Fuel catalyst assembly

Abstract

A fuel catalyst assembly or pellet comprises a casting (2, 2', 20), wherein the casting comprises at least two noble metals, in combination with at least two additional components (4, 6; 4', 6'; 24) made of two further, different metals.

Description

[0001] Title: Fuel Catalyst Assembly

[0002] Field of the disclosure

[0003] The present disclosure relates to fuel catalysts and more particularly to a fuel catalyst assembly. to the disclosure

[0004] Existing fuel catalysts come in a variety of shapes and sizes of pellets with their own unique make up of individual metal elements to create catalyst pellets. They are usually encapsulated in a cylinder and placed in the fuel line of a combustion engine or fuel supply. Some catalysts are small pellets and can be added to a fuel tank.

[0005] Summary of the disclosure

[0006] The present disclosure provides a fuel catalyst assembly comprising a casting, wherein the casting comprises at least two, three or four noble metals, in combination with at least two additional components made of two further, different metals. A fuel catalyst assembly of this form may promote smoother running of a combustion engine, cleaner combustion, improved power output and cost saving benefits.

[0007] Two additional, discrete components may be attached to the casting by passing through the middle of the casting and being held together by complementary male and female screw threads formed thereon.

[0008] The fuel catalyst assembly may be in the form of a pellet. The assembly may use at least two, three or four noble metals in a cast form and have two further metal elements that are included in the assembly with the cast product to make up 4 to 6 metals that catalyse the chemical reaction required to perform the clean burn combustion process. The further metal elements may be (preferably pure) copper and (preferably pure) mild steel. The two further metals (preferably copper and mild steel) can be in a mesh, tube or cage in combination with the casting (or multiple castings), or studs attached to the casting.

[0009] The fuel catalyst casting or nugget may comprise or consist of the elements tin, antimony, lead and bismuth, with: tin inclusion ranging between 46 - 76%; antimony inclusion ranging between 12 - 33%; bismuth inclusion ranging between 5 - 18%; and lead traces ranging between .5 - 3%.

[0010] The fuel catalyst assemblies may be used singularly or in multiple quantities depending on the application they are being used for.

[0011] The nuggets may be moulded using this unique formula to promote a beneficial catalytic chemical reaction when a liquid or gaseous hydrocarbon fuel or biofuel comes into contact with them. This is not a harmful reaction to the fuel source but gives a positive reaction to induce an improvement during the combustion process. The design of the assemblies, both in materials used, and the physical attributes they are made to, maximises the combustion process of fuels when at the optimum fuel-to- air ratio.

[0012] This is achieved by capitalising upon the catalytic reaction of the fuel after it has come into contact with the assemblies prior to combustion. Not only may this improve combustion efficiency, but it may also assist in burning off any harmful carbon deposit built up in the combustion chamber and on any components within it, and then keep any further carbon build up to a minimum. This may promote smoother running, cleaner combustion, improved power output and cost saving benefits.

[0013] The fuel catalyst assemblies may be used in a singular or multiple formation that can be inserted into the fuel tank and / or fitted into the fuel line depending on the type of application they are being used for. The nuggets may promote ongoing enhanced combustion, performance and savings for up to 100,000 miles or in some cases up to 10 years. The nuggets utilise a proven technology that is cost effective.

[0014] The fuel catalyst assemblies may be specifically designed for each application. In some cases, this is simply placing assemblies in the fuel tank through the fuel filler cap, or on larger applications installing a purpose-built unit into the fuel line itself. Both options are equally effective, but the in-line version will usually be necessary on some applications.

[0015] The fuel catalyst assemblies are developed and designed for applications to include all motor vehicles, from mopeds and motorcycles right through the spectrum to large commercial vehicles.

[0016] The fuel catalyst assemblies are also suitable for all industrial plant, horticulture and garden machinery, and also marine applications from small recreational jet skis and pleasure craft up to container ships, cruise liners, and naval vessels.

[0017] The fuel catalyst assemblies are also suitable for any heating source using hydrocarbon fuels including LPG and natural gas, or biofuels, such as domestic and industrial catering equipment and boilers. In fact, any combustion process may benefit from fuel catalyst assemblies as described herein.

[0018] The fuel catalyst assembly in its singular form can be placed into the neck of any vehicle fuel tank. It may be small enough to pass through a filler neck of both petrol and diesel units / cars, lorries and the like.

[0019] The fuel catalyst assembly may be inserted into the filler cap point and a small amount of fuel may be used to effectively wash the assembly into the tank itself. If more fuel catalyst assemblies are required for different sized engines, then the process is repeated until the desired amount (for example 2, 3, 4, 5, 6, 8 or more) is reached. The present disclosure also provides an in-line fuel catalyst apparatus for insertion in a fuel flow path, the apparatus comprising a tube defining a tube interior space, and a plurality of fuel catalyst assemblies (as described herein) mounted in the tube interior space.

[0020] If an in-line unit is preferred, a tube may be provided containing fuel catalyst assemblies according to the present disclosure. For example, 20 to 100 or more assemblies may be located in the tube, depending on the combustion engine size. In addition, metal mesh material, comprising copper for example, may be provided in the tube. Also, or alternatively, a ferrite material may be provided in the tube.

