Abstract:
The present device a hydrogen generator includes a housing for an electrolytic core, wherein the housing containing electrolyte solution. The electrolytic core includes an inner cathode concentrically oriented inside an outer anode immersed in the electrolyte solution for electrolysis. Additionally a vertically oriented separation pipe concentrically surrounds the upper part of the anode such that there is an overlap portion between the anode and the separation pipe, wherein the separation pipe extending above an electrolyte level. There is also a device for applying electrical power to the anode and cathode to create electrolysis there between which releases hydrogen and oxygen gases.

Description:
[0001]    This application claims priority from U.S. provisional application 61/267,580 filed Dec. 8, 2009 by Robert Talarico under the title: METHOD AND APPARATUS FOR ENCHANCING COMBUSTION IN AN INTERNAL COMBUSTION ENGINE THROUGH USE OF A HYDROGEN GENERATOR. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The present invention relates generally to internal combustion engines and the use of electrolytic generated hydrogen and oxygen to enhance combustion efficiencies and cleanliness and more particularly to an electrolyser device designed for use in automobiles or other vehicles that produces the requisite amount of hydrogen and oxygen through an electrolysis process. 
       SUMMARY OF THE INVENTION 
       [0003]    The present invention employs a unique electrolyte cell, combination anode and cathode and gas feed controls in an easily adaptable environment within the fuel system to produce hydrogen gas in an electrolysis process on demand and to enhance combustion without the need for storage tanks and the like in a safe and efficient manner. 
         [0004]    The hydrogen generator includes: a housing for an electrolytic core, the housing containing electrolyte solution, wherein the electrolytic core includes an inner cathode concentrically oriented inside an outer anode immersed in the electrolyte solution for electrolysis. It also includes a vertically oriented separation pipe concentrically surrounds the upper part of the anode such that there is an overlap portion between the anode and the separation pipe, wherein the separation pipe extending above an electrolyte level a means for applying electrical power to the anode and cathode to create electrolysis there between which releases hydrogen and oxygen gases. 
         [0005]    Preferably wherein the anode and cathode are vertically oriented cylinders. 
         [0006]    Preferably wherein the overlap portion between the anode and the separation pipe being at least 10% of the overall length of the anode. 
         [0007]    Preferably wherein the separation pipe further includes vent holes located just above the electrolyte level. 
         [0008]    Preferably wherein the portion of the separation pipe above the electrolyte level defining an upper portion of the housing for collecting gases therein. 
         [0009]    Preferably wherein the anode and cathode being of unequal lengths and partially overlapping along an overlap length. 
         [0010]    Preferably wherein the anode being shorter than the cathode such that a cathode non overlap length is along the bottom of the cathode. 
         [0011]    Preferably wherein the cathode non overlap length being at least 10% of the length of the cathode. 
         [0012]    Preferably wherein the housing being a T shaped housing including a smaller lower portion defining a lower volume and a larger central portion defining a central volume, wherein the smaller lower portion houses electrolyte solution and the electrolytic core and central portion houses electrolyte solution. 
         [0013]    Preferably wherein the central volume is at least 50 percent larger than the lower volume. 
         [0014]    Preferably wherein the central volume is at least 100 percent larger than the lower volume. 
         [0015]    Preferably wherein the housing being a cross shaped housing including a smaller lower portion defining a lower volume, a larger central portion defining a central volume, and an upper portion defining an upper volume for collecting gases, wherein the smaller lower portion houses electrolyte solution and the electrolytic core, and the central portion houses electrolyte solution. 
         [0016]    Preferably wherein the portion of the separation pipe above the electrolyte level defining the upper portion of the housing for collecting gases. 
         [0017]    Preferably wherein the exterior and interior surface of the anode is coated with tantalum and the interior surface of the anode is additionally coated with platinum. 
         [0018]    Preferably wherein the cathode exterior and interior surface is coated with tantalum. 
         [0019]    Preferably further including a heating element for heating the electrolyte solution. 
         [0020]    Preferably wherein the heating element extending centrally within the separation pipe and the electrolytic core. 
         [0021]    Preferably further including are circulating pump in fluid communication with the housing for circulating electrolyte solution through the housing and through a cooling radiator for cooling the electrolyte solution. 
         [0022]    Preferably wherein the power means including a power supply connected to a pulse width modulator connected in parallel to a large capacitor for delivering power to the electrolytic core. 
