Low pressure gas vaporizer and method of operation

• US 6,044,825 A
• Filed: 02/21/1997
• Issued: 04/04/2000
• Est. Priority Date: 02/21/1996
• Status: Expired due to Term

• Current Assignee: Westport Power Inc. (Westport Fuel Systems, Inc.)
• Original Assignee: GFI Control Systems, Inc. (Teleflex Incorporated)
• Inventors: Carter, Steven A., Knappers, Michael, Khadim, Neil M.
• Primary Examiner(s): MCMAHON, MARGUERITE J
• Application Number:
  US08/803,672
• Time in Patent Office: 1,138 Days
• Field of Search: 123/557, 123/543, 123/546, 123/547, 123/545, 123/549
• US Class Current: 123/557
• CPC Class Codes: F02M 21/0239 Pressure or flow regulators therefor
• CPC Class Codes: F02M 21/06 Apparatus for de-liquefying, e.g. by heating
• CPC Class Codes: Y02T 10/30 Use of alternative fuels, e.g. biofuels

Abstract

A fuel vaporizer and method of fuel vaporization are described for use with a fuel such as propane, that is know to tend to liquefy at low temperatures and to vaporize at high temperatures. The vaporizer and method described pertain to a series of internal walls and cavities which promote heat-exchange and transfers heat from a fluid engine coolant to the fuel. The transfer of heat and vaporization of fluid occurs by virtue of movement of the fuel through a series of countercurrent passages created by the walls and cavities, with increasing cross-sectional dimensions in the passages to accomodate the expansion of fuel from the liquid to the gaseous state. The heat is transferred by conduction across a metallic interface which forms part of the vaporizer and which separates the fuel from the coolant.

Claims

1. A fuel vaporizer for use with a fuel which tends to liquefy at low temperatures and to vaporize at high temperatures, said vaporizer comprising:

heat-exchange means adapted to transfer heat from a fluid engine coolant to said fuel; and

an interface which forms part of said vaporizer and which separates said fuel from said coolant, said heat being transferred by conduction across said interface, said interface comprising a series of successively connected passages intermediate a starting point where said fuel enters said vaporizer and an end point where said fuel exits said vaporizer, each of said successively connected passages, commencing with a passage most proximate said starting point, being of lesser cross-sectional area than an immediately adjacent successively connected passageway progressing in a direction toward said endpoint, to thereby provide successively increasing cross-sectional area to accommodate said fuel as it changes state from mostly liquid at said starting point to mostly gaseous by said end point.

2. A vaporizer according to claim 1, each passage having one or more passageways, the passage proximate said end point having a combined cross-sectional area greater than a combined cross-sectional area of a passage proximate said starting point.

3. The vaporizer according to claim 1, in which said low temperature comprises ambient winter temperature, and wherein said high temperature comprises a temperature above said ambient winter temperature.

4. The vaporizer according to claim 1, in which said low temperature is less than approximately 15°

C., and wherein said high temperature is above approximately 15°

C.

5. The vaporizer according to claim 1, wherein a passageway proximate said endpoint directs the fuel tangentially into a cylindrical chamber so as to cause swirl of said fuel about a circumferential periphery of the cylindrical chamber.

6. In a fuel vaporizer for use with a fuel that tends to liquefy at low temperatures and to vaporize at high temperatures, said vaporizer having heat-exchange means adapted to transfer heat from a fluid engine coolant to said fuel, wherein heat is transferred by conduction across a metallic interface which forms part of said vaporizer and which separates said fuel from said coolant, wherein:

said vaporizer defines for said fuel a path along which said fuel travels while heat transfer takes place, said path including, in the order encountered by said fuel;

a chamber for receiving said fuel,

a single, sinuous passage adjacent said chamber but substantially separated therefrom by a wall which defines a plurality of small-diameter apertures through which fuel in said chamber can be sprayed against a wall of said passage, said passage having one blind end, and having another end toward which said fuel travels and at which said passage branches into two portions through which it communicates with,

a pair of sinuous passages generally parallel with each other and with said single sinuous passage, but disposed such that fuel contained therein travels generally in the opposite direction from fuel travel in said single sinuous passage, the cross-sectional area of the combination of said pair of sinuous passages being greater than that of said single sinuous passage, so as to permit expansion of the volume of said fuel as it gradually vaporizes due to said heat input, said pair of sinuous passages at the downstream end thereof communicating with the ends of

a triplicity of sinuous passages generally parallel with each other and with said pair of sinuous passages, but disposed such that fuel contained therein travels generally in the opposite direction from fuel travel in said pair of sinuous passages, the crosssectional area of the combination of said triplicity of sinuous passages being greater than that of said pair of sinuous passages, so as to permit further expansion of the volume of said fuel as it continues to vaporize due to said heat input.

