WO2010145022A1

WO2010145022A1 - Electrolysis cell and hybrid vehicle conversion kit

Info

Publication number: WO2010145022A1
Application number: PCT/CA2010/000924
Authority: WO
Inventors: Richard Wachter; Murray Heath; Ned Pavlovic
Original assignee: South Shore Resources Inc.
Priority date: 2009-06-17
Filing date: 2010-06-17
Publication date: 2010-12-23

Abstract

An electrolysis cell for generating a gas from a fluid comprises: an inlet defining an inlet bore contiguous with an inlet aperture, the inlet for receiving the fluid into the cell; an outlet defining an outlet bore contiguous with an outlet aperture, the outlet for releasing the gas from the cell; and at least one conductive plate defining a plate fluid inlet aperture that is in closed fluid communication with the inlet aperture and the outlet aperture, the conductive plate for receiving and transmitting an electrical current through the fluid to generate the gas; wherein the inlet aperture, the plate fluid inlet aperture, and the outlet aperture together form a passageway that extends into the inlet, through the plate, and out of the outlet.

Description

Electrolysis Cell and Hybrid Vehicle Conversion Kit

Cross Reference to Related Application

[0001] This application claims priority under 35 U. S. C. 119 from United

States provisional patent application number 61/187,716 filed on June 17, 2009.

Field of the Invention

[0002] The present application relates to hybrid vehicles. More specifically, the present application relates to an electrolysis cell and a hybrid conversion kit.

Background of the Invention

[0003] Throughout this application, various documents are referenced for describing various aspects of the state of the art to which this invention pertains. The disclosures of those documents are hereby incorporated by reference into the present disclosure in their entirety.

[0004] At present, the overall efficiency of an internal combustion engine is only in the range of 70% to 80%. Potential and generated energy is typically lost in the form of heat, friction, and unburned hydrocarbon fuel. The unburned hydrocarbon fuel is lost through the exhaust gases in the form of emissions, contributing to pollution.

[0005] The inefficiency of internal combustion engines has been addressed in a variety of ways, one of which is the controlled addition of hydrogen and oxygen to the air/fuel mixture within the internal combustion engine. This controlled addition of hydrogen and oxygen can result in an increase in fuel efficiency of about 30% or more and can reduce emissions by about 60% or more. [0006] One process used for the production and delivery of hydrogen and oxygen to an internal combustion engine is electrolysis of an aqueous fluid, to produce gases that are then mixed with the fuel and air supplied to the engine.

Electrolysis is an electrolytic process that uses electrical energy to catalyze the decomposition of water (H₂O) into oxygen (O₂) and hydrogen (H₂). Many hydrogen cells of the prior art produce hydrogen that is stored in a storage tank for use in the combustion mixture. However, since hydrogen is combustible, it is considered unsafe to have such a tank attached to the outside of the vehicle. Additionally, the bulk and weight of these tanks can be unwieldy and may counteract the fuel efficiency benefits of adding hydrogen to the combustion mixture.

[0007] Additionally, many known hydrogen cells are quite large as they must be immersed in a coolant. These are referred to as wet cells.

[0008] Exemplary prior art hydrogen cells are disclosed in U.S. Patent Nos.

6,336,430, 6,833,206, 7,168,465, 7,240,641, 7,261,062, and 7,482,767 and in

U.S. Patent Application Publication Nos. 2004/0025807, 2007/0209608, and

2009/0134041.

[0009] Although effective electrolysis cells and hybrid conversion kits exist, improvements are desired. It is therefore an object of an aspect of the following to provide a novel electrolysis cell and hybrid conversion kit incorporating same.

Summary of the Invention

[0010] In accordance with an aspect, there is provided an electrolysis cell for generating a gas from a fluid, the cell comprising: an inlet defining an inlet bore contiguous with an inlet aperture, the inlet for receiving the fluid into the cell; an outlet defining an outlet bore contiguous with an outlet aperture, the outlet for releasing the gas from the cell; and at least one conductive plate defining a plate fluid inlet aperture that is in closed fluid communication with the inlet aperture and the outlet aperture, the conductive plate for receiving and transmitting an electrical current through the fluid to generate the gas; wherein the inlet aperture, the plate fluid inlet aperture, and the outlet aperture together form a passageway that extends into the inlet, through the plate, and out of the outlet. [0011] In accordance with another aspect, the plate further comprises an exhaust aperture that is in fluid communication with the plate inlet fluid aperture and the outlet aperture. In an aspect, the cell comprises at least one positive conductive plate and at least one negative conductive plate. In another aspect, the positive conductive plate is made of titanium, such as 20 gauge titanium grade 2. In a further aspect, the positive conductive plate comprises a platinum coating, such as a platinum coating having a thickness of 1 μm. In an aspect, the negative conductive plate is made of nickel, such as 24 gauge nickel 200. In another aspect, the cell comprises about 2 to about 50 plates, about 10 to about 12 plates, or about 20 to about 30 plates. In a further aspect, the gas comprises hydrogen and the fluid comprises water with dissolved mineral salts.

