Patent Application
20090044786
1. Field of the Invention
The present invention relates to carburetors, and more particularly to high-efficiency carburetors that more completely burn gas and produce fewer emissions.
2. Background and Related Art
In the usual internal combustion engine, or the like, the fuel is normally introduced into the carburetor for mixing with an air stream, and the fuel-air mixture is directed to the manifold and to the combustion chamber for burning. The carburetor operates on a simple physical principal wherein air drawn into the engine by the downward suction of a piston enters the top of the carburetor bore and travels downwardly therethrough, and through a Venturi. A main fuel nozzle communicates between a bowl of fuel and the interior of the carburetor in the proximity of the Venturi, and as the air passes through the Venturi, the speed of the flow stream increases and the pressure drops slightly in the Venturi. The drop in pressure pulls the fuel from the fuel bowl for injection into the carburetor bore through the nozzle, whereupon the fuel mixes with the air stream, forming a fine spray of atomized particles. This air-fuel mixture passes through the carburetor into the intake manifold, whereupon the fuel-air mixture is distributed to the engine cylinders for compression and combustion.
It is recognized that one secret of fuel economy is directly related to the ratio of air to fuel, and the efficient vaporization of the fuel-air mixture prior to burning thereon in order to achieve a more complete burning of the fuel for efficient use of the fuel and reduction of pollutants released into the atmosphere. Many efforts have been and are being made to improve the fuel efficiency. For example, a sonic apparatus has been developed wherein the fuel is disturbed by high-frequency energy for decomposition to the fuel to produce a substantial “cloud” of fuel. This reduction of fuel particles to such small sizes, and of relatively uniform particle size, increases the combustion efficiency. However, even with this improved procedure, there is still fuel loss and pollution resulting from unburned elements of the fuel.
Emissions from conventional internal combustion gasoline engines are formed when hydrocarbon fuel, such as gasoline, is burned incompletely into hydrocarbon (HC) and carbon oxides (CO). The formation of pollutant CO, HC and nitrous oxide (NOx) is a function of the proportional amounts of air and fuel introduced into the combustion chamber. Lean air-to-fuel ratios generally have decreased CO and HC emissions because of the greater quantity of oxygen available for combustion. When the air-to-fuel ratio becomes too rich, both HC and CO emissions increase.
NOx emissions are an exponential function of flame temperature. At low temperatures, nitrogen and oxygen will not unite to form any significant amount of NOx. Low temperatures are achieved at both rich and lean air-to-fuel ratios because of the dilutant effect exerted by unburned fuel in the rich case and the excess of air in the lean case. When the internal combustion engine operates at its stiochiometric point, the amount of fuel is matched exactly with the amount of oxygen for complete combustion. This point falls somewhere between 14.5 and 15 pounds of air per pound of fuel, and may vary somewhat depending on the type of fuel used.
Internal combustion engines will operate effectively at air-to-fuel ratios of 18:1 or even leaner ratios. The operation of the engine under these conditions is contingent on getting the right air-to-fuel mixture into all of the cylinders. With present carburetor technology, the air-to-fuel ratio of the fuel mixture to all of the cylinders is not constant. Some of the cylinders may be fed properly while others may be too lean and still others may be too rich. In any circumstance with fuel mixtures outside the desired range, there will be an increase in emissions.
Embodiments of the invention provide a carburetor for attaching to fuel-burning engines, such as are used for automobiles and other vehicles. The embodiments of the carburetor generate improved engine efficiency and reduced engine emissions by improving combustion of fuel. This is done by delivering a consistent, nebulized fuel at a desired air-to-fuel mixture appropriate for the specific engine and engine needs, such as 15:1 or 18:1. The nebulized fuel has a very small particle size that improves the mixture of air and fuel into a fog or mist of fuel in the air that is essentially unaffected by gravity over the short term. This mixture is directed to the engine and is then combusted. The improved mixture of air and fuel and small fuel particle size provides for efficient and fuller combustion. This improved combustion not only improves the efficiency of the engine, but also reduces emissions as fewer un-combusted fuel products remain after combustion.
