HYDROGEN FUEL ASSIST DEVICE FOR AN INTERNAL COMBUSTION ENGINE AND RELATED METHODS

Abstract

A hydrogen fuel system for an internal combustion engine comprises a water reservoir and a fuel cell formed from a plurality of fuel cell stacks in fluid communication with the water reservoir. Each fuel cell stack includes at least one gasket disposed between two components of the fuel cell stack, the gasket including: a through hole formed therein for passage of hydrogen or oxygen through the gasket; and a plurality of channels formed in the gasket adjacent the through hole, each of the plurality of channels extending from an edge of the through hole to an edge of the gasket, the channels being sized and shaped to allow passage of hydrogen or oxygen to or from the through hole to or from the edge of the gasket.

Description

RELATED CASES

This application is related to U.S. patent application Ser. No. 12/263,076, filed Oct. 31, 2008, now issued as U.S. Pat. No. 8,186,315; and is related to U.S. Provisional Patent Application Ser. No. 61/001,564, filed Nov. 2, 2007, each of which is hereby incorporated herein by reference in its entirety.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to internal combustion engines and more particularly to hydrogen fuel additives for improving engine performance.

2. Related Art

Hydrogen can be beneficial as a secondary fuel that can be added to a primary fuel, such as gasoline or diesel fuel, for use in internal combustion engines. For example, hydrogen and oxygen, when mixed with the air/fuel mixture of the primary fuel of the engine can increase the performance of the engine by increasing the mileage and fuel economy of the vehicle with respect to the primary fuel. Additionally, hydrogen can also increase the horsepower output of the engine, and reduce the amount of undesirable emissions from the engine. Conveniently, hydrogen and oxygen can be generated through electrolysis of an aqueous solution with the hydrogen and oxygen given off being mixed with the fuel and air supplied to the engine.

Some electrolysis systems have been developed that produce hydrogen and oxygen specifically for use in internal combustion engines. Typically, these systems use electrolysis cells to separate water into hydrogen and oxygen and then draw off the hydrogen and oxygen for combination with the primary air/fuel mixture of the internal combustion engine. Unfortunately, these systems have inherent production and safety issues. For example, typical electrolysis cells usually produce far less hydrogen than is desired for injection into the air/fuel mixture in the engine. Additionally, typical electrolysis cells have a relatively short life span due to the corrosive effects of the aqueous solution in an electrically charged environment. Moreover, the hydrogen and oxygen produced by such electrolysis cells is difficult to separate. Consequently, the hydrogen and oxygen gasses are directed from the cell to the engine in a combined state which can be relatively volatile.

Another issue with typical hydrogen generation systems is that the electrolysis cells often operated in such systems can be run independently from the engine, such that the cell can continue to produce explosive hydrogen even when the engine is not running. Producing combustible or explosive hydrogen gas is not desirable if the engine is not running and using up the hydrogen gas as it is produced since the gas can accumulate, combust, or explode if not stored or disposed of properly.

SUMMARY OF THE INVENTION

In accordance with one aspect of the invention, a hydrogen fuel system for an internal combustion engine is provided, including a water reservoir and a fuel cell formed from a plurality of fuel cell stacks in fluid communication with the water reservoir. Each fuel cell stack can have at least one cathode, at least one anode and a proton exchange membrane for separating water from the water reservoir into hydrogen and oxygen when an electrical current is applied across the at least one cathode and at least one anode. Each fuel cell stack can include at least one gasket disposed between two components of the fuel cell stack. The gasket can include a through hole formed therein for passage of hydrogen or oxygen through the gasket, and a plurality of channels formed in the gasket adjacent the through hole, each of the plurality of channels extending from an edge of the through hole to an edge of the gasket, the channels being sized and shaped to allow passage of hydrogen or oxygen to or from the through hole to or from the edge of the gasket.

In accordance with another aspect of the invention, a hydrogen fuel system for an internal combustion engine is provided, including a water reservoir and a fuel cell formed from a plurality of fuel cell stacks in fluid communication with the water reservoir. Each fuel cell stack can have at least one cathode, at least one anode and a proton exchange membrane for separating water from the water reservoir into hydrogen and oxygen when an electrical current is applied across the at least one cathode and at least one anode. At least one separator can be in fluid communication with the fuel cell stacks, the separator being operable to separate a mixture of gas and liquid into gas and liquid components. The separator can include an outer housing with a float suspended therein, an inlet, operable to introduce the gas and liquid mixture into the outer housing, a gas outlet, operable to allow gas to exit the outer housing, and a liquid outlet, operable to allow liquid to exit the outer housing. The separator can be operable to maintain a sufficient level of the gas and liquid mixture within the outer housing to allow gas to separate from the gas and liquid mixture and exit from the outer housing.

The present invention also provides methods for implementing the various systems described herein, as well as methods for generating hydrogen, methods for separating oxygen and/or hydrogen from a liquid, etc.

