Abstract:
A supplementary intercooler cools engine air after it has passed through the turbocharger of a vehicle&#39;s turbocharged internal combustion engine, but before it enters the engine. The unit has an inlet for capturing the turbo&#39;s air charge and an outlet for routing the air charge to the engine after passing through the intercooler. A container stores water until it is needed and a water pump transfers water from the container to the unit. This loosened bond of water is then sprayed on capacitor plates under turbo pressure to be converted into hydrogen and injected into the air intake stream making it a totally “hydrogen-on-demand” intercooler.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims the benefit of Provisional Patent Application Ser. No. 61/517,504, filed Apr. 21, 2011, by the present inventors, which is incorporated by reference herein. 
    
    
     BACKGROUND 
     This application relates generally to intercoolers, namely charge air coolers, for automotive use, and more particularly to intercoolers for forced induction internal combustion engines. 
     In a turbocharged engine, power is increased by providing air under pressure to the engine&#39;s cylinders. This allows an increased amount of fuel to be burned, producing more power. 
     A turbocharger pressurizes the air and also raises its temperature to 300 to 500 degrees. An intercooler (charge-air cooler, or CAC) reduces the air intake temperature before it goes into the engine. The result is less stress on the turbocharger(s) and engine parts. A decrease in air intake temperature provides a denser intake charge to the engine and allows more air and fuel to be combusted per engine cycle, increasing the output of the engine. 
     Injecting water into the air intake stream can help cool combustion as it vaporizes and turns into steam. Water can also be injected between the turbo and the intercooler. Introducing cool water into the intake stream before the intercooler can lead to a greater temperature drop before the intercooler, and cooler intake air temperatures. 
     Electrolysis of water is the decomposition of water into oxygen and hydrogen gas due to an electric current being passed through the water. An electrical power source is connected to two electrodes or two plates which are placed in the water. Hydrogen bubbles form on the negative side of the circuit (cathode) and oxygen bubbles appear at the positive side of the circuit (anode). Hydrogen does not like to be alone so it joins with oxygen right as it leaves the cell. This new gas is called oxyhydrogen (HHO). The terms oxyhydrogen (HHO) and hydrogen are often used interchangeably, even though they are not technically the same thing. 
     HHO generators electrolyze a small amount of water and pass it into the car&#39;s intake where it replaces some of the volume of gasoline or diesel, helps the engine to burn more cleanly with less deposits and puts out fewer emissions. 
     A hydrogen-on-demand system stores hydrogen gas as water until it is needed. The electricity used to convert water into hydrogen may come from the vehicle&#39;s alternator and batteries. Hydrogen-on-demand systems do not fuel the vehicle, instead the hydrogen is thought to speed up the combustion process. An acid, base or salt can be added to the water supply to drop the electrical resistance of the water. With a catalyst in the water, it takes less electricity to produce the desired amount of HHO gas. 
     SUMMARY OF THE INVENTION 
     The invention presents an improved apparatus and method for cooling engine air after it has passed through the turbocharger of a vehicle&#39;s turbocharged internal combustion engine, but before it enters the engine. In an embodiment, water and turbo heated air are forced through the unit and “oxy-hydrogen” steam is produced. Output from the unit enters the intake manifold introducing cooled hydrogenated steam air mass. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       For a more complete understanding of the features and advantages of the present invention, reference is now made to the detailed description of the invention along with the accompanying figures in which corresponding numerals in the different figures refer to corresponding parts and in which: 
         FIG. 1  is a side elevation view of a supplementary intercooler embodying principles of the present invention; 
         FIG. 2  is a sectional view through the main casing body of a supplementary intercooler as viewed from the inlet side, showing positively charged and negatively charged plates inserted therein, according to an embodiment; 
         FIG. 3  is a schematic illustration of a supplementary intercooler system connected to the vehicle&#39;s electrical system, according to an embodiment; 
         FIGS. 4 and 6B  show embodiments of a capture nozzle to capture turbo pressure to route it to the unit; and 
         FIGS. 5 and 6C  show embodiments of a venturi-style injector nozzle that may be placed into the intake manifold of a car or truck engine. 
