IPC분류정보
국가/구분 |
United States(US) Patent
등록
|
국제특허분류(IPC7판) |
|
출원번호 |
US-0108831
(2011-05-16)
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등록번호 |
US-8677751
(2014-03-25)
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발명자
/ 주소 |
- VanDyne, Ed
- Brown, Jared William
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출원인 / 주소 |
|
대리인 / 주소 |
|
인용정보 |
피인용 횟수 :
3 인용 특허 :
13 |
초록
▼
Disclosed is a super-turbocharger system that increases power and efficiency of an engine. The system uses the exothermic properties of a catalytic converter to extract additional energy from exhaust heat that is used to add power to the engine. Compressed air is supplied and mixed with exhaust gase
Disclosed is a super-turbocharger system that increases power and efficiency of an engine. The system uses the exothermic properties of a catalytic converter to extract additional energy from exhaust heat that is used to add power to the engine. Compressed air is supplied and mixed with exhaust gases upstream and/or downstream from a catalytic converter that is connected to an exhaust manifold. The gaseous mixture of exhaust gases and compressed air is sufficiently rich in oxygen to oxidize hydrocarbons and carbon monoxide in the catalytic converter, which adds heat to the gaseous mixture. In addition, a sufficient amount of compressed air is supplied to the exhaust gases to maintain the temperature of the gaseous mixture at a substantially optimal temperature level. The gaseous mixture is applied to the turbine of the super-turbocharger, which increases the output of said super-turbocharger, which increases the power and efficiency of said engine. The engine throttle is used to control the pressure level of the compressed air to ensure proper flow of cooling gases and oxidation gases.
대표청구항
▼
1. A method of improving performance of an engine system, wherein said engine system comprises: an engine,a super-turbocharger that is both mechanically driven by said engine and driven by exhaust gases from said engine comprising: a catalytic converter connected to an exhaust conduit proximate to a
1. A method of improving performance of an engine system, wherein said engine system comprises: an engine,a super-turbocharger that is both mechanically driven by said engine and driven by exhaust gases from said engine comprising: a catalytic converter connected to an exhaust conduit proximate to an exhaust outlet of said engine such that pollutants in hot exhaust gases from said engine are reduced and said catalytic converter produces converted exhaust gases,a compressor of said super-turbocharger connected to a source of air so that said compressor provides a supply of compressed air to a compressed air conduit that is coupled to an intake of said engine,a throttle in said compressed air conduit to increase pressure levels of said compressed air to a level that is greater than exhaust gas pressure levels, anda compressed cooling air conduit connected to said compressed air conduit so that said compressed air cooling conduit supplies a portion of said supply of compressed air, upstream from said throttle, to said converted exhaust gases so that said portion of said supply of compressed air is mixed with said converted exhaust gases to produce a gaseous mixture; the method comprising: supplying said gaseous mixture to a turbine that is mechanically coupled to said compressor so that turbine rotational mechanical energy is generated by said turbine from said gaseous mixture;generating a control signal from a controller that regulates said portion of said compressed air that is mixed with said converted exhaust gases to maintain said gaseous mixture below a maximum temperature;operating said engine with a fuel mixture to at least create a stoichiometric mixture; wherein a transmission is connected to said compressor and provides propulsion train rotational mechanical energy from a propulsion train of said engine to said compressor to reduce turbo-lag when said flow of said gaseous mixture through said turbine is not sufficient to drive said compressor to a desired boost level, and extracts excess turbine rotational mechanical energy from said turbine that is applied to said propulsion train. 2. A method of improving performance of an engine system, wherein said engine system comprises: an engine that operates with a rich fuel mixture to increase output power and performance of said engine system,a super-turbocharger that is both mechanically driven by said engine system and driven by exhaust gases from said engine system, and a throttle valve in a compressed air conduit downstream from a compressor of said super-turbocharger; the method comprising: generating a supply of compressed air from said compressor of said super-turbocharger that compresses intake air in response to a control signal to generate said supply of compressed air in said compressed air conduit coupled to the intake of said engine;controlling said throttle valve to control pressure levels of said compressed air in said compressed air conduit to be greater than pressure levels of said exhaust gases from said engine;mixing a portion of said supply of said compressed air, upstream from said throttle valve, with said exhaust gases from said engine to produce a gaseous mixture of said exhaust gases and said compressed air;supplying said gaseous mixture to a catalytic converter that produces an exothermic reaction that adds heat to said gaseous mixture to generate a converted gaseous mixture at an output of said catalytic converter;detecting oxygen levels of said gaseous mixture that enter said catalytic converter;detecting said temperature levels of said converted gaseous mixture exiting said catalytic converter;adjusting said portion of compressed air, in response to said oxygen levels, to provide a sufficient amount of said portion of compressed air to substantially oxidize hydrocarbons and carbon monoxide present in said gaseous mixture in said catalytic converter, while maintaining a predetermined temperature level of said converted gaseous mixture;supplying said converted gaseous mixture to a turbine of said super-turbocharger to drive said turbine with said converted gaseous mixture so that said exothermic reaction in said catalytic converter increases power generated by said turbine. 