Hydrocarbon processing devices and systems for engines and combustion equipment

Description of equivalent WO 2006034243 A2

0001HYDROCARBON PROCESSING DEVICES AND SYSTEMS FOR ENGINES AM>

COMBUSTION EQUIPMENT

0003Cross-Reference to Related Applications

0004This application claims priority to U.S. Provisional Application Serial No.

000560/610,775 filed on September 17, 2004 which is hereby incorporated by reference.

0006Technical Field

0007The present invention relates to hydrocarbon processing devices and systems

0008and, more particularly, to catalytic devices and systems that are constructed to modify the

0009combustion characteristics of hydrocarbon fuels and emissions for the purpose of emissions

0010reduction and to increase the overall performance characteristics of the engine.

0011Description of Related Art

0012Toxic exhaust emissions, such as carbon monoxide, unburned fuel, unburned

0013carbon, soot, and oil vapor are usually present in the exhaust gases emitted from internal

0014combustion engines. These toxic compounds are commonly a result of incomplete

0015combustion which may be caused by a fuel quality being incompatible with the required

0016combustion process, incomplete mixing of the fuel and air, or insufficient heat to provide

0017fuel decomposition, etc. Most fuels contain a wide variety of dissimilar hydrocarbon

0018compounds with corresponding variable rates of vaporization, decomposition, and

0019combustion reaction intensities. Some fuels vaporize quickly, decompose easily and burn

0020smoothly, while others vaporize very slowly, decompose incompletely to form unstable compounds that burn very fast and even detonate. Still others simply polymerize into

0021clusters, absorb heat energy and simply escape out the exhaust as pollution.

0022Ideally then, for an internal combustion engine, or combustion equipment, to

0023function at its optimum potential with minimum toxic emissions and greatest possible

0024efficiency with lower maintenance, vibration and operating temperatures, the fuel must be

0025able to vaporize and decompose easily and to propagate combustion reactions with

0026controlled, stable velocities with an absolute minimum of shock waves.

0027Fuels, such as aviation fuel, gasoline, diesel fuel, propane and natural gas

0028are all made up of the same building blocks, hydrogen and carbon. The difference between

0029natural gas and diesel, for example, is simply how many carbon and hydrogen atoms are

0030attached to each other in each molecule of fuel. The molecules of natural gas, for example,

0031are very small and light since they contain only one carbon and four hydrogen atoms. This

0032means that each molecular cluster of natural gas contains only one atom of carbon and only

0033four atoms of hydrogen. It is so light that it is a gas at room temperature. When it burns,

0034it essentially decomposes into carbon and hydrogen which in turn bond to oxygen separately

0035to form carbon dioxide gas, CO2, and water vapor, H2O. Every molecule of fuel produces

0036one carbon dioxide molecule and two water molecules during combustion, which are the

0037ultimate exhaust products of clean burning natural gas.

0038Diesel fuel, however, has many more atoms of carbon and hydrogen stuck

0039together, for example C 15 H32. This means, in this example, that every molecule contains

0040fifteen carbon atoms and thirty-two hydrogen atoms bonded into one molecular cluster.

0041These molecules are so heavy that they form dense liquids at room temperatures. In order

0042to burn, or rather, chemically combine with oxygen to produce heat, each of the fifteen

0043carbon atoms and thirty two hydrogen atoms must break apart from each other so that every single carbon atom can form, with oxygen, carbon dioxide, CU2, and every hydrogen atom

0044can form, with oxygen, water vapor, H2O. This is exactly the same process as burning

0045natural gas, CHU, but because there are so many more atoms clustered into each molecule,

0046it is a lot more difficult to break all of the atoms apart from each other. When the atoms do

0047not break apart cleanly and easily they do not all form CO2 and H2O. Instead a lot of

0048carbon atoms form their own clusters, without oxygen, to form soot, which is usually what

0049you see as black smoke coming from the exhaust system on many large diesels. As well,

0050many molecules of partially decomposed fuel leave the exhaust completely unburned

0051accounting for the acrid smell diesel engines are notorious for.

0052The idea is that natural gas burns clean because it is composed of light

0053molecules of only one carbon atom and four hydrogen atoms stuck together and diesel fuel

0054burns poorly because it is composed of heavy molecules of, for example, fifteen carbon

0055atoms and thirty two hydrogen atoms stuck together. The burning process itself doesn't

0056change, disregarding the speed and reaction time of combustion in this example, only the

0057complexity of molecular disintegration into atoms makes it more difficult to burn cleanly all

0058of the atoms. It is very clear that in order to burn all of the atoms in any given fuel, the

0059molecules of the fuel must be shattered.

0060Clean burning high performance liquid fuels, such as high octane aviation

0061fuel, are made of the same components as diesel fuel and natural gas. However, their

0062molecular structures are refined in such a way as to have weak molecular bonds allowing

0063them to decompose easily and quickly. The refining process can be very simple or

0064increasingly complex, depending on the desired molecular bonding structure. To refine

0065fuel it helps to understand that crude oil contains every type of hydrocarbon cluster

0066imaginable from very light liquids to heavy oils and even tar all mixed up together. Refiners ideally want to separate each group out so that the light liquids can be used tor

0067aviation (high octane properties) and the middle groups, which are heavier, to be used as

0068diesel fuel etc. Distillation practices help separate some of these fuels into their similar

0069molecular weight categories but it is relatively slow and not an exact science. The

0070distillation process basically relies on the principal that when heated at low temperatures the

0071lighter weight molecules, because they are bonded with only a few carbon and hydrogen

0072atoms, become gases and subsequently rise to the top of the distillation tower and are

0073extracted. When the temperature is raised slightly higher, the next heavier group of

0074hydrocarbon clusters rise to the top for extraction and so on. As the hydrocarbon clusters

0075become bigger however, they do not easily separate or break apart from each other. The

0076bigger the molecule, the stronger the forces of attraction hold them together. Refiners

0077learned in the 1930's that if they ran hydrocarbon fluids through metal catalysts the electro¬

0078chemical reactions between the hydrocarbon clusters and metal in the catalyst caused the

0079hydrocarbon molecules to break apart into smaller clusters. This is because the electron

0080orbits that are shared between the clusters of atoms are drawn, or rather, detached from

0081each other effectively breaking the links holding them together. These links, somewhat like

0082a chain, break apart at random and usually the molecules become lighter and smaller but of

0083any given number of atoms in their cluster, i.e. molecular weight is less but there may be

0084any random number of atoms in each cluster. This is considered a non-selective catalytic

0085reaction because the molecules are affected and reduced but not selectively to a certain size

0086or structure.

0087The combustion of hydrocarbon based fuels does not have to produce toxic

0088pollution. The chemical reactions involved in the combustion process produces heat

0089energy. Although this heat energy is the desired product of combusting fuel, it is difficult to manipulate and convert into controlled energy. The burning or combustion of

0090hydrocarbon fuels, in an internal combustion engine, produces a wide spectrum of

0091electromagnetic radiation, which only a portion of can be converted into useable heat, or

0092rather, pressure. The rest is usually wasted because the gaseous molecules in the

0093combustion chamber are unable to absorb some of the intense radiation produced during

0094combustion reactions. Some of the energy that is absorbed effectively accelerates the

0095vibration levels of the gaseous molecules allowing them to apply greater pressure on their

0096surroundings. In an internal combustion engine, this pressure is converted into mechanical

0097movement or power. Only about one third of the heat energy produced during combustion,

0098however, is converted into useable pressure. The remainder of this energy is not entirely

0099lost, but unfortunately can be responsible for the production of NO-x emissions, excess

0100vibration, excess heat in other parts of the combustion apparatus, and even excessive noise.

0101As well, spontaneous, incomplete combustion reactions produce other types of unwanted,

0102toxic emissions, such as carbon monoxide and soot.

0103Inconsistencies in combustion reactions as a result of a fuel's composition or

0104combustion equipment, being unable to completely burn the fuel, are largely responsible for

0105the formation of toxic emissions. However, another reason is that internal combustion

0106engines are unable to contain all of the pressure, created from the heat of burning gases,

0107allowing pressure and contaminants to enter the crankcase cavity. These contaminants

0108combine with the vaporized lubricating oil in the crankcase to produce blow-by emissions

0109and pressure that must be vented from this part of the engine. Blow-by emissions contain

0110complex hydrocarbon compounds of varying molecular weights and configurations. An

0111inadequate ventilation system will reduce the service life of an engine if these harmful,

0112toxic gases are not allowed to escape. These toxic fumes are either directed back into the air intake system of the engine, where their complex molecular conπgurations impeαe me

0113oxidation-reduction process causing a loss of power, an increase in exhaust emissions and

0114contamination of engine internal components with carbon based residue, or because of these

0115reasons, the toxic fumes are simply vented into the atmosphere.

0116NO-x emissions can also be a result of a fuel's poor combustion

0117characteristics, assuming properly functioning equipment and correct air-fuel ratios for

0118complete combustion. When the fuel does not vaporize and decompose easily, the reaction

0119time once combustion is initiated, is delayed with a corresponding increase in combustion

0120intensity. The combustion zone may accelerate from a relatively slow speed to an

0121extremely high speed almost instantaneously. This extreme imbalance in velocity produces

0122significantly higher energy levels, radiation with shorter photon emissions, which may

0123ultimately become actinic. Photolysis is a term used to describe chemical decomposition by

0124electromagnetic radiation. It can occur when combustion reactions accelerate to a range

0125where the photon emissions released contribute to further chemical reactions, rather than

0126normal thermal decomposition reactions of regular, controlled combustion. The actinic

0127radiation produced during non- uniform, intense, combustion reactions tends to decompose,

0128not only the fuel's molecular clusters, but the otherwise inert nitrogen molecules as well,

0129ultimately contributing to undesirable chemical reactions and the production of unwanted

0130toxic NO-x emissions. In order to reduce unwanted, toxic emissions, the combustion

0131process ideally requires manipulation.

0132Combustion is a chemical process involving the transfer of electrons between

0133atoms known as oxidation-reduction. In this process liquid fuels must be vaporized and

0134dissociated into atoms or free radicals before they can combine with oxygen to form new

0135substances. Under ideal conditions, a great deal of energy is released and carbon dioxide and water are formed. Combustion is a process that is not completely understood, it seems,

0136however, that free radicals are the key elements to promote and propagate controlled

0137chemical reactions. Radicals are the reactive intermediates responsible for dissociating the

0138large clusters making up the fuel's molecular compounds into individual atoms when they

0139only then can be oxidized to produce heat. This is a chain branch disintegration process

0140that progresses throughout the combustion chamber until the fuel is consumed. Under ideal

0141conditions, using high quality fuels, the reaction rate, chemical reactivity, is rapid and the

0142combustion zone proceeds progressively but smoothly throughout the combustion chamber.

0143The intensity of the reaction zone, which ultimately determines the intensity of

0144electromagnetic energy released, has a significant effect on the vibrational energies

0145imparted on the molecules in the combustion chamber, which significantly affects their heat

0146release potential. The vibrational energies obtained by the gaseous molecules in the

0147combustion chamber, under ideal combustion reactions, are transformed into organized

0148molecular motion that in turn produces maximum momentum, or rather maximum potential

0149mechanical energy. Organized molecular motion of a working fluid, namely the nitrogen

0150and products of combustion in the combustion chamber, enables the electromagnetic energy

0151produced during combustion to be transformed into controlled pressure with minimum

0152entropy. Entropy, or wasted heat energy, is largely a result of random, chaotic vibration

0153energies released during uncontrolled, excessively rapid combustion reactions.

0154Ideally, for an engine, or combustion equipment, to function at their

0155maximum potential with minimum toxic emissions and greatest efficiency with lower

0156maintenance, vibration and operating temperatures (minimum entropy), the fuel must be

0157able to decompose easily and to propagate combustion reactions with controlled, stable

0158velocities with an absolute minimum of shock waves. As well, toxic crankcase emissions should not be vented into the atmosphere or air intake system witnout consiαeraoie

0159modifications made to their molecular structures.

