Abstract:
This disclosure relates to a dry cell system for separating water into hydrogen and oxygen in combination with catalytic-type chemicals and materials. The separated hydrogen/oxygen are provided into the air intake system of an internal combustion engine and used therein to greatly improve the operation of said internal combustion engine, both in regards to fuel consumption as well as detrimental exhaust products.

Description:
RELATED APPLICATIONS 
       [0001]    This application claims priority benefit of U.S. Ser. No. 61/300,561, filed Feb. 2, 2010. 
     
    
     BACKGROUND OF THE DISCLOSURE 
     Field of the Disclosure 
       [0002]    This disclosure relates to a dry cell system for separating water into hydrogen and oxygen in combination with catalytic-type chemicals and materials. The separated hydrogen/oxygen are provided into the air intake system of an internal combustion engine and used therein to greatly improve the operation of said internal combustion engine, both in regards to fuel consumption as well as detrimental exhaust products. 
       SUMMARY OF THE DISCLOSURE 
       [0003]    As a dry cell system, the reservoir, including the electrolyte and the water reservoir, is kept separate from the hydrogen generator. As the gas is created in the hydrogen generator, it is expelled therefrom and utilized in the engine almost immediately. This increases safety, among other benefits, as there is not an accumulated quantity of hydrogen gas or oxygen gas, which is potentially explosive in this environment. 
         [0004]    In most wet cell HHO generators, the distance between the anode and cathode is approximately 0.125″, and in dry cell generators the distance between plates is approximately 0.025″. Thus, it follows that a dry cell generator will also take up less space, although the gas created must either be used or be removed for storage, as there is no region within the generator for storage. Furthermore, the system disclosed herein operates without any substantial pressure differential between the produced gas and the surrounding atmosphere. A venture effect is utilized to draw off the HHO gas, and thus the HHO gas need not pass through any potentially dangerous pump. 
         [0005]    The disclosed generator has also proven to operate at a relatively low temperature, less than 212° F. 
         [0006]    In one form, electrolyte chemicals, including boron in the form of boric acid, which may be combined with potassium hydroxide as a catalyst, have been found to greatly increase the HHO production in the HHO generator. An unexpected result has been found in that the boron decreases the foaming effect of the dry cell, which increases the efficiency of the stabilization tank. In addition, the boric acid decreases the freezing temperature of the water electrolyte, acts as a refrigerant, and functions as an electric conductivity stabilizer. The use of potassium hydroxide (KOH) has been found to be exemplary in several embodiments as a catalyst in the disclosed system. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0007]      FIG. 1  is a highly schematic view of the improved combustion engine air supply system, in one form. 
           [0008]      FIG. 2  is an exploded view of the HHO generator, in one form. 
           [0009]      FIG. 3  is a view of the components of the HHO generator, in one form. 
       
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0010]    Tests have shown that the disclosed embodiments increase the gas efficiency and lower carbon emissions in both gas and diesel engines. 
         [0011]    In order to provide a sufficient amount of hydrogen and oxygen gas in a dry cell environment, the combustion engine air supply system  20 , as shown in  FIG. 1 , comprises a plurality of interoperating parts in one embodiment. While the fluid system substantially comprises a recycling system, we will begin with a description of the electrolyte stabilization tank  24 , which includes a chemical solution fill tube and safety relief diaphragm  26 , and an HHO gas outlet  28 , which is coupled by way of a piece of tubing  35  to a scrubber  30 , such as by way of an HHO inlet  32 . The electrolyte stabilization tank  24  may further comprise at least one HHO inlet  34 , also coupled by way of a section of tubing  35  to a hydrogen generator  36 , which will be described in some detail. Furthermore, the electrolyte stabilization tank  24  comprises a water supply inlet  38  coupled by way of a section of tubing to an electrolyte stabilization pump. Furthermore, a water supply outlet  40  may be provided, which couples by way of a section of tubing  41  to a water supply inlet  42  on an energy HHO circulation pump  44 . To allow for determination of the volume of fluid within the electrolyte stabilization tank  24 , a sight glass  46  or equivalent measuring apparatus may be utilized. A fill switch  48  may also be utilized, which includes signal wires  50  that are coupled, in one form, to an electronic control box  52 , which controls the electrolyte stabilization pump and other controls and devices. Grounding the stabilization tank had been found to eliminate a negative build up of electric charge within the tank, increasing the overall effectiveness of the apparatus. 
