Super cooled air and fuel induction system for internal combustion engines

• US 7,841,322 B2
• Filed: 11/13/2008
• Issued: 11/30/2010
• Est. Priority Date: 11/16/2007
• Status: Active Grant

• Current Assignee: Dynamic Fuel Systems, Inc.
• Original Assignee: Dynamic Fuel Systems, Inc.
• Inventors: Bach, Jeff
• Primary Examiner(s): Huynh; Hai H
• Application Number:
  US12/270,195
• Publication Number:
  US 20090126691A1
• Time in Patent Office: 747 Days
• Field of Search: 123/1.A, 123/543, 123/557, 123/435, 123/559.1, 123/480, 123/27.GE, 123525-527, 701103-105
• US Class Current: 123/543
• CPC Class Codes: F02B 29/0418 the intake air cooler having a bypass or multiple flow paths within the heat exchanger to vary the effective heat transfer surface
• CPC Class Codes: F02B 29/0437 Liquid cooled heat exchangers
• CPC Class Codes: F02B 29/0475 the intake air cooler being combined with another device, e.g. heater, valve, compressor, filter or EGR cooler, or being assembled on a special engine location
• CPC Class Codes: F02B 33/00 Engines characterised by provision of pumps for charging or scavenging
• CPC Class Codes: F02B 37/00 Engines characterised by provision of pumps driven at least for part of the time by exhaust
• CPC Class Codes: F02D 19/027 Determining the fuel pressure, temperature or volume flow, the fuel tank fill level or a valve position
• CPC Class Codes: F02D 19/0631 by estimation, i.e. without using direct measurements of a corresponding sensor
• CPC Class Codes: F02D 19/0647 the gaseous fuel being liquefied petroleum gas [LPG], liquefied natural gas [LNG], compressed natural gas [CNG] or dimethyl ether [DME]
• CPC Class Codes: F02D 19/066 Retrofit of secondary fuel supply systems; Conversion of engines to operate on multiple fuels
• CPC Class Codes: F02D 19/0668 Treating or cleaning means; Fuel filters
• CPC Class Codes: F02D 19/081 Adjusting the fuel composition or mixing ratio; Transitioning from one fuel to the other
• CPC Class Codes: F02D 19/10 peculiar to compression-ignition engines in which the main fuel is gaseous
• CPC Class Codes: F02D 41/0025 Controlling engines characterised by use of non-liquid fuels, pluralities of fuels, or non-fuel substances added to the combustible mixtures
• CPC Class Codes: F02D 41/1446 the characteristics being exhaust temperatures
• CPC Class Codes: F02D 41/34 with means for controlling injection timing or duration
• CPC Class Codes: F02M 21/0287 characterised by the transition from liquid to gaseous phase F02M21/06 takes precedence; Injection in liquid phase; Cooling and low temperature storage
• CPC Class Codes: F02M 21/042 Mixer comprising a plurality of bores or flow passages
• CPC Class Codes: Y02T 10/12 Improving ICE efficiencies
• CPC Class Codes: Y02T 10/30 Use of alternative fuels, e.g. biofuels

Abstract

The instant invention provides an apparatus and system for cooling the air charge of an internal combustion engine. More specifically, the instant invention provides an air-induction system suitable to provide cooled air charges to turbocharged, supercharged or naturally aspirated internal combustion engines to increase power output while reducing engine emissions. The system utilizes gaseous fuel stored as a liquid wherein the liquefied gaseous fuel is vaporized and warmed at least partially with heat removed from the intake air charge supplied to the engine from the turbocharger or supercharger. In a preferred embodiment, the compressed intake combustion air is first cooled in an aftercooler against an ambiently cooled coolant and is subsequently cooled further by the chiller of the instant invention which utilizes the change in phase, between liquid and gas, of the alternative fuel to cool the incoming air charge. The fuel, in the gaseous phase, is then supplied to the engine in a controlled manner for combustion by the engine. The operation of this system is measured and controlled by a control box mounted in the engine compartment.

