Electrolytic Hydrogen Generator and Method

Abstract

An electrolytic generator to produce a stoichiometric mixture of hydrogen gas and oxygen gas features a case penetration. An electrode extends through the case penetration and clamps a support plate to the inside of the case. The electrode and the support plate are electrically insulated from the case by a non-conducting bushing located within the case and between the support plate and the inside surface of the case. First and second plates are interleaved and maintained in a spaced apart relation along the first and second plate fasteners.

Claims

1. An HHO generator, the HHO generator comprising: a. a generator case, said generator case being configured to contain an electrolyte; b. a core disposed within said case, said core being configured to generate an HHO when said core is immersed in said electrolyte and a DC current is passed through said core; c. a non-conducting plate, said non-conducting plate being disposed between said core and said case, said non-conducting plate being immersed in said electrolyte when said core is immersed in said electrolyte, whereby said non-conducting plate will reduce a leakage of electricity between said core and said case through said electrolyte.

2. The HHO generator of claim 1, the HHO generator further comprising: a plurality of said non-conducting plates, said core defining a plurality of sides, a one of said plurality of non-conducting plates being disposed between each of said plurality of sides of said core and said case, each of said non-conducting plates being immersed in said electrolyte when said core is immersed in said electrolyte, whereby said plurality of non-conducting plates reduces said leakage of electricity between said core and said case through said electrolyte.

3. The HHO generator of claim 2 wherein said plurality of non-conducting plates define junctions between said non-conducting plates, said junctions not being water tight, whereby said electrolyte may move around said junctions within said case.

4. The HHO generator of claim 3 wherein said core is a one of a plurality of said cores, each of said cores being disposed within said case, each said core being separated from an adjacent core by another of said non-conducting plates, said another non-conducting plate being immersed in said electrolyte when said plurality of cores are immersed in said electrolyte, whereby said non-conducting plates that are disposed between said adjacent cores reduces a leakage of electricity between said adjacent cores through said electrolyte.

5. The HHO generator of claim 4 wherein each of said non-conducting plates that are disposed between said adjacent cores extends above a level of said electrolyte in said case when said cores are immersed in said electrolyte.

6. The HHO generator of claim 4 wherein said plurality of non-conducting plates that surround a core define a chamber, said chamber defining a flow path for circulation of said electrolyte when said core is generating said HHO, said chamber having sides and a bottom, a dimension of said sides and said bottom being selected to generally equal a horizontal liquid cross section of said core, whereby said electrolyte will move at a generally constant speed as said electrolyte circulates through and about said core.

7. The HHO generator of claim 1 wherein said non-conducting plate is composed of a plastic.

8. The HHO generator of claim 1 wherein said case is composed of an electrically conducting metal.

9. The HHO generator of claim 6 wherein said electrically conducting metal is stainless steel.

10. A method of generating HHO, the method comprising: a. providing a generator case; b. providing a core disposed within said case, said core being configured to generate an HHO when said core is immersed in an electrolyte and a DC current is passed through said core; c. providing a non-conducting plate, said non-conducting plate being disposed between said core and said case, said non-conducting plate being immersed in said electrolyte when said core is immersed in said electrolyte, whereby said non-conducting plate will reduce a leakage of electricity between said core and said case through said electrolyte; d. immersing said core and said non-conductive plate in said electrolyte within said case, said case containing and contacting said electrolyte; e. passing a DC current through said core.

11. The method of claim 10, further comprising: a. providing a plurality of said non-conducting plates, said core defining a plurality of sides; b. disposing a one of said plurality of non-conducting plates between each of said plurality of sides of said core and said case, each of said non-conducting plates being immersed in said electrolyte when said core is immersed in said electrolyte, whereby said plurality of non-conducting plates reduces said leakage of electricity between said core and said case through said electrolyte.

12. The method of claim 11 wherein said electrolyte may move around said non-conducting plates within said case.

13. The method of claim 12, further comprising: a. providing a plurality of said cores; b. disposing each of said cores within said case; c. separating each said core being an adjacent core by another of said non-conducting plates wherein said another non-conducting plate is immersed in said electrolyte when said plurality of cores are immersed in said electrolyte, whereby said non-conducting plates that are disposed between said adjacent cores reduces a leakage of electricity between said adjacent cores through said electrolyte.

14. The method of claim 13 wherein said con-conducting plates that are disposed between said adjacent cores extend to above a surface of said electrolyte when said cores are immersed in said electrolyte.

15. The method of claim 13, further comprising: a. defining a chamber about each of said plurality of cores, each said chamber being defined by said non-conducting plates surrounding said core, each said chamber defining a flow path for circulation of said electrolyte when said core is generating said HHO, said chamber having sides and a bottom; b. selecting a dimension of said sides and said bottom to generally equal a horizontal liquid cross section of said core, whereby said electrolyte will move at a generally constant speed as said electrolyte circulates through and about said core.

16. The method of claim 10 wherein said step of providing said non-conducting plate comprises: providing said non-conducting plate composed of a plastic.

17. The method of claim 10 wherein said step of providing said case comprises: providing said case composed of an electrically conducting metal.

18. The method of claim 17 wherein said step of providing said case comprises: providing said case composed of stainless steel.

Description

V. BRIEF DESCRIPTION OF THE DRAWINGS

[0056] FIG. 1 is a section view of an HHO generator.

[0057] FIG. 2 is a photograph of the HHO generator.

[0058] FIG. 3 is a perspective view of a core.

[0059] FIG. 4 is a cutaway detail of the electrode and core mounting.

[0060] FIG. 5 is top view of a core.

[0061] FIGS. 6a and 6b are views of a pair of adjacent plates of a core.

[0062] FIG. 7 is a detail of a core in operation.

[0063] FIG. 8 is a side view of a core in operation.

[0064] FIG. 9 is a top view of six cores in series.

