The present invention relates to reducing emissions from diesel engines and in particular mixing hydrogen with crankcase fumes to facilitate combustion of the crankcase fumes producing useful energy.
Diesel engines are commonly used in commercial applications such as trucks and stationary engines. These engines typically have much higher compression ratios than gasoline engines, and as a result, a substantial amount of diesel blow-by escapes past the piston rings. Unlike gasoline engines which use a simple crankcase ventilation, the diesel blow-by is generally vented to the outside, and presents a source of unpleasant fumes. The diesel engines typically cannot simply vent the crankcase to the engine intake, because the diesel blow-by includes components which will degrade the diesel engine operation.
U.S. patent application Ser. No. 11/330,466 for “HYDROGEN AUGMENTED DIESEL CRANKCASE VENTILATION,” a parent of the present application, discloses a system combining hydrogen and crankcase fumes in the intake of a diesel engine, whereby the hydrogen facilitates burning the crankcase fumes to reduce emissions and to improve mileage. The system of the '466 application includes a filter 36 in the line carrying the crankcase fumes to the engine intake. In some cases, liquids included in the crankcase fumes have filled the filter and prevented optimal operation of the system. Further, many diesel engines draw air from the intake manifold which is pumped into a tank and used to actuate, for example, air brakes. Drawing hydrogen into such a system may result in undesirable conditions.
Further, difficulty has arisen in the insertion of hydrogen gas into the engine intake air stream. Such systems, known as fumigation systems, introduce gaseous hydrogen into the engine through the air intake stream. Such hydrogen fumigation systems are simple, but lack efficiency. The benefits of hydrogen fuel enhancement depend on volumetric delivery which known fumigation systems do not provide. Thus, known hydrogen fumigation systems have failed to obtain the full benefit of hydrogen fuel enhancement.
For these and other reasons, an improved hydrogen reactor and injection system for augmenting crankcase ventilation in an internal combustion engine system is needed.
The present invention addresses the above and other needs by providing a hydrogen augmented crankcase ventilation system which includes hydrogen injection to facilitate the combustion of crankcase fumes, for example blow-by, in the engine. The system preferably includes a hydrogen generation system as a hydrogen source and introduces the hydrogen into the engine through the engine's fuel injection system. A fumes hose connects the crankcase to the air intake, and a clean air hose connects a clean air source to the crankcase. An orifice or a vacuum regulator cooperates with the fumes hose and may be included to regulate crankcase vacuum. A filter resides inline with the fumes hose to capture solids or liquids which enter the fumes hose from the crankcase, and a drain hose drains captured liquid back into the engine. A back flow preventor may be included to cooperate with the clean air hose to prevent a back flow of crankcase fumes through the clean air hose.
In accordance with another aspect of the invention, there is provided an engine and a hydrogen augmented crankcase ventilation system. The engine includes an engine air intake, and an engine crankcase. The hydrogen augmented crankcase ventilation system includes a hydrogen source, a first hose connecting the hydrogen source to the engine fuel system, a second hose connecting the engine crankcase to an engine air intake, and third hose in fluid communication with the engine crankcase carrying a third flow of fresh air into the crankcase. The first hose carries a first flow including hydrogen from the hydrogen source to the engine fuel system to mix the hydrogen with liquid engine fuel. The second hose carries a second flow from the engine crankcase to the engine air intake, such that the second flow is mixed with air received by the diesel engine through the engine air intake.
In accordance with another aspect of the invention, hydrogen is introduced into the combustion process by utilizing the engine's already-existing fuel delivery system. By producing, collecting and mixing measured amounts of gaseous hydrogen into the fossil fuel stream, the present invention provides the proper amount of hydrogen without the need for the kinds of computer-regulated monitoring systems used by sophisticated fumigation systems.
