1. Field of the Invention
The present invention relates to plasma generators, and more particularly to devices having a combustion nozzle that generates microwave plasma from a combustion flame.
2. Discussion of the Related Art
In a typical combustion engine, the efficiency of the engine is dependent on the efficient combustion of the fuel-air mixture in the combustion chamber. Also, the pollution characteristics of the engine are highly affected by the combustion efficiency.
Several approaches have been proposed to enhance the combustion efficiency. For example, U.S. Pat. No. 7,671,309 discloses a microwave combustion system that generates pulses of microwave energy to ignite a fuel mixture in a cylinder. This system, like the other existing systems, limits the usage microwave energy to ignite the fuel-air mixture. The efficiency of the engine can be enhanced by transferring the microwave energy to the fuel-air mixture (or the flame), thereby electronically exciting the fuel-air mixture (or the flame) in the engine. As such, the existing systems fail to provide any method to enhance the combustion efficiency by transferring the microwave energy. Accordingly, there is a need for systems that can transfer the microwave energy to fuel-air mixture (or flame) to enhance the combustion efficiency.
According to one aspect of the present invention, a nozzle for generating both a combustion flame and plasma from microwaves and the combustion flame is disclosed. The nozzle includes a hollow cylindrical housing through which combustible material flows, and a rod-shaped conductor disposed in the housing. The rod-shaped conductor transmits microwaves along the surface thereof and has a distal end disposed in proximity to and surrounded by a proximal end portion of the housing. During operation, a combustion flame is formed in proximity to the proximal end portion of the housing, and the microwaves transmitted along the surface heat up the flame to generate plasma in proximity to the distal end of the rod-shaped conductor.
According to another aspect of the present invention, a nozzle for generating both a combustion flame and plasma from microwaves and the combustion flame is disclosed. The nozzle includes a hollow cylindrical housing through which gas flows, and a rod-shaped conductor disposed in the housing. The rod-shaped conductor transmits microwaves along a surface thereof and has a distal end disposed in proximity to and surrounded by a proximal end portion of the housing. The rod-shaped conductor is a tube so that combustible material can flow through the tube. During operation, a combustion flame is formed in proximity to the distal end of the rod-shaped conductor and the microwaves transmitted along the surface heat up the flame to generate plasma in proximity to the distal end of the rod-shaped conductor.
According to yet another aspect of the present invention, a plasma generating system is disclosed. The system includes: a microwave generator for generating microwaves, a power supply connected to the microwave generator for providing power thereto, a microwave cavity, a waveguide operatively connected to the microwave cavity for transmitting the microwaves thereto, an isolator for dissipating microwaves reflected from the microwave cavity, and a nozzle secured to the microwave cavity. The nozzle includes a hollow cylindrical housing through which combustible material flows, and a rod-shaped conductor disposed in the housing. The rod-shaped conductor transmits microwaves along the surface thereof and has a distal end disposed in proximity to and surrounded by a proximal end portion of the housing. During operation, a combustion flame is formed in proximity to the proximal end portion of the housing and the microwaves transmitted along the surface heat up the flame.
According to still another aspect of the present invention, a plasma generating system is disclosed. The system includes: a microwave generator for generating microwaves, a power supply connected to the microwave generator for providing power thereto, a microwave cavity, a waveguide operatively connected to the microwave cavity for transmitting the microwaves thereto, an isolator for dissipating microwaves reflected from the microwave cavity, and a nozzle secured to the microwave cavity. The nozzle includes a hollow cylindrical housing through which gas flows, and a rod-shaped conductor disposed in the housing. The rod-shaped conductor transmits microwaves along a surface thereof and has a distal end disposed in proximity to and surrounded by a proximal end portion of the housing. The rod-shaped conductor is a tube so that combustible material can flow through the tube. During operation, a combustion flame is formed in proximity to the distal end of the rod-shaped conductor and the microwaves transmitted along the surface heat up the flame to generate plasma in proximity to the distal end of the rod-shaped conductor.
