EP2171249A1 - Hydrogen and oxygen gases, produced on-demand by electrolysis, as a partial hybrid fuel source for internal combustion engines - Google Patents

Abstract

A process encompassing hydrogen and oxygen gases as a partial fuel source when utilized together with a fossil-based fuel to power conventional internal combustion engines. Hydrogen and oxygen gases are produced by electrolysis in an electrolyser unit(s), on-demand and on-board a vehicle, or in stationary applications, eliminating the need of highly-pressurized hydrogen storage tanks. When said gases are introduced into the combustion chamber of the engine, via the air intake assembly, they increase the efficiency of the combustion burn by enriching the air to fuel ratio, resulting in a reduction of the fossil-based fuels required for optimum engine performance, said gases effectively becoming a partial hybrid fuel source. The process includes scalability for all size and types of installations, cold-weather applications and longer operating capabilities. As an additional benefit, in direct correlation, this process reduces carbon dioxide emissions, and, in varying quantities, other greenhouse gas emissions.

Description

TITLE OF THE INVENTION

HYDROGEN AND OXYGEN GASES, PRODUCED ON-DEMAND BY ELECTROLYSIS, AS A PARTIAL HYBRID FUEL SOURCE FOR INTERNAL COMBUSTION ENGINES

PREFERRED EMBODIMENT, SPECIFICATIONS AND DETAILED DESCRIPTION

Said process consisting of the following

(a) The process for producing hydrogen and oxygen gases as a partial fuel source for internal combustion engines, further including one or multiple electrolyser units according to claim #12 , arranged in tandem, and electrically connected in parallel or in series when more than one unit is required for optimum engine operation Said containment modules (electrolyser unit/units) constructed of specific non-metallic plastic compounds or tempered glass in pre-determined shapes (cylindrical or geometric) (Figures 5A, 5B, 5C, 5D1, 5D2) and "scaled to size" as warranted by the end use and more specifically including plastics made of Polypropylene, Kraylon plastic, ABS plastic, polyvinyl chloride (PVC), ultra high density weight (UHMWPE) polyethylene, ultra high density polypropylene (UHDPP), but not excluding any other type of plastic or glass-based products suitable for said containment modules Said containment modules may be manufactured to specifications by an injection-mould operation or by an extrusion process, obtained as commercially available modules, and where necessary, said hydrolyser modules may be further constructed, for certain applications, in specially engineered modules made of Polypropylene (UHMW-PP) "sheeting", in a variety of thicknesses, parts cut to specifications and assembled by a plastic welding operation to required sizes, specifications, installation limitations, thickness limitations, as well as internal plate assembly limitations, or any other pertinent criteria Said process also includes UHMW (ultra high molecular weight) Polyethylene or Polypropylene plastic pre-engmeered by a mechanical cavity extraction process where blocks or cylinders are used and when special applications are warranted, furthermore, said process shall not exclude any other type of plastic compounds, glass based compounds, or suitable metallic composites as may be needed to meet specific end-use requirements