[0012] In accordance with another aspect, there is provided a hybrid conversion kit comprising the cell described herein and an electronic control module in electrical communication with the cell.

[0013] In an aspect, the kit comprises at least one other component selected from the group consisting of: a reservoir; cell fluid; tubing; a wiring harness; an air inlet manifold valve; a check valve; a sensor; clamps; and instructions for use. In an aspect, the kit comprises a reservoir, tubing, and a wiring harness. [0014] In accordance with another aspect, there is provided a vehicle comprising the cell or the kit described herein. [0015] In accordance with another aspect, there is provided a method of generating a gas from a fluid, comprising applying an electrical current to the cell described herein.

[0016] Other features and advantages of the present invention will become apparent from the following detailed description. It should be understood, however, that the detailed description and the specific examples while indicating embodiments of the invention are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from said detailed description.

Brief Description of the Drawings

[0017] Embodiments will now be described with reference to the accompanying drawings in which:

[0018] Figure 1 is a front perspective view of a hydrogen cell;

[0019] Figure 2A is a back perspective view of an inlet body of the hydrogen cell shown in Figure 1;

[0020] Figure 2B is a front perspective view of the inlet body shown in Figure

2A;

[0021] Figure 2C is a transparent top view of the inlet body shown in Figure

2A;

[0022] Figure 2D is a transparent back elevation view of the inlet body shown in Figure 2A;

[0023] Figure 3A is a back perspective view of an outlet body of the hydrogen cell shown in Figure 1;

[0024] Figure 3B is a front perspective view of the outlet body shown in

Figure 3A; [0025] Figure 3C is a transparent top view of the outlet body shown in Figure

3A;

[0026] Figure 3D is a transparent back elevation view of the outlet body shown in Figure 3A;

[0027] Figure 4A is a front elevation view of a plate of the hydrogen cell shown in Figure 1;

[0028] Figure 5A is a perspective view of a spacer bushing of the hydrogen cell shown in Figure 1;

[0029] Figure 5B is a perspective view of a mounting flap of the hydrogen cell shown in Figure 1;

[0030] Figure 6 is a perspective view of the components of a hybrid conversion kit incorporating the hydrogen cell shown in Figure 1;

[0031] Figure 7 is a perspective view of a reservoir of the hydrogen conversion kit shown in Figure 6;

[0032] Figure 8 is a perspective view of an electronic control module of the hydrogen conversion kit shown in Figure 6;

[0033] Figure 9A is a top plan view of a circuit of the electronic control module shown in Figure 8;

[0034] Figure 9B is a bottom plan view of the circuit shown in Figure 9A; and

[0035] Figures 1OA and 1OB are schematic circuit diagrams of a circuit of the electronic control module shown in Figure 8.

Detailed Description of the Embodiments

[0036] An electrolysis cell and hybrid conversion kit incorporating the electrolysis cell are disclosed herein. The electrolysis cell disclosed herein includes an inlet and an outlet, with conductive plates disposed thereinbetween. There is a fluid passageway, or bore, that extends into and through the inlet, through the plates, and through and out of the outlet. The application of an electrical current to the plates causes electrolysis of the fluid, for example water, therein, separating the hydrogen and oxygen from the water portion of the fluid and producing oxygen and hydrogen gases that can be mixed with engine fuel to improve combustion efficiency which thereby reduces vehicle emissions. The electrolysis cell is modular, in that more plates can be added between the inlet and the outlet. In this way, the electrolysis cell can be expanded to provide increased amounts of gas. The hybrid conversion kit incorporating the electrolysis cell is easy to apply, without damage, to a vehicle. It does not need to be permanently installed. In this way, the hybrid conversion kit can be moved from one car to another if a new vehicle is purchased. The electrolysis cell described herein is a dry cell, meaning water is immersed inside the cell, instead of the cell being immersed in water (referred to as a wet cell). Since the electrolysis cell described herein is a dry cell, it is small and easy to install wherever needed. Furthermore, because the fluid is immersed in the cell, the outer portions of the cell plates act as cooling fins that reduce heat build-up within the cell.

[0037] An embodiment of the electrolysis cell will now be described with reference to the figures. In this embodiment, the electrolysis cell is a hydrogen cell 20 and the hydrogen cell 20 is used to generate hydrogen from water. Advantageously, electrolytes to speed or catalyze the electrolysis reaction are also contained in the water. Figure 1 shows the hydrogen cell 20. The hydrogen cell 20 has an inlet body 22 with an inlet port 24 and an outlet body 26 with an outlet port 28. The inlet port 24 is for coupling to a fluid source and the outlet port 28 is for coupling to the air intake manifold of a vehicle directly or indirectly, as will be described. The inlet body 22 and the outlet body 26 are made of a heat resistant nylon and are connected together by corresponding screws and inset nuts in each corner of the hydrogen cell 20. Two stainless steel spacer bushings 30, mounted on two of the screws, maintain the inlet body 22 and the outlet body 26 in a spaced arrangement. A male wire pigtail 32 and a female wire pigtail 34 are attached to respective spacer bushings 30. One pigtail is for the negative power supply and one pigtail is for the positive power supply.

