Vapor fueled engine

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US 2005/014.5226A1 Jul. 7, 2005

WAPORFUELED ENGINE Startup, the reading will typically be at, e.g., 4 volts, indi cating a too rich mixture but desirable for Startup and

RELATED APPLICATION warming of the engine. After a time delay to accommodate 0001. This is a continuation-in-part of co-pending U.S. warm up, any reading above or below, e.g., 3, will activate patent application Ser. No. 10/706,507 entitled “Vapor the control for opening and closing the valve or valves which Fueled Engine' filed on Nov. 11, 2003, and claims priority control ambient air flow and vaporized fuel flow (more to said 507 application. accurately an enriched mixture of air and fuel). For example, a 3.2 reading will produce an opening of the ambient air

FIELD OF THE INVENTION valve and/or a closing of the vaporized fuel flow. A 2.8 reading will produce the reverse.

0002 This invention relates to the use of vaporized fuel to power an engine and, more particularly, to improvements 0009. Whereas it would be presumed and has been that enhance fuel efficiency. assumed that an established fixed Setting of fuel-to-air mixture would produce a Stabilized mixture throughout the

BACKGROUND OF INVENTION operation of the engine, Such has been determined to be not the case. There are many variables that need to be controlled 0003. It is known that under some conditions the use of or accommodated. The liquid fuel temperature is known to Vaporized fuel verSuS liquid fuel for gasoline powered have the greatest impact on hydrocarbon emissions and fuel vehicles can reduce the emission of hydrocarbons conveyed efficiency, and that temperature will vary by Small but very into the atmosphere, while also increasing fuel efficiency. Significant degrees of temperature due to environmental The problem that has lingered is how to obtain and retain changes, i.e., temperature, elevation, humidity, and the like. those benefits over the changing conditions in which Such Thus, in the preferred embodiment, a quantity of fuel to be vehicles are typically driven. Vaporized is precisely temperature controlled to Substan SUMMARY OF THE INVENTION tially eliminate the effect of such environmental variables. 0010 Regardless, there still remain significant changes 0004. As known and as described in the commonly that are not controlled simply by maintaining the liquid fuel owned U.S. patent application Ser. No. 10/002,351, now temperature. These remaining variables are accordingly U.S. Pat. No. 6,681,749, (incorporated herein by reference), accommodated by monitoring the 02 Sensors. To the extent fuel efficiency can be improved by heating a quantity of that the fuel mixture strays from the desired reading from the gasoline to cause vaporization, directing the vapor into a 02 monitor, the mixture is corrected, i.e., by changing the Stream of ambient air, establishing a desired air-to-fuel Setting of a valve or valves.

mixture and directing the mixture into the intake manifold of an engine. 0011 Whereas the above improvements are considered the primary features for the preferred embodiment, the 0005. Whereas the system as disclosed in the above following is also considered to provide additional benefit. application has resulted in Significant improvement, it has not achieved the consistency of operation desired. 0012 Again in the preferred embodiment, a quantity of 0006. It is known that there is an optimum fuel-to-air liquid fuel, e.g., one gallon of fuel, is inserted into a mixture that needs to be maintained. A fuel-to-air mixture of Vaporization tank. The fuel occupies, e.g., the lower half of 1 to 20 is likely too rich resulting in an unacceptable the tank, and a heating element and temperature Sensor is percentage of hydrocarbons in the fuel that are not properly provided in the fuel-containing portion of the tank. The combusted and fuel efficiency is reduced. A 1 to 40 mixture temperature is Set and maintained at, e.g., 74 degrees, and that temperature causes vaporization of the fuel, the vapor is too lean with today’s catalytic converters (CATs) and rising from the liquid Surface into the upper half of the tank. produces an emission of nitrogen oxide that is prohibited by Within the tank, in the upper half, there is an ambient air the EPA emission standards. A fuel-to-air mixture of about 1 to 30 is about optimal for current gasoline engines used in inlet and a vaporized fuel outlet. A sequence of baffles vehicles and an objective of the invention is to control the directs air from the inlet and across the Surface of the liquid fuel to the outlet which is connected to an outer first conduit.