Additional features and advantages of the invention will be apparent from the detailed description which follows, taken in conjunction with the accompanying drawings, which together illustrate, by way of example, features of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an exemplary schematic view of a hydrogen fuel system in accordance with an embodiment of the present invention, shown in a closed configuration;

FIG. 2 is a perspective view of a housing containing an embodiment of the hydrogen fuel system of FIG. 1, disposed in an engine compartment shown with hydrogen and oxygen lines extending from the housing to an engine gas interface;

FIG. 3 is a perspective view of the housing of FIG. 2, disposed in an engine compartment, shown with hydrogen and oxygen lines extending from the housing;

FIG. 4 is a top perspective view of the housing containing the hydrogen fuel system of FIG. 1, disposed in an engine compartment, shown with hydrogen and oxygen lines extending from the housing;

FIG. 5 is a top perspective view of housing containing the hydrogen fuel system of FIG. 1, disposed in an engine compartment, shown with a lid on the housing removed;

FIG. 6 is a perspective view of a fuel cell of the hydrogen fuel system of FIG. 1;

FIG. 7 is an exploded perspective view of the fuel cell of FIG. 6;

FIG. 8 is an exploded perspective view of one of a plurality of fuel cell stacks that together form the fuel cell of FIG. 6; and

FIG. 9 is an exploded side view of the fuel cell stack of FIG. 8;

FIG. 9B is a front view of a gasket in accordance with an embodiment of the invention;

FIG. 9C is a rear view of the gasket of FIG. 9B;

FIG. 9D is a sectional view of a portion of the gasket of FIG. 9B;

FIG. 9E is a magnified view of a portion of the gasket shown in FIG. 9D;

FIG. 10 is a perspective view of an engine gas interface of the hydrogen fuel system of FIG. 1;

FIG. 11 is a flow chart illustrating the logic of a computer controller of the hydrogen fuel system of FIG. 1;

FIG. 12 is a front view of an in-vehicle display of the hydrogen fuel system of FIG. 1;

FIG. 13 is a perspective view of a hydrogen fuel system in accordance with another embodiment of the present invention;

FIG. 14 is a top view of the hydrogen fuel system of FIG. 13; and

FIG. 14B is a sectioned view of a gas/liquid separator in accordance with an embodiment of the invention.

DETAILED DESCRIPTION

Reference will now be made to the exemplary embodiments illustrated in the drawings, and specific language will be used herein to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended. Alterations and further modifications of the inventive features illustrated herein, and additional applications of the principles of the inventions as illustrated herein, which would occur to one skilled in the relevant art and having possession of this disclosure, are to be considered within the scope of the invention.

The embodiments of the present invention described generally herein provide for a hydrogen fuel assist device that can generate hydrogen and oxygen that can be mixed with the air and primary fuel being used in an internal combustion engine in order to improve engine performance. The hydrogen system can include a fuel cell that can be formed by a plurality of fuel cell stacks that include at least one anode, cathode, and a proton exchange membrane (PEM). Water can be introduced into the fuel cell and drawn through each fuel cell stack where the PEM separates the water into hydrogen gas and oxygen gas. A hydrogen line can draw the hydrogen off the fuel cell stacks and a water line can draw off excess water and oxygen. An oxygen separator can receive the excess water and oxygen and can separate the water from the oxygen. The water can be returned to the fuel cell stack and an oxygen line can receive the oxygen. An engine gas interface (EGI) can receive the hydrogen and the oxygen from the hydrogen and oxygen lines. The EGI can inject the hydrogen and oxygen into an intake, such as the air box, manifold, carburetor, and the like, of the internal combustion engine. The hydrogen and oxygen can mix in the intake with the ambient air drawn into the intake. Fuel from the internal combustion engine's fuel tank can be added to the hydrogen, oxygen, and air mixture which can be burned in the engines combustion chambers to increase the performance of the engine.

As illustrated in FIGS. 1-5, a hydrogen fuel system, indicated generally at 10, is shown in accordance with an embodiment of the present invention for use in providing hydrogen and oxygen to an internal combustion engine, indicated generally at 6 (FIGS. 2, 4-5), as a secondary fuel source with respect to a primary fuel source such as gasoline or diesel fuel. In one aspect, the internal combustion chamber can be operatively associated with a motor vehicle 4 (FIG. 2). The hydrogen fuel system 10 can include a water reservoir 20, a fuel cell, indicated generally at 30, an oxygen line 50, a hydrogen line 70, an engine gas interface 80, and a vibration sensor 90.

The water reservoir 20 can be a container that can hold water, such as tap water, distilled water, or the like. In one aspect the water reservoir 20 can be a bottle. In another aspect, the water reservoir 20 can be a quadrangular container sized and shaped to fit within a battery storage area of an engine compartment of a vehicle. In yet another aspect, the water container 20 can hold approximately 1 liter of water and can be disposed in a box or housing containing the hydrogen fuel system 10 underneath the fuel cell 30. It will be appreciated that other sizes and shapes of water containers can be used so long as they fit and can be placed within an open space inside the engine compartment of the vehicle. A fill port 22 can be fluidly couple to the water reservoir 20 to fill the reservoir with water.

