Patent Abstract:
The invention is directed to a combination heater and electrical generator designed to allow continual use of the heating system in the absence of an external source of electricity. The system shares fuel and electrical inputs and also shares exhaust outputs so to facilitate ease of use installation as well as affording a small installation footprint.

Full Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application is a Continuation in Part of pending U.S. patent application Ser. No. 12/824,857 filed on Jun. 28, 2010 entitled “Heat Exchange Module for Cogeneration Systems and Related Method of Use,” which in turn is a Continuation in Part of pending U.S. patent application Ser. No. 12/760,256 filed on Apr. 14, 2010 entitled “High Efficiency Cogeneration System and Related Method of Use,” the contents of which are incorporated by reference herein. 
    
    
     FIELD OF THE INVENTION 
     This invention is directed toward an integrated backup electrical generator and heating system designed allow continual use of the heating system in the absence of an external source of electricity, the system sharing fuel and electrical inputs and sharing exhaust output so to facilitate ease of installation. 
     BACKGROUND OF THE INVENTION 
     Cogeneration represents a relatively new concept in the field of generating electricity. Traditionally, electricity has been created by centralized facilities—typically through burning a fossil fuel like coal—which is then transported through an electrical grid to individual residential and commercial facilities. 
     Within the past several years, cogeneration systems have been developed to essentially reduce both need and reliance on these electrical grids. More specifically, cogeneration systems typically employ a heat engine (typically an internal combustion engine) or a power station located in proximity to the residential or commercial facilities it serves so to simultaneously generate both electricity and useful heat. Most cogeneration systems utilize a centralized reservoir of fossil fuel to create electricity, heat running water and air, and in some instances even provide energy back into the grid for credit. 
     Recently, there have been several forms of cogeneration systems developed for use in residential homes and smaller commercial facilities. These systems have been dubbed “mini-cogeneration” systems due to their modest size and performance. Another common name associated with these systems is a distributed energy resource (“DER”) system. 
     Regardless of the moniker, these systems produce usually less than 5 kW of power. Instead of burning fuel to merely heat space or water, some of the energy is converted to electricity in addition to heat. This electricity can be used within the home or business, and if permitted by municipal grid management entities may be sold back to the municipal electricity grid. A recent study by the Claverton Energy Research Group found that such a cogeneration system offered the most cost effective means of reducing CO 2  emissions—even compared to use of photovoltaic devices for the production of energy. 
     Apart from the energy conservation associated with mini-cogeneration systems, the technology also offers additional logistical benefits. Such cogeneration systems often offer more reliable energy solutions to residential dwellings in rural areas wherein it is difficult access the electrical grid. Alternatively, these systems offer more stable energy supplies in areas often affected by natural disasters such as hurricanes, tornadoes and earthquakes—where the downing of power lines will often lead to large periods with a lack of energy. 
     While there exists multiple benefits for micro-cogeneration systems, they currently possess several drawbacks. First, current cogeneration systems still create a certain degree of byproduct from the burning of fossil fuels that must be released into the atmosphere. This creates a secondary safety issue as there is a risk that unless this toxic byproduct is sufficiently vented that it could cause a build up of carbon monoxide within the residence. Second, most of the heat engines used in micro-cogeneration systems are not highly efficient, resulting in the waste of expensive fossil fuels. Finally, many cogeneration systems fail to adequately harvest all much of the heat byproduct created from the heat engines, which could be used to heat air and water to be used throughout a facility. 
     Under normal conditions, residential heating systems require the use of electricity. Even when the main source of combustion is a fossil fuel, such as oil, natural gas, or propane there is almost always a need for electricity to at least power an air blower motor, power water pumps in a boiler unit, or to provide power to a transformer and igniter in a steam unit. 
     In the case of a power failure during the winter months, homes and homeowners can potentially be in a considerable amount of danger. Water pipes can freeze in only a few hours in the absence of an internal heat source. Additionally, the temperature within the home can rapidly fall to dangerously low levels, placing homeowners in peril. 
     Portable gasoline generators—normally for the purpose of providing power to lights and appliances during a power outage—are not typically equipped or installed to provide power to heat-providing sources. 
     Additionally, in warmer months, tropical storms, lightning, power blackouts due to overloaded power grids, and other phenomenon cause residences to lose electrical power. The loss of television, fan, lights, refrigerators, and other appliances is an inconvenience, if not dangerous. During widespread losses in electricity, pumping gasoline for use in a generator is difficult for most gas pumps rely on electric power to operate. 
     Most natural gas sources operate during loss of electrical power. Installing a natural gas or propane automatic generator, which is wired to a home&#39;s breaker or fuse panel, could prevent all the above mentioned problems. Such installations however require extremely expensive equipment, the installation of gas pipes, new electrical connections, and in most applications are extremely expensive upgrades. 
     Air-cooled fossil fuel generators produce a substantial amount of heat and exhaust under normal operation, yet are designed to operate outdoors where there is sufficient air available for cooling and exhaust discharge. Attempting to operate a generator within a confined environment is met with a significant amount of mechanical challenges, including cooling and discharging heat and exhaust gasses in a safe manner. 
     Accordingly, there is a need in the field for a highly efficient electricity generation system wherein an indoor generator is easily and cost effectively integrated with an existing furnace or boiler to provide seamless backup power to a facility and provide a means for a fuel-powered heating system to operate. Such a system should comprise a scheme for extracting generator exhaust gasses in a safe and efficient manner that is additionally cost effective to implement. Finally, such improved system should preferably be compact, self-contained and easy to use. 
     SUMMARY OF THE INVENTION 
     It is therefore an object of the present invention to provide an integrated electrical generator and heating system comprising a heating apparatus for the purpose of providing heat to an interior space that comprises a fuel burner that produces heat, a heat exchanger that is heated by the burner, a draft inducer to promote an influx of combustion air and exhausting of exhaust gas created by the burner, and a flue in communication with the draft inducer. The flue defines the path for the heating apparatus exhaust gas to escape from the system. The flue is made from a material chosen from the group comprising one or more of the following materials: polyvinyl chloride, metal, vitreous enamel, transite, and other materials known in the art. The heater fuel input line is in communication with the burner to provide fuel to the burner. The heating apparatus is at least one of a furnace, boiler, and electric element heater, and provides heat through intermediary fluid movement, the fluids chosen from the group consisting of air, steam, and water. 