0160There are a number of different catalytic devices or the like that attempt to

0161treat the fuel prior to it being mixed with oxygen in a combustion space. One such fuel

0162catalyst is commercially available from Rentar Environmental Solutions, Inc. and is

0163constructed so that a reaction occurs in the catalyst device which separates the clustered

0164molecules so more of the fuel molecules surface area is exposed to oxygen at the time of

0165combustion.

0166The Rentar catalyst falls into the category of being a non-selective catalyst

0167because it contains a mixture of many dissimilar metals that randomly break the fuel's

0168molecular structures as the fuel passes through it. The fuel molecules may become smaller

0169but not necessarily smoother or better burning, which is what a selective catalyst would

0170accomplish. This is why aviation fuel is considerably more expensive because the

0171molecular structures of the fuel molecules are arranged in such a way as to not only break

0172apart easily and cleanly but also burn very smoothly. Selective catalysts are very difficult

0173to design because the temperature, pressure and reactivity must be chosen carefully in order

0174to obtain the desired restructured molecule.

0175Other emissions equipment and related devices that serve to solve the above

0176problems likewise suffer from certain deficiencies and disadvantages. In particular, the

0177following is a list of different types of emissions equipment, along with their associated

0178deficiencies: (a) PCV (positive crankcase ventilation system) - contamination, poor

0179combustion, worse emissions; (b) EGR (exhaust gas re-circulation) - contamination and

0180power loss; (c) catalytic converter - increased back pressure, power loss, heat generation;

0181(d) particle matter traps - increased back pressure, power loss, regular maintenance schedules, carbon accumulation issues; (e) retarded timing, to reduce JNo-x emissions -

0182carbon accumulations, power loss, higher hydrocarbon emissions; (f) filters etc. for

0183crankcase emissions - require periodic cleaning, non catalytic, require wires or electrical

0184connections, liquid or filtering mediums are too restrictive for most diesel engines, liquid

0185and vapor separators are generally large and non universal; (g) fuel catalysts - are generally

0186made of unusual materials, difficult to obtain or produce, expensive, restrictive to fluid

0187flow, un-useable for crankcase emissions, non-uniform assembly procedures produces

0188inconsistent reactions, installation sensitive in regards to position, distance close to engine

0189for heat, vibration or increased reactivity, many require specific tortuous passages of fluid

0190flow, agitation, turbulence, electrical stimulation, friction or even special housing materials

0191to produce the desired reactions.

0192It would thus be desirable to produce a selective catalyst (catalytic device)

0193for use in a wide range of different applications, including in fuel lines and fuel systems to

0194treat and process fuel prior to it being combusted, in crankcase ventilation systems for

0195treating and processing harmful emissions from the crankcase and in other engine related

0196locations where emissions and. /or fuel can be processed prior to discharge and/or

0197combustion.

0198Summary

0199The present invention is directed to catalytic devices and systems that are

0200constructed to modifying the molecular configurations of hydrocarbon based emissions and

0201fluid fuels for the purpose of improving the combustive properties of these materials,

0202improving energy transfer associated with combustion that takes place in these locations,

0203reducing the levels of emissions, etc. According to one exemplary embodiment, a catalytic device tor processing a

0204fluid containing hydrocarbons includes a catalytic body formed of at least three metallic

0205materials arranged in a layered structure. The layered structure has a compressed region

0206formed along a longitudinal length of the layered structure .

0207In another aspect, a catalytic device fluid containing hydrocarbons includes a

0208reactive body formed of a plurality of materials arranged in a layered structure. The

0209plurality of materials is formed of at least two different catalytic materials. The reactive

0210body has an inner core member and at least one inner cavity formed within the body. In

0211addition, the layered structure has regions of different densities and is permeable to the

0212fluid along the length thereof to permit flow of the fluid through the layered structure,

0213including through the inner core member.

0214The present invention is also directed to a system for processing a fuel

0215containing hydrocarbons that includes a source of fuel and a fuel line that is in fluid

0216communication with the source of fuel, as well as a catalytic body disposed within the

0217source of fuel and in fluid communication with the fuel line such that fuel is drawn into

0218contact with the catalytic body as it is drawn into the fuel line for delivery to another

0219location. The catalytic body is formed of a plurality of metallic materials arranged in a

0220layered structure that is rolled into a predetermined shape and is permeable to fluid flow.

0221The rolled layered structure has a compressed region formed along its longitudinal length.

0222In another aspect, a system for processing for processing emissions

0223containing hydrocarbons includes: a source of emissions and a catalytic body disposed

0224within a flow path of the emissions such that the emissions are drawn into contact with the

0225catalytic body as the emissions flow from one location to another location. The catalytic

0226body is formed of at least three metallic materials arranged in a layered structure that is rolled into a predetermined shape and is permeable to fluid flow. The rolled layered

0227structure has a compressed region formed along its longitudinal length, wlierein the

0228plurality of metallic materials are formed of at least two different materials. The catalytic

0229body further has an inner core member having a first density and a region that has a second

0230density which is less than the first density, wherein the compressed region is formed in a

0231region where the inner core member has a maximum density.

0232In one embodiment, the source of emissions is a component of crankshaft

0233equipment associated with a combustion engine, with the flow path of the emissions flow

0234traveling through a crankshaft ventilation tube in which the catalytic body is disposed.

0235In yet another aspect, the present invention is directed to a method for

0236processing a fuel containing hydrocarbons and hydrocarbon containing emissions from a

0237crankcase ventilation system including the steps of: (a) directing the fuel through a first

0238catalytic device; and (b) directing the hydrocarbon containing emissions through a second

0239catalytic device that is disposed in the crankcase ventilation system.

0240Brief Description of Drawings

0241The foregoing and other features of the present invention will be more

0242readily apparent from the following detailed description and drawings of illustrative

0243embodiments of the invention wherein like reference numbers refer to similar elements

0244throughout the several views and in which:

0245Fig. 1 is a perspective view of various layers of material that are used to

0246form a catalytic hydrocarbon processing system according to a first embodiment;

0247Fig. IA is a cross-sectional view taken along the line IA-I A of Fig. 1; Fig. 2 is perspective view of the layers of material ot Fig. 1 rolled into a

0248cylinder;

0249Fig. 3 is a cross-sectional view of the cylindrically shaped rolled layers of

0250material taken along the line 3-3 of Fig. 2;

0251Fig. 4 is a perspective view, partially broken away, of the cylindrically

0252shaped rolled layers disposed in a housing to form the catalytic hydrocarbon processing

0253system according to the first embodiment;

0254Fig. 5 is a perspective view of various layers of material that are used to

0255form a catalytic hydrocarbon processing system according to a second embodiment;

0256Fig. 5 A is a cross-sectional view taken along the line 5A-5A of Fig. 5;

0257Fig. 6 is a perspective view of the layers of material of Fig. 5 rolled into a

0258cylinder;

0259Fig. 7 is a cross-sectional view of the cylindrically shaped rolled layers of

0260material taken along the line 7-7 of Fig. 6 and after being compressed at one end thereof;

0261Fig. 8 is a cross-sectional view illustrating the placement of the catalytic

0262hydrocarbon processing system of Fig. 4 inside a liquid fuel tank;

0263Fig. 9 is a cross-sectional view illustrating the placement of the catalytic

0264hydrocarbon processing system of Fig. 4 inside a crankcase ventilation conduit;

0265Fig. 10 is a perspective view of various layers of material that are used to

0266form a catalytic hydrocarbon processing system according to a third embodiment;

0267Fig. 1OA is a cross-sectional view taken along the line 10A-10A of Fig. 10;

0268Fig. 11 is a perspective view of the layers of material of Fig. 12 rolled into a

0269cylinder and including a number of notches formed at one end to define a support structure;

0270Fig. 12 is a perspective view of the rolled catalytic cylinder of Fig. 11; Fig. 13 is a cross-sectional view of the rolled catalytic cylinder taken along

0271the line 1343 of Fig. 12;

0272Fig. 14 is a perspective view, partially broken away, illustrating the rolled

0273catalytic cylinder of Fig. 12 in a housing;

0274Fig. 15 is a perspective view of various layers of material that are used to

0275form a catalytic hydrocarbon processing system according to a fourth embodiment;

0276Fig. 15A is a cross-sectional view taken along the line 15A-15A of Fig. 15;

0277Fig. 16 is a perspective view of the layers of material of Fig. 15 rolled into a

0278cylinder that serves as a catalytic device;

0279Fig. 17 is a perspective view, in cross-section, taken along the line 17-17 of

0280Fig. 16 illustrating a dense inner core of the rolled cylinder; and

0281Fig. 18 is a perspective view, partially broken away, illustrating the rolled

0282cylinder placed into a housing.

0283Detailed Description of the Preferred Embodiments

0284An object of the present invention is to achieve a catalytic processing system

0285and method of altering the combustion characteristics of hydrocarbon fuels and emissions

0286for the purpose of emissions reduction and to provide greater control of the vibrational

0287energies imparted on the molecules occupying the combustion chamber, or zone, during

0288and after combustion. The catalytic devices and systems made in accordance with the

0289present invention preferably alter, through electro-chemical means, the molecular structures

0290of hydrocarbon emissions and fluid fuels in order to improve chemical reactions and

0291combustion intensities during the combustion process for the reduction of emissions and

0292improved energy transfer. In view of the foregoing and the problems associated with conventional

0293devices, the present hydrocarbon catalytic processing system is constructed to produce

0294chemically reactive intermediates from recycled crankcase emissions according to one

0295exemplary embodiment. Without wishing to be bound by any particular theory, it is

0296believed that these normally toxic poor burning compounds are converted into reactive

0297fragments that, not only burn better when admitted into the combustion chamber, but they

0298significantly enhance the combustion characteristics of hydrocarbon fuels. This effectively

0299eliminates the problems normally associated with recycled, untreated toxic crankcase

0300emissions that normally aggravate and disrupt the combustion process. This is a bi-

0301functional catalyst containing hydrogenating and acidic components. While not being

0302bound to any particular theory, the materials inside are chosen specifically for their abilities

0303to breakdown the hydrocarbon components by forming from them carbonium ions

0304(positively charged molecular fragments) by way of the protons in the acidic function.

0305These ions are so reactive that they change their internal molecular structures spontaneously

0306and breakdown to smaller, reactive fragments. Adding free radicals or reactive

0307intermediate compounds directly into the combustion chamber to mix with the air and fuel

0308has a profound effect on the oxidation- reduction process. Instead of the combustion

0309process proceeding only by thermal agitation and random molecular collisions, these newly

0310introduced reactive particles immediately dissociate large fuel molecules into fragments

0311exposing them to the oxygen far sooner and under cooler temperatures. The effects of

0312enhanced free radical activity and their subsequent chain branch disintegration reactions are

0313immediately transposed into producing a smoother, slower and more controlled combustion

0314process. When the combustion process is smooth and more controlled the electromagnetic energy is transformed more completely into unified thermal energy, which is significantly

0315more useful, and more importantly, produces significantly lower toxic emissions.

0316As well, this processing system is adaptable to hydrocarbon fluid fuels by

0317simply splicing and installing the device onto the fuel line of the desired combustion

0318equipment. In this adaptation the fuel is simply directed through the catalyzing system and

0319processed and converted into having molecular structures with improved combustion

0320characteristics. Unlike processing crankcase emissions into reactive intermediates,

0321however, the fuels' molecular structures are modified or rearranged into having, more

0322controllable decomposition characteristics, improved chemical reactivity, and stabilized

0323combustion propagation reaction characteristics. Fuels with the resultant modified

0324molecular configurations produce more consistent levels of electromagnetic energy release

0325ultimately providing improved energy or work transfer and most importantly, lower toxic

0326emissions release.

0327In an alternative embodiment of the present invention, the hydrocarbon fuels that are

0328treated with the catalytic device are low molecular weight hydrocarbon fuels. Low

0329molecular weight hydrocarbon fuels that can be employed include, for example, natural

0330gas, ethylene, acetylene, propane, butane as well as other low molecular weight

0331hydrocarbons that are known in the art of combustion. Thus, the catalytic devices of the

0332present invention are also contemplated for use with the low molecular weight

0333hydrocarbons used as a fuel source in furnaces, boilers, and even barbeques. Typically,

0334when the catalyst device is used in this capacity it can be attached to the fuel line of the

0335desired equipment.