         FIG. 6A  is a sectional view showing coils of a supplementary intercooler as viewed from the inlet side according to an embodiment. 
         FIG. 6D  is a side elevation view partly in cross section of a supplementary intercooler embodying principles of the present invention. 
         FIG. 6E  is a cross section showing a pressure switch and capacitor coils of a supplementary intercooler as viewed from the outlet side in accordance with an embodiment. 
         FIG. 7  shows plates of a supplementary intercooler in accordance with another embodiment. 
     
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
     While the making and using of various embodiments of the present invention are discussed in detail below, a practitioner of the art will appreciate that the present invention provides applicable inventive concepts which can be embodied in a variety of specific contexts. The specific embodiments discussed herein are illustrative of specific ways to make and use the invention and do not limit the scope of the present invention. 
     One embodiment of the supplementary intercooler is illustrated in  FIG. 1 . Intercooler  10  has a main body casing  11  and inlet cone  12  and outlet cone  14 . Water is transferred from a water holding container (not shown in  FIG. 1 ) by water pump  20  through filter  21  and injected into inlet cone  12  of the unit. The water may be positively charged such as by a 12 volt plate submerged in the water (not shown). The positively charged water is ideally insulated from ground until it reaches the negatively charged “injector nozzle”  26  in the intercooler  10 . This in turn is sprayed onto the inner core plates. The injector nozzle  26  is preferably made of stainless steel and grounded with a ground strap. This arrangement is believed to loosen the bond between the hydrogen atom and the oxygen molecule in the water and assist in the hydrogen production. 
     In the example embodiment of  FIG. 1 , supplementary pressure is achieved by “capture” nozzle  42  allowing a selected portion (for example 33 ⅓%) of the turbo-pressure to be routed into the inlet  12  of the supplementary intercooler  10 . The turbo pressurized air not passing through the unit can be diverted by bypass or equalizer tubes  44  which route the diverted air to the engine. In the example of  FIG. 1 , the equalizer tubes  44  go from one side of the unit to the other, and there are a total of four (4) tubes - two (2) tubes per side of the unit. The equalizer tubes may be used when not using an intercooler from the turbocharger to the supplementary intercooler, when all the air flow is moving through the unit before going into the engine, or when the unit is used on gasoline engines. 
       FIG. 2  shows capacitor coils  34  comprising positive  34   a  and negative  34   b  plates inserted in main body casing  11  according to an embodiment. Turbo pressure is captured by nozzle  42  and routed into the inlet cone  12 . As turbo heated pressure is being forced through the supplementary intercooler, the capacitor coils  34  heat up to produce “oxy-hydrogen” steam and moisture droplets. The water pump  20  and the capacitor coils  34  are activated by electric pressure activated switch  24 . In one embodiment, the switch  24  is turned on at 2 psi turbo-pressure to transfer electrical power to the pump  20  and the capacitor coils  34 . 
     In the example of  FIG. 2 , the positive plates  34   a  have a fiberglass screen mat covering the entire plate (matted front and back on all positive plates). This allows the water to linger on the positive plate  34   a  to make contact with the negative plate  34   b . This then produces “oxy-hydrogen.” The water is forced through the plates by turbo-pressure. The negative plates  34   b  consist of silicone spacers  48  attached to the plates (silicone spacers added on front and back of short plates and only on front of long plate). Each silicone spacer is 0.0028 (thousands) in thickness (height) and 13/64 th  around and placed in strategic areas on both sides of the plates. There are 613 spacers per plate on each side of the plate. The plates  34  are configured alternating the negative to the positive, e.g., with a negative to a positive to a negative, etc. There is a 0.0028 (thousands) air gap between each plate. This roll is then inserted into main body casing  11 . A magnetic “core” or rod  29  may be placed into the center of the capacitor coils. This rod is believed to assist in hydrogen production using lower amps to achieve the “oxy-hydrogen.” The purpose is to maintain high voltage in the capacitor and it also allows air to move freely through the center. 
