Patent Abstract:
A system and method for delivering catalytic molecular structure to a combustion chamber is disclosed. Catalyst base materials are reduced to a micronic fog by a device using the ultrasonic vibration of a piezoelectric disc. The liquid base materials evaporate instantly upon entering the engines air stream therefore releasing pure catalyst molecules into the combustion zone, thus reducing the time taken for catalytic combustion to the lowest denominator possible and allowing for the greatest effect achievable. This further reduces the amount of catalyst needed in the base solution compared to any other type of device or additive. The system also allows a user to control the delivery rate of the catalyst to the combustion chamber.

Full Description:
FIELD OF THE INVENTION 
       [0001]    This invention relates generally to combustion and, more specifically, to a catalyst delivery system for delivering a controlled amount of catalyst in a molecular form to a combustion chamber. 
       BACKGROUND OF THE INVENTION 
       [0002]    The concept of adding a catalyst to a combustion process is not new. However, there is no proven process that gives greater catalytic effect on combustion than for the catalyst to be proportionally and correctly mixed with the incoming air stream. 
         [0003]    Some have attempted to coat the combustion chamber with nanoparticles. But, this has not been very successful because the combustion chamber will not stay coated under the extreme conditions of temperature and pressure. To try to recoat the combustion chamber by adding varying nanosubstances (solids) or dissolved rare earth compounds to the incoming air stream are not reliable, controllable or efficient. Simply coating the surfaces of a combustion chamber will have an effect at the outer edges of the combustion, but not at the core or ignition point and throughout the combustion. 
         [0004]    Others have tried to add catalytic solutions directly to the fuel. However, the catalyst is weakened by the sheer nature of the catalyst molecules having to release themselves from the fuel molecules before having a catalytic effect on the overall combustion reaction in the millisecond that the combustion lasts. 
         [0005]    Others have also simply placed Platinum balls into the fuel line or fuel tank, expecting the Platinum molecules to release into the fuel and cause a catalytic effect. Each of the aforementioned methods may have some level of success, but none of them seems to have a way to control the amount or the quality of catalyst delivered. Also, none of them appear to address a controlled repeatability and correct ratio of catalyst to fuel or the longevity of the catalyst delivery process. 
         [0006]    Therefore, a need exists for a delivery system that improves the amount of actual catalytic material that reaches the combustion chamber. A need also exists for a delivery system that allows a user to control the delivery rate of the catalyst to the combustion chamber. One of the primary purposes of the invention is to reduce the overall fuel consumption of combustion devices and at the same time reduce the gaseous pollution and particulate matter created by the inefficient combustion of today&#39;s engines. It is a well known fact that catalyst(s) have a positive effect on combustion. What has always been a challenge is a way to control the amount and size of the catalyst to achieve the greatest effect on the combustion and this invention does that. 
       SUMMARY OF THE INVENTION 
       [0007]    It is an object of the present invention to provide a delivery system that improves the amount of catalyst that reaches a combustion chamber. 
         [0008]    It is another object of the present invention is to provide a catalyst delivery system that reduces the overall fuel consumption of combustion devices. 
         [0009]    Another object of the present invention is to provide a catalyst delivery system that reduces particulate matter created by inefficient combustion in present day engines. 
         [0010]    Another object of the present invention is to provide a catalyst delivery system that reduces the overall pollution, e.g. NOx, Co2, etc., created by inefficient combustion in present day engines. 
         [0011]    Still another object of the present invention is to provide a catalyst delivery system that reduces the engine and exhaust temperatures created by inefficient combustion in present day engines. 
         [0012]    Still another object of the present invention to provide a delivery system that allows a user to control the delivery rate of catalyst to a combustion chamber based on the amount of fuel being consumed. 
         [0013]    Yet another object of the present invention is to provide a delivery system that allows a user to control the size of the catalytic molecules to achieve the greatest effect on combustion. 
       BRIEF DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0014]    In accordance with one embodiment of the present invention, a dry micro fog device for a combustion engine is disclosed. The device comprises a hollow chamber having a collection area for base materials, a piezoelectric disc for transforming base materials into a micro aerosol, wherein the piezoelectric disc is coupled to the hollow chamber, below the collection area, a top cover sealing a top portion of the hollow chamber, wherein the cover has an opening for delivering the micro aerosol from the hollow chamber to an air intake of the combustion engine, and a bottom cover sealing a bottom portion of the hollow chamber. 
