Ross SPIROS -- Improvements by the co-inventor of Yull
Brown's HHO gas generator : claims 3 forms of over-unity

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**Spiro Ross SPIROS**  
**Electrolysis**

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**Improvements by the co-inventor of Yull
Brown's HHO gas generator : claims 3 forms of over-unity**



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[**http://www.bibliotecapleyades.net/ciencia/ciencia\_quantum08.htm**](http://www.bibliotecapleyades.net/ciencia/ciencia_quantum08.htm)

**Ross Spiros**

  
Australian inventor and past business partner and researcher with
Yul Brown (the famous Australian that put the hydrogen revolution
on the map with his aBrown Gasa technologies).  
  
Mr. Spiros went on to refine and improve the efficiencies and
commercialization of the original inventions by producing a unique
technology where the cells are cost effective, efficient and can
produce all transportation fuels commercially.  
  
Ross is co-owner of Eco Global Fuels LLC, the worldas first and
only producer of 100 percent renewable, alcohol-based
transportation fuels, using water, sunlight and catalysisas.
Decades of research have enabled the technology to harness the
power of water and sunlight for the manufacture of hydrogen in the
most efficient, cost-effective and ecologically sound manner ever
created.  
  
When combined with carbon dioxide extracted from the atmosphere,
this hydrogen is immediately converted into an alcohol-based
liquid fuel for safe and reliable transport.  
  


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**PATENTS**

  

**IMPROVEMENTS IN ELECTROLYSIS SYSTEMS AND
THE AVAILABILITY OF OVER-UNITY ENERGY**  
**WO9528510**  
**AU2248695**

  
A looped energy system for the generation of excess energy
available to do work is disclosed. The system comprises an
electrolysis cell unit (150) receiving a supply  of water to
liberate separated hydrogen gas (154) and oxygen (156) by
electrolysis driven by a DC voltage (152) applied across
respective anodes and cathodes of the cell unit (150). A hydrogen
gas receiver (158) receives and stores hydrogen gas liberated by
the cell unit (150), and an oxygen gas receiver (160) receives and
stores oxygen gas liberated by the cell unit (150). A gas
expansion device (162) expands the stored gases to recover
expansion work, and a gas combustion device (168) mixes and
combusts the expanded hydrogen gas and oxygen gas to recover
combusted work. A proportion of the sum of the expansion work and
the combustion work sustains electrolysis of the cell unit to
retain operational gas pressure in the gas receivers (158, 160)
such that the energy system is self-sustaining, and there is
excess energy available from the sum of energies.  
  
**Technical Field of the Invention**  
The present invention relates to the generation of hydrogen gas
and oxygen gas from water, either as an admixture or as separated
gases, by the process of electrolysis, and relates further to
applications for the use of the liberated gas. Embodiments of the
invention relate particularly to apparatus for the efficient
generation of these gases, and to use of the gases in an internal
combustion engine and an implosion pump. The invention also
discloses a closed-loop energy generation system where latent
molecular energy is liberated as a form of 'free energy' so the
system can be self-sustaining.  
  
Reference is made to commonly-owned International patent
application No.PCT/AU94/000532, having the International filing
date of 6 September 1994.  
  
**Background Art**  
The technique of electrolysing water in the presence of an
electrolyte such as sodium hydroxide (NaOH) or potassium hydroxide
(KOH) to liberate hydrogen and oxygen gas (H2, 02) is well known.
The process involves applying a DC potential difference between
two or more anode/cathode electrode pairs and delivering the
minimum energy required to break the H-O bonds (i.e. 68.3 kcal per
mole @ STP).  
The gases are produced in the stoichiometric proportions for O2:H2
of 1:2 liberated respectively from the anode (+) and cathode (-).  
  
Reference can be made to the following texts: "Modern
Electrochemistry, Volume 2, John O'M. Bockris and Amulya K.N.
Reddy, Plenum Publishing Corporation", "Electro-Chemical Science,
J. O'M. Bockris and D.M. Drazic, Taylor and Francis Limited" and
"Fuel Cells, Their Electrochemistry, J. O'M. Bockris and S.
Srinivasan, McGraw-Hill Book Company".  
  
