Abstract:
A fuel heater and vaporizing system includes a source of fuel, a thermal source from an engine, and a heat exchanger for thermally contacting the source of heated fluid so as to heat fuel flowing through the heat exchanger. The heat exchanger has a saddle shape and fits over the thermal source of engine heat. The fuel heater and vaporizing system may also contain a catalyst for causing the heated fuel to crack prior to distribution to an end use device. In an alternative arrangement, the fuel heater and vaporizing system may also extract its heat from the engine&#39;s other heated parts including a muffler or an exhaust pipe, exhaust manifold, valve cover, turbo housing, engine block, transmission and the like.

Description:
BACKGROUND 
       [0001]    The present invention relates to a fuel vaporizer system for heating fuel such as gasoline, alcohol, kerosene, diesel, or ethanol, to be used in engines and generators. 
         [0002]    It has been recognized that the efficiency and fuel economy of an internal combustion engine can be improved by preheating the fuel supplied to the engine. Fuel preheating can be accomplished by passing the fuel in route to the engine in heat relationship with engine coolant and/or engine exhaust and/or engine heat from oil and/or engine components. U.S. Pat. No. 4,582,040; U.S. Pat. No. 4,700,047; U.S. Pat. No. 4,349,001; and U.S. Pat. No. 4,463,739 illustrate some of these heating systems. 
         [0003]    Despite the existence of these systems, there remains a need for a fuel heater and vaporizing system which is easy to install and which heats the fuel in a manner which reduces emissions from the engine or the generator, and the like. 
       SUMMARY OF THE INVENTION 
       [0004]    In accordance with the present disclosure, there is provided a fuel heater and vaporizing system which broadly comprises a source of fuel, a source of heated fluid and/or engine exhaust, and/or hot engine component(s), and a heat exchanger for thermally contacting the source of heated fluid and/or engine exhaust, and/or hot engine component(s), which heat exchanger has a saddle shape and fits over the source of heated fluid and/or engine exhaust, and/or hot engine component(s). 
         [0005]    In accordance with the present disclosure, there is provided a fuel heater and vaporizing system comprises a source of fuel; a thermal source; and a heat exchanger configured to thermally couple to the thermal source, the heat exchanger having a saddle shape and being configured to fit over the thermal source. 
         [0006]    In an alternative embodiment the heat exchanger has an inlet for receiving fuel from the fuel source, an outlet for discharging fuel, and a hollow passageway extending between the inlet and the outlet. 
         [0007]    In an alternative embodiment the heat exchanger has a first sidewall with the inlet, a second sidewall with the outlet, and at least one of an arcuate shaped region and multi-angled region between the first and second sidewalls. 
         [0008]    In an alternative embodiment the heat exchanger has an open bottom to allow the heat exchanger to be placed over the thermal source. 
         [0009]    In an alternative embodiment the heat exchanger further has at least one coupler configured to hold the heat exchanger in place. 
         [0010]    In an alternative embodiment a catalyst system for cracking the heated fuel is included. 
         [0011]    In an alternative embodiment the catalyst system comprises a catalyst holder and a plurality of at least one of rods and ribbons of dissimilar metals within the catalyst holder for creating a galvanic reaction. 
         [0012]    In an alternative embodiment the plurality of rods and ribbons include a plurality of rods and ribbons formed from a first material and at least one rod/ribbon formed from a second material. 
         [0013]    In an alternative embodiment the first material is aluminum or an aluminum alloy, nickel chrome alloy and the second material is one of zinc, a zinc alloy, and zinc plated steel. 
         [0014]    In an alternative embodiment the plurality of rods and ribbons formed from the first material are present in a ratio of 2:1 with respect to the at least one rod/ribbon formed from the second material. 
         [0015]    In an alternative embodiment the catalyst holder has a plurality of rods/ribbons formed from the second material. 
         [0016]    In an alternative embodiment the source of heated fuel is at one of an exhaust muffler, turbo assembly and an exhaust pipe from an engine. 
         [0017]    In an alternative embodiment the fuel heater and vaporizing system further comprises a fuel line containing ambient fuel; an inlet line communicating with the fuel line for delivering fuel to the heat exchanger; and an outlet line communicating with the heat exchanger and the fuel line for delivering heated fuel. 
         [0018]    In an alternative embodiment the fuel heater and vaporizing system further comprises a valve for allowing blending of the heated fuel with the ambient fuel. 
         [0019]    Further in accordance with the present disclosure, there is provided a fuel heater and vaporizing system comprises a heat exchanger for heating a fuel to be supplied to an end use device and a catalyst system for receiving fuel from the heat exchanger and for cracking the heated fuel. 
         [0020]    In an alternative embodiment the catalyst system comprises a catalyst holder and a plurality of metallic rods and/or ribbons within the catalyst holder for creating a galvanic reaction. 
