GB2549369A

GB2549369A - Hydrogen fuel generator and its method of use

Info

Publication number: GB2549369A
Application number: GB1702299.7A
Authority: GB
Inventors: Joseph Patrick O'neill Kevin
Original assignee: Individual
Current assignee: Individual
Priority date: 2016-02-16
Filing date: 2017-02-13
Publication date: 2017-10-18
Also published as: GB201702299D0; GB201602690D0

Abstract

A hydrogen fuel generator (10) is described, for use with an internal combustion engine (ICE, 100). The generator (10) comprises: a chamber for receiving an electrolyte comprising water; at least one anode electrode (which can be defined by the housing 12) and at least one cathode electrode (26) for passing an electric current through the electrolyte (figure 5, 78); and control means positioned at least in part between the electrodes for controlling the electric current. The generator (10) can be a wet cell and the housing of said generator (10) may be elongate (12) in appearance with flanged ends (14). The control means may take the form of a plurality of control plates (figure 4, 38) which are disposed within the housing (12), where said control plates (figure 4, 38) are electrically isolated from each other and the electrodes. The electrolyte (figure 5, 78) may comprise an aqueous solution with added alkali salts such as sodium or potassium hydroxide (KOH, NaOH). The outflow (74) of the generator (10) can be fed downstream of the air intake of the ICE (100).

Description

HYDROGEN FUEL GENERATOR AND ITS METHOD OF USE

Technical Field Of The Invention

This invention relates to a hydrogen fuel generator and its method of use. In particular, this invention relates to a wet cell hydrogen fuel generator for generating hydrogen as a fuel enhancement in an internal combustion engine.

Background

It is known to use a mixture of hydrogen and conventional hydrocarbon fuel in an internal combustion engine in a process known as “hydrogen fuel enhancement” so as to improve fuel economy and performance, and reduce emissions.

Currently there are three main options for utilising hydrogen as a fuel enhancement with internal combustion engines. These methods include (i) generating hydrogen through electrolysis of water, (ii) storing hydrogen on the vehicle as a second fuel source, or (iii) converting conventional hydrocarbon fuel into hydrogen with a catalyst. The latter two approaches both suffer the problem that highly explosive liquids and gases have to be processed and stored on the vehicle itself. The risk of explosion is then greatly increased if the vehicle is subsequently involved in an accident. For these reasons, research has been focused on obtaining hydrogen as a fuel enhancement through electrolysis of water, which is a safe and stable fuel source.

One way in which hydrogen can be obtained for use as a fuel enhancement is through electrolysis of water. An electric current passed through water causes decomposition into hydrogen and oxygen gas. The mixture of hydrogen and oxygen gas produced by electrolysis of water in a 2:1 mixture is sometimes referred to as “HHO” or “Brown’s Gas”, and it is this mixture of hydrogen and oxygen gas that has been proposed as a fuel enhancement in an internal combustion engine.

There are two main types of water electrolysis cells proposed for this purpose. These include a “dry cell” where water is contained in a separate header tank and is drawn into the electrolysis chamber to generate hydrogen and oxygen gas on demand. These dry cells tend to be overly complicated, requiring exhaustive process controls, sensors, pumps, actuators and valves to operate, and can be expensive to manufacture and use. For these reasons they have not enjoyed any real commercial success.

The second type of water electrolysis cell is a “wet cell” hydrogen fuel generator. The basic principle of operation is that an electrical power source (usually the battery on a vehicle) is connected between two spaced apart electrodes positioned in a chamber. An electrolyte solution, which can be pure water, distilled water, or water in solution with salts, is contained between the electrodes, and an electric current is passed therethrough, which according to Ohm’s Law, is directly proportional to the potential difference applied across the two electrodes and inversely proportional to the resistance of the electrolyte solution. The electric current causes positive ions, including hydrogen ions, to move towards the negatively charged cathode electrode and negative ions, including hydroxide ions, to move towards the positively charged anode electrode. At sufficient potential difference, this cause electrolysis with oxygen gas being produced at the anode and hydrogen gas being produced at the cathode. Whilst these two gases can be obtained and streamed separately, they are often mixed as Brown’s Gas, and supplied to the air intake of the internal combustion engine.

The resultant mixture of hydrogen and oxygen gas is more energetically potent and generates a more efficient fuel bum than simply using hydrocarbon fuel alone in an internal combustion engine. This fuel enhancement effect gives improved fuel economy and performance, and also lowers emissions and reduces carbon build-up. Although much research has been undertaken on investigating and modelling the effects of hydrogen and oxygen gas as a fuel enhancement, many of the benefits of using hydrogen and oxygen gas as a fuel enhancement are not entirely understood.

There are still problems with known wet cell hydrogen fuel generators of this type. They tend to be bulky, requiring extensive aftermarket installation, and are often situated in the vehicle’s trunk, which tends to limit their appeal. Other problems include controlling the electrolysis process as the temperature of the water in the electrolysis chamber rises, since the splitting reaction potential (needed to liberate hydrogen and oxygen gas at the electrodes) reduces as the temperature increases. The temperature of the water rises as more hydrogen and oxygen gas is liberated, which produces more heat and a positive feedback effect can occur and there is the risk of a thermal runaway condition resulting where instead of hydrogen and oxygen gas being produced, steam is obtained from the electrolysis chamber which does not have any fuel enhancement effect.