A discussion of experimental work in relation to electrolysis
processes can be obtained from "Hydrogen Energy, Part A, Hydrogen
Economy Miami Energy Conference, Miami Beach, Florida, 1974,
edited by T. Nejat Veziroglu, Plenum Press". The papers presented
by J. O'M. Bockris on pages 371 to 379, by F.C. Jensen and F.H.
Schubert on pages 425 to 439 and by John B. Pangborn and John C.
Sharer on pages 499 to 508 are of particular relevance.  
  
On a macro-scale, the amount of gas produced depends upon a number
of variables, including the type and concentration of the
electrolytic solution used, the  anode/cathode electrode pair
surface area, the electrolytic resistance (equating to ionic
conductivity, which is a function of temperature and pressure),
achievable current density and anode/cathode potential difference.
The total energy delivered must be sufficient to disassociate the
water ions to generate hydrogen and oxygen gases, yet avoid
plating (oxidation/reduction) of the metallic or conductive
non-metallic materials from which the electrodes are constructed.  
  
**Disclosure of the Invention**  
The invention discloses a looped energy system for the generation
of excess energy available to do work, said system comprising: an
electrolysis cell unit receiving a supply of water and for
liberating separated hydrogen gas and oxygen gas by electrolysis
due to a DC voltage applied across respective anodes and cathodes
of said cell unit; hydrogen gas receiver means for receiving and
storing hydrogen gas liberated by said cell unit; oxygen gas
receiver means for receiving and storing oxygen gas liberated by
said cell unit; gas expansion means for expanding said stored
gases to recover expansion work; and gas combustion means for
mixing and combusting said expanded hydrogen gas and oxygen gas to
recover combustion work; and wherein a proportion of the sum of
the expansion work and the combustion work sustains electrolysis
of said cell unit to retain operational gas pressure in said
hydrogen and oxygen gas receiver means such that the energy system
is self-sustaining and there is excess energy available from said
sum of energies.  
  
The invention further discloses a looped energy system for the
generation of excess energy available to do work, said system
comprising: an electrolysis cell unit receiving a supply of water
and for liberating separated hydrogen gas and oxygen gas by
electrolysis due to a DC voltage applied across respective anodes
and cathodes of said cell unit; hydrogen gas receiver means for
receiving and storing hydrogen gas liberated by said cell unit;
oxygen gas receiver means for receiving and storing oxygen gas
liberated by said cell unit; gas expansion means for expanding
said stored gases to recover expansion work; and fuel cell means
for recovering electrical work from said expanded hydrogen gas and
oxygen gas; and wherein a proportion of the sum of the expansion
work and the recovered electrical work sustains electrolysis of
said cell unit to retain operational gas pressure in said hydrogen
and oxygen gas receiver means such that the energy system is
self-sustaining and there is excess energy available from said sum
of energies.  
  
The invention further discloses a method for the generation of
excess energy available to do work by the process of electrolysis,
said method comprising the steps of: electrolysing water by a DC
voltage to liberate separated hydrogen gas and oxygen gas;
separately receiving and storing said hydrogen gas and oxygen gas
in a manner to be self-pressuring; separately expanding said
stores of gas to recover expansion work; combusting said expanded
gases together to recover combustion work; and applying a portion
of the sum of the expansion work and the combustion work as said
DC voltage to retain operational gas pressures and sustain said
electrolysing step, there thus being excess energy of said sum
available.  
  
The invention further discloses a method for the generation of
excess energy available to do work by the process of electrolysis,
said method comprising the steps of: electrolysing water by a DC
voltage to liberate separated hydrogen gas and oxygen gas;
separately receiving and storing said hydrogen gas and oxygen gas
in aniaaner to be self-pressuring; separately expanding said
stores of gas to recover expansion work; passing said expanded
gases together through a fuel cell to recover electrical work; and
applying a portion of the sum of the expansion work and the
recovered electrical work as said DC voltage to retain operational
gas pressures and sustain said electrolysing step, there thus
being excess energy of said sum available.  
  