[0065] FIG. 10 is a top view of six cores in the casing.

[0066] FIG. 11 is a graph of current (logarithmic) versus voltage (linear) as actually measured for a core.

[0067] FIG. 12 is a schematic representation of the graph of FIG. 11 for different resistances.

[0068] FIG. 13 is a schematic circuit diagram of the apparatus utilizing a ballast resistor.

[0069] FIG. 14 is a schematic circuit diagram of the apparatus utilizing a source of constant current.

[0070] FIG. 15 is a schematic circuit diagram of the apparatus and a control system.

[0071] FIG. 16 is photograph of a core of a prototype.

[0072] FIG. 17 is photograph of core connected in series.

[0073] FIG. 18 is a photograph of the electrolyte separator.

[0074] FIG. 19 is a photograph of the six cores connected in series with the insulating panels.

[0075] FIGS. 20, 20a and 20b are top, side and end views of the ballast resistor.

[0076] FIGS. 21, 21a and 21b are top, side and end views of the support plate.

[0077] FIGS. 22 and 22a are top and side views of the non-conducting bushing.

[0078] FIGS. 23 and 23a are views of the electrode.

[0079] FIGS. 24, 24a and 24b are front, side and end views of the plate connectors that join the cores in series.

[0080] FIGS. 25, 25a and 25b are front, side and end views of the size plate.

[0081] FIGS. 26 and 26a are front and side views of the size plate.

[0082] FIGS. 27, 27a and 27b are front, side and end views of the size plate.

[0083] FIG. 28 is a circuit diagram for control system bias.

[0084] FIG. 29 is a circuit diagram of the control system driver.

[0085] FIG. 30 is a circuit diagram of the controls for replenishing electrolyte and monitoring temperature of the electrolyte.

[0086] FIG. 31 is a circuit diagram of the pulse generator for controlling gas production.

[0087] FIG. 32 is a circuit diagram for the control display.

[0088] FIGS. 33, 33a and 33b are views of a full size stainless steel plate for a core.

[0089] FIG. 34 is a circuit diagram of an alternative constant current switching power supply.

[0090] FIG. 35 is a schematic circuit diagram of the generator circuit powered by the constant current switching power supply.

V. DESCRIPTION OF AN EMBODIMENT

[0091] Overview

[0092] FIGS. 1 and 2 illustrate the electrolytic HHO generator 2. HHO is a stoichiometric mixture of hydrogen gas 12 and oxygen gas. Electrolyte 4 is contained within a case 6. Electrolyte 4 may be any suitable electrolyte known in the art, but a solution of potassium hydroxide (KOH) in distilled water has proven suitable in practice. Case 6 has a body 8 and may have a lid 10. Lid 10 is attached to bottom of body 8 by bolts 11. Case 6 has an inside 3 and an outside 5. Alternatively, case 6 may be sealed, as by welding, so that there is no lid 10 or other removable access panel.

[0093] Where a removable lid 10 is used, lid 10 is attached to bottom of case 6 to prevent escape of hydrogen gas 12 generated during operation of the apparatus. Hydrogen gas (H2) 12 has a very low viscosity and readily passes through conventional gaskets and sealants. Placing lid 10 at the bottom of the body 8 provides that the lid 10 to body 8 connection is submerged in the electrolyte 4. The electrolyte effectively seals the lid 10 to body 8 connection, preventing escape of hydrogen gas 12.

[0094] Cores 14 are electrically connected in series and submerged in electrolyte 4. The cores 14 are supported within the case 6 by electrode assembly 16. Electrode assembly 16 penetrates case 6 at electrode penetration 7 and is sealed to prevent leakage of electrolyte through the electrode penetration 7. If a removable lid 10 is not used, electrode assembly 16 penetrates the bottom or side of case 6 below the level of the electrolyte 4 when the HHO generator 2 is in operation.

[0095] The number of cores 14 contained within the case 6 determines the suitable voltage at which the generator 2 operates. Six cores are suitable for the typical internal combustion engine power system of 12 VDC. An HHO generator 2 featuring two cores 14 would be suitable for operation at 4 VDC. The appropriate size for the stainless steel plates 38 is selected to correspond to the selected number of cores 14, filling the available volume of the case 6 with cores 14 and providing the maximum surface area of stainless steel plates 38 available for electrolysis.

[0096] Cores 14 may be of any convenient size. Any combination of sizes of cores that will physically fit within the case 6 may be used. For example, by selecting an appropriate size for cores 14, sets of two, three, four, five or six cores 14 may be installed in the case 6.

[0097] The size of a core 14 is determined by the size of the stainless steel plates 38 from which the core 14 is constructed. All other parts are interchangeable. Stainless steel plates 38 of different sizes are illustrated by FIGS. 25, 26, 27 and 32. For example, to achieve a generator 2 having five cores 14, three cores 14 having size stainless steel plates 38, as shown by FIG. 27, and two cores 14 having size stainless steel plates 38, as shown by FIG. 26, may be placed within the case 6. As a second example, to achieve a generator 2 having two cores 14, both of the two cores 14 can be composed of full size stainless steel plates 38, as illustrated by FIG. 32, and placed within the case 6.

[0098] The cores 14 contained in two or more cases 8 may be electrically connected to provide additional surface area available for electrolysis at a given design voltage. For example, two cases 8 each containing six cores 14 may be connected in series for operation at 24 VDC. A single case 6 containing six cores 14 has proven suitable in practice for motor vehicle applications.