fuel-to-air mixture to maintain the ratio in the range Sub The ambient air temperature is stabilized by its movement Stantially at, e.g., 1 to 30. over the liquid and in the process mixes with the rising fuel 0007 Consistent with the above objective, the mixture is Vapor. AS expelled through the outlet and into the first monitored and adjusted throughout operation of the engine. conduit, Such becomes the vaporized fuel heretofore alluded This is accomplished automatically by the use of valves that to and which is perhaps more correctly identified as an control the flow of vapor fuel and/or ambient air that is enriched fuel air mixture. A Secondary Source of ambient air mixed prior to entry of the vapor fuel into the engine's intake is conducted through a Second conduit and merges with the manifold. The valves are coupled to a control that is in turn vaporized fuel of the first conduit. Prior to said joining of the coupled to a vehicle's 02 sensor which senses 02 emissions air and vaporized fuel, at each or a Selected one of the first in a vehicle's exhaust (a Standard feature on most modern and Second conduits, control valves are provided which vehicles.) It has been learned that the 02 emissions are control the flow volume from the respective conduits to vary directly related to hydrocarbon emissions which as the amount of ambient air and vaporized fuel that is com explained is a reflection of the fuel-to-air mixture. bined into a third conduit or continuing conduit (also 0008. In the preferred embodiment, an electrical output referred to as a mixing chamber) which in turn conveys the from the 02 sensor is transmitted to the mentioned control. mixture to the engine's intake manifold. It is known that the desired reading for the Voltage output of 0013 A further problem for which a solution had to be the Sensor as measured by the control is, e.g., 3 volts. At derived was the discovery that the proceSS as described,

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when Vaporizing the common gasolines that are commer accordance with the present invention. A gasoline-powered cially available, generates a liquid residual that does not engine as labeled, includes an intake port 10 connected to readily vaporize, e.g., at the temperature Setting considered the engine's throttle body. The engine, when operating, otherwise optimal. Over a period of time, this liquid residual draws air and fuel through port 10. The engine includes an becomes a greater and greater portion of the liquid content exhaust pipe 12 that is equipped with an 02 sensor 14. The of the vaporization tank. Thus, a provision is made for a engine, intake port 10 and 02 detector 14 may be standard periodic purging of the liquid residual from the tank. equipment provided for a conventional gasoline-driven 0.014 Whereas it was determined that the residual liquid vehicle, and the remainder of the components of the illus burned acceptably well in conventional engines, and par trated embodiment are incorporated into the System to ticularly to the extent that the systems of the preferred achieve the objectives of the present invention. embodiment are adaptable and applied as retrofits to Such 0022. Item 16 represents an air box through which ambi conventional engines, a first Solution is the alternate running ent air is drawn when operating the engine. Air conducting of the engine, i.e., on vaporized fuel as described above, and conduits 18 and 20 from air box 16 provide the desired then, as desired, converting back to conventional liquid fuel airflow to the remainder of the system as will be described. operation wherein the residual liquid is used to fuel the engine. A recycling procedure may be established to (a) fill 0023 Conduit 20 includes a valve 22 that controls the the tank with e.g., a gallon of liquid gasoline; (b) vaporizing volume of air directed through conduit 20 and which is 80% of the fuel and then Switching to conventional engine conveyed to a vapor producing tank 26 via the tanks top or operation to burn off the liquid residual; and (c) refill the cover 24.

tank and Switch back to vaporized fuel. Other Solutions are 0024 Conduit 18 includes a valve 28 which controls the certainly contemplated. The residual can be simply extracted Volume of ambient air that is directed into a mixing chamber from the tank on a periodic basis, Stored until refueling is 30.

required, and then disposed of or preferably transferred for use in a conventional engine use. 0025 Returning to the vapor-producing tank 26, the tank 0.015 A further enhancement to fuel economy was dis is provided with flow control apparatus, e.g., baffles, which covered by incremental increases in the temperature Settings will be later explained, but for this overview description it for heating the fuel in the vaporization tank. For example, it will be understood that air from conduit 20 (as controlled by may be found optimal to heat the fuel to a temperature of e.g. valve 22) enters the tank 26 through the top 24, liquid fuel 80 degrees at the outset, but the chemical makeup of that fuel 28 is drawn from a gas tank 32 via conduit 34, hot water changes as the more active component of the fuel vaporizes. heating coils immersed in the liquid fuel via inlets and The same temperature produces leSS Vapor and the engine outlets 36, 38 heat the gas/fuel 28 and generate vapors 40. will detectably lose power. At a detected power loSS it may The vapors are picked up by the airflow from air conduit 20 be desirable to raise the temperature e.g. to 82 degrees which and directed out through conduit 42 to the mixing chamber will increase vaporization and reinstate the power. Whereas 30 but controlled by valve 44. The air vapor mixture of theoretically the heat can be repeatedly increased to the conduit 42 is intermixed in mixing chamber 30 with ambient point where virtually all of the fuel is vaporized, it is air from conduit 18, and the mixture is directed through the considered a more desirable practice to Stop the incremental intake port 10 and from there into the combustion tank of the heating at a point where the residual component can Still be engine.