(b) The process for producing hydrogen and oxygen gases as a partial fuel source for internal combustion engines according to claim #13 further including the internal components of said hydrolyser units consisting of two or more flat, solid or perforated, non-magnetic stainless steel plates (as shown in Figures 1OA, 1OB, 1OC, 1OD, 10D1, 1OE, 10E1, 10E2) including different types of stainless steel, and more specifically, types SS304, SS306, SS310, SS314, and SS316, including variable gauges such as 16 or 18 gauge and up to and including 24 gauge where necessary, but not excluding any other gauge sizes or conductive materials as may be required, and furthermore, all of which is determined by the size of the units required for specific installations including the necessary shape and sizing of said plates as required so as to fit inside said containment modules or hydrolyser unit/units according to claim #12 (Figures 5A₁ 5B, 5C, 5D1, 5D2) Said plates form the basis of the internal plate assemblies required for the production of said gases and said plate assemblies constructed in variable sizes and variable number of plates so as to optimize said hydrogen and oxygen gas production within the size limitations, containment module limitations, amount of gas required, amount of electrical input, all of which is required for optimum operation of the engine Said plates separated by plastic-based spacers, bolts, nuts, washers and lock washers, preferably made of certain compounds such as nylon, polyethylene, polypropylene or UHMW but not excluding any other suitable plastic compounds having a neutral and inert reaction to said hydrolytic solution composed of a pre-determined mixture of potassium hydroxide and distilled or demineralised water but not excluding any other chemicals acting as hydrolytic agents necessary for the process of electrolysis and which include but are not limited to such other hydrolytic agents such as sodium hydroxide, sodium bicarbonate, sodium carbonate, sodium citrate as examples of alternative hydrolytic substances that may be used as a hydrolytic agent Said plates set at a distance between the plates ideally at 9525 centimetres (3/8 inch) (Figure 10B) but not excluding any other suitable spacing, from 3175 centimetres (1/8 inch) to a range of up to 5 08 centimetres (2" inches), that may be required for optimum electrolyser performance, without preset spacing restrictions and as such, said spacing as may be necessitated by the size of the electrolyser units and the level of hydrogen/oxygen gas output required for optimum engine performance The plate assembly is constructed in such a way so as to create cells and install said cell assemblies in such a manner as to allow said hydrolytic solution to freely flow through said containment modules and be able to completely cover the said plate assembly The metallic internal components connecting the necessary plates for an electrical current to pass are made of SS304 or 18 8 stainless steel and include eye bolts, various type and sizes of bolts, nuts, washers, lock washers and stainless steel rods where necessary Said stainless steel components vary in size depending on the required size of the electrolyser units Said stainless steel components create an electrical contact between the plates in the plate assembly, and are used as the electrical input posts, for the anode and cathode connections, so as to allow DC electric current to flow through said plates activating the electrolysis process Internal components also include non-reactive (to the hydrolytic solution) neoprene or vulcanized rubber washers, and said rubberized components may include Hypolon rubber, in the required composition and hardness (dura), and in sizes suitable to seal all openings in the containment module/modules so as to create an internally airtight containment module Said containment modules or hydrolyser unit/units contain a pre-determined level of an electrolytic solution as described above and further detailed, such as a mixture of water (steam distilled water preferable) and potassium hydroxide (KOH) in a pre-measured concentration of between a half percent concentrate .5% to a 60% concentration of hydrolytic solution level so as to produce an optimum amount of said gases and for maximum efficiency in the operation of the unit/units but not excluding the use of any other type of electrolytic solution such as de-iodinated sodium or a mixture of crystallized sodium bicarbonate when used in warm-weather climates In certain applications, multiple internal plate assemblies (for example, two or more plate assemblies which may consist of a minimum of 2 or more individual plates - possibly six (6) plates per plate assembly as shown in Figure 10E or eight (8) plates per plate assembly as shown in Figures 1OA and 1OB ) are installed in a single containment module Said plate assemblies, with multiples of two plate assemblies (Figure 10E2) to four plate assemblies (Figure 10E1) and additional assemblies, if required, are installed in a single containment module (Figure 10E) so as to maximize space, size, hydrolytic solution, electrical input or any other restrictions necessary for optimum efficiency In certain applications, such as in cold-weather climates, the electrolytic solution must have a much lower freezing temperature than water, allowing operations of the electrolyser units to operate in sub-zero ( 0 degrees Centigrade / 32 degrees Fahrenheit and up to minus -50 degrees C / minus -70 degrees F ) temperatures Sufficient electrolytic solution is maintained at all times so as to completely cover the stainless steel plates ( as shown in Figures 10D and 10D1 as examples and applicable in all versions of said hydrolyser units) so as to maintain a maximum, controlled and constant flow of said gases for optimal efficiency or, at a very minimum for partial efficiency covering at least one half of the plate surfaces to maintain a partial efficiency in the operations of the hydrolyser unit/units, should hydrolytic solution not be maintained above the plates Said process includes commercially available mechanical or digital float switches as well as valves and fittings in various formats required for gas delivery, water refill entry and exit points, pressure release valves at pre-determined PSI (pounds per square inch) settings, check valves and, in certain applications rupture discs All such valves and settings compatible with the electrolytic solution where necessary Also included in the process are the required tubing and conduits, correctly sized electrical wiring in conjunction with said electrical source according to claim # 5 and for power supply packs according to claim # 6, as well as commercially available warning lights, ammeters, voltage meters, electrical connectors, water level indicator gauges or sight glasses, and thermometers where applicable Furthermore, said process includes or may include a mam container casing custom made to allow all of the major components of said electrolysis process to fit into its interior or be attached to it, and may include, but not be limited to 1) a two-piece custom made, weather resistant box made of stainless steel, diamond plate steel or aluminum, 2) a modified commercially available cylindrical or square shaped steel gas tank specially modified with cut-out access panels or 3) by a custom made container casing specifically constructed for said process, allowing installation of all or most components of said complete process on the frame of Class 8 tractor trailer cabs for example, further including 4) a cylindrical stainless steel container casing similar to commercially available air filter truck casings but custom made specifically for said process, and further including 5) a custom built battery-type tray with a cover with snap closures similar to commercially available battery boxes used on semi trailer trucks ( c ) The process for producing hydrogen and oxygen gases as a partial fuel source for internal combustion engines further including a process to refill said hydrolyser unit/units from a separate and independent water-filled reservoir according to claim 1 Said independent, custom-made water-filled reservoir specially constructed of a high-heat resistant plastic such as polypropylene or polycarbonate, but not excluding other high-heat resistant plastic compounds, or, in a metal composite such as stainless steel but not excluding other heat-resistant metal (Figures 1A, 2B, 2B1, 2B2, 2B3) Furthermore, said reservoir is custom made in a double-walled construction with an inner-foam insulation between the walls for use in installations in cold-weather climates, using a high-heat resistant plastic compound or metal composite for the walls Said double-walled reservoirs capable of withstanding an inflow of constant highly-heated liquid (anti-freeze solution or coolant) as required according to claim # 2 that is heated to approximately 85 degrees Centigrade (200 degrees Fahrenheit) and to withstand extreme cold temperatures reaching minus -50 below zero centigrade temperatures so as to withstand the freezing of said water stored inside said reservoirs for cold-weather applications without damage to said reservoir Said process according to claim # 1 further including a custom manufactured reservoir in a single-walled construction with no added insulation using a suitable plastic compound or metal composite as described above for use in warm-weather climates which is not required for extreme heat or extreme cold applications Said reservoirs custom constructed so as to fit within size and shape limitations and to accommodate the water volume requirements for the complete process in specific applications

Said reservoirs further include one of the following configurations dependent on installation and size limitations

(c-i) a separate and independent central pre-filled water reservoir (Figures 1A 2B) according to claim 1 , together with a holding unit (Figure 1A), and preferably with steam distilled water, but not excluding de-mineralized water or tap water, and when such installation allows for said reservoir to be placed at a higher level than the electrolyser unit/units, allowing the water to flow downwards by gravity force through a feeder tube or multiple tubes via a parallel system into a single hydrolyser or multiple hydrolyser units dependent on the end use of said process Said process used in warm-weather climates while in cold- weather climates, this reservoir heated through a conductive and / or convective heat transfer system according to claim 2 (Figures 2B2, 2B3, 3A&3B ), this process further including a water level control via a special valve (collectively shown in Figures 4A-1A / 4A 1B / 4A2 / 4A3) according to claim #3 but not excluding, as a secondary function, the use of commercially available mechanical or digital, vertical or horizontal float switches together with an electrically activated solenoid switch to regulate the water levels in said hydrolyser unit/units as may be applicable for certain installations Said special valve according to claim # 3 automatically maintains the proper level of hydrolytic solution as water is released into said hydrolyser unit /units from said central reservoir, when float section of said valve is mechanically activated as said hydrolytic solution level lowers during the process of electrolysis is actively functioning As the process of electrolysis slowly causes the level of said hydrolytic solution to lower, refilling of said hydrolyser unit / units is equally and automatically maintained and controlled by said special valve