7. The vaporizer claimed in claim 6, in which said vaporizer further comprises three sinuous fins, each of said triplicity of sinuous passages enclosing one of said fins without making any substantial contact therewith, said sinuous fins being in contact with said heating means by which they can be heated and thus transfer heat into any fuel disposed in said triplicity of sinuous passages;

whereby the presence of said three fins has the effect of converting said triplicity of passages into six smaller-section passages.

8. The vaporizer claimed in claim 7, in which said heating means includes electrical means.

9. The vaporizer claimed in claim 6, in which said single sinuous passage is substantially sinusoidal and defines a concave portion adjacent each of said apertures, said apertures being disposed to spray fuel generally tangentially into said respective concave portion, so as to maximize the vaporization potential of the impact of fuel against said wall.

10. The vaporizer claimed in claim 9, in which said single passage has a lower floor which rises toward said downstream end of said single passage, so that fuel which remains in the liquid state tends to be trapped within said single passage.

11. The vaporizer claimed in claim 10, in which said pair of passages each have a lower floor which rises toward said downstream end thereof, so as to trap fuel that remains in the liquid state.

12. The vaporizer claimed in claim 11, in which, at said downstream end of said pair of passages, said passages merge together to form a unitary flow, said vaporizer further comprising obstruction means at the location where said pair of passages merge, such that impact of said fuel with said obstruction means promotes turbulence in said fuel, thus enhancing heat flow into said fuel.

13. The vaporizer claimed in claim 6, wherein overpressure at a gaseous fuel exit port of said vaporizer is relieved by a check valve having an O-ring seal which is fitted around a piston of said check valve and said piston is biased upwardly by a spring.

14. A fuel vaporizer for use with a fuel, such as propane, that tends to liquefy at low temperatures and to vaporize at high temperatures, said vaporizer having a body comprising:

means defining a first path for the flow of engine coolant therethrough,

means defining a second path for the flow of fluid fuel therethrough,

means defining a heat-exchanger through which heat can be transferred from said coolant to said fuel by conduction across a metallic interface which forms part of said vaporizer and which separates said fuel from said coolant,

said second path for said flow of fuel including, in the order encountered by said fuel;

chamber for receiving said fuel,

a single, sinuous passage adjacent to said chamber but substantially separated therefrom by a wall which defines a plurality of small-diameter apertures through which fuel in said chamber can be sprayed against a wall of said passage, said passage having, one blind end, and having another end toward which said fuel travels and at which said passage branches into two portions through which it communicates with,

a pair of sinuous passages generally parallel with each other and with said single sinuous passage, but disposed such that fuel contained therein travels generally in the opposite direction from fuel travel in said single sinuous passage, the cross-sectional area of the combination of said pair of sinuous passages being greater than that of said single sinuous passage, so as to permit expansion of the volume of said fuel as it gradually vaporizes due to said heat input, said pair of sinuous passages at the downstream end thereof communicating with the ends of a triplicity of sinuous passages generally parallel with each other and with said pair of sinuous passages, but disposed such that fuel contained therein travels generally in the opposite direction from fuel travel in said pair of sinuous passages, the cross-sectional area of the combination of said triplicity of sinuous passages being greater than that of said pair of sinuous passages, so as to permit further expansion of the volume of said fuel as it continues to vaporize due to said heat input.

15. The fuel vaporizer claimed in claim 14, in which said vaporizer further comprises three sinuous fins, each of said triplicity of sinuous passages enclosing one of said fins without making any substantial contact therewith, said sinuous fins being in contact with heating means by which said fins can be heated and thus transfer heat into any fuel disposed in said triplicity of sinuous passages;

whereby the presence of said three fins has the effect of converting said triplicity of passages into six smaller-section passages.

16. The fuel vaporizer claimed in claim 15, in which said heating means includes electrical means.

17. The fuel vaporizer claimed in claim 14, in which said single sinuous passage is substantially sinusoidal and defines a concave sinusoidal portion adjacent each of said apertures, said apertures being disposed to spray fuel generally tangentially into the respective sinusoidal portion, so as to maximize the vaporization potential of the impact of fuel against the wall.

18. The fuel vaporizer claimed in claim 17, in which said single passage has a lower floor which rises toward the downstream end of the single passage, so as to trap fuel that remains in the liquid state.

19. The fuel vaporizer claimed in claim 18, in which said pair of passages each has a lower floor which rises toward the downstream end thereof, so as to trap fuel that remains in the liquid state.

