Note: Descriptions are shown in the official language in which they were submitted.
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EMISSION CONTROL DEVICE AND METHOD
FIELD OF THE INVENTION
The present invention relates generally to an apparatus and method for
treating
exhaust gases, and more particularly to a combustion engine treatment device
for removing
and/or reducing pollutants contained in the combustion engine effluent gases.
In particular,
the present invention reduces carbon dioxide, substantially reduces
hydrocarbons and
virtually eliminates the exhaust of carbon monoxide.
~r~CKGROITND OF THE INVENTION
With the increasing use of automobiles, trucks, aircraft, and other combustion
engine vehicles, growing concern over the gaseous pollutants emitted by these
sources is
justifiably mounting. Carbon monoxide, the toxic by-product of incomplete
combustion,
is a major contributor to air pollution and poses a very real threat to public
health. Carbon
dioxide, although non-toxic, is recognized as an air pollutant that directly
causes the
"greenhouse effect." Modern fuels generate excessive amounts of carbon
dioxide, which
scientists report are contaminating the atmosphere worldwide. Today's engines
also
generate an unhealthy amount of toxic hydrocarbons which are generally
responsible for
eye irritation, nasal congestion and breathing difficulties.
In addition to the problems caused by exhaust emissions from combustion
engines,
significant exhaust pollution is also created from industrial effluent stacks.
Exhaust
pollution is also a significant problem with stray booths, styrene
manufacturing and burning
of hazardous waste among a variety of industrial processes.
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Numerous devices and methods are known in the art for the control of exhaust
gas
contaminants. Electrostatic precipitation is widely used in such applications
and involves
the application of high voltages to electrodes positioned in the exhaust gas
stream. This
profess induces ionization of gas particles, which in turn cause particulates
suspended in
the gas to acquire a charge from contact with the ionized gas particles. The
charged
particles are then collected at oppositely charged diodes, which must be
eventually
"cleaned" or "scrubbed". A significant drawback of electrostatic precipitation
is that only
minute particulate matter can be precipitated out of the exhaust stream. The
process is
ineffective at removing gaseous contaminants such as carbon monoxide and
carbon dioxide.
Eurners, activated carbon and water curtains are widely used to reduce
hydrocarbon
and volatile organic compound emissions. ~Iowever, these pollution control
devices are
impractical for use with internal combustion engine vehicles. Additionally, a
significant
drawback of burners and water curtains is a large operation cost and activated
carbon is
easily clogged when treating a particulate laden air stream.
In efforts to meet increasingly more stringent vehicle emissions standards,
some
manufacturers have begun using multiple catalytic converters. However, a
conventional
catalytic converter is expensive since about one troy ounce of platinum or
rhodium is used
in its manufacture.
DESCRIPTION Oh' TIi~ PRIOR ART
Applicant is aware of the following IJ. S. Patent concerning emission
controls:
LTS 1'at. No. Inventor Issue Date Title
5,419,123 Masters OS-30-1995 EMISSI~N C~NTR~I, DEVICE AND
lV.iETI~OD
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Masters, LT.S. Patent 5,419,123, discloses an emission control device and
method
for treating exhaust gases to reduce pollutants contained therein. The device
includes a
treatment chamber having a first metal screen, a second metal screen and a
perforated
chemical substrate disposed between the first and second metal screens. An
electrode
disposed a distance from the first screen and is applied a voltage so that
sparks are
generated between the electrode and the first screen.
Although the Masters patent may reduce emissions in the exhaust gas it has
several
limitations. Since an electrode is used to deliver the spark the electrified
area is
concentrated to a portion of the first screen and hence is not evenly
distributed over the
entirety of the screen. Consequently, a portion of the gas stream is not
sufficiently treated.
This problem become more pronounced if the plug becomes angled towards or away
from
the first screen.