     The integrated electrical generator and heating system also comprises a fuel-powered electrical generator including an electrical input, a first electrical output, a generator fuel input line, an air intake conduit, and an exhaust conduit. The generator accepts electrical service from an electrical power grid through the electrical input. The generator delivers electricity to the heating apparatus through the first electrical output. The generator accepts the air required for combustion through the intake conduit, and exhausts combustion exhaust gases through the exhaust conduit, wherein the exhaust conduit of the generator communicates with the flue of the heating apparatus. 
     The generator utilizes a fuel to generate electricity chosen from the group comprising natural gas, liquefied petroleum gas, fuel oil, coal, and wood. The generator generates at least one of 120 VAC single-phase power, 240 VAC single-phase power, 240 VAC three-phase power, and 480 VAC three-phase power. 
     The integrated electrical generator and heating system additionally comprises at least one normally closed relay that communicates electrical service from the power grid to the first electrical output when the generator is powered off. The relay communicates electricity generated by the generator to the first electrical output when the generator is powered on. An electrical exhaust gas relay is activated by the generator when the generator is generating power and signals the exhaust gas relay to signal the draft inducer to activate so that the draft inducer can generate a vacuum to evacuate at least one of generator exhaust gas and heating apparatus exhaust gas from the system. 
     Additionally, a second electrical output communicates with at least one electrical power receptacle, and at least one normally closed relay communicates electrical service from the power grid to the second electrical output when the generator is powered off. The relay communicates electricity generated by the generator to the second electrical output when the generator is powered on. The exhaust conduit of the generator communicates with the flue of the heating apparatus using a Y-pipe. 
     A housing encases the generator that has an emergency leak conduit in communication with the exhaust conduit of the generator and at least one intake port on the housing. Also at least one fan is proximate the leak conduit port, the fan being activated when the generator is powered on to create a negative pressure within the housing causing air external to the housing to enter into the housing through the intake port. 
     A pressure switch communicates with the heating apparatus proximate the flue and also communicates with the generator, wherein the pressure switch detects a negative pressure induced by the draft inducer and disables the generator when the draft inducer is not functional. 
     The fuel to power the heating apparatus is of the same type of fuel to power the generator, and the heater fuel input line communicates with the generator fuel input line and both the heating apparatus and generator share a common source of fuel. 
     A heat exchange module for employing usable heat created by a cogeneration system coupled to a generator is also contemplated in this disclosure. This cogeneration system is coupled to a generator and comprises a heating apparatus for the purpose of providing heat to an interior space. The heating apparatus comprises a fuel burner that produces heat, a heat exchanger that is heated by the burner, a draft inducer to promote an influx of combustion air and exhausting of exhaust gas created by the burner, and a flue in communication with the draft inducer. The flue is a path for the heating apparatus exhaust gas to escape from the system, and a heater fuel input line in communication with the burner to provide fuel to the burner. 
     Additionally, this embodiment of the invention comprises a fuel-powered electrical generator including an electrical input, a first electrical output, a generator fuel input line, an air intake conduit, and an exhaust conduit. The generator accepts electrical service from an electrical power grid through the electrical input, and the generator delivers electricity to the heating apparatus through the first electrical output. The generator accepts air required for combustion through the intake conduit and exhausts combustion exhaust gas through the exhaust conduit. At least one normally closed relay communicates electrical service from the power grid to the first electrical output when the generator is powered off, and the relay communicates electricity generated by the generator to the first electrical output when the generator is powered on. An electrical exhaust gas relay is activated by the generator when the generator is generating power, and signals the draft inducer to activate. The draft inducer generates a vacuum that evacuates at least one of generator exhaust gas and heating apparatus exhaust gas from the system. A second heat exchanger having a collection chamber and at least one heat exchange conduit captures the generator&#39;s exhaust gas for the purpose of heating at least one heat exchange conduit. The heat exchange conduit contains water that is heated by the heat exchange conduit. The heated water in the heat exchange conduit is used as water for at least one of a water heater and a radiant heating system. It should be noted that all of the embodiments of the integrated electrical generator and heating system described above are applicable as embodiments of the heat exchange module for employing usable heat created by a cogeneration system coupled to a generator. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       For a fuller understanding of the invention, reference is made to the following detailed description, taken in connection with the accompanying drawings illustrating various embodiments of the present invention, in which: 
         FIG. 1  is a schematic illustrating the overall positioning of the cogeneration system in light of the electricity grid; 
         FIG. 2  is a diagram illustrating placement of the cogeneration system and various connections with the existing furnace, air-conditioning and air handlers; 
         FIG. 3  illustrates the primary components of the cogeneration system including the catalytic converter and cooling manifolds; 
         FIG. 4  is a schematic illustrating the various components of the control system, which includes a battery; 
         FIG. 5  is a schematic that illustrates the components of the first cooling manifold; 
         FIG. 6  illustrates the components of the heat exchange module; 
         FIG. 7  is a schematic illustrating the module controller; 
         FIG. 8  is a schematic illustrating the integrated electrical generator and heating system; and 
         FIG. 9  is a schematic illustrating a heat exchange module for employing usable heat created by a cogeneration system coupled to a generator. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     The present invention will now be described more fully hereinafter with reference to the accompanying drawings, in which preferred embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Like numbers refer to like elements throughout, and prime notation is used to indicate similar elements in alternate embodiments. 
     Positioning and Location of Cogeneration System 
       FIG. 1  and  FIG. 2  both illustrate, by way of example, one positioning and location of the preferred cogeneration system  500 .  FIG. 1  provides a general illustration of a conventional centralized power generation system. Here, a central power plant  100  generates electricity for disbursement to a plurality of various residential and commercial facilities  300  throughout a distinct geographic area. Such central power plant  100  can create electricity through an energy source  430 , such as conventional burning of fossil fuels (typically coal) through nuclear energy or harnessing geothermal energy. 
     Positioned between the central power plant  100  and the residential or commercial facility  300  is the electric grid  200 . This electric grid  200  consists of various transformers, power stations and power lines that transport electricity from the central power plant  100 . This electricity is then supplied to residential or commercial facilities  300  for use. 