[0099] In operation of the six-core 14 embodiment, a DC voltage of approximate 12 volts is applied across electrode assemblies 16 at a current flow of approximately 100 amps. The electrolysis reaction occurs within the cores 14. As illustrated by FIGS. 1, 7, 8, 10, and 19, leakage of electricity between adjacent cores 14 and between the cores 14 and the body 8 or lid 10 is reduced by non-conductive plastic plates 18 that are interposed between the cores 14 and between the ends, sides and bottom of the cores 14 and the body 8 and lid 10. The connections between plastic plates 18 are not water tight and electrolyte may move around the plate 18 junctions; however, plates 18 define chambers 20 around each core 14 and define a flow path for electrolyte circulation through and around each core 14 during operation of the apparatus.

[0100] The electrolytic reaction within the apparatus is violent and liquid electrolyte must be separated from the hydrogen gas 12 prior to use. The gas-electrolyte separator is illustrated by FIG. 1 and comprises a perforated separator plate 22 and stainless steel wool 24. In use, hydrogen gas 12 and electrolyte 4 spray pass through perforations 26 in separator plate 22 and enter stainless steel wool 24. The electrolyte 4 spray collects on the stainless steel wool 24 and returns to the pool of electrolyte 4 covering the cores 14. The hydrogen gas 12 passes through the outlet 28 for injection into the internal combustion engine or for other use. The portion of the separator plate that is beneath the outlet may be un-perforated, or the perforations may be blocked as by a plastic plate, to force the hydrogen gas 12 to follow a longer flow path to the outlet 28 and hence pass through more stainless steel wool 24 and achieve better separation from electrolyte 4.

[0101] The separator plate 22 is retained in position by nuts 30 attached to studs 32. Stand-offs 34 maintain the separator plate the desired distance from the top of body 8. FIG. 18 illustrated the perforated separator plate 22 and stand-offs 34.

[0102] Penetrations 36 in the top of the body 8 provide access for one or more sensors (not shown) and allow connection to a pump to replenish the distilled water in the electrolyte 4. The case 6, body 8, lid 10 penetrations 36 and outlet 28 are illustrated by the photograph of FIG. 2, in which six cores 14 are contained within the same case 6. Conventional automotive spark plugs 37 shown by FIG. 2 have proven suitable in practice to seal case penetrations for sensors connections, such as electrolyte level sensors, because the spark plug 37 can convey an electrical signal through the stainless steel case and because the spark plug 37 and its stainless steel gasket form an effective seal against escape of hydrogen gas.

Construction of the Cores

[0103] The construction of each of the cores 14 is illustrated by FIGS. 3, 5, 6, 8, 16, 17 and 19. As shown by FIGS. 3, 5, and 8, each core 14 includes a plurality of stainless steel plates 38. FIGS. 3, 5 and 8 include a relatively small number of plates 38 in each core 14 for ease of illustration. In the case of FIG. 3, a total of fourteen plates 38 are illustrated, with seven plates 38 being positively charged and seven negatively charged. The actual number of plates 38 is limited only by the space available and by how thin the plates can be constructed with the requisite mechanical strength to resistance deformation and to prevent touching of adjacent plates 38. In practice, providing each of the six cores with forty plates 38 each has proven suitable.

[0104] As shown by FIGS. 3, 5 and 8, each core 14 features two core connectors 40. Electrical current is applied to the core 14 at core connector 40. One core connector 40 is connected mechanically and electrically to half of the plates 38 in the core 14 and the other connector is attached to the other half of the plates in the core 14. When counting the plates 38 from one side of the core 14 to the other, odd number plates 38 in the core 14 are connected to one connector 40 and even number plates 38 are connected to the other connector 40. An elongated core fastener, which can be a bolt 42, attaches each connector 40 to its corresponding plates 38. Washers 44 on the bolt 42 and interposed between the plates 38 separate the plates 38 and determine the spaced-apart relation between the plates 38. Each plate 38 features a cutout 46 to prevent the plate 38 from touching the bolt 42 or washers 44 of the other set of plates 38. The bolt 42 is in threaded engagement with its corresponding core connector 40, firmly bolting the plates 38 and washers 44 to the core connector 40 and maintaining the even or odd numbered plate 38 in parallel, spaced-apart alignment. Any other suitable means to attach the elongated core fastener 42 to the core connector 40 may be used, such as welding the plates 38 to the elongated fastener 42 or to the core connector 40, providing an interference fit between the plates and elongated fastener 42, or providing an interference fit between the elongated fastener 42 and the core connector 40. The use of stainless steel bolts 42 and washers 44 to join the even or odd plates 38 has proven suitable in practice to convey a large electrical current with low resistance.

[0105] The bolts 42, core connector 40 and washers 44 do not connect the even numbered plates 38 to the odd numbered plates 38. The even and odd numbered plates 38 are connected and held in alignment with respect to each other to form the completed core 14 by non-conducting core plate connectors 48. The non-conducting core plate connectors 48 are selected from the list consisting of a rod, a clip, a pin, a fiber and an adhesive. Where a non-conducting connector 48 is a rod, the rod may be threaded and penetrate connecting holes 51 through both the even and odd numbered plates 38. Non-conducting spacers 52 may be interposed between adjacent plates 38. Nuts 50 may hold threaded rods 48 in position. The even and odd numbered plates 38 may be joined by any other electrically non-conductive means that allows circulation of electrolyte 4 between the plates 38 while maintaining a separation between the plates 38. FIGS. 3 and 5 show only two non-conducting threaded rods 48 and the associated nuts 50 and washers 52 for clarity of illustration. The actual number of non-conducting threaded rods 48, nuts 50 and washers 52 is any number required to maintain the plates 38 in alignment. FIG. 16 shows a core with seven non-conducting threaded rods 48.

[0106] The assembled core 14 has the three dimensional rectangular shape 53, illustrated by FIG. 3, with the two core connectors 40 disposed on opposing corners of the three dimensional rectangular shape 53. When cores 14 are connected in series, the core connectors 40 join adjacent cores 14, as illustrated by FIGS. 9, 10, 17 and 19.