Additionally, since the voltage is applied to the electrode via standard
wiring there
are significant losses such that only about 30% of the voltage generated is
applied to the
electrode. Accordingly, for 15K volts to be delivered to the plug about SOIL
volt must be
supplied. This high voltage is particularly problematic when used with an
automobile since
it can cause random cycling frequency in the automobile's circuitry sufficient
to send false
codes to the automobile's computer or even damage the computer.
furthermore, by placing the first and second screens on opposite sides of the
substrate sparks are not generated between the screens.
S~JM1VIA1~Y OF T~ INVENTI~N
The present invention provides an apparatus and method for reducing or
eliminating
emissions from a gas stream. The gas stream is treated by a treatment chamber
in series
with a second chamber having perforated strata. The treatment chamber includes
a first
metal grid supplied with high voltage and a second metal grid grounded to the
treatment
chamber to generate sparks over the entirety of the first grid to the second
grid thereby
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causing electronic ionization. Since aII of the air stream is required to flow
through the first
and second grids, all of the air stream is fully treated. The second metal
grid is
conductively connected to the second chamber and, therefore, the entire
connection and the
second chamber are also electronically ionized. Due to the treatment caused by
electronic
ionization the strata can fully perform with significantly less use of noble
metals than with
conventional catalytic converters. Although maximum pollution reduction occurs
with the
use of about one 1/10 troy ounce of platinum, rhodium, or palladium, favorable
results are
achieved without the use of any noble metal.
A further advance is a high efficiency induction coil. The coil applies
voltage from
a source to the first screen at an efficiency of at Ieast eighty percent
thereby causing very
hot sparks between the first grid and the second grid. Additionally, this coil
is configured
to dampen the magnetic field created by the induction coil. Dampening the
magnetic field
is particularly important in automotive applications and other applications
which are
integrated with a computer since the magnetic field can create random cycling
current in
the electrical system so as to cause false signals to be sent to the computer.
The present invention substantially reduces carbon dioxide and hydrocarbons
and
virtually eliminates the exhaust of carbon monoxide. The system can be used to
treat
emissions from industrial effluent stacks, spray booth, styrene manufacturing,
burning
hazardous waste, purifying air streams among a variety of other industrial
processes, and
is particularly useful for treating emissions from the combustion of carbon or
fossil fuels.
The system can be installed as original equipment, an add on device or as an
after market
device.
~BLEATS ~F' T)EIE gNVENTI~N
The principal object of the present invention is to provide an improved
apparatus
and method for reducing pollutants from a gas stream. The apparatus includes a
first body
form a f rst chamber. first and second metal girds are fixed within the first
chamber so that
the gas stream entering the first chamber passes through the grids. An
electrical connector
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is attached to either the first grid of the second grid and connects that grid
to a voltage
source causing electrical sparks to be generated between the first grid and
the second grid.
A pulsing mechanism pulses the applied voltage at a predetermined frequency. A
second
body forming a second chamber has a perforated strata through which the gas
stream flows.
Another object of the invention is to provide a voltage difference between the
first
grid and the second grid of at least 20,000 volts. Additionally, the pulsing
mechanism is
capable of pulsing the voltage at a frequency of greater than 1,600
pulses/minute.
A further object of the present invention is to fix the nearer of the first or
second
grid a distance between 2.54 cm (1 inch) and 30.48 cm (12 inches) from the
strata.
Additionally, another object is to space the first grid from the second grid a
distance
between 0.635 cm (1/4 inch) to 2.54 cm (1 inch).
Another object of the present invention is to use an electrical connector
which is
adapted to apply at least 80 percent of the voltage the connector receives.
A further object of the present invention is to for the electrical connector
to include
a plurality of bare wires juxtaposed in a first curvilinear row and coiled
equal-distantly
about a curvilinear centerline thereby forming a curvilinear helix shape. A
plurality of
insulated wires are juxtaposed in a second curvilinear row and coiled around
the bare wires.
An insulated center-wire is positioned along the curvilinear centerline and
disposed within
the bare wires and the insulated wires.
A still further object is for the electrical connector to use four or five
bare wires,
three insulating wires and an insulated center-wire.
