Patent Application
20240125469
The present invention relates, generally, to a hydrotorch assembly that generates and uses hydrogen gas for performing multiple tasks, such as, heating, welding, soldering, brazing, and cutting. More particularly, the present invention pertains to a hydrotorch assembly that is safe to use and prevents flame burn back.
Conventional oxyacetylene torches mix and burn oxygen and acetylene to produce a hot flame. However, the acetylene and oxygen are stored in high pressure tanks thereby increasing the cost thereof.
Hydrogen based torches that burn hydrogen to produce flame are also known in the art. Most hydrogen torches produce hydrogen directly through electrolysis for burning. Due to the explosiveness of hydrogen gas, the hydrogen torch is rarely used today.
It is therefore an object of the present invention to provide a hydrogen gas based torch assembly that is safe to use and prevents flame burn back from reaching the electrolysis unit.
It is also an object of the invention to provide a hydrogen gas-based torch assembly having a hydrogen generator that is suitable to produce a variable flow rate of hydrogen gas.
The present invention meets these objects by providing a hydrotorch assembly that is configured to use compressed air for extinguishing flame to prevent the burnback.
The hydrotorch assembly also includes a bubble tank having distilled water and arranged between a hydrogen generator and a torch to prevent burn back from reaching the hydrogen generator.
According to an aspect of the present invention, the hydrotorch assembly includes a hydrogen generator to electrolytically produce hydrogen gas, and a torch connected to the hydrogen generator to receive the hydrogen gas. The torch includes a gas conduit through which the hydrogen gas flows, an air conduit connected to the gas conduit to introduce a compressed air inside the gas conduit, and a control valve to control the introduction of the compressed air inside the gas conduit via the air conduit. The control valve may comprise a mechanical on-off valve to enable and disable the flow of compressed air to the first gas conduit of the torch.
According to a further aspect of the invention, there is provided a hydrotorch assembly comprising a hydrogen source, and a hydrogen supply line having a first end connected to and in fluid communication with the hydrogen source. A torch having a first gas conduit is also provided. The first gas conduit includes an inlet connected to a second end of the hydrogen supply line, and an outlet connected to and in fluid communication with a nozzle through which exiting gas is ignited to produce a flame that extends outwardly from the nozzle. A compressed air source, and a compressed air supply line having a first end connected to and in fluid communication with the compressed air source are also provided. A second end of the compressed air source supply line is connected to the first gas conduit near the inlet and in fluid communication with the first gas conduit and the hydrogen supply line. A control valve is disposed in the compressed air supply line for controlling the supply of compressed air to the first gas conduit of the torch.
The hydrogen source may further comprise a hydrogen generator for generating hydrogen gas on demand. A power source may be provided for providing electrical power to the hydrogen generator, and a rheostat for controlling the rate of hydrogen production. The hydrogen generator may further includes an electrolyzer electrically coupled to the power source and having a cathode and an anode disposed within the hydrogen generator, with the hydrogen generator being filled with an electrolyte solution. The electrolyte solution may be a mixture of potassium hydroxide and distilled water.
In addition, a bubble tank may be provided having an inlet port connected to and in fluid communication with the hydrogen source along a first length of the hydrogen supply line and an outlet port connected to and in fluid communication with the torch at a point along a second length of the hydrogen supply line. The bubble tank may be filled with distilled water, and may further include two outlet ports located at a top end of the bubble tank to enable an even flow of hydrogen gas through the bubble tank.
A valve may be disposed in the first gas conduit of the torch for controlling the flow of gas supplied to the nozzle.
The hydrotorch assembly may further an oxygen source, and an oxygen supply line having a first end connected to and in fluid communication with the oxygen source, and a second end connected to and in fluid communication with a second gas conduit of the torch. The second gas conduit of the torch may include an inlet connected to and in fluid communication with the second end of the oxygen supply line and a second end connected to and in fluid communication with the nozzle of the torch. A gas control valve may be disposed in the second gas conduit for controlling the flow of oxygen from the oxygen source to the nozzle.
The compressed air source may include a compressor to compress air to a desired pressure; an air reservoir connected to and in fluid communication with the compressor for receiving and storing said compressed air; and a sensor for measuring and monitoring the pressure inside the air reservoir. The compressor may be electrically coupled to the power source, and a relay may be provided for enabling and disabling the supply of power from the power source to the compressor based upon information provided by the sensor.
These and other objects, features and advantages of the present invention will become apparent from a review of the following drawings and detailed description of the preferred embodiments of the invention.
The present invention can best be understood in connection with the accompanying drawings. It is noted that the invention is not limited to the precise embodiments shown in the drawings, in which:
For purposes of promoting an understanding of the principles of the invention, reference will now be made to the embodiments illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended. The invention includes any alterations and further modifications in the illustrated devices and described methods and further applications of the principles of the invention that would normally occur to one skilled in the art to which the invention relates.