[0107] All of the metal internal components of the apparatus 2 that will come in contact with liquid electrolyte 4 are composed of stainless steel. Although stainless steel is an electrical conductor, it not a good conductor and is selected for this application based on its ability to survive in the hostile environment of the electrolyte 4 and high DC current flow. The HHO generator 2 circuit elements that are exposed to electrolyte 4 and through which current will flow, which includes the plates 38, connectors 40, bolts 42, washers 44 and support plate 64, all are composed of stainless steel. The electrical resistance within the stainless steel is significant. To provide adequately low resistance, the dimensions of stainless steel parts through which current will flow are constructed with much larger dimensions than would be the case if those components were composed of a better conductor, such as copper.

[0108] The electrode 60 is composed of a metal that is a better conductor than stainless steel. Electrode 60 may be composed of copper, silver, aluminum or an alloy that contains copper, silver or aluminum. An example of a suitable alloy for electrode 60 is brass. Use of a relatively good conductor such as brass for the electrode 60 provides that electrode 60 may be much smaller than if the electrode 60 is composed of stainless steel. The relatively small brass electrode 60 allows case penetration 7 to be smaller and to be more easily sealed against leakage of electrolyte 4 or HHO 56 than if the case penetration 7 were large to accommodate a stainless steel electrode 60. A copper or brass electrode 60 is subject to corrosion if the copper or brass electrode 60 comes in contact with the electrolyte 4. Bushing 64 and O-rings 68 prevent electrolyte 4 from contacting and corroding electrode 60.

[0109] The arrangement of the connectors 40, bolts 42, washers 44 and plates 38 also is selected to balance the electrical resistance seen at each location in the core 14, so that each plate 38 within the core 14 receives the same amount of current flow and no plate 38 or pair of plates 38 is starved of electrical current flow. This balancing of resistances through the core 14 causes each pair of plates 38 to generate similar amounts of HHO 56.

[0110] The balancing of resistances caused by the configuration of the core 14 is illustrated by FIG. 3 and FIGS. 6a and 6b. Electrical current 54 travels a similar distance from the first core connector 40 to the second core connector 40, which are located at opposite corners of the core 14, regardless of which pair of plates 38 the current 54 flows through and regardless of what location on the pair of plates 38 the current 54 flows through. Because the current flows through a similar distance through the stainless steel connector 40, bolts 42, washers 44, and plates 38 for each available flow path through the core 14, the resistance is similar for each available flow path through the core 14. Because the resistance is similar, the current flow through the plates 38 is balanced and the entire area of each pair of plates 38 will produce HHO 56, with no location on the plates 38 starved for electrical power. The plates 38 on the outside of the core 14 interact with only one other plate 38, rather than two, and are not as productive as the remaining plates 38 in the core 14.

[0111] The configuration of the cores 14 for balanced resistance can also be carried through for the series connection of six cores 14, as shown by FIGS. 9, 10 and 19. FIG. 9 is a top view of a series of six cores 14, each connected at a corner to another core 14 using the core connector 40. Each of the cores 14 is internally balanced, as described above. FIG. 10 is a cutaway of the body 8 and show the six cores 14 of FIG. 9 installed. Plastic plates 18 separate the cores 14 and also separate the cores 14 from the body 8 sides, ends and lid 10. The plastic plates 18 prevent electrical leakage between each cores 14 and body 8, lid 10 and other cores 14.

[0112] From FIG. 9, when multiple cores 14 are connected in series, the HHO generator will have a first end core 57, a second end core 59 and intermediate cores 61. The first core connector 40 of the first end core 57 is attached to the first support plate 64. The second core connector 40 of the second end core 59 is attached to the second support plate 64. Each of the other core connectors 40 of the end cores 57, 59 and intermediate cores 61 are shared between two adjacent cores 14, with the core connector 40 serving as the first core connector 40 for one core 14 and as the second core connector 40 for the adjacent core 14.

Circulation of the Electrolyte

[0113] The plastic plates also define a chamber 20 directing electrolyte flow around and through the core 14. FIGS. 7 and 8 illustrate the flow of electrolyte 4 when the apparatus 2 is in operation. As shown by FIG. 7, when current is passing from a plate 38 through the electrolyte 4 to the adjoining plate 38, water in the electrolyte 4 electrolyzes into bubbles of HHO 56 consisting of a mixture of gaseous hydrogen gas 12 and oxygen. The buoyancy of the hydrogen gas 12 causes it to rise, indicted by arrows 58. The moving HHO bubbles 56 also move the surrounding electrolyte 4, causing the electrolyte 4 to circulate through the core 14, as illustrated by FIG. 8.

[0114] FIG. 8 is an end view of the operating core 14 enclosed within the core 6. The circulating electrolyte 4 rises through the core 14, flows substantially within the chamber 20 defined by plastic panels 18 downward around the outside of the core 14 and upward through the bottom of the core 14, all as indicated by arrows 60. The circulation is violent and acts to strip bubbles of hydrogen 12 and oxygen from the plates 38, making those locations on the plates 38 available to electrolyze water into additional hydrogen 12 and oxygen.

[0115] Surface treatment of the plates 38 assists in electrolysis and stripping of bubbles of HHO 56. In the manufacturing process, the plates 38 are sanded to create vertical scratches in the surface of each plate 38. The vertical scratches are oriented with the long dimension of the scratches in the direction of electrolyte 4 flow. The scratches provide greater surface area on the plates 38, contributing to bubble formation. The orientation of the scratches aids the stripping of the bubbles from the plates 38. The sanding during manufacturing also serves to remove contaminants from the surface of the plates 38 that could interfere with current flow and hence electrolysis.

[0116] To assist in circulation of the electrolyte 4, the dimensions on the sides and bottom of the chamber 20 are selected to generally equal the horizontal liquid cross section of the core 14. As a result, electrolyte 4 moves at a generally constant speed as it circulates through and around the core 14.