[0021] Such a tube may be fitted somewhere in a fuel line, so that the chemical reaction is reached earlier. The fuel line may be cut and the in-line unit (a tube filled with individual assemblies) installed ready for the fuel to pass through the in-line unit. The fuel passes over and around each assembly to create the chemical reaction to the fuel before the combustion process. The in-line tube may be connected to the fuel line by using fuel pipe and fuel clip connectors.

[0022] Brief description of the drawings

[0023] Examples of fuel catalyst assemblies according to the present disclosure will now be described with reference to the accompanying schematic accompanying drawings, wherein:

[0024] Figures 1 to 4 are side, plan, perspective and cross-sectional side views of a fuel catalyst assembly according to an example of the present disclosure;

[0025] Figures 5 to 9 are plan, side, cross-sectional side and two perspective views of a fuel catalyst assembly according to a further example of the present disclosure;

[0026] Figures 10 and 11 are perspective views showing component parts of the fuel catalyst assembly shown in Figures 5 to 9; and

[0027] Figures 12 to 15 are side, end, plan and perspective views of a fuel catalyst assembly according to another example of the present disclosure Detailed description

[0028] Fuel catalyst assemblies according to the present disclosure seek to maximise the surface area of the cast element or nugget 2, 2’, 20 in variations of peaks and troughs. The number and size of indentations and projections (recesses and protrusions) defined by the outer surface of the cast element may be selected to achieve the desired surface area. These fluctuations in the surface profile may also increase turbulence in a fluid flowing over the assembly, to increase further the amount of fluid brought into contact with the surface of the assembly.

[0029] In addition to this, the nugget may have recessed areas to capture two studs (4, 6; 4’, 6’; 24) formed of copper and mild steel, respectively.

[0030] These studs may be connected to the cast nugget in various ways. One stud may be located on one side of the cast nugget and the other element may be located on the other side of the nugget. For example, the studs may be attached to the casting by: female and male interconnecting threads on the studs; tapped knurled surfaces on the casting and / or the studs to locate and retain the studs on an inner aperture circumference of the casting, preferably with flow holes through the connecting copper and mild steel studs; female and male interlocking knurled fixings with or without flow holes; and a friction or burr fitting.

[0031] The tightening methods used to attach the studs can be by way of security hex head, snake eye head, standard slot or clean head with flow hole, for example.

[0032] When multiple cast nuggets are required in particular applications the two further metals of copper and mild steel can be introduced in a mesh or tube or cage containing the cast nuggets rather than studs. The number and layout of the fuel catalyst assemblies may depend on the installation and where in-line, in-tank or infilter installation is needed and where the fuel catalyst assemblies can be used most effectively. The metals forming the casting may be cast together by heating ingots of metals to a heat where the metals are of sufficient liquidity for either pouring into moulds or for centrifugal spin cast methods. Various moulds or centrifugal casting requires a degree of expertise for each cast method and their smelted temperature requirements. To increase crystallisation of the final cast catalyst, air and mist-water may be introduced and applied depending on the particular casting method.

[0033] The casting may be formed in a single piece. However, Figures 10 and 11 illustrate how the assemblies shown in Figures 5 to 9 may be constructed using two sets of six cast segments 8 and a pair of central, semi-circular components 10 and 12. The twelve segments and two semi-circular components may be clamped together by the two studs 4’, 6’. Alternatively, the casting 2’ shown in Figures 5 to 9 may be formed as a single cast item.

[0034] The cast element 20 shown in Figures 12 to 15 defines several troughs or channels (labelled 22 in Figure 13) in its outer surface to increase its surface area. The troughs may extend longitudinally for the full length of the cast element. They also may extend across opposite end faces of the element.

[0035] A single casting may for example have a height of approximately 8 - 12mm and a diameter or length of approximately 8 - 25mm.

Claims

Claims1. A fuel catalyst assembly comprising a casting, wherein the casting comprises at least two noble metals, in combination with at least two additional components made of two further, different metals.

2. An assembly of claim 1, wherein the casting comprises at least three noble metals.

3. An assembly of claim 2, wherein the casting comprises at least four noble metals.

4. An assembly of any preceding claim, wherein the casting comprises at least four metals.

5. An assembly of any preceding claim, wherein the two additional components are formed of copper and mild steel, respectively.

6. An assembly of any preceding claim, wherein the two additional components are attached to the casting by passing into the casting from opposite sides of the casting and being coupled together.

7. An assembly of claim 6, wherein the two additional components are connected together by complementary male and female screw threads formed thereon.

8. An assembly of any of claims 1 to 5, wherein the two additional components form a mesh, tube or cage which contains the casting.

9. An assembly of claim 8, wherein the mesh, tube or cage contains a plurality of the castings.

10. An assembly of any preceding claim, wherein the noble metals comprise antimony and bismuth.

11. An assembly of any preceding claim, wherein the casting comprises the elements tin, antimony, lead and bismuth.

12. An assembly of claim 11, wherein tin forms 46 - 76% of the casting, antimony forms 12 - 33% of the casting, bismuth forms 5 - 18% of the casting, and lead forms .5 - 3% of the casting.

13. An in-line fuel catalyst apparatus for insertion in a fuel flow path, the apparatus comprising a tube defining a tube interior space, and a plurality of fuel catalyst assemblies according to any preceding claim mounted in the tube interior space.

14. An apparatus of claim 13, wherein copper mesh is provided in the tube interior space.

15. An apparatus of claim 13 or claim 14, wherein ferrite material is provided in the tube interior space.

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