(C-Ii - a ) a separate and independent pre-filled water reservoir (Figure 1A, 2B) according to claim #1 , preferably with steam distilled water, but not excluding de-mineralized water or tap water if necessary, that, when installation does not allow said reservoir to be placed at a higher level than the electrolyser unit/units and whereby a gravity feed cannot be applied and when cold-weather climates are not instrumental in the efficient functioning of said refill system, the process will allow the water to flow into the electrolyser unit/units through one or more delivery conduits, this process utilizing a pump apparatus installed in a suitable position between said reservoir and said hydrolyser unit/units, so as to allow the flow of water, when said pump is manually activated by the user with an on / off switch and as determined by a water level warning light, warning gauge or sight glass as to when level of said hydrolytic solution is low and a quantity of new water must be introduced to refill said hydrolyser unit/units This process used in warm-weather climates while in cold-weather climates, said reservoir will be heated through a conductive and / or convective heat transfer system according to claim 2 and this process further including a water level control via the special valve according to claim # 3, preset at a maximum water fill level in said hydrolyser unit/units, but not excluding the use of commercially available mechanical or digital float switch, in a horizontal or vertical format, so as to regulate the water levels in said hydrolyser unit/units

(c-ii - b ) a separate and independent pre-filled water reservoir (Figure 1A, 2B) according to claim 1 , preferably with steam distilled water, but not excluding de-mineralized water or tap water if necessary, that, when installation does not allow said reservoir to be placed at a higher level than the electrolyser unit/units and whereby a gravity feed cannot be applied and when cold-weather climates are not instrumental in the efficient functioning of said refill system, the process will allow the water to flow into the electrolyser unit/units through one or more delivery conduits, this process utilizing a pump apparatus installed in a position between the exit point of said reservoir and said hydrolyser unit/units so as to allow the flow of distilled or de-mineralized water, when said pump is activated automatically when said hydrolytic solution level inside the hydrolyser unit/units drops to a pre-determined level as indicated by a compatible (to said hydrolytic solution) and commercially available, mechanical or digital float switch/switches, mounted inside said hydrolyser unit/units in either a horizontal or vertical position, sending an electronic signal, further automatically activating said pump, with power from a battery source, whereby said pump when activated will allow said water to be released from the central pre-filled water reservoir so as to maintain a pre-determined hydrolytic solution level in the hydrolyser unit/units This process used in warm-weather climates while in cold-weather climates, this reservoir will be heated through a conductive and / or convective heat transfer system according to claim # 2

(C-M - c ) a separate and independent pre-filled water reservoir (Figure 1A, 2B) according to claim # 1 , preferably with steam distilled water, but not excluding de-mineralized water or tap water if necessary that, when installation does not allow said reservoir to be placed at a higher level than the electrolyser unit/units and where a gravity feed cannot be applied and when cold-weather climates are not instrumental in the efficient functioning of said refill system, the process will allow the distilled or de-mineralized water to flow into the electrolyser unit/units through one or more delivery conduits, this process utilizing a solenoid valve, set in the closed position until activated, to open by an electronic signal sent from pre-positioned float switche/s, said solenoid valve installed in a position between said central reservoir according to claim 1 and said hydrolyser unit/units so as to allow the flow of water, when said solenoid valve is activated automatically, when hydrolytic solution level inside the hydrolyser unit/units drop below a pre-determined level as indicated by a compatible (to said hydrolytic solution) and commercially available mechanical or digital float switch/s, mounted inside said hydrolyser unit/units in either a horizontal or vertical position, and when activated, sending an electronic signal, further activating said solenoid valve to open, with power from a battery source, whereby said solenoid valve, when activated will allow said distilled or de-mineralized water to be released from the central pre-filled water reservoir so as to maintain a pre-determined hydrolytic solution level in the hydrolyser unit/units This process used in warm-weather climates while in cold-weather climates, this reservoir will be heated through a conductive and / or convective heat transfer system according to claim # 2

(c-iii) an atmospheric water recovery system that utilizes the process of dehumidification in a specially designed unit that will effectively remove moisture and humidity from the air through a specially constructed and modified dehumidifier, and convert it to water Said water, through a conduit or series of conduits, in parallel, will be fed from the reservoir of said dehumidifier unit to the electrolyser unit/units As dehumidification occurs above a minimum of plus +5C degree temperature, installation of this system is limited, in the first instance, to applications in warm-weather climates or in applications where heated air, and sufficient moisture and humidity in the air is available, and where installations allow for the size of the unit to be used In a secondary instance, in certain applications, said heated air originates by diverting heated exhaust from the exhaust assembly by introducing a separator Y-type attachment along the exhaust pipe, diverting one part of the exhaust to circulate, through a series of special conduits and said warm air made to circulate around said dehumidifier unit, causing a warmer air and moisture atmosphere to allow for dehumidification The other part of the Y-separator along said exhaust system shall oe used to exhaust normal vehicular or internal combustion engine emissions The process may also fully utilize all of the exhaust system if all said exhaust gases are redirected through the area where said dehumidifier unit is located so as to warm up and add humidity in the air surrounding the dehumidifier This process may be used in certain specialized applications such as installations on trains, boats, heavy equipment, stationary generating stations and other such type of installations The said atmospheric water recovery system is used preferably in warm-weather climates where temperatures of plus +5 degrees C prevail and where minimum atmospheric humidity levels prevail In this process, water derived through dehumidification is collected in a central reservoir and redistributed via a conduit or multiple conduits into the hydrolyser unit/units by either a gravity feed as described in ( c-i ) or by a mechanical pump manually or automatically activated as described in (c-ii a and c-n b ), or by an automatically activated solenoid valve switch as described in (c-n c ) In the case described in (c ιι-a), said water level control inside the hydrolyser unit/units will be maintained by said special valve according to claim # 3 whereas in the applications described in (c-n b) and (C-II c) said water level control inside the hydrolyser unit/units will be maintained by either a single or multiple, horizontally or vertically mounted, mechanical or digital float switches as certain installations may warrant