Electrical Characteristics of the Cores

[0117] The inventors herein have discovered that the surfaces of the plates 38 and the electrolyte 4, when in operation, behave like a diode. This discovery has profound effects on the design of the electrolysis apparatus 2 and of any electrolysis apparatus for any purpose.

[0118] A demonstration of this effect is illustrated by FIG. 11. FIG. 11 shows the results of an actual test of an actual pair of plates 38 in electrolyte 4. The y axis of the graph of FIG. 11 is logarithmic and is the measured current flowing between the plates 38. The x axis is linear and is the applied DC voltage. Of interest is the region of the graph around 2 volts that plots as a straight line, meaning that current flow in this region changes exponentially for a linear change in voltage. Experience has shown that with increasing voltage (more than about 2.25 vDC on FIG. 11), the plot changes from exponential to linear. FIG. 11 shows the very beginning of this transition. The above describes the behavior of a diode.

[0119] The general shape of a response curve of a diode is illustrated by FIG. 12. The different response curves represent systems having different electrical resistances. As the overall resistance of the system drops, the efficiency of hydrogen gas 12 production increases while on the exponential portion of the slope. The greatest efficiency is achieved by operating within the exponential portion of the curve (which graphs as a straight line) and at the highest current flow for a given applied voltage. This corresponds to the lowest overall resistance of the system.

Achieving Low Resistance

[0120] As noted above, achieving low resistance with stainless steel as a conductor requires that the stainless steel have a relatively large cross-sectional area. FIG. 4 illustrates the penetration of the case 6 by the electrode 60 and support of the cores 14 within the body 8.

[0121] As shown by FIG. 4, electrode 60 penetrates case 6 through an electrode penetration 7. Electrode 60 is composed of brass, which contains copper and is a better conductor than stainless steel. Electrode 60 therefore can be of smaller cross sectional area than the other components in the electrical flow path and the electrode penetration 7 of case 6 can be relatively small in diameter. Since the electrode 60 is not exposed to the electrolyte 4, brass is adequately durable. Core 14 having core plate 38 is supported by core connector 40, which is bolted to support plate 62. Electrode 60 is in threaded engagement with support plate 62. Support plate 62 and electrode 60 are electrically insulated from case 6 by non-conducting bushing 64. Electrolyte 4 is prevented from escaping through the electrode penetration by the clamping action of electrode nut 66 pulling support plate 62 against the inside 3 of case 6. O-rings 68 further prevent leakage of electrolyte 4 through electrode penetration 7. O-rings 68 are disposed in first and second annular grooves 71, 73 on opposite sides of non-conductive bushing 64. Electrode 60 passes through O-ring openings 69 and through bushing opening 65, defined by non-conducting bushing 64. The relatively large-dimensioned stainless-steel parts of the electrode assembly 16 also serve to firmly support the cores 14.

[0122] One embodiment of support plate 62 is shown in tops, side and end views by FIGS. 21, 21a and 21b. Non-conducting bushing is shown in plan by FIG. 22 and by cross section FIG. 22a. Electrode 60 is shown as a threaded rod by FIG. 23 and in end view by FIG. 23a. Core connector 40 is shown in top, side and end views by FIGS. 24, 24a and 24b.

[0123] Other design features to achieve low resistance include choosing a relatively large diameter for bolt 42 and washers 44, and selecting a robust core connector 40. Another feature to achieve a low resistance is to locate adjacent plates 38 very close to each other within core 14. Any touching of the plates 38 would cause a short, damaging the core 14 and interfering with HHO 56 production. The core 14 design features described above, including the non-conducting core plate connector 48, the plurality of non-conducting spacers 52 and the connector nut 50, allow very close location of adjacent plates 38 in a core 14, providing low resistance between adjacent plates 38. Ramping of the current on shutoff, as discussed below, prevents arcing between the plates 38 due to inductive kick and allows the plates 38 to be located close together.

Limiting Current Flow Through the Electrolyte

[0124] A persistent problem with prior art electrolysis units for hydrogen generation has been the overheating and boiling of the electrolyte 4. The problem is caused by an inherent characteristic of the diode nature of the electrolyte 4 and the cooperating surfaces of the plates 38; namely, as the plates 38 and the electrolyte 4 heats as a result of the very high current flow through the cores 14, the resistance of the electrolyte 4 and cooperating surfaces of the plates 38 goes down. Since the resistance goes down, current flow through the plates 38 and through the electrolyte 4 will go up. The effect of the increased current flow is to heat the electrolyte 4 even more, causing a further drop in the resistance. The result is runaway heating of the electrolyte 4 and failure of the HHO generator 2.

[0125] The inventors have developed two solutions to the problem. The first is illustrated by FIG. 13. FIG. 13 is a schematic circuit diagram. A generating system 70 supplies approximately 14 volts DC, which is typical for a motor vehicle or stationary internal combustion engine. The generating system 70 applies positive voltage to a ballast resistor 72 that is located outside the case 6 and hence is not in contact with the electrolyte 4. The ballast resistor 72 has a small resistance, on the order of 0.01 to 0.02 ohms. The ballast resistor 72 is configured to handle a high current, such as 100 amps. A ballast resistor 72 composed of a bar of stainless steel and as shown in FIG. 2 and in FIGS. 20, 20a and 20b has proven suitable in practice. The length and hence the resistance of the ballast resistor 72 can be selected by selecting the appropriate attachment points 73.