         [0015]    In accordance with another embodiment of the present invention, a catalyst delivery system for a combustion engine is disclosed. The delivery system comprises an amount of liquid containing at least one catalyst, a hollow chamber having a collection area for the liquid, a piezoelectric disc for transforming the liquid into a micro aerosol, wherein the piezoelectric disc is coupled to the hollow chamber, below the collection area, a top cover sealing a top portion of the hollow chamber, wherein the cover has an opening for delivering the micro aerosol from the hollow chamber to an air intake of the combustion engine, a bottom cover sealing a bottom portion of the hollow chamber, and a control mechanism for maintaining a constant level of liquid in the collection area. 
         [0016]    In accordance with another embodiment of the present invention, a method for delivering catalyst to a combustion engine is disclosed. The method comprises the step of providing a dry micro fog device comprising a hollow chamber having a collection area, a piezoelectric disc coupled to the hollow chamber and coupled below the collection area, a top cover sealing a top portion of the hollow chamber, wherein the cover has an opening, and a bottom cover sealing a bottom portion of the hollow chamber. The method comprises the further steps of providing a liquid catalyst solution in the collection area, vibrating the piezoelectric disc, reducing the liquid catalyst solution to a micro aerosol comprising catalytic molecules that are between approximately 1.7 microns to 3 microns in size, and creating a venturi effect with the air flowing through the air intake to draw the aerosol from the hollow chamber into the air intake through the opening of the top cover. 
         [0017]    The foregoing and other objects, features, and advantages of the invention will be apparent from the following, more particular description of the preferred embodiments of the invention, as illustrated in the accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0018]      FIG. 1  is a front view of one embodiment of a catalyst delivery system of the present invention. 
           [0019]      FIG. 2  is a side cross-sectional view of the dry fog device of the catalyst delivery system of  FIG. 1 . 
           [0020]      FIG. 3  is a cross sectional view of the collection area, bottom cover, and piezoelectric disc of the dry fog device of  FIG. 2 . 
           [0021]      FIG. 4  is a side internal view of the dry fog device of  FIG. 2 . 
           [0022]      FIG. 5  is an elevated perspective view of the catalyst delivery system of  FIG. 1  with the dry fog device shown in phantom lines coupled at the docking station on the air intake. 
           [0023]      FIG. 5A  is an elevated perspective internal view of the dry fog device of  FIG. 2 . 
           [0024]      FIG. 5B  is an elevated perspective internal view of another embodiment of the dry fog device. 
           [0025]      FIG. 5C  is an elevated perspective internal view of another embodiment of the dry fog device. 
           [0026]      FIG. 6  is a top perspective view of the delivery tube and splash guard of the dry fog device. 
           [0027]      FIG. 7  is a bottom perspective view of the delivery tube and splash guard of  FIG. 6 . 
           [0028]      FIG. 8  is a top perspective view of another embodiment of the delivery tube and splash guard of the dry fog device. 
           [0029]      FIG. 9  is a top view of the delivery tube and splash guard of the dry fog device of  FIG. 6 . 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0030]    The novel features believed characteristic of the invention are set forth in the appended claims. The invention will best be understood by reference to the following detailed description of illustrated embodiments when read in conjunction with the accompanying drawings, wherein like reference numerals and symbols represent like elements. 
         [0031]      FIGS. 1-9  show a catalyst delivery system for a combustion engine, referred to as system  10 , of the present invention. The system  10  comprises a dry micro fog device  12  and a control mechanism  14  to control the amount of catalyst that reaches the combustion chamber, piezoelectric frequency, and the delivery rate of catalyst to a combustion chamber. 
         [0032]    Referring to  FIG. 1 , an embodiment of the catalyst delivery system  10  is shown. The dry fog device  12  is shown coupled to a side portion of an air intake  58  of a combustion engine. It should be clearly understood, however, that substantial benefit may be derived from the dry fog device  12  being coupled to a different portion of the air intake  58 . The dry fog device  12  converts base materials, such as a catalytic solution  16 , into a micro aerosol  17  that is then delivered into the air intake  58 . It should be clearly understood that the base materials may be water, water/glycol, oil, alcohol, esters, etc. 