(c-v) a separate and independent pre-filled water reservoir, in the form of commercially available bottles or containers, and according to claim 1 , preferably with steam distilled water, but not excluding de-mineralized water or tap water if necessary, used to refill said hydrolyser units manually when installations of said separate central water reservoirs are not practical A manual feed into the top end of said special valve according to claim # 3 will refill said hydrolyser unit / units and the proper level of hydrolytic solution will be controlled when said special valve, through the closure of the float assembly inside said valve is activated and stops the water from further entering into the hydrolyser unit / units This manually controlled process used for small installations, such as under the hood of vehicles and where it is relatively simple to refill said hydrolyser unit / units with a minimum requirement of water A commercially available water level gauge, either a transparent tube type model or sight glass, may be incorporated into the hydrolyser unit / units as an additional feature to visually determine when the proper level of hydrolytic solution has been reached inside the hydrolyser unit / units (note water level gauges or sight glasses are not part of this claim)

( d ) The process for producing hydrogen and oxygen gases as a partial fuel source for internal combustion engines according to claim # 2 further including a conductive or convective heat transfer system, separately or together so as to use the heat generated by the engine when said engine is operating Sources of said heat from the normal operations of an internal combustion engine include the exhaust or tailpipe where hot exhaust emissions are released into the atmosphere, the engine manifold, the anti-freeze or coolant generated by the radiator which is heated to approximately 200 degrees Fahrenheit and the actual exhaust emission gases Using these sources of heat through a conductive or convective heat transfer process or together through a joint conductive/convective heat transfer process forms the basis of claim # 2 and further includes one of the following systems

( d- 1) The process for producing hydrogen and oxygen gases as a partial fuel source for internal combustion engines according to claim # 2 further including a combination conductive and convective heat transfer system where said hydrolyser unit/units - is/are required for cold- weather climates encompassing a system of wires or strapping (Figures 3A, 3B ) which is connected at one end to said independent water supply reservoir and, at the other end to a high heat-generating source, such as a vehicular emission tailpipe or engine manifold Said system encompassing a multiple number of highly conductive wires or flat strapping made from aluminum, but not excluding any other suitable high-heat conductive metals such as copper or steel, and may be covered by or encased in a high-heat resistant type blanket made of either Nomex, fibreglass or asbestos, acting as a heat insulator One end of said assembly utilizes heat resistant brackets and/or straps so as to hold said assembly around the exhaust pipe between the motor and muffler or, in certain applications around the engine manifold, both heat sources radiating heat under normal engine operations and heating, by conductive heat transfer, the wire or strapping metal, said elements as may be embedded in or covered by said blanket Additionally, an insulating material such as insulated tubing placed around the grouping of said wire/strapping harness along the length of the transfer portion further insulating the harness so as to avoid any heat loss, and further connecting the opposite end of said harness around the holding apparatus (Fιgure3A, 3B) of the independent water-supply reservoir, constructed from a metallic based, highly heat-conductive enclosure such as aluminum and into which the independent plastic-based reservoir may be inserted and supported by said metallic holding apparatus so as to provide sufficient heat to unfreeze or to keep the water contained in the water-filled reservoir from freezing in cold-weather installations when the vehicle is in operation and further enabling an adequate pre-determmed supply of water to reach the hydrolyser unit/units Said process to be used in stationary applications such as stationary electrical generating stations (Gen-Sets) Said holding apparatus covered by a similar blanket with embedded heat conductive wires/strapping of the opposite end of said wire assembly Additional individual strands of said wiring assembly may be inserted into the tubing conduits through specially designed rubberized membranes so as to create an air tight entry and exit point within the assembly, this, to provide a conductive and convective heat source to avoid said steam distilled water in the conduit/conduits from freezing before reaching the hydrolyser units Dependent on the size of the water reservoir and the hydrolyser units used for specific installations, a correlated size of blanket, mechanically engineered and constructed to effectively transfer, through a conductive heat transferring process allowing for the flow of water into said hydrolyser units The water refill delivery system further includes one or multiple strands of conductive and convectively heated wire to be inserted into the special valve casing preventing said water supply from freezing in cold-climate applications and installations