20. The fuel vaporizer claimed in claim 19, in which, at the downstream end of said pair of passages, said passages merge together to form a unitary flow, said vaporizer further comprising obstruction means at the location where said pair of passages merge, such that impact of said fuel with said obstruction means promotes turbulence in the fuel, thus enhancing heat flow into the fuel.

21. A method of vaporizing a fuel that tends to liquefy at low temperatures and to vaporize at high temperatures, utilizing a vaporizer having heat-exchange means adapted to transfer heat from a fluid engine coolant to the fuel, wherein heat is transferred by conduction across a metallic interface which forms part of said vaporizer and which separates said fuel from said coolant, the method comprising the steps:

passing said fuel into a chamber defined by said vaporizer,

then passing, said fuel into a single, sinuous passage adjacent to said chamber but substantially separated therefrom by a wall which defines a plurality of small-diameter apertures, by spraying said fuel through said apertures against a wall of said single passage,

then passing said fuel into a pair of sinuous passages generally parallel with each other and with said single sinuous passage, whereby said fuel travels generally in the opposite direction from fuel travel in said single sinuous passage, the cross-sectional area of the combination of said pair of sinuous passages being greater than that of said single sinuous passage, so as to permit expansion of the volume of said fuel as it gradually vaporizes due to said heat input,

then passing said fuel into a triplicity of passages generally parallel with each other and with said pair of sinuous passages, but disposed such that fuel contained therein travels generally in the opposite direction from fuel travel in said pair of sinuous passages, the cross-sectional area of the combination of said triplicity of sinuous passages being greater than that of said pair of sinuous passages, so as to permit further expansion of the volume of said fuel as it continues to vaporize due to said heat input.

22. The method claimed in claim 21, in which said vaporizer includes three sinuous fins disposed such that each of said sinuous passages encloses one of said fins without making any substantial contact therewith, said method including the further step of transferring heat from an outside source to said sinuous fins whereby said fins can be heated and thus transfer heat into any fuel disposed in said triplicity of sinuous passages.

23. The method claimed in claim 22, in which said heat applied to said fins is derived from an electrical source.

24. The method claimed in claim 21, in which said single sinuous passage defines a concave sinusoidal portion adjacent each of said apertures, and wherein, as part of said method, said apertures spray fuel generally tangentially into the respective sinusoidal portion, so as to maximize the vaporization potential of the impact of fuel against the wall.

25. A fuel vaporizer and pressure regulator for use with a fuel that tends to liquefy at low temperatures and to vaporize at high temperatures, said vaporizer and pressure regulator comprising:

spring means;

valve means for regulating pressure of fuel exiting said vaporizer and pressure regulator, said valve means being controlled by a force exerted thereon by said spring means,

modulating means for altering said force exerted by said spring means at low temperature to allow said valve means to open to a greater extent in low temperature conditions.

26. The vaporizer and pressure regulator according to claim 25, wherein said modulator means comprises:

a movable member, coupled at one end thereof to said spring means; and

a wax element coupled to another end of said movable member, said wax element having a given consistency which changes in accordance with temperature so as to cause movement of said movable member.

27. The vaporizer and pressure regulator according to claim 26, wherein said movable member comprises a piston, said movable member another end being disposed within a diaphragm member, said diaphragm member being in contact with and movable by said wax element upon a change in temperature.

28. A fuel pressure regulator for use with a fuel which tends to liquefy at ambient winter temperatures and to vaporize at temperatures above ambient winter temperatures, said fuel pressure regulator having a pressure regulating stage which comprises:

spring means;

valve means for opening a port to allow fuel to enter said regulator, said valve means being controlled by a force exerted thereon by said spring means; and

modulator means for reducing said force exerted by said spring means when temperatures are ambient winter temperatures.

29. The regulator according to claim 28, wherein said ambient winter temperatures are temperatures below about 15°

C.

30. The regulator according to claim 29, wherein said modulator means comprises:

a movable member coupled at one end thereof to said spring means; and

a wax element coupled to another end of said movable member, said wax element having a given consistency which changes in accordance with temperature so as to cause movement of said movable member.

31. The regulator according to claim 30, wherein said movable member comprises:

a lever arm; and

a piston having an end which contacts said lever arm, said lever arm, which acted upon by said piston, reducing the force exerted by said spring means.

32. The regulator according to claim 30, wherein said movable member comprises a piston one end of which resides within a diaphragm member, said diaphragm member being in contact with and movable by said wax element upon a reduction in temperature.

33. The regulator according to claim 30, wherein said change in consistency of the wax element comprises a change in volume.