3. The method of claim 2 wherein said predetermined temperature level is a temperature level that will not damage said turbine. 4. The method of claim 2 wherein said predetermined temperature level is approximately 950° C. 5. A method of improving performance of an engine system, wherein the engine system comprises: an engine,a super-turbocharger that is both mechanically driven by said engine and driven by exhaust gases from said engine, anda throttle valve in a compressed air conduit downstream from a compressor of said super-turbocharger; the method comprising: supplying a fuel mixture to said engine system to at least create a stoichiometric mixture;applying said exhaust gases from said engine system to an NOx converter, which converts said exhaust gases to produce NOx converted gases;generating a supply of compressed air from said compressor of said super-turbocharger that is supplied to said compressed air conduit;controlling said throttle valve to control pressure levels of said compressed air in said compressed air conduit so that said pressure levels of said compressed air are greater than pressure levels of said exhaust gases from said engine:mixing a first portion of said supply of said compressed air upstream from said throttle valve with said NOx converted gases to produce a first gaseous mixture of said NOx converted gases and said compressed air;supplying said first gaseous mixture to a hydrocarbon/carbon monoxide converter that performs an exothermic reaction which is produced by residual fuel, hydrocarbons and carbon monoxide present in said NOx converted gases resulting from use of said rich fuel mixture, said exothermic reaction generating heat and producing hydrocarbon/carbon monoxide converted gases;mixing a second portion of said supply of compressed air upstream from said throttle valve with said hydrocarbon/carbon monoxide converted gases to cool said hydrocarbon/carbon monoxide converted gases to a desired temperature to produce cooled hydrocarbon/carbon monoxide converted gases;driving a turbine of said driven turbocharger with said cooled hydrocarbon/carbon monoxide converted gases so that said exothermic reaction in said hydrocarbon/carbon monoxide converter increases power generated by said turbine. 6. The method of claim 5, wherein said desired temperature is a temperature that will not damage said turbine. 7. The method of claim 5, wherein said first portion of compressed air is an amount that will allow said hydrocarbon/carbon monoxide converter to substantially fully oxidize hydrocarbons and carbon monoxide in said NOx converted gases. 8. A method of increasing the performance of a piston engine system, wherein said piston engine system comprises: a piston engine,a super-turbocharger that is both mechanically driven by said engine and driven by exhaust gases from said piston engine, anda throttle valve in a compressed air conduit coupled to an intake of said piston engine downstream from a compressor of said super-turbocharger; the method comprising: supplying a rich fuel mixture to said piston engine system to increase output power of said piston engine system;applying said exhaust gases from said piston engine system to an NOx converter, which converts said exhaust gases to produce NOx converted gases;generating a supply of compressed air from said compressor of said super-turbocharger that compresses intake air in response to a control signal to generate said supply of compressed air in a compressed air conduit coupled to an intake of said piston engine;controlling said throttle valve to control pressure levels of said compressed air in said compressed air conduit so that pressure levels of said compressed air are greater than pressure levels of said exhaust gases from said piston engine;mixing a portion of said supply of said compressed air upstream from said throttle valve with said NOx converted gases to produce a gaseous mixture of said NOx converted gases and said compressed air;supplying said gaseous mixture of said NOx converted gases and said compressed air to a hydrocarbon/carbon monoxide converter to produce hydrocarbon/carbon monoxide converted gases;detecting a temperature level of said hydrocarbon/carbon monoxide converted gases;adjusting said portion of said supply of said compressed air to adjust said temperature level of said hydrocarbon/carbon monoxide converted gases to a desired temperature level;supplying said hydrocarbon/carbon monoxide converted gases to a turbine of said driven turbocharger to drive said turbine with said hydrocarbon/carbon monoxide converted gases. 9. The method of claim 8, wherein said desired temperature level is a temperature level that will not damage said turbine. 10. The method of claim 8, wherein said process of mixing said portion of said supply of said compressed air with said NOx converted gases comprises: mixing said portion of said supply of said compressed air in an amount that is sufficient to substantially fully oxidize hydrocarbons and carbon monoxide in said NOx converted gases. 