(d-ιι) The process for producing hydrogen and oxygen gases as a partial source for internal combustion engines according to claim 2 further including a convective heat transfer system where said water reservoir contains an assembly system of tubes ( Figures 2B2, 2B3 ) constructed of copper or stainless steel, and may include any other type of tubing such as commercially available highly-heat resistant rubberized tubing compatible to an anti-freeze or coolant solution and normally used in the operation of a vehicle radiator system Said assembly to form a conduit system of tubing through which an anti-freeze solution may be circulated, said anti-freeze solution diverted from a vehicle's radiator cooling system through a Y-connector or T-connector bypass allowing said anti-freeze solution to circulate through the heating conduits placed inside said independent water reservoir and immersed in the steam-distilled water supply but not excluding de- minerahzed or tap water Under normal vehicle operations, said anti-freeze or coolant solution shall be heated, and when diverted through said assembly of conduits immersed in said reservoir, said anti-freeze or coolant solution shall provide heat to said distilled or de- minerahzed water through a combination of conductive and convective heat transfer allowing said water to be fed into said hydrolyser unit/units from the central reservoir Said reservoir casing, according to claim # 1 and further described, in detail, in preceding section "c", constructed of a single-walled highly heat-resistant plastic compound or a metal composite such as stainless steel, capable of withstanding highly-heated water up to 200 degrees centigrade Furthermore, said reservoir may be constructed in a double- walled formation with an insulating substance such as insulating foam between both walls, so as to provide further insulation of said water reservoir for use in extreme cold-weather climates Conduits transferring said anti-freeze or coolant fluid from said radiator source to said reservoir are constructed of copper tubing, stainless steel tubing, high-heat resistant rubber-based tubing or specially adapted and commercially available hoses designed and compatible for use with heated anti-freeze or coolant solutions All connecters similarly constructed of substances adapted to highly heated anti freeze or coolant solutions, the foregoing all commercially available

(d-ιιι) The process for producing hydrogen and oxygen gases as a partial fuel source for internal combustion engines according to claim 2 further including a double-walled insulated metal container, capable of withstanding highly-heated water and into which a commercially available heating element is inserted Said element to be heated by a separate and independent electrical source according to claim # 5, such as an auxiliary 12 or 24 volt direct current battery and recharging system and converting said direct current electrical energy into alternating current using a commercially available inverter Said process designed in such a manner as to unfreeze water stored in said reservoir for use in cold-weather applications when heating element is activated and designated for larger installations such as stationary electrical generating stations or heavy machinery In the circumstance of stationary generating stations, the electrical current produced by said Gen- Set may be output in an alternating current mode and therefore said heating element may receive the required electrical energy from the Gen-Set operation and said heating element may be based on an alternating current eliminating the need for an initial direct current electrical energy source from the battery and the use of an inverter

(e) The process for producing hydrogen and oxygen gases as a partial fuel source for internal combustion engines according to claim # 9 further including a central, mechanically induced low pressure gas relay device (Figure 8A) with one or several conduits transferring said gases from the hydrolyser unit/units into a single relay device constructed ideally from ABS plastic but not limited to ABS plastic and may include other plastic-based materials such as Polypropylene or metallic construction with the main criteria for said gas relay device to be air tight Said device allowing for multiple input conduits and one-way check valves at one end and a single or multiple output conduits and one-way check valve/valves at the other end for transferring said gases collected in the central gas relay unit from one or from a series of hydrolyser units, and then transferring said gases, via a single or multiple conduits, into the air intake system of the internal combustion engine and subsequently into the combustion chambers of said internal combustion engine, creating a mechanical pressure whereby one or several conduits transferring said gases from the hydrolyser unit/units into the gas relay system at low pressures and, in certain applications and installations, dependent on the size of said hydrolyser unit/units, less than one atmosphere of pressure of said gases is delivered into said gas relay device, while the exiting conduit/s shall be of a smaller diameter or in less numbers as compared to the intake conduits creating a quasi mechanical turbo-type effect increasing the pressure of said gases entering into the combustion chambers resulting in a higher air to fuel ratio and resulting in a higher reduction of fossil-based fuels while maintaining an effective operation of said engine

( f ) The process for producing hydrogen and oxygen gases as a partial fuel source for internal combustion engines according to claim # 8 further including a customized splash guard device ( Figures 7A1, 7A2 IB ) to prevent the hydrolytic solution from swishing back and forth in moving vehicular applications with additional adjustments necessary for marine vehicles or vertical movement applications Said splash guard device comprising a customized UHMW plastic ring, custom vulcanized or neoprene rubber washers, a suitable number of stainless steel #18 8 bolts, washers, lock washer and nuts to connect said components Said splash guard device constructed in such a manner so as to allow said hydrogen and oxygen gases to flow through to the gas outlet valve but limit the amount of hydrolytic solution in passing through the splash guard device and preventing the electrolytic solution from reaching said gas outlet valve A simplified splash guard consisting of a solid UHMW or Polypropylene in a solid or perforated format, said plastic shield strategically placed in such a position within the containment module so as said hydrolytic solution is deflected away from said gas outlet valve/valves and so as said hydrolytic solution will not enter into said gas outlet valve/valves specifically adaptable for applications where smaller unit/units are utilized

( g ) The process for producing hydrogen and oxygen gases as a partial fuel source for internal combustion engines according to claim # 3 further including a specially engineered, customized and scalable valve/valves ( Figures 4A-1a, 4A-1b 4A2 4 A3) made of a chemical resistant plastic such as UHMW, ABS, polyethylene, polypropylene or Kraylon but not excluding any other type of inert plastic compatible for use with said hydrolytic solution that maintains a pre-determined fill level of the hydrolytic solution in the hydrolyser unit/units, and including either a ball, stem or bullet shaped float made of a high density vulcanized rubber compound (Hypolon), but not excluding a UHMW stem or bullet shaped float with a polypropylene foam or polyethylene foam insert to achieve maximum floatation, and, not excluding any other type of product that is chemical resistant to said hydrolytic solution and having a density of .9 (water having a density of 1) or lower than the density of said hydrolytic solution so as to be buoyant in said hydrolytic solution The purpose of said valve is to maintain an adequate water level within the hydrolyser unit/units for maximum gas production The construction of said valve is such that it mechanically regulates water flow into the hydrolyser unit/units at a very slow rate, in proportion to the decreasing levels of the electrolyte solution as the process of electrolysis itself slowly lowers the level of the electrolyte solution while maintaining the same KOH concentration Distilled or de-mineralized water is passed through said valve from the central water-filled reservoir according to claim # 1 either through a gravity feed and include the variants according to sections (c-i ) and (c-ii a ) or by a manual feed as described in section ( c-v )

