Supercharged Air Cooling via Propane Phase Change
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Solution Overview
Problem
Diesel engines face inefficiencies and high emissions due to incomplete combustion and overheated intake air, which are exacerbated by supercharging, and existing solutions for using alternative fuels require costly modifications or complex cooling systems.
Innovation Solution
A system that injects liquefied propane into a chiller assembly to cool the incoming air charge, converting it to a gaseous state and using a programmable microprocessor-controlled fuel injector to optimize propane supply based on engine conditions, thereby enhancing combustion efficiency and reducing emissions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If diesel fuel is injected into the combustion chamber near the end of the compression stroke, then the engine produces power, but incomplete combustion occurs resulting in high particulate emissions and high flame temperatures causing increased NOx emissions
Solution Approach 1:
The patent introduces gaseous fuel (natural gas, propane, or butane) into the combustion chamber before the compression stroke begins, allowing the fuel to mix with air and be pre-compressed. This preliminary action ensures more complete combustion occurs before the diesel injection, reducing particulate emissions and controlling flame temperatures to minimize NOx formation while still producing engine power.
2Object-generated harmful factors
If the amount of diesel injected into the combustion chamber is reduced, then particulate and NOx emissions are reduced, but engine power is reduced
Solution Approach 1:
The patent changes the fuel composition parameter by introducing gaseous fuel (natural gas, propane, or butane) in addition to or instead of diesel. This parameter change allows the engine to operate with lower diesel injection quantities (reducing emissions) while the gaseous fuel compensates for the power loss, maintaining engine output through more complete combustion.
3Object-generated harmful factors
If a diesel engine is converted to use alternative gaseous fuels, then more complete combustion and lower emissions occur, but substantial modification to the engine is required
Solution Approach 1:
The patent designs a multi-functional system where a single gaseous fuel injection apparatus can deliver fuel to multiple cylinders simultaneously, and the system can operate in dual-fuel mode (combining gaseous fuel with diesel) or standalone gaseous fuel mode. This universal design reduces the need for separate injection systems for different fuel types, minimizing modifications while achieving complete combustion and lower emissions.
4Adaptability or versatility
If a diesel engine is converted to a spark-ignited engine or direct gaseous-fuel injection system, then alternative fuels can be used, but substantial modification including replacement of cylinder heads, pistons, and fuel injection systems is required
Solution Approach 1:
The patent uses diesel fuel as an intermediary ignition source to ignite the gaseous fuel in a dual-fuel configuration. This intermediary approach allows the engine to burn gaseous fuel (achieving complete combustion and lower emissions) while retaining the original diesel injection system and combustion chamber design, avoiding the need for spark plugs, direct gaseous injection systems, or other substantial modifications.
5Power
If supercharging is used to compress the incoming air charge, then engine power is increased, but the temperature of the air charge increases reducing air density and limiting available mass of intake air
Solution Approach 1:
The patent utilizes the phase transition of gaseous fuel from a cold state upon injection into the hot compressed air charge. The cold gaseous fuel acts as a cooling medium, absorbing heat from the superheated air during mixing and compression, thereby reducing the overall temperature of the intake charge. This temperature reduction increases air density and the available mass of intake air, allowing the supercharger to deliver more effective power increases.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system improves combustion uniformity, reduces particulate and NOx emissions, increases engine power, and allows diesel engines to operate efficiently on propane, minimizing exhaust pollutants and energy consumption.
Implementation Method 1
introducing liquid propane into a chiller assembly to cool the incoming air charge
Implementation Method 2
converting it to a gaseous state as the incoming air charge is cooled
Implementation Method 3
the intake air is cooled by heat exchange with surrounding air using a radiator such as a fin and tube heat exchanger
Data Source
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AI summary
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.