In accordance with another aspect of the invention, the entire reactor mechanism is made out of an elastomeric material which encases the reactor cell to provide safety and durability and contains the water utilized in the hydrogen production process. Known hydrogen generators are aluminum or stainless steel and are not well-suited for the variety of operating conditions in everyday use. Failures are common when the known systems are stressed and the aluminum or stainless steel construction provides no benefit over the elastomeric material of the present invention.
The above and other aspects, features and advantages of the present invention will be more apparent from the following more particular description thereof, presented in conjunction with the following drawings wherein:
Corresponding reference characters indicate corresponding components throughout the several views of the drawings.
The following description is of the best mode presently contemplated for carrying out the invention. This description is not to be taken in a limiting sense, but is made merely for the purpose of describing one or more preferred embodiments of the invention. The scope of the invention should be determined with reference to the claims.
Hereafter, the term “gases” refers to “hydrogen” in reference to a gasoline internal combustion engine and a mixture of “hydrogen and oxygen” in a diesel internal combustion engine, the difference being that efficiency calls for the presence of oxygen in a diesel engine and the absence of oxygen in a gasoline engine during combustion.
A process of electrolysis of water (H2O) results in the decomposition of a water-based solution into oxygen (O2) and hydrogen (H2) gases. Electric power is connected to electrodes comprising anodes and cathodes. Hydrogen will appear at the cathode(s) (the negatively charged electrode), and oxygen will appear at the anode (the positively charged electrode). The chemical reaction is:
2H2O2H2+O2
thus, the number of hydrogen molecules generated is twice the number of oxygen molecules generated, and the rate of production of the gasses is proportional to the total electrical charge that was sent through the water.
A known diesel cycle engine 10 is shown in
An improved diesel cycle engine 10a with a hydrogen augmented diesel crankcase ventilation system according to the present invention is shown in
The hydrogen source 26 is connected to the fuel line 25 by a hydrogen hose 28 at a Y block 27. A hydrogen flow 30 including hydrogen gas is carried by the hydrogen hose 28 from the hydrogen source 26 to the fuel line 25. The hydrogen flow 30 may consist essentially of hydrogen gas produced by a hydrogen generator from water, or consist essentially of a combination of both hydrogen gas and oxygen gas produced by the hydrogen generator from water.
In another embodiment, a separate oxygen hose may carry the oxygen gas to the fuel line 25.
The breather 22 (see
The air intake 11 may provide the air flow 15 to the diesel cycle engine through a supercharger 14, or directly to the intake manifold 13 or to the diesel cycle engine 10a. A supercharge generally provides greater vacuum in the fumes hose 32, but in many cases, the intake manifold vacuum in a normally aspirated (i.e., non-supercharged) engine is sufficient. Preferably, the supercharger 14 is a turbo supercharger (or turbocharger). Further, the engine 10a may include two or more superchargers, one or more of which may be turbo superchargers.
The hoses 52 and 32 carry the fumes flow 34 comprising blow-by and other crankcase fumes (e.g., fumes generated by the breakdown of engine oil) and material which previously was vented to the atmosphere through the breather 22 (see
A restriction 38 restricts the fumes flow 34, which restriction 38 preferably cooperates with the hose 32 or the hose 52, and more preferably resides proximal to the connection point of the hose 32 to the air intake 11. The restriction 38 regulates (or limits) the fumes flow 34 into the air intake 11. The restriction 38 may be manually adjustable or may be self adjusting, for example, like a pressure or vacuum regulator, or may, for example, be a fixed size replaceable orifice, a variable orifice, or a clamp to squeeze the outside of the hose 32 or the hose 52 to restrict the fumes flow 34. The restriction 38 may be used to adjust crankcase vacuum and preferably results in between approximately one pound and approximately four pounds of crankcase vacuum, and more preferably results in approximately two pounds of crankcase vacuum. In general, a larger engine will operate with a higher crankcase vacuum, and a small engine will operate with a lower crankcase vacuum. The restriction 38 may further cooperate with a vacuum regulator in the clean air hose 48 to regulate crankcase vacuum.