These and other advantages and features of the invention will become apparent to those persons skilled in the art upon reading the details of the invention as more fully described below.
The fuel may be a mixture of combustible material and air and prepared in a suitable storage, such as the fuel tank 31, before injection into the nozzle. Alternatively, the fuel may be pure combustible material and atmospheric air may be mixed with the fuel at the nozzle exit. For the purpose of illustration, the fuel is considered a flammable gas in the following sections, even though the fuel may be in liquid or solid state.
The microwave supply unit 11 provides microwaves to the microwave cavity 24 and may include: a microwave generator 12 for generating microwaves, a power supply for supplying power to the microwave generator 14, and an isolator 15 having a dummy load 16 for dissipating reflected microwaves that propagates toward the microwave generator 12, and a circulator 18 for directing the reflected microwaves to the dummy load 16. It is noted that the microwave cavity 24 can be a portion of the waveguide 13, i.e., the dimension and material of the microwave cavity 24 are similar to those of the waveguide 13. As such, the terms microwave cavity and waveguide are used interchangeably.
In one embodiment, the microwave supply unit 11 further includes a coupler 20 for measuring fluxes of the microwaves, and a tuner 22 for reducing the microwaves reflected from the microwave cavity 24. The components of the microwave supply unit 11 shown in
The nozzle 26 includes: a housing/shield 36 attached to the cavity wall and a gas channel 42 for having a flow of fuel therethrough, a rod-shaped conductor 40 having a portion 41 disposed in the microwave cavity 24 for receiving microwaves from within the microwave cavity 24, a ring-shaped dielectric tube 38, preferably formed of quarts, for preventing electric arc between the rod-shaped conductor 40 and the inner surface of the housing 36, a ring-shaped rod-holder 44 for securely holding the rod-shaped conductor 40 in place relative to the housing 36, and a cooling gas tube 48 extending through the cavity 24 and forming a channel for the cooling gas. The housing 36 provides a mechanical support of the nozzle 26 and has a hole through which the fuel received from the fuel tank 31 via the gas line 52 is injected. At least some parts of an outlet portion of the housing 36 can be made of electrically conducting material, such as metal. The conducting materials used as part of the housing 36 will act as a shield and improve plasma efficiencies. The rod-holder 44 is formed of dielectric material, such as plastic, nylon, or Teflon. The cooling gas tube 48 may be formed of any suitable material that is transparent to microwaves and includes one or more holes 46 through which the heated air is discharged.
The fuel, which can be a mixture of methane and air, for instance, flows through the channel 42 and exits the nozzle 26 at the distal end of the nozzle. A suitable ignition mechanism (not shown in
The heat energy generated by the flame 27 is transferred to the rod-shaped conductor 40 and the rod-holder 44 that is tightly fitted around the rod-shaped conductor 40. The rod-holder 44, which is formed of a dielectric material, could be damaged by the heat energy unless the heat energy is properly dissipated. The inlet hole 51 is aligned with the proximal end (or, equivalently, inlet) of the cooling gas tube 48 so that the cooling gas flows through the tube 48. The cooling gas flowing through the cooling gas tube 48 extracts the heat energy from the rod-shaped conductor 40 and the rod-holder 44. The heated cooling gas exits through the holes 46 formed in the cooling gas tube 48 and subsequently through the outlet holes 50 formed in the cavity wall.
The collection portion 41 of the rod-shaped conductor 40 acts as an antenna to collect microwaves from the microwave cavity 24, and focuses the collected microwaves to a distal tip to generate plasma 28 from the flame 27. More specifically, the microwave energy discharged at the distal end of the nozzle heats up the flame 27 into plasma so that the gas species in the flame is electronically and/or thermally excited. Such excitation, which results in substantial increase in the intensity of light emanating from the plume 28, is believed to enhance the combustion efficiency.