A water pump 24 can be coupled to the water reservoir 20. The water pump 24 can pump water from the reservoir to the fuel cell stack 30. The water pump 24 can have a pump controller 28 to selectively engage and disengage the water pump. The pump controller 28 can be an electronic device, such as a programmable microprocessor, that can respond to an electronic signal to engage or disengage the pump 24.

The fuel cell 30 can be in fluid communication with the water reservoir 20 and electrically coupled to an electrical power supply such as the battery of the internal combustion engine. For example, a water line 26 can extend from the water reservoir 20 to the fuel cell 30 and the pump 24 can pump water from the reservoir to the fuel cell through the water line. Additionally, electrical cables 102 can couple the fuel cell 30 to a battery (not shown) of the internal combustion engine 6. Thus, in use, water can be pumped from the water reservoir 20 by the water pump 24 into the fuel cell 30 which can electrolyze the water to separate the water into hydrogen and oxygen when an electrical current is applied to the fuel cell.

Referring to FIGS. 6-9, in one aspect, the fuel cell 30 can be formed by a plurality of fuel cell stacks, indicated generally at 150. The fuel cell 30 can have a cathode 32 and an anode 34 that are electrically coupled to an electricity source such as a vehicle battery (not shown). Additionally, each fuel cell stack 150 can have a cathode 132, an anode 134. The cathodes 132 and anodes 134 of each of the fuel cell stacks 150 can be electrically coupled to the cathode 32 and anode 34 that are coupled to the electricity source. For example, the cathode 32, anode 34, and fuel cell stacks 150 can be welded together to form the fuel cell 30 and the welds can provide a continuous electrical path from the fuel cell cathode 32 to the fuel cell anode 34.

A proton exchange membrane 36 can be disposed between each of the anodes 134 and the cathodes 132 of each of the fuel cell stacks 150. The proton exchange membrane 36 can separate water into hydrogen and oxygen when water is drawn through the proton exchange membrane 36 and an electrical current is applied across the proton exchange membrane. In one aspect, the proton exchange membrane 36 can include polyflouride ionomer material or resin that is coated with catalyst coating, such as platinum, that promotes electrolysis of the water molecule. Other materials known in the art, such as Nafion®, Polybenzimidazole (PBI), phosphoric acid, or the like, can also be used to form the proton exchange membrane 36. When water is separated into hydrogen and oxygen by the proton exchange membrane 36, substantially pure hydrogen collects on one side 36a (FIG. 9) of the proton exchange membrane 36 and oxygen collects on an opposite side 36b (FIG. 9) of the proton exchange membrane 36.

Gaskets, indicated generally at 38, can be disposed between the various parts of the fuel cell stack 150 in order to seal the fuel cell members together to form a water tight fuel cell. The gaskets 38 can be formed of a polycarbonate material.

Additionally, an end plate 40 and a supply plate 42 can be used to complete the fuel cell 30 and to direct fluid flow into, through, and out of the fuel cell 30. The end plate 40 and supply plate 42 can be formed of a composite material such as fiberglass.

The gaskets 38 can be configured to receive and direct the flow of hydrogen or oxygen from the proton exchange membrane 36 to a hydrogen path, indicated by dashed lines at 160 in FIGS. 7 and 8 or oxygen path 170. Thus, the gasket 38a on the side of the proton exchange member that generates the hydrogen can have at least one channel 162 that can receive the hydrogen generated by the PEM 36 and direct the hydrogen to a through hole 164 in the gasket 38a. The through hole 164 in the gasket 38a can be aligned with corresponding through holes in adjacent fuel cell stack components to form the hydrogen path 160 that extends throughout the fuel cell 30 and which allows hydrogen to travel from the fuel cell to a hydrogen outlet 166. The hydrogen outlet 166 can be fluidly coupled to the hydrogen line 70.

Similarly, the gasket 38b on the side of the proton exchange member 36 that generates the oxygen can have at least one channel 172 that can receive the oxygen generated by the PEM 36 and direct the oxygen to a through hole 174 in the gasket 38b. The through hole 174 in the gasket 38b can be aligned with corresponding through holes in adjacent fuel cell stack components to form the oxygen path 170 that extends throughout the fuel cell 30 and which allows oxygen and un-separated water to travel from the fuel cell to an oxygen outlet 176. The oxygen outlet 176 can be fluidly coupled to the oxygen line 50.

In one aspect, each fuel cell stack 150 can include several layers or screen stacks 46 that can form the anodes and cathodes. The screens 46 can filter and aid in separation of the water into hydrogen and oxygen. The screens 46 can include titanium or stainless steel members coated with noble metals such as gold, platinum, silver, and the like. The screens 46 can be welded together and each of the individual fuel cell stacks 150 can be welded together to form the fuel cell. The gaskets 38 can have an aperture 180 that can receive the screen stacks 46 such that the gasket can seal around the screens.