A second air filter 40 may for convenience be connected to the oil fill tube 20 by a clean air hose 48 and a coupling 46 to provide clean air to the crankcase, but may be connected to the crankcase through any appropriate passage. The air filter 40 allows a clean air flow 42 of clean air to enter the crankcase to support a flow through the crank case and into the hose 32, and/or to help cool the crankcase. A back flow preventor 44 may reside inline in the clean air hose 48 to prevent blow-by or other fumes, liquids, or solids from escaping the diesel cycle engine 10a through the air filter 40. The back flow preventor 44 may further include a vacuum regulator to regulate the crankcase vacuum. The crankcase vacuum is preferably regulated to be between approximately one and approximately four pounds.
While hoses 28, 32, 48, and 52 are referenced above, metal or plastic tubing may be used as well, or any suitable conduit, may be used to carry the flows 30, 34, and 42. Also, the hose 52 and the hose 48 may connect with the crankcase at any suitable point using any suitable connection, and are not limited to connecting through existing connection points.
A second embodiment of an improved diesel engine 10b including a hydrogen augmented diesel crankcase ventilation system according to the present invention is shown in
A third embodiment of an improved diesel engine 10c including a hydrogen augmented diesel crankcase ventilation system according to the present invention is shown in
A side view of an example of a suitable filter 36a according to the present invention is shown in
A diagram of a hydrogen reactor and injection system according to the present invention is shown in
A reserve tank 101 provides water to the reactor 104 through a reserve tank pump 107 controlled by a proximity switch 151 mounted to the side of the reactor 104. When the water level in the reactor 104 drops below the proximity switch 151, the reserve tank pump 107 is turned on to resupply the reactor 104 with water. The reserve tank includes a heat sink 6 at the base of the tank and a filter 152 preventing debris from escaping the reserve tank into the reactor 4.
A flow of gas from the reactor 104 passes through a first check valve 130 to a compressor 125. If the compressor 125 were to exceed a safe temperature and reach a flash point, an explosion could result. The check valve 30 protects against flames in the compressor 125 entering the reactor 104. The compressed gas from the compressor 125 enters a hydrogen storage tank 126. The compressor 125 is preferably constructed from non-metallic material to prevent electrolysis in the compressor 125.
A high pressure regulator 137 monitors the pressure level in the hydrogen storage tank 126. When the pressure exceeds an upper limit, the high pressure regulator 137 switches the compressor 125 off. When the pressure drops below a lower limit, the high pressure regulator 137 switches the compressor 125 on.
The high pressure gasses from the hydrogen storage tank 126 pass through a linear regulator 138 and into a Y block 136. The linear regulator 138 includes a reference port connected to the fossil fuel supply which adjusts the pressure of the gasses continuously to be equal to, or slightly above, the pressure of the fossil fuel supply to facilitate and regulate mixing in the Y block 136. The exact setting of the linear regulator 138 generally will be tuned to a specific application, or preset to a target application.
The fossil fuel flow from a fossil fuel tank flows through a fuel pump and also into the Y block 141. The gasses and the fossil fuel are mixed in the Y block 141 and proceed through an atomizer 140 which atomizes and mixes the hydrogen and fossil fuel in the fuel stream before injection through fuel injectors for combustion in the engine.
A line from the hydrogen storage tank 126 also flows through a scrubber control valve 35 and a hydrogen scrubber tube 134 (see
Typically, modern engines include a bypass fuel system, and fossil fuel not required by the engine is returned to the fossil fuel tank. In the instance of the present system, the returned fossil fuel and hydrogen mixture is separated in a hydrogen/fossil fuel separator and the fossil fuel is returned to the fossil fuel tank and the hydrogen (along with aldehydes, esters and other fuel fumes) is returned to the reactor 104.