     When a residential or commercial facility employs the invention, it must also include various components to properly service the overall apparatus. This includes a fuel source  400  that supplies a sufficient amount and quantity of energy to the cogeneration system  500 . Such fuel source  400  may include, but is certainly not limited to, a reservoir  410  of fossil fuels, such as petroleum, oil, propane, butane, ethanol, natural gas, liquid natural gas (LNG) or fuel oil. Alternatively, the fuel source  400  may alternatively be a fuel line  420  such as a natural gas or propane line supplied by a municipality. Regardless, either fuel source  400  must supply sufficient energy to power the cogeneration system  500 —which in turn can create electricity and usable heat for the furnace  600  and other appliances. 
       FIG. 1  also illustrates how the cogeneration system  500  can supply energy back to the electricity grid  200  for credits. This occurs when the cogeneration system  500  supplies a greater level of energy than required by the facility  300 . While  FIG. 1  shows the placement of the cogeneration system in light of the electric grid  200 ,  FIG. 2  shows the interconnectivity within the residential facility  300  itself. As illustrated, an energy source  430  stored within a reservoir  410  (or fed by a fuel line  420 ) is supplied to the cogeneration system  500 . Spending of this energy source  430  within the cogeneration system  500  creates two forms of energy: electricity  601  and usable heat  602 . The electricity  601  can provide energy to the residential facility  300 , as well as power both the furnace  610  and the air-conditioning unit  620 . Alternatively, the furnace  610  can be supplied energy directly from the reservoir  410 . 
     In addition, usable heat  602  created by the cogeneration system  500  can be used to heat air from a return air handler  630  prior to being introduced into the furnace  610  for heating. By doing so, the system essentially pre-heats the incoming cooler air prior to being warmed by the furnace  610 , which in turn requires less energy (and results in less strain on the furnace  610 ). This is one of many forms of energy conservation contemplated by the invention. 
     Once heated air leaves the furnace  610 , it is positioned within a supply air handler  640  to be circulated throughout the residential facility  300 . Alternatively, when cooler air is desired, the convention contemplates having the air conditioning unit  620  supply cooler air to the supply air handler  640 . As such, the apparatus taught by the invention requires interplay and interconnectivity between the cogeneration system  500 , the furnace  610 , the air conditioning unit  620  and both air handlers  630  and  640  to ensure efficient cooling and heating of air circulated throughout the home. 
     The Cogeneration System 
       FIG. 3  illustrates, by way of example, the components that make up the cogeneration system  500 . As shown, the primary components of the apparatus include a reservoir  410  capable of housing an energy source  430  (which can be a fossil fuel), a regulator system  504 , a modified combustion engine  520  (hereinafter referred to simply as a “modified engine”), a catalytic converter  530 , and two cooling manifolds  540  and  550  which help treat the various hot gasses  603  which form as byproduct from the modified engine  520 . Other additional or substitute components will be recognized and understood by those of ordinary skill in the art after having the benefit of the foregoing disclosure. 
     As illustrated in  FIGS. 2 and 3 , the first component of the cogeneration system  500  is the fuel source  400 , which can be a reservoir  410  (or alternatively a fuel line  420 ). The reservoir  410  is of a size and dimension to provide a sufficient amount and quantity of an energy source  430  to fuel the cogeneration system  500  for a defined period of time preferably thirty days. Moreover, the reservoir  410  is designed to maintain a variety of fossil fuels including petroleum, natural gas, propane, methane, ethanol, biofuel, fuel oil or any similar and related fuel known and used to create energy via combustion. The reservoir  410  is typically housed outside of the residential facility  300  for safety and aesthetics. 
     Regardless of the type, the energy source  430  is drawn out of the reservoir  410  and treated for injection into the modified engine  520  through a regulator system  504 . This regulator system  504  ensures that the energy source  430  is fed to the modified engine  520  at a specific pressure and flow rate—regardless of the outside temperature, pressure or weather conditions. Because the cogeneration system  500  will be employed in a variety of conditions from low lying areas to the mountains, in tropical climates to arctic regions, the regulator system  504  must be self-regulating, robust and capable of handling large swings in weather conditions. 
     As illustrated in  FIG. 3 , the regulator system  504  includes four primary components: two fuel valves  505  and  506 , a fuel pump  507  and a pressure regulator  510 . Other related and additional components will be recognized and understood by those of ordinary skill in the art upon review of the foregoing. The energy source  430  is drawn from the reservoir through the fuel pump  507  for transport into the modified engine  520 . 
     Positioned between the reservoir  410  and fuel pump  507  are a plurality of fuel valves  505  and  506 . More specifically, there is a first fuel valve  505  and second fuel valve  506 —which function to help regulate the flow and velocity of the energy source  430 . The underlying purpose of both fuel valves  505  and  506  is to ensure redundancy in case one valve malfunctions, becomes clogged or becomes inoperable. 
     A pressure regulator  510  is positioned after the fuel pump  507  to ensure the proper pressure of the energy source  430  prior to entry into the modified engine  520 . The energy source  430  travels throughout both fuel valves  505  and  506 , the fuel pump  507  and the pressure regulator  510  through a sixteen gauge shell, two inch fire rated insulation acoustic lined conduit  508  which includes a sixteen gauge interior body with powder coating. 
     Once the pressure of the power source  430  stabilizes through use of the pressure regulator  510 , the fuel then enters the modified engine  520 . As illustrated with reference to  FIG. 6 , the modified engine  520  can act as a regular combustion engine to burn the power source  430 , which in turn drives one or more pistons  521  to turn a shaft  522  that rotates an alternator  523  to create electricity. 
     With reference to  FIG. 6 , byproducts of the modified engine  520  include usable heat  602 , as well as hot gases  603 . These hot gases  603  include, but are not necessarily limited to, HC, CO, CO 2 , NO x , SO x  and trace particulates (C9PM0). When leaving the modified engine  520 , these hot gasses  603  have a pressure between 80 to 100 psi and a temperature between 800 to 1200 degrees Fahrenheit. These high pressure and temperature hot gasses  603  are then transported into the catalytic converter  530  for treatment. 
     The modified engine  520  illustrated in both  FIG. 3  and  FIG. 6  ensures delivery of usable electricity to not only the residential facility  300  but also the electricity grid  200 . As shown in  FIG. 3 , this is achieved through combination of a vibration mount  524  and a harmonic distort alternator  525 —both of which are attached to the modified engine  520 . The vibration mount  524  is positioned below the modified engine  520  through a plurality of stabilizing legs. 