11. A method of improving performance of an engine system, wherein said engine system comprises: an engine that operates with a rich fuel mixture to increase output power of said engine;a super-turbocharger that is both mechanically driven by said engine system and driven by exhaust gases from said engine system, and a throttle valve in a compressed air conduit coupled to an intake of said engine downstream from a compressor of said super-turbocharger; the method comprising: generating a supply of compressed air from a compressor that is supplied to a compressed air conduit;controlling said throttle valve to control pressure levels of said supply of compressed air in said compressed air conduit so that said pressure levels of said supply of compressed air are greater than pressure levels of the exhaust gases from said engine;mixing a first portion of said supply of said compressed air with said exhaust gases from said engine at a location that is upstream from said throttle valve to produce a first gaseous mixture of said exhaust gases and said compressed air;supplying said first gaseous mixture to a catalytic convertor that produces an exothermic reaction that adds heat to said first gaseous mixture to generate a converted first gaseous mixture at an output of said catalytic converter;detecting oxygen levels of said first gaseous mixture that enter said catalytic converter;mixing a second portion of said compressed air with said converted first gaseous mixture downstream from said catalytic converter to produce a cooled second gaseous mixture of said converted first gaseous mixture said second portion of said compressed air detecting said temperature levels of said cooled second gaseous mixture;adjusting said first portion of compressed air, in response to said oxygen levels, to provide a sufficient amount of said first portion of compressed air to substantially oxidize hydrocarbons and carbon monoxide present in said first gaseous mixture in said catalytic converter;adjusting said second portion of compressed air to control a temperature level of said cooled second gaseous mixture that is less than a predetermined temperature level;supplying said cooled second gaseous mixture to a turbine of said driven turbocharger to drive said turbine with said cooled second gaseous mixture so that said exothermic reaction in said catalytic converter increases turbine rotational mechanical energy generated by said turbine;transmitting said turbine rotational mechanical energy from said turbine to said compressor that uses said turbine rotational mechanical energy to compress a source of air to produce said supply of compressed air when said flow of said cooled second gaseous mixture through said turbine is sufficient to drive said compressor;extracting a portion of said turbine rotational mechanical energy from said turbine and applying said portion of said turbine rotational mechanical energy to a propulsion train when said portion of said turbine rotational mechanical energy from said turbine is not needed to run said compressor;providing propulsion train rotational mechanical energy from said propulsion train to said compressor to prevent turbo-lag when said flow of said gaseous mixture through said turbine is not sufficient to drive said compressor. 12. The method of claim 11, wherein said predetermined temperature level of said cooled second gaseous mixture is below a temperature at which said cooled second gaseous mixture would cause damage to said turbine. 13. The method of claim 12, wherein said predetermined temperature level of said cooled second gaseous mixture is below approximately 950° C. 14. The method of claim 11, wherein efficiency of said engine is improved by not using a waste gate to expel excess converted first gaseous mixture. 15. The method of claim 14, wherein said engine further comprises: a transmission that couples said portion of said turbine rotational mechanical energy and said propulsion train rotational mechanical energy between said propulsion train and a shaft connecting said turbine and said compressor. 16. The method of claim 15, wherein said engine further comprises: a second mixing chamber having at least one opening in an exhaust conduit that is connected to a compressed air conduit so that said second portion of compressed air flows through said at least one opening and mixes with said hotter exhaust gases in said exhaust conduit. 17. An engine system comprising: an engine that operates with a rich fuel mixture to increase output power of said engine;a super-turbocharger that is both mechanically driven by said engine system and driven by exhaust gases from said engine system;a catalytic converter connected to an exhaust conduit proximate to an exhaust outlet of said engine such that pollutants in said exhaust gases from said engine are reduced and said catalytic converter produces converted exhaust gases that are heated by oxidation of hydrocarbons and carbon monoxide present in said exhaust gases resulting from use of said rich fuel mixture;a compressor of said super-turbocharger that is connected to a source of air so that said compressor generates a supply of air that is applied to a compressed cooling air conduit;a compressed cooling air conduit coupled to said compressor; a throttle valve located in said compressed cooling air conduit that increases pressure levels of said compressed air to a level that is greater than pressure levels of said exhaust gases from said engine;a feedback valve coupled to said compressed cooling air conduit that supplies a portion of said supply of compressed air from said compressed cooling air conduit to a mixing chamber to mix said portion of