Patent ID: 12256485

DETAILED DESCRIPTION OF THE INVENTION

The disclosed invention relates to apparatus and methods for generating energy from pulsed electric power sources.

Without being bound by theory, the pulse energy generator systems disclosed herein involve the conversion of molecular hydrogen into atomic hydrogen. Pulsing energy to dissociate hydrogen to liberate atomic hydrogen. Some hydrogen recombines back to molecular hydrogen may be facilitated by a catalyst surface coating disposed to inside walls of a reactor chamber. This process allows the collapse of the wave function of the molecular hydrogen, at which time it becomes extremely exothermic. Other surface materials, such as oxygen-free copper, platinum alloys or other conductive surfaces, can be used.

Producing either a direct current pulse or an alternating current pulse on electrode materials can liberate a compression wave that can produce atomic hydrogen, and thus produce heat.

FIGS.1A and1Bshow a radio frequency driven reactor chamber with an interior water flow heat exchanger. Sealed reactor chamber100includes a tube102fabricated of oxygen free copper. In an embodiment, the tube102has a diameter of about 1 inch. The tube102includes a vacuum port104which may be used to evacuate the tube and introduce hydrogen into the tube. A heat exchange tube106is disposed within tube102to permit water or other heat exchange fluid to flow through heat exchange tube106, as indicated by arrow108. In an embodiment, the heat exchange tube has a diameter of about 0.5 inches. The heat exchange tube106is fabricated of oxygen free copper. Ceramic seals110are provided to create a gaseous seal between the exterior surface of the heat exchange tube and the interior surface of the tube102.

An inner surface of the sealed reactor chamber has a surface coating comprising a catalyst. In the embodiments shown inFIGS.1A and1B, a catalyst coating112is disposed on an inner surface of tube102and a catalyst coating114is disposed on an outer surface of heat exchange tube106. Catalyst coating112,114comprises a catalyst selected from tungsten, nickel, titanium, platinum, palladium, and mixtures thereof. Without being bound by theory, it is presently believed the catalyst promotes antibonding of molecular hydrogen over bonding of molecular hydrogen. In the embodiments shown inFIGS.1A and1B, the catalyst coating112,114comprises catalyst particles having a size of about 450 mesh (32 μm). The catalyst particles are coated with glass to bond to the inner surfaces of the reactor chamber. The catalyst coating112,114has a thickness of at least 1 μm.

A radio frequency feed antenna116is coupled to the reactor chamber100. The radio frequency feed antenna116is connected to a plasma power supply118, in this case a radio frequency power supply. The plasma power supply generates a plasma inside the reactor chamber100. A plasma pulse controller120is connected to the plasma power supply118to turn the plasma power supply on and off and to generate plasma pulses inside the reactor chamber100. The plasma controller my include suitable microprocessors and circuitry to produce a plasma pulse having a desired duration and deadtime between pulses having a desired duration.

FIG.1Billustrates the reactor chamber100ofFIG.1Awith an additional outer water jacket heat exchanger. The outer water jacket heat exchanger includes an outer water jacket122which comprises a tube having a diameter of about 1.75 inches. Rubber seals124seal an outer surface of the tube102and an inner surface of the outer water jacket122.

FIGS.2A through2Dshow configurations of a direct arc reactor chamber. Sealed reactor chamber200includes a tube202fabricated of oxygen free copper. In an embodiment, the tube202has a diameter of about 0.75 inches. In the embodiment ofFIG.2A, each end of tube202includes ceramic electrical feedthroughs204to permit electric connection to cathode filaments206. In the embodiment ofFIG.2B, each end of tube202includes ceramic electrical feedthroughs204to permit electric connection to a cathode filament206and to an anode208. In the embodiment ofFIGS.2C, one end of the tube202includes ceramic electrical feed throughs204to permit electric connection to cathode filaments206. In the embodiment ofFIGS.2D, one end of the tube202includes ceramic electrical feed throughs204to permit electric connection to a cathode filament206and to an anode208.