     The function and purpose of the vibration mount  524  is to ensure that the modified engine  520  is not only secure but also that it does not create a distinct frequency—through the turning of the various pistons  521 , shaft  522 , and alternator  523  (shown in greater detail in FIG.  6 )—to risk degrading the quality of usable electricity flowing from the cogeneration system  500 . This is because the electricity grid  200  requires a very specific and regulated electricity supply. 
     The uniform feed of electricity to both the facility  300  and electricity grid  200  is further aided by the harmonic distort alternator  525 . As shown in  FIG. 3 , the harmonic distort alternator  525  is positioned directly on the modified engine  520  and prior to both the residential facility  300  and electricity grid  200 . This harmonic distort alternator  525  regulates the amplification and voltage of electricity. In addition, a subsequent electricity filter  527  can be used to provide a final regulation of the electricity. A more detailed description of this system is offered in  FIG. 6  described in greater detail below. 
       FIG. 3  also illustrates the placement, positioning and utility of the catalytic converter  530 . The catalytic converter  530  functions to help ensure the proper treatment of the hot gases  603  created by combustion within the modified engine  520 —in order to reduce levels of toxic byproducts being released into the atmosphere. 
     Overall efficiency of the catalytic converter  530  is based upon two primary chemical properties: (a) selection of the correct platinum based catalytic material, and (b) regulation of the proper temperature and pressure of the hot gases  603  when entering the catalytic converter  530 . More specifically, the invention contemplates feeding the various hot gases  603  into the catalytic converter  530  at between 800 to 1000 degrees Fahrenheit and at a pressure ranging between 80 to 100 psi. The preferred catalytic material is a combination of palladium and platinum. More specifically, the preferred catalyst contemplated by the invention includes 5-30% palladium and 70-95% platinum by weight. However, other percentages are contemplated by the invention. Based upon the invention, the catalytic converter  530  is 99.99% efficient in converting the various hot gases  603  into non-toxic treated byproduct  604 . 
     Hot gases  603  treated by the catalytic converter  530  are then transported into one or more cooling manifolds  540  and  550 . As shown in both  FIGS. 3 and 5 , each cooling manifold  540  includes a series of heat exchangers tasked with cooling the various hot gases  603  to essentially ambient temperature. Within each manifold, cooling water  543  is supplied from an external water supply line  542  (usually the same as used by the facility  300 ) in a first conduit  544 . This first conduit  544  encapsulates a second conduit  545  in which hot gases  603  flow through the manifold  540 . Based upon the temperature gradient created between both conduits  544  and  545 , the hot gases  603  are cooled while the cooling water  543  is warmed. 
     As shown in greater detail in  FIG. 3 , once the hot gases  603  are cooled, they leave the cooling manifold  530  and enter into a liquid separator  560 . At this point, the hot gases  630  are at or near ambient temperature. Moreover, much of the hot gases  603  have been filtered for either removal into the atmosphere or recycled for re-treatment in the catalytic converter  520 . Such hot gases  603 —which are mostly light by-products—are filtered by the liquid separator  560 . The liquid separator  560  creates a sufficient vacuum within the remaining hot gases  603  to remove these light-weight byproducts  604  for eventual off-gassing. 
     As shown in  FIG. 3 , it is preferred that there be at least two cooling manifolds  540  and  550  to separate and bring the hot gases  603  to ambient temperature: a first cooling manifold  540  and second cooling manifold  550 . As shown, the second cooling manifold  550  feeds into a second liquid separator  565 —which functions the same as the first liquid separator  560 . There are two contemplated designs for the invention. First, the first cooling manifold  540  can feed into a second cooling manifold  550  to create an “in series” design. Alternatively, both cooling manifolds  540  and  540  can work in parallel—such that they both receive hot gases  603  from the catalytic converter  530  to be cooled and separated by both liquid separators  560  and  565  also in parallel. 
     Materials drawn from both liquid separators  560  and  565  are then placed in a separator loop  570 . This loop  570  functions to circulate the various cooled by-products and allow off gassing through a vent  590 . The vent  590  may be aided by a fan  580 . 
     Control and Storage of Generated Electricity 
       FIG. 4  illustrates, by way of example, one manner in which electricity created by the cogeneration system  500  is controlled, stored and sold back to the electricity grid  200 . As shown and described in greater detail above, electricity is generated in the modified engine  520  through combustion of an energy source  430 . This electricity is sent to the harmonic distort alternator  525  to ensure the current matches the consistency of electricity found in the electricity grid  200 . 
     In the embodiment shown in  FIG. 4 , electricity leaves the distort alternator  525  and flows into the control panel  650 . The control panel  650  includes several components to filter and regulate the incoming electricity. First, the control panel  650  includes a regulator  651  that helps purify the current of the electricity coming from the modified engine  520 . Second, the control panel  650  includes a filter  652  that normalizes any noise or distortion remaining within the current. 
     Filtered and regulated electricity can then be directed to two receptacles: either a battery  660  (which alternatively can be an inverter) for later use or directly to the facility  300 . As shown in  FIG. 4 , the cogeneration system  500  can include a battery  660  capable of storing electricity for later use by the facility  300 . Attached to the battery is an automatic transfer switch  670 . The switch  670  functions to gauge energy needs of the residential facility  300 . If the home needs or anticipates greater energy use, the switch  670  ensures that electricity is drawn from the battery for use by the facility  300 . 
     As further shown in  FIG. 4 , electricity can flow either from the control panel  650  or the battery  660  into the breaker panel  680  of the facility  300 . The breaker panel  680  allows various appliances throughout the residential facility  300  to be supplied with electricity from the cogeneration system  500 . Excess energy not needed by the breaker panel  680  to supply the energy needs of the facility  300  is then transported to the electricity grid  200 . Prior to transport to the electricity grid  200 , it is preferable that current flows through a meter  690  to measure the credits appropriate for the residential facility  300  to receive from the public utility. 