It is an object of the present invention to provide a hydrogen fuel generator and its method of use which overcomes or reduces the drawbacks associated with known products of this type. The present invention provides a wet cell hydrogen fuel generator that can be used with, or retrofitted to, a vehicle with an internal combustion engine to give a fuel enhancement effect. It is an object of the present invention to provide a compact and simple self-contained unit that has a small physical size and footprint and that can be installed in an engine compartment. It is a further object of the present invention to provide a wet cell hydrogen fuel generator with a small physical size such that it reaches optimum working temperatures sooner and thereby produces an optimum fuel enhancement effect more quickly. It is a further object of the present invention to provide a wet cell hydrogen fuel generator that is more stable and is not susceptible to unwanted positive feedback effects or thermal runaway conditions which otherwise lead to undesirable steam generation. Use of the present invention enabling a vehicle with an internal combustion engine to exhibit increased fuel economy and performance, and reduced emissions and engine wear.

Summary Of The Invention The present invention is described herein and in the claims.

According to the present invention there is provided a hydrogen fuel generator for use with an internal combustion engine, comprising: a chamber for receiving an electrolyte comprising water; at least one anode electrode and at least one cathode electrode for passing an electric current through the electrolyte causing electrolysis of water; and control means positioned at least in part between the at least one anode and at least one cathode for controlling the electric current.

An advantage of the present invention is that it can be used as a hydrogen fuel enhancement for an internal combustion engine which increases fuel economy and performance, and reduces emissions and engine wear.

Preferably, the hydrogen fuel generator is a wet cell hydrogen fuel generator.

Further preferably, the chamber further comprises: an elongate housing having a flange at each end thereof; and a complementary shaped top plate and a complementary shaped base plate for connection with the respective flanged end.

In use, the elongate housing may be formed having a generally square cross section in plan view and in use is positioned in a vertical configuration with the top plate being uppermost.

Preferably, the top plate is secured to the respective flanged end at the uppermost part of the housing via a complementary shaped elastomeric seal or gasket.

Further preferably, the base plate is secured to the respective flanged end at the lowermost part of the housing via a complementary shaped elastomeric seal or gasket.

In use, the flanged ends, the top plate, the base plate and elastomeric gaskets may each include a plurality of apertures for securement by threaded fasteners and threaded nuts.

Preferably, the head of the threaded fasteners is selected from the group consisting, but not limited to, any one of the following: slotted head, Allen® head, Phillips head and hexagonal bolt.

Further preferably, the elastomeric gaskets are formed from 3mm thick EPDM rubber.

In use, the housing may form the anode electrode via a lug formed in one of the box section side walls of the housing.

Preferably, the cathode electrode is provided by two spaced apart cathode plates which extend upwardly inside the housing from the base plate.

Further preferably, a plurality of insulating inserts are provided, each insert having an internal through bore and having one face that is wider than the head of the threaded fastener or threaded nut with which it is to be used, and a narrower elongate shaft having an outer diameter that can be received by the apertures formed in the flanged ends, the top plate, the base plate and elastomeric gaskets.

In use, the insulating inserts may be formed from high-density polyethylene (HDPE) plastics material or acetyl based plastics material.

Preferably, when assembled, the housing is formed as a cuboid, cylinder, triangular prism or hexagonal prism.

Further preferably, a drainage hole in the front wall of the housing is provided through which the electrolyte can be drained and replaced in use.

In use, a pair of apertures in the front wall of the housing may be provided for connection to a clear viewing tube connected between a pair of elbows.

Further preferably, the hydrogen fuel generator further comprising a slot or other shape defined in the front or side wall of the housing and an overlapping transparent acrylic window being sealed in place using a suitable adhesive.

Preferably, a threaded fill hole is positioned in the top plate and which can be sealed off by use of a threaded plug.

Further preferably, the height of the housing is around 225mm and the width of the housing, not including the flanged ends, is around 100mm.

In use, the chamber may be capable of receiving around 1.5 litres of electrolyte.

Preferably, the height of the housing is in the region of around 100mm to around 300mm.

Further preferably, the control means further comprises a plurality of control plates disposed inside the housing, each of the plurality of control plates being electrically isolated from one another and the anode electrode and the cathode electrode.

In use, 3, 6 or 9 control plates may be located on each of the outer sides of the pair of cathode plates in the housing.

Preferably, the plurality of control plates increases the electrical resistance of the electrolyte.

Further preferably, the plurality of control plates are formed from 316L stainless steel having a thickness of around 1.5mm.

In use, the plurality of control plates may be held in place isolated from the housing and the cathode plates extending from the base plate, by two pairs of insulating spacers situated towards the top and bottom of the housing.

Preferably, a pair of insulating top spacers are located on top of the cathode plates in use and positioned orthogonally to the cathode plates, each of the insulating top spacers being formed having a generally flat top face, a pair of side faces which extend downwardly from each side of the top face and a pair of end faces that extend downwardly from each end of the top face, such that the top face, side faces and end faces in combination define a slotted grating which is adapted to receive the top of the cathode plates and control plates.