         [0033]    Maintaining an optimal level of catalytic solution  16  above the piezoelectric disc  26 , maintains the peak of efficiency of the micro aerosol  17  (see  FIG. 4 ) output at all times and allows the piezoelectric disc  26  to operate for the longest length of time. The level of catalytic solution  16  will depend upon the type of liquid being nebulized; oil, water, water/glycol, etc. The viscosity of the liquid will determine the level in the collection area  24  that will provide for the best micronic fog effect. 
         [0034]    In this embodiment, the system  10  has a supply of additional catalytic solution  16  that may be added to the collection area  24  through an inlet valve  52 . In  FIG. 1  the additional catalytic solution  16  is held in a housing  48  and the flow of the catalytic solution  16  to and from the housing  48  is controlled by the control mechanism  14 . The additional catalytic solution  16  may be stored directly in the housing  48  or, for convenience, may be kept in disposable bags placed within the housing  48 . Furthermore, the housing  48  may be available in several sizes, allowing it to hold various amounts of catalyst solution, depending upon the maintenance cycle of the combustion engine. 
         [0035]    When the amount of catalytic solution  16  in the collection area  24  falls below a desired level, additional catalytic solution  16  will be pumped from the housing  48  and to the collection area  24  via a length of tubing  56  that connects the housing  48  to the inlet valve  52 . In order to maintain an optimal level of catalytic solution  16  in the collection area  24  above the piezoelectric disc  26  (see  FIGS. 2-3 ), the dry fog device  12  also has an outlet valve  54  that allows any overflow of catalytic solution  16  to be drained from the collection area  24  and pumped to the housing  48  via another length of tubing  56  that connects the outlet valve  54  to the housing  48 . As shown, the outlet valve  54  is positioned at a level below the inlet valve  52  and is positioned at the desired level. 
         [0036]    In another embodiment, the control mechanism  14  may comprise a sensor placed within the collection area  24  for identifying the level of catalytic solution  16  remaining in the collection area  24 . Once the sensor detects that the level of catalytic solution  16  has fallen below the desired level, the control mechanism  14  will then pump additional catalytic solution  16  to the collection area  24  via tubing  56  connecting the housing  48  to the inlet valve  52 . 
         [0037]    As shown in  FIG. 1 , the control mechanism  14  of the system  10  comprises a pump and electronics assembly  64 . The control mechanism  14  also has inputs  46  to receive power from the engine and/or an independent power source. The tubing  56  connected to the inlet valve  52  and outlet valve  54  are also connected to the pump and electronics assembly  64  of the control mechanism  14 . Electrical wiring  62  also connects the piezoelectric disc  26  of the dry fog device  12  to the control mechanism  14 . 
         [0038]    The control mechanism  14  is shown in  FIG. 1  as being coupled to the housing  48  and shown separated from the dry fog device  12 . This allows the pump and electronics assembly  64 , the driver circuit, and power connections to be held remote from any sonic vibration or disruptive impact vibration destruction caused by the dry fog device  12  when the piezoelectric disc  26  is being operated. While this is preferred, it should be clearly understood that substantial benefit may still be derived from the control mechanism  14  being coupled directly to the dry fog device  12 . While this is the control mechanism  14  shown in the Figures, it should be clearly understood that any suitable control mechanism  14  may be used to control the flow of catalytic solution  16  between the dry fog device  12  and the housing  48  containing additional catalytic solution  16 . 
         [0039]    Referring now to  FIGS. 2-5 , the dry fog device  12  of the system  10  is shown coupled to an air intake  58 . In this embodiment, the dry fog device  12  has a hollow chamber  18 . While the hollow chamber  18  is shown as being L-shaped and attached to the side of the air intake  58 , it should be clearly understood that substantial benefit may be derived from the hollow chamber  18  having an alternative shape and being coupled to a different area of the air intake  58 . 
         [0040]    A docking station  66  is coupled over an opening  82  in the air intake  58 . The docking station  66  is shown as having a curved portion  68  that conforms to the curve of the air intake  58  and has an opening  84  that is aligned with the opening  82  in the air intake  58 . The docking station  66  also has a straight portion  70  that connects to a top portion  20  of the hollow chamber  18 . The straight portion  70  of the docking station  66  and the top portion  20  of the hollow chamber  18  may be threaded and held together by a locking ring (shown in  FIG. 5 ). However, it should be clearly understood that the straight portion  70  of the docking station  66  and the top portion  20  of the hollow chamber  18  may be coupled in any other suitable way as long as an air tight connection is created between the air intake  58  and the dry fog device  12 . 