         [0012]    The HHO circulation pump  44  not only comprises the water supply inlet  42 , but also comprises a water supply outlet  54 , which couples by way of a section of tubing  55  to a water supply inlet  56  of the hydrogen generator  36 . The hydrogen generator  36  also comprises a hydrogen product supply outlet  58 , which is coupled by way of a section of tubing to the HHO inlet  34  on the electrolyte stabilization tank  24 . These inlets  56  and outlets  58  may be formed on both the first side and second side  62  of the hydrogen generator  36 . 
         [0013]    The HHO scrubber unit  30  comprises the HHO inlet  32  as well as an HHO outlet  64 , which couples by way of a length of tubing  68  to an HHO inlet  66  of the feed injector  78 , which in one form is in line between an automotive air cleaner and a throttle body  70 , so as to provide the HHO gas from the scrubber unit  30  to the combustion chambers of the internal combustion engine. In one form, the throttle body  70  comprises a throttle plate  72 , which controls the throttle position sensor (TPS), which regulates the pulse width of the wave signal controlling the hydrogen generator  36 . In this form, a pulse wave modulator (PWM) may be utilized to provide the correct waveform to the hydrogen generator  36 . In this embodiment, as the throttle is opened wider, a signal is sent to the hydrogen generator  36  to produce more HHO gas which is delivered to the feed injector  78 . 
         [0014]    In another form, a Hall effect sensor is coupled to the fuel injector input. The output from the Hall effect sensor is then used to regulate the pulse width of the wave signal controlling the hydrogen generator  36 . At idle, the positive portion of the wave sent to the injector will be quite short in duration, and when power is applied the engine, the positive portion of the wave will be considerably longer. The fuel injector signal therefore defines the power/control signal sent to the hydrogen generator either directly to the anode/cathode or to the control box  52 , which in turn powers the hydrogen generator  36 . While many common Hall effect sensors will not be capable of surviving the heat generated by an internal combustion engine, Hall effect sensors built for industrial or military use are normally capable of handling such environments. 
         [0015]    In one form, the electrolyte stabilization tank  24  contains a chemical solution, which is pumped out from the water supply outlet  40  through the hydrogen generator  36  to release the HHO gas. The HHO gas released by the hydrogen generator  36  and any remaining liquid therein is then returned to the stabilization tank  24  through the supply outlet  58  to the inlet  34 . 
         [0016]    For optimum performance, the HHO inlet  34  is above the normal operating fluid level in the stabilization tank  24 . As the HHO gas outlet  28  is vertically above the HHO inlet  34 , the electrolyte fluid is thus returned to the stabilization tank  24  and the HHO gas can be withdrawn therefrom. As previously mentioned, the liquid level is maintained by the electrolyte fill switch  48 , which in turn operates the electrolyte stabilization pump, which maintains the proper electrolyte level in the stabilization tank  24  by pumping in water as needed. As with most electrolysis systems, distilled water may be preferred. 
         [0017]    The automatic fill system comprises the fill switch  48 , control box  52 , and electrolyte stabilization pump, and it maintains the chemical electrolyte at the desired concentration. As the system is in operation, the water is consumed in the gas making process; however, the electrolyte chemicals are not consumed in the gas making process and generally cycle between the stabilization tank  24  and the hydrogen generator  36 . This system provides a stabilized reservoir for the chemical solution. The hydrogen and oxygen (HHO) produced in the hydrogen generator  36  and reentering the stabilization tank  24  are heated through the electrolysis process. In order to maintain temperature stability, the oxygen gas coming in contact with the stainless steel headspace in the stabilization tank  24  chills the stainless steel body of the stabilization tank  24 , thus maintaining a low temperature for both the electrolyte fluid and the gas itself. This refrigeration effect helps to maintain the lower temperature at which the air supply system  20  is designed to function. The lowered temperature is conducive to combustion, thus resulting in increased power supply to the internal combustion engine. 
         [0018]    The HHO circulation pump  44 , in one form, is a diaphragm-style pump that maintains pressure when the air supply system  20  is engaged. In one form, the constant positive pressure of up to 24 PSI is maintained between the circulation pump  44  and the feed injector  78 . In one form, if and when the maximum output pressure of the circulation pump  44  is reached, such as by an occlusion of the line, the circulation pump  44  will turn off. During use, a very low pressure differential will be maintained to enable flow of the fluid between the circulation pump  44  and the feed injector  78 . The circulation pump  44  draws the electrolyte from the electrolyte stabilization tank  24 , forcing it through the hydrogen generator  36 , which causes the electrolyte and gas to flow back into the stabilization tank  24 , where the gas and liquid are then separated. This constant flow prevents the accumulation of contaminants and chemicals on the generator plates shown in  FIG. 3 . 