Further preferably, insulating bottom spacers are located on each of the outer sides of the pair of cathode plates in use and orthogonal to the insulating top spacers, each of the insulating bottom spacers being formed having a generally flat base face, a pair of side faces which extend upwardly from each side of the base face and a pair of end faces that extend upwardly from each end of the base face, such that the base face, side faces and end face in combination define a slotted grating which is adapted to receive the bottom of the control plates.

In use, the plurality of control plates may be secured to the cathode plates using a plurality of high-density polyethylene (HDPE) threaded fasteners which are secured by HDPE threaded nuts and a plurality of HDPE washers are positioned between successive control plates to space them apart and to electrically isolate them from each other and the cathode plates and housing forming the anode electrode.

Preferably, the plurality of control plates are spaced apart from the base plate by a distance of around 1mm to 4mm.

Further preferably, the hydrogen fuel generator is formed from a welded construction and/or machined and/or pressed and/or cast and/or forged from a suitable metal material.

Preferably, the outer surfaces of the hydrogen fuel generator are powder coated.

In use, the housing, top plate, base plate and cathode plates may be all formed from 316L stainless steel.

Preferably, the electrolyte is pure water, distilled water, and/or water in solution with salts.

Further preferably, the salts are alkali salts including Sodium hydroxide (NaOH) or Potassium hydroxide (KOH) mixed at a ratio 5g to lOg of powdered alkali salt dissolved in 1.5 litres of pure water.

Use of the hydrogen fuel generator may give a fuel enhancement effect.

Preferably, a fuse is placed between the positive terminal of the battery and the anode electrode, the fuse rated between 20A to 50A.

Further preferably, an operating relay is provided which controls the operation of the hydrogen fuel generator and dash-mounted controller display unit which displays the current drawn by hydrogen fuel generator.

In use, the controller display unit may show an analogue ammeter, or display the current drawn by the hydrogen fuel generator as a digital output.

Preferably, the current drawn by the hydrogen fuel generator is between 5A and 20A.

Further preferably, the outflow of hydrogen and oxygen gas is fed via tube downstream of the air intake of the internal combustion engine.

Also according to the present invention there is provided a method of producing hydrogen and oxygen gas for use as a hydrocarbon fuel enhancement, comprising the steps of: applying an electric current between an anode electrode and cathode electrode of the hydrogen fuel generator as hereinbefore described; and injecting hydrogen and oxygen gas downstream of the air intake of an internal combustion engine.

It is believed that a hydrogen fuel generator and its method of use in accordance with the present invention at least addresses the problems outlined above.

It will be obvious to those skilled in the art that variations of the present invention are possible and it is intended that the present invention may be used other than as specifically described herein.

Brief Description Of The Dra wings

The present invention will now be described by way of example only, and with reference to the accompanying drawings, in which:

Figure 1 is an exploded perspective view from the side and above of the hydrogen fuel generator in accordance with the present invention;

Figure 2 shows an exploded perspective view from the side and above of the electrolysis chamber which forms the anode and cathode of the hydrogen fuel generator of Figure 1;

Figure 3 illustrates a perspective view from the side and above of the cathode of the hydrogen fuel generator of Figure 1 and shows further detail of the control plates that limit the electrolysis process;

Figure 4 is a perspective view from the front and above of a second embodiment of the present invention and shows an alternative way of securing the control plates of the hydrogen fuel generator;

Figure 5 shows a high-level schematic diagram showing how a hydrogen fuel generator in accordance with the present invention can be utilised as a fuel enhancement for an internal combustion engine; and

Figure 6 illustrates a side plan view of a third embodiment of the present invention which is configured having a viewing window to allow the user to monitor the level of the electrolyte solution in the hydrogen fuel generator.

Detailed Description Of The Preferred Embodiments The present invention has adopted the approach of utilising a wet cell hydrogen fuel generator that can be used with, or retrofitted to, a vehicle with an internal combustion engine to give a fuel enhancement effect. Use of the present invention enabling a compact and simple self-contained unit to be provided that has a small physical size and footprint and that can be installed in an engine compartment. Advantageously, the present invention provides a wet cell hydrogen fuel generator with a small physical size such that it reaches optimum working temperatures sooner and thereby produces an optimum fuel enhancement effect more quickly. Further advantageously, the present invention provides a wet cell hydrogen fuel generator that is more stable and is not susceptible to unwanted positive feedback effects or thermal runaway conditions which otherwise lead to undesirable steam generation. Use of the present invention enabling a vehicle with an internal combustion engine to exhibit increased fuel economy and performance, and reduced emissions and engine wear.

Referring now to the drawings, a hydrogen fuel generator 10 according to the present invention is illustrated in Figures 1 to 3. Specifically, the hydrogen fuel generator 10 is a “wet cell” hydrogen fuel generator which in this exemplary embodiment facilitates the electrolysis of water to produce a mixture of hydrogen and oxygen gas which is to be mixed with hydrocarbon fuel as a fuel enhancement for an internal combustion engine.

The hydrogen fuel generator 10 is configured as an elongate housing 12 formed from square box-section material, and having a flanged end 14 at each end of the elongate housing 12. The hydrogen fuel generator 10 also comprises a complementary shaped top plate 16 and a complementary shaped base plate 18 which, when assembled, form an housing or chamber in which electrolysis of water can take place.