         [0041]    The hollow chamber  18  has a collection area  24  (shown in  FIGS. 2-4 ) near a bottom portion  22  of the hollow chamber  18 . Base materials, such as catalyst solution  16  are held in the collection area  24 . While it is shown that the base materials be a liquid catalyst solution  16 , it should be clearly understood that substantial benefit may still be derived from the base materials being in gel or powder form. 
         [0042]    A nebulizer, such as a piezoelectric disc  26  (shown in  FIGS. 2-3 ), is located near the bottom portion  22  of the hollow chamber  18 , below the collection area  24 . The piezoelectric disc  26  transforms the catalyst solution  16  into an aerosol  17  (shown in  FIG. 4 ) within the hollow chamber  18 . A bottom cover  34  seals the bottom portion  22  of the hollow chamber  18  and is shown as defining a recessed area  36  (shown in  FIGS. 2-3 ) for housing the piezoelectric disc  26 . The bottom cover  34  is also shown as housing the electrical wires  62  (shown in  FIGS. 2-3 ) that connect the piezoelectric disc  26  to the pump and electronics assembly  64  of the control mechanism  14 . The bottom cover  34  is shown as being threaded to correspond with a threaded bottom portion  22  of the hollow chamber  18 . It should be clearly understood, however, that the bottom cover  34  may be coupled to the bottom portion  22  of the hollow chamber  18  in any suitable way as long as an air-tight connection is formed. 
         [0043]    The dry fog device  12  may also have anti-splashing material, such as open cell foam  74  (shown in  FIGS. 2-4 ), placed within the collection area  24  for preventing splashing within the collection area  24  during the vibrations caused by the operating engine and/or the equipment that the engine is housed in. The open cell foam  74  is shown conforming to the shape of the hollow chamber  18 , lining the inner walls of the collection area  24 . The open cell foam  74  will also define a hollow center portion  76  directly above the piezoelectric disc  26 , allowing the piezoelectric disc  26  to be submerged in the catalytic solution  16 . The bottom portion  22  of the hollow chamber  18  is also shown defining a flange  78  (shown in  FIGS. 2-4 ), on top of which the open cell foam  74  will sit. 
         [0044]    As shown in  FIGS. 2 and 3 , when the bottom cover  34  is coupled to the bottom portion  22  of the hollow chamber  18 , the recessed area  36  of the bottom cover  34  comprises a flange  80  that is aligned with the flange  78  of the bottom portion  22  of the hollow chamber  18 . The piezoelectric disc  26  is situated between two O-rings  44 ; one O-ring  44  placed below the flange  78  of the bottom portion  22  of the hollow chamber  18  and one O-ring  44  placed above the flange  80  of the bottom cover  34 . This O-ring configuration reduces leakage from the collection area  24  and keeps the piezoelectric disc  26  in place within the recessed area  36  of the bottom cover  34 . 
         [0045]    Referring to  FIGS. 5A-5C , the dry fog device  12  also has a top cover  28  that seals the top portion  20  of the hollow chamber  18 . The top cover  28  has an opening  30  for delivering aerosol  17  from the hollow chamber  18  to the air intake  58  of the combustion engine. Airflow within the air intake  58  blows across the opening  30 , creating a venturi effect, thereby causing the aerosol  17  to be pulled from the hollow chamber  18  through the opening  30  in the top cover  28  and into the air intake  58 . The top cover  28  may also have a pressure balance hole  32  to relieve any excess negative pressure in the hollow chamber  18 , though one is not required. 
         [0046]    In another embodiment, the dry micro fog device  12  may have a delivery tube  38  (shown in  FIGS. 2 ,  4 ,  5 ,  5 A, and  5 B) that passes through the opening  30  of the top cover  28 . The delivery tube  38  has a first end  40  that is located within the hollow chamber  18  and is located above the collection area  24 . The delivery tube  38  also has a second end  42  that is located within the air intake  58 . The second end  42  of the delivery tube  38  is preferably placed at a specific position within the air intake to ensure optimal function. This specific position is determined according to the size of the air intake  58  and the velocity of the air blowing through the air intake  58 . Generally, the second end  42  of the delivery tube  38  will be placed more than one quarter inch away from the inner perimeter of the air intake  58 . This will assure that the delivery tube  38  is not placed in the eddy of the air stream in the intake  58 , whether reverse or turbulent air stream. 