Cathode filaments206are fabricated of tungsten. In some embodiments, the cathode filament206is tungsten doped with thorium or another material that has a low work function when heated, such as barium, calcium, and aluminum oxides used in common dispenser cathodes. In some embodiments, the cathode filament is tungsten doped with thorium in an amount ranging from 1 to 2 weight percent. Also, lanthanum hexaborides can be sputtered onto the surface of the tungsten filament and can emit electrons. These materials facilitate electrons to be injected into the plasma, help to reduce the cathode from sputtering away, and increase cathode lifespan.

An inner surface of the reactor chamber200has a surface coating comprising a catalyst. In the embodiments shown inFIGS.2A through2D, a catalyst coating212is disposed on an inner surface of tube202. Catalyst coating212comprises a catalyst selected from tungsten, nickel, titanium, platinum, palladium, and mixtures thereof. The catalyst coating212comprises catalyst particles having a size of about 450 mesh (32 μm). The catalyst particles are coated with glass to bond to the inner surfaces of the reactor chamber. The catalyst coating212has a thickness of at least 1 μm.

One or more ceramic baffles214are disposed between the cathode filaments or between the cathode filament and anode.

The cathode filaments208are connected to a plasma power supply218. In the embodiments shown inFIGS.2A and2C, the plasma power supply218is an AC power supply. In the embodiments shown inFIGS.2B and2D, the plasma power supply218is a DC power supply. The plasma power supply218generates a plasma inside the reactor chamber200. A plasma pulse controller220is connected to the plasma power supply218to turn the plasma power supply on and off and to generate plasma pulses inside the reactor chamber200. The plasma controller my include suitable microprocessors and circuitry to produce a plasma pulse having a desired duration and deadtime between pulses having a desired duration.

Another related direct arc reactor chamber configuration includes an anode end of copper or other metal tube, and a heated filament cathode on the other end of the tube, used in DC pulse mode.

Another direct arc reactor chamber configuration is a self-ionizing cathode in which the oxide coatings or a lanthanum hexaboride coating are deposited on the ends of the cathode, thereby eliminating a filament transformer. This configuration can operate in AC mode.

The following examples and experimental results are given to illustrate various embodiments within the scope of the present disclosure. These are given by way of example only, it is understood that the following examples are not comprehensive or exhaustive of the many types of embodiments of the present disclosure that can be prepared in accordance with the present disclosure.

In the examples, power input was measured using an oscilloscope. It was found that using a 0.01-ohm shunt resistor in line as the input side of the power supply works well along with power meters. The plasma power supply can be regulated switch mode or a linear power supply. It can be batteries, modified with a capacitor and switching transistor, such as field-effect transistor (FET), insulated-gate bipolar transistor (IGBT), Triac (three terminal AC switch), or silicon-controlled rectifier (SCR) or other switching devices.

In the examples, the measured heat energy out into water was done by measured temperature change and time. Typically, the experiments operated for about 180 seconds, which when multiplied by 4.185 joules per degree C. per gram of water can yield an average energy output. The electrode material was also taken into account and water was insulated to reduce heat loss. This does not take into consideration the energy to dissociate water molecule into hydrogen and oxygen. The 38 Hz or other plasma pulse rates were controlled by a microprocessor.

Example 1. The radio frequency driven reactor chamber shown inFIG.3A. This reactor chamber300was a vacuum break 6 inches long alumina ceramic tube302, and diameter of 1.75 inches. The ends of the ceramic tube302were terminated with a 2.75-inch ConFlat® vacuum fitting304that was sealed with a 0.5-inch oxygen-free copper heat exchange tube306through the center of the vacuum fitting304to permit water to pass through the center of the reactor chamber300. The center 0.5-inch oxygen-free copper tube was coated with glass and further coated with 450 mesh tungsten powder (99.9% purity) until covering the glass.

A pulsed radio frequency at 433 MHz was delivered by a 12 gage induction coil310, magnetically coupled at ¼ wave at 17.3 cm, wrapped around a 18 gage loading coil312. The radio frequency was pulsed at a 10 percent duty cycle and at 50 Hz. Winding was on the outside of the ceramic tube. The reactor chamber was configured to allow water to flow in the center of reactor chamber through the heat exchange tube306and to flow outside of the windings for cooling/heat exchange purposes through an outer water jacket inlet322and an outer water jacket outlet324.