As best shown in Figure 1, the elongate housing 12 is formed having a generally square cross section in plan view and is designed to be used in a vertical configuration with the top plate 16 being uppermost in use. The top plate 16 is secured to the respective flanged end 14 at the uppermost part of the housing 12 via a complementary shaped elastomeric seal or gasket 20. As is best described later, threaded fasteners 28 and threaded nuts 30 secure the flanged end 14, top plate 16 and complementary shaped top gasket 20 through a plurality of apertures 15 in the flanged end 14, a plurality of apertures 17 in the top plate 16 and a plurality of apertures 21 in the top gasket 20. A watertight and/or gastight seal is produced between the top plate 16 and the housing 12.

The housing 12 sits on the generally flat base plate 18. The base plate 18 is secured to the respective flanged end 14 at the lowermost part of the housing 12 via a complementary shaped elastomeric seal or gasket 22. As is best described later, threaded fasteners 28 and threaded nuts 30 secure the flanged end 14, base plate 18 and complementary shaped base gasket 22 through a plurality of apertures 15 in the flanged end 14, a plurality of apertures 19 in the base plate 18 and a plurality of apertures 23 in the base gasket 22. A watertight and/or gastight seal is produced between the base plate 18 and the housing 12.

As best shown in Figure 1, the housing 12 is electrically isolated from the top plate 16 via the top gasket 20, and electrically isolated from the base plate 18 via the base gasket 22. In this manner the housing 12 forms the anode electrode of the electrolysis process, and is connected to the positive terminal of the vehicle’s battery 84 via lug 24 formed in one of the box section side walls of the housing 12.

The cathode electrode is provided by two spaced apart cathode plates 26 which extend upwardly inside the housing 12 from the base plate 18. The electrolyte solution 78 which is use is pure water, distilled water, or water in solution with salts, is contained between the anode and cathode electrodes inside the sealed chamber formed by the housing 12, top plate 16 and base plate 18. A potential difference, which typically ranges from 12V in most vehicles, up to 24V in military and commercial truck applications, is applied across the anode lug 24 and the cathode plates 26, to be described later. This causes decomposition of the water into hydrogen and oxygen gas which exits the housing 12 via gas outflow 74 situated in the centre of the top plate 16. An elbow 76 is used to then supply the hydrogen and oxygen gas to the internal combustion engine 100.

As mentioned, the housing 12, top plate 16 and base plate 18 are all electrically isolated from each other via elastomeric gaskets 20, 22. In a preferred embodiment, the elastomeric gaskets 20, 22 are each formed from 3mm thick EPDM (ethylene propylene diene monomer (M-class) rubber. The skilled person will appreciate that EPDM rubber exhibits outstanding heat resistance and excellent electrical insulating properties, and similar materials could be utilised for this purpose.

To prevent the threaded fastener 28 and threaded nut 30 from causing an electrical short between the housing 12 and the top plate 16 and/or the base plate 18, an insulating insert 32 having an internal through bore is used. The insulating insert 32 is designed having one face that is wider than the head of the threaded fastener 28 or threaded nut 30 with which it is to be used, and a narrower elongate shaft 34 having an outer diameter that can be received by apertures 15, 17, 19, 21, 23. A separate insulating washer 36 is placed on the other side of the insulating insert 32 such that, when assembled, the housing 12, top plate 16 and base plate 18 are all electrically isolated from each other.

The skilled person will appreciate that insulating inserts 32 and insulating washers 36 can be formed from high-density polyethylene (HDPE) plastics material or acetyl based plastics material, or any material that has high mechanical strength and electrical insulating properties. In a preferred embodiment, the diameter of the face of the insulating insert 32 is 12mm. The outer diameter of the elongate shaft 34 is 8mm and the diameter of the through bore is 6mm.

In all of the embodiments of the invention shown in Figures 1 to 6, the head of the threaded fastener 28 is a hexagonal bolt for engagement with an open or ring spanner (not shown). Equally the skilled person will appreciate that an Allen® head, slotted or

Phillips head, could be utilised. In a preferred embodiment, the threaded fasteners 28 and threaded nuts 30 are provided having M6 ISO metric screw threads.

The construction of the hydrogen fuel generator 10 can be any suitable form of metal fabrication, i.e. from a welded construction. Equally, the hydrogen fuel generator 10 can be machined, pressed, cast or forged from a suitable metal. In a preferred embodiment, the housing 12, top plate 16, base plate 18 and cathode plates 26 are all formed from 316L stainless steel.

When assembled, the housing 12 is formed as a generally square shape in plan view, as best shown in Figure 1, although the skilled person will understand that the housing 12 could be shaped in other geometrical configurations, such as having a rectangular, triangular or, hexagonal or cylindrical cross section or the like.

As best shown in Figure 2, the front wall of the housing 12 includes three apertures which are disposed along its centre line. The bottommost aperture is a drainage hole 62 through which the electrolyte solution 78 in the hydrogen fuel generator 10 can be drained and replaced, if required. Although not shown in the drawings, an elbow and tap can be positioned at the drainage hole 62 to permit the outflow of the electrolyte solution 78.