0336As described in great detail below, the catalytic devices and systems

0337according to the present invention are based on a layered structure formed of dissimilar metallic materials and manipulated into a particular shape. The arrangements ot dissimilar

0338metallic materials, to overlap each other one layer at a time to virtually any desired depth,

0339satisfies a solution to the many previous experienced undesirable characteristics, such as

0340ease of manufacturing, complete and reproducible consistency in density of dissimilar

0341elements, flow capacity, and, of course, performance improvements. Each of the preferred

0342materials, in screen form, needs only to be one layer in thickness and when overlapped

0343with one another, form what may be described as an electrolytic capacitor. Without

0344wishing to be bound by any particular theory, it is believed that the hydrocarbon fluids,

0345liquid or vapor, emissions or fuel, act as the electrolyte to effectively activate the

0346electrochemical reactions necessary for the electron transfer process to proceed. The ions

0347produced as a result of the electrochemical reactions are so reactive that they change the

0348crankcase emissions or fuel's molecular structures spontaneously, breaking them down to

0349smaller reactive fragments. When hydrocarbons, emitted from the crankcase emissions

0350vent tube, are processed, the hydrocarbons are broken down into reactive fragments, that

0351when introduced into the combustion chamber, dissociate the fuel molecules into their

0352constituent elements by way of free radical chain reactions. This has significant effects on

0353the combustion process.

0354When hydrocarbon fuels are passed through the catalytic elements, electron

0355transfer reactions cause the fuel molecules to undergo any number of structural

0356reorganization reactions. These reactions can include isomerization, aromatization,

0357dehydrogenation and even polymerization conversion processes. Any number of these

0358reactions are possible and they result in altering and improving the fuel's combustion

0359characteristics. Generally, the fuel's newly altered molecular structures resist spontaneous

0360detonation reactions allowing a smoother, more controlled combustion process. The active sites responsible for producing the electron transfer reactions in this catalytic reactor likely

0361occur at the contact surfaces between the specific dissimilar metallic elements as well as

0362other metallic faces of the elements.

0363By using dissimilar metallic materials, there is a great degree of latitude in

0364how to construct and shape the catalytic device and in one exemplary embodiment, the

0365dissimilar metallic materials are cut into long strips, with the widths and lengths determined

0366by its application, longer strips. When rolled together, this type of layered structure

0367provides more reactive sites and wider strips provide a greater surface area for larger

0368applications. The dissimilar metallic materials can be positioned evenly over one another to

0369form specific alternating layers of dissimilar metallic screens with similar thickness and

0370densities and then the screens are rolled together in such a way as to form a cylinder with

0371multiple, alternating contact sites of these dissimilar elements. This method allows the

0372hydrocarbon fluids to pass through the alternating layers of elements effectively providing

0373multiple reactive sites at every point of contact between the metallic elements and

0374hydrocarbons. This method allows complete adjustability to the desired number of reaction

0375sites required by the intended application of this catalytic reactor. This flexibility is

0376important because some hydrocarbon compounds, fuels and emissions, and their potential

0377applications require more processing than others. Many fuels, such as diesel fuel for

0378example, require more reactive sites to effectively process their molecular structures into

0379ones with having improved combustion characteristics. While other fuels, such as gasoline,

0380require less reaction sites in order to avoid over processing, which would ultimately reduce

0381combustion efficiency. As well, crankcase emissions are sensitive to over processing and

0382therefore may require a certain level of reactivity, which again, is determined by adjusting

0383the number of alternating layers of metallic screen elements. This adjustability allows unlimited applications trom me smallest engine s

0384fuel line to the largest diesel engine's crankcase ventilation tube, with only the requirements

0385of cutting wider strips and\or longer lengths of catalytic screen materials to accommodate

0386the required applications.

0387Described below are several embodiments that embody the present invention

0388and function as improved catalytic devices/catalytic processing systems as illustrated in the

0389accompanying figures.

0390In accordance with one aspect of the present invention, a catalytic

0391hydrocarbon processing system 100 according to a first embodiment is illustrated in Figs.

03921-4. As best shown in Fig. 4, the catalytic hydrocarbon processing system 100 includes a

0393first catalytic body (catalytic device) 110 that is formed of a plurality of separate materials

0394that are formed according to a predetermined shape and disposed within a housing 120.

0395According to one embodiment that is illustrated in Figs. 1-4, the first catalytic body 110 is

0396formed of three separate, different materials (dissimilar materials), namely, a first material

0397112, a second material 114, and a third material 116, that are layered with respect to one

0398another and are formed according to a predetermined shape as by rolling or otherwise

0399manipulating the structure. However, it will be appreciated that two materials or four or

0400more materials can be used to form the body 110.

0401To form the layered structure illustrated in Fig. 1, the first material 112 is

0402cut into a first strip, the second material 114 is cut into a second strip, and the third

0403material 116 is cut into a third strip. The strips 112, 114, 116 can be formed to have

0404predetermined widths; however, the width of each strip 112, 114, 116 is preferably the

0405same. However, the lengths of the strips 112, 114, 116 are preferably not the same, with

0406the first strip 112 having a length that is greater than the length of the other two strips 114, 116, which in the illustrated embodiment have approximately the same lengtns. AS

0407described below, by forming the first strip 112 in a length greater than the other lengths,

0408the first strip forms and completes a final wrapping layer when the three materials 112,

0409114, 116 are rolled into the cylindrically shaped structure shown in Fig. 2.

0410The three materials 112, 114, 116 are arranged such that the first material

0411(strip) 112 is the outermost material, the third material 116 is the innermost material and

0412the second material 114 is the intermediate material due to its position between the first and

0413third materials 112, 116. The three strips 112, 114, 116 are made of catalytic materials

0414that are suitable for the intended application and environment (e.g., chemically modifying

0415the molecular structures of the hydrocarbons in the hydrocarbon containing fluid (fuel,

0416emissions, etc.)) and according to one exemplary embodiment, the materials 112, 114, 116

0417are three different metallic materials (as used herein "metallic materials" refers to materials

0418that are either metals or metal alloys or a combination thereof). For example and according

0419to one embodiment, the first strip 112 can be a stainless steel layer, the second strip 114

0420can be a copper layer, and the third strip 116 can be an aluminum layer. By having a

0421layered structure defined by a plurality of metal mesh materials, the total amount of surface

0422area where dissimilar metals are in contact with one another is substantially increased

0423compared to other designs where the metals are not in layered structures but instead are

0424arranged as two separate metal regions. By employing a layered structure formed of

0425multiple catalytic materials, the hydrocarbon containing fluid (e.g., fuel or gas) that is to be

0426treated by the catalytic device (system 100) of the present invention contacts large surface

0427areas of adjacent dissimilar metals which provide reactive sites where the hydrocarbons can

0428be processed into safer, reactive fragments in the manner described hereinbefore. While

0429not being bound to any particular theory, the present applicants believe that each of the metallic screens has different catalytic properties resulting in a particular tiuiα Demg

0430catalytically modified in a particular way when contacting one metallic screen and

0431therefore, a combination of dissimilar metallic catalytic materials permits the fluid to be

0432catalytically processed in different ways as the fluid contacts the different dissimilar

0433metallic screens. The layered nature of the present devices presents a compact design.

0434As previously mentioned, any number of different dissimilar catalytic

0435materials can be used in the practice of the present invention, including metals, metal

0436alloys, and combinations thereof. For example, one or more of the catalytic materials can

0437be a transition metal selected from the group consisting of: Scandium, Titanium,

0438Vanadium, Chromium, Manganese, Iron, Cobalt, Nickel, Copper, Zinc, Yttrium,

0439Zirconium, Niobium , Molybdenum, Technetium, Ruthenium, Rhodium, Palladium, Silver,

0440Cadmium, Hafnium, Tantalum, Tungsten, Rhenium, Osmium, Iridium, Platinum, Gold,

0441Mercury, Rutherfordium, Dubnium, Seaborgium, Bohrium, Hassium, Meitnerium,

0442Ununnilium, Unununium, Ununbium; or they can be one or more of the materials that are

0443commonly known as the "other metals" on the periodic table and include Aluminum,

0444Gallium, Indium, Thallium, Tin and Lead. One exemplary catalytic material that is used in

0445the production of the catalytic systems of the present invention is stainless steel. As is

0446known, a stainless steel material refers to any of a number of steels that are alloyed with at

0447least 10 or 12 percent chromium and sometimes contain other elements and that are

0448resistant to corrosion or rusting associated with exposure to water and moist air. It will be

0449appreciated that the above list is not intended to be an exhaustive list of suitable catalytic

0450materials, but instead, merely lists exemplary materials that are suitable for certain intended

0451applications. To assemble tne tirst catalytic body iiυ, tne tnree materials iiz, 114, no

0452are arranged as overlaying strips of material in the order described above and with the

0453strips having the same width. The length of the first strip 112 is greater than the lengths of

0454the second and third strips 114, 116 and in one embodiment, the second and third strips

0455114, 116 have a length that is equal to or less than ¹A the length of the first strip 112. As a

0456result, when the three layers/strips 112, 114, 116 are laid over one another, one end or

0457edge 111 of the layered structure contains all three layers 112, 114, 116 that are positioned

0458evenly, while the opposite end or edge 113 contains only the edge of the first layer 112. At

0459the end 111, the three layered structure (catalytic body 110) is cut along two lines, namely,

0460a first cut line 117 and a second cut line 119, that are arranged in a non-parallel manner.

0461In other words, the first and second cut lines 117, 119 are formed along axes that intersect one another. The lengths and precise positions of these cut lines 117, 119 are variable

0462depending upon the particular application; however, the first and second cut lines 117, 119

0463extend to the end 111 so as to form a pair of outer strips or layered structures 130, 132 that

0464are on either side of an inner section or inner layered structure 134. The outer layered strips 130, 132 and the inner section 134 are each separate from one another so that each is

0465independent and separate from the others and can be folded and/or rolled independently.

0466It will be appreciated that the lengths and positions of the first and second cut

0467lines 117, 119 determine the width of the inner layered structure 134 and thereby,

0468determine the density of the inner core of the body 110 as explained below in greater detail.

0469In addition, the lengths of the first and second cut lines 117, 119 determine the outer

0470diameter of the inner core of reactive materials (layers 112, 114, 116). This measurement

0471is typically determined by the intended application for the system 100. For example, a

0472small inner core diameter is typically used in automotive applications, boilers, muffler systems (emissions systems), or barbeques or other similar type applications, wniie a larger

0473inner core is used on diesel engines or furnaces, etc. Also, liquid fuel processing devices

0474usually require a denser inner core than that required for vented crankxase emissions

0475applications.

0476The inner section 134 formed between the two cut lines 117, 119 is rolled

0477very tightly toward the second end 113 for a predetermined distance. In particular, the

0478inner section 134 is rolled until a point or line 139 is reached by the rolled inner section

0479134. The pair of outer layered strips 130, 132 is folded along first and second fold lines

0480136, 138, respectively, toward the second end 113 so as to fold the outer layered strips

0481130, 132 on top of itself. In the illustrated embodiment, the line 139 and the fold lines 136,

0482138 are formed along the same transverse axis across the width of the layered body 110.

0483However, the line 139 and the fold lines 136, 138 do not have to be co-linear but instead

0484can be offset from one another.

0485Once the outer layered strips 130, 132 are folded and pressed flat against the

0486remaining layered materials, the entire layered structure is then tightly rolled in such a way

0487to form the rolled catalytic structure shown in Fig. 2 and generally indicate at 140. The

0488rolled structure 140 is partially hollow in that the ends 142, 144 thereof are in the form of a

0489pair of hollow cylinders that define inner end compartments or cavities 146 which are

0490formed as a result of the outer layered strips 130, 132 being folded prior to rolling the

0491entire layered structure as shown in Fig. 3. Another result of this construction is that the

0492dense inner core (inner section 134) forms the inside of the rolled structure 140.