Each screen layer 46 can contribute to the electrical potential of the overall stack. For example, each layer can contribute approximately 2 volts to the overall voltage of the fuel cell stack 150. Additionally, the welds joining the fuel cell stacks 150 can facilitate the flow of electrical current throughout the fuel cell 30 and can provide a substantially continuous electrical pathway across the fuel cell.

In one embodiment, the fuel cell 30 can be a reversible hydrogen fuel cell. For example, as described above, each fuel cell stack 150 can include an anode 32 and a cathode 34 separated by a proton exchange membrane 36. When operating as a fuel cell, hydrogen can be introduced into the fuel cell stack 30 and drawn through the proton exchange membrane 36 where the hydrogen can combine with oxygen to produce water and electricity. The chemical reaction producing the water can generate the electricity that can be drawn off as an electrical current useful for powering electrical equipment. As noted above, each fuel cell stack 150 can produce approximately 2 volts, and the fuel cell 30 can have between about 6 and 7 layers in order to produce about 14 volts, thereby being compatible with the electrical system of a motorized vehicle, such as a car, truck and the like.

Additionally, the fuel cell stack 30 can also be operated in reverse in order to electrolyze water into hydrogen and oxygen, as discussed above. For example, water can be introduced into the fuel cell 30 and an electric current can be applied to the anode 32 and the cathode 34. When the electric current is applied, the water can be drawn through the proton exchange membrane 36 to separate the water into hydrogen and oxygen. Advantageously, because the fuel cell stack 30 has sufficient layers to be compatible with the electrical system of a motorized vehicle, the fuel cell stack can be electrically coupled to the electrical power source of the internal combustion engine 6, such as a battery or generator of the vehicle, and does not require an additional electrical power source.

FIGS. 9B through 9E illustrate another embodiment of a gasket 380 in accordance with an aspect of the invention. In this embodiment, the gasket includes a through hole 374 which can be aligned with corresponding through holes in adjacent fuel cell stack components to form an oxygen or hydrogen path that extends through the fuel cell. In this embodiment, a plurality of channels 372 (372a through 372e are shown by example) can be formed in the gasket adjacent the through hole. Each of these channels can extend from an edge of the through hole to an edge of the gasket (in the case shown, the edge of the gasket is the edge that abuts the aperture or “through space” 180). The channels can be sized and shaped to allow passage of hydrogen or oxygen to or from the through hole to or from the edge of the gasket. Thus, similar in function to the channels 162, 174 above, the channels 372 can allow oxygen, hydrogen, water, or mixtures thereof to flow from the center of a fuel cell stack to the path that extends through the fuel cell stack.

The channels 372 generally run perpendicularly to the through holes 374. Whereas the through holes extend through the fuel cells from one end of the cell to another, the channels extend from a through to another, laterally offset location that is not, generally, horizontally offset from the through hole.

The channels 372 in the embodiment shown are arranged in a triangular pattern, with an apex that terminates at the through hole 374. The present inventors have found that, by distributing the terminal locations of the channels along the edge of the gasket adjacent the aperture 180, much greater flow from the aperture to the through hole can be obtained. In addition, the plurality of channels provide redundancy, should one or more of the channels become blocked or otherwise unusable. Raised portions 376 can be formed between the channels to define or separate the channels one from another.

The plurality of channels utilized has been shown to dramatically increase membrane productivity (e.g., watts/cm²). They also increase seal performance, prevent deformation of the membrane, and control cell temperature, thereby increasing the viability of commercialization of the PEM technology.

It is noted that, typically, the surface illustrated in FIG. 9B (and 9C) will, when the fuel cell is assembled, be abutted against another gasket surface that can be, but is not necessarily, primarily flat. Thus, the raised portions (376 and 382, 384 discussed below, among others) shown in FIGS. 9B and 9C can be optimized to press against, and provide a secure seal with, a counterpart gasket component. FIGS. 9D and 9E illustrate one exemplary geometry of the raised portions. In this embodiment, the raised portion 382 is formed integrally with the gasket material. It includes a generally rounded profile having a diameter of approximately 0.015 inches. The rounded profile has been found to provide a good seal against a counterpart, flat gasket material (counterpart gasket not shown), particularly when the adjacent gaskets are pressed together in a fuel cell arrangement. In some aspects, the raised portions will be formed in a generally elongate bead that extends across the gasket (FIGS. 9D and 9E being a cross sectional view of that longitudinal bead).

While not so required, in one embodiment, the gasket can include a supplemental raised portion 384 that can be formed atop the at least one raised portion 382. The supplemental raised portion can also include a substantially rounded cross section that is smaller in width than is the rounded cross section of the raised portion (in one example, the supplemental raised portion includes a diameter of about 0.007 inches). In the embodiment shown, the raised portion and the supplemental raised portion are substantially collinear: that is, the supplemental raised portion is positioned directly atop the raised portion.