         [0021]    In an alternative embodiment the plurality of rods includes a plurality of rods and/or ribbons formed from a first metallic material and at least one rod/ribbon formed from a second metallic material. 
         [0022]    In an alternative embodiment the first metallic material is aluminum or an aluminum alloy and the second material is one of zinc, a zinc alloy, and zinc plated steel. 
         [0023]    In an alternative embodiment the plurality of rods and/or ribbons formed from the first material are present in a ratio of 2:1 with respect to the at least one rod/ribbon formed from the second material. 
         [0024]    In an alternative embodiment the catalyst holder has a plurality of rods and/or ribbons formed from the second material. 
         [0025]    In an alternative embodiment the heat exchanger is placed into thermal conductive contact with a thermal source of an engine. 
         [0026]    In an alternative embodiment the thermal source is one of a radiator hose containing a heated coolant, an exhaust manifold, a turbo charger housing, an engine block, and an engine valve cover. 
         [0027]    In an alternative embodiment the heat exchanger has an open-bottom saddle shaped formed by first and second spaced apart sidewalls and an intermediate arcuate shaped region in which the fuel to be heated flows. 
         [0028]    Further in accordance with the present disclosure, there is provided a process for heating a fuel to be supplied to an end use device comprises the steps of providing a heat exchanger having an inlet, an outlet, and an arcuate shaped intermediate region. The process includes placing the heat exchanger into thermally conductive contact with a source of heat; heating the fuel by flowing the fuel through the heat exchanger while the heat exchanger is in contact with the source of heat; and cracking the fuel. 
         [0029]    In an alternative embodiment the source of heat comprises one of a radiator hose, an exhaust manifold, a turbo charger housing, an engine block, and an engine valve cover, the process further comprises thermally coupling the heat exchanger to at least one of, the radiator hose, an exhaust manifold, a turbo charger housing, an engine block, and an engine valve cover. 
         [0030]    In an alternative embodiment the cracking step comprises providing a catalyst system having a catalyst holder in which a plurality of rods and/or ribbons formed from dissimilar materials is placed and flowing the heated fuel into the catalyst holder and around the plurality of rods and/or ribbons. 
         [0031]    In an alternative embodiment the process further comprises blending the heated fuel with fuel at ambient temperature. 
         [0032]    In an alternative embodiment the process further comprises operating at least one valve responsive to at least one of a thermostat control and a manual control. 
         [0033]    Further in accordance with the present disclosure, there is provided a fuel heater and vaporizing system which broadly comprises a heat exchanger for heating a fuel to be supplied to an end use device, and a catalyst system for receiving fuel from the heat exchanger and is utilized as a catalyst for cracking the heated fuel. 
         [0034]    Still further in accordance with the present disclosure, there is provided a process for heating a fuel to be supplied to an end use device comprises the steps of providing a heat exchanger having an inlet, an outlet, and an arcuate shaped intermediate region, placing the heat exchanger into thermally conductive contact with a source of heat, heating the fuel by flowing the fuel through the heat exchanger while the heat exchanger is in contact with the source of heat, and cracking the fuel. 
         [0035]    Other details of the fuel vaporizing system are set forth in the following detailed description and the accompanying drawings wherein like reference numerals depict like elements. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0036]      FIG. 1  is a schematic representation of the fuel heating and vaporization system of the present invention; 
           [0037]      FIG. 2  is a sectional view of a catalyst holder used with the fuel heating and vaporization system of  FIG. 1 ; and 
           [0038]      FIG. 3  is a schematic representative of an alternative fuel heating and vaporization system including a temperature range controller; 
           [0039]      FIG. 4  is a schematic representation of an alternative embodiment of the fuel heating and vaporization system of the present invention. 
       
    
    
     DETAILED DESCRIPTION 
       [0040]    Referring now to  FIG. 1 , there is shown a system  10  for preheating fuel to be supplied to a motor engine, such as a diesel engine, or a diesel generator for generating electric power, and other diesel engine applications. The fuel which is heated and vaporized may be gasoline, alcohol, kerosene, diesel, or ethanol. Depending upon the type of fuel, the fuel will be heated at different temperature ranges. 
         [0041]    The fuel heating and vaporizing system  10  includes a heat exchanger  12  into which fuel is introduced and heated. The heat exchanger  12  preferably has sidewalls  14  and  16  and an arcuate shaped region  18  connecting the sidewalls  14  and  16 . The sidewall  14  has an inlet  20  into which fuel to be heated is introduced from a source of fuel or simply a tank  22  via a connection line  23 . A fuel pump  24  may be provided to create a flow of fuel from the tank  22  to the inlet  20 . 