[0126] If the temperature of the electrolyte 4 and the corresponding surfaces of the plates 38 increases, then the resistance of the HHO generator 2 goes down and current flow through the circuit increases exponentially with increasing electrolyte 4 temperature. Since the increased current is flowing through the cores 14, the same increased current also is flowing through the ballast resistor 72, which is connected in series with the cores 14. From the familiar V=IR relation of voltage, current and resistance in the ballast resistor 72, the increase in current through the ballast resistor 72 causes an increase in the voltage drop across the ballast resistor 72. Because the generating system 70 features a constant supplied voltage, the increased voltage drop across the ballast resistor 72 results in a lower voltage across the cores 14. The lower voltage across the cores 14 results in an exponentially lower current flow through the cores 14 (see FIGS. 11 and 12), reducing the heat released into the electrolyte 4 and allowing the electrolyte 4 and cores 14 to cool. Because the ballast resistor 72 is outside the case 6 (see FIG. 2), the heat generated in the ballast resistor 72 is dissipated into the air and does not heat the electrolyte 4.

[0127] The thermal response of the ballast resistor 72 also contributes to moderating current flow through the cores 14. The ballast resistor 72 has a resistance that increases with increasing temperature and heating the ballast resistor 72 increases its resistance. An increase in current flow due to overheating of the electrolyte 4 will increase the temperature of the ballast resistor 72 and hence will increase the resistance of the ballast resistor 72. The increase in resistance increases the voltage drop across the ballast resistor 72 and reduces the voltage drop across the cores 14. The drop in voltage across the cores 14 exponentially reduces current flow through the cores 14, allowing the electrolyte 4 to cool.

[0128] The dynamic interaction of voltage and current flow of the ballast resistor 72 and of the combination of the electrolyte 4 and the corresponding surfaces of the plates 38 defines a negative feedback relation. The negative feedback relation stabilizes the temperature of the electrolyte 4 and the surfaces of the plates 38 and prevents run-a-way heating of the electrolyte 4.

[0129] In FIG. 13, each of the six cores 14 is illustrated as a diode, which reflects its electrical characteristics. The R(internal) resistor 74 is a schematic representation of all other resistance in the system, including all resistance of wiring, internal components of apparatus, the plates 38, bolts 42, washers 44, core connectors 40, and electrode assembly 16. R(internal) 74 represents a loss of efficiency of the system. The lower the R(internal) 74, the higher the efficiency of the system.

[0130] The second solution to the problem of overheating of the electrolyte 4 is illustrated by FIG. 14. The system of FIG. 14 utilizes a current source 75 that provides constant current, say, 100 amps. The system achieves constant current by using data from a current sensor 76 to advise a voltage controller 78 to control the voltage supplied to the circuit. Since the current is constant, the electrolyte 4 will not overheat and is thermally stable, even if the resistance of the electrolyte 4 decreases due to heating.

[0131] Other power sources can supply a constant current to the generator and thus avoid overheating of the electrolyte. Examples are the switching power sources illustrated by FIGS. 34 and 35. FIG. 34 is a schematic diagram of a two phase current source. From FIG. 34, the cores 14 are represented electrically by the three series diodes (DC1,DC2,DC3) connected to the top. The source works on the negative side; hence the nominal operating voltage is 6 volts. The nominal voltage source, on the left, is 12 to 15 volts. The two switches (MN1, MN2) on the bottom operate 180 degrees out of phase. At peak current output one switch carries 100 amps through L1 and the other switch is open. L2 returns 100 amps through the fly back diode DF2 for a total of 200 amps through DC1, DC2 and DC3. The input power is equal to 100 amps12 volt=200 amps6 volts=1200 Watts.

[0132] FIG. 35 is a schematic circuit diagram for a three phase current source. The cores 14 are represented electrically by the two series diodes (DC1, DC2) connected to the top. The source works on the negative side; hence the nominal operating voltage is 4 volts. The nominal voltage source, on the left, is 12 to 15 volts. The three switches on the bottom operate 120 degrees out of phase. At peak current output one switch carries 100 amps through L1 and the other two switches are off. (L2, and L3 return each 100 amps through the fly back diodes (DF2, DF3) for a total of 300 amps. The input power is 100 amps12 volt=300 amps4 volts=1200 Watts.

[0133] The switching power sources illustrated by FIGS. 34 and 35 offer essentially no resistance, and hence higher overall HHO 56 production efficiency, unless the power source is limiting current flow to protect the HHO generator 2. The switching power sources of FIGS. 34 and 35 also offer the advantages of simplicity and hence lower cost.

Controlling Gas Production

[0134] A. Limiting Electrical Load to Available Electrical Generating Capacity

[0135] The hydrogen generator 2 is equipped with two HHO flow control features. One feature tailors the electrical load that the apparatus 2 places on the electrical generating system 70 to the capabilities of the generating system 70. The second feature permits the dynamic variation of the HHO 56 flow rate during operation of the motor vehicle or stationary engine while retaining high efficiency in generating HHO 56.

[0136] The first feature allows for the selection of the electrical load impedance of the hydrogen generator 2. Selection of a lower load impedance provides higher HHO 56 flow rates but results in higher demands on the electrical generating system 70. Conversely, selection of a higher load impedance results in lower HHO 56 output but reduces the electrical demands on the electrical generating system 70. The user thus can select a load impedance of the hydrogen generator 2 that matches the capabilities of the available electrical generating system 70.

[0137] For example, a user may choose to run the hydrogen generator 2 on the existing excess power of the electrical generating system 70 of a motor vehicle or stationary engine by selecting an appropriately high impedance for the hydrogen generator 2. If the electrical generating system 70 of the motor vehicle or stationary engine does not have sufficient excess capacity to generate the desired amount of HHO 56, the user can choose to install a more powerful electrical generator 70. This feature of matching the load impedance of the hydrogen generator 2 to the capability of the electrical generating system 70 is believed to be unique to the invention.