(h) The process for producing hydrogen and oxygen gases as a partial fuel source for internal combustion engines according to claim #4 further including the capacity to scale up or scale down the size of said electrolyser unit/units ( Figures 5A, 5B, 5C, 5D, 5D1, 5D2, 1A) to accommodate the intended application and installation requirements and taking into account the amount of hydrogen/oxygen gases that must be manufactured through the process of electrolysis to effectively create a partial fuel source that, when combined with any other fossil-based fuel, reduces the amount of said fossil-based fuel normally required to operate said internal combustion engine and replacing such energy required with said hydrogen/oxygen gases to fuel and effectively operate an internal combustion engine and increasing torque and horsepower Scaling includes variables in sizes of said hydrolyser units from 10 16 cm x 10 16 cm x 5 08 cm (4"x4"x2") as an example of a small size, and 91 44 cm x 76 2 cm x 50 8 cm (36"x30"x20") as an example of the large size unit, both as examples of geometrically-shaped formats but not excluding such sizes in cylindrical formats, and furthermore, not excluding said component modules not being limited to said sizes, but dependent on the application and installation limitations The intention of said scaled units is to have the capacity to install the process under the hood of a small vehicle or any application limited by available space and installation restrictions and including scaling up to installations on locomotives, boats, heavy mining, forestry or farming equipment and stationary generating stations as examples for installation of said process where larger energy requirements are necessary

( i ) The process for producing hydrogen and oxygen gases as a partial fuel source for internal combustion engines according to claim # 5 further including an independent and dedicated electrical power source in the form of a commercially available auxiliary battery in the required voltage/amperage for applications in down-scaled or up-scaled sized unit/units according to claim # 4 and controlled by a specially engineered power supply pack according to claim # 6 regulating the electrical output for safely maximizing the production of said gases within the electrolyser unit/units, with recharging of said battery by a traditional alternator system, said power supply enclosed in a weather-proof containment box where installations warrant

( j ) The process for producing hydrogen and oxygen gases as a partial fuel source for internal combustion engines according to claim # 5 further including an independent and dedicated electrical power source in the form of a commercially available auxiliary battery in the required voltage/amperage for applications in scaled units according to claim # 4 and controlled by a commercially available "battery isolator", which allows for the recharging of two or more separate battenes by a traditional alternator recharging system encompassing one or more alternators as required, and together with a specially designed power supply pack, regulating the electrical output for safely maximizing the production of said gases within the electrolyser unit/units Use of said battery isolators and alternator recharging systems bypasses the use of a vehicle's own battery and as such becomes a dedicated independent electrical power source according to claim # 5 Said process ideally designated for installations that require more electrical energy that regular batteries within a vehicle can produce

(k-ι) The process for producing hydrogen and oxygen gases as a partial fuel source for internal combustion engines according to claim # 5 further including an independent electrical power source in the form of a dual alternator set-up and activated by a single drive belt with power generated from the crankshaft of the motor in a vehicle, with said secondary alternator set in such a manner that would exclusively and independently recharge said independent auxiliary battery as an added accessory and, as such, the electrical power being generated and required for the process of electrolysis will be produced directly from one of the two said alternators of the dual alternator set-up and further regulated by a specially engineered power supply pack or commercially available voltage regulator, which will regulate a specified voltage / amperage, for safely maximizing the production of said gases within the electrolyser unit/units, said power supply enclosed in a weather-proof box This process eliminates the use of the vehicle's own battery and alternator and provides for a completely independent electrical source for the electrolysis process according to claim # 5

(R-H) The process for producing hydrogen and oxygen gases as a partial fuel source for internal combustion engines according to claim # 5 further including an independent electrical power source in the form of a single alternator with a double pulley that when said alternator is activated by a single belt drive from the engine crankshaft, the second pulley shall be installed so as to generate an independent electrical current and controlled by a power supply pack or commercially available voltage regulator so as to deliver the proper amount of DC electrical current to the hydrolyser unit/units This process geared primarily, but not exclusively, for stationary generating electrical stations and larger installations

( I ) The process for producing hydrogen and oxygen gases as a partial fuel source for internal combustion engines according to claim # 6 further including a manually adjustable custom made power supply pack that sets and regulates the required amount of electrical current required for the process of electrolysis in the production of hydrogen and oxygen gases

(m) The process for producing hydrogen and oxygen gases as a partial fuel source for internal combustion engines according to claim # 6 further including a variable power supply pack or commercially available variable voltage regulator that automatically regulates the amount of electrical current required for the production of hydrogen and oxygen gases by the process of electrolysis Said power supply pack or said voltage regulator is activated and controlled by the driver's throttle control foot pedal when operator steps on the gas pedal and increases or decreases the speed of said vehicle, allowing adjustment of the injector openings and automatically adjusting the amount of fossil-based fuel to enter the combustion chambers Said adjustable voltage regulator and multi-functional power supply pack is constructed so as to automatically increase or decrease the electrical amperage and is directly controlled and correlated by the driver's throttle control foot pedal when operator steps on the gas pedal and increases or decreases the speed of said vehicle Reduction or increase in the amount of the required fossil-based fuel controlled by the vehicle's computer sends a signal that adjusts the timing of the injector openings, and conversely adjusts the amount of hydrogen/oxygen gases entering into the combustion chamber, subsequently adjusting the normally required amount of fossil-based fuel to enter into the combustion chambers of the internal combustion engine by allowing for shorter or longer time opening sequences of the fuel injectors, measured in milliseconds, permitting the effective operation of said engine Said adjustable power supply further includes a rheostat type device designed in such a manner as to control the amount of amperage output having the capacity to regulate the amperage and conversely, the amount of hydrogen /oxygen gases generated and delivered into said hydrolyser unit/units by activating one or more in series of said power supplies, this process controlled and activated by the foot pressure of the driver on the gas pedal and throttle control and in direct relation to the speed of the vehicle directly related and controlled by the RPMs required for maintaining speed at optimum engine performance and further includes adjustment to the "duty cycle" of the vehicle's injector valves controlling the flow of fossil-based fuel into the combustion chambers Said power supply or voltage regulator enclosed in a weather-proof box, when necessary