[0038] A plurality of conductive plates 36 are disposed between the inlet body 22 and the outlet body 26 and are electrically connected to one another. Preferably, a minimum of about ten plates 36 is used in a hydrogen cell 20 intended for use in a car or small truck. In another aspect, about 30 plates are used in a hydrogen cell 20 that is intended for use in a heavy duty truck. An annular gasket (not shown) is disposed between each pair of plates, acting as a seal and spacer to form a pool between the plates where the water can collect for the electrolysis reaction. In this embodiment, the gasket is a high heat resistant rubber sealed gasket that is about 1 mm to about 3 mm in thickness.

[0039] The plates 36 are arranged in an alternating arrangement, such that one plate 36 is attached to the bushing 30 that is electrically connected to the male pigtail 32 and the adjacent plate 36 is attached to the bushing 30 that is electrically connected to the female pigtail 34. The next adjacent plate 36 is attached to the bushing 30 that is electrically connected to the male pigtail 32. This alternating arrangement continues through the plates. Plates 36 that are connected to the pigtail providing the negative power supply are referred to as negative plates 36 and are made from a conductive material such as 24 gauge nickel 200. Plates 36 that are connected to the pigtail providing the positive power supply are referred to as positive plates and are made from a conductive material such as 20 gauge titanium grade 2 that is coated with a 1 μm layer of platinum. [0040] In this embodiment, each and every plate 36 is attached to one or the other bushing 30. In this way, electrical current flows from the male pigtail 32, near the inlet body 22, to the female pigtail 34, near the outlet body 26. It will be understood however, that with minor modifications, only the plates that are closest to the inlet body 24 and the outlet body 26 may be connected to the bushings and thus in direct electrical communication with the male and female pigtails 32 and 34, respectively. Any additional plates 36 are disposed in between the plates 36 that are connected to the spacer bushings 30 and are frictionally held in between the inlet body 24 and the outlet body 26 using the spacer bushings 30. The spacer bushings 30 are sized such that, when they are attached between the inlet body 24 and the outlet body 26, sufficient pressure is applied to the plates 36 to seal them against fluid leakage using the gaskets and to maintain the plates 36 in position. Two mounting flaps 38 act as additional spacer bushings and are also used to connect the inlet body 22 and the outlet body 26 to one another with screws that pass through the mounting flaps 38 at the remaining two corners of the hydrogen cell 20. The mounting flaps 38 are also used to mount the hydrogen cell 20 in a desired position on a vehicle.

[0041] The inlet body 22 is shown in isolation in Figures 2A, 2B, 2C, and 2D.

The inlet body 22 has an inwardly facing surface 40 facing the plates 36 and an outwardly facing surface 42. The inlet port 24 defines a bore 44 that extends into the inlet body 22. The inwardly facing surface 40 has a manufacturing guide 46 and an inlet aperture 48 (Figures 2A and 2D). The manufacturing guide 46 aids in positioning the plates 36 properly between the inlet body 24 and the outlet body 26. The inlet aperture 48 opens into the bore 44. Water for the electrolysis enters the inlet body 22 via the inlet port 24. The water passes through the bore 44 and exits through the inlet aperture 48 towards the plates 36. [0042] The outlet body 26 is shown in isolation in Figures 3A, 3B, 3C, and

3D. As with the inlet body 22, the outlet body 26 has an inwardly facing surface 50 facing the plates 36 and an outwardly facing surface 52. The outlet port 28 defines a bore 54 that extends into the outlet body 26. The inwardly facing surface has an outlet aperture 56 (Figures 3B and 3D) that opens into the bore 54. Hydrogen generated by electrolysis, as will be described, enters the outlet body 26 via the outlet aperture 56. The hydrogen passes through the bore 54 and exits through the outlet port 28.

[0043] One of the plates 36 is shown in isolation in Figure 4A. Each plate 36 has a fluid inlet aperture 60 and an exhaust aperture 58. When a plurality of the plates 36 are assembled together in series, and with the inlet body 22 and the outlet body 26, the fluid inlet aperture 60 is in fluid communication with the inlet aperture 48 of the inlet body 22, while the exhaust aperture 58 is in fluid communication with the outlet aperture 56 of the outlet body 26. The fluid inlet apertures 60 and the exhaust apertures 58 of side-by-side plates are in fluid communication with one another such that when water enters into the plates 36 via the fluid inlet apertures 60 of the plates 36 in series, the water fills up between the plates 36. When the water is electrolyzed the generated gas exits through the outlet aperture 56 via the exhaust apertures 58.