said supply of compressed air with said converted exhaust gases so that said portion of said supply of compressed air is mixed with said converted exhaust gases to produce a gaseous mixture;a turbine of said super-turbocharger that is mechanically coupled to said compressor and coupled to said mixing chamber so that said turbine is driven by said gaseous mixture;a controller that generates a control signal that controls said feedback valve to regulate said portion of said supply of compressed air to maintain said gaseous mixture below a maximum temperature;a transmission that provides engine rotational mechanical energy from said engine to said compressor to reduce turbo-lag when said flow of said exhaust through said turbine is not sufficient to drive said compressor to a desired boost level, and extracts excess turbine rotational mechanical energy from said turbine and applies said excess turbine rotational mechanical energy to said engine. 18. An engine system that operates with a rich fuel mixture comprising: an engine of said engine system that operates with a rich fuel mixture that increases output power of said engine;a super-turbocharger that is both mechanically driven by said engine system and driven by exhaust gases from said engine system, said super-turbocharger having a turbine and a compressor that that provides a supply of compressed air to a compressed air conduit coupled to an intake of said engine;a throttle valve disposed in said compressed air conduit downstream from said compressor that increases pressure of said compressed air;a mixing chamber that mixes exhaust gases from said engine system with a portion of said supply of compressed air upstream from said throttle valve to produce a gaseous mixture of said exhaust gases and said compressed air;a catalytic converter connected downstream from said mixing chamber that produces an exothermic reaction that adds heat to said gaseous mixture to generate a converted gaseous mixture at an output of said catalytic converter;an oxygen sensor that senses oxygen levels of said gaseous mixture entering said catalytic converter and generates an oxygen sensor signal;a temperature sensor that senses said temperature levels of said converted gaseous mixture exiting said catalytic converter and generates a temperature sensor signal;a controller that generates a control signal in response to said oxygen sensor signal and said temperature sensor signal that controls said portion of said supply of compressed air provided to said catalytic converter so that said portion of said supply of compressed air is sufficient for said catalytic converter to substantially oxidize hydrocarbons and carbon monoxide in said gaseous mixture while maintaining a temperature level of said converted gaseous mixture exiting said catalytic converter that is less than a predetermined temperature level, and controls operation of said throttle to control pressure levels of said compressed air in said compressed air conduit so that said pressure levels of said compressed air in said compressed air conduit are greater than pressure levels of said exhaust gases;wherein said turbine is driven with said converted gaseous mixture so that said exothermic reaction in said catalytic converter increases power generated by said turbine. 19. The engine system of claim 18, wherein said predetermined temperature level is a temperature level that is less than a temperature that will damage said turbine. 20. The engine system of claim 18, wherein said predetermined temperature level is approximately 950° C. 21. An engine system comprising: a piston engine that operates with a rich fuel mixture to increase output power of said piston engine system and generates exhaust gases that are rich with carbon monoxide and hydrocarbons;a super-turbocharger, that is both mechanically driven by said engine system and driven by exhaust gases from said engine system;a NOx converter coupled to receive said exhaust gases and produce NOx converted gases in an oxygen deficient environment resulting from said rich fuel mixture;a compressor of said driven turbocharger that provides compressed air that is applied to a compressed air conduit of said engine system;a throttle located downstream from said compressor in said compressed air conduit of said engine system that increases pressure levels of said compressed air to a level that is greater than pressure levels of said exhaust gases;a compressed cooling air conduit that supplies portion of said compressed air from said compressed air conduit upstream from said throttle to said NOx converted gases so that said NOx converted gases are mixed with said portion of said compressed air to produce a gaseous mixture;a hydrocarbon/carbon monoxide converter coupled to receive said gaseous mixture and oxidize hydrocarbons and carbon monoxide present in said gaseous mixture in an exothermic reaction resulting from residual fuel in said rich fuel mixture which generates heat and produces to produce a hydrocarbon/carbon monoxide converted gaseous mixture;a turbine of said super-turbocharger that is coupled to receive said hydrocarbon/carbon monoxide gaseous mixture and generate turbine rotational mechanical energy from said hydrocarbon/carbon monoxide converted gaseous mixture so that said exothermic reaction in said hydrocarbon/carbon monoxide converter increases turbine rotational mechanical energy generated by said turbine. 22. The engine system of claim 21, further comprising: a controller that generates a control signal that regulates said portion of said compressed air to maintain said gaseous mixture below a maximum temperature and controls said throttle so that pressure levels of said compressed air are increased to exceed said exhaust gas pressure levels over a range of operating conditions of said engine system. 