Returning to FIGS. 1-5, the oxygen line 50 can be fluidly coupled to the fuel cell 30 and can receive and transport oxygen away from the oxygen outlet 176 of the fuel cell. The oxygen line 50 can be formed from a hollow tube, pipes, channels, and the like. In on aspect, the oxygen generated by the fuel cell 30 can be mixed with excess water from the electrolysis process such that oxygenated water, or water having excess oxygen, is produced. In this case, the oxygen line 50 can feed into an oxygen separator 52 that can separate the oxygen from the water. The water can then be returned to the reservoir 20 or fuel cell stack 30 for further electrolysis, and the oxygen can be directed to the engine gas interface 80.

Similarly, the hydrogen line 70 can also be fluidly coupled to the fuel cell 30 to receive hydrogen from the hydrogen outlet 166, and transport hydrogen away from the fuel cell 30. The hydrogen line 70 can be formed from a hollow tube, pipes, channels, and the like.

Referring to FIGS. 1-2 and 10, the engine gas interface 80 can be fluidly coupled to the oxygen line 50 and the hydrogen line 70 and can receive hydrogen and oxygen from the hydrogen and oxygen lines. The engine gas interface 80 can also be operatively coupled to an engine intake 8 such as an air box, manifold, carburetor, fuel injector, and the like. The engine gas interface 80 can operate to receive hydrogen from the hydrogen line 70 and the oxygen from the oxygen line 50 and introduce the hydrogen and oxygen into the engine intake 8. The hydrogen and oxygen can mix with the air and fuel mixture in the intake 8 prior to entering a piston combustion chamber of the internal combustion engine 6.

It is a particular advantage of the present invention that the oxygen and the hydrogen are substantially pure and kept separated from one another until being mixed in the engine intake 8 just prior to combustion in the engine 6. It will be appreciated that pure hydrogen is less combustible or explosive when not in the presence of oxygen. Thus, the hydrogen system of the present invention minimizes the risk of inadvertent combustion or explosion of the hydrogen by keeping the hydrogen and oxygen separated until just prior to use.

The vibration sensor 90 can be operatively coupled to the internal combustion engine. For example, in one embodiment the vibration sensor can be coupled to the engine gas interface 70. In this way, when the engine gas interface 70 is placed on the engine intake 8, the engine gas interface 70 will receive vibrations from the engine 6 when the engine is running, and the vibrations in the engine gas interface 70 will be detected by the vibration sensor 90.

In one aspect, the vibration sensor 90 can be an accelerometer that can detect vibration of the internal combustion engine 6 when the engine is running The vibration sensor 90 can operate to deactivate the fuel cell stack 30 when the sensor does not detect vibration from the engine, such as when the engine is not running.

A controller 100 can be operatively coupled to the fuel cell stack 30 and the vibration sensor 90 to activate the fuel cell stack. The controller 100 can include hardware, firmware, and/or software that can be programmed to allow activation of the fuel cell 30 when the vibration sensor detects vibration of the engine, and prevent activation of the fuel cell 30 when the vibration sensor 90 does not detect vibration from the engine 6.

In one aspect, the controller 100 can be an electronic, programmable device such as a computer, microcomputer, EPROM, integrated circuit board, and the like, that can have a program that can follow the logic illustrated in the flow chart shown in FIG. 11. Thus, the hardware, firmware and/or software of the controller 100 can receive input from the vibration sensor 90 and activate the fuel cell 30 to separate water into hydrogen and oxygen when the vibration sensor detects vibration from the engine 6. Similarly, the controller 90 can deactivate the fuel cell stack 30 when the vibration sensor 90 does not detect vibration from the engine 6. In this way, the hydrogen system 10 of the present invention advantageously minimizes the risk of inadvertent combustion or explosion of hydrogen because the fuel cell stack supplies hydrogen only on demand from the controller and does not store hydrogen or produce hydrogen when the engine is not running.

Additionally, the controller 100 can be coupled to other sensors to detect and monitor the status of other components of the hydrogen fuel system 10. For example, the controller 100 can monitor the water level of the water reservoir 20 and the temperature of the water reservoir and the fuel cell 30 in order to prevent damage to the fuel cell 30 or fuel cell components from freezing.

Returning again to FIGS. 1-5, the hydrogen fuel system 10 can also include an impact sensor 94. In one aspect, the impact sensor 94 can be an accelerometer that can be operatively coupled to the fuel cell 30. The impact sensor 94 can be coupled to the vibration sensor 90. The impact sensor 94 can detect an impact to the vehicle and deactivate the fuel cell 30 if an impact is detected in order to prevent the production of hydrogen in a vehicle that has been disabled by a collision.

Drain valves 60 can be fluidly coupled to drain the water, oxygen and hydrogen from the fuel cell stack 30 and the hydrogen line 70 and the oxygen line 50. For example, the drain valves 60 can be solenoid valves coupled to the controller 100 such that the controller can activate the solenoid valves to drain system when selected by the user or when adverse operating conditions are detected by the sensors coupled to the controller. The drain valves 60 can also include check valves to reduce backflow of hydrogen or oxygen into the fuel cell 30.