0493Fig. 3 is a cross-sectional view of the rolled structure 140 and illustrates the

0494formation of the dense inner core (inner section 134), as well as the hiollow cylindrical ends

0495142, 144. In addition, the three general material layers 112, 114, 116 are illustrated. The actual diameter of the hollow cylinder tormed at ends 142, 144 can vary

0496and will depend upon the precise intended application for the system 100. For example, on

0497a 450 hp diesel engine crankcase ventilation line, the diameter of the hollow cylinder can be

0498about one inch, while in a small fuel line application, the diameter may be only about ¹A

0499inch. For other applications, the diameter can be outside of either of the above values.

0500It will be appreciated that as the materials 112, 114, 116 are rolled over one

0501another to form the cylindrical structure 140, each layer 112, 114, 116 represents a contact

0502site for chemical reactivity. With relatively little effort or expense, the rolled cylindrical

0503catalytic structure 140 can be adjusted to any desired diameter and/or reactivity to fit a

0504given application. The densities of the materials 112, 114, 116 have an effect in

0505determining the number of alternating dissimilar materials and in one exemplary

0506embodiment, the materials 112, 114, 116 are provided in screen form, with the density

0507being calculated by the material thickness and openings per square inch. In one exemplary

0508embodiment, the materials 112, 114, 116 are each in the form of a screen materials that is

0509approximately 0.010 to 0.040 inch thick with approximately 20 openings formed in the

0510screen per square inch. However this is merely one exemplary type of screen that is

0511suitable for certain intended applications for the system 100. Very fine material, for

0512example, with 60, or more openings per square inch, is possible for fuel applications but

0513may restrict the crankcase ventilation excessively. It is desirable to produce the maximum

0514number of reactivity sites in the minimum space necessary, but it is also very important to

0515maintain as minimum restriction as practical. Hydrocarbon emissions, as vented from large

0516diesel engine crankcase vents, are capable of blocking excessively small passages and it is a

0517factor that must be considered when configuring the density of the structure 140 for its

0518intended application. Once the overall diameter or the roll ot reactive materials has been

0519determined, the final layer (first layer 112 in the embodiment of Figs. 1-4) is wrapped

0520around the roll to form an outer shell of this material (i.e., an outer winding) as shown in

0521Figs. 2-3. The entire roll of materials (the rolled structure 140) is then slightly compressed

0522along the circumference of the outer diameter in the center region 141 of the structure 140

0523and perpendicular to a longitudinal axis L of the structure 140. The compression in this

0524center region 141 effectively increases the density of the materials in the center region 141

0525where the inner core 134 is located.

0526As will be described below, as the hydrocarbon fluids enter one end 142,

0527144 of the rolled structure 140 and pass through the compressed center section, the fluids

0528are slightly restricted causing an increased flow of fluid in the other areas of the reactive

0529elements 112, 114, 116 due to the resistance caused by the compression. This allows a

0530greater use of reactive sites inside the roll of materials without restrictive plates or other

0531accessories inserted to divert or control the fluid flow. Once compressed in this manner,

0532the materials 112, 114, 116 retain this shape and no further procedures or materials are

0533required for assembling the reactive components of the system 100.

0534The general flow of the fluid is indicated by arrows in Fig. 3 and it can be

0535seen that there are two distinct filter regions or areas 102, 104 where the fluid passes

0536through the filtering elements defined by the rolled structure 140. More specifically, the

0537fluid initially enters at one end of the structure 140 and flows longitudinally within the

0538hollow end 142 until the fluid contacts the dense core 134 which acts as permeable barrier

0539in that it causes some but not all of the fluid to flow radially outward through the

0540cylindrical rolled structure 140. This flow through the screens 112, 114, 116 enables the

0541fluid to contact multiple reactive sites (catalytic reactive surfaces) due to the fluid having to flow from the inner opening of the rolled structure 140 to an exterior location, it will be

0542understood, however, that the dense core 134 is formed of a fluid permeable material (i.e.,

0543the tightly compressed screens 112, 114, 116) that permits some fluid to continue to flow

0544along the longitudinal axis of the structure 140 through the dense core 134 and to the other

0545end 144. The fluid that passes through reactive elements associated with the first region

0546102 then must pass back through the reactive elements 112, 114, 116 associated with the

0547second region 104 (a region on the opposite side of the dense core 134). In this manner,

0548the fluid is placed into contact again with catalytic reactive sites or surfaces defined by the

0549elements 112, 114, 116, where further catalytic reactions can occur and the hydrocarbon

0550based fluid can be further processed before exiting through the outlet. This flow path

0551results because in order for the fluid to exit the housing 120, the fluid must pass back into

0552the hollow cylindrical cavity 146 at the end 144 since it is this area that is in fluid

0553communication with the outlet of the housing 120 through which the fluid must flow in

0554order to exit. It will be appreciated that the above described flow path is also dictated and

0555controlled by pressure differentials that are found throughout the system 100 and within the

0556housing 120 and in one embodiment, a pump mechanism draws the fluid along this flow

0557path. As in most systems, the fluid wants to flow along a path of least resistance and

0558therefore, flows to locations of lesser pressure, which is why the dense core 134 acts as a

0559flow director that causes fluid to flow in a radially outward direction toward the housing

0560120.

0561In a number, if not most, applications, it is convenient to have the rolled

0562cylindrical structure 140 disposed within housing 120; however, it will be understood that

0563the housing 120 is not an essential component of the system 100 which can be thought of as

0564functioning as an electrolytic capacitor. In other words, the system 100 can function without the housing 120 by simply placing the rolled structure 140 in the environment ot

0565the intended application, which can be in a fuel line, crankshaft emissions equipment, or

0566any other situation where emissions are generated and are available for modification by the

0567present system 100 into other compositions which are environmentally more friendly.

0568The housing 120 has a hollow body 122 that defines an inner compartment

0569or cavity 124 that receives and holds the first catalytic body 110. The body 122 has an

0570inlet 126 formed at one end thereof and an outlet 128 formed at the opposite end. The inlet

0571126 can be in the form of an inlet fitting to permit the housing 120 to be fiuidly connected

0572to a first external member, while the outlet 128 can be in the form of an outlet fitting to

0573permit the housing 120 to be fiuidly connected to a second external member depending

0574upon the precise application in which the system 100 is employed.

0575The housing 120 is chosen to have a number of characteristics to satisfy

0576reliable function in the environment that it will be used in. For example, the housing 120 is

0577preferably made so that it includes one or more of the following characteristics: fuel and

0578oil resistant, heat resistant to at least 250^° F, light weight, sufficient strength to support the

0579materials 112, 114, 116 disposed within, etc. The housing 120 can have any number of

0580different shapes so long as the shape does not interfere with its intended function. One

0581preferred material is thin walled stainless steel tubing because of its corrosion resistance,

0582malleability, requires no painting or coating and it is durable. It is also preferred that the

0583ends of the housing 120 can be sealed, as shown, and to have the illustrated threaded inlet

0584fitting 126 and threaded outlet fitting 128 enabling fluids to enter the housing 120 and

0585contact the rolled structure 140, flow through the reactive elements, and flow out of the

0586structure 140 and out of the housing 120 without leaking or other unnecessary restriction. The specific materials cnosen to torm me catalytic Doαy i iu (tiyαrocaroon

0587catalyst) are able to alter hydrocarbon compounds in liquid or vapor form. As well, the

0588materials produce no known negative or detrimental effects in the intended applications in

0589engines, combustion equipment, barbeques, or any other setting where undesired emissions

0590are created. The metal materials used to form the layers 112, 114, 116 are all safe to work

0591with and are malleable and by selecting the materials in screen form, allows a vast range

0592and diversity in the density of the materials, as well as in formability and consistency.

0593These features also make it possible to use this catalytic processing structure 140 in almost

0594any system that may require hydrocarbon processing and modifying. Modifying

0595hydrocarbon compounds with these specific materials, in the arrangements disclosed herein,

0596produces electro-chemical reactions that are not harmful to the catalyst or the equipment it

0597is installed on. In addition, there is no danger of heat buildup or radiation and the catalytic

0598reactions will occur under most temperatures, hot or cold. External heat sources, to

0599promote reactivity, are not necessary, as well, electricity or vibration is not required to

0600effect the electrochemical reactions occurring within the system 100. Also, the system 100

0601is capable of instilling electrochemical reactions with most hydrocarbon fluids. These

0602features make it possible to use the system 100 to process hydrocarbon emissions, fuels and

0603lubricants in vapor or liquid form.

0604Generally, it is convenient, as well as practical, to install the system 100 on

0605or near the equipment requiring the altered hydrocarbon compounds, for combustion or

0606other purposes. This may include the fuel supply line for furnaces or combustion

0607equipment or the crankcase emissions ventilation tube on internal combustion engines. The

0608device 100 needs only to be installed in such a way as to have the hydrocarbon fuels or

0609emissions directed into one end of the threaded fittings 126, 128 on the housing 120 and allowed to pass into and through the rolled structure 14U where the πuiα can De processeα,

0610and then directed out of the structure 140 to a combustion chamber or intake system or

0611some other member depending upon the specific application. The threaded fittings 126,

0612128 on each end of the housing 120 make it adaptable, using proper adapters, to virtually

0613any fuel line or crankcase ventilation tube, with secure leak proof connections. The

0614distance from the equipment is not an important issue as it has been found that the freshly

0615processed hydrocarbons emitted from the system 100 remain active for quite some time.

0616The unit can be installed in any position, horizontal, vertical or inclined with no adverse

0617effects. The present system 100 does not require maintenance and there are no fluids to

0618spill, freeze, or change or even filters to clean. Although the system 100 is designed to be

0619as lightweight and compact as possible, within reason, it is desirable to secure the unit to

0620supporting member or bracket, etc., when convenient or necessary to the required

0621installation.

0622When installing the system 100 on a crankshaft ventilation tube, especially

0623on large diesel engines, it is preferable to have the toxic gases emitted from the engine to

0624rise slightly to enter the system 100, as by flowing into the inlet 126. This permits excess

0625condensed fluid to drain back into the engine when the engine is not operating. Most

0626applications and installations are straightforward and relatively simple but nevertheless

0627require deliberate, intelligent thought to effect a secure, functional and safe installation.

0628Once again, based on Applicant's knowledge, there are no dangerous or negative side

0629effects known to exist with this catalytic processing system. An installation should be

0630trouble free and functional for several years.

0631It will be understood that the above examples and recited intended

0632applications are merely exemplary and not limiting of the present invention since the catalytic devices disclosed herein have a wide variety ot possible applications, in general,

0633the devices of the present invention is suitable where there is a desire or need to chemically

0634modify a hydrocarbon structure in a fluid, such as fuel or emissions, in order to increase

0635performance, reduce undesirable byproducts, etc.

0636Turning now to Figs. 5-9, a catalytic hydrocarbon processing system 200

0637according to a second embodiment is illustrated. The system 200 is similar to the system

06381OO in that it contains a catalytic body 210 that is formed of a plurality of separate materials

0639that are formed according to a predetermined shape. According to one embodiment, the

0640catalytic body 210 is formed of three separate, different materials (dissimilar materials),

0641namely, a first material 212, a second material 214, and a third material 216, that are

0642layered with respect to one another and are formed according to a predetermined shape as

0643is the case with the first embodiment. Similar to the first embodiment, the three materials

0644212, 214, 216 are metals and in one embodiment, the materials are the same as the

0645materials of the first embodiment. In other words, the first material 212 is stainless steel,

0646the second material 214 is copper and the third material 216 is aluminum.

0647The three materials 212, 214, 216 are preferably in screen form and are cut

0648into strips of even, predetermined widths and lengths, for the required application, and are

0649overlapped evenly over one another. While, the illustrated embodiment shows the three

0650materials 212, 214, 216 having the same width and the first material 212 having a longer

0651length, it will be appreciated that the lengths of all three materials 212, 214, 216 can be the

0652same. As described above with reference to the first embodiment, by cutting the layer of

0653the first material 212 to a greater length, the final wrapping layer (outer winding) of the

0654rolled structure is defined by the first material 212. However, the lengths of the three materials can be the same. In the illustrated embodiment, the second and third materials

0655214, 216 have lengths that are less than the length of the first material 212.