effectively used as a liquid fuel. For example, the tempera 0026 Reference is now also directed to FIG. 2 which ture can be increased in 1 or 2-degree increments up to 100 illustrates an automatic control process for the air, Vapor, and degrees (or where substantially 80% of the fuel is vapor fuel flow rates referred to in FIG. 1. Each valve 22, 28 and ized). At that point the process is interrupted and the 44 are opened and closed as desired (between any of the Vaporizing tank purged and refilled with fresh fuel. unlimited positions between fully opened and fully closed) 0016. The invention will be more fully appreciated and by motors, e.g., Stepper motorS 22'28" and 44'. understood by reference to the following detailed descrip 0027. It has been determined that fuel efficiency can be tion and drawings referred to therein. measured by the hydrocarbons that are emitted from the DESCRIPTION OF THE FIGURES vehicle exhaust. Unfortunately, the elimination of hydrocar 0017 FIG. 1 is a schematic overview of a preferred bons from gasoline-produced engines currently available embodiment of the invention; cannot be total as Such produces an undesired and unper mitted emission of nitrogen oxides. Thus, one first deter 0.018 FIG. 2 is an operational diagram of the system mines the level of nitrogen oxide that is permitted and then utilized for the embodiment of FIG. 1; the lowest level of hydrocarbons that will stay within the 0.019 FIG. 3 is an exploded view of the vaporization tank limits permitted for the restriction on nitrogen oxide. of FIG. 1; and 0028. It has further been determined that 02 detectors for 0020 FIG. 4 is a further exploded view illustrating in detecting a level of 02 in the vehicle's exhaust and which particular the control valves of the system of FIGS. 1 and have been incorporated into the exhaust System of later 2. model vehicles, are directly related to the level of hydro carbons in that Same exhaust. Thus, one can determine what

DESCRIPTION OF THE PREFERRED 02 reading of the detector 14 produces the optimum fuel EMBODIMENT efficiency. For example, a desired hydrocarbon level may be 0021 Reference is made to FIG. 1, which provides a determined to exist when the 02 monitor produces a reading Schematic Overview of the components of a System in of 3 volts.

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0029) Returning to FIG. 1, it has been determined that Baffle grid 56 includes fastener tabs 60 and assembled to the fuel efficiency is achieved by controlling the ratio of fuel fastener tabs 60 is a lower baffle plate 62 having spaced to-air mixture achieved at the mixing chamber 30 from circular opening 64. The baffle plate 62 is seated below the which the mixture enters the engine intake throttle body. It upper edge of box 48 (defined by flange 84) and affixed to is known that the vapor-air-mixture directed into the mixing the flange 84 is an upper baffle plate 66. Extending flanges chamber 30 from conduit 42 is too rich, e.g., 1 part fuel to 68 of baffle plate 66 protrude laterally from the box and 10 parts air, and of course the air only from conduit 18 has provide the means to secure the box 48 to the body of the Zero parts fuel. The desired mixture may be that which vehicle. Upper flange 68 has rectangular openings 70. achieves a 30 to 1 ratio, e.g., of 2 cubic feet of air, through 0037) Secured to the upper baffle plate 66 and in align valve 28 for each cubic foot of air/vapor through valve 44. ment with an air inlet to be described is a Secondary upper 0030. Whereas the valves 28 and 44 can be set to achieve baffle plate 72, reduced in size and Secured to the upper plate the desired mixture at a given point in time, it has been 66 so as to cover a substantial portion of the opening 70'. learned that many factors affect the ratio achieved in the Provided in this Secondary plate is a plurality of Small holes, Vapor/fuel mixture flowing through conduit 42. e.g., five holes 74 having a size of about a quarter inch in 0.031 Assuming a specific hydrocarbon emission is diameter. Baffle plate 72 provides an impediment to airflow desired, a reading of the 02 detector will verify that this from air inlet 78 and diverts the air flow laterally and desired mixture has been achieved, as that reading also downwardly within the tank 26.