         [0023]    Preferably wherein the capacitor is at least 5 farads. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0024]    The invention will now be described by way of example only with reference to the following drawings in which: 
           [0025]      FIG. 1  is a schematic cross-sectional view of the hydrogen generator together with the gas feed components. 
           [0026]      FIG. 2  is a schematic cross-sectional view of the hydrogen generator showing schematically the flow of the off gas bubbles. 
           [0027]      FIG. 3  is a schematic cross-sectional elevational view of the anode and cathode configuration. 
           [0028]      FIG. 4  is a schematic top end plan view of the anode and cathode showing the various coatings applied to the exterior surfaces. 
           [0029]      FIG. 5  is a enlarged schematic cross-sectional view taken along lines  5 - 5  of  FIG. 3  showing the material compositions and coatings of the anode and cathode. 
           [0030]      FIG. 6  is a partial schematic cross-sectional view of the upper portion of the hydrogen generator together with the gas feed components. 
           [0031]      FIG. 7  is a schematic electrical wiring diagram of the electrical and electronic components used in association with the hydrogen generator. 
           [0032]      FIG. 8  is a schematic flow chart showing the steps for coating the anode tube. 
           [0033]      FIG. 9  is a schematic flow chart showing an alternate method and steps involved with coating the cathode. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0034]    The present device and method for enhancing combustion in an internal combustion engine through the use of a hydrogen generator is shown generally as hydrogen generator  100  together with gas feed components  103  in  FIG. 1 . 
         [0035]    Referring to  FIG. 1  the major components of hydrogen generator  100  include electrolytic cell  101  and gas feed components  103 . Depending on the application some or all of the gas feed components  103  may be utilized. 
         [0036]    Electrolytic cell  101  includes a housing  104  having a lower portion  118 , a central portion  114  and an upper portion  110 . Electrolytic core  102  includes the anode  124 , a cathode  128  which are connected electrically at anode terminal  126  and cathode terminal  130 . Anodes  124  and cathode  128  are housed within lower portion  118  whereas separation pipe  112  extends from the top of lower portion  118  all the way to the top of upper portion  110 . The portion of the separation pipe  112  above the electrolyte level  134  defines the upper portion  110  of the housing  104  for collecting gases therein. 
         [0037]    Lower portion  118  defines a lower volume  120  which essentially is the volume within the lower portion  118  of housing  104 . Although not apparent from the drawings tower portion  118  is preferably cylindrical in shape and anode  124  and cathode  128  are preferably concentrically mounted cylinders. Lower portion  118  also includes a removable bottom cap  122  for mounting of the anode  124 , cathode  128  as well as anode terminal  126  and cathode terminal  130  therein. 
         [0038]    Electrolytic cell  101  also preferably includes a heating element  502  which enters upper portion  110  at a element entry  506  which is sealed off with as seal  504 . Heating element  502  extends downwardly and is centrally located within separation pipe  112  and cathode  128  in order to heat the electrolyte when required. Heating element  502  is controlled by a thermistor or a thermocouple  142 . 
         [0039]    Housing  104  includes a housing jacket  169  which includes at lower portion  118  a bottom cap  122  and core sides  175 . Housing jacket  169  further includes in the central portion  114  a bottom wall  171  and a top wall  172  and side walls  177 . Housing jacket  169  farther includes in the upper portion  110 , upper side walls  179  and top cap  160 . In some cases housing  104  may be made of cylinders with the central portion  114  being a cylinder mounted in a horizontal position and the upper portion  110  and lower portion  118  being cylinders mounted in vertical positions, wherein the cylinders are welded or otherwise connected together. 
         [0040]    Separation pipe  112  extends and overlaps with anode  124  and cathode  128 . In particular the bottom of separation pipe  112  extends below the cathode anode top  125  thereby creating an overlap portion  181  as shown in  FIGS. 1 and 2 . Preferably overlap portion  181  being at least 10% of the overall length of the anode. 
         [0041]    Central portion  114  defines a central volume  116  which houses among other electrolyte solution  132  shown in the diagrams and having electrolyte level  134 . The space created between the top of electrolyte level  134  and top wall  172  is shown as free space  135 . Separation pipe  112  has defined therein vent holes  148  which provide communication between free space  135  and the interior of separation pipe  112 . Electrolyte solution  132  is circulated through electrolytic cell  101  and diverted through cooling pipes  136  and cooling radiator  138  with re-circulating pump  140 . 
         [0042]    Referring to  FIG. 2  electrolyte solution  132  flows as shown by the arrows  166  in  FIG. 2 . 