       FIG. 7  shows the positively charged and negatively charged plates in accordance with another embodiment. In one example, internal capacitor coils  34  consisting of five (5) plates, seven (7) inches wide, are wound together. The plates are rolled in a manner like that of electrolytic capacitors. They are rolled together into a four (4) inch diameter roll with a 0.0028 (thousands) air gap between each plate. This roll is then inserted into main body casing  11 . In an embodiment, the metal used as the coil in the unit comprises an alloy of chromium, nickel, etc. 
     Preferably, there is a four (4) inch silicone “O” ring  35  placed in front of the capacitor coil  34  to keep the coils from grounding out to the inlet cone  12  that is threaded into the main casing  11 . The entire casing unit consisting of the main body  11  and the in and out portions  12  and  14 , is preferably made of aluminum. The inlet and outlet portions  12  and  14  are preferably removable with an “O” ring with each portion to prevent air leakage. 
       FIG. 3  is a schematic illustration of a supplementary intercooler system embodying principles of the present invention. In operation, air flow from turbocharger  61  is sent to the unit or bypassing the unit via one or more of valves  53 ,  54  and/or  55  which control and balance the air flow. When pressure transducer  23  senses a preselected turbo pressure, switch  24  closes the circuit with battery  19 , activating pump  20  to transfer water from the water tank  51  into main body casing  11 . Hydrogen is produced in the main body  11  and routed to the engine  62 . The circuit could also be configured so that pump  20 a transfers other fuels such as methane, helium, etc. from additive tank  52  into main body casing  11  when switch  24  is actuated. 
       FIGS. 5 and 6C  show a venturi style injector nozzle that is placed into the intake manifold of a car or truck engine (not shown) according to an embodiment to keep the turbo-pressure from equalizing. The nozzle  40  is preferably designed with a hole  41  drilled into the back of the nozzle at about a 45 degree angle. As the air is forced through this hole, it creates a vacuum signal, the same principle the way an insecticide sprayer works. This then gives the hydrogen steam and moisture droplets direction to enter into the intake manifold. 
     In one embodiment, on the inlet cone  12 , there are seven (7) threaded ports  25 . Those that are not used, are capped. Both inlet and outlet sides of the cones may have these ports and may be configured the same. One of the ports may be used for the pressure switch  24  on one end, the inlet portion  12 , of the cone. Other fuels, such as methane, helium, etc., can be added, if desired, to the air intake via one or more of the other available ports. In the example of  FIG. 6D , inlet cone  12  has a 23 degree ¼ inch tapped port. This port is used for the injector nozzle  26 . A ¼-⅛ inch reducer is placed into this port. The reducer is of Teflon® and is to prevent the transference of heat to the injector nozzle. The injector stem is also insulated with silicone rubber. All this keeps the injector from experiencing heat vapor locking. 
     In the example of  FIG. 6D , the main body  11  has a water pump platform  16  welded onto it. It has eight (8) press-fit cooling fins  18  attached to the body housing, two (2) mounting brackets  19  welded onto it at the bottom of the unit, an ⅛ inch tap port for the capacitor wires to exit with a protective seal to prevent air leakage. 
     Ammonia hydroxide can be added to the water to further enhance hydrogen/nitrogen output. Also methanol can be added to the water to keep the water from freezing. Because of the design of the unit, running out of water will maintain a cool charge going into the intake manifold, comparable to a normal intercooler. 
     The benefits of this invention include: 
     a) To give a much needed, cooler air charge into the engine. 
     b) To continually keep the internal parts of the engine clean and free of soot, which also eliminates the need for soot recovery systems. This also lowers crank-case pressure. 
     c) To lower combustion temperatures while giving a higher BTU rate to the fuel. Lowers the emissions. All these prolong engine life, lower oil temperatures, increase the horsepower, therefore, increases miles per gallon and does not require any computer manipulations in any form, fashion or way. 
     The invention can also be used with other systems for reducing intake air charge temperatures, such as conventional Air/Air and Liquid/Air intercoolers. 
     While this invention has been described with reference to illustrative embodiments, this description is not intended to be construed in a limiting sense. Various modifications and combinations of the illustrative embodiments as well as other embodiments of the invention, will be apparent to persons skilled in the art upon reference to the description. It is, therefore, intended that the appended claims encompass any such modifications or embodiments.