         [0042]    The heat exchanger  12  has an outlet  26  through which the heated fuel leaves the heat exchanger. The heat exchanger  12  may have a hollow interior through which the fuel flows from the inlet  20  to the outlet  26 . The hollow interior may comprise a single passageway  27  for the fuel or may have walls or baffles  28  which create a plurality of passageways within the hollow interior. The baffles  28  are configured to direct the fuel flow and to increase the surface area of the heat exchanger  12 . 
         [0043]    As can be seen from  FIG. 1 , the arcuate shaped region  18  fits over a hose  30  which contains a heated fluid. The hose  30  may be a radiator hose and the heated fluid may be the heated coolant which flows through the radiator hose. Alternatively, the hose  30  can be part of the exhaust system which is heated via the exhaust side of the engine. Still further, the hose  30  may be any fluid conduit which contains a heated fluid. Portions  34 ,  36  of the sidewalls  14  and  16  are in contact with the sidewalls of the hose  30 . In a preferred embodiment, the heat exchanger  12  has a saddle shape formed by the arcuate shaped region  18  and the sidewalls  14  and  16 . The sidewalls  14  and  16  taper inwardly to ensure a tight fit of the heat exchanger  12  around the hose  30 . This causes the hose  30  to be slightly depressed so as to be pushed into place and held in position. If the hose  30  is rigid, then the two sidewalls  14  and  16  may be straight to enable the heat exchanger  12  to fit snugly over the hose or pipe  30 . The heat exchanger  12  has a bottom opening  32  which allows the heat exchanger to be easily placed over the hose or pipe  30 . If desired, one or more couplers  38 , such as, straps, fasteners, bolts, screws and the like may be provided to hold the heat exchanger  12  in place with the respect to the engine component, hose or pipe  30 . 
         [0044]    The heat exchanger  12 , and in particular, the portions of the sidewalls  14  and  16  contacting the hose  30  and the portion of the arcuate shaped region  18  contacting the hose, may be formed from any suitable thermally conductive material known in the art. For example, the heat exchanger  12  and the aforementioned portions thereof may be formed from a metallic material or a plastic material which is thermally conductive and resistant to higher temperatures. In use, the arcuate shaped region  18  and the contact portions  34  and  36  of the sidewalls  14  and  16  are placed in contact with the hose or pipe  30  so that heat, i.e., thermal energy, is conductively transferred from a thermal source  56  to the fuel flowing into and through the heat exchanger  12 . The thermal source  56  can include at least one of an engine coolant, engine exhaust, transmission fluid, engine heat from oil, hydraulic fluid, and hot engine components. 
         [0045]    One of the advantages of the heat exchanger  12  described herein is that there is a reduced potential for leaks since there is only an inlet, an outlet, and an intermediate hollow passageway in the sidewalls  12  and  14  and the arcuate shaped region  18 . 
         [0046]    After the fuel has been heated in the heat exchanger  12 , the fuel may flow to a catalyst system  39 . The catalyst system  39  includes a catalyst holder  40 . The heated fuel is caused to flow to an inlet  41  of the catalyst holder  40  via a connecting fuel line  42 . In the catalyst holder  40 , the heated fuel is cracked. This is done by providing the catalyst holder  40  with a plurality of rods and/or wires and/or ribbons formed from different materials, and in particular dissimilar metallic materials which create a galvanic response. 
         [0047]    As shown in  FIGS. 1 and 2 , the catalyst holder  40  is formed by a cylindrical tube  44  having end caps  46  and  48 . The end cap  46  includes the inlet  41  and the end cap  48  includes an outlet  50 . The cylindrical tube  44  creates a volumetric space  52  in which the heated fuel flows. As can be seen from  FIG. 2 , a plurality of solid rods and/or ribbons and or wires  60  and  61  are positioned within the space  52 . The rods and/or ribbons  60  and  61  are present in multiples of three. The fuel flowing in the catalyst holder  40  flows around the rods and/or ribbons  60  and  61  and causes the rods and/or ribbons  60  and  61  to become heated. The plurality of solid rods and/or ribbons and or wires  60  and  61  can be configured as braided or twisted together. The braided configuration increases the contact area between the dissimilar materials. In an exemplary embodiment, the braided plurality of solid rods and/or ribbons and or wires  60  and  61  can be inserted along the fuel flow path, in the fuel line  42  and/or the hollow passageway  27  or space  52 . The braided configuration can accommodate a high volume of ion production per length of plurality of solid rods and/or ribbons and or wires  60  and  61 . 