         [0043]    In addition to circulating electrolytic solution  132 , re-circulating pump  140  also passes the electrolyte solution  132  through a cooling radiator  138  shown schematically in  FIGS. 1 and 2 . In this manner the temperature of electrolyte solution  132  can be controlled. 
         [0044]    Hydrogen generator  100  also includes gas feed components  103  shown in  FIG. 1  and also in  FIG. 6 . Gas line  150  is connected near the top of upper portion  110  providing for communication of gases from the top of separation pipe  112  into gas line  150 . 
         [0045]    Off gas bubbles  170  shown in  FIG. 2  are created through electrolysis in electrolytic core  102 . Off gas bubbles  170  include hydrogen gas as well as oxygen gas as well as water vapour which percolates upwardly within separation pipe  112  until it reaches the upper portion  110  filling the upper volume  108  with the off gas bubbles  170 . This gas then passes through gas line  150 . The gases first pass through s vapour filter  508  which sends any entrained water back into housing  104 . Vapour filter  508  can be a porous metal filter or other filter systems known in the art which dries the gas prior to proceeding through gas line  150 . Flow of gas through gas line  150  is controlled with a needle valve  152 , a one way valve  154  and eventually is communicated to the gas outlet  156  which communicates with the intake portion of an internal combustion engine for example. Some or all of these components may not be necessary depending upon the operating set up. 
         [0046]    Due to the high amount of vacuum created in internal combustion engines on the intake side of the motor, the amount of vacuum within gas line  150  and ultimately within the upper volume  108  of upper portion  110  of electrolytic cell  101  may be quite significant. Therefore in order to control the electrolysis process and to ensure it proceeds in a uniform and controlled manner a relief valve  146  is mounted onto the upper portion  110  of housing  104  communicating with the upper volume  108  of upper portion  110  thereby allowing air to enter into the upper volume  108  should the vacuum within upper volume  108  exceed a pre-determined value. The negative pressure  168  in the upper volume  108  of upper portion  110  aids the evolution and the movement of off gas bubbles  170  from the lower portion  118  through the central portion  114  and ultimately through to the top of upper portion  110 . 
         [0047]    In regard to housing  104 , the reader will note that the lower portion  118  of housing  104  has a lower width LW  164  defined by core sides  175 . The central portion  114  of housing  104  has a central width CW  162  defined by side walls  177  and the upper portion  110  has an upper width UW  160  defined by the upper side walls  179  of housing jacket  169 . 
       Anode and Cathode Configuration 
       [0048]    Referring now to  FIGS. 3 ,  4  and  5  which show the arrangement to the cathode relative the anode and the coatings that are used for both the cathode and anode. 
         [0049]    Referring to  FIG. 3  which is a schematic cross-sectional view of the entire length of the anode and cathode, the reader will note that the anode  124  and cathode  128  are two concentric cylinders mounted one within the other and spaced apart with non-conductive spacers  172 . The cathode  128  is somewhat longer and extends significantly lower than the anode  124 .  FIG. 3  schematically depicts the overlap length  191  which is the length along which the anode  124  and the cathode  128  are positioned in overlap fashion.  FIG. 3  also depicts the cathode non overlap length  193  which is the bottom  520  most portion of the cathode  128  which is not mounted in overlap orientation with respect to the anode  124 . The cathode non overlap length  193  aids in the circulation of the electrolyte solution  132  through the gap  195  which is the space defined between the anode  124  and the cathode  128 . Preferably the cathode non overlap length  193  being at least 10% of the length of the cathode. 
         [0050]    Referring now to  FIGS. 4 and 5 , the materials used for the anode  124  and the cathode  128  are depicted including the coatings that are applied upon the surfaces of the anode  124  and cathode  128 . 
         [0051]    The core of both the anode  124  and cathode  128  is preferably stainless steel  180  and  188 , however it could be other materials known in the art to be efficient in working as an anode  124  and cathode  128 . 
         [0052]    Referring first of all to cathode  128  which is the inner most concentric cylinder, stainless steel core  188  is coated with tantalum  190  on the interior and also coated with tantalum  190  on the exterior of cathode  128 . Therefore, cathode  128  is completely coated with tantalum on both the interior and exterior surfaces. In some cases it is not necessary to coat the cathode  128 . 
         [0053]    Referring now to anode  124  which is preferably comprised of a stainless steel core  180  is coated on the exterior surface with tantalum  182 , and on the interior surface with tantalum  184  and then further coated with platinum  186  on the interior surface of anode  124 . 