Referring to
In an embodiment, the hydrogen generator 106 includes an electrolyzer 120 having a cathode and anode and electrically coupled to the power source 110, and an electrolyte solution. As the electricity is supplied to the electrolyzer 120, the electrolysis of the electrolyte solution is initiated, causing a production of the hydrogen gas. The generated hydrogen gas flows to the torch 104 via the bubble tank 114. In an embodiment, the electrolyte solution includes a mixture of potassium hydroxide and distilled water. In some embodiments, the potassium hydroxide and the distilled water is mixed in 3 is to 1 ratio. Also, the hydrogen generator 106 includes an inlet 122 to enable a user to pour a mixture of potassium hydroxide and distilled water inside the electrolyzer 120.
Further, the rheostat 112 controls the electric power supply (i.e., electric current) being supplied to the electrolyzer 120 from the power source 110 to control a rate of generation of the hydrogen gas by the electrolyzer 120. Moreover, the power source 110 includes a converter to convert alternating current to direct current and provides the direct current to the hydrogen generator 106.
Further, the torch 104 includes a nozzle 130 through which a gas, for example, hydrogen gas or oxygen gas, exits the torch 104 and burns to generate a flame that extends outwardly of the nozzle 130, a first gas conduit 132 to facilitate a flow of the hydrogen gas, to the nozzle 130. Further, the torch 104 includes a second gas conduit 136 to facilitate a flow of oxygen gas to the nozzle 130 from an oxygen reservoir (not shown) stored inside a housing 137 the hydrogen generator assembly 102, and a gas control valve 138 connected to the second gas conduit 136 to control a flow of the oxygen gas to the nozzle 130 from the oxygen reservoir. A thumb bar valve 134 (i.e., inlet valve 134) may also be provided for controlling a flow of oxygen to the nozzle 130 through the second gas conduit. In an embodiment, the thumb bar inlet valve 134 and the gas control valve 138 may be mechanical valves suitable to be operated by a technician to enable and disable the flow of oxygen gas to the nozzle 130 as well as to facilitate and control a flow rate of oxygen gas being delivered to the nozzle 130. Further, the torch 104 includes an air conduit 140 connected to the first gas conduit 132 and configured to provide a flow of compressed gas inside the first gas conduit 132 to extinguish the flame and prevent a burn back.
In an embodiment, the torch 104 also includes a control valve 142 connected to the air conduit 140 at a location upstream of the connection of the air conduit 140 with the first gas conduit 132 to control the flow of the compressed air to the first gas conduit 132. In an embodiment, the control valve 142 is an ON-OFF valve to enable and disable the flow of compressed air to the first gas conduit 132. In some embodiments, the control valve 142 may be a mechanical valve suitable for manual actuation by the technician.
To provide the compressed air to the air conduit 140, the hydrogen generator assembly 102 may include a compressor 144 to compress the air to a desired pressure. Further, the hydrogen generator assembly 102 includes an air reservoir 150 to receive the compressed air from the compressor 144 and to store the compressed air. It may be appreciated that at least one pressure sensor 146 is configured to monitor or determine a value of pressure inside the air reservoir 150. Also, the hydrogen generator assembly 102 includes a pressure gauge 152 to display a pressure of the compressed air in the air reservoir 150. Additionally, the hydrogen generator assembly 102 may include a relay 160 (i.e., a switch) to enable or disable a supply of electric power to the hydrogen generator 106 from the power source 110. Moreover, the hydrogen generator assembly 102 may include a knob 162 adapted to be operated by the technician to switch on and switch off the hydrogen generator assembly 102 as well as to control an amount of the hydrogen gas generated by the hydrogen generator 106. In some embodiments, the hydrogen generator assembly 102 may include two separate switches/knobs to switch on-switch off the hydrogen generator 106 and to control a production rate of the hydrogen gas.
Also, the hydrotorch assembly 100 includes a first tube 164, a second tube 166 and a third tube 168 connected to the torch 104 to facilitate a flow of hydrogen gas, the oxygen gas, and the compressed air to the torch 104, respectively. As shown, the first tube 164 is coupled to the first gas conduit 132, the second tube 166 is connected to the second gas conduit 136, and the third tube 168 is connected to the air conduit 140.
Additionally, the hydrogen generator assembly 102 may include a first light 170 (i.e., a fault light 170) adapted to be actuated when one or more faults is detected in the hydrogen generator assembly 102. In some embodiments, the hydrogen generator assembly 102 includes a second light 172 (i.e., on-off light 172) to indicate a power on and a power off condition of the hydrogen generator assembly 102. The second light 172 is actuated when the hydrogen generator assembly 102 is switched on. The hydrotorch generator assembly 102 also includes a level indicator 174 having a plurality of lights 176 to indicate the level of the electrolyte inside the hydrogen generator 106.