indicates the hydrocarbons in the exhaust. AS explained, a 0038 Completing the assembly is the top or cover 24 fixed Setting will not likely achieve the optimum ratio over which has a complex shape which can be described as a any given period of time. Any temperature change, any distorted pyramid shape. The apex of the pyramid shape is elevational change and even differences in fuel make up will positioned at one end whereat an air inlet 78 is provided A skew the vapor/fuel mixture flowing from the tank 26 to the vapor air outlet 80 is provided at the same end but along the mixing chamber 30. side wall of the pyramid shape. The flange 82 forming the 0032. Accordingly, the valves 22, 28 and 44 are operated peripheral edge of the top 24 includes bolt holes which line by stepper motors 22, 28' and 44 (illustrated in the flow up with bolt holes in flange portion 76 of baffle plate 66 and chart of FIG. 2 and in exploded perspective view in FIG. 4) with bolt holes in a flange 84 forming the peripheral edge of which Stepper motors are automatically operated by com box 48. Bolts (not shown) are inserted through the aligned puter C. Computer C monitors the 02 and thus the hydro bolt holes to fasten the components together. A float 86 carbon emissions in exhaust 12 and should those readings contained in the box 48 determines the level of liquid indicate too high or too low hydrocarbons, the Stepper gasoline contained in the box. The liquid gasoline enters the motors are activated by the computer to change the relative box through conduit 34 and a recycling conduit 90 is fluid volumes from conduit 18 and conduit 42. Should the provided to drain and/or circulate the gasoline in the vapor reading Show a too high hydrocarbon level, the vapor/air izing tank 26 as may be desired.

flow of conduit 44 needs to be lessened, e.g., the valve 44 0039. In operation liquid gasoline is filled to a level of closed, or, e.g., the valve 28 opened, or, e.g., both closing of about% inch in the bottom of the box 48 which is above the valve 44 and opening of valve 28. position of the heater coils 50 and below the top of the baffle 0033. The adjustment may take place in stages, i.e., a 1 grid 56. The baffle grid 56 and baffle plate 62 primarily closing of valve 44, a re-reading of the 02 detector followed prevent Sloshing of the gasoline during driving of the by repeated partial closing of valve 44 or alternatively the vehicle. As the liquid gasoline vaporizes (induced by the partial opening of valve 18 or a combination of both. Valve heating coil 50) air from inlet 78 is dispersed across the 22 can also be a factor as restricting air flow into conduit 20 liquid surface via baffle plates 72 and 68 which collects will slow the flow of air to the tank 26, thus to conduit 42, vapors 40 (see FIG. 1) and is then directed through outlet 80 while also diverting more airflow through valve 28. and to the mixing chamber 30 via conduit 42 as previously discussed.

0034. The structure as described enables the designer to 0040 AS gasoline is vaporized and drawn from the design a System that will theoretically provide the desired Surface of the liquid gasoline, the gasoline level diminishes result in fuel-to-air mixture (e.g., 1 to 30) as deemed which is detected by the float 86. As determined desirable by desirable, but then in recognition of the impact of Small the System, the gasoline is replenished through inlet 34. environmental changes that produce Substantial deviations After Some period of time, the gasoline Starts to become in efficiency, provide automatic adjustments that are respon

Sive to real time readouts from an exhaust monitor, e.g., an contaminated (does not vaporize) and it is desirable to purge 02 detector. the tank. This can be done by converting the engine to gasoline use and drawing the residual gas of the tank 26 0035) Reference is now made to FIG.3, which illustrates through the conventional gas injection System. It can also be the components of the vaporizing tank 26. The tank 26 Simply drained into a holding tank and utilized for other consists of a metal box 48 having dimensions of about power equipment, e.g., a powered law mower. 4"x8"x12". Fitted to the bottom of the tank is a hot water coil 50 that includes an inlet 52 and outlet 54 which, when 0041 AS explained in the Summary of the Invention, a assembled to the box 48, extends from the box via inlet 52" further improvement is the controlled modification to the and outlet 54'. temperature of the fuel in the vaporization tank. The tem perature at the outset is established to provide a desired 0036) Seated onto the box bottom and over the coil 50 is vaporization of a quantity of fresh fuel, e.g. 74 degrees (but a baffle grid 56. The plates of the baffle grid 56 include slots note this initial desired temperature will likely change with 58 which enable the seating of the grid over the coil 50. different fuel types and for example 80 may be just as valid