         [0054]    Therefore, anode  124  ultimately has an exterior surface coating of tantalum  182  and an interior surface coating of platinum  186 . 
         [0055]      FIG. 8  shows schematically the steps and the method used to coat the anode for example. A stainless steel cylindrical anode  302  is used. Chemical vapour deposition techniques are used to deposit a coating of tantalum onto all exterior and interior surfaces of anode tube step  304 . 
         [0056]    Step  305  plating platinum onto the interior surface of anode  124  by chemical or physical vapour deposition or electroplating or any other process known in the art which may be suitable. 
         [0057]    Therefore in the process schematically shown in flow chart form  FIG. 8 , anode  124  is first coated with tantalum on both sides using vapour deposition and then is coated with platinum on only the interior surface by either chemical vapour deposition and/or by using an electroplating process. Persons skilled in the art will know that other plating processes such as electroplating or other means may also be used. 
         [0058]      FIG. 9  shows in flow chart schematic fashion the method for coating the cathode  128 . Preferably the cathode  128  is made of stainless steel tubing which is a stainless steel cylindrical tube which is then subject to the chemical vapour deposition of tantalum onto both the exterior and interior surfaces of the tube resulting in a cathode  128  which is coated on all surfaces with a chemical vapour deposited layer of tantalum. 
       Electrical Wiring 
       [0059]    Referring now to  FIG. 7  the electrical wiring is shown schematically in  FIG. 7  as electrical wiring  200 . 
         [0060]    Electrical wiring  200  includes a battery  218  which is normally an automotive battery and/or the vehicle battery which is grounded on one end  220  and power is applied through a circuit breaker  216  and a relay  214  thereby powering the electrical wiring circuit  200  as shown in  FIG. 7 . Power is applied to radiator fan motors  202  shown as F in  FIG. 7 , re-circulating pump motors  204  shown as M in  FIG. 7 , a timer relay shown as  206  together with a thermistor or thermocouple  142  which is mounted in the electrolytic core  102 . 
         [0061]    Power is further applied to a large capacity capacitor  208  which is grounded at  210  and finally power is applied to the cathode terminal  130  and the anode terminal  126  through the pulse width modulator  137  as shown in the electrical wiring diagram, which in turn applies power to the cathode  128  and anode  124 . Capacitor  208  is at least 5 farads in size. 
         [0062]    In addition a heating element  502  is controlled with a thermocouple  142  and a relay  206 . 
       In Use 
       [0063]    The electrolytic core  102  is comprised of two cylindrical metal tubes namely the anode  124  and the cathode  128 . The placement of the tubes is concentric and are held in place with a non-conductive heat and chemical resistant spacers  172 . The inner tube preferably being the cathode  128  is longer than the outside tube preferably being the anode  124  at the bottom while they are flush at the cathode anode top  125 . The difference in length creates a cathode non overlap length  193  and a overlap length  191  where both the cathode and the anode are in overlap fashion. Preferably the non overlap length  193  is at least five percent (5%) of the overlap length  191 , and preferably at least 10% of the over lap length  191 . This configuration helps the electrolyte solution  132  to flow more easily into gap  195  which is the space between the cathode  128  and the anode  124 . The inventors have found that hydrogen production can be significantly increased by providing for the cathode non overlap length  193  as depicted in  FIG. 3  of the drawings, as it will guide and assist the water flow in between the anode and the cathode to flow in more easily. 
         [0064]    Both the anode  124  and optionally the cathode  128  are coated entirely with tantalum to avoid oxidation. The tantalum coating shown as  182 ,  184  and  190  in  FIG. 5  is normally a few microns in thickness, usually about 50 microns however it could be somewhat less or somewhat more depending upon the life expectancy required from the cathode  128  and the anode  124 . In order to have proper galvanic conductivity through the electrolyte between the electrodes, another conductive metallic layer usually is necessary. In this case a further coating of the interior surface of the anode  124  with the platinum  186  is preferable to aid the conduction process. Normally the bulk of the electrolysis takes place between the inside surface of the anode and the outside surface of the cathode and coating the whole surface of the anode with platinum for example is both unnecessary and costly. In practice it has been found in order to optimize the production of hydrogen and oxygen and to maximize the life of both the cathode and the anode, it is not necessary to apply the platinum metallic layer to either the interior surface or the exterior surface of the cathode. 