         [0047]    In the embodiment shown in  FIG. 5B , airflow within the air intake  58  blows across the open second end  42  of the delivery tube  38  creating a venturi effect, thereby causing the aerosol  17  to be pulled from the hollow chamber  18  through the delivery tube  38  and into the air intake  58 . The second end  42  of the delivery tube  38  may flex due to the violence of the venturi effect. 
         [0048]    As shown in  FIGS. 5-5A , the second end  42  of the delivery tube  38  may be T-shaped so that a portion of the second end  42  is in line with the air intake  58 . Airflow within the air intake  58  will blow through the open T-shaped second end  42  creating a venturi effect within the T-shaped second end  42 , thereby causing the aerosol  17  to be pulled from the hollow chamber  18  through the delivery tube  38  and into the air intake  58 . This T-shaped configuration reduces the violence of the venturi effect. 
         [0049]    Referring to  FIGS. 6-9 , the dry fog device  12  may also have a splash guard  60  (also shown in  FIGS. 2 ,  4 , and  5 ) coupled to the first end  40  of the delivery tube  38  for preventing large particles of catalytic solution  16  from entering the delivery tube  38 . The splash guard  60  is shown as being a disc coupled to the first end  40  by a plurality of prongs. The splash guard  60  may be solid (shown in  FIGS. 6 ,  7 , and  9 ) or the splash guard may be porous (shown in  FIG. 8 ). It should be clearly understood that the splash guard  60  may be coupled to the first end  40  in any suitable way as long as the open first end  40  is not obstructed. It should also be clearly understood that substantial benefit may be derived from the splash guard  60  being integral to the first end  40  or from there being no splash guard  60 . 
         [0050]    All component parts, including plastics, wiring, tubes, connectors, metals and catalyst are designed to withstand the atmospheric conditions and the contamination conditions in or around the combustion engine. 
       Statement of Operation 
       [0051]    The catalyst delivery system  10  may be constructed with a combustion engine, or more preferably, will be adaptable to an existing combustion engine. In the case of an existing combustion engine, an opening  82  in the air intake  58  must be made. A docking station  66  will be coupled to the air intake  58 , making sure to align the opening  84  of the docking station  66  with the opening  82  in the air intake  58 . The top portion  20  of the hollow chamber  18  will then be coupled to the straight portion  70  of the docking station  66 . If a delivery tube  38  is used, the second end  42  of the delivery tube  38  should be positioned at its optimal location within the air intake  58 . 
         [0052]    The collection area  24  of the hollow chamber  18  will be filled with catalytic solution  16 . The piezoelectric disc  26  may then be operated and controlled by the control mechanism  14 . By controlling the voltage, a user may control the piezoelectric disc  26  frequency and therefore control the aerosol output (consumption of catalytic solution  16 ). This will assure reduction in pollution and fuel consumption. 
         [0053]    The piezoelectric disc  26  may be operated at frequencies between approximately 1.6-2.4 megahertz, thus creating an aerosol  17  (or dry fog) of catalytic molecules between approximately 1.7-3 microns in size. These molecules are so small that they quickly evaporate when introduced into the in-coming air stream in the air intake  58 , thereby releasing pure unattached catalyst into the combustion zone. This not only increases the catalytic effect and reliability, but also simultaneously reduces the amount of catalyst needed in the base solution. Furthermore, the greatly reduced size of the catalyst molecules reduces the possibility of the catalyst attaching to any surface before reaching the combustion engine. 
         [0054]    The piezoelectric disc  26  has a finite life cycle which has been greatly increased by the present invention. The control mechanism  14  causes the piezoelectric disc  26  to have an ON/OFF cycle from approximately 10-20 milliseconds to approximately 10-40 milliseconds (and so on). By having the OFF cycle of the piezoelectric disc  26  set at 1-4 times the length of the ON cycle, the life cycle of the piezoelectric disc  26  is increased exponentially. This will also control the amount of aerosol  17  outflow. The ON/OFF cycles may be changed as needed to extend the life of the piezoelectric disc  26  as desired. 
         [0055]    While the invention has been particularly shown and described with reference to preferred embodiments thereof, it will be understood by those skilled in the art that the foregoing and other changes in form and details may be made therein without departing from the spirit and scope of the invention.

Technology Classification (CPC): 5