It is another particular advantage of the hydrogen fuel system described herein that the fuel cell 30, the water pump 24, the oxygen separator 52, the controller 100, and the water reservoir 20 can be housed together in a single housing as a turn-key or off the shelf unit. In one aspect, the fuel cell 30, the pump 24, the oxygen separator 52, the controller 100, and the water reservoir 20 can be contained in a housing 12 sized and shaped to fit within a space the size of an automotive battery. In another aspect, the water reservoir 20 and fuel cell 30 can be disposed in a common housing 12 with the water reservoir 20 occupying a lower portion of the housing 12 and the fuel cell 30 disposed on top of the water reservoir 20.

The housing 12 can have an insulation layer 16 (FIG. 5). The insulation layer 16 can help to maintain an above freezing temperature of the fuel cell to reduce the likelihood of damage to the fuel cell due to freezing.

Additionally, the housing 12 can have a lid 14. The lid 14 can also have means for insulating the fuel cell 30. For example, in one aspect the lid 14 can have an insulative blanket to trap and retain heat. In another aspect, the lid 14 can include liquid antifreeze that can maintain a relatively constant temperature.

As shown in FIG. 12, the hydrogen fuel system 10 can also include an in-vehicle display 110. The in-vehicle display 110 can be operatively coupled to the controller 100. The in-vehicle display can indicate the operational status of the fuel cell 30 to operators positioned in the vehicle. In one aspect, the in-vehicle display 110 can indicate the acceptable status of the water level of the reservoir, vibration of the engine, and a temperature of the fuel cell. For example, the in-vehicle display 110 can include LED indicators 112 that can light green for an acceptable status and red for an unacceptable status. Additionally, in another aspect, the in-vehicle display 110 can be a wireless display that can receive and display information transmitted from the controller 100.

In use, a user can enter the cab of a vehicle and start the internal combustion engine of a vehicle. The user can then activate the in-vehicle display. The in-vehicle display can register the status of the water reservoir, the temperature of the fuel cell, and vibration from the engine. If the water reservoir is too low, the temperature of the fuel cell is too low, or vibration from the engine is not detected, the controller can prevent the activation of the fuel cell. If the status of the water reservoir, the temperature of the fuel cell and the vibration from the engine are all acceptable, the user can then activate the fuel cell stack. The pump can then pump water from the water reservoir into the fuel cell stack. An electric current can be applied to the anode and cathode of the fuel cell stack and the water being drawn through the PEM of the fuel cell stack can be separated into hydrogen and oxygen. The hydrogen can enter the hydrogen line and the oxygen along with excess water can enter the oxygen line. The water and oxygen can enter an oxygen separator that can separate the oxygen from the water. The oxygen can reenter the oxygen line and the water can be sent back to the fuel cell stack for further electrolysis. The hydrogen and oxygen can then travel through the hydrogen and oxygen lines to the engine gas interface. The engine gas interface can be coupled to an engine intake and can inject the hydrogen and engine gas intake into the air/fuel mixture of air drawn into the intake through the air filter and the fuel from the fuel tank of the vehicle. The hydrogen and oxygen can mix with the air/fuel mixture and can then enter the chamber of a piston of the engine. The piston can be fired to combust the air/fuel-hydrogen/oxygen mixture. In this way, the hydrogen fuel system can add hydrogen as a secondary fuel to the primary fuel of the vehicle, thereby advantageously increasing the performance of the internal combustion engine.

As illustrated in FIGS. 13-14, a hydrogen fuel system, indicated generally at 300, is shown in accordance with another embodiment of the present invention for use in providing hydrogen and oxygen to an internal combustion engine as a secondary fuel source with respect to a primary fuel source such as gasoline or diesel fuel. The fuel system 300 can be similar in many respects to the hydrogen fuel system 10 described above and shown in FIGS. 1-11. The hydrogen fuel system 300 can include a water reservoir 20, a pair of fuel cells 30, indicated generally at 330, pair of oxygen separators 52, a water pump 24 and a controller 100.

FIG. 14B illustrates one exemplary separator 520 that can be used to separate gas from a gas-liquid mixture. In this embodiment, the separator can include an outer housing 500 that includes a float 502 suspended therein. The float is allowed to move upwardly and downwardly, and has a buoyancy designed to maintain an optimum level of liquid within the separator. An inlet 504 can be operable to introduce the gas and liquid mixture into the outer housing. A gas outlet 506 can be operable to allow gas to exit the outer housing. A liquid outlet 508 can be operable to allow liquid to exit the outer housing.