( n ) The process for producing hydrogen and oxygen gases as a partial fuel source for internal combustion engines according to claim # 7 further including a dust and dirt filter apparatus (Figure 6) required for specific installations of the hydrolyser units where high levels of dirt and road dust or other similar conditions prevail Said filter apparatus comprising a shield made of metal or plastic, covering an air duct on the exterior side panel of the main container casing including a dust and dirt filter insert

( o ) The process for producing hydrogen and oxygen gases as a partial fuel source for internal combustion engines according to claim # 10 further including a manually dischargeable, moisture build-up collector unit ( Figure 9) to eliminate excess moisture build up in the electrolyser unit/units and in the conduits of the electrolyser unit/units Said moisture collector unit located in a position along the conduit between the hydrolyser unit/units and the air intake assembly system in certain applications and installations but does not exclude installation along the conduit/conduits between the hydrolyser unit/units and the gas relay device according to claim # 9 where applicable Said moisture collector unit/units to contain an absorbent or deflective filtering substance that can trap moisture and excess dried-out hydrolytic solution that results from atmospheric temperature variations and condensation in the operations of said process Said moisture collector unit specially constructed from a plastic (ABS plastic) or metal composite, pressure sealed, to allow an input and output for the gases as well as a drain outlet or drain valve so as to easily drain said unit with said accumulated moisture and so as to easily replace the disposable filtering substance ( p ) The process for producing hydrogen and oxygen gases as a partial fuel source for internal combustion engines according to claim # 11 further including a manual adjustment and/or replacement of the resistance in the vehicle's computer so as to alter the "duty cycle" and more specifically the opening and closing of the timing sequence of the fuel injector openings that controls the flow of fossil-based fuel into the combustion chambers of the internal combustion engine Shorter opening sequences of said injector openings result in the reduction of said fossil-based fuel and vice-versa, longer opening sequences result in more fuel entering the combustion chambers Introducing hydrogen and oxygen gases into the combustion chamber will result in a more complete combustion burn by raising the air to fuel ratio and results in a faster and more complete burn of the fossil-based fuel by increasing the efficiency of the combustion, and at the same time, said gases maintain or increase torque, horsepower and octane levels by replacing the reduced quantity of fossil- based fuels This process allows for less fossil-based fuels required for efficient engine performance with said reduction of said fuels replaced with said hydrogen/oxygen gases produced by electrolysis as a partial fuel source while maintaining engine efficiency

( q ) The process for producing hydrogen and oxygen gases as a partial fuel source for internal combustion engines according to claim # 14 further including a computer-based system for measuring the output of greenhouse gas emissions and measured against a predetermined baseline so as to evaluate and quantify the emissions being reduced to which green credits may be applied and whereas said credits for reducing said greenhouse gases individually or under the heading of CO2e (carbon dioxide equivalent) wherever said emission reduction credits may be applicable on credit exchanges Said process to include mobile emission measuring sensors to be placed in a cluster or suitable position on board a vehicle within the exhaust assembly of said vehicles for measuring "mobile emission reductions" Furthermore, where applicable, said emission measuring devices include installation in stationary applications where said reduction of emissions shall warrant quantification by a recognized government body or trading entity Said process capable of measuring baselines as well as emission reductions in a mobile or stationary application Recording of said emission reductions shall be recorded and saved in a pre-programmed computer program Said results shall then be transferred to a central computer via an onboard GPS system where available or via a download of said data from a memory based data gathering device and transferred into a central system where said system is qualified to measure and determine quantified values of green credits for trading on world credit exchanges FIELD OF THE INVENTION

This invention relates to a complete system for providing a partial hybrid fuel source for internal combustion engines (ICEs) and in particular, producing sufficient amounts of hydrogen and oxygen gases through electrolysis so as to partially fuel ICEs Introducing hydrogen/oxygen gases as a partial fuel source into the combustion process results in a decrease in the consumption of fossil-based fuels, greenhouse gas emissions and air pollution

BACKGROUND OF THE INVENTION

Numerous patents currently exist that use hydrogen/oxygen gases produced by electrolysis as an enhancement agent or a supplemental additive to fuels such as gasoline and diesel fuel including propane and natural gas While current internal combustion engines have a very high degree of efficiency, the need for huge new sources of fossil-based fuels to power the ever increasing number of vehicles on the planet and the ever increasing need for stationary generating stations powered by fossil fuels to produce electricity has resulted in world-wide problems such as global warming, climate change, global dimming, air pollution, increases in smog levels causing respiratory problems, increase in the number of weather-related natural disasters, accelerated extinction of animal and plant species, melting of polar ice caps, as examples caused by the production of carbon dioxide from the combustion of fossil-based fuels With the position of major oil suppliers, some having reached a level of ' peak oil", and with governments around the world attempting to find solutions for their future energy requirements, and with diminishing oil reserves and ever escalating prices of existing oil production, it has become absolutely imperative to find an alternative to using oil as an energy source or at best, "significantly reducing the consumption of fossil fuels" to fulfill current and future energy needs While newer technologies such as hybrids, fuel cells, wind power, solar power, wave power, bio-diesel bio-gas, ethanol blend fuels, highly- pressured hydrogen gas, propane or natural gas and other technologies are currently available, all these technologies have an overall, long term negative impact on the environment or are not economically viable alternatives The principal objective of this invention is to provide a complete system that is easy to use and financially viable for use by all segments of the mass market to reduce the use of fossil-based fuel consumption and conversely, reduce carbon dioxide and other greenhouse gas emissions As outlined in the "CLAIMS", several new and innovative components have been incorporated so as to provide a complete process that will allow hydrogen and oxygen gases produced by electrolysis to be used as a partial fuel source in applications where internal combustion engines are used taking into account climatic conditions as well as effective, viable and economical considerations Furthermore, the novelty aspect of this invention is based on the fact that several components encompassing this invention, as claimed in the specifications within this application, include the ability to scale the process, into smaller or larger assemblies, so as to have the versatility to adapt and to allow installation of the process to most market segments, including the ability of extending the operating time between fill-ups of the containment module and the ability to operate in cold-weather climates