[0044] Each of the positive and negative plates 36 have the same dimensions. In this embodiment, the plates 36 have a thickness of about 0.20 inches and a radius of about 1.750 inches. Each inlet aperture 60 and outlet aperture 58 of plates 36 are about 1.250 inches wide and about 1.650 inches apart from one another and define an outer radius of about 1.250 inches. The portion 59 of the plates 36 that is used to connect the plates 36 to the bushing 30 is offset at a 45° angle with respect to the apertures 58, 60. [0045] The spacer bushings 30 and mounting flaps 38 are shown in isolation in Figures 5A and 5B. As described above, the spacer bushings 30 and mounting flaps 38 act as spacers through which screws pass to hold the inlet body 22, the outlet body 26, and the plates 36 together to form the hydrogen cell 20. The hydrogen cell 20 thus formed has a hermetically sealed passageway that extends from the inlet port 24, through the plate apertures 60 and 58, to the outlet port 28. [0046] The hydrogen cell 20 is attached to a vehicle by the mounting flaps

38. Preferably, the hydrogen cell 20 is attached to the vehicle in a location with air flow, such as between the grill and the radiator. In use, the hydrogen cell 20 is flooded with water via the inlet port 24, filling all of the apertures within the hydrogen cell 20. During operation, an electric current is run through the plates 36, causing electrolysis of the water that is contained therein. Electrolysis of the water produces hydrogen and oxygen, both of which are forced out of the outlet port 28. These gases are then routed into the air intake manifold of the vehicle, as will be described, for improving engine efficiency and reducing emissions by introducing the hydrogen into the combustion chamber of the cylinders to more effectively burn fuel.

[0047] Referring now to Figure 6, the hydrogen cell 20 described above is provided as part of a kit 62. The kit comprises the hydrogen cell 20; a fluid reservoir 64; cell fluid 66 to add to the reservoir 64; a length of tubing 68 to couple the hydrogen cell 20 and the reservoir 64 to one another; an electronic control module 70 to control the hydrogen cell 20; a wiring harness 72 for coupling the electronic control module 70 to both a power source and to the hydrogen cell 20; an air intake manifold barb 74 for connecting the tubing 68 to the air intake manifold; a check valve 76 for preventing back flow of gas from the air intake manifold into the reservoir 64; a system on/off sensor 78; and clamps 80. The kit 62 also includes instructions for installation and use. The kit 62 does not require a separate hydrogen storage tank as hydrogen is produced on demand and is fed immediately into the combustion mixture, as will be described below.

[0048] The reservoir 64 is shown in isolation in Figure 7. The reservoir 64 includes a tank 82 that has a cap 84. The cap 84 can be opened and closed to add the water to the tank 82. Mounting brackets 86 are included on the reservoir 64 for attaching the reservoir 64 to a vehicle. The reservoir includes three ports: a fluid port 88, for coupling to the inlet port 24 of the hydrogen cell 20; a gas port 90, for coupling to the outlet port 28 of the hydrogen cell 20; and an exhaust port 92, for coupling to the air intake manifold of the vehicle. The fluid port 88, gas port 90, and exhaust port 92 are coupled to the inlet port 24, outlet port 28, and manifold, respectively, using the tubing 68. The air intake manifold barb 74 is used at one end of a length of tubing 68 to couple the tubing 68 coming from the exhaust port 92 to the air intake manifold of the vehicle. The other end of the length of tubing 68 is coupled to the exhaust port 92. The check valve 76 is disposed in the length of tubing 68 between the exhaust port 92 and the air intake manifold barb 74 by cutting the tubing 68 and inserting the check valve 76. The check valve 76 is a one-way valve that permits only gas to flow from the reservoir to the air intake manifold, thus preventing fluid from entering the combustion chamber from the reservoir. The check valve 76 also prevents backflow of gas from the air intake manifold if the engine backfires for example.

[0049] The electronic control module 70 is shown in isolation in Figure 8.

The electronic control module 70 includes a housing 94. The housing 94 encloses a controller circuit 96. The circuit 96 is coupled to an on/off power switch 98 disposed within the housing 94. The circuit 96 is also coupled to a first connector 100 for the wiring harness 72 and a second connector 102 for the sensor 78. The sensor 78 in this embodiment is a Hall sensor that, during installation, is coupled to the alternator of the vehicle and during use outputs an electrical signal when the alternator is running, therefore to detect that the vehicle's engine is running. The sensor 78 provides the signal to activate the electronic control module 70 to allow current to pass to the hydrogen cell 20. The wiring harness 72 powers the electronic control module 70, which in turn powers the hydrogen cell 20, by linking the electronic control module 70 to the vehicle's battery. Referring again to Figure 6, the wiring harness 72 has a first wire 104 for connecting to the male pigtail 32 of the hydrogen cell 20 and a second wire 106 for connecting to the female pigtail 34 of the hydrogen cell 20. In this embodiment, the first and second wires 104 and 106 and the male and female pigtails 32 and 34 are configured so that they can only connect in one way, thus reducing the chance that an installer connects the electronic control module 70 to the hydrogen cell 20 incorrectly. The wiring harness 78 also has a negative wire 108 for connecting to the "-" terminal, or cathode, of the battery and a positive wire 110 for connecting to the "+" terminal, or anode, of the battery. The positive wire 110 includes a removable fuse 112. Preferably, the negative wire 108 is black and the positive wire 110 is red.