0656The three materials 212, 214, 216 are in screen form and are all formed of

0657dissimilar metallic materials with relative similarities in terms of their thickness, density

0658and openings per unit area. For example, the screens can have a thickness between about

06590.010 to about O.04O inch and the screens can have between about 10 and about 60

0660openings per square inch, e.g., 20 openings per square inch.

0661The three layered structure (catalytic body 210) has a first end 211, where all

0662three materials 212, 214, 216 are present in a layered manner, and an opposing second end

0663213 where only the first material 212 is present. The layered structure is then rolled

0664beginning at the first end 211 and in a direction toward the second end 213 to form a

0665cylinder with a center opening 215 of a predetermined diameter that depends upon the given

0666application. In one embodiment, the diameter of the opening 215 is uniform along the

0667longitudinal length of the rolled structure from the first end 211 to the second end 213.

0668These materials 212, 214, 216 when rolled together form a rolled cylindrical structure 220

0669defined by alternating layers of dissimilar metallic screens. Once the roll of materials has

0670reached a predetermined diameter, which is variable depending upon the precise

0671application, a final of the first material 212 (e.g., stainless steel) is wrapped around the

0672outer circumference of the rolled structure 220. In other words and as previously

0673mentioned, the first material 212 can have a greater length so as to form an outer winding

0674or wrapping of the first material 212. The length of the first material 212 that extends

0675beyond the end edges of the overlaid second and third materials 214, 216 can be selected so

0676that the first material 212 makes one complete circumferential winding around the outer

0677circumference of the rolled structure 220. The rolled structure 220 thus contains a tirst open end 222 and an opposing

0678second open end 224 with the center opening 215 extending completely therethrough from

0679the first end 222 to the second end 224. According to one exemplary embodiment, the one

0680of ends 222, 224 is closed as by applying a compressive force F at the end 224 and in a

0681direction that is perpendicular to the longitudinal axis of the rolled structure 220. The force

0682F sufficiently compresses the rolled structure 220 at the end 224 so as to constrict and close

0683the center opening 215 in this area of compression at the one end 224. The degree of

0684compression along the longitudinal axis can be varied depending upon the nature of the

0685force F and therefore, the extent and length of the rolled structure 220 that is compresses

0686and constricted can be varied. In the illustrated embodiment, a compressive force F is

0687applied to a degree that causes about Vz of the length of the rolled structure 220 to be

0688compressed, thereby restricting and closing off about ¹A the length of the center opening

0689215. Thus, the compressed rolled structure 220 defines a catalytic component/filtering

0690device that is open only at one end, namely, the end 222.

0691When processing hydrocarbons fluids at the open end 222 (where center

0692opening 215 remains open), a conduit member 230 can be inserted into the open center

0693opening 215 at the end 222. Trie conduit member 230 is an open ended elongated hollow

0694member, such as a tube, that has an outer diameter that is about equal to the diameter of the

0695center opening 215 so that a frictional fit results between the conduit member 230 and the

0696rolled structure 220 when the conduit member 230 is inserted therein. The conduit member

0697230 thus provides a pathway through the center of the compressed rolled structure 220 and

0698terminating at the compressed end 224. The conduit member 230 and the rolled materials

0699can be held in place using any number of conventional techniques. For example, a clamp

0700250 can be disposed about the outer circumference of the rolled structure 220 near or at the end 222. When the first material 212 forms the outer winding, the clamp 23U is thus

0701disposed about this outer winding. Alternatively, the conduit member 230 and the rolled

0702materials can be held in place by a compression fit around the outer diameter of the rolled

0703structure 220. Other means for holding the structure can be used, such as hook and loop

0704type strap, etc.; however and according to some embodiments, no means is needed to hold

0705the structure in place in its rolled form.

0706Fig. 8 illustrates one particular application for the system 200, in its

0707cylindrical rolled structure 220 form, as shown in Fig. 7, and in particular, the system 200

0708is shown as being used in combination with a liquid fuel tank, generally indicated at 260.

0709The liquid fuel tank 260 includes a body or housing 262 with one or more openings 264 to

0710permit insertion of a conduit or the like. The housiag 262 defines an interior chamber of

0711compartment 266. The system 200 is placed within the inner chamber 266, with the

0712conduit that is inserted through the opening 264 being an extended length of the conduit

0713member 230 in one embodiment or can be another conduit member, such as a fuel line 270,

0714that is attached to the end of the conduit member 23O.

0715Fuel that is present in the inner chamber 266 can be drawn through the

0716filtering elements (the layers 212, 214, 216 of the rolled structure 220) and into the hollow

0717conduit member 230 inserted into the center of the rolled structure 220 and in turn

0718delivered to a fuel line 270 that is connected to the conduit member 230 and then

0719transported through the fuel line 270 to a combustion source, generally indicated at 272. In

0720this embodiment, the catalytic device (system 200) requires no housing and it is easily

0721adaptable and adjustable to a wide varied of fuel tank systems. As previously mentioned,

0722the modification and treatment of the hydrocarbons occurs due to the contact between the

0723fluid containing the hydrocarbons and the surface area of the rolled structure 220. The flow path of the fluid (e.g., fuel or gas emissions) is generally indicated

0724by arrows in the cross-sectional view of Fig. 7. Since the conduit member 230 and the fuel

0725line 270 are operatively connected to a pump or the like, the fluid is drawn to the interior of

0726the rolled structure 220 due to a pressure differential. In particular, the pressure within the

0727conduit member 230 and the center opening 215 is less than the exterior pressure, due to

0728the effects of the pump, and therefore, the hydrocarbon containing fluid to be processed is

0729drawn through the reactive elements (layers 212, 214, 216) and into the center opening 215

0730where the fluid can then be drawn into the conduit member 230 and then delivered to

0731another location, as by use of the fuel line 270, etc.

0732As a result of the compressed nature of the rolled structure 220 along its

0733longitudinal length thereof, the rolled structure 220 has different densities along its length

0734and in particular, the compressed region where the center opening 215 is restricted and

0735closed off defines the area of the greatest density, while the open area of the structure 220

0736at the opposite end has a lesser density. However, it will be understood that the rolled

0737structure 220 is fluid permeable along its entire length and therefore, fluid can flow radially

0738inward from the exterior, through the reactive elements and into the interior of the rolled

0739structure 220, thereby being exposed to reactive sites. While fluid can flow through the

0740compressed region of the rolled structure 220, this is a flow path of greater resistance and

0741therefore, a greater amount of fluid will flow through the reactive elements in the other

0742non-compressed regions of the rolled structure 220. In any event, the hydrocarbon

0743containing fluid does flow through the reactive materials in order to flow out through the

0744conduit member 230.

0745In yet another exemplary application, the system 200 can be employed in

0746crankcase emissions processing again without the use of a housing as shown in Fig. 9. A crankcase ventilation tube 280 is simply directed to a convenient location along me

0747associated air intake system at a location between an air filer and a turbo charger (Lf so

0748equipped) or a manifold, if not turbo equipped. The catalytic system 200 (rolled structure

0749220) is installed directly into an air intake tube and is connected to the crankcase ventilation

0750tube at a location generally indicated at 282. This permits the crankcase emissions to be

0751drawn out of the engine and directed into the air intake system and through the catalytic

0752elements (layers 212, 214, 216), where the emissions is processed and immediately"

0753disposed into the intake air stream and combusted in the combustion chamber. The benefits

0754of this embodiment are that a housing is not required which in turn ultimately saves weight,

0755saves installation time and manufacturing cost just to name a few of the associated

0756advantages.

0757As with the first embodiment, the catalytic system 200 according to this

0758embodiment can be used in a wide variety of applications beyond the ones describ&d above

0759and more particularly, the catalytic system 200 is suitable for use in an environment where

0760the processing of hydrocarbon emissions with minimal resistance to fluid flow is desired.

0761Turning now to Figs. 10-14, a catalytic hydrocarbon processing system 300

0762according to a third embodiment is illustrated. The system 300 is similar to the systems

0763100 and 200 in that it contains a catalytic body 310 that is formed of a plurality of separate

0764materials that are formed according to a predetermined shape. According to one

0765embodiment, the catalytic body 310 is formed of three separate, different materials,

0766namely, a first material 312, a second material 314, and a third material 316, that are

0767layered with respect to one another.

0768Similar to the previous embodiments, the three materials 312, 314, 316 are

0769metals and in one embodiment, the materials are the same as the materials of the pxior embodiments. In other words, the tirst material 312 is stainless steel, me seconα material

0770314 is copper and the third material 316 is aluminum.

0771The three materials 312, 314, 316 are preferably in screen form and are cut

0772into strips of even, predetermined widths and lengths, for the required application, and are

0773overlapped evenly over one another. While, the illustrated embodiment shows the three

0774materials 312, 314, 316 having the same width and the first material 312 having a longer

0775length, it will be appreciated that the lengths of all three materials 312, 314, 316 can be the

0776same. As described above with reference to the first embodiment, by cutting the layer of

0777the first material 312 to a greater length, the final wrapping layer (outer winding) of the

0778rolled structure is defined by the first material 312. However, the lengths of the three

0779materials can be the same. In the illustrated embodiment, the second and third materials

0780314, 316 have lengths that are less than the length of the first material 312.

0781The three materials 312, 314, 316 are in screen form and are all formed of

0782dissimilar metallic materials with relative similarities in terms of their thickness, density

0783and openings per unit area. For example, the screens can have a thickness between about

07840.010 to about 0.040 inch and the screens can have between about 10 and about 60

0785openings per square inch, e.g., 20 openings per square inch. One difference is that in this

0786embodiment, the final wrapping of stainless steel mesh material is sufficiently strong to

0787support the entire rolled assembly of reactive materials in their environment.

0788The three layered structure (catalytic body 310) has a first end 311, where all

0789three materials 312, 314, 316 are present in a layered manner, and an opposing second end

0790313 where only the first material 312 is present. The layered catalytic body 310 is then cut

0791in several locations, as described below, so as to form a built-in base structure 320 and a

0792dense center core 322 at one end a formed hollow center cylindrically shaped rolled catalytic structure 330 that is defined by the multiple adjustable layers ot catalytic materials

0793312, 314, 316. The center section (center core 322) is specifically designed to form a

0794restrictive, but not solid, core of catalytic materials allowing the fluid contacting it to be

0795diverted resulting in an effective improvement of a circulation of the fluid through the body

0796310 of reactive elements (materials 312, 314, 316), while still allowing fluids to pass

0797through it. This effectively solves the problem of crankshaft emissions condensing into

0798liquid as in other devices where the liquid contacted a solid restrictive plate utilized in a

0799number of previous designs. In addition, the non-solid center core 322 effectively allows

0800fluids to pass through it where necessary. For example, when drainage is required as a

0801result of excessive fluid accumulation or when fluid fuels are required to pass through it for

0802increased catalytic reactivity. This effectively allows multiple uses without internal

0803modifications for each specific application.

0804The layered structure 310 is formed such that the three layered structure at

0805the first end 311 has a uniform first width that extends a predetermined distance from the

0806first end 311 to a point 315 where the width of the layered structure 310 increases to a

0807second width that this greater than the first width. This results in a shoulder 317 being

0808formed at the point 315 where the width of the structure 310 increases and in the illustrated

0809embodiment, the shoulder 317 is a formed at a right angle to the section of the layered

0810structure 310 that has the smaller first width. The precise relationship between the values

0811of the first and second widths can be varied; however, in one embodiment, the second

0812width can be about two times the value of the first width. In the illustrated embodiment,

0813the layered structure 310 has a uniform second width from the point 315 to a point 319

0814where the second and third materials 314, 316 terminate and only the first material 312 is

0815present from the point 319 to the second end 313. The layer of first material 312 that forms the outer wrapping (i.e., the length of first material 312 that extends from the point

0816319 to end 313) can have a varying width. In particular, this layer of first material 312 can

0817have the second width from the point 319 to another point 321 where the width of the first

0818material layer increases to a third width that is greater than the first and second widths.

0819Preferably, the layer of first material has a uniform width (third width) from the point 321

0820to the second end 313.