Reference is made to the following patents, prior art on record and in the public domain The objective of this patent is to add new innovative components as presented in the "CLAIMS" so as to use the process of producing hydrogen and oxygen gases, from the electrolysis of water, as a partial fuel source for internal combustion engines

Patent Documents and other References cited as follows

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OTHER REFERENCES

Dynamic Fuels Systems lnc and Canadian Hydrogen Energy Company Ltd - " Statement of

Claim" - filed July 12, 2004, Federal Court of Canada - Court File No T-1297-04 Dynamic Fuels Systems lnc and Canadian Hydrogen Energy Company Ltd - 'Amended Statement of Claim" - filed September 8, 2004, Federal Court of Canada - Court File No T-1297- 04 SUMMARY OF THE INVENTION

"Hydrogen and oxygen gases, produced on-demand by electrolysis, as a partial hybrid fuel source for internal combustion engines,"

A process, based on the electrolysis of water, producing hydrogen and oxygen gases, on-demand and in certain applications such as on-board vehicles, and including stationary applications such as in stationary generating stations (Gen-Sets), and all, without requiring highly pressurized hydrogen storage tanks, with said gases becoming a partial fuel source by partially reducing the amount of fossil-based fuel originally required to power an internal combustion engine, the process, by enriching, with the use of hydrogen / oxygen gases, the air to fuel mix ratio, causing a more efficient combustion burn effectively resulting in using less of the fossil-based fuel required and replacing said reduction of fossil-based fuels with hydrogen and oxygen gases created through the electrolysis of water in specially designed electrolyser units Consequently, the process of reducing fossil-based fuel consumption shall furthermore directly reduce emissions in various percentages of the mass or the composition of greenhouse gases as compared against a pre-measured baseline of particular individual gases, namely particulate matter or opacity (PM), NOx, SOx, CO, THC, Methane and, in particular, in "direct correlation" to the reduction of fuel consumption, a near equivalent (99%) amount in reducing carbon dioxide (CO2) emissions

Said process including but not limited to the following market segments

Transportation sector- Class 8 HGVs - trucks and buses, small and medium size delivery vehicles (Classes 1-7), SUVs, taxis, cars, vans, government and public works vehicles, municipal bus fleets, municipal maintenance fleets, garbage trucks, police, ambulance, fire trucks, snowmobiles, small watercraft, motorcycles, scooters, lawn mowers, snow blowers Locomotives -

Marine sector - small, medium and large boats and marine vehicles Mining sector - large mining vehicles and equipment, machinery used in underground mines, tar sands production (vehicles and generating stations) Farming sector- tractors, combines and all types and sizes of farming vehicles Warehousing operations - propane and natural gas powered fork-lift trucks Energy sector - Stationary gasoline or diesel powered electric generating stations (Gen-Sets)

Claims

CLAIMS. Improvements over currently available technology:

(1 ) consist of a separate and independent central reservoir for re-filling the electroiyser unit/units with water by an automatic or manually controlled process:

(2) consist of a specially designed heating system to heat water in a central reservoir so as to unfreeze or prevent water from freezing in cold climate applications through a conductive and / or connective heat transfer system; a dehumidification method; or an electrically heated element for certain applications;

(3) consist of a custom designed valve for automatically maintaining water levels inside the hydrolyser unit/units;

(4) are characterized by the capacity to scale, using one or multiple hydrolyser units, allowing, for example, small scale installations from lawn mowers or installations under the hood of vehicies. up to larger unit/units for insta^llations on trains, heavy mining, forestry or farming equipment as well as stationary generating stations;

(5) comprising an independent and dedicated eiectricai power source/s with a specialized recharging system;

(6) consisting of an automatically or manually adjustable voltage regulator and multifunctional power supply pack regulating voltage and amperage input in a weather- resistant package;

(7) consisting of a dust filtering system;

(8) consisting of custom designed spiash guards;

(9) consisting essentially of a central mechanically-induced low pressure gas relay device creating a quasi-turbo effect;

(10) consisting of a dischargeable moisture collector system;

(11 ) characterized by a modification of the timing of the fuel injector opening sequences in the vehicle's computer, specifically controlling the duty cycle

(12) consisting of specially designed, pre-engineered and scalable containment modules for end-use requirements in non-metallic, plastic-based components and formulations;

(13) consisting essentially of pre-engineered internal plate assemblies, specifically designed and scalable to end-use requirements constructed from non-magnetic, metal-based plates, plastic-based components and fittings and all compatible with a hydrolytic solution;

(14) characterized by a computer-based system, based on an on-board portable emissions measuring device including sensors installed directly, in strategic locations on vehicles, so as to effectively measure greenhouse gas emissions and to identify, qualify and quantify said emissions with the capability of calculating mobile emission reduction credits (MERCs) so as to evaluate values for trading on world carbon credit exchanges.