Moreover, the hydrogen generator assembly 102 may include a controller 180 arranged in communication with the at least one pressure sensor 146, the rheostat 112, the knob 162, the relay 160, the compressor 144, the hydrogen generator 106, the power source 110, the first light 170, the second light 172, the pressure gauge 152, the level indicator 174, and the air reservoir 150. The controller 180 is configured to receive inputs from the at least one pressure sensor 146 and controls the relay 160 based on the inputs from the at least one pressure sensor 146. In an embodiment, the controller controls the relay 160 to prevent the electric power supply to the hydrogen generator 106 when the pressure of air inside the air reservoir 150 is a below a threshold value. In an embodiment, the threshold value is 50 psi. Further, the controller 180 is configured to control the rheostat 112 to control the amount of electric power supplied to the hydrogen generator 106 based on a position of the knob 162 to control the production rate of the hydrogen gas by the hydrogen generator 106.
Further, the controller 180 is configured to control the operation of the compressor 144 based on the inputs of at least one pressure sensor 146. In an embodiment, the controller 180 is configured to shut down the compressor 144 when a value of the pressure determined by the at least one pressure sensor is above a first predetermined value and starts the compressor 144 when the value of the pressure determined inside the air reservoir reaches a second predetermined value. In an embodiment, the second predetermined value is 90 psi, while the first predetermined value is 115 psi.
Moreover, the hydrogen generator assembly 102 may include at least one fan 182 to control a temperature of the various components, for example, the hydrogen generator 106, the compressor 144, etc., of the hydrogen generator assembly 102. The at least one fan 182 may be operated continuously during the working of the hydrotorch assembly 100. In some embodiments, the at least one fan 182 may switch on and switched off depending on a temperature of one or more components of the hydrogen generator assembly 102.
The controller 180 is also configured to actuate the first light 170 if the controller 170 detects a fault in one or more components of the hydrogen generator assembly 102. Moreover, the controller 180 is configured to control the actuation of one or more lights 176 of the level indicator 174 depending the level of the electrolyte inside the hydrogen generator 106.
Operation of the hydrotorch assembly 100 is now described. For initiating a flame at the exit of the nozzle 130 of the torch 104, the technician first switches on the hydrotorch assembly 100 using the knob 162. Accordingly, the controller 180 may check the pressure of the air reservoir 150 based on the inputs of the at least one pressure sensor 146. The controller 180 may control the relay 160 to keep the electrical supply disabled to the hydrogen generator 106 if the pressure inside the air reservoir 150 is below the threshold value. Accordingly, the controller 180 may start the compressor 144 to increase the pressure inside the air reservoir 150. The controller 180 controls the relay 160 to enable the flow of electric supply to the hydrogen generator 106 when the pressure inside the air reservoir 150 is equal to or above the threshold value. Further, the controller 180 may shut down the compressor 144 when the pressure inside the air reservoir reaches above the first predetermined pressure. Moreover, during the working of the hydro-torch assembly, the controller 180 may keep monitoring the pressure inside the air reservoir 150 after the compressor 144 is switched off, and restarts the compressor 144 when the pressure inside the air reaches the second predetermined value.
Upon enabling the supply of electric power to the hydrogen generator 106, the controller 180 may check a position of the knob 162 to determine a desired flow rate of the hydrogen gas, and accordingly controls/operates the rheostat 112 to control the amount of electric power being supplied to the hydrogen generator 106. Accordingly, the hydrogen generator 106 starts generating hydrogen gas that flows to the first gas conduit 132 via the bubble tank 114. To ignite the flame, the technician may open the inlet valve 134 so that the hydrogen gas exits the torch 104 via the nozzle 130. Subsequently, the technician ignites the hydrogen gas exiting the nozzle 130 by using a suitable igniter and starts the flame at the outlet of the nozzle 130.
To quench the flame, the technician opens the control valve 142 to introduce the compressed air inside the first gas conduit 132. Due to the flow of the compressed gas inside the first gas conduit 132, a supply of the hydrogen gas to the nozzle 130 is stopped, and therefore the flame is extinguished. Subsequently, the technician closes the inlet valve 138 and the control valve 142. Due to the introduction of the compressed air inside the first gas conduit 132, a burn back reaching the hydrogen generator 106 is prevented. Also, since the bubble tank 114 containing the water is arranged between the torch 104 and the hydrogen generator 106, the flame is prevented from reaching the electrolyzer 120 by the water. Accordingly, the hydrotorch assembly 100 provided a hydrogen gas based welding, heating, cutting torch assembly, while ensuring a safety of the entire operation. Moreover, as the hydrotorch assembly 100 provides for controlling a production rate of the hydrogen gas, a temperature of the flame can be controlled to carry out multiple tasks, such as, but not limited to, welding, cutting, brazing, etc.
The foregoing descriptions of specific embodiments of the present disclosure have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the present disclosure to the precise forms disclosed, and obviously many modifications and variations are possible in light of the above teaching. The exemplary embodiment was chosen and described in order to best explain the principles of the present disclosure and its practical application, to thereby enable others skilled in the art to best utilize the present disclosure and various embodiments with various modifications as are suited to the particular use contemplated.