A high vacuum turbo pump was used to outgas the reactor chamber300under a bake out for several hours. Hydrogen was back filled into the clean, room temperature reactor chamber300and sealed. Radio frequency power was increased to 50 watts. Those skilled in the art of radio transmitter at 433 MHz, understand that a coaxial cable needs to be phased in due to coherent lengths of wavelengths. The reactor chamber was phased in until standing wave reflected was minimized about 1.5:1. A ratio of 1:1 means 0% standing wave reflected and a ratio of 2:1 means 10% standing wave reflected. A ratio of 2:1 is marginally acceptable. A ratio of 1.5:1 is normal. The reactor chamber was pulsed at 10% duty cycle. The reactor showed a pink glow discharge, and cooling water was circulated. Cooling water was pumped at a rate of about 2 gallons a minute from the bottom of a holding tank having a capacity of about 1100 milliliters that was measured before the pump was placed in the tank. A temperature gage calibrated in C degrees was also placed into the holding tank. The tank was allowed to equalize to room temperature. Calculation used ((milliliters of water)(4.185 Joules)(T1−T2))/time (180 seconds)=Watts out.

Table 1 contains the results of four, three-minute tests.

TABLE 1WaterWaterInput PowerHydrogenTemperatureTemperaturePowerLevelPressureStartEndOutputTest(Watts)(Torr)(° C.)(° C.)(Watts)1501521.028.21842502529.136.81973506537.043.416441002544.251.8194

Example 2. Radio Frequency driven reactor shown inFIG.3B.FIG.3Bshows the inside core of the reactor chamber300ofFIG.3Awith a modified center water flow heat exchange tube306. This reactor chamber is similar to the reactor chamber of Example 1, except that the 0.5 inch copper middle core was replaced with a 0.75 inch oxygen-free copper core. The center 0.75 inch copper core was coated with catalyst coating326comprising glass and 450 mesh tungsten powder covering the glass. The plasma power supply operated at a radio frequency 433 MHz. It was pulsed at 50 Hz and a duty cycle of about 7 to 10 percent.

Table 2 contains the results of two, three-minute tests.

TABLE 2WaterWaterInput PowerHydrogenTemperatureTemperaturePowerLevelPressureStartEndOutputTest(Watts)(Torr)(° C.)(° C.)(Watts)1502525.734.523521006535.144.9251

Note: Specific heat of the 316 stainless steel ConFlat® ends is 0.49 J. They heated up. They were not included in this calculation.

Example 3. Radio Frequency reactors with inner antenna:

This radio frequency reactor chamber was made with oxygen-free copper tubing. A middle copper tube was 0.75-inch diameter. The outer surface was coated with glass and coated with 450 mesh tungsten powder until covering the glass. The middle copper tube was 17.3 centimeters long and welded to a ceramic feedthrough that allowed fluids to flow through. An outer tube was 1.5-inch diameter. It was longer to accommodate the welding to the feedthroughs. A radio frequency source was connected to the middle tube as an antenna. The reactor chamber was filled with hydrogen. Table 2 contains the results of two, three-minute tests at 27 MHz frequency.

TABLE 2WaterWaterInput PowerHydrogenTemperatureTemperaturePowerLevelPressureStartEndOutputTest(Watts)(Torr)(° C.)(° C.)(Watts)1501522.327.513321002528.133.4135

Note: This reactor chamber was more stable and easer to tune and maintain compared to the reactor chambers of Examples 1 and 2.

Example 4. Direct Arc Reactor Chamber:

A direct arc reactor chamber was prepared from a beryllium oxide ceramic tube terminated with an iron-nickel-cobalt alloy (Kovar) ends with a dispenser cathode on one end and the other end acting as an anode. Kovar material has a coefficient of thermal expansion matched to beryllium oxide ceramic tube. The bore ceramic was 0.040-inch diameter and was 3 inch in length with outer return paths. The reactor chamber was processed on vacuum station and baked out to 300° C. for 12 hours on an ion pump to clean and outgas the chamber. The plasma power supply was run at low current, approximately 2 amps, sufficient to maintain the plasma from going out and was increased up to 6 amps with a 10% duty cycle at 50 Hz.