Apertures 64a and 64b are for connection to a clear viewing tube 68, connected between elbows 66a, 66b. In use, the user is then able to easily monitor the level of the electrolyte solution 78 in the housing 12. In order to replenish the electrolyte solution 78, a threaded fill hole 70 is positioned in the top plate 16, behind the central gas outflow 74, which can be sealed off by use of a threaded plug 72.

The skilled person will understand that to monitor the level of the electrolyte solution 78 in the housing 12, the viewing tube 68 and elbows 66a, 66b can be replaced with a sealed elongate viewing enclosure having an slot or other shape defined in its front wall and an overlapping transparent acrylic window which can be sealed in place using a suitable adhesive, as shown in Figure 6. The rear wall of the viewing enclosure having a pair of apertures which meet with the apertures 64a and 64b disposed in the front wall of the housing 12.

In a preferred embodiment, the height of the housing 12 is 225mm. The width of the housing 12, not including the flanged ends 14, is 100mm. Such a size produces a chamber capable of receiving around 1.5 litres of electrolyte solution 78. This is in no way intended to be limiting as the height of the housing 12 can be varied in any number of sizes and hence capacities. The height of the housing 12 for most vehicle applications is in the region of 100mm to 300mm to ensure a small, slimline physical size and footprint.

Figure 3 illustrates a perspective view of the pair of cathode plates 26 which extend from, and are welded to, the base plate 18 of the hydrogen fuel generator 10. Figure 3 shows detail of the control plates 38 that limit the electrolysis process in use. To control the electrolysis process a series of baffle or control plates 38 are disposed inside the housing 12. Each of the plurality of control plates 38 is electrically isolated from the anode electrode (defined by the elongate housing 12) and the cathode electrode formed by the cathode plates 26 extending from the base plate 18. As best shown in Figure 3, a number of control plates 38, ranging usually in multiples of three, are located on each of the outer sides of the pair of cathode plates 26 in the housing 12. The plurality of control plates 38 serve to increase electrical resistance of the electrolyte solution 78 and therefore limit the current flowing through the hydrogen fuel generator 10. The control plates 38 are manufactured from 316L stainless steel, and in a preferred embodiment are 1,5mm in thickness.

In the embodiment shown in Figure 3, the control plates 38 are held in place isolated from the housing 12, and the cathode plates 26 extending from the base plate 18, by two pairs of insulating spacers situated towards the top and bottom of the housing 12. In a preferred embodiment, a pair of insulating top spacers 40a, 40b are located on top of the cathode plates 26 and positioned orthogonally to the cathode plates 26. As best shown in Figure 3, each of the insulating top spacers 40a, 40b is formed having a generally rectangular-shape in plan view with a generally flat top face 44 and a pair of side faces 46 which extend downwardly from each side of the top face 44. A pair of end faces 48 also extend downwardly from each end of the top face 44, such that the top face 44, side faces 46 and end faces 48 in combination define a slotted grating which is adapted to receive the top of the cathode plates 26 and control plates 38.

The best view of this is shown in Figure 3, which shows that each of the top insulating spacers 40a, 40b includes two rows of slots 50a to 50f, 50i to 50n separated by a central spacer 52. The pair of cathode plates 26 sit inside each of slots 50g, 50h situated adjacent to the sides of the spacer 52 which support the top insulating spacers 40a, 40b in place. For the embodiment shown in Figure 3, twelve control plates 38 can be inserted into slots 50a to 50f, 50i to 50n, although for clarity purposes only one control plate 38 is depicted in dotted lines and held in slot 50a.

At the bottom of the housing 12, and situated directly on the base plate 18, insulating bottom spacers 42a, 42b are located on each of the outer sides of the pair of cathode plates 26 and orthogonal to the insulating top spacers 40a, 40b. As shown in Figure 3, each of the insulating bottom spacers 42a, 42b is formed having a generally rectangular-shape in plan view with a generally flat base face 54 and a pair of side faces 56 which extend upwardly from each side of the base face 54. A pair of end faces 58 also extend upwardly from each end of the base face 54, such that the base face 54, side faces 56 and end faces 58 in combination define a slotted grating which is adapted to receive the bottom of the control plates 38.

Each of the insulating bottom spacers 42a, 42b includes one row of slots 60a to 60f. For the embodiment shown in Figure 3, six control plates 38 can be inserted into slots 60a to 60f in each of the insulating bottom spacers 42a, 42b, thereby giving a total of twelve control plates 38 used in the embodiment shown in Figure 4. For clarity purposes however only one control plate 38 is depicted in dotted lines, and retained in slot 60a of insulating bottom spacer 42a.

Figure 4 shows a second embodiment of the hydrogen fuel generator 10. The construction of the second embodiment is very similar to that of the first embodiment and corresponding features have been given the same reference numerals. The second embodiment differs from the first embodiment in that instead of insulating top spacers 40a, 40b and insulating bottom spacers 42a, 42b securing the control plates 38 in place, these are secured to the cathode plates 26 using a number of high-density polyethylene (HDPE) threaded fasteners 75 which are secured by HDPE threaded nuts 79. A series of HDPE washers 77 are positioned between successive control plates 38 to space them apart and to electrically isolate them from each other and the cathode plates 26 and housing 12 forming the anode electrode, although for clarity purposes only three washers 77 are depicted in Figure 4. In all of the embodiments of the invention, the gap between successive control plates 38 to space them apart is in the region of around 1mm to 4mm.