The invention further discloses an internal combustion engine
powered by hydrogen and oxygen comprising: at least one cylinder
and at least one reciprocating piston within the cylinder; a
hydrogen gas input port in communication with the cylinder for
receiving a supply of pressurised hydrogen; an oxygen gas input
port in communication with the cylinder for receiving a supply of
pressurised oxygen; and an exhaust port in communication with the
cylinder and wherein the engine is operable in a two-stroke manner
whereby, at the top of the stroke, hydrogen gas is supplied by the
respective inlet port to the cylinder driving the piston
downwardly, oxygen gas then is supplied by the respective inlet
port to the cylinder to drive the cylinder further downwardly,
after which time self-detonation occurs and the piston moves to
the bottom of the stroke and upwardly again with said exhaust port
opened to exhaust water vapour resulting from the detonation.  
  
The invention further discloses an implosion pump comprising a
combustion chamber interposed, and in communication with, an upper
reservoir and a lower reservoir separated by a vertical distance
across which water is to be pumped, said chamber receiving admixed
hydrogen and oxygen at a pressure sufficient to lift a volume of
water the distance therefrom to the top reservoir, said gas in the
chamber then being combusted to create a vacuum in said chamber to
draw water from said lower reservoir to fill said chamber,
whereupon a pumping cycle is established and can be repeated.  
  
The invention further discloses a parallel stacked arrangement of
cell plates for a water electrolysis unit, the cell plates
alternately forming an anode and cathode of said electrolysis
unit, and said arrangement including separate hydrogen gas and
oxygen gas outlet port means respectively in communication with
said anode cell plates and said cathode cell plates and extending
longitudinally of said stacked plates, said stacked cell plates
being configured in the region of said conduits to mate in a
complementary manner to form said conduits such that a respective
anode cell plate or cathode cell plate is insulated from the
hydrogen gas conduit or the oxygen gas conduit.  
  
**Brief Description of the Drawings****Figs. 1 1a-16 of noted International application no.
PCT/AU94/000532 are reproduced to aid description of the present
invention, but herein denoted as Figs. la-6:****Figs. la and 1b show an embodiment of a cell plate;****Figs. 2a and 2b show a complementary cell plate to that of
Figs. la and lb;****Fig. 3 shows detail of the perforations and porting of the
cell plates of Figs. la, lb, 2a and 2b;****Fig. 4 shows an exploded stacked arrangement of the cell
plates of Figs. la, lb, 2a and 2b;****Fig. 5a shows a schematic view of the gas separation system
of Fig. 4;****Fig. 5b shows a stylised representation of Fig. 5a;****Fig. 5c shows an electrical equivalent circuit of Fig. 5a;
and****Fig. 6 shows a gas collection system for use with the cell
bank separation system of Figs. 4 and 5a.****The remaining drawings are:****Figs. 7a and 7b are views of a first cell plate;****Figs. 8a and 8b are views of a second cell plate;****Fig. 9 shows detail of the edge margin of the first cell
plate;****Fig. 10 shows an exploded stacked arrangement of the cell
plates shown in** **Figs. 7a and 8a;****Fig. 11 is a cross-sectional view of three of the stacked
cell plates shown in****Fig. 10 in the vicinity of a gas port;****Figs. 12a and 12b respectively show detail of the first and
second cell plates in the vicinity of a gas port;****Fig. 13 is a cross-sectional view of a cell unit of four
stacked cell plates in the vicinity of an interconnecting shaft;****Fig. 14 shows a perspective view of a locking nut used in
the arrangement of Fig. 13;****Fig. 15 shows an idealised electrolysis system;****Figs. 16-30 are graphs supporting the system of Fig. 15 and
the availability of over-unity energy;****Figs. 31a to 31e show a hydrogen/oxygen gas-driven internal
combustion engine; and****Figs. 32a-32c show a gas-driven implosion pump.** **![](1.jpg)  ![](2.jpg)  
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![](33.jpg) ![](34.jpg) ![](35.jpg)****Detalled Description and Best Mode of Performance**The following description of Figs. la-6 is taken from
PCT/AU94/000532.  
  