         [0019]    Operation of the air supply system  20  is facilitated by the above-described fluid flow, which moves the gas bubbles off of the generator plates  74 , shown in  FIGS. 2 and 3 . This removal of the gas bubbles is accomplished as quickly as they are formed, thus increasing the cell efficiency of the hydrogen generator  36 . Production is also improved by cooling the liquid electrolyte stabilizing production fluctuations due to temperature changes within the system. As previously described, this cooling is accomplished by contact of the oxygen gas being discharged into the stainless steel headspace of the electrolyte stabilization tank  26 , causing an oxygen-to-stainless-steel reaction referred to as an element refrigeration action. 
         [0020]    The common term fluid is used herein to define gasses, liquids, and combinations thereof. 
         [0021]    This described constant flow through the system ensures a constant stirring action of the fluid flow, such that the chemicals are well mixed with the water being added by the chemical stabilization pump. The scrubber  30  is designed to protect the appliance/internal combustion engine from damage caused from actual droplets of liquid, should the gas-creating equipment for some reason become overfilled in the stabilization tank  24 , or some other malfunction occur. 
         [0022]    Another sight glass  82  provides visual observation should liquid accumulate in the scrubber. A petcock  76  may be provided near the lower end of the sight glass, through which the sight glass is easily emptied. 
         [0023]    The input  66  comprises a delivery siphon or feed injector  78 , which in one form comprises a 90° hose barb fitting with one portion tapered  80 , as shown in  FIG. 1 . The siphon  78  is inserted into the engine air intake system as previously described, allowing the engine vacuum to draw the HHO gas through the tube leading from the gas scrubber outlet  64 , thus decreasing any potential pressure in the entire gas production system. Utilizing the vacuum pressure of the engine lowers the overall vapor pressure, which then allows for a significant increase in gas production. 
         [0024]    As shown in  FIG. 2 , the hydrogen generator  36  comprises a plurality of plates  74 , including at least one front cover plate  84 , which includes the inlet  56  and outlet  58 , as previously described. A back cover plate  86  is also included, as well as a plurality of gaskets  88 . In one form, the cover plate  84 , back plate  86 , and gaskets  88  are formed of a non-conductive, hydrophilic material. Testing has shown that the commercial product Polyoxymethylene (Delrin) is exemplary for construction of the cover plate  84  and back plate  86 . Prior applications using insulating materials that were not hydrophilic absorbed a small volume of water/catalyst and deformed after extended use. While only a few of the gaskets  88  are labeled in  FIG. 2 , it can be appreciated that in most embodiments every other layer of the plates  74  will be a gasket  88  to ensure fluid retention. At least one cathode  90  will also be utilized. Where it is desired to have the fluid electrolyte pass through the cathode  90 , a plurality of water (fluid) ports  92  will be included, as shown in  FIG. 3 . The fluid ports  92  allow fluid to travel between one HHO generator cell  96  and another. At least one cathode  94  may also be used, which may not include a fluid port where it is not desired to allow the fluid to flow between adjacent HHO generator cells. Each HHO generator cell  96  will also include at least one anode  98 . The use of anodes and cathodes is commonly known in the art of HHO generation. To increase the volume of each HHO generator cell  96 , a plurality of neutral plates  100  may also be included. As shown and previously described, each of the plates  74  will have a gasket  88  therebetween. To ease in manufacture of the hydrogen generator  36 , each of the plates and gaskets may include a plurality of voids  102  through which a plurality of fasteners, such as (stainless steel) bolts, may be passed. By tensioning nuts onto these bolts, the entire hydrogen generator  36  is drawn together, compressing the gaskets  88  into the final, fluid-tight form. 
         [0025]    As with any other electrolysis system, electric voltage is applied between the anodes and the associated cathodes. In one form, the voltage is applied as a monopole square wave into a resonant circuit which is tuned to the specific Q value of the solution used as an electrolyte. 
         [0026]    In one embodiment, a water reservoir  104  is fluidly coupled to the electrolyte stabilization tank through conduit  39  so as to maintain the fluid level within the electrolyte stabilization tank. The fill switch  48  may be coupled to a pump or valve between the water reservoir  104  and the electrolyte stabilization tank so as to allow water to flow into the electrolyte stabilization tank when the volume drops below a preset limit. 
         [0027]    Testing has shown that marine grade, 316L stainless steel exhibits substantially better production and corrosion resistance than other tested materials. 
         [0028]    While the present invention is illustrated by description of several embodiments and while the illustrative embodiments are described in detail, it is not the intention of the applicants to restrict or in any way limit the scope of the appended claims to such detail. Additional advantages and modifications within the scope of the appended claims will readily appear to those sufficed in the art. The invention in its broader aspects is therefore not limited to the specific details, representative apparatus and methods, and illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the spirit or scope of applicants&#39; general concept.