gas is
being injected, the resulting affect on the mileage by the hydrogen
gas, and/or miles to empty based on the use of hydrogen gas. The
injection controller 122 may be configured to provide other outputs
to a user operating the engine, as well as provide outputs, such as
in a log file, to users that service the engine, such as a mechanic
or technician. The user interface device 560 may also indicate the
emissions of the vehicle, such as a meter than moves based on the
measured emissions using the hydrogen gas. The user interface
device 560 may also indicate whether the supplementary fuel system
is on or off, if the fuel system needs service, such as if the
aqueous solution level is low or empty, or the like. The user
interface device 560 may be used to display the outputs of the
injection controller 122, or other outputs associated with the
hydrogen fuel generator 110. The user interface device 560 may also
display other indicators that are related to other systems than the
supplementary fuel system. For example, the user interface devices
560 may be integrated with the user interface devices 560 of the
vehicle containing the engine. In another embodiment, the injection
controller 122 provides the outputs 522 to another system
associated with the engine 150, such as an on-board computer of the
vehicle housing the engine 150, for example.
[0064] FIG. 5B is a flow diagram of one embodiment of a method of
injection control for delivery of hydrogen to an engine. The method
550 is performed by processing logic that may comprise hardware
(circuitry, dedicated logic, etc.), software (such as is run on a
general purpose computer system or a dedicated machine), firmware
(embedded software), or any combination thereof. In one embodiment,
the injection controller 122 of the injection control system 120
performs the method 550. In another embodiment, the computing
system of an engine management system performs the method 500.
Alternatively, other components of the supplementary fuel system
can perform some or all of the operations of method 550.
[0065] Referring to FIG. 5B, processing logic begins with receiving
one or more engine parameters, such as when the interrupt
controller is programmed. After programming, and during operation,
the processing logic receives one or more operating parameters of
an engine (block 522). Next, the processing logic determines a
desired amount of hydrogen gas to deliver to the engine (block
554), and controls an injector to deliver the desired amount to the
engine (block 556). In one embodiment, the processing logic
determines a desired amount of hydrogen gas to deliver using a
three-dimensional map, stored in memory, which represents a pulse
width of the injector for a given set of measurements, such as RPM
and pressure. In another embodiment, the processing logic
determines the desired amount using a look-up table. In another
embodiment, the processing logic may implement an algorithm that
computes the desired amount based on the engine parameters
programmed by the user and the monitored operating parameters of
the engine. In another embodiment, a computer in a system using the
engine and hydrogen fuel generator is configured to execute
instructions that cause the computer to perform the method.
[0066] In another embodiment, the processing logic also displays
emission outputs to a user via a user interface device (block 558),
such as a meter, digital display, or graphical user interface to
indicate the increase/decrease in mileage, emissions, and/or the
like. The processing logic may also display or provide various
other outputs, such as fuel efficiency in terms of miles per gallon
or distance to empty.
[0067] FIG. 6 illustrates a diagrammatic representation of a
machine in the exemplary form of a computer system 600 for
injection control of hydrogen gas into an engine. Within the
computer system 600 is a set of instructions for causing the
machine to perform any one or more of the methodologies discussed
herein, may be executed. In alternative embodiments, the machine
may be connected (e.g., networked) to other machines in a LAN, an
intranet, an extranet, or the Internet. The machine may operate in
the capacity of a server or a client machine in a client-server
network environment, or as a peer machine in a peer-to-peer (or
distributed) network environment. The machine may be a PC, a tablet
PC, a STB, a PDA, a cellular telephone, a web appliance, a server,
a network router, switch or bridge, or any machine capable of
executing a set of instructions (sequential or otherwise) that
specify actions to be taken by that machine. Further, while only a
single machine is illustrated, the term "machine" shall also be
taken to include any collection of machines that individually or
jointly execute a set (or multiple sets) of instructions to perform
any one or more of the methodologies discussed herein for injection
control of hydrogen gas into the engine, such as the method 550
described above. In one embodiment, the computer system 600
represents various components that may be implemented in the
injection control system 120 as described above. Alternatively, the
injection control system 120 may include more or less components as
illustrated in the computer system 600.