Another object of this invention is to provide a method of treating exhaust
gasses
to reduce pollutants contained therein. The method includes the steps of
passing exhaust
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gasses through a first body forming a chamber. The gasses are passed through a
first grid
and a second grid fixed within the chamber. The grids are separated a
predetermined
distance from each other. ~loltage is supplied from a voltage source to either
the first or the
second gird to generate sparks between the first grid and the second grid.
The~voltage is
pulsed at a predetermined frequency. The exhaust gasses also pass through a
strata.
A further obj ect of the invention is to provide a voltage difference between
the first
grid and the second grid of at least 20,000 volts at a frequency of at least
1,600
pulses/minute.
~1~EF DESC1ZIPTI~N ~F 'f~-IE DRAV601NGS
The foregoing and other objects will become more readily apparent by referring
to
the following detailed description and the appended drawings in which:
Figure 1 is a diagrammatic view of an embodiment of the present invention
shown
in use as an emission control device;
Figure 2 is a perspective view shown in partial cut-away of a induction coil;
Y 5 Figure 2a is a perspective view of a detail showing the induction coil of
Figure 2;
Figure 3 is a perspective view shown in partial cut-away of a treatment
chamber;
Figure 4 is a perspective fragmentary view taken along line 4-4 of Figure 1
showing
a second chamber having a strata; and
Figure 5 is an perspective view shown in partial cut-away showing an
alternative
embodiment of the second chamber having baffles.
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DE'fAILE~ DESCItIPTI~N
Figure 1 generally illustrates a system 10 for treating exhaust gases by
reducing
pollutants contained therein. The system 10 includes a voltage source 12, an
induction coil
14, a f rst chamber 16 and a second chamber 18. The first chamber 16 includes
a
continuous outer wall 20 an intake end 22 and an exhaust end 24. A first metal
grid 26 is
disposed within the treatment chamber and separated from the outer wall 20 by
an insulator
28. A second metal grid 30 is disposed within and attached to the treatment
chamber 16 a
predetermined distance from the first metal grid 26. The voltage source 12 is
connected to
the~first metal grid 26 via the induction coil 14. A frequency mechanism 32 is
provided for
pulsing the voltage supplied to the first metal grid 26 at a predetermined
optimum
frequency. .
As shown in Figures 2 and 2-A, the induction coil 14 comprises a standard plug
wire
34, a plurality of copper wires 36 juxtaposed in a row and a plurality of
insulated copper
wires 38 juxtaposed in a row. The insulated copper wires 38 are wrapped
throughout the
length of the copper wire 3 6 cluster, and the combination thereof is wrapped
throughout the
length the plug wire 34. Although.any number of arrangements are possible,
preferably the
insulated copper wires 38 are a group of three, and four or five wires
comprise the cluster
of copper wires 36. And eyelet can be provided to ground the induction coil
14. The wires
34, 36, 38 are standard wires. For example, the plug wire can be 8 mm, the
copper wires36
can be 18 gauge and the insulated wires 38 can be 18 gauge.
The first chamber 16 a segment of an exhaust gas conduit 40. Although the
first
chamber 16 is shown in Figure 1 as upstream of the second chamber 18, the
first chamber
16 can also be placed generally anywhere in-line in the exhaust system such
as, for
example, after the second chamber 18. Referring to Figure 3, the first chamber
16 is
preferably cylindrical and formed of metal. The first and second metal grids
26, 30 are
perpendicular to a central axis 40 of the first chamber 16. The grids 26, 30
have a meshed
pattern and completely fill the cross-sectional area of the first chamber 16
so that all of the
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exhaust gases pass therethrough. The first grid 26 is insulated from, and
secured to, the
continuous wall 20 by any conventional means 28. The second grid 30 is
conductively
secured to the continuous wall 20 by any conventional means such as welding.
It is
preferred that the grids 26, 30 are fabricated from chromium, stainless steel
or magnesium
alloy. Flowever, other conductive compositions can also be used. The induction
coil 14
passes through the continuous wall 20 and attaches to the first grid 26 to
directly apply
voltage thereto. When voltage is applied to the first grid 26, the entire grid
26 is placed at
the supplied voltage potential causing a myriad of electrical sparks to be
generated across
the gap between the first grid 26 and the second grid 30. Although the first
grid is shown
upstream of the second grid 30, this positioning can be reversed.