[0138] The load impedance is selected at the time of installation of the apparatus 2 on the motor vehicle or stationary engine and requires partial disassembly of the apparatus 2. One way to select the load impedance of the hydrogen generator 2 is to adjust the resistance of the ballast resistor 72, as shown by FIGS. 2, 13, 15, 20, 20a and 20b. From FIG. 20 one way to adjust the resistance of the ballast resistor 72 is to select the length of the ballast resistor 72 through which electrical current will flow when the apparatus 2 is in operation and generating HHO 56. The longer the length of the ballast resistor 72 through which current will flow, the higher the load impedance. Selecting the length of the ballast resistor 72 does not require changing the ballast resistor 72 and can comprise selecting the locations 73 on the ballast resistor 72 at which electrical connections are made. The ballast resistor features 72 a series of mounting holes 73 along its length. The variable resistor 80 is mounted to the ballast resistor 72 at a selected mounting hole 73, defining the length of the ballast resistor 72 through which current will flow and hence the load impedance.

[0139] B. Physically Constricting the Flow of Hydrogen Gas Coupled with Rapid Switching of the Hydrogen Generator on and Off

[0140] The second control feature is to vary the HHO flow rate, including dynamically varying the HHO 56 flow rate while the motor vehicle or stationary engine is in operation.

[0141] For the cores 14 to generate HHO 56 efficiently, voltage across each core 14 and hence current flow through the cores 14 must fall within narrow ranges. As a result, the apparatus 2 is either on, with the design current flowing through the cores 14 and the cores 14 efficiently producing HHO 56, or it is off, with no current flowing through the cores 14 and the cores 14 producing no HHO 56. Switching the apparatus off and stopping current flow to the cores 14 is achieved by raising the impedance of variable resistor 80 of FIGS. 2 and 15 to a very high value. Switching the apparatus on and allowing current to flow through the cores 14 is achieved by lowering the impedance of variable resistor 80.

[0142] The controller 82 controls variable resistor 80 and defines how much hydrogen 12 will be supplied to the internal combustion engine by determining how much of the time the apparatus is on with current flowing through the cores 14. The controller 82 cycles rapidly between on and off based on signals from a pulse generator illustrated by FIG. 31 and described below. Experience has shown that for best results the off time should be fixed and the on time varied to obtain the desired HHO 56 flow rate. A fixed off time of approximately two seconds has proved suitable in practice. The on time is determined by the amount of hydrogen gas 12 production selected by the operator and an on time of up to 20 seconds has proved suitable in practice.

[0143] The HHO 56 flow rate to the internal combustion engine must be maintained during the off periods. To achieve a continuous flow of HHO 56, and as shown by FIG. 1, the apparatus 2 is equipped with a flow constrictor 86 and with a head space 84 in the case 6 above the elevation of the electrolyte 4. When the apparatus 2 is on, HHO 56 generated in the cores 14 collects in the head space 84, which acts as a reservoir for the HHO 56. HHO 56 pressure builds in the head space 84 and HHO gas 56 continuously exits through the flow constrictor 86 and to the internal combustion engine. When the apparatus 2 is off and HHO 56 is no longer generated, HHO 56 continues to flow under pressure from the head space 84 and through the flow constrictor 86 to the engine. The headspace 84 and the flow constrictor 86 in combination dampen fluctuations in flow of HHO from the apparatus 2.

[0144] The flow rate, both during the off and the on periods, is defined by the differential HHO 56 pressure across the flow constrictor 86 and by the resistance to gas flow created by the flow constrictor 86. The resistance to gas flow of the flow constrictor 86 and the volume of the headspace 84 are selected so that adequate differential pressure across the flow constrictor 84 is maintained during the off periods to provide a desired flow rate of HHO to the engine both during on and off periods.

[0145] The flow constrictor 86 comprises a tube. The resistance to gas flow of the flow constrictor 86 is adjusted by selecting the length and internal diameter of the tube. A stainless steel tube having an internal diameter of 27 mil has proven suitable in practice as the flow constrictor 86. A design HHO 56 pressure within the headspace 84 of approximately two atmospheres has proven suitable in practice. In testing of a prototype apparatus 2, a substantially constant HHO 56 flow rate was perceived through direct observation of bubbles of HHO 56 in a water jar for HHO 56 flow rates of between 1% and 99% of the design maximum.

[0146] C. Ramping of Voltage and Current

[0147] Turning the apparatus 2 on and off creates a periodic load of approximately 100 amps on the electrical generating system 70. As a result, the apparatus 2 is prone to a large inductive kick of thousands of volts if the switching edges are not controlled. Inductive kick is a well-known phenomenon in which the inductance of a circuit will cause a voltage spike in circuit components upon a sudden breaking of the circuit. An inductive kick in the apparatus 2 could cause a high potential across the gap between the plates 38, resulting in a spark jumping the gap. Because of abundant free hydrogen 12 and oxygen between the plates 38, the spark could ignite the hydrogen 12 in the body 8.

[0148] In the control system illustrated by FIG. 15, a variable resistor 80 ramps the applied voltage from power supply 70 either up or down. Ramping of the voltage and current up and down prevents the inductive kick. The variable resistor 80 can be in the form of one or more n-MOSFETs in parallel. A set of three 80 amp n-MOSFETS has proven suitable in practice. The internal resistance 74 is minimized by placing the MOSFETs directly on the ballast resistor 72, as illustrated by FIG. 2. The n-MOSFETS are driven by a control voltage ramp circuit which results in a smooth transition of the switch-on resistance from 0.001 ohms to megohms.

[0149] The control system of FIG. 15, including the controller 82 and n-MOSFET switch 80, has been built and tested with results showing no more than a few volts across the cores 14 during switching.

[0150] D. Controller Circuit Diagrams

[0151] FIGS. 28 through 32 are circuit diagrams of the controller 82. FIG. 28 illustrates the biasing circuit, which provides a 5 volt and a 10 volt regulated voltage source powered by standard automobile battery voltage for the other circuits in the system. The regulated voltage sources are referenced from two Zener diodes (D1, D2) and buffered through two operational amplifiers provided by the LF444B integrated circuit. Q21 and Q22 provide low impedance outputs for the driven circuitry. The capacitors C1, C2, C21 and C22 provide power supply rejection at elevated frequencies and noise reduction. Diode D3 protects the circuit from high or low over voltage stress. The circuit can withstand +/40 volt applied to the power terminal without incurring damage. The function range of input voltage is 11V to 30V.