0821In this region of the layer of first material 312 from the point 321 to the

0822second end 313, a plurality of linear side cuts 324 are formed in the material along one side

0823edge 321 thereof. The side cuts 324 are spaced apart from one another and are parallel to

0824one another, with a length of each side cut 324 generally being the difference between the

0825second and third widths to permit sections or tabs 326 formed between the cuts 324 to be

0826folded over along a fold line that is generally co-linear with the edge 321.

0827The layered structure is then rolled beginning at the first end 311 and toward

0828the second end 313. At the start of the rolling procedure, the tight center core 322 of the

0829dissimilar metallic screens 312, 314, 316 is formed as the layered structure 310 is tightly

0830rolled in this narrower region from the first end 311 to the point 319 (where the layered

0831structure has the first width). The predetermined distance from the first end 311 to the

0832point 319 ultimately determines the overall diameter of the dense core 322 that is formed as

0833the layered structure 310 is rolled.

0834The layered structure 310 is further rolled in the direction of the second end

0835313 after it is rolled past the point 319. As the layered structure 310 is rolled from the

0836point 319 to the second end 313, the rolled structure increases in its width due to the

0837difference between the first width and the second width. As the layered structure 310 is

0838rolled in this manner and the wider section of overlapping materials is encountered, a hollow cylinder 323 is formed m trie center area parallel and m line witn me αense core

0839322. The rolling procedure is continued until the desired predetermined number of layers

0840or density is reached. Once the desired predetermined potential reactivity has been

0841obtained, due to the structure having the predetermined number of layers or density, the

0842final layer (outer final wrapping) is formed around the body of the reactive elements in such

0843a way as to remain flush with the end of the cylinder of materials with the open center core

0844and extending a predetermined distance below the other end of the roll of materials which

0845has the dense inner core 322.

0846The base structure 320 is formed at one end of the catalytic structure 330 and

0847serves to form a support structure to hold the body of the rolled structure 330 a

0848predetermined distance from a housing end cap when the system 300 is assembled. The

0849base structure 320 is formed by folding select tabs 326 along a fold line that is co-linear

0850with edge 321 so as to form a plurality of legs that are circumferentially disposed about the

0851cylindrical end of the rolled structure 330. It will be appreciated that each tab 326 that is

0852folded along the fold line forms a notch or window 327 through which the entering fluid to

0853be treated can flow radially outward from inside the rolled structure 330 to an exterior

0854location. In one embodiment, every other tab 326 is folded to form one notch 327 and

0855thus, define an alternating pattern of notches and legs. The unfolded tabs 326 that define

0856the legs thus act as spacers since these tabs 326 serve to space the dense inner core 322

0857from the end of the housing.

0858This design and method of assembly eliminates the need for restrictive

0859plates, a support tube or accessories, to hold or otherwise position the roll of catalytic

0860materials a given distance from the end cap, thereby effectively allowing an unrestricted

0861flow of hydrocarbon fluids into and out of the rolled structure 330 (catalytic device). Since this device is reversible , this embodiment permits the hydrocarbon fluids to expand in the

0862hollow center section formed by the roll structure 330 (i.e., the center opening in the dense

0863inner core 322) and in the hollow cylinder 323 formed at the other end of the structure 330

0864of reactive elements/materials or in the chamber that is formed by positioning the rolled

0865structure 330 away from the housing end cap due to the tabs 326 of the base structure 320.

0866The expansion of these fluids in both of these sections improves circulation and allows

0867condensed fluids to easily pass through the device (rolled structure 330) without interfering

0868with the ongoing chemical reactions between the reactive elements. In addition, the final

0869layer (outer wrapping) of the first material 312 secures the roll of reactive elements (layers

0870312, 314, 316) in position without coming apart or otherwise becoming unraveled, thereby

0871effectively allowing this catalytic component to be shipped or stored separately from the

0872housing.

0873It will also be understood that it is possible to eliminate the procedure for

0874notching and bending the layer of first material 312 to form the supporting member (base

0875structure 320) for positioning the reactive elements away from the end cap by simply

0876positioning two similar rolls of materials (e.g., rolled structure 330) in line with their dense

0877inner cores contacting each other. When positioned into a housing in this alternative

0878arrangement, the hollow center cylinders 323 are each in line with the end cap openings

0879and as a result, fluid entering or exiting the device (rolled structure 330) is allowed to

0880expand in the cylindrical openings (cavities 323). Once installed in a suitable housing,

0881these designs allow nearly unlimited potential in their applications with having the ability to

0882safely and effectively process most hydrocarbon fluids, emissions, or fuels. The flow of

0883hydrocarbon fluids need only be connected to one end of the housing's end cap fitting (inlet

0884126 or outlet 128) and allowed to flow through the device, where the hydrocarbons may activate the electrochemical reactions with the arranged elements and become reorganized

0885and converted. The hydrocarbon fluids then simply pass out of the other end cap fitting

0886and continue flowing to the intended combustion equipment or desired end use. This

0887embodiment, like the other embodiments, can be installed in any desirable position or

0888preferable or convenient location along the fuel line or crankcase ventilation tube on the

0889required application, such as an internal combustion engine, furnace, turbine, etc., or it can

0890be installed in any other setting where it is desired to treat hydrocarbon fluids in the manner

0891described herein.

0892The flow paths of the hydrocarbon fluids are generally indicated by the

0893arrows in Figs. 13 and 14. In this embodiment, the hydrocarbon fluids enter the housing

0894120 through the inlet fitting 126 which in this case is shown as being at the bottom for mere

0895convenience and for illustration purposes. As with the other embodiments, the fluid will

0896flow according to a number of different paths, with a preference toward the paths of least

0897resistance. In terms of this embodiment, the fluid flows into the base structure 320 toward

0898the dense inner core 322. Some of the fluid continues its axial flow longitudinally and

0899flows into the denser inner core 322; however, the density of this region makes this a flow

0900path of greater resistance and therefore, the fluid typically will flow along flow paths of

0901less resistance. For example, the fluid can radially flow out through the windows created

0902by the notches 327 to the exterior space between the exterior (final wrapping) of the rolled

0903structure 330 and the inside of the housing 120. In addition, fluid can flow through the

0904mesh screens around these notches 327 to this exterior space. Fluid that travels in this

0905manner is then passed back through the reactive materials (layers 312, 314, 316 of the

0906rolled structure 330) so as to expose the hydrocarbon fluids to the reactive materials and

0907permit the fluid to flow into the cylindrical opening 323 formed at the end of the rolled structure 33O. The cylindrical opening 323 is arranged in proximity and in fluid

0908communication with the outlet fitting of the housing 120 so that the fluid passes through the

0909opening or compartment 323 in order to exit the housing 120. Since some type of pump or

0910the like is operatively connected to the outlet fitting as by an outlet conduit or the like, the

0911compartment 323 is an area of lower pressure within the housing 120 and as a result, the

0912fluid flows toward this location as when the fluid lies in the exterior space between the

0913rolled structure 330 and the housing 120.

0914Now turning to Figs. 15-18, a catalytic hydrocarbon processing system 400

0915according to a fourth embodiment is illustrated. The system 400 is similar to the other

0916previously described systems in that it contains a catalytic body 410 that is formed of a

0917plurality of separate materials that are formed according to a predetermined shape and

0918arranged in a predetermined manner. According to one embodiment, the catalytic body

0919410 is formed of three separate, different materials, namely, a first material 412, a second

0920material 414, and a third material 416, that are layered with respect to one another.

0921Similar to the previous embodiments, the three materials 412, 414, 416 are

0922metals, such as one of the transition metals or other metals described above, or an alloy or

0923other metallic material. In one embodiment, the materials are the same as the materials of

0924the prior embodiments. In other words and according to one exemplary embodiment, the

0925first material 412 is stainless steel, the second material 414 is copper and the third material

0926416 is aluminum. However, it is clearly within the scope of the present invention that other

0927materials can be used and in one alternate embodiment, only copper and aluminum

0928materials are used; however and as mentioned herein, the present applicants have

0929discovered that the catalytic properties of the systems 100, 200, 300, 400 are enhanced

0930when three metals are used and in particular, when the three above metals are used. The three materials 412, 414, 416 are preferably in screen torm in tήeir pure

0931elemental densities, within practical limitations, or alternatively, a suitable material can be

0932coated with the metal element and its oxide to produce the desire screen material. When

0933the materials 414, 416 are copper and aluminum, these materials are widely available in

0934their pure or nearly pure elemental densities in screen form and in several thicknesses and

0935densities that are suitable for the present applications, as measured by the screen's wire

0936diameter and the area opening. When the first material 412 is stainless steel, it is obviously

0937a mixture of different metals and the grade or type is not critical so long as it is stainless

0938steel and in screen form with similar density and thickness as the other two materials.

0939In this embodiment, the materials 412, 414, 416 are cut and positioned in

0940such a way as to form multiple contact sites of alternating dissimilar metallic elements in

0941the vertical and horizontal planes to the fluid flow (which can be a liquid or vapor fluid

0942flow) when the layers are rolled into a cylindrically shaped layered structure 420. In the

0943illustrated embodiment, the base layer is formed of the first material 412 (e.g., stainless

0944steel), while the second and third materials 414, 416 are cut into strips of predetermined

0945widths and lengths, for the required application, and are laid over the base layer of first

0946material 412. While, the illustrated embodiment shows the three materials 412, 414, 416

0947having the same width and the first material 412 having a longer length, it will be

0948appreciated that the lengths of all three materials 412, 414, 416 can be the same. As

0949described above with reference to the first embodiment, by cutting the layer of the first

0950material 412 to a greater length, the final wrapping layer (outer winding) of the rolled

0951structure is defined by the first material 412. However, the lengths of the three materials

0952can be the same. In the illustrated embodiment, the second and third materials 414, 416

0953have lengths that are less ttian the length of the first material 412. The layered structure (catalytic body 410} has a tirst end 411, wnere all tnree

0954materials 412, 414, 416 are present in a layered manner, and an opposing second end 413

0955where only the first material 412 is present. The layered catalytic body 410 includes a

0956dense center core 430 that is formed generally in a central region of the rolled structure 420

0957between the ends 411, 413, with a pair of cylindrically shaped compartment or cavities 432

0958being formed at the ends 411, 413 on either side of the dense center core 330.

0959The layered structure is cut and configured so that the first end 411 has a

0960first width that extends from the first end 411 to a point 431 where the width of the layered

0961structure 430 increases to a second width greater than trie first width. A shoulder 433 is

0962thus formed at point 431 and delineates the regions of trie structure having the first and

0963second widths. In the illustrated embodiment, the structure 430 has the second width from

0964the point 431 all the way to the second end 413, with the strips of the second and third

0965materials 414, 416 terminating at a point 435 that is prior to the second end 413. This

0966distance of the first material 412 from the point 435 to the second end 413 is sufficient to

0967form the outer wrap or winding of the rolled structure 420. It will be appreciated that this

0968type of arrangement causes the formation of the dense inner center core 430 in the middle

0969or central inner region of the rolled structure 420, with the cylindrically shaped

0970compartment or cavities 432 being formed at the ends 422, 424 on either side of the dense

0971center core 430. The diameter and depth of the cylindrical compartments 432 and the

0972center core 430 are variable depending on the particular intended application. However,

0973and regardless of the variability in these dimensions, the above method of assembly always

0974produces consistent ratios of alternating dissimilar elements.

0975As the materials 412, 414, 416 are rolled together in this arrangement, the

0976number of alternating dissimilar elements and potential catalytic reactivity increases until the desired predetermined diameter ot the intended application is oDtameα. i ne iinai outer

0977later in the form of only a screen of first material (e.g., stainless steel) and can be simply

0978crimped around its outer circumference to the rolled structure 420 in position. If required

0979to increase the density of the center core region 430, the entire roll of materials (rolled

0980structure 420) can be slightly compressed (at location 421) along the circumference of the

0981outer diameter in the center and perpendicular to the longitudinal axes. The compression at

0982this point, as shown in Fig. 17, helps hold the materials tightly in their rolled

0983configurations. In addition, it allows center core to become more restrictive for certain

0984applications, such as fuel processing. The density of the center core 430 restricts the fluid

0985flow, as in the prior embodiments, ultimately increasing fluid circulation in other regions of

0986the cylinder 420 of reactive elements. In addition, in this configuration, the cylinder 420 of

0987alternating dissimilar materials occurs in the horizontal and vertical planes to the fluids

0988passing through these materials, thereby effectively increasing trie potential reactivity. The

0989rolled structure 420 of catalytic materials can be placed in the housing 120 as shown in Fig.