     The Cooling Manifolds 
       FIG. 5  illustrates, by way of example, the first cooling manifold  540 . The preferred first cooling manifold  540  functions essentially as a heat exchanger to necessarily cool the various hot gases  603 , generated from the modified engine  520 , which have been treated by the catalytic converter  530 . Based upon treatment, the combination of platinum and palladium within the catalytic converter  530 , resulting in 99.99% conversion of these various hot gases  603  into inert and safe treated byproduct  604 . The remaining non-treated hot gases  603  and treated byproduct  604  are then separated and filtered through the first cooling manifold  540  (in combination with the first liquid separator  560 ) through a temperature gradient effectuated by interaction with cooling water. 
     As illustrated in  FIG. 5 , the first cooling manifold  540  includes, but is not necessarily limited to, a collection chamber  541 , a water supply line  542 , cooling water  543 , a first conduit  544 , a second conduit  545 , a third conduit  546 , a plurality of connecting elbows  552  and a condensate drain  553 . While  FIG. 5  denotes six portions of the first conduit  544  in parallel relation to one another, the invention contemplates up to twenty-one such portions to ensure effective treatment and separation of the various hot gasses  603  and treated byproduct  604 . Moreover, while  FIG. 5  shows the various parts and functionality of the first cooling manifold  540 , it is understood that these are the same primary components also found in the second cooling manifold  550 . 
     As further shown in  FIG. 5 , hot gases  603  and treated byproduct  604  flow from the catalytic converter  530  into the collection chamber  541  of the first cooling manifold  540 . This collection chamber  541  allows both hot gases  603  and treated byproduct  604  to be positioned for cooling via the heat exchanger  547  created within the first cooling manifold  540 . 
     Positioned parallel to the collection chamber  541  is a heat exchanger  547  that consists of a plurality of conduits  544 — 546  in which the actual heat exchange takes place. The first conduit  544  is larger in both length and diameter in comparison to the second conduit  545  and the third conduit  546 . Moreover, it is preferable that the first conduit  544  is of a sufficient size and dimension to encapsulate and fit over both the second conduit  545  and the third conduit  546 . 
     The first conduit  544  includes a water intake  548  and a corresponding water discharge  549 . Connected to the first conduit  544  through the water intake  548  is a water supply line  542 . The water supply line  542  provides cooling water  543  to the first cooling manifold  540 —typically from the municipal water supply available in the facility  300 —which is at ambient temperature. However, the cooling water  543  can alternatively be any liquid capable of heat exchange. Thus, this water supply line  542  helps fill the first conduit  544  with cooling water  543  to help in the heat exchange process. 
     Positioned within the first conduit  544  of the heat exchanger  547  is the second conduit  545 . Both hot gases  603  and treated byproduct  604  enter the second conduit  545  through the chamber collection  541 . Heat exchange occurs when the warmer second conduit  545  is cooled by the surrounding cooling water  543  positioned within the first conduit  544 . This heat exchange can cause portions of the gaseous treated byproduct  604  to liquefy—causing separation with the hot gases  603 . 
     Warmed cooling water  543  is then removed and repositioned through an outlet  549  in the first conduit  544 , which in turn feeds a second heat exchanger  547  positioned directly below the first heat exchanger  547 . This removed warmed cooling water  543  then flows into the inlet  548  of the second heat exchanger to fill another first conduit  544 . This process of removing, repositioning and re-feeding cooling water  543  can continue throughout as many heat exchangers  547  as necessary to effectuate appropriate separation. 
     After use within the various heat exchangers  547  positioned within the cooling manifold  540 , the cooling water  543  is then removed and emptied into a heat exchange module  800  (described in greater detail below). Upon leaving the cooling manifold  540 , the cooling water  543  is typically well above ambient temperature and is typically above 140 degrees Fahrenheit. Such cooling water  543  constitutes useful heat that can be used for a variety of various applications including, but certainly not limited to, assisting in heating water for use and consumption throughout the home or commercial facility. 
     Positioned within the second conduit  545  of each heat exchanger  547  is a third conduit  546 . The third conduit  546  functions primarily to collect the various cooled and now liquefied treated byproduct  604 . Positioned on the bottom of each third conduit  546  are perforations sufficient to collect liquid by product  604  cooled within the second conduit  545 . Positioned at the distal end of the third conduit  546  is a connecting elbow  552 . Positioned outside of both the first conduit  544  and second conduit  545 , the connecting elbow  552  further effectuates liquefaction and condensing of the byproduct  604  (via air cooling) and then transports this liquid to the first liquid separator  560 . 
     As further shown in  FIG. 5 , the distal end of each third conduit  546  contains a connecting elbow  552 , which horizontally feeds into a centralized condensate drain  553 . This condensate drain  553  functions to house and maintain all of the liquid treated byproduct  604  from the various third conduits  546  of each heat exchanger  547 . This resulting byproduct  604  can then be removed from the cogeneration system  500  through a disposal—which can be part of residential facilities  300  regular sewer or septic lines (or alternatively can be vented). 
     Likewise, cooled hot gases  603  (which remain in the second conduit  544 ) are then transported to the next heat exchanger for additional cooling. This continues until the hot gases  603  reach near ambient temperature. This also helps ensure any treated byproduct  604  is properly separated for placement in the condensate drain  553 . Any remaining hot gases  603  may be recycled back from the first cooling manifold  540  into the catalytic converter  530 . Alternatively, these hot gases  603  may be additionally treated and cooled in a second cooling manifold  550 . 
     Preferably, the liquid treated byproduct  604  is passed through the first liquid separator  560  shown in both  FIG. 3  and  FIG. 5 . This liquid separator  560  includes a partial vacuum that can draw any additional undesirable light gases out of the treated byproduct  604 . These gases  605  can either be retreated in the catalytic converter  540  via a recycle stream or alternatively vented from the cogeneration system  500  to a passageway outside of the residential facility  300 . Once these gases  605  are extracted through the partial vacuum, the remaining treated byproduct  604  can be drained through the residential facility&#39;s  300  septic or sewer system. 
     The Heat Exchange Module 
     The invention is further directed to a heat exchange module  800  (hereinafter the “module  800 ”).  FIG. 6  provides, by way of example, one embodiment of the module  800 . As shown and illustrated, the module  800  includes six primary components (a) a first inlet  810  for injecting cooling water  543  (or any other similar cooling fluid), (b) a second inlet  820  for introducing the cold water supply  825  (typically from a municipal source), (c) contact coils  830  which function to effectuate heat exchange, (d) the insulated housing  840  which positions and maintains the contact coils  830 , (e) the first outlet  850  for removing the cooling fluid  543 , and (f) the second outlet  860  for removing the treated water supply  825 . 