[0152] FIG. 29 illustrates the driver circuit. The driver circuit controls the power to the electronic board, the ON/OFF of the generator 2, and a false ON alarm. The false ON alarm sounds when the unit is OFF and it becomes active due to some external activity; for example, if the circuit is shorted as by a screwdriver or other conductor so that the variable resistor 80 no longer controls current flow through the generator 2, or if the variable resistor 80 is stuck in the on position. The purpose of the false ON alarm is to alert the operator that the unit still is active even though shut off. The LM311 generates a pulse signal that activates a buzzer (Buzz) when P14 has an unintended path to ground. S1 of the driver circuit of FIG. 69 is a mechanical switch that powers the board and turns on a red indicator. Q1, Q2, Q3 and Q4 provide the gate drive for the variable resistor 80. C0 controls the ON/OFF speed, RO defaults the gate drive to zero voltage. The pulse mode is activated by simply canceling the current from RB with a larger current from the oscillator circuit through Q4 and Q2. M1 is the variable resistor 80 and is a 240 amp VMOS comprised of three parallel V groove MOSFETs. The speed of the OFF/ON activation is controlled to maintain minimal inductive kick back when switching up to 240 amps.

[0153] FIG. 30 shows the refill circuit. The refill circuit senses the amount of liquid electrolyte 4 in the case 6 and adds more liquid from a storage container when the level drops below the sensor position. The sensor is connected to a modified spark plug that penetrates case 6. The sensor is maintained at the battery voltage when not in contact with the liquid. When the sensor comes in contact with the liquid, the sensor drops to the voltage of the liquid. When the liquid drops below the level of the sensor the LM311 comparator flips and the output of the comparator drives a signal to the water pump switch adding more liquid to the case 6. When the sensor re-contacts the liquid the pump is turned OFF. The re-fill tube contains a one way valve that prevents the liquid from back flowing.

[0154] FIG. 31 shows the pulse generator circuit. The pulse generator circuit creates pulses of varying duty cycle, where the OFF time is set to constant value (e.g., two seconds) with R9 and the ON time is varied by rotating a potentiometer (100 k) provided on the control panel (e.g., 0.2 seconds to 20 seconds). By tuning the generator 2 in this way the flow rate of HHO gas can be varied. The 74LS123 is a dual single shot integrated circuit whose pulse duration is controlled by the resistance R9 and R6+100 k pot and C3 and C4. Pins 4, 5 12 and 13 are TTL outputs. M4 and M5 are connected to the TTL outputs and drive LED G and LED Y on the front panel. Output 13 drives the ON/OFF switch of the HHO unit through the DRIVE circuit. The overall result is operator-controlled HHO flow rate.

[0155] FIG. 32 illustrates the panel circuit. The panel circuit provides the ON/OFF switches and the LED displays. The panel is interfaced to the control board via a 20 pin ribbon cable. The 5 position switch selects temperature, battery voltage, core voltage, ballast resistor voltage, and 5 volt reference. The unit has a full ON mode and a pulse override mode. The pulse override mode is controlled by the 100 kOhm pot. The circle with the wiggle line is a thermal fuse that resets automatically in the event of over current due to unwanted connection between parts of the circuitry.

[0156] In the version of the control system 82 illustrated by FIGS. 68-72, the HHO flow rate is manually controlled by the operator. The controller 82 also can be configured to vary the flow rate of HHO automatically based on engine speed, on the load applied to the engine or on other variables as appropriate.

LIST OF NUMBERED ELEMENTS

[0157] Electrolytic hydrogen generator 2 or HHO generator 2 [0158] Inside 3 [0159] Electrolyte 4 [0160] Outside 5 [0161] Case 6 [0162] First and second electrode penetrations 7 [0163] Body 8 [0164] Interior volume 9 [0165] Lid 10 [0166] Bolts 11 [0167] Hydrogen gas 12 [0168] Cores 14 [0169] Electrode assembly 16 [0170] Plastic plates 18 [0171] Chamber 20 [0172] Separator plate 22 [0173] Stainless steel wool 24 [0174] Perforations 26 [0175] Nuts 30 [0176] Studs 32 [0177] Stand-offs 34 [0178] Penetrations 36 [0179] First and second sets of core plates 38 [0180] First and second core connector 40 [0181] First and second elongated core fastener (bolt) 42 [0182] A corner, a first corner 43 [0183] First and second washers 44 [0184] An opposing corner, a second corner 45 [0185] A clearance cutout 46 [0186] A core perforation 47 [0187] Non-conducting core plate connector 48 [0188] Non-conducting nut 50 [0189] A connecting hole 51 [0190] Non-conducting spacer 52 [0191] Three-dimensional rectangular shape 53 [0192] Electrical current flow 54 [0193] HHO 56 [0194] A first end core 57 [0195] Direction of gas flow 58 [0196] A second end core 59 [0197] First and second electrodes 60 [0198] Intermediate cores 61 [0199] First and second support plates 62 [0200] First and second non-conducting bushings 64 [0201] Bushing opening 65 [0202] Electrode nut 66 [0203] A first and a second O-ring 68 [0204] O-ring opening 69 [0205] Generating system 70 [0206] First annular groove 71 [0207] Ballast resistor 72 [0208] Second circular grove 73 [0209] Internal resistance 74 [0210] Current source 75 [0211] Current meter 76 [0212] Voltage controller 78 [0213] Variable resistor 80 [0214] Controller 82 [0215] Headspace 84 [0216] Flow constrictor 86