099018, with the housing 120 having fittings 126, 128 and end caps to allow the hydrocarbon

0991fluids to pass into and through the catalytic materials 412, 414, 416, where they are

0992suitably processed and discharged out of the other end of the housing 120. This design is

0993reversible and with threaded fittings on each end of the housing 120, it is adaptable to most

0994fuel lines or crankcase emissions ventilation tubes on internal combustion engines.

0995The configuration in Figs. 15-18 allows considerably more dissimilar metal

0996reactive sites for applications requiring greater hydrocarbon processing and conversion

0997reactions, such as required by certain liquid fuel burning equipment. This method of

0998assembly is fast and requires no tooling change in the assembly plant, it does not restrict the

0999flow of fluid excessively and takes up very little space for the extend of its increased reactivity. The open center (open cavities 432) on each end 411, 413 allows fluid, to

1000expand as it enters and exits the rolled structure 420. This helps make use of a greater

1001surface area of materials with minimum space and more importantly, minimum resistance.

1002Also, the strips of materials are arranged in a staggered, non-uniform order, to alloΛV a

1003greater reactivity, as a result of dissimilar materials in a linear plane as well as a

1004perpendicular plane. In other words, the second and third materials 414, 416 are disposed

1005in two layers that are parallel to one another and are disposed on the first layer 412, which

1006is thus in a plane parallel to the other two layers prior to rolling or otherwise manipulating

1007the layered structure into its desired shape. With each of these two planes, the strips 414,

1008416 alternate with respect to one another across the width of the first layer 412.

1009The present construction permits more chemical reactions with a minimum

1010space and minimal restriction. The two outer ends 411, 413 of the cylinder 420 of catalytic

1011materials are hollow and define the cavities 432, with predetermined diameters and the

1012center region or section is dense core 430 effectively allowing the fluids to pass throughout

1013the catalytic materials. This design requires no restrictive plates or retaining screens and

1014can be made very consistently and rapidly.

1015The flow paths of the hydrocarbon fluids flowing through the system 400

1016(i.e., rolled structure 420 thereof) is essentially the same as the flow paths of the

1017hydrocarbon fluids flowing through the system 100 and is generally indicated by the arrows

1018in Fig. 17. As with the first system 100, the dense core 430 at least partially restricts the

1019flow of the hydrocarbon fluids in that the fluid entering the cavity 432 closest to the inlet

1020fitting flows radially outward through the reactive elements (screens 412, 414, 416) due to

1021the presence of the dense core 430 within the flow path that extends longitudinally the

1022length of the rolled structure 420. In yet another embodiment, two ot me metallic elements associateα witn me

1023layered catalytic device are in screen form, e.g., aluminum and copper with approximately

102420-30 openings per square inch and a thickness of approximately .020 of an inch, and a

1025third metallic element is in the form of a stainless steel screen that is thin, non-perforated

1026and cut to be narrower in width than the other two materials. The metallic materials are cut

1027into predetermined length and width strips, for the chosen application, for example 2 inches

1028wide for the aluminum and copper and 1 inch wide for the non-perforated stainless steel

1029and with all having sufficient lengths to form approximately a 2 inch outside diameter

1030cylinder when positioned evenly over one another and rolled together, for most automotive

1031applications, fuel or crankcase emissions processing applications. The metallic materials

1032are cut and positioned over one another evenly in any preferred order but with having the

1033non-perforated stainless steel material centered evenly in such a way as to have equal

1034margins of the other materials on either side. The metallic materials are cut and rolled

1035together in such a way as to form a tight central core of predetermined depth, which may

1036be variable for different applications. For example, a small engine's crankcase ventilation

1037tube may require a dense central core of ^λh inch in depth and a large diesel engine fuel line

1038application may require a dense central core of approximately three inches in depth. As the

1039central core is formed by rolling the pre cut narrow portion of layered materials together,

1040the outer ends of the cylinder forms a hollow cylinder on each end of the dense central core

1041when the wider portion of layered materials are reached. The hollow cylindrical ends are

1042of predetermined diameter and depth for the chosen application, for example 3/8 of an inch

1043in diameter and ¹A of an inch in depth for most automotive applications and approximately

10441 inch in diameter and 1 inch in depth for large diesel engine crankcase applications. When rolled together, the dissimilar metallic elements form a cylinder ot evenly positioned

1045alternating layers with hollow central ends and a dense core.

1046The non-perforated material in this embodiment, being narrower than the

1047other screen materials, is positioned evenly and uniformly throughout the layers of

1048dissimilar, alternating screens inside the cylinder. This allows the hydrocarbon fluids

1049passing into the cylinder of metallic elements to be separated and divided as they pass

1050through and parallel with the arranged cylinder of materials. This effectively provides a

1051means of dividing the flow of hydrocarbon fluids. The input and output regions of the

1052cylinder of dissimilar elements, parallel to the flow path of hydrocarbon fluids, do not

1053restrict the lateral, or perpendicular flow of fluids, because they are perforated. This

1054permits the entering or exiting hydrocarbon fluids to freely flow throughout the arranged

1055elements with little restriction. However, the non-perforated material effectively eliminates

1056any lateral passage of these fluids once they encounter this region. In this region the fluids

1057are in contact with the three dissimilar metallic elements for a longer time interval allowing

1058greater possibility for the molecules to become modified. After passing through the central

1059core region containing the non-perforated element, the hydrocarbon fluids are allowed once

1060again to pass laterally throughout the arranged metallic screen material and be allowed to

1061enter the hollow portion extending from the central core region of the cylinder of arranged

1062materials to exit the device through the end cap's fitting. This arrangement, of this

1063embodiment, allows a greater division of the flow of hydrocarbon fluids resulting in a

1064greater opportunity for molecular modification when in contact with the dissimilar metallic

1065elements. Flow capacity is not appreciably reduced and there are no plates or other

1066components necessary for producing a thorough distribution of fluids throughout the device.

1067As well, this method of assembly provides an inexpensive and rapid manufacturing process while effectively providing consistency in material arrangement ana densities aurmg

1068production and allows diversity in application requirements and arrangements with no re¬

1069tooling of manufacturing equipment.

1070For different applications, the materials are simply cut into wider and/or

1071longer strips to satisfy nearly any desired application requirement, from small engines' fuel

1072or crankcase ventilation tubes to very large industrial furnaces fuel lines. Once the cylinder

1073of dissimilar materials has been formed, for the required application, it is placed in an

1074appropriate container. This housing is preferably made of stainless steel tubing with end

1075caps that can be sealed onto the housing body and threaded fittings at each end to allow

1076fluids to pass into and out of the device. This allows the unit to be connected to an engine's

1077crankcase ventilation tube or fuel line, liquid or vapor, in such a way as to have these fluids

1078pass into one end of the housing's threaded end caps where the fluids are able to pass

1079throughout the dissimilar metallic elements inside the device and allowed to escape out the

1080other end cap fitting and into the desired end use, such as combustion chamber or intake air

1081system, as required for each application. The housing chosen for containing the cylinder of

1082dissimilar metallic elements is variable in length and diameter to conform to the roll of

1083materials placed inside of it, which in turn is determined by the required application. For

1084example a typical six cylinder automobile engine may require a device for fuel or crankcase

1085ventilation emissions processing with dimensions that are approximately one and a half

1086inches in diameter and two inches in length. A large diesel engine may require a device

1087that is larger, for example with an outer diameter of approximately three inches and a

1088length of approximately five inches. The cylinder of materials, once placed inside of the

1089container, can be sealed in the housing by welding the end caps on, threading them on, or

1090even pressing them in place, as long as the unit is leak resistant in its application, whether it be on a high pressure fuel line or a negative pressure crankcase ventilation tube. The end

1091cap is preferably fitted with threaded fittings, for example an automotive application may

1092require ¹A inch national pipe thread fittings and a large diesel engine may require 1 inch

1093national pipe thread fittings. The threaded fittings allow appropriate adapters to be used in

1094connecting the device to the required application, whether it is a fuel line or crankcase

1095ventilation tube.

1096As with the other embodiments of this device, the installation is

1097straightforward and logical. Fuel line installation requirements are simply that this device

1098be connected to the fuel line of the desired equipment whether it is an engine, or furnace,

1099or even a barbecue, in such a way as to have the fuel supply line connected to the device

1100before it passes into the combustion apparatus. This may involve simply cutting the fuel

1101supply line anywhere convenient and practical between the fuel supply tank and combustion

1102apparatus. The fuel line is connected to the device in such a way as to have the fuel, vapor

1103or liquid, enter the device and flow throughout the reactive elements and be allowed to exit

1104the device and continue along its fuel line to the combustion application. The connection of

1105the fuel line to the device can be made with the appropriate fittings and clamps to secure a

1106leak proof environment. Distance from the combustion equipment and the device is not

1107important, as the length of time or distance the freshly modified fuel must endure after

1108being catalyzed has little effect on its newly altered reactivity. External heat and vibration

1109have little effect on the function of this device as long as the installation location does not

1110create a dangerous environment for the fuel passing through the device. This may include

1111insufficiently safe distances from an excessively hot burner or manifold etc. These simple

1112guide lines are no different than those outlined by a combustion equipment manufacturer's

1113fuel line routing guide line in accordance to safety etc. It is important to note that this device requires no external Heating, vibration, electrical stimulation or otner procedures to

1114aid in its function. It is bi-directional in its installation and it can be installed in any

1115convenient position necessary for the required installation, vertical, inclined, or horizontal

1116etc.

1117When installing the device on an engine's crankcase ventilation tube it is

1118only necessary to have the vented emissions pass into and through the device where they

1119are modified and allowed to pass out of the device and directed to the engine's fresh air

1120intake system, after the air filter and before the turbo charger, if equipped. It is preferable,

1121when convenient, to install the device in such a way as to have any condensed liquids drain

1122back into the engine when the engine is not running. This is accomplished by simply

1123installing the device in a location, such as slightly above the output connection of the vented

1124crankcase emissions that will allow occasional drainage. The device is bi-directional and

1125can be installed in any position convenient to the required application. There are no liquids

1126or filtering mediums to clean or replace. There is no required maintenance and the service

1127life of the device is expected to be several years, regardless of operational hours. The

1128hoses transporting the crankcase emissions from the engine to the device and from the

1129device to the air intake system are chosen to suite each given application. Large engines

1130may require 1 inch inside diameter hoses and small engines may require only 3/8 diameter

1131hoses. The hoses are connected to the device's input and output fittings simply with

1132suitable clamps to provide leak proof connections. On many diesel engines that do not

1133recycle crankcase emissions, a fitting may have to be installed in a convenient location

1134between the engine's air filter and turbo charger, if equipped. This fitting allows the

1135freshly modified crankcase emissions exiting the device to be drawn into the engine's

1136combustion chamber. The size of the fitting and hoses are chosen to allow minimum restriction without being excessively large tor the required application. The device does

1137not produce excess heat during its operation and it is not affected by extremes in ambient

1138temperatures, hot or cold.

1139In yet another embodiment, a catalytic device made in accordance with any

1140of the above embodiments can be used in a two stroke muffler environment. More

1141specifically, the catalytic device can be disposed along the emissions flow path prior to the

1142emissions being delivered into the muffler itself for chemically modifying (decomposing)

1143the hydrocarbons. One of the advantages of the catalytic devices of the present invention is

1144that the catalytic devices do not generate heat since the reaction that occurs therein is not

1145exothermic but instead is endothermic. This is desirable in a motorcycle environment,

1146where a two stroke muffler would be used, since the body of the operator of the motorcycle

1147is placed in close proximity to the muffler system and therefore, the inclusion of an

1148exothermic catalytic device near the body (legs) of the operator would be undesirable and

1149could lead to injury or at the very least discomfort due to the heat buildup.