23. The engine system of 21, further comprising: a transmission that extracts excess turbine rotational mechanical energy from said turbine and converts excess turbine rotational mechanical energy to propulsion train rotational mechanical energy. 24. The engine system of claim 21, wherein said portion of said compressed air supplies a sufficient amount of oxygen to cause said hydrocarbons and carbon monoxide to be substantially fully oxidized in said hydrocarbon/carbon monoxide converter. 25. The engine system of claim 24, wherein said portion of said compressed air is sufficient to cool said hydrocarbon/carbon monoxide converted gaseous mixture to a desired temperature. 26. The engine system of claim 21, wherein said portion of said compressed air is sufficient to cool said hydrocarbon/carbon monoxide converted gaseous mixture to a desired temperature. 27. The engine system of claim 21, further comprising: an additional compressed cooling air conduit that supplies an additional portion of said compressed air that is mixed with said hydrocarbon/carbon monoxide converted gaseous mixture to cool said hydrocarbon/carbon monoxide converted gaseous mixture to a temperature level below a maximum temperature level that would cause damage to said turbine. 28. An engine system comprising: a piston engine that generates exhaust gases;a super-turbocharger, that is both mechanically driven by said engine system and driven by exhaust gases from said engine system;a NOx converter coupled to receive said exhaust gases and produce NOx converted gases;a compressor of said driven turbocharger connected to a source of air that provides compressed air that is applied to a compressed air conduit of said engine system;a throttle located downstream from said compressor in said compressed air conduit of said engine system that increases pressure levels of said compressed air to a level that is greater than pressure levels of said exhaust gases;a feedback valve that supplies a portion of said compressed air upstream from said throttle that is mixed with said NOx converted gases to produce a gaseous mixture;a hydrocarbon/carbon monoxide converter connected to receive said gaseous mixture and oxidize hydrocarbons and carbon monoxide in said gaseous mixture to produce a hydrocarbon/carbon monoxide converted gaseous mixture;a turbine of said super-turbocharger that is coupled to receive said hydrocarbon/carbon monoxide gaseous mixture and generate turbine rotational mechanical energy from said hydrocarbon/carbon monoxide converted gaseous mixture. 29. The engine system of claim 28, further comprising: a controller that generates a first control signal that regulates said portion of said compressed air to maintain said gaseous mixture below a maximum temperature and a second control signal that controls operation of said throttle. 30. The engine system of claim 29, further comprising: a transmission that extracts excess turbine rotational mechanical energy from said turbine and converts said excess turbine rotational mechanical energy to propulsion train rotational mechanical energy. 31. The engine system of claim 30, wherein said transmission provides propulsion train rotational mechanical energy from a propulsion train to said compressor to reduce turbo-lag when said flow of said exhaust gases through said turbine is not sufficient to drive said compressor to a desired boost level. 32. The engine system of claim 30, wherein said transmission extracts excess turbine rotational mechanical energy from said turbine to maintain rotational speeds of said compressor to drive said compressor to a desired boost level. 33. The engine system of claim 30, wherein said transmission extracts excess turbine rotational mechanical energy from said turbine to maintain rotational speeds of said compressor below a predetermined maximum rotational speed at which damage would occur to said compressor. 34. The engine system of claim 30, wherein said transmission provides propulsion train rotational mechanical energy from a propulsion train to said compressor to drive said compressor to a desired boost level when said flow of said exhaust through said turbine is not sufficient. 35. The engine system of claim 34, wherein said feedback valve allows said portion of said compressed air to be mixed with said NOx converted gases to avoid surge and achieve a desired boost level when said flow of compressed air through said compressor would otherwise cause surge in said compressor. 36. The engine system of claim 28, wherein said portion of said compressed air supplies a sufficient amount of oxygen to cause said hydrocarbons and carbon monoxide to be substantially fully oxidized in said hydrocarbon/carbon monoxide converter. 37. The engine system of claim 36, wherein said portion of said compressed air is sufficient to cool said hydrocarbon/carbon monoxide converted gaseous mixture to a desired temperature. 38. The engine system of claim 28, wherein said portion of said compressed air is sufficient to cool said hydrocarbon/carbon monoxide converted gaseous mixture to a desired temperature. 39. The engine system of claim 28, further comprising: a second feedback valve that supplies a second portion of said compressed air that is mixed with said hydrocarbon/carbon monoxide converted gaseous mixture to cool said hydrocarbon/carbon monoxide converted gaseous mixture to a temperature level below a maximum temperature level that would cause damage to said turbine.
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