     As illustrated in  FIG. 6 , the central component of the module  800  is the insulated housing  840 . The insulated housing  840  is hard, resilient, non-corrosive and watertight. Moreover, the insulated housing  840  includes an inner shell  841 , which has a top side  842 , a corresponding bottom side  843 , and a cylindrical middle portion  844 . The cylindrical middle portion  844  is located between both sides  842  and  843  and preferably includes multi-layers of insulate  845 . 
     The insulate  845  includes a first insulate layer  846 , a second insulate layer  847  and a third insulate layer  848 . These three layers of insulate  845  are positioned outside the inner shell  841  which helps effectuate heat transfer, as well as maintain an above ambient temperature environment within the insulated housing  840 . Moreover, the inner shell  841  is made of a lightweight and durable material such as a ceramic, composite, glass or metal. More specifically, the inner shell  841  can be of uni-body construction and formed from aluminum. 
     Positioned on the top side  842  of the inner shell  841  is the first inlet  810 . The first inlet  810  functions to inject cooling water  543  from either cooling manifold ( 540  or  550 ) into the module  800 . The first inlet  810  connects to a vertical injector  811  which introduces the now warmed cooling water  543  into the bottom of the inner shell  841 . Upon residing within the inner shell  841  for a pre-specified period of time, the cooling water  543  can be removed from the insulated housing  840  through the first outlet  850 . The cooling water  543 —now cooled through contact with the cold water supply  825 —can return to either cooling manifold ( 540  or  550 ) to help further effectuate heat exchange with the hot gases  603 . 
     As further shown and illustrated in  FIG. 6 , the top end  841  of the insulated housing  840  also includes the second inlet  820 . The second inlet  820  functions to introduce the cold water supply  825  into the module  800 . This cold water supply  825  is typically from a municipal authority (such as a city water line) or well. More specifically, the second inlet  820  flows into a plurality of contact coils  830  positioned within the inner shell  841 . While the contact coils  830  can take many a shape and form, they are preferably curved in a manner that maximizes their overall surface area—which allows greater thermal contact between the warmer cooling water  543  and the cold water supply  825 . Upon treatment within the contact coils  830 , the now warmed water supply  825  is removed from the module  800  and transported to a tankless water heater  900 . 
     Prior to entry in the tankless water heater  900 , the now warmed water supply  825  is well above ambient temperature. Accordingly, the heating of this warmed water supply  825  requires less energy within the tankless water heater  900  in order to supply warm water to various parts of the home or commercial facility (in comparison with traditional tankless water heaters  900  which receive water directly from a municipal source). Moreover, this efficiency is no longer dependent upon the temperature of the water supply  825  provided by a municipal authority (or outside well)—or based upon the outside weather conditions. Put another way, implementation of the module  800  allows use of the tankless water heater  900  in any geographic location—regardless of whether the home or commercial facility is in a warm weather climate. 
     One issue presented by the module  800  is the risk of pressure differentials. Because the cooling water  543  (positioned within the inner shell  841 ) transitions from hot to cold (upon heat exchange with the municipal or well based water supply  825 ) such cooling water  543  can have thermal expansion. Accordingly, the invention contemplates a pressure relief valve  880  positioned on the top side  542  to exhaust and remove any necessary excess cooling water  543  created through heat exchange. An emergency drain pan  881  can be positioned below the bottom side  842  of the insulated housing  840  to collect such excess cooling water  543 . Alternatively, fluid received from the pressure relief valve  880  can be returned to either manifold  540  or  550 . 
       FIG. 6  further shows how usable heat—provided in the form of heated cooling water  543 —can be used to effectuate heat exchange with other components of the cogeneration system  100 , such as the air and heating systems. One secondary heat exchange contemplated by the module  800  includes pre-heating air prior to introduction into the furnace of the home or commercial facility. This can be accomplished through a secondary air exchanger  890 . 
     As shown and illustrated in  FIG. 6 , the secondary air exchanger  890  first includes an exchange feed  891  which draws heated cooling water  543  from the insulated housing  540 . Preferably, this exchange feed  891  is located and positioned on the top side  542  of the inner shell  541 . The exchange feed  891  then transports the heated water supply  825  into an air exchanger  890 . The purpose and functionality of the air exchanger  890  is to allow the heated water supply  825  to heat up (warm) an incoming air feed  896  prior to entry into the furnace. This can be accomplished by either a misting system  897  or a series of micro-coils  898  (or combination of both). Upon heat exchange, the heated water supply is collected and then either (a) fed back into the module  800  through a return feed  899  or (b) alternatively recycled back to either cooling manifold ( 540  or  550 ) to be rewarmed and then returned to the module  800 . 
     The Module Controller 
     In addition,  FIG. 7  shows how a controller  950  can be connected to the module  800 , as well as its components  960  (i.e., the air exchanger  890 , the first inlet  810  and the first outlet  850 ). The controller  950  functions to regulate and time introduction and removal of cooling water  543  throughout these components to optimize efficiency of the system. In one embodiment contemplated by the invention, the controller  950  can measure the internal temperature of the inner shell  841  and gauge whether to draw warmed cooling water  543  from the cooling manifolds ( 540  or  550 ) or stagnant cooling water  543  through the first outlet  550 . 
     Alternatively, the controller  950  can order removal of cooling water  543  from the insulated housing  840  for purposes of introduction into the air exchanger  890  (based upon communication with the furnace). Similarly, once cooling water  543  is removed for use in the air exchanger  890 , the controller  950  can determine if there is sufficient fluid within the inner shell  841  and draw more cooling water  543  from one or more manifolds ( 540  and  550 ). This helps to ensure not only that there is no stagnation of the cooling water  543  within the insulated housing  540 , but also that the temperature of such cooling water  543  can effectively make thermal contact with (and warm) the cooling coils  830 . 
     Overview of the Heater and Electrical Generator System 
     Referring initially to  FIG. 8 , this embodiment of the invention describes an integrated heating/electrical generation system  1000  comprising an electrical generator  1002 , preferably situated indoors, which is integrated with a heating apparatus  1004 . In a preferred embodiment the heating apparatus  1004  is a furnace. In another embodiment, the heating apparatus  1004  is a boiler. The heating apparatus  1004  shares a common exhaust gas exit  1006  with the generator  1002 . 