The control plates are also spaced apart from the base plate 18 by a vertical distance of around 2mm, and denoted as line A in Figure 4. Although other distances, generally between around 1mm to 4mm, are equally as suitable. Again the use of control plates 38 and particularly nine control plate plates 38 situated on each side of the cathode plates 26 serves to control the electrolysis process and therefore limit the current flowing through the hydrogen fuel generator 10.

Figure 5 shows the wet cell hydrogen fuel generator 10 in use with, or retrofitted to, a vehicle with an internal combustion engine 100 and which gives a fuel enhancement effect. As shown schematically in Figure 5, the hydrogen fuel generator 10 is positioned in a vertical configuration with gas outflow 74 positioned uppermost from top plate 16. The position of the hydrogen fuel generator 10 should be substantially upright and ideally located in the engine bay of the vehicle (not shown).

In use, the hydrogen fuel generator 10 is powered by connecting the anode lug 24 to the positive terminal of the vehicle battery 84. It is the current drawn from the battery 84 that is used to power the electrolysis decomposition of the electrolyte solution 78. To prevent an overcurrent condition occurring, a fuse 86 is placed between the positive terminal of the battery 84 and the anode lug 24. The fuse 86 is typically rated between 20A to 50A.

An operating relay 88 controls the operation of the hydrogen fuel generator 10, which can be via a switch (not shown) on or near the dash-mounted controller display unit 82 which also displays the current drawn through a shunt resistor 90. The controller display unit 82 can show an analogue ammeter, or display the measured current drawn by the hydrogen fuel generator 10 as a digital output. The hydrogen fuel generator 10 can also be powered automatically with the vehicle’s ignition (not shown), with the operating relay 88 used to subsequently control the operation of the hydrogen fuel generator 10 independent of the ignition.

The cathode plates 26 are earthed to the body of the vehicle by earth connection 80. A separate earth connection 80 is shown in Figure 5, although the skilled person will appreciate that that the base plate 18 could be bolted directly to the body of the vehicle (not shown) by removing one or more of the insulating washers 36 from the underside of base plate 18.

In use, at ambient temperature, the current drawn by the hydrogen fuel generator 10 is between 5 A and 10A. As the temperature of the electrolyte solution 78 increases when hydrogen and oxygen gas is liberated, the current drawn by the hydrogen fuel generator 10 can rise to between 10A and 20A. This gives the optimum rate of generation of hydrogen and oxygen gas at the outflow 74 without drawing undue current from the vehicle battery 84 which is replenished by alternator 102. In the high-level schematic diagram of Figure 5, the skilled person will appreciate that none of the alternator’s 102 on-board charging system and/or regulators are shown.

The current drawn by the hydrogen fuel generator 10 increases as the temperature of the electrolyte solution 78 increases. It is understood that the control plates 38 prevent unwanted positive feedback effects or thermal runaway conditions which otherwise lead to unwanted steam generation by increasing the distance travelled by the reacting ions in the electrolyte solution 78. As the gap between successive control plates 38 is reduced, the electrical resistance of the electrolyte solution 78 increases which, in turn, reduces the current drawn by hydrogen fuel generator 10. The user can monitor the current on display 82 and, if required, add alkali salts such as Sodium hydroxide (NaOH), which is more commonly known as “caustic soda”, or Potassium hydroxide (KOH) and/or draw off the electrolyte solution 78 to arrive at an optimum electrolysis current. In the preferred embodiment of the hydrogen fuel generator 10 with a chamber capable of containing around 1.5 litres of electrolyte solution 78, optimum hydrogen and oxygen gas production occurs if around 5g to lOg of powdered Sodium hydroxide or Potassium hydroxide is dissolved in 1.5 litres of pure water.

The outflow 74 of oxygen and hydrogen gas is fed via tube 92 downstream of the air intake 94 of the internal combustion engine 100, which can use petrol or diesel as the hydrocarbon fuel. For schematic illustration, only the electronic control unit (ECU) 96 and mass airflow sensor (MAS) 98 are shown, although the skilled person will appreciate that other engine control components are required. By placing the hydrogen and oxygen gas downstream of the air intake 94, this prevents the ECU 96 from overcompensating for the reduction in demand of the hydrocarbon fuel, and instead rely on concentrations of hydrogen and oxygen gas to assist the potency and bum of the hydrocarbon fuel.

Utilising the hydrogen fuel generator 10 in this manner leads to a fuel enhancement effect in terms of improved fuel economy and performance, and reduced emissions and engine wear.

Figure 6 shows a third embodiment of the hydrogen fuel generator 10. The construction of the third embodiment is very similar to that of the first and second embodiments and corresponding features have been given the same reference numerals. The third embodiment differs from the first and second embodiments in that instead of a clear viewing tube 68 being connected between elbow pieces 66a, 66b, a viewing window 104 is disposed in one or more front or side walls of the housing 12. The skilled person will appreciate that much of the detail of the threaded fasteners 28 and threaded nuts 30 connecting the flanged ends 14, and the electrical and gas connections to the generator 10 have been omitted from Figure 6 for clarity purposes.