Argon gas was used for starting the reactor chamber before hydrogen was placed in the reactor. Direct arcs may be produced in argon, or other noble gas, using less energy compared to using pure hydrogen. The direct arc reactor chamber was initially run with argon at 1 torr during start up until it was stabilized. Stability of the direct arc reactor chamber is observed when plasma power supply voltages remain stable and do not increase out of control. Input power was 550 watts, and the plasma pulse frequency was 50 Hz. Plasma power supply voltage was 90 volts at 6 amps. Half of the argon was evacuated down to 0.5 torr and then the reactor chamber was back filled with hydrogen to 1 torr. The glow discharge of reactor was now red due to the presence of atomic hydrogen, and the power level was stable. Water flow was circulating on the outside of the reactor from a small pump in 5 gallons of water or 19,927 ml. Red silicon rubber seals were used to electrically isolate the water from the cathode and anode ends. The cathode end had no cooling. In 60 seconds, the initial water temperature increased from 22.2° C. to 25.16° C. An output of 1375 watts output was calculated.

Note: The silicon seals did not hold up and started leaking.

Example 5. The direct arc reactor chamber of Example 4 was re-engineered with ⅜-inch copper tubing wrapped around the outer ceramic side in order to water cool the reactor chamber and anode, but the cathode was left with no cooling.

The re-engineered direct arc reactor chamber was tested as described in Example 4. It was back filled with hydrogen to 1.2 torr. It was operated for 3 minutes. The output power of 1425 watts was calculated.

Note: The direct arc reactor chamber was unable to have higher hydrogen pressures without higher voltages. The more hydrogen the more reaction and output power. The reactor ultimately went unstable. In this case, the instability was caused by outgassing of oxygen. Instability may be caused by failing to adequately clean and fully vacuum process the reactor chamber.

FIG.4shows an optional water flow channel400configured to receive multiple direct arc reactor chambers200, such as those shown inFIGS.2A-2D. In an embodiment, the water flow channel400may be fabricated of a metal, such as copper tube. The water flow channel includes a plurality of inserted tubes402, into which the reactor chambers200are removably disposed. The inserted tubes402may be fabricated of metal, such as copper.

FIGS.5A-5Cillustrate an optional water flow channel configuration to receive multiple radio frequency driven reactor chambers, similar to the reactor chambers100shown inFIGS.1A-1B.FIG.5Ashows a reactor chamber500with inner water flow510for heat exchange passing through the interior of the reactor chamber and outer water flow512for heat exchange passing on an outer surface of the reactor chamber. Water flow512is a counter current cross flow configuration.FIG.5Bshows a reactor chamber500with an alternative outer water flow514configuration. Water flow514is a co-current flow configuration. It will be appreciated that many other water flow configurations for heat exchange may be used herein.

FIG.5Cis a schematic cross-sectional end view showing a cluster of four reactor chambers520disposed within a water flow channel522. The water flow channel522permits outer water flow524on the outside of the reactor chambers520and inner water flow526on the inside of the reactor chambers520.

FIG.6Ashows a radio frequency driven reactor chamber600configured to operate at a higher plasma frequency, such as for example 433 MHz up to 915 MHz, and beyond. The reactor chamber600is similar to the reactor chamber100, shown inFIG.1A.

Reactor chamber600includes a tube602fabricated of oxygen free copper or stainless steel. In an embodiment, the tube602has a diameter of about 1.8 inches. The tube602includes a vacuum port604which may be used to evacuate the tube and introduce hydrogen into the tube. A heat exchange tube606is disposed within tube602to permit water or other heat exchange fluid to flow through heat exchange tube606, as indicated by arrow608. In an embodiment, the heat exchange tube has a diameter of about 0.75 inches. The heat exchange tube606is fabricated of oxygen free copper. Ceramic seals610are provided to create a gaseous seal between the exterior surface of the heat exchange tube606and the interior surface of the tube602.