     The Heating Apparatus 
       FIG. 8  illustrates the flow of electricity, air, and exhaust of the system  1000 , as well as illustrating the system&#39;s  1000  major components. The generator  1002 , in a preferred embodiment, is a 3 kW electrical generator comprising a natural gas fuel source  1008 , the fuel source reaching the generator by a fuel input line  1009 . In alternate embodiments, the fuel source  1008  is at least one of propane, fuel oil, and liquefied petroleum gas. The generator  1002  serves the purpose of providing electricity to the heating apparatus  1004  through a first electrical output  1010  and to electrical outlets  1012  through a second electrical output  1014 . 
     The generator  1002  is of a type well-known in the art, wherein a fuel-powered engine (not shown) actuates an alternator (not shown) to generate alternating current (AC) power. A control panel (not shown), also well known in the art, on the generator indicates the status of the generator  1002  utilizing at least an AC voltmeter, run timer, and circuit breakers. The control panel also comprises electrical outputs  1010 ,  1014  and an auto idler circuit for automatically reducing engine RPM in the absence of an electrical load. 
     Still referring to  FIG. 8 , the generator  1002  receives an electrical input  1016  from a local electrical service  1018 , such that would typically be found in a facility or a commercial site. This local electrical service  1018  is a junction that receives electricity from a municipal power grid  1020 . The electrical input  1016  passes to a relay  1022  in communication with the generator and the electrical outputs  1010 ,  1014 . The relay  1022  is normally closed, so electricity into the relay  1022  passes directly through the relay to the electrical outputs  1010 ,  1014 , thus an external electrical source, such as the municipal power grid  1020  is ultimately responsible for providing power to the heating apparatus  1004  and the electrical outlets  1012 . In the case of a loss of electrical service  1018 , electricity generated by the generator  1002  is provided to the relay  1022 , wherein the power of the generator causes the relay  1022  to actuate so that the electricity generated by the generator is routed to the electrical outputs  1010 ,  1014 . In a preferred embodiment, the relay  1022  actuates automatically upon generator  1002  power input, the generator  1002  automatically sensing a loss of electrical input  1016  and starting the generator  1002  engine. 
     In this embodiment, unlike a traditional portable or standby generators, an appliance connected directly to the generator  1002  operates under normal conditions even when the generator  1002  is powered off. The same holds true for items plugged into the outlets  1012 , as these too maintain electrical current in the absence of generator  1002  power. This improvement allows for the convenience of an automatic transfer switch without the need for an automatic transfer switch, and is accomplished utilizing at least one series of normally closed relays  1022  which allow electrical current to travel through the relay  1022  to the heating apparatus  1004  and electrical outlets  1012 . No energy is required to keep the relay  1022  contact in the closed position, since the relay  1022  is normally closed in a non-energized state. Therefore even upon failure of the relay  1022 , electrical outlets  1012  and the heating apparatus  1004  still receive electricity. In the event of a power failure, the generator  1002  automatically powers on due to an engine start relay circuit (not shown), wherein the engine start relay is normally open when the generator receives electricity from the local electrical service  1018 , but upon loss of electricity closes and causes the engine to start. When the generator  1002  is generating electricity, the relay  1022  is placed in an open state that connects electrical connections  1010 ,  1014  to the generator  1002  effectuating a transfer of electricity source from the local electrical service  1018  to that of the generator  1002 . 
     The generator  1002  comprises an air intake conduit  1033  that provides air to the generator&#39;s  1002  engine. There is also an exhaust conduit  1024  in communication with the engine so that combustion gasses have a route to exit from the generator  1002 . 
     In a preferred embodiment, the generator  1002  is enclosed by a housing  1036 . The purpose of the housing  1036  is to provide for a more visually streamlined installation, and also to contain any exhaust gasses that inadvertently escape from the generator  1002 . The housing  1036  comprises an emergency leak conduit  1038  in communication with the exhaust conduit  1024  for the purpose of scavenging exhaust gasses from within the housing  1036 . To provide fresh air to the housing  1036 , an intake port  1040  provides a path into the inside of the housing  1036  and the fresh air is used as a vehicle to aid in the exhaust of the gasses that may inadvertently escape from the generator  1002 . To maintain a negative pressure to evacuate the housing  1036 , a fan  1042  is in communication with the leak conduit  1038 . The fan  1042  is activated when the generator is powered on by an electrical connection  1044  that provides power to the fan  1042 , the connection being mediated by the relay  1022 . The fan  1042 , when powered on, creates a negative pressure within the housing  1036 , which causes air external to the housing  1036  to enter into the housing  1036  through the intake port  1040  and then exits, along with scavenged exhaust gasses, the housing  1036  through the leak conduit  1038 . When the generator  1002  is off, no power is provided to the fan  1042 , for the relay is in the normally closed position. Should exhaust gas leakage occur, the leaked gas could not escape the cabinet, and would instead be drawn into the flue  1032 . In a preferred embodiment, an alarm  1033  communicating with both a carbon monoxide sensor  1035  and a shut-down circuit on the generator  1002  prevents the generator  1002  from operating when exhaust gasses are detected by the carbon monoxide sensor  1035  and also provides an audible signal. 
     The generator  1002  generates power that is appropriate for the installation wherein the generator resides. For residential applications, the generator generates electricity that is compatible with the requirements of a household. In the United States, this would typically be 120 VAC single-phase power and 240 VAC single-phase power. In industrial settings, the generator generates at least one of single-phase and three-phase power ranging from 110 VAC to 480 VAC. 
     The Heating Apparatus 
     With continuing reference to  FIG. 8 , the system  1000  comprises a heating apparatus  1004  for the purpose of providing heat to an interior space. In a preferred embodiment, the heating apparatus  1004  is a natural gas furnace, such furnace types being well known in the art. In another embodiment, the heating apparatus  1004  is a boiler. In yet a different embodiment, the heating apparatus  1004  is an electric element heater. The heating apparatus  1004 , in the case of a natural gas furnace, comprises a burner  1026  for burning natural gas to heat a heat exchanger  1028 . The heating apparatus  1004  provides heat to an interior space utilizing intermediary fluid movement of a heat exchanger  1028 , the heat exchanger  1028  utilizing at least one of air, steam, and water to mediate heating. The heating apparatus  1004  utilizes a combustible fuel to generate a flame in the burner  1026  that heats the heat exchanger  1028 , the fuel being at least one of natural gas, liquefied petroleum gas, fuel oil, coal, and wood. In a preferred embodiment, the fuel is delivered from the fuel source  1008  through the fuel input line  1009  to the burner  1026 . 