The rod-shaped conductor 40 may be made of any material that can conduct microwaves. The rod-shaped conductor 40 can be made out of copper, aluminum, platinum, gold, silver, and other conducting materials. The term rod-shaped conductor is intended to cover conductors having various cross sections such as a circular, oval, elliptical, or an oblong cross section or combinations thereof.
The nozzle 26 is detachably secured to a ring-shaped flange 33 by one or more fasteners 35, where the flange 33 is permanently secured to the cavity 24. It should be apparent to those of ordinary skill in the art that the nozzle 26 can be secured to the microwave cavity 24 by other suitable mechanisms, such as welding, and that the flange 33 can be detachably secured to the microwave cavity 24 by fasteners without deviating from the scope of the present teachings.
The ring-shaped dielectric tube 38 may be secured to the inner wall of the housing 36 by a suitable mechanism, such as glue or screw (not shown in
As illustrated in
It is well known that the microwaves captured by an electrically conducting body travel along the surface of the body, and that the depth of the skin responsible for microwave penetration and migration is a function of the microwave frequency and the conductor material. Typically, the microwave penetration distance can be less than a millimeter from the surface of the body. Thus, a rod-shaped conductor 87 of
It is well known that some precious metals are good microwave conductors. Thus, to reduce the unit price of the device without compromising the performance of the rod-shaped conductor, the skin layer of the rod-shaped conductor can be made of precious metals that are good microwave conductors, while cheaper conducting materials can be used for inside of the core.
It is noted that each of the rod-shaped conductors in
The rod-shaped conductor 104 is a tube having a through-pass hole that extends throughout the entire length of the conductor 104. The fuel is injected through the proximal end (or, the bottom tip) of the rod-shaped conductor 104. At the distal end (or the upper tip) of the rod-shaped conductor 104, a combustion flame is formed by use of a suitable ignition mechanism (not shown in
The rod-shaped conductor 104 is held in position relative to the housing 106 by a holding mechanism, where the holding mechanism includes a collet 108 (such as ER16 collet manufactured by DeAlmond Tool at Amarillo, Tex.), a collet holder 112 secured to the waveguide 102 by fasteners 114 and configured to accept the collet 108, and a knob 110 for tightening (or loosening) the collet 108.
The waveguide 102 includes at least one inlet hole 126 for receiving a cooling gas therethrough and one or more outlet holes 128 aligned with a channel 109 of the nozzle 100. The combustion flame 127 formed at the upper tip of the rod-shaped conductor 104 generates heat energy during operation and the heat energy is transferred to the rod-shaped conductor 104 by conduction. The cooling gas extracts the heat energy from the rod-shaped conductor 104 as it flows along the surface of the rod-shaped conductor 104 and is discharged at the nozzle exit.
Two walls, 116a and 116b, are disposed in the waveguide 102, forming an enclosed space 117 surrounded by the two walls and the waveguide walls. The cooling gas injected into the enclosed space 117 through the inlet hole 126 exits the space through the outlet holes 128. The walls 116a and 116b may be formed of a material that is transparent to the microwave so that the microwave can pass through the walls, and thus the portion of the rod-shaped conductor 104 extending through enclosed space 117 can collect the microwaves. During operation, the collected microwaves travel along the rod-shaped conductor 104 and plasma 128 may be generated at the distal end of the rod-shaped conductor 104 using the microwave energy.
In a step 212, microwaves are transmitted to the microwave cavity (or, equivalently waveguide). Next, the transmitted microwaves are received by the configured portion of the rod-shaped conductor in step 214. Subsequently, the collected microwave is focused at the tip of the rod-shaped conductor to heat the gas particles of the combustion flame into plasma in step 216.
While the present invention has been described with reference to the specific embodiments thereof, it should be understood that the foregoing relates to preferred embodiments of the invention and that modifications may be made without departing from the spirit and scope of the invention as set forth in the following claims.