As shown in Figure 4 and 5 the second chamber 18 is preferably cylindrical and
has
a metal shell 42. The second chamber 18 includes a proximal diffusion end 44,
a central
portion filled with strata 46 and a distal end 48 for exhausting the treated
exhaust gases.
The strata 46 can be formed of silica or metal having between 7.9 holes per cm
(20 holes
per inch) and 157.5 holes per cm (400 holes per inch) to allow the exhaust gas
stream to
flow therethrough. Larger holes 50 are preferred when treating heavier
emissions such as
emissions from a diesel engine while smaller holes 50 are used with lighter
emissions.
Preferably, the holes 50 are generally linear and parallel with a central axis
of the second
chamber 18. Flowever, a honeycomb strata can be used. Typically the strata 46
will
contain about 1/10 of one troy or less of noble metals such as palladium,
platinum or
rhodium. Alternatively, the strata can be formed without containing noble
metals. As
shown in Figure 5 the distal end 48 can be provided with a series of baffles
52 which
muffles sound and can serve to replace a standard muffler.
In operation, pollutant laden exhaust gas stream flows through the exhaust gas
conduit 40 into the first chamber 16 through the intake end 22, pass through
the first grid
26, then through the second grid 30 before exiting the exhaust end 24. A
predetermined
distance betweenthe first and second grids 26, 30 typically ranges from 0.635
cm (1/4 inch)
to 2.54 cm (one inch) depending on the voltage of the first grid 26. In
general, the grids 26,
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30 are spaced apart 0.318 cm (1l8 inch) for the first 20K volts and then an
additional 0.318
cm (1/8 inch) for each l OK volt increment. The first chamber 16 can be
located anywhere
in-line the exhaust system but generally is placed between 2.54 cm (one inch)
and 30.48 cm
(12 inches) from the second chamber 18.
Any voltage source and pulsing mechanism sufficient to supply the necessary
voltage at the proper frequency can be used. The applicant has determined that
a voltage
of at least 20K volts at a pulse rate of at least 1600 pulses/minute is
preferred for optimizing
reduction of carbon monoxide, carbon dioxide and hydrocarbons depending on the
exhaust
gas stream being treated. Typically the voltage will be in the range of 40K to
1 OOK volts
and the pulse rate will be in the range of 1500 to 10,000 pulses/minute. In
general, wetter
exhaust such as exhaust from a diesel internal combustion engine requires
higher voltage
and pulse frequency than emissions from lighter fuels such as unleaded
gasoline or propane.
For example, with a gasoline powered automotive IC engine, an output between
40K - 60K
volts at 2000 - 3000 pulses/minute is preferred for optimizing reduction of
carbon
monoxide, hydrocarbons and carbon dioxide. The voltage and frequency are also
set in
proportion to the displacement of the engine with the upper values more
suitable for larger
engines.
A voltage source 12 can be any voltage source which provides the predetermined
voltage. A pulsing mechanism can be any device which sets the voltage at the
proper
frequency. As an example, and not to so limit the present invention, Figure 1
illustrates that
the voltage source 12 can comprise a voltage box 54 and an automotive battery
56. The
primary windings of the voltage box 54 is supplied with 3 volts from a 12 volt
automotive
battery 56 and outputs 40K volts to the induction coil 14 at a pulse rate of
about 2500
pulses/minute. As a further example, small engines such as two cycle engines
which have
a magneto, can supply voltage at the proper frequency to the first grid 26 by
the magneto
without use of a battery or voltage box.