Claims

1. A supplemental fuel injection system for internal combustion engines comprising:

a supply of primary fuel;

a device supplying said primary fuel to an internal combustion engine;

an air compressor supplying air to said internal combustion engine;

a pressure monitor in an air outlet side of said air compressor, said pressure monitor monitoring the pressure of air leaving said air compressor;

a temperature sensor in an exhaust of said internal combustion engine, said temperature sensor measuring the temperature of said exhaust of said internal combustion engine;

a device supplying supplemental fuel to said air prior to said air entering said internal combustion engine; and

a control device controlling the device supplying supplemental fuel, said control device including a programmable microprocessor connected to said device supplying supplemental fuel to vary the amount of supplemental fuel on an as needed, customized and preprogrammed basis for said internal combustion engine;

said device supplying said supplemental fuel to said air includes a heat exchanger, said heat exchanger having a first inlet supplying said supplemental fuel in liquid form to said heat exchanger, a first outlet removing said supplemental fuel in a gaseous form from said heat exchanger, a second inlet supplying said air to said heat exchanger and a second outlet removing said air from said heat exchanger at a temperature lower than the temperature of said air entering said heat exchanger, said air exiting from said heat exchanger entering said internal combustion engine.

2. The supplemental fuel injection system of claim 1 including a supplemental fuel injector positioned downstream of said air exiting from said heat exchanger and upstream of said internal combustion engine.

3. The supplemental fuel injection system of claim 1 wherein said heat exchanger is located upstream of said air compressor.

4. The supplemental fuel injection system of claim 1 wherein said heat exchanger is located downstream of said air compressor.

5. The supplemental fuel injection system of claim 1 including a module positioned within reach of a operator of a vehicle, said module communicating with said programmable microprocessor to vary the amount of said supplemental fuel in a mode, said mode consisting essentially of an on/off mode, a manual adjustment mode, an auto calibration mode and a continuous learn mode.

6. The supplemental fuel injection system of claim 5 including an indicator adjacent said operator, said indicator indicating a problem with the operation of said internal combustion engine.

7. The supplemental fuel injection system of claim 5 wherein said module indicates various operating parameters of said internal combustion engine.

8. The supplemental fuel injection system for an internal combustion engine of claim 1 wherein said amount of said supplemental fuel is for treatment of said exhaust of said internal combustion engine.

9. A kit for adding a secondary fuel system to an internal combustion engine comprising:

an air compressor supplying air to said internal combustion engine;

a pressure monitor in an air outlet side of said air compressor, said pressure monitor monitoring the pressure of air leaving said air compressor;

a temperature sensor in an exhaust of said internal combustion engine, said temperature sensor measuring the temperature of said exhaust of said internal combustion engine;

a device supplying supplemental fuel to said air prior to said air entering said internal combustion engine; and

a control device controlling the device supplying said supplemental fuel, said control device including a programmable microprocessor connected to said device supplying said supplemental fuel to vary the amount of supplemental fuel on an as needed, customized and preprogrammed basis for said internal combustion engine;

said device supplying said supplemental fuel to said air includes a heat exchanger, said heat exchanger having a first inlet supplying said supplemental fuel in liquid form to said heat exchanger, a first outlet removing said supplemental fuel in a gaseous form from said heat exchanger, a second inlet supplying said air to said heat exchanger and a second outlet removing said air from said heat exchanger at a temperature lower than the temperature of said air entering said heat exchanger, said air exiting from said heat exchanger entering said internal combustion engine.

10. The kit of claim 9 including a supplemental fuel injector positioned downstream of said air exiting from said heat exchanger and upstream of said internal combustion engine.

11. The kit of claim 9 wherein said heat exchanger is located upstream of said air compressor.

12. The kit of claim 9 wherein said heat exchanger is located downstream of said air compressor.

13. The kit of claim 9 including a module positioned within reach of a operator of a vehicle, said module communicating with said programmable microprocessor to vary the amount of said supplemental fuel in a mode, said mode consisting essentially of an on/off mode, a manual adjustment mode, an auto calibration mode and a continuous learn mode.

14. The kit of claim 13 including an indicator adjacent said operator, said indicator indicating a problem with the operation of said internal combustion engine.

16. The kit of claim 13 wherein said module indicates various operating parameters of said internal combustion engine.

17. The supplemental fuel injection device of claim 16 including a module positioned within reach of a operator of a vehicle, said module communicating with said programmable microprocessor to vary the amount of said supplemental fuel in a mode, said mode consisting essentially of an on/off mode, a manual adjustment mode, an auto calibration mode and a continuous learn mode.

15. A supplemental fuel injection device comprising;

a heat exchanger, said heat exchanger having a first inlet supplying supplemental fuel in liquid form to said heat exchanger, a first outlet removing said supplemental fuel from said heat exchanger in a gaseous form, a second inlet supplying air to said heat exchanger and a second outlet removing said air from said heat exchanger at a temperature lower than the temperature of said air entering said heat exchanger, said air exiting from said heat exchanger entering an internal combustion engine; and

at least one injector supplying said gaseous supplemental fuel to said air exiting said heat exchanger.