A detailed view of the reactor 104 according to the present invention is shown in
The hydrogen and oxygen gases are drawn from the oxygen cap 19 and the hydrogen cover 117 and compressed by the compressor 125 and stored in the hydrogen storage tank 126. The oxygen gasses flow through the oxygen regulator and check valve 130 and may be limited or prevented from flowing further in the system depending on the application. The unused oxygen is expelled through an exhaust line or vent on the check valve 30.
The reactor 104 is made from high-impact elastomeric materials that are impervious to the kinds of high acid or alkali conditions result from the chemical reactions that occur during electrolysis of dissimilar metals in high PH solutions. The reactor 104 is made to withstand erosion factors from its own cross-sectional strength, and to resist ozone and stress produced by varying environmental (e.g, temperature and moisture) and operating conditions (driving on rough roads, braking, and turning). The elastomeric materials must be resilient such that they cannot distort and will remain inflexible during fully encumbered periods (i.e., ultra-high pressure of compressed gasses in small spaces). The reactor core base is also elastomeric so that any sudden impact can be directed to open the incoming electrical circuit and shut down the transmission of electricity. Using low durometer elastomeric materials also dampens the effects of road and engine vibrations. An example of a suitable elastomeric material is vulcanized rubber.
The cathodes 121 are preferably thoriated tungsten (or similar material) and are arranged in a circle or ellipse at specific angles tangent with a lowest point of the anode 113. The reactor anode 113 and cathode 121 components are partially encased by the elastomeric material along with their respective connections 115 and 113 to the power source. The anode 113 and cathodes 121 are held in specific geometric positions within the cast material in order to insure correct alignment and location of each component.
The base 104a includes a reactor heat sink 106 with exposed downward pointing fins. A reactor insulator 123 resides under the cathodes 121 and a scrubber manifold 132 also resides under the cathodes 121 and is connected to the hydrogen scrubber tube 134 to receive a flow of hydrogen gas. A fill tube 102 receives water from the reserve tank 101. The foundation of the reactor 104 is preferably parabolic and supports the reactor cells. In the event of an impact from outside the reactor 104, the parabola design causes the circuits connecting and powering the anode and cathode components of effected reactor cells to open and directs all fluids in the reactor base 104a up into the plenum chamber 118 to prevent any possibility of a fire or explosion.
Each reactor 104 is designed to keep the cathodes 121 and anode 13 submerged in the electrolytic solution at all times. By remaining submerged, the reactor components are not exposed to oxidation or erosion in the atmosphere, which can significantly reduce efficiency. Also, by keeping the cathodes 114 and anode 116 submerged in the electrolytic solution, the reactor's operating temperature remains stable and therefore improves durability and prolongs the reactor's life. All reactor core components which transfer or provide power to the core are encapsulated or covered. Only the hydrogen-producing surfaces of the cathodes 121 and anode 113 are exposed to the electrolytic solution. The configuration of the reactor 104 described above reduces energy requirements and minimizes loss of energy.
While the most common application of the hydrogen reactor and injection system according to the present invention is to diesel and gasoline powered vehicles, the present invention is equally advantageous when applied to generators, industrial engines, stationary engines or any internal combustion engine.
While the invention herein disclosed has been described by means of specific embodiments and applications thereof, numerous modifications and variations could be made thereto by those skilled in the art without departing from the scope of the invention set forth in the claims.
The present application is a Continuation in Part (CIP) of U.S. patent application Ser. No. 11/781,826 filed Jul. 23, 2007 which Continuation in Part (CIP) of U.S. patent application Ser. No. 11/330,466 files Jan. 12, 2006, the present application further claims the priority of U.S. Provisional Patent Application Ser. No. 61/173,172 filed Apr. 27, 2009, which applications are incorporated in their entirety herein by reference.
Number | Date | Country | |
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61173172 | Apr 2009 | US |
Number | Date | Country | |
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Parent | 11781826 | Jul 2007 | US |
Child | 12537076 | US | |
Parent | 11330466 | Jan 2006 | US |
Child | 11781826 | US |