Figure 6 shows that the elongate viewing window 104 is disposed in a cut-out 106 in one of the front or side walls of the housing 12. The viewing window 104 is formed from a clear acrylic material, which is adhered inside the cut-out 106 using a suitable adhesive or any suitable fixing means. The length of the viewing window 104 is such that the drainage hole 62 in the front wall has been positioned instead in one of the side walls of the housing 12. In this way, the length of the viewing window 104 is such that it allows the user to easily monitor the level of the electrolyte solution 78 in the housing 12.

Various additions and alternations may be made to the present invention. For example, although particular embodiments refer to implementing the present invention with domestic automotive vehicles, this is in no way intended to be limiting as, in use, the present invention can be implemented to any number of land, sea and air vehicles powered by an internal combustion engine.

The invention is not intended to be limited to the details of the embodiments described herein, which are described by way of example only. It will be understood that features described in relation to any particular embodiment can be featured in combination with other embodiments.

It is contemplated by the inventor that various substitutions, alterations, and modifications may be made to the invention without departing from the spirit and scope of the invention as defined by the claims. Examples of these include the following:

The small physical size and footprint of the hydrogen fuel generator 10 according to any of the embodiments described herein means that it can be installed in the engine compartment of the vehicle (not shown). Alternatively, the generator 10 can be fitted inside the boot compartment of the vehicle. Wherever the generator 10 is installed it can be powder coated to match the colour of the vehicle to make it inconspicuous, or coated with any colour according to the user’s wishes.

Claims

1. A hydrogen fuel generator for use with an internal combustion engine, comprising: a chamber for receiving an electrolyte comprising water; at least one anode electrode and at least one cathode electrode for passing an electric current through the electrolyte causing electrolysis of water; and control means positioned at least in part between the at least one anode and at least one cathode for controlling the electric current.

2. The hydrogen fuel generator as claimed in claim 1, wherein the hydrogen fuel generator is a wet cell hydrogen fuel generator.

3. The hydrogen fuel generator as claimed in claims 1 or 2, wherein the chamber further comprises: an elongate housing having a flange at each end thereof; and a complementary shaped top plate and a complementary shaped base plate for connection with the respective flanged end.

4. The hydrogen fuel generator as claimed in claim 3, wherein the elongate housing is formed having a generally square cross section in plan view and in use is positioned in a vertical configuration with the top plate being uppermost.

5. The hydrogen fuel generator as claimed in claims 3 or 4, wherein the top plate is secured to the respective flanged end at the uppermost part of the housing via a complementary shaped elastomeric seal or gasket.

6. The hydrogen fuel generator as claimed in claim 3, wherein the base plate is secured to the respective flanged end at the lowermost part of the housing via a complementary shaped elastomeric seal or gasket.

7. The hydrogen fuel generator as claimed in claims 5 or 6, wherein the flanged ends, the top plate, the base plate and elastomeric gaskets each include a plurality of apertures for securement by threaded fasteners and threaded nuts.

8. The hydrogen fuel generator as claimed in claim 7, wherein the head of the threaded fasteners is selected from the group consisting, but not limited to, any one of the following: slotted head, Allen® head, Phillips head and hexagonal bolt.

9. The hydrogen fuel generator as claimed in any of claims 5 to 7, wherein the elastomeric gaskets are formed from 3mm thick EPDM rubber.

10. The hydrogen fuel generator as claimed in claim 3, wherein the housing forms the anode electrode via a lug formed in one of the box section side walls of the housing.

11. The hydrogen fuel generator as claimed in claim 3, wherein the cathode electrode is provided by two spaced apart cathode plates which extend upwardly inside the housing from the base plate.

12. The hydrogen fuel generator as claimed in claim 7, further comprising a plurality of insulating inserts, each insert having an internal through bore and having one face that is wider than the head of the threaded fastener or threaded nut with which it is to be used, and a narrower elongate shaft having an outer diameter that can be received by the apertures formed in the flanged ends, the top plate, the base plate and elastomeric gaskets.

13. The hydrogen fuel generator as claimed in claim 12, wherein the insulating inserts are formed from high-density polyethylene (HDPE) plastics material or acetyl based plastics material.

14. The hydrogen fuel generator as claimed in any of claims 3 to 13, wherein, when assembled, the housing is formed as a cuboid, cylinder, triangular prism or hexagonal prism.

15. The hydrogen fuel generator as claimed in any of claims 3 to 14, further comprising a drainage hole in the front wall of the housing through which the electrolyte can be drained and replaced in use.

16. The hydrogen fuel generator as claimed in any of claims 3 to 15, further comprising a pair of apertures in the front wall of the housing for connection to a clear viewing tube connected between a pair of elbows.

17. The hydrogen fuel generator as claimed in any of claims 3 to 15, further comprising a slot or other shape defined in the front or side wall of the housing and an overlapping transparent acrylic window being sealed in place using a suitable adhesive.

18. The hydrogen fuel generator as claimed in claim 3, wherein a threaded fill hole is positioned in the top plate and which can be sealed off by use of a threaded plug.

19. The hydrogen fuel generator as claimed in any of claims 3 to 15, wherein the height of the housing is around 225mm and the width of the housing, not including the flanged ends, is around 100mm.