[0068] The exemplary computer system 600 includes a processing
device 602, a main memory 604 (e.g., read-only memory (ROM), flash
memory, dynamic random access memory (DRAM) such as synchronous
DRAM (SDRAM) or DRAM (RDRAM), etc.), a static memory 606 (e.g.,
flash memory, static random access memory (SRAM), etc.), and a data
storage device 616, each of which communicate with each other via a
bus 630.
[0069] Processing device 602 represents one or more general-purpose
processing devices such as a microprocessor, central processing
unit, or the like. More particularly, the processing device 602 may
be a complex instruction set computing (CISC) microprocessor,
reduced instruction set computing (RISC) microprocessor, very long
instruction word (VLIW) microprocessor, or a processor implementing
other instruction sets or processors implementing a combination of
instruction sets. The processing device 602 may also be one or more
special-purpose processing devices such as an application specific
integrated circuit (ASIC), a field programmable gate array (FPGA),
a digital signal processor (DSP), network processor, or the like.
The processing device 602 is configured to execute the processing
logic (e.g., injection control 626) for performing the operations
and steps discussed herein.
[0070] The computer system 600 may further include a network
interface device 622. The computer system 600 also may include a
video display unit 610 (e.g., a liquid crystal display (LCD) or a
cathode ray tube (CRT)), an alphanumeric input device 612 (e.g., a
keyboard), a cursor control device 614 (e.g., a mouse), and a
signal generation device 620 (e.g., a speaker).
[0071] The data storage device 616 may include a computer-readable
storage medium 624 on which is stored one or more sets of
instructions (e.g., injection control 626) embodying any one or
more of the methodologies or functions described herein. The
injection control 626 may also reside, completely or at least
partially, within the main memory 604 and/or within the processing
device 602 during execution thereof by the computer system 600, the
main memory 604 and the processing device 602 also constituting
computer-readable storage media. The injection control 626 may
further be transmitted or received over a network via the network
interface device 622.
[0072] While the computer-readable storage medium 624 is shown in
an exemplary embodiment to be a single medium, the term
"computer-readable storage medium" should be taken to include a
single medium or multiple media (e.g., a centralized or distributed
database, and/or associated caches and servers) that store the one
or more sets of instructions. The term "computer-readable storage
medium" shall also be taken to include any medium that is capable
of storing a set of instructions for execution by the machine and
that causes the machine to perform any one or more of the
methodologies of the present embodiments. The term
"computer-readable storage medium" shall accordingly be taken to
include, but not be limited to, solid-state memories, optical
media, magnetic media, or other types of mediums for storing the
instructions. The term "computer-readable transmission medium"
shall be taken to include any medium that is capable of
transmitting a set of instructions for execution by the machine to
cause the machine to perform any one or more of the methodologies
of the present embodiments.
[0073] The injection control module 632, components, and other
features described herein (for example in relation to FIGS. 1, 5A,
and 5B) can be implemented as discrete hardware components or
integrated in the functionality of hardware components such as
ASICS, FPGAs, DSPs or similar devices. In addition, the injection
control module 632 can be implemented as firmware or functional
circuitry within hardware devices. Further, the injection control
module 632 can be implemented in any combination hardware devices
and software components.
[0074] The foregoing description, for purpose of explanation, has
been described with reference to specific embodiments. However, the
illustrative discussions above are not intended to be exhaustive or
to limit the invention to the precise forms disclosed. Many
modifications and variations are possible in view of the above
teachings. The embodiments were chosen and described in order to
best explain the principles of the invention and its practical
applications, to thereby enable others skilled in the art to
utilize the invention and various embodiments with various
modifications as may be suited to the particular use
contemplated.
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