During use, in the absence of sufficient liquid, the float 502 will fall (due to the force of gravity) to the bottom of the housing 500 such that any liquid entering the housing will be restricted from exiting through the liquid outlet 508. As a sufficient amount of liquid enters the housing, the float will be raised from its lowermost position, and some liquid will be allowed to exit the outlet 508. As the gas-liquid mixture remains in the housing, gas will separate from the mixture (and, under optimal conditions, leave only the liquid behind) and is allowed to exit upwardly from the housing through the gas outlet 506. By maintaining a sufficient amount of liquid (or liquid-gas mixture) within the housing, the process has sufficient time to allow for the separation of gas from the liquid (or the liquid-gas mixture). If the level of fluid in the housing decreases too much, the float will stop the flow of liquid from the liquid outlet 508, causing the housing to fill again with liquid-gas mixture.

The float 502 can be attached to, or formed integrally with, an upper post 510 and a lower post 512. Each post is held within a respective post guide 514, 516. In this manner, the float is restricted from lateral movement, but is allowed to freely move vertically upwardly and downwardly. The float includes a seat 519, and a corresponding seal 517 is formed in or adjacent the lower post guide 516. Thus, as the float lowers downwardly, the seat fits snugly against the seal to prevent liquid from exiting the housing. The lower post 512 can include two or more differing diameters, to allow differing rates of liquid flow from the housing. In the position shown in FIG. 14B, a larger diameter portion of the lower post is positioned in the seat 517. As the float rises upwardly, however, a lesser diameter portion of the lower post fills the seat throat, which allows liquid to flow from the housing at a higher rate.

The housing 500 can include a liquid barrier 522 that can serve to prevent or limit liquid from exiting the gas outlet 506. In the embodiment shown, the barrier comprises a generally circular plate within the outer housing. The plate includes an outer diameter 524 that is slightly less than an inner diameter 526 of the housing. In this manner, a gap 528 is created between the plate and the housing wall. The gap prevents most, if not all, liquid from splashing or otherwise passing beyond (e.g., above) the plate to ensure that only gas is exiting the housing via outlet 506. In addition to the configuration shown, the liquid barrier can also comprise a hole (not shown) formed in the plate 522, which allows gas to pass therethrough. So long as the hole is positioned through the plate in an area that is not vertically aligned with (e.g., that is vertically offset from) the outlet port 506, nearly all liquid will be prevented from exiting via the outlet port.

It will be appreciated that the concepts of the present invention can be used with any internal combustion engine that has an electrical power source such as a battery. Accordingly, the hydrogen fuel system 300 can be used with larger automotive vehicles such as semi tractor trailers and the like. Advantageously, the hydrogen fuel system 300 has a pair of fuel cells 30, which can produce more hydrogen for engines with larger displacement.

The present invention also provides for a method for providing hydrogen fuel to vehicle having an internal combustion engine including adding water from a water reservoir to a fuel cell stack positioned in an engine compartment of the vehicle. An electric current from an electricity source of the internal combustion engine can be provided to the fuel cell stack to separate the water into hydrogen and oxygen. Hydrogen from the fuel cell stack can be delivered to an engine gas interface coupled to an intake of the internal combustion engine. The engine gas interface can have a vibration sensor configured to deactivate the fuel cell stack when the vibration sensor does not detect vibration from the engine. The hydrogen can be injected into the intake of the engine to mix the hydrogen with a air and a primary fuel of the engine prior to combustion of the primary fuel in a piston of the engine.

The present invention also provides for a method for retrofitting an internal combustion engine of a vehicle with a hydrogen fuel assist system including securing a fuel cell stack within an engine compartment of the vehicle. The fuel cell stack can separate water into hydrogen and oxygen. A water reservoir can be coupled to the fuel cell stack to provide water to the fuel cell stack. An engine gas interface can be coupled to an intake of the engine. The engine gas interface can have a vibration sensor configured to deactivate the fuel cell stack when the vibration sensor does not detect vibration from the engine. A hydrogen line can be extended between the fuel cell stack and the engine gas interface to provide hydrogen from the fuel cell stack to the intake of the engine. The hydrogen can mix in the engine intake with air and fuel from a fuel tank of the engine prior to combustion in a piston of the engine.

It is to be understood that the above-referenced arrangements are only illustrative of the application for the principles of the present invention. Numerous modifications and alternative arrangements can be devised without departing from the spirit and scope of the present invention. While the present invention has been shown in the drawings and fully described above with particularity and detail in connection with what is presently deemed to be the most practical and preferred embodiment(s) of the invention, it will be apparent to those of ordinary skill in the art that numerous modifications can be made without departing from the principles and concepts of the invention as set forth herein.

Claims

1. A hydrogen fuel system for an internal combustion engine, comprising:

a water reservoir;

a fuel cell formed from a plurality of fuel cell stacks in fluid communication with the water reservoir, each fuel cell stack having at least one cathode, at least one anode and a proton exchange membrane for separating water from the water reservoir into hydrogen and oxygen when an electrical current is applied across the at least one cathode and at least one anode;

each fuel cell stack including at least one gasket disposed between two components of the fuel cell stack, the gasket including: a through hole formed therein for passage of hydrogen or oxygen through the gasket; and a plurality of channels formed in the gasket adjacent the through hole, each of the plurality of channels extending from an edge of the through hole to an edge of the gasket, the channels being sized and shaped to allow passage of hydrogen or oxygen to or from the through hole to or from the edge of the gasket.