[0050] The circuit 96 will now be described with reference to Figures 9A and

9B, which each show one side of the board layout of the printed circuit board (PCB) for the circuit 96, and 1OA and 1OB, which show a schematic diagram of the circuit 96. The circuit 96 combines a synchronous buck power converter variable output supply with four sensor inputs Pl, P2, P3, and P4. Input Pl requires an active high signal. Inputs P2 and P3 require an active low signal. The fourth input P4 is configurable to support an analog voltage or an active low signal from a HALL effect sensor (not shown in schematic). The on/off function of the output power supply to the hydrogen cell 20 is controlled based on inputs received at P1-P4. For example, all sensor inputs are required to be in an active state before the output supply turns on.

[0051] All inputs are protected from over voltage and noise transients through the use of resistance, capacitance and zener diode clamping. Reference ID Nos. R1-R4, R17, D1-D4, D12, Cl, C4, C5, C7, and ClO provide this protection. [0052] The digital input logic state for each of the digital inputs P1-P3 is biased either high or low with pull up, pull down resistors to provide the inactive logic state when no connection is present. Reference ID Nos. R5, R8, R9, R28 provide this function. Clean logic level switching is provided by a Hex Schmitt Inverter U3. All inputs pass through this inverter U3. Additionally, the active high input is passed through another inverter U7 to obtain the opposite active state. These signals are passed to a 4-input AND function chip U2. This chip U2 requires all input levels to be logic high before its output goes to its high state. [0053] Analog input at Sen_A and Sen_B from the magnetic sensor 78 at the alternator of the vehicle is additionally protected from over voltages using Zener diodes D13 and D14, and is amplified by the operational amplifier (Op Amp) U5. The amplifier circuit uses a standard inverting signal design. Gain is controlled by R21, C13, and R24. The Op Amp U5 is biased near ground by the resistor network R19 and R7. Output is DC connected through resistor R18 to the Hex Schmitt Inverter U3. The Op Amp U5 provides sufficient signal gain as to cause Hex inverter U3 to switch states. The digital pulses are then applied via Sen_D to a retriggerable monostable multivibrator chip Ul. This chip Ul acts as a digital filter and maintains a constant logic high state as long as the input digital pulses are applied within 100 milliseconds. The output from Ul is applied to U3 for logic state correction and then to U2, thereby supplying the fourth sensor input signal. [0054] Output from U2 is applied to U3 and then to Ql MFEET transistor. This transistor controls the on/off state of the output power supply. [0055] D16, U4, C9, C6, and C2 form the basis of a standard low voltage linear regulator circuit. D16 blocks negative transients coming from the vehicle's supply. Capacitors provide filtering and regulator stability. The U4 regulator provides 5 volts to the analog and digital circuits.

[0056] Six light emitting diodes (LEDs) are used within the electronic control module 70 to provide a visual indication of the state of the input sensors and the input and output power supplies. The follow functions are indicated by LEDs: input power DlO; output power D9; magnetic sensor D8; vehicle ignition D7; and level sensor control D6 and D5. The LEDs are illuminated when in the active state. [0057] The power supply design is based on the vehicle manufacturers' typical application's circuit. Some deviations from the general design guide have been incorporated to improve the power handling. First, the center frequency loop was reduced to decrease the switching loss in the power transistors and to provide a higher top end voltage adjustment. This was accomplished because the duty cycle ratio of the on/off was increased. Second, the power transistors selected have very low "on" resistance, further reducing the power loss. Advantageously, the supply is capable of providing more than 100 watts at 10 volts with only the printed circuit board (PCB) as a heat sink. The active parts associated with the circuit are U6, Q2 and Q3. Output voltage is adjustable by adjusting R37. Shut down operation is performed by Ql.