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The inventive induction coil 14 is configured to deliver at least 80% of the
voltage
to the first grid 26 and to dampen the magnetic.field created by the induction
coil 14 so to
not create amperage greater than 0.5 amp, and preferably not greater than 0.4,
amp in
adjacent wiring. Current supplied through the plug wire 34 creates a magnetic
field. This
magnetic field is dampened by the combination of copper wires 3 6 and the
insulated copper
wires 38. Dampening the magnetic field is particularly important in automotive
applications and other applications which are integrated with a computer since
the magnetic
field can create random cycling current in the electrical system. At a level
of about 0.5 aiilp
false signals are sent to the computer.
While not wishing to be bound to any particular theory, it is believed that
exhaust
gas pollutants are treated by electronic ionization at both the chemical and
thermal level.
Electronic ionization is caused by supplying voltage at a frequency to the
first grid 26.
Electronic ionization occurs between the first and second screens 26, 30.
Additionally, the
exhaust gas conduit 40 and second chamber 18 including the strata 46 are
ionized. Since
the farst grid 26 receives all the exhaust gas air stream and the voltage is
supplied to the
entirety of the first gird 26, all of the exhaust gas is fully treated by
electronic ionization.
Ez~haust gas exiting the first chamber 16 enters the second chamber 18 and
passes
through the strata 46. The second chamber 18 treats the exhaust gas stream by
use, of a
catalyst in addition to electronic ionization. Presently, the preferred strata
46 contains about
one troy ounce of noble metals such as, for example, platinum, or palladium,
which serve
as a catalyst. The catalyst oxidizes carbon monoxide and hydrocarbon
pollutants to form
carbon dioxide and water. The strata 46 also has the benefit of producing
oxygen (OZ)
during operation of the emission control system 10. ~zone (~3) is created at
the first grid
26. The strata 46 oxidizes the ozone and generates oxygen therefrom.
Alternatively, the second chamber 18 can be made of metal without use of a
noble
metal. The applicant has found that the pollutant removal efficiency of the
system 10 free
of noble metals is comparable to that of current catalytic converters, but
less than the
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preferred embodiment. Although the present invention can be used with a
standard
catalytic converter, the reduction or elimination of noble metals from the
second chamber
18 provides a significant cost savings.
Another important benefit of the present invention is its extremely short
start-up
time. 'The system 10 can be at full operating condition in as little as thirty
seconds. For
automotive use, voltage is supplied to the first chamber 16 as soon as the
ignition is turned
to the "key-on" position thereby generating electrical sparks before exhaust
gasses are
generated. Furthermore, although higher temperatures can be used, the second
chamber 18
fully operates at low heat typically in the range of 54°C
(130°F) to 93°C (200°F) as
measured at the outside shell 42. This shell temperature correlation to an
exhaust gas
temperature of about 204°C (400°F). Conventional catalytic
converters take four or five
minutes of engine warm-up time to reach operating temperatures of about
316°C (600°F)
at the outside shell and 982°C (1800°F) for the exhaust gas.
Since the system 10 operates
at low heat, extensive heat shielding is not required for the second chamber
18.
I S Additionally, since the system 10 operates independently of the engine, it
does not require
expensive interactive controls with the engine, nor is a thermocouple
necessary. ,
Although the present invention has been explained primarily in use with an
automobile, the present invention is not limited to such. For example, the
system 10 could
be mounted to an industrial effluent stack, to an exhaust stack from a spray
booth, or to
other such effluent stacks. Fox each the first chamber 16 could be supplied
pulsed voltage
from any number of independent sources.
SZJ1VII~~I OF TIE ACIIIEVE1VIENT OF TIIE OBJECTS
OF TIE INVENTION
From the foregoing, it is readily apparent that I have invented an improved
method
and apparatus for reducing or eliminating pollutants, including gaseous
pollutants, from an
exhaust gas stream.
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It is also apparent that the reaction occurs at the grids and the catalytic
converter arid
is operable at a low temperature.
It is to be understood that the foregoing description and specific embodiments
are
merely illustrative of the best mode of the invention and the principles
thereof, and that
various modifications and additions may be made to the apparatus by those
skilled in the
art, without departing from the spirit and scope of this invention, which is
therefore
understood to be limited only by the scope of the appended claims.
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