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a start temperature). A temperature Sensor previously utilized Such as monitoring the fuel Volume and initiating referred to is utilized to control the heat generated by a Switch-over, e.g. when 80% of the fuel is depleted. heating Source, e.g. the indicated water heating coils 0046) Whereas the above is considered a preferred immersed in the liquid fuel. embodiment, the reader will readily understand that numer 0042. The power generated by the engine at the initial ouS modifications and variations may be made without fuel temperature is monitored and when a determined power departing from the intended Scope of the invention. Accord loSS is detected, the temperature of the fuel in the vaporiza ingly, the invention is not limited to the Structures as tion tank is increased, e.g. by 1 or 2 degree increments. The described above but fully encompasses the definitions of the loss of power is simply a result of the above described appended claims.

Vaporization process. The liquid gasoline produces more What is claimed is:

Vapors initially than it does as time goes on. The engine 1. A fuel Supply assembly for a gasoline fueled engine requires a quantity of vapor to run correctly and that quantity which includes a combustion chamber for combusting fuel of vapor exists when the gasoline is fresh but not after Some and an exhaust for the combusted fuel, which assembly time vaporizing. This loss of power is detected by the 02 comprises:

Sensor that reports the air to fuel ratio. Many things Such as high or low levels of hydrocarbons, carbon dioxide and a vaporizing tank, a quantity of liquid gasoline fuel oxygen can be derived from the 02 sensor. When there is a contained in the tank, a heating Source for heating the loSS of power, the hydrocarbons and carbon dioxide levels liquid gasoline fuel to promote vaporization of the fuel, go extremely low and the oxygen level goes extremely high and a temperature control for controlling the heating as well as higher air to fuel ratio. Any or all of these can be Source and thereby the temperature of the liquid fuel as utilized as a signal for loSS of power. contained in the tank;

0043. The initial cure to the power loss is to adjust either a conduit arrangement intermixing vaporized gasoline the ambient air valve 28 or vapor value 44 or both. As the fuel from the tank with ambient air, and for conveyance Vaporization process continues, the ambient air valve will thereof to the combustion chamber of a gasoline fueled close and the vapor valve will open in response to the leSS engine, Said conduit arrangement including control and less potent liquid gasoline that is producing the required lable Valving for controlling the intermixture of Said vapor. Eventually the vapor valve will be fully opened and Vaporized fuel and ambient air; the free air valve will be fully closed. At this point the a monitor monitoring the exhaust for the combusted fuel temperature of the fuel is increased. Heating the gasoline in and determining thereby a variation from a desired 1 or 2 degree increments is enough to increase the produc intermixture of Said vaporized fuel and ambient air, tion to adequately provide the needed fuel vapors to the Said controllable Valving responsive to Said monitor for engine. AS the heat is increased, the vapor valve moves away altering the intermixture of Said vaporized gasoline fuel from its fully opened position until the new temperature is and Said ambient air to achieve the desired intermix no longer adequate at which time the vapor valve opens and ture; and will eventually will be fully opened until more heat is added an engine power Sensor for Sensing engine power loSS to the liquid gasoline. The proceSS will repeat itself until a when receiving the desired intermixture and inducing a predetermined temperature is reached at which time the higher temperature of Said liquid fuel in Said tank to remaining liquid is drained, e.g., using the Stock fuel injec offset said power loSS.

tion System. 2. A fuel Supply assembly as defined in claim 1, including 0044) The formula for signaling the change from vapor to a System design that determines depletion of the fuel to a liquid fuel is as follows: highest allowed heat of liquid pre-established residual level and initiating termination of gasoline plus vapor valve fully opened plus input that the the vaporization at Said level.

engine is no longer being provided the needed vapor to 3. A fuel Supply assembly as defined in claim 2 perform properly equals Switch from vapor System to Stock wherein said depletion is determined by a maximum tem fuel injection System and burn-off residual liquid. perature of Said liquid fuel, Said System design responsive to Said maximum temperature for initiating termination.

004.5 The system is designed so that the residue in the 4. A fuel Supply assembly as defined in claim 2 wherein tank does not become So contaminated that it cannot be Said depletion is determined by a minimum liquid fuel level effectively used as a liquid fuel Supply. For example, it may in Said vaporizing tank and Said System design responsive to be determined that a power loss detected with the fuel in the Said minimum liquid fuel level for initiating termination. tank heated to 100 degrees will trigger the Switch-over, i.e., purging of the tank. Other triggering mechanism may be k k k k k