[0058] In an aspect, the electronic control module 70 is provided with a heat sensor to detect the temperature of the hydrogen cell 20. If the hydrogen cell 20 reaches a threshold temperature, the power supply to the hydrogen cell 20 is cut off temporarily to allow the hydrogen cell 20 to cool. [0059] It will be understood that modifications are possible to the above- described electronic control module 70 and circuit 96. For example, a simple relay switch is contemplated herein. Furthermore, it will be understood that the electronic control module 70 functions could be performed using a single programmable semiconductor, as would be understood by a skilled person. [0060] The kit 62 is coupled to a vehicle as follows. Ensuring the vehicle is turned off, the electronic control module 70 is attached to the vehicle in an accessible location. In one embodiment, the electronic module 70 is attached to the vehicle near the battery. The hydrogen cell 20 is then attached to the vehicle using the mounting flaps 38 and is placed in a cool location. In an embodiment, the hydrogen cell 20 is placed between the grill and the radiator. The reservoir 64 is then attached to the vehicle above the hydrogen cell 20 so that the water can be gravity-fed into the hydrogen cell 20. In an embodiment, the reservoir 64 is placed about 6" to about 10" above the hydrogen cell 20. The tubing 68 is measured and cut to appropriate lengths and is used to couple the fluid port 88 and the gas port 90 of the reservoir 64 to the inlet port 24 and outlet port 28, respectively, of the hydrogen cell 20. The clamps 80 are used to secure the tubing in place. [0061] A hole is then drilled into the air intake manifold of the vehicle. The hole is sized to receive the air intake manifold barb 74, to which another length of tubing 68 is attached. In this way, one end of the tubing 68 is in sealed fluid communication with the inside of the intake manifold. The other end of the tubing 68 is attached to the exhaust port 92 of the reservoir 64, with the check valve 76 disposed at a point in the tubing 68 that is between the exhaust port 92 and the air intake manifold barb 74. This creates a closed pathway from the reservoir 64 to the hydrogen cell 20, back to the reservoir 64 and out into the manifold of the vehicle. At this point, the reservoir 64 is filled with the cell fluid 66 and the cap 84 is tightly closed. In an aspect, the cell fluid is an aqueous solution containing 290 ppm dissolved mineral salts. In particular, the content of the mineral salts is as follows: 270 ppm HCO₃, 71 ppm Ca, 2.7 ppm Cl, 25 ppm Mg, 2.6 ppm NO₃, 0.7 ppm K, 1 ppm Na, and 5.9 ppm SO₄. There is no need for a catalyst additive in the cell fluid of the invention.

[0062] The wiring harness 72 is then plugged into the first connector 100 of the electronic control module 70. The first wire 104 and the second wire 106 of the wiring harness 72 are connected to the male pigtail 32 and the female pigtail 34, respectively, of the hydrogen cell 20. The sensor 78 is plugged into the second connector 102 of the electronic control module 70. The sensor 78 is then attached to the alternator, with the engine of the vehicle turned off, by any means known to a skilled person, such as with a strong silicone.

[0063] The wiring harness 72 is then connected to the vehicle's battery by coupling the negative wire 108 with the "-" terminal on the battery and by coupling the positive wire 110 with the "+" terminal on the battery. The negative wire 108 and the positive wire 110 are secured in place using plastic tie straps. Three of the LEDs in a row will light up inside of the electronic control module 70 to indicate that the electronics are installed correctly.

[0064] When the vehicle is turned on and the alternator is started, two additional LEDs are caused as described above to light up inside of the electronic control module, showing five LEDs lit up in a row. The electronic control module 70 powers the hydrogen cell 20 and electrolysis of the water commences. Electrolysis of water produces hydrogen and oxygen gas. These gases are released from the hydrogen cell 20 via the outlet port 28 and enter the reservoir 64 via the gas port 90. The gases bubble through the water remaining in the reservoir, which advantageously acts to cool the gases. The gases rise to the top of the reservoir 64 and exit via the exhaust port 92. The gases then enter the air intake manifold where the gases are mixed with the fuel and air mixture already in the air intake manifold. The addition of hydrogen gas to the fuel and air mixture increases the efficiency of the subsequent combustion process. By increasing the efficiency of combustion, much less unburned fuel is released into the environment in the form of emissions. In one non-limiting example, the hydrogen cell 20 described herein reduces vehicle exhaust emissions by 96% and provides a fuel savings, in terms of increased miles per gallon, of 25%.

[0065] It will be understood that the electrolysis cell and hydrogen conversion kit described herein can be used on any type of vehicle regardless of make or model, although minor modifications may be needed. The vehicle may be a watercraft, flying vehicle, or terrestrial vehicle. It may be a car, truck, or heavy duty vehicle. As described above, the electrolysis cell is modular in that it can be expanded by simply adding additional plates. For example, a typical car or SUV would use 10 to 12 plates. A heavy duty vehicle such as a transport truck would use 20 to 30 plates. It will be understood that the number of plates used in the hydrogen cell can be varied by the manufacturer or end user and is considered non- limiting. Any number of plates can be used in the hydrogen cell 20 described herein. For example, hydrogen cells 20 having from about two to about 50 plates are conterriplated herein, as well as any range or number the re in between. To adjust between a 4-cylinder car and a 6- or 8-cylinder car, the current applied to plates and therefore the amount of hydrogen produced can be adjusted using the electronic control module which will be pre-set by the manufacturer. [0066] Although the electrolysis cell has been described above as being used to generate hydrogen and oxygen gases from water, it will be understood that the electrolysis cell could also be used to generate other gases from other reactant materials. In a hydrogen cell that produces hydrogen and oxygen from water, the water source is non-limiting. The water could be tap water, for example, or distilled water. The water could be pure or it could be an aqueous solution including dissolved mineral salts or other electrolytes such as salts, acids, or bases. Seawater could be used, as could Draino™, or baking soda, or sodium hydroxide. It will be understood that when less pure water sources are used the hydrogen cell will have to be cleaned more frequently, due to potential contaminants in the water source. Certain fluids may be caustic and therefore harmful to metal. If caustic fluids are desired for use, the hydrogen cell components will require more frequent replacement. Alternatively, the components of the hydrogen cell could be fabricated from materials that are more resistant to the fluid of choice. [0067] The negative conductive plates have been described above as being made from 24 gauge nickel 200. However, it will be understood that any grade or gauge of nickel and indeed any conductive material is suitable for fabrication of the plates. For example, the plates could be fabricated from other conductive materials such as stainless steel.