         [0048]    The rods and/or ribbons  60  may be formed from aluminum, an aluminum alloy, nickel chrome alloy and the like. The rods and/or ribbons  61  may be formed from zinc, a zinc alloy, zinc plated steel, nickel, chromium, platinum, copper and aluminum. In a preferred embodiment, the ratio of the rods and/or ribbons  60  to the rods and/or ribbons  61  is 2:1. In other words, there are two rods/ribbons  60  for each rod/ribbon  61 . As noted above, the dissimilar materials of the rods/ribbons  60  and  61  create a galvanic response which comprises a stream of metallic ions which helps to crack the fuel. Cracking helps improve the emissions that are put out by the end use device  70 , namely an engine or a generator, to which the heated and cracked fuel flows. 
         [0049]    Referring now to  FIG. 1 , the heated and cracked fuel flows from the catalyst holder  40  to the end use device  70  via fuel line  72 . Fuel which has been heated and treated with ions using the system  10  including catalyst system  40  of the present invention is better atomized in the end use device  70  and thus burns cleaner, leading to reduced emissions. If desired, the catalyst system may have the rods/ribbons  60  and  61  laying on top of one another in the hollow outlet side of the heat exchanger  12  between the outer wall  14  and the inner wall  16 . 
         [0050]    While the source of heat has been described as being a radiator hose  30 , it could be an exhaust muffler or exhaust pipe  80  on top of a motor. Referring now to  FIG. 3 , there is shown an embodiment wherein a heat exchanger  12  placed on top of a muffler or exhaust pipe  80 . The heat exchanger  12  may be configured as shown in  FIG. 1 . In this embodiment, the heat exchanger  12  receives fuel from a fuel line  82  containing fuel at ambient temperature via valve  84  and inlet line  86 . Ambient temperature refers to the temperature of the environment where the fuel is stored in source  81 . The system further has a heated fuel outlet line  88  which may be open or closed via valve  90 . The heated fuel exiting the heat exchanger  12  may be mixed or blended with the fuel in the fuel line  82 . By doing this, the temperature of the fuel flowing to the motor  92  may be controlled. One or more controllers  94  may be provided to control the valves  84  and  90  and this regulates the flow of fuel to/from the heat exchanger  12  and the temperature of the fuel. For example, if desired, the valve  90  may be operated so that (1) only heated fuel flows to the motor  92 ; (2) only ambient temperature fuel flows to the motor  92 ; or (3) a blend of heated/ambient fuel at a desired temperature flows to the motor  92 . 
         [0051]    Referring to  FIG. 4 , another alternative embodiment of a heating and vaporizing system  100  can be seen. The heating and vaporizing system  100  includes a heat exchanger  110  having sidewalls  112 . The sidewalls  112  form a volumetric space  114 . The sidewalls  112  can be aligned to form a multi-angled region  115  configured to receive an engine component  113 , such as a hose  30  shown at  FIG. 1 , or other engine component that produces thermal energy. An inlet  116  is formed in the sidewall  112  at a first location  118 . An outlet  120  is formed in the sidewall  112  at a second location  122  distally from the first location  118 . Fuel flow  124  (shown as arrows) can be directed through the volumetric space  114  from the inlet  116  to the outlet  120 . 
         [0052]    Baffles  126  can be located in the volumetric space  114  and configured to direct the fuel flow  124  in a serpentine fashion and configured to maximize the heat transfer to the fuel flow  124 . The baffles  126  also are configured to situate a catalyst material  128  in a position to maximize the ionic activity between the fuel flow  124  and the catalyst  128 . The catalyst material  128  in the form of braided wire can also be located along the fuel flow path in the space  114 . The volumetric space  114  can include legs  130  that are hollow. The legs  130  can also facilitate storage of the catalyst  128 . A port  132  can be included in the heat exchanger  110  that is configured to vent air entrapped in the fuel flow  124 . The port  132  can also be utilized to add fuel into the heat exchanger  110 . As in the embodiments described above, the heat exchanger  110  is configured to thermally couple with a heated engine source, such as a valve cover or exhaust manifold. The relatively hot valve cover or exhaust manifold is a thermal source  134  or simply a source of heat. 
         [0053]    The fuel heater and vaporizing system described herein may be used with any internal combustion engine, diesel engine, or any electrical generator which burns fuel. The fuel heater and vaporizing system  10  described herein has particular utility in heating and vaporizing diesel fuel used in diesel engines and for heating and vaporizing fuel used in engines that drive barges and diesel generator power plants and other diesel engine applications. 
         [0054]    The fuel heater and vaporizing system described herein allows the combustion process to change allowing more O2 to the hydrocarbon molecules, thus releasing more energy and burning some of the H2 that is released during use of the device. 
         [0055]    There has been provided in accordance with the instant disclosure a fuel heating and vaporizing system. While the fuel heating and vaporizing system has been described in the context of a specific embodiment thereof, other unforeseen alternatives, modifications, and variations may become apparent to those skilled in the art having read the foregoing detailed description. Accordingly, it is intended to embrace those alternatives, modifications, and variations as fall within the broad scope of the appended claims.