2. The system of claim 1, wherein the gasket includes at least one raised portion attached to or formed thereon, the raised portions operable to create a seal with an adjacent gasket.

3. The system of claim 2, wherein the at least one raised portion comprises an elongate bead formed across the gasket, the elongate bead having a substantially rounded cross section.

4. The system of claim 3, further comprising a supplemental raised portion, formed atop the at least one raised portion, the supplemental raised portion having a substantially rounded cross section that is smaller in width than is the rounded cross section of the at least one raised portion.

5. The system of claim 4, wherein the at least one raised portion and the supplemental raised portion are substantially collinear.

6. The system of claim 1, wherein the plurality of channels define an array of channels arranged in a triangular pattern, with an apex of the triangle terminating at the through hole.

7. The system of claim 1, wherein the gasket includes an outer perimeter and an inner through space, and wherein each of the plurality of channels extends from a through hole formed in the outer perimeter to the through space defined within the outer perimeter.

8. The system of claim 1, wherein each fuel cell stack further includes:

a first and second stack of screens;

a proton exchange member disposed between the first and second stack of screens and having a first side and second side;

a first gasket disposed between the first stack of screens and the first side of the proton exchange member; and

a second gasket disposed between the second stack of screens and the second side of the proton exchange member.

9. The system of claim 1, further comprising a separator, in fluid communication with the fuel cell stacks, the separator being operable to separate a mixture of gas and liquid into gas and liquid components, the separator including an outer housing within which a float is suspended, the float operable to allow a sufficient amount of the gas and liquid mixture to be maintained in the outer housing to allow gas to separate from the gas and liquid mixture and exit the outer housing.

10. The system of claim 9, wherein the float includes an upper post and a lower post, each post being held within a post guide to restrict movement of the float laterally while allowing movement of the float upwardly and downwardly.

11. A hydrogen fuel system for an internal combustion engine, comprising:

a water reservoir;

a fuel cell formed from a plurality of fuel cell stacks in fluid communication with the water reservoir, each fuel cell stack having at least one cathode, at least one anode and a proton exchange membrane for separating water from the water reservoir into hydrogen and oxygen when an electrical current is applied across the at least one cathode and at least one anode; and

at least one separator, in fluid communication with the fuel cell stacks, the separator being operable to separate a mixture of gas and liquid into gas and liquid components, the separator comprising:

an outer housing with a float suspended therein;

an inlet, operable to introduce the gas and liquid mixture into the outer housing;

a gas outlet, operable to allow gas to exit the outer housing; and

a liquid outlet, operable to allow liquid to exit the outer housing;

the separator being operable to maintain a sufficient level of the gas and liquid mixture within the outer housing to allow gas to separate from the gas and liquid mixture and exit from the outer housing.

12. The system of claim 11, wherein the float includes an upper post and a lower post, each post being held within a post guide to restrict movement of the float laterally while allowing movement of the float upwardly and downwardly.

13. The system of claim 11, further comprising a liquid barrier disposed within the outer housing, the liquid barrier operable to allow gas to exit upwardly past the liquid barrier while restricting liquid from passing the liquid barrier.

14. The system of claim 13, further comprising at least one opening defined in or adjacent the liquid barrier, the at least one opening allowing the passage of material from the float section beneath the liquid barrier to the area above the liquid barrier.

15. The system of claim 14, wherein the opening is a gap formed between an outer diameter of the liquid barrier and an inner diameter of the outer housing, the gap allowing gas to pass beyond the liquid barrier but restricting liquid from passing beyond the liquid barrier.

16. The system of claim 14, wherein the gas outlet is positioned above the liquid barrier in a location vertically offset from the opening formed in or adjacent the liquid barrier.

17. The system of claim 11, further comprising a seat, coupled to or forming a part of the lower post, the seat being operable to prevent liquid from exiting the outer housing unless a sufficient amount of liquid is present within the outer housing.

18. The system of claim 17, wherein the seat is affixed to the float to be thereby moveable with the float to allow liquid to flow from the outer housing when a sufficient level of liquid is present within the outer housing.

19. The system of claim 11, wherein each fuel cell stack includes at least one gasket disposed between two components of the fuel cell stack, the gasket including:

a through hole formed therein for passage of hydrogen or oxygen through the gasket; and

a plurality of channels formed in the gasket adjacent the through hole, each of the plurality of channels extending from an edge of the through hole to an edge of the gasket, the channels being sized and shaped to allow passage of hydrogen or oxygen to or from the through hole to or from the edge of the gasket.

20. The system of claim 19, wherein the plurality of channels define an array of channels arranged in a triangular pattern, with an apex of the triangle terminating at the through hole.