An inner surface of the sealed reactor chamber has a surface coating comprising a catalyst. In the embodiment shown inFIG.6A, a catalyst coating612is disposed on an inner surface of tube602and a catalyst coating614is disposed on an outer surface of heat exchange tube606. Catalyst coating612,614comprises a catalyst selected from tungsten, nickel, titanium, platinum, palladium, and mixtures thereof. Without being bound by theory, it is presently believed the catalyst promotes antibonding of molecular hydrogen over bonding of molecular hydrogen. In the embodiment shown inFIG.6A, the catalyst coating612,614comprises catalyst particles having a size of about 5 to 10 nm.

A radio frequency feed antenna616is coupled to the reactor chamber600. Reactor chamber600uses only one ceramic electrical feedthrough618that reduces manufacturing expense. The antenna floats inside the outer metal tube602and an inner heat exchange tube606using machine ceramic washers to keep it isolated.

FIG.6Bis an outside view of the radio frequency driven reactor ofFIG.6Adisposed inside an outer water jacket heat exchanger620. The outer water jacket heat exchanger620may be fabricated of any suitable water compatible material, such as polyvinylchloride (PVC) or stainless steel.

FIG.6Cis a schematic cross-sectional end view showing a cluster of four reactor chambers630disposed within a water flow channel632. The water flow channel632permits outer water flow634on the outside of the reactor chambers630and inner water flow636on the inside of the reactor chambers630.

Example 6. A small direct arc reactor chamber700was built using an oxygen-free copper tube702, 0.75-inch diameter and 2-inch length, as shown inFIG.7. The tube702includes a vacuum port704which may be used to evacuate the tube and introduce hydrogen into the tube.

Each end of the reactor chamber700contained a thorium-doped tungsten filament cathode706made from 0.4-inch diameter tungsten wire having five turns at 0.25-inch diameter. The thorium concentration in the tungsten was 2 wt. % to help ionize the gases for electron emission and arc formation. Each cathode was spaced3millimeters distance from each other. Each end of tube702included ceramic electrical feedthroughs708to permit electric connection to cathode filaments706.

An interior surface of the reactor chamber included a catalyst coating712. The catalyst coating712comprised tungsten and nickel nano-particles having a size in the range of 5 to 20 nanometers.

This small direct arc reactor chamber700operated at a voltage of 390 volts DC, and 20 microfarads capacitor, and a plasma pulse frequency of 20 Hz. The capacitor pushes stored energy as a pulse E=1/2CV2, where C is 20 microfarads, V is the voltage, and E is the energy in joules.

The direct arc reactor chamber was started as described above in Example 4. There was insufficient water cooling of the direct arc reactor chamber. The input power average was kept low, under 7 watts. The output power was extrapolated from the mass of the copper and the temperature change. It was calculated to be 107 watts.

Example 7. The pulse energy generator system was built having a reactor chamber placed over a tungsten-coated half-inch spiral copper coil that was 5 inches long. The assembly was placed inside a 4-inch inner diameter tube 12 inches long with a 6-inch ConFlat® vacuum flange. The system was evacuated and filled with hydrogen gas to 36 torr. A DC power supply was operated for 3 seconds, with a low duty cycle of 3 percent. The average input power was 20 watts. The ending water temperature change was 2.5 degrees C. with 1000 ml of water circulating with a water pump. The output power was 58.12 watts.

Example 8. The pulse energy generator system of Example 6 was operated. The hydrogen gas was adjusted to 76 torr. Almost 3.3 degree C. temperature change was observed over 180 seconds, which showed 76.67 watts output power.

Example 9. The pulse energy generator system shown inFIG.8includes a reactor chamber800having an alumina ceramic tube802. A magnetic loop antenna804was wrapped around an alumina ceramic tube802. The ceramic tube802was 1.6-inch diameter and 3.5 inches in length having a 0.125-inch wall thickness. The magnetic loop antenna coil804comprised a 0.060-inch diameter and 27.3-inch wire length, cut for 433 MHz. The ceramic tube802further included a 0.025-inch diameter secondary wire coil806placed into 31 grooves cut into the ceramic at 0.030-inch depth.