[0068] Likewise, the positive plates need not be made from 20 gauge titanium grade 2. Titanium is desirable for use, since it will not leech over time. However, any conductive material could be used. The platinum coating is an optional feature, but desirable because it causes negligible amounts of heat and does not deteriorate over time. However, other coatings such as nickel could be used, or the plates could be used without a coating.

[0069] Similarly, the bushings could consist of a plurality of washers to space the inlet and outlet bodies the required width to seal the plates together. The inlet and outlet bodies could be made of injection molded nylon or plexi-glass sheets, cut to the size required to hold the plates in position. [0070] It will be understood that many components of the above-described hydrogen cell 20 can be modified by making compensatory modifications in other components of the hydrogen cell 20. For example, the size of the apertures in the plates can be varied. When small apertures are used, there is more resistance and the plates generate more heat and may be more difficult to cool. However, the plates will also have a greater surface area and will thus generate more hydrogen. The increased heat can be compensated for by using fewer plates. The reverse is also possible. If larger apertures are used, there is less resistance, lower heat, and reduced hydrogen output. Hydrogen output can then be increased by using one or more extra plates. In a similar manner, the shape of the plates can be varied. If more surface area is required to produce more hydrogen, the plates and the gaskets can be made square or any other suitable shape. If the plates are spaced close together using very thin gaskets, the hydrogen will be produced more quickly. The plates will thus get hot more quickly as well. If the plates are placed farther apart, hydrogen will be produced more slowly, but the plates will not heat up as much. A skilled person can readily experiment with these parameters to arrive at a suitable hydrogen cell 20.

[0071] The inlet body has been described as having a manufacturing guide.

It will be understood that this guide aids in positioning the plates but is not required for the successful operation of the hydrogen cell described herein. The conductive plates have also been described above as having two apertures. However, it will be understood that a single aperture in each of the conductive plates is contemplated herein. In such an aspect, the inlet aperture, the plate apertures, and the outlet aperture would form a continuous fluid pathway where fluid enters and gas escapes. [0072] The hydrogen cell has been described above as including spacer bushings and mounting flaps mounted on screws for holding the inlet body, the plates, and the outlet body together. It will be understood that these components could be held together by other means, including, for example, a surrounding housing or clamps. Additionally, the screws could be substituted with any other type of fastener known to a skilled person without affecting the successful operation of the hydrogen cell herein described. It will be understood that a plurality of washers could be used instead of a single bushing. In an aspect, a washer will be placed between each adjacent pair of plates on the fastener that holds the inlet body and the outlet body together. It will also be understood that the mounting flaps on the hydrogen cell and the reservoir are optional features as the hydrogen cell and the reservoir may be attached to a vehicle in other ways, such as by a strap, by welding, by a bracket, by an adhesive, or by other known means. Similarly, the sensor could be attached to the alternator by means other than silicone, as would be known to a skilled person.

[0073] The reservoir has been described above as being located above the hydrogen cell so that the water can be gravity-fed into the hydrogen cell. However, it is also contemplated that reservoir could be located beside or below the hydrogen cell and the water could be pumped into the hydrogen cell using a pump. [0074] The electric current that is applied to the hydrogen cell has been described above as coming from a battery, such as the battery of the vehicle. An auxiliary battery or any other source of electricity is contemplated herein. For example, the electricity could be generated by solar power or wind power, with concomitant power-regulating circuitry for providing a direct current to the electronics. The electricity could be applied to the hydrogen cell via the pigtails in a similar or the same manner as has been described above. Alternatively, the electricity could be applied directly to the plates and separate pigtails would not be required. [0075] The hybrid conversion kit has been described above as including many components. The kit could include only the hydrogen cell and electronic control module. It could further include the reservoir. All other components are optional and could be obtained by a vehicle owner or an installer, for example. [0076] The reservoir has been described as having three ports.

Alternatively, the reservoir could have a single port for feeding water into the hydrogen cell. The hydrogen that is generated in the cell could then be fed directly into the intake manifold of the vehicle.

[0077] The electronic control module has been described above as having a plurality of LEDs for indicating the status of the hydrogen cell. These indicators are optional features and are not required for the successful operation of the hydrogen cell and kit. Examples

[0078] Testing of the hydrogen cell described herein was performed in order to evaluate its impact on fuel economy, fuel efficiency and engine emissions. The results show that the hydrogen cell described herein provides increased fuel economy and fuel efficiency and reduced fuel emissions. The results are statistically significant and repeatable.