1150The present applicants have also found that in the catalytic devices made in

1151accordance with the above embodiments, the formation of the innermost layer (e.g., third

1152layer 116) from aluminum yielded increased results and performance since this innermost

1153layer is in general the last layer or surface that the fluid contacts prior to being discharged

1154from the catalytic device. It will therefore be appreciated that instead of forming this

1155innermost layer from aluminum, this innermost layer can be formed of a metal that is

1156formed in the same group in the period table that contains aluminum. In particular,

1157Gallium, Indium, and Thallium may be used in some applications as the innermost layer.

1158The following Examples illustrate some of the potential applications and

1159advantages associated with the catalytic devices of the present invention and as embodied and described above. The tollowing Jbxamples are therefore merely exemplary and

1160illustrative and do not serve to limit the scope of the present invention in any way.

1161Example 1

1162A catalytic device made in accordance with the present invention was

1163installed on a 1998 one ton delivery truck that is equipped with a 6.5 liter turbo diesel

1164engine. The vehicle is equipped with a CDR valve (enclosed crankcase) and as is

1165commonly known, CDR valves require routine replacement every 30,000 km because of

1166sludge buildup on the valve.

1167The catalytic device was installed in July 2003 when the truck had a mileage

1168of 70,0OO km. The truck ran approximately 12 hours a day for 5 days a week as part of the

1169continuous delivery operation and would travel about 300 km each day. In February 2005,

1170after 20 months of operation in which the truck traveled 130,000 km, the catalytic device

1171was removed for inspection and testing. The results of the visual inspection and testing

1172were that the catalytic device has identical flow characteristics as when it was new prior to

1173installation in the CDR valve. The catalytic device did not contain any buildup or suffer

1174from flow restriction. No maintenance was performed and the catalytic device was not

1175contaminated with sludge.

1176A new catalytic device was installed and the vehicle was test driven, with no

1177apparent changes in sound or performance, indicating that the original device did not

1178degrade in function after long term use.

1179The following benefits and advantages have been realized as a result of the

1180incorporation of the catalytic device of the present invention in the vehicle: increased engine power, improved drivability (taster acceleration, less vibration), reduction in

1181exhaust emissions, and. quieter operation producing less drive fatigue.

1182Example 2

1183A catalytic device made in accordance with the present invention was

1184installed on a drag line in February 2005. The drag line is powered by an 8 cylinder

1185Detroit Diesel 2 stroke 300 hp engine that was built in 1976. The engine has two open

1186crankcase vents (road tubes) that emitted the carcinogenic gases directly below the

1187operator's cab. The cab is not airtight and therefore, these toxic gases rise directly into the

1188operator's cab resulting in the operator complaining of headaches, throat irritation, burning

1189eyes and coughing.

1190The drag line also received a number of complaints from home owners in

1191locations adjacent to where the drag line is being used to perform beach excursion in a

1192tourist region. In particular, the diesel exhaust emissions were excessive and irritating.

1193Fuel additives and the hiring of a diesel specialist to adjust the engine specifications and

1194operations conditions failed to improve the situation.

1195The applicants installed a crankshaft catalytic device, enclosing the vent line,

1196and installed a catalytic device along the fuel line, with each of the catalytic devices being

1197one of the devices described hereinbefore. The use of the catalytic devices according to the

1198present invention in these select locations resulted in remarkable improvements being

1199observed. More specifically, the emissions problem no longer exists and both the

1200neighbors and the operator no longer experience health problems. There is no longer a

1201need to use expensive emission reduction fuel additives. The following benefits and advantages have been realized as a result oi me

1202incorporation of the catalytic device of the present invention in both the crankcase vent line

1203and fuel line: increased engine power (operator is able to move 25% more sand per day),

1204quieter operation, less vibration and the engine oil stays cleaner for a longer period of time.

1205Example 3

1206As part of the daily operations at a processing plant, diesel equipment is used

1207indoors and the resulting emissions from this equipment caused major health concerns from

1208the workers after several workers were hospitalized and there was a general feeling that the

1209ventilation system indoors is inadequate.

1210In response to the problem, the company fitted three diesel engines that are

1211used indoors with a catalyst system that includes one or more of the catalytic devices

1212disclosed herein and installed in fuel lines and/or vent lines. As a result of this action, the

1213diesel emissions problem has been entirely eliminated and the air quality test performed for

1214the Workers Compensation Board after the installation of the catalytic systems of the

1215present invention showed the diesel emissions to be only 1/7 of the maximum allowable

1216limits.

1217Example 4

1218A catalytic device made in accordance with one of the embodiments of the

1219present invention was installed as part of a crankcase emissions systems in a 4.3 liter V6

1220Chevrolet vehicle that had 110,000 km on it. After the vehicle had traveled 60,000 km

1221with the catalytic device of the present invention installed in the crankcase equipment, the

1222engine was examined and in particular, the carburetor was removed to observe the intake manifold which was remarkably clean. In addition, the rear mam Dearmg snoweα no

1223abnormal wear and the inside of the oil pan was amazingly clean, especially in view of the

1224fact that the engine is a 10 year old engine. In sum, the internal working components and

1225areas of the engine were remarkably clean as a result of the catalytic device of the present

1226invention which served to process and chemically modify the hydrocarbons into segments

1227that are cleaner and result in a much more efficient and cleaner operation of the engine,

1228which results in improved emissions and engine performance.

1229Example 5

1230In yet another application, a catalytic device made in accordance with one of

1231the embodiments of the present invention was installed on a 3.5 hp lawn mower engine and

1232more specifically, the catalytic device was installed as part of the crankcase vent line. Prior

1233to the installation of the catalytic device of the present invention, the spark plug of the lawn

1234mower was observed to have heavy residue and blackening due to 4 years of use without

1235having been cleaned. After one hour of use with the catalytic device installed, a significant

1236improvement was observed when the spark plug was taken out and observed. The spark

1237plug was observed after two hours of operation and then several months later.

1238The results of the use of the present catalytic device were dramatic in that

1239there was no carbon buildup on the valves of the spark plug and the overall cleanliness of

1240the spark plug components substantially improved and there was a substantial decrease in

1241the amount of residue that was on the spark plug.

1242The catalyst (catalytic devices) disclosed herein and made in accordance with

1243the present invention can be characterized as being a selective catalyst. In order to describe

1244why a selective catalyst is so useful and desirable, it is helpful to understand the intricacies of the combustion process. For example, it is lαiown to add an additive to tuei in an

1245attempt to chemically modify the fuel to create a cleaner burning fuel and in particular, it is

1246standard practice for oil refiners to add tetra-ethyl lead as an additive for aviation fuels.

1247The lead was simply a carrier for the very reactive ethyl radical. These reactive fragments

1248initiated chain reactions in combustion allowing fire to commence easier, sooner, smoother

1249and more controllably. AU of these factors equal more power, lower operating

1250temperatures, less vibration and lower emissions.

1251The selective catalyst according to the present invention, produces similar

1252reactive compounds and positive results as that achieved from aviation fuel additives and

1253refining, but without the requirements of a lead carrier. This allows safety and diversity

1254because it can be used not just for high performance aviation engines, but all engines and

1255combustion equipment. The catalytic devices according to the present invention are

1256distinctly different from other known catalysts because of the safe reactive intermediates

1257that they produce. The catalytic device functions as an endothermic reactor and has an

1258indefinite life span.

1259The catalytic devices made in accordance with any of trie disclosed

1260embodiments and in accordance with the teaching of the present invention offer a number

1261of advantages including the following: improved ignitability of all hydrocarbon fluid fuel,

1262easier starting, less explosive ignition characteristics, reduced ignition lag in diesel engines,

1263slower flame propagation, lower ignition temperature, greater range of flammability limits,

1264air- fuel ratios become less critical, excess oxygen not as detrimental to combustion

1265equipment-flames are not as oxidizing, increased flame stability with all combustion

1266equipment, detonation reduction, reduced ring fluctuations, vibration reduction by flame

1267stabilizing, more controlled vibration energy of molecules in combustion chamber, increased energy loss of molecules in combustion chamber, sound ot combustion reduced,

1268power, torque and acceleration increase, compression pressure increase, lower opacity,

1269carbon clusters in exhaust and combustion equipment, lower carbon monoxide, CO, levels

1270in exhaust, lower hydrocarbon levels in exhaust, lower oxides of nitrogen emissions, No-x,

1271in exhaust, lower levels of carbon dioxide, Co-2, reduced fuel, increased oil cleanliness, -

1272less carbon, fuel, water, acid contamination, reduced exhaust gas temperatures, reduced

1273coolant temperatures, reduced lubricating oil temperatures, reduced automatic transmission

1274temperatures, reduced valve and valve seat temperatures, to name just a few.

1275One of the advantages and differences between the present invention and

1276previous catalytic devices and systems is that the present invention produced safe reactive

1277intermediates during the catalytic process where the hydrocarbon containing fluid contacts

1278the reactive sites of the present catalytic devices and is processed and treated such that the

1279hydrocarbon molecular structures are chemically altered. The formation of the reactive

1280intermediates using the catalytic devices of the present invention provides the following

1281advantages: (1) increased chemical reactivity which (a) assists fuel decomposition; (b)

1282assists vaporization of liquid fuels; and (c) assists decomposition of carbon clusters; (2)

1283reduces required heat to promote chemical reactivity for combustion; (3) removes carbon

1284which results in (a) reduced ring sticking; (b) reduced valve sticking (c) reduced valve seat

1285contamination; (4) reduces carbon build up in manifolds; (5) reduces or eliminates sludge in

1286intake from re-circulated emissions; and (6) cleans and eliminates the formation of carbon

1287deposits on injectors, spark plugs, emissions control equipment, etc.

1288As previously mentioned, one particularly advantageous application for the

1289catalytic devices of the present invention is in a crankcase ventilation enclosure. The

1290following advantages are realized when the catalytic devices of the present invention are incorporated into a crankcase ventilation setting: eliminates open crankcase vent system on

1291all internal combustion engines; allows vacuum in crankcase of engines without concern of

1292oil contamination; produces ionic field allowing the removal of water and carbon sludge

1293from crankcase; eliminates problems of combustion contamination associated with recycled

1294crankcase emissions; elimination of open crankcase vent on large diesel engines eliminates

1295outside contaminants from entering crankcase cavity of engine; vacuum in crankcase cavity

1296helps rings to seal, more completely, the compression pressures from entering crankcase

1297cavity; eliminates maintenance associated with crankcase emissions; vacuum in crankcase

1298cavity reduces gasket leaks, vacuum in crankcase cavity reduces lubricating oil cavitations,

1299and when lighter fractions of oil are vaporized and drawn out of the crankcase cavity of the

1300engine, the lubricating oil maintains its viscosity.

1301However, it will be appreciated that the catalytic devices and systems can be

1302used in a wide array of environments and applications beyond the ones disclosed herein. In

1303general, the catalytic devices can be used in most, if not all, settings where hydrocarbon

1304fluid are present and there is a need or desire to chemically alter and modify the

1305hydrocarbons, on a molecular level, in order to improve operation efficiency and/or

1306reducing emissions, etc. Such settings range from vehicles (tracks, heavy equipment,

1307motorcycles) to enclosed structures where generators, boilers or other equipment are

1308operated, and to small engine driven machinery, such as lawn mowers, etc.

1309Thus, while there have been shown, described, and pointed out fundamental

1310novel features of the invention as applied to a preferred embodiment thereof, it will be

1311understood that various omissions, substitutions, and changes in the form and details of the

1312devices illustrated, and in their operation, may be made by those skilled in the art without

1313departing from the spirit and scope of the invention. For example, it is expressly intended that all combinations of those elements and/or steps which perform substantially trie same

1314function, in substantially the same way, to achieve the same results are within the scope of

1315the invention. Substitutions of elements from one described embodiment to another are also

1316fully intended and contemplated. It is also to be understood that the drawings are not

1317necessarily drawn to scale, but that they are merely conceptual in nature. It is the

1318intention, therefore, to be limited only as indicated by the scope of the claims appended

1319hereto.

1320AU references, publications, pending and issued patents are herein each

1321incorporated by reference in their entirety.