This ceramic coil transformer was inserted into a 2-inch oxygen free copper tube808which had a catalyst coating810of tungsten powder on the inside of the copper tube. The catalyst coating810was made with 45 μm size tungsten powder bonded with glass with sodium silicate to the copper. An inner oxygen free copper tube812was disposed within the ceramic tube802. The tube812had 0.75-inch diameter and a catalyst coating814on the outside of the tube. The catalyst coating814was made with 45 μm size tungsten powder bonded with glass with sodium silicate to the exterior surface of tube812. The tube812was inserted into the ceramic tube802. Oxygen free copper washers were mounted on the ends, together with an electrical feedthrough816and a vacuum pinch off tube818. One end of the magnetic loop antenna coil804was coupled a ground820. An exterior water jacket822was provided to permit water flow for heat exchange on the exterior surface of reactor chamber800.

In testing, the reactor chamber800was phased in using a slider to tune in with a standing wave ratio (SWR) of about 1.2. Higher frequencies have shorter wavelengths. 433 Mhz has a standing wave of 69.3 centimeters for the antenna to radiate from the transmitter. Because a coaxial cable extends to the antenna, in this case a magnetic loop antenna inside the reactor, the actual distance is greater than 69.3 cm, typically greater than 200 centimeters long. The sliding tube within a tube is brass metal used to either lengthen the total length or shorten the total length so that it becomes a length which is a multiple number to the standing wavelength. For example, 200 centimeters total cable and antenna would be extended by the slider to about 207 centimeters, so that it would have a length of about 3 times 69.3 cm and has 3 full standing waves and 9 nodes. This would radiate close to 90% power into the reactor chamber. If the length was less than 207 centimeters, such as 200 centimeters, then 7 centimeters would reflect back into the transmitter causing a lot of waste heat and detuning the resonance of the antenna. Less power would be delivered into the reactor chamber basically detuning the resonance. Longer wavelengths can be tuned using a variable capacitor and inductor.

The RF input power was calculated to be 70 watts, pulsed at 40 percent duty cycle with a plasma pulse frequency at about 45 Hz. The output power was calculated to be 135 watts.

Example 10. The pulse energy generator system shown inFIG.9includes a reactor chamber900. The reactor chamber900included an outer tube908made of 2 inch diameter oxygen free copper. Tube908had a catalyst coating910of tungsten powder on the inside of the copper tube. The catalyst coating910was made with 45 μm size tungsten powder bonded with glass with sodium silicate to the copper. An inner oxygen free copper tube912was disposed within the tube908. The inner tube912had 0.75-inch diameter and a catalyst coating914on the outside of the tube. The catalyst coating914was made with 45 μm size tungsten powder bonded with glass with sodium silicate to the exterior surface of tube912. The inner tube912was inserted into the outer tube908. A magnetic loop antenna coil904was disposed between the inner tube912and the outer tube908. Oxygen free copper washers were mounted on the ends, together with an electrical feedthrough916and a vacuum pinch off tube918. One end of the magnetic loop antenna coil904was coupled a ground920. An exterior water jacket922was provided to permit water flow for heat exchange on the exterior surface of reactor chamber900.

The configuration of reactor chamber900was substantially the same as reactor chamber900of Example 8, but without the inner ceramic core and just a magnet loop antenna cut for 433 MHz. The antenna904was phased in using an adjustable slider in which the standing wave reflected was minimized. The input power was 70 watts, and the output power was 100 watts. The average output power was 140% over the input power.

In Example 10 the initial duty cycle was 40 percent. Upon reducing the duty cycle to 20 percent, the input power was reduced to 35 watts while keeping the output power the same. Thus, it was measured that the reduced duty cycle reduced the input power and kept the output power the same.

While this disclosure has been particularly shown and described with references to preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the scope of the disclosure encompassed by the appended claims.