[0079] Emission testing was conducted and validated at two separate Drive

Clean Centres, which are Ontario, Canada's mandatory vehicle emissions inspection facilities. Vehicles must undergo an emissions test every 2 years to identify pollutants. If the vehicle exceeds the limit of emissions allowed under the programs guidelines the vehicle FAILS and must be repaired to a level required to PASS before a valid license plate sticker will be issued. The test results are summarized below: Example 1: 1993 Cheyrolet 1/2 Ton Truck V8 Engine: Mileage & Emission Test

Without Unit: 20.04 MPG Without Unit: 8.52 KM/L

With Unit: 25.87 MPG With Unit: 11.00 KM/L

CO % Emissions - 36.36 %

NO ppm Emissions - 14.50 %

HC ppm Emissions - 58.82 %

Summary: When the hydrogen cell described herein was used, there was a 29.09% increase in MPG and a 29.12% increase in KM/L. There was also a 22.54 % fuel savings per gallon (or liter). Carbon monoxide emissions were decreased by 36.36%, nitric oxide emissions were reduced by 14.50% and hydrocarbon emissions were reduced by 58.82%.

Example 2: 2002 Volkswagen Cabrio: Mileage & Emission Test

Without Unit: 29 MPG Without Unit: 12.33 KM/L

With Unit: 35 MPG With Unit: 14.88 KM/L

CO % Emissions Original Reading 0 No Change

NO ppm Emissions Original Reading 0 No Change

HC ppm Emissions - 96.62 %

Summary: When the hydrogen cell described herein was used, there was a 20.69% increase in MPG and a 20.68% increase in KM/L. There was also a 17.14% fuel savings per gallon (or liter). Hydrocarbon emissions were reduced by 96.62%. [0080] When introducing elements disclosed herein, the articles "a", "an",

"the", and "said" are intended to mean that there are one or more of the elements. The terms "comprising", "having", "including" are intended to be open-ended and mean that there may be additional elements other than the listed elements. [0081] The above disclosure generally describes the present invention.

Changes in form and substitution of equivalents are contemplated as circumstances may suggest or render expedient. Although specific terms have been employed herein, such terms are intended in a descriptive sense and not for purposes of limitation.

[0082] The description as set forth is not intended to be exhaustive or to limit the scope of the invention. Many modifications and variations are possible in light of the above teaching without departing from the purpose, spirit and scope of the following claims. It is contemplated that the use of the present invention can involve components having different characteristics. It is intended that the scope of the present invention be defined by the claims appended hereto, giving full cognizance to equivalents in all respects.

Claims

WHAT IS CLAIMED IS:

1. An electrolysis cell for generating a gas from a fluid, the cell comprising:

- an inlet defining an inlet bore contiguous with an inlet aperture, the inlet for receiving the fluid into the cell;

- an outlet defining an outlet bore contiguous with an outlet aperture, the outlet for releasing the gas from the cell; and

- at least one conductive plate defining a plate fluid inlet aperture that is in closed fluid communication with the inlet aperture and the outlet aperture, the conductive plate for receiving and transmitting an electrical current through the fluid to generate the gas; wherein the inlet aperture, the plate fluid inlet aperture, and the outlet aperture together form a passageway that extends into the inlet, through the plate, and out of the outlet.

2. The cell of claim 1, wherein the plate further comprises an exhaust aperture that is in fluid communication with the plate inlet fluid aperture and the outlet aperture.

3. The cell of claim 1 or 2, comprising at least one positive conductive plate and at least one negative conductive plate.

4. The cell of claim 3, wherein the positive conductive plate is made of titanium.

5. The cell of claim 4, wherein the titanium is 20 gauge titanium grade 2.

6. The cell of any one of claims 3 to 6, wherein the positive conductive plate comprises a platinum coating.

7. The cell of claim 6, wherein the platinum coating has a thickness of 1 μm.

8. The cell of any one of claims 3 to 7, wherein the negative conductive plate is made of nickel.

9. The cell of claim 8, wherein the nickel is 24 gauge nickel 200.

10. The cell of any one of claims 1 to 9, comprising about 2 to about 50 plates.

11. The cell of claim 10, comprising about 10 to about 12 plates.

12. The cell of claim 10, comprising about 20 to about 30 plates.

13. The cell of any one of claims 1 to 12, wherein the gas comprises hydrogen and the fluid comprises water with dissolved mineral salts.

14. A hybrid conversion kit comprising the cell of any one of claims 1 to 13 and an electronic control module in electrical communication with the cell.

15. The kit of claim 14, comprising at least one other component selected from the group consisting of: a reservoir; cell fluid; tubing; a wiring harness; an air inlet manifold valve; a check valve; a sensor; clamps; and instructions for use.

16. The kit of claim 15, comprising a reservoir, tubing, and a wiring harness.

17. A vehicle comprising the cell of any one of claims 1 to 13 or the kit of any one of claims 14 to 16.

18. A method of generating a gas from a fluid, comprising applying an electrical current to the cell of any one of claims 1 to 13.