The nebulized fuel is provided to the engine by the carburetor of embodiments of the invention. The carburetor includes a plurality of nebulizers that nebulize a thin film of fuel covering a vibrating plate. The vibrating plate of each of the nebulizers vibrates at a high frequency, such as at 2.4 megahertz (MHz), and this vibration ejects a fog or mist of fuel particles into an air/fuel mixture channel that passes above the nebulizers in serial fashion. Air is drawn into the air/fuel mixture channel, passes over each of the plurality of nebulizers in turn, gradually becoming fully supplied with nebulized fuel particles, before passing to a nebulized fuel outlet. The nebulized fuel outlet resides within a Venturi narrowing of a main channel of the carburetor, and the Venturi narrowing provides a reduced air pressure area that performs the function of drawing the air through the air/fuel mixture channel over the nebulizers, thus drawing out the mixture of air and nebulized fuel.
The objects and features of the present invention will become more fully apparent from the following description and appended claims, taken in conjunction with the accompanying drawings. Understanding that these drawings depict only typical embodiments of the invention and are, therefore, not to be considered limiting of its scope, the invention will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:
A description of embodiments of the present invention will now be given with reference to the Figures. It is expected that the present invention may take many other forms and shapes, hence the following disclosure is intended to be illustrative and not limiting, and the scope of the invention should be determined by reference to the appended claims.
Embodiments of the invention provide a carburetor for attaching to fuel-burning engines, such as are used for automobiles and other vehicles. The embodiments of the carburetor improve engine efficiency and reduce engine emissions by improving combustion of fuel. This is done by supplying a consistent, nebulized fuel at a desired air-to-fuel mixture appropriate for the specific engine and engine needs, such as 15:1, 18:1, or even higher. The nebulized fuel has a very small particle size that improves the mixture of air and fuel into a fog or mist of fuel in the air that is essentially unaffected by gravity over the short term. This mixture is delivered to the engine and is then combusted. The improved mixture of air and fuel and small fuel particle size provides for efficient and fuller combustion. This improved combustion not only improves the efficiency of the engine, but also reduces emissions as fewer un-combusted fuel products remain after combustion.
The nebulized fuel is delivered to the engine by the carburetor of embodiments of the invention. The carburetor includes a plurality of nebulizers, atomizers, or particle generators (“nebulizers”) that nebulize a thin film of fuel covering a vibrating plate. The vibrating plate of each of the nebulizers vibrates at a high frequency, generally over 1 MHz and such as at 2.4 MHz, and this vibration ejects a fog or mist of fuel particles into an air/fuel mixture channel that passes above the nebulizers in series fashion. Air is drawn into the air/fuel mixture channel, passes over each of the plurality of nebulizers in turn, gradually becoming fully supplied with nebulized fuel particles, before passing to a nebulized fuel outlet. The nebulized fuel outlet resides within a Venturi narrowing of a main channel of the carburetor, and the Venturi narrowing generates a reduced air pressure area that performs the function of drawing the air through the air/fuel mixture channel over the nebulizers, thus simultaneously drawing out the nebulized fuel mixed with air.
Nebulizers, atomizers, or particle generators (“nebulizers”) may be used for a variety of industry applications. For carburetion, the nebulized fuel can be transported in a mist or fog of microparticles from the carburetor to the combustion cylinders making automobiles more efficient, particularly in cold weather and over short distances.
There are a number of different types of nebulizers, including at least: (a) cross flow pneumatic nebulizers; (b) threaded cross flow nebulizers, (c) Babington-type nebulizers; (d) ultrasonic nebulizers; and (e) fretted or porous disk nebulizers.
The concept underlying ultrasonic nebulizing of liquids is simple. When ultrasonic energy is supplied to a liquid, capillary waves are generated. If enough ultrasonic energy is applied the waves rupture at the liquid surface to form aerosol-sized droplets. The ultrasonic nebulizer is that it has a tendency to generate aerosol in a cyclic manner. That is, cavitation develops between the surface having the ultrasonic input and the liquid. When this happens, energy is not transferred to the liquid.
The main body 10 is illustrated from below in
In use, fuel fills the main body fuel reservoir 32, as governed by the carburetor float 28. The fuel flows through the main body fuel channel 30 to the nebulizer channels 26, and forms a thin film over the top of each of the vibrating plates. The vibration of the vibrating plates nebulizes the fuel into a mist or fog of very small fuel particles, on the order of a few microns, and this mist or fog of particles is essentially unaffected by gravity and may thus be distributed and mixed into air passing above the nebulizers 22 for combustion. The very fine particles so produced burn more completely and more efficiently than has been accomplished with carbureted engines in the past, and produce fewer emissions. The result is a more-efficient, low-emissions vehicle that obtains a high mileage per unit of fuel than a vehicle equipped with past carburetors. Of course, one of skill in the art will recognize that embodiments of the invention may be used with any engine, not just those associated with vehicles, or with any other application where an improved efficiency or fuel burn may be desired.