         [0065]    Electrolytic cell  100  has a cross shaped housing  104  which contains a separation pipe  112  which is oriented vertically and overlaps somewhat with the anode  124  and cathode  128  at the overlap portion  181 . Not depicted housing  104  may also be T shaped wherein the upper portion  110  and central portion  114  are of similar dimensions. Preferably however central volume  116  is significantly greater than lower volume  120  and preferably central volume  116  is 50% larger than lower volume  120  and more preferably is 100% larger than lower volume  120 . The separation pipe encircles and overlaps the cathode and anode top  125  along the overlap portion  181  and extends to the top of the upper portion  110  of housing  104 . Separation pipe  112  includes vent holes  148  to allow for the flow of gases including hydrogen and oxygen gas which is trapped in the free space  135  of the central portion  114  of housing  104 . Due to the cross shaped housing  104 , the central volume  116  is significantly larger than the lower volume  120  and provides a large reservoir of electrolyte solution  132  to be housed within central volume  116 . Therefore, replenishment of electrolytic solution  132  is minimized. 
         [0066]    Secondly, circulation of the electrolyte solution  132  through cooling pipe  136 , cooling radiator  138  and re-circulating pump  140  is aided by gravity as depicted in  FIG. 2 . The inlet of the solution is near the upper portion of central portion  114  and the outlet is on the bottom wall  171  of central portion  114 . The use of separation pipe  112  channels the evolution of off gas bubbles  170  and helps the flow of electrolyte solution  132  into the lower portion  118  as shown by the arrows  166  in  FIG. 2 . Rising off gas bubbles  170  will tend to move electrolyte solution  132  upwardly within separation pipe  112  thereby encouraging flow of electrolyte solution  132  downwardly outside of separation pipe  112  as depicted by flow arrow  139 . In addition, the use of separation pipe  112  which projects substantially above the electrolyte level  134  ensures that electrolyte solution  132  is not pulled through gas line  150  should there be a strong vacuum or negative pressure  168  in the upper volume  108 . In addition, relief valve  146  is included in case of an over negative pressure  168  condition. 
         [0067]    The electrolyte is preferably comprised of distilled water and potassium hydroxide and optionally a small amount of denatured alcohol. Other electrolytes may also be suitable such as calcium chloride and small amounts of ethylene carbonate may also be used. Potassium hydroxide acts as a catalyst to induce the electrolytic process and the denatured alcohol is to prevent freezing. If applied in the right concentration of approximately 25% or more by weight, the electrolytic solution won&#39;t freeze up to temperatures of −40° Celsius. Alternately the heating element  502  can be used to prevent freezing. Optionally also a small amount of methylene carbonate is added to the solution for its chemical and thermal stabilizing properties. This electrolyte under normal conditions may not need to be replenished in the system since typically it does not degenerate or is used up by the electrolyses process. Usually only water needs to be added from time to time to the electrolytic cell  101 . 
         [0068]    Capacitor  208  shown in  FIG. 7  of the electrical wiring diagram  200  has a very high farad value of approximately 1.5 to 9 farads preferably 6 farads to be able to ensure that the power obtained from an automobiles 12 volt battery and alternator are continuous enough to ensure that hydrogen production can be maintained even during low production periods of electricity from the alternator. Use of the high farad capacitor  208  creates a higher sustained input of power into electrolytic cell  101  without large power fluctuations effecting the operation of the hydrogen generation. The adjustable needle valve  152  regulates the amount of hydrogen gas that enters the cars intake manifold at the gas outlet  156 . One way pressure valve  154  allows the hydrogen gas to flow one way into the engine through the throttle body or air intake manifold and prevents hydrogen gas to flow backwards which would decrease efficiency and prevent sparks to enter back into the system. 
         [0069]    The adjustable relief valve  146  relieves negative or dead vacuum pressure which increases the flow of hydrogen through gas line  150  to gas outlet  156  and into the engine intake. Relief valve  146  prevents negative vacuum pressure to reduce or stop the delivery of hydrogen through gas line  150  and out through gas outlet  156  and into the engine intake manifold. The vacuum help pulls gas from the upper volume  108  of hydrogen generator  100  and in addition relief valve  146  allows a weak flow of air to pass in from the outside into upper volume  108 . This adjustable leak created by relief valve  146  prevents the full force of the vacuum from acting in the upper volume  108 , which could stop or severely decrease the delivery of the hydrogen gas to the engine. 
         [0070]    It should be apparent to persons skilled in the arts that various modifications and adaptation of this structure described above are possible without departure from the spirit of the invention the scope of which defined in the appended claim.