20. The hydrogen fuel generator as claimed in claim 1, wherein the chamber is capable of receiving around 1.5 litres of electrolyte.

21. The hydrogen fuel generator as claimed in any of claims 3 to 15, wherein the height of the housing is in the region of around 100mm to around 300mm.

22. The hydrogen fuel generator as claimed in claim 1, wherein the control means further comprises a plurality of control plates disposed inside the housing, each of the plurality of control plates being electrically isolated from one another and the anode electrode and the cathode electrode.

23. The hydrogen fuel generator as claimed in claim 22, wherein 3, 6 or 9 control plates are located on each of the outer sides of the pair of cathode plates in the housing.

24. The hydrogen fuel generator as claimed in claims 22 or 23, wherein the plurality of control plates increases the electrical resistance of the electrolyte.

25. The hydrogen fuel generator as claimed in any of claims 22 to 24, wherein the plurality of control plates are formed from 316L stainless steel having a thickness of around 1.5 mm.

26. The hydrogen fuel generator as claimed in any of claims 22 to 25, wherein the plurality of control plates are held in place isolated from the housing and the cathode plates extending from the base plate, by two pairs of insulating spacers situated towards the top and bottom of the housing.

27. The hydrogen fuel generator as claimed in claim 26, wherein a pair of insulating top spacers are located on top of the cathode plates in use and positioned orthogonally to the cathode plates, each of the insulating top spacers being formed having a generally flat top face, a pair of side faces which extend downwardly from each side of the top face and a pair of end faces that extend downwardly from each end of the top face, such that the top face, side faces and end faces in combination define a slotted grating which is adapted to receive the top of the cathode plates and control plates.

28. The hydrogen fuel generator as claimed in claim 27, wherein insulating bottom spacers are located on each of the outer sides of the pair of cathode plates in use and orthogonal to the insulating top spacers, each of the insulating bottom spacers being formed having a generally flat base face, a pair of side faces which extend upwardly from each side of the base face and a pair of end faces that extend upwardly from each end of the base face, such that the base face, side faces and end face in combination define a slotted grating which is adapted to receive the bottom of the control plates.

29. The hydrogen fuel generator as claimed in any of claims 22 to 25, wherein the plurality of control plates are secured to the cathode plates using a plurality of high-density polyethylene (HDPE) threaded fasteners which are secured by HDPE threaded nuts and a plurality of HDPE washers are positioned between successive control plates to space them apart and to electrically isolate them from each other and the cathode plates and housing forming the anode electrode.

30. The hydrogen fuel generator as claimed in claim 29, wherein the plurality of control plates are spaced apart by a distance of around 1mm to 4mm.

31. The hydrogen fuel generator as claimed in claim 29, wherein the plurality of control plates are spaced apart from the base plate by a distance of around 1mm to 4mm.

32. The hydrogen fuel generator as claimed in any of the preceding claims, wherein the hydrogen fuel generator is formed from a welded construction and/or machined and/or pressed and/or cast and/or forged from a suitable metal material.

33. The hydrogen fuel generator as claimed in claim 29, wherein the outer surfaces of the hydrogen fuel generator are powder coated.

34. The hydrogen fuel generator as claimed in claim 29, wherein the housing, top plate, base plate and cathode plates are all formed from 316L stainless steel.

35. The hydrogen fuel generator as claimed in claim 1, wherein the electrolyte is pure water, distilled water, and/or water in solution with salts.

36. The hydrogen fuel generator as claimed in claim 35, wherein the salts are alkali salts including Sodium hydroxide (NaOH) or Potassium hydroxide (KOH) mixed at a ratio 5g to lOg of powdered alkali salt dissolved in 1.5 litres of pure water.

37. The hydrogen fuel generator as claimed in claim 1, wherein use of the hydrogen fuel generator gives a fuel enhancement effect.

38. The hydrogen fuel generator as claimed in claim 1, further comprising a fuse placed between the positive terminal of the battery and the anode electrode, the fuse rated between 20A to 50A.

39. The hydrogen fuel generator as claimed in claim 1, further comprising an operating relay which controls the operation of the hydrogen fuel generator and dash-mounted controller display unit which displays the current drawn by hydrogen fuel generator.

40. The hydrogen fuel generator as claimed in claim 39, wherein the controller display unit can show an analogue ammeter, or display the current drawn by the hydrogen fuel generator as a digital output.

41. The hydrogen fuel generator as claimed in claim 1, wherein the current drawn by the hydrogen fuel generator is between 5A and 20A.

42. The hydrogen fuel generator as claimed in claim 1, wherein the outflow of hydrogen and oxygen gas is fed via tube downstream of the air intake of the internal combustion engine.

43. A method of producing hydrogen and oxygen gas for use as a hydrocarbon fuel enhancement, comprising the steps of: applying an electric current between an anode electrode and cathode electrode of the hydrogen fuel generator of claim 1; and injecting hydrogen and oxygen gas downstream of the air intake of an internal combustion engine.

44. A hydrogen fuel generator as described herein with reference to Figures 1 to 6 of the accompanying drawings.

45. A method of producing hydrogen and oxygen gas for use as a hydrocarbon fuel enhancement as hereinbefore described.