As may be seen in
To assist in understanding the configuration of the top plate 12,
As may be appreciated by one of skill in the art by reference to
As may be appreciated by one of skill in the art, the movement of air and/or the air fuel mixture through the air/fuel mixture channel 62 is driven by the Venturi effect of the Venturi narrowing 18 of the main channel 20. The Venturi narrowing 18 causes a reduction in air pressure for air passing through the main channel 20. As the nebulized fuel outlet 16 is located at the Venturi narrowing 18, the nebulized fuel outlet 16 experiences this reduced air pressure. This reduced air pressure draws the air/nebulized fuel mixture from the air/fuel mixture channel 62 through the nebulized fuel outlet channel, and thus causes air to enter the air/fuel mixture channel 62 through the air intake hole 60, which acts as a source of higher-pressure air. The air pressure differential between the air intake hole 60 and the nebulized fuel outlet 16 thus drives air flow through the air/fuel mixture channel 62.
The nebulizers 22 may be any type of nebulizer that provides a sufficiently small particle size of the fuel. By way of example, the nebulizers 22 may be of a type typically called ultrasonic. One manufacturer of nebulizers that may be used with embodiments of the invention is Sonaer Inc., which has a place of business at 145 Rome Street Farmingdale, N.Y. 11735. In particular, it is envisioned that Sonaer®'s model 241CST 2.4 MHz ultrasonic nebulizer is a nebulizer that will function appropriately in conjunction with embodiments of the invention. The Sonaer® nebulizer has a stated average particle size of 1.7 microns, and a nebulization rate of approximately 250 milliliters per hour. Therefore, an embodiment of the invention as illustrated in the Figures having four nebulizers 22 could provide up to 1 liter of nebulized fuel per hour of operation. Although other nebulizers and frequencies of nebulizers may be used in conjunction with embodiments of the invention, it is anticipated that the nebulizers used should be capable of providing a sufficient volume of nebulized fuel having an appropriate average and/or maximum particle size for best fuel combustion and efficiency. It is within the skill of one of ordinary skill in the art to evaluate the nebulization and combustion characteristics of various nebulizers for use with embodiments of the invention. For example, one of skill in the art will recognize that the particle size provided by the nebulizers 22 is inversely related to the frequency of vibration, so that higher frequencies will produce a smaller average particle size. Thus, a frequency of vibration of the nebulizer 22 that is too low will not provide a sufficiently small particle size for full combustion.
Based on the above discussion, one of skill in the art may readily understand various modifications of the illustrated embodiment that may be provided and still fall within the spirit and essential characteristics of the present invention. For example, in a case where a particular engine does not require the fuel supply rate delivered by the embodiment discussed above, an alternate embodiment may be provided having fewer nebulizers 22. For example, one embodiment may have two nebulizers 22 and another may have three nebulizers 22 where the illustrated embodiment in the Figures has four nebulizers 22. Regardless of the number of nebulizers, the air/fuel mixture channel 62 passes over each of the nebulizers 22 in serial fashion.
In other alternate embodiments where a greater fuel supply rate is necessary, more than four nebulizers 22 may be used. For example, five, six, seven, eight, or more nebulizers 22 may be used in embodiments of the invention. In one embodiment, a dual carburetor may be provided, where the dual carburetor includes eight nebulizers 22 arranged to have two series of four nebulizers 22 with two independent air/fuel mixture channels 62, one for each of the two series of nebulizers 22. Alternatively, a single air/fuel mixture channel 62 may be used with an embodiment having a greater number of nebulizers 22 than four. It is envisioned, thus, that embodiments of the invention may be scaled for essentially any application and fuel delivery needs.
Although an essentially circular carburetor has been illustrated, it is envisioned that other shapes of carburetors and concomitant arrangements of nebulizers 22 may be provided, as long as the air/fuel mixture channel 62 may serially access the series of nebulizers 22. For example, an approximately square or rectangle carburetor may be provided having four or six nebulizers 22, respectively. In such an arrangement, the air/fuel mixture channel 62 may have one or more straight segments in order to pass over each of the nebulizers 22. In one embodiment, a linear carburetor and air/fuel mixture channel 62 may be provided. Thus, many different embodiments of the carburetor shape and the specific number and arrangement of the nebulizers 22 may be provided. Each such embodiment is embraced by the spirit of the invention.
The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims, rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.