     To ensure an adequate influx of air for combustion from the air source  1030 , the heating apparatus  1004  comprises a draft inducer  1034 . The draft inducer  1034  is a device well known in the art comprising an electric fan to create a positive draft that aids in the proper exhaust of combustion gasses. The draft inducer  1034  is in communication with the flue  1032 , and is proximate the burner  1026 . In a preferred embodiment, the draft inducer  1034  promotes exhaust of combustion gasses and also promotes the influx of air from an air source  1030  for combustion. 
     The burner  1026  of the heating apparatus  1004  requires a source of air  1030  that provides the air required for the combustion process. Additionally, a flue  1032  is in communication with the burner  1026  that allows the heating apparatus  1004  to exhaust combustion gasses from the heating apparatus  1004  through the exhaust gas exit  1006  of the system  1000 . The flue  1032  is a conduit constructed of heat-resistant material that provides a point where exhaust gasses may be safely disbursed, which is typically to a point outside the structure being heated. The flue  1032  is constructed from polyvinyl chloride (PVC), metal, vitreous enamel, or transite. 
     Heating Apparatus and Generator Interaction 
     With continuing reference to  FIG. 8 , the generator  1002  is installed in close proximity with the heating apparatus  1004 , since both of these units  1002 ,  1004  utilize common electrical service  1016 , fuel source  1008 , and exhaust gas exit  1006 . 
     The flue  1032  of the heating apparatus  1004  is in communication with the exhaust conduit  1024  of the generator  1002  at a Y-junction  1046 . Therefore, the heating apparatus  1004  shares a common exhaust gas exit  1006  with the generator  1002 . The emergency leak conduit  1038  in communication with the exhaust conduit  1024  is therefore also in communication with the common exhaust gas exit  1006 . In a preferred embodiment, the flue  1032 , exhaust conduit  1024 , and the Y-junction  1046  are made of polyvinyl chloride pipe. 
     The power for the electrical outlets  1012  and the heating apparatus  1004  are relayed through a relay  1022  associated with the generator  1002 , thus a single input source of electrical service  1018  powers the electrical outlets  1012  wherein the generator  1002  is installed and provides power to the heating apparatus  1004 . When electrical service  1018  is not provided, the same electrical connections  1010 ,  1014  are utilized for electricity delivery to electrical outlets  1012  and the heating apparatus  1004 , yet the generator  1002  provides the electricity in that case. 
     When the generator  1002  is powered on, electricity is provided by the generator  1002  to actuate an exhaust gas relay  1047 , which provides power to the draft inducer  1034 . The draft inducer  1034  is activated to expel the generator&#39;s exhaust through the common exhaust gas exit  1006  even if the furnace is not producing heat. The draft inducer  1034  also induces the evacuation of the generator&#39;s  1002  housing  1036 . In one embodiment, the draft inducer  1034  is installed before the burner  1026 , and in another embodiment, the draft inducer  1034  is installed after the junction of the Y-pipe  1046 . 
     A pressure switch  1048  communicates with the heating apparatus proximate the flue  1032 , the draft inducer  1034 , and also communicates electrically with the generator  1002 . In a preferred embodiment, the pressure switch  1048  is a diaphragm type switch well known in the art wherein the switch monitors the relative pressure within the flue  1032  compared to the ambient pressure, detecting when the draft inducer  1034  is functioning. If the draft inducer  1034  is not functioning, the pressure switch  1048  detects the lack of a lower pressure in the flue  1032  and sends an electrical signal to the generator  1002 , disabling the generator  1002  for safety purposes. 
     The fuel source  1008  in a preferred embodiment of the invention is shared, so that a common fuel line  1009  is utilized by both the generator  1002  and the heating apparatus  1004 . 
       FIG. 8  exemplifies that the generator  1002  shares electrical service  1018 , fuel source  1008 , and an exhaust gas exit  1006 , so the installation of a generator to work in conjunction with a home&#39;s existing heating apparatus is a relatively simple installation. Specifically, the generator  1002  utilizes the existing furnace or boiler&#39;s induction system (collectively  1030 ,  1034 ,  1032 ,  1006 ) to form a vacuum to extract the emissions from the generator  1002 . The generator communicates with the heating apparatus exhaust gas relay  1047  which controls and energizes the heating system&#39;s induction fan to evacuate both generator  1002  and heating apparatus  1004  exhaust gases to the outdoors. The generator&#39;s  1002  exhaust conduit  1024  contacts the heating apparatus  1004  flue  1032  and this is accomplished using a Y-fitting  1046  that is easily integrated into an existing flue  1032  installation. The pressure switch  1048  may be installed in the system at the same time as the Y-fitting  1046 . By sharing existing fuel and exhaust lines, this installation scheme drastically reduces labor and material cost. This indoor generator  1002  system  1000  also reduces or eliminates the chances of harmful escaping emissions. 
       FIG. 9  illustrates how the generator  1002  can be incorporated into the cogeneration system  500  ( FIGS. 1 ,  2 ) described herein. In this embodiment, the generator  1002  provides power for a facility  300  and the electrical grid  1020 , yet the generator&#39;s exhaust is fed into a catalytic converter  530  and cooling manifolds  540 ,  550  as part of the cogeneration system  500  scheme. The generator  1002  is in communication with a heating apparatus  1004  and shares a common fuel source  1008  and electrical service  1018  with the heating apparatus  1004 . The primary difference the configuration of the generator  1002  in this embodiment of the invention illustrated in  FIG. 9 , as compared to the combination generator/heating apparatus system  1000  illustrated by  FIG. 8 , is that the exhaust from the generator is not merely exhausted, but rather harnessed in at least one cooling manifold  540 ,  550 . 
     Many modifications and other embodiments of the invention will come to the mind of one skilled in the art having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is understood that the invention is not to be limited to the specific embodiments disclosed, and that modifications and embodiments are intended to be included within the scope of the appended claims.

Technology Classification (CPC): 8