Figs. la and 2a show embodiments of a first and second type of
cell plate 90,98 as an end view. Figs. 1b and 2b are partial
cross-sectional views along the respective mid-lines as shown.
Common reference numerals have been used where appropriate. The
plates 90,98 can have the function of either an anode (+) or a
cathode (-), as will become apparent. Each comprises an electrode
disc 92 that is perforated with hexagonally shaped holes 96. The
disc 92 is made from steel or resinbonded carbon or conductive
polymer material. The disc 92 is housed in a circular rim or
sleeve 94. The function of the perforations 96 is to maximise the
surface area of the electrode disc 92 and minimise the weight over
solid constructions by 45 %.  
  
By way of example, for a disc of diameter 280 mm, the thickness of
the disc must be 1 mm in order to allow the current density (which
ranges from 90 A / 2,650 cm2 - 100 A / 2,940 cm2 of the anode or
cathode) to be optimal. If the diameter of the plate is increased,
which consequently increases the surface area, it is necessary to
increase the thickness of the plate in order to maintain
uniformity of conductance for the desired current density.  
  
The hexagonal perforations in a 1 mm disc have a distance of 2 mm
between the flats, twice the thickness of the plate in order to
maintain the same total surface area prior to perforation, and be
1 mm away from the next adjacent perforation to allow the current
density to be optimal. A 1 mm (flat-to-flat) distance between the
hexagonal perforations is required, because a smaller distance
will result in thermal losses and a larger distance will add to
the overall weight of the plate.  
  
The sleeve 94 is constructed of PVC material and incorporates a
number of equally spaced shaft holes 100,102. The holes are for
the passage of interconnecting shafts provided in a stacked
arrangement of the plates 90,98 forming the common conductor for
the respective anode and cathode plates. The further two upper
holes 104,106 each support a conduit respectively for the out-flow
of oxygen and hydrogen gases. The further holes 108,110 at the
bottom of the sleeve 94 are provided for the inlet of water and
electrolyte to the respective cell plates 90,98.  
  
Fig. 3 shows an enlarged view of a portion of the cell plate 90
shown in Fig.la. The port hole 104 is connected to the hexagonal
perforations 96 within the sleeve 94 by an internal channel 112. A
similar arrangement is in place for the other port hole 106, and
for the water/electrolyte supply holes 108,110.  
  
If it is the case that the hydrogen and oxygen gases liberated are
to be kept separate (i.e. not to be formed as an admixture), then
it is necessary to separate those gases as they are produced. In
the prior art this is achieved by use of diaphragms that block the
passage of gases and effectively isolate the water/electrolyte on
each side of the diaphragm. Ionic transfer thus is facilitated by
the ionically conductive nature of the diaphragm material (i.e. a
water - diaphragm - water path). This results in an increase in
the ionic resistance and hence a reduction in efficiency.  
  
Fig. 4 shows an exploded stacked arrangement of four cell plates,
being an alternative stacking of two (anode) cell plates 90 and
two (cathode) cell plates 98. The two ends of the stacked
arrangement of cell plates delineates a single cell unit 125.  
  
Interposed between each adjacent cell plate 90,98 is a PTFE
separation 116. Although not shown in Fig. 4, the cell unit
includes separate hydrogen and oxygen gas conduits that
respectively pass through the stacked arrangement of cell plates
via the port holes 106,104 respectively. In a similar way,
conduits are provided for the supply of water/electrolyte,
respectively passing through the holes 108,110 at the bottom of
the respective plates 90,98. Only two pairs of anode/cathode cell
plates are shown. The number of such plates can be greatly
increased per cell unit 125.  
  
Also not shown are the interconnecting conductive shafts that
electrically interconnect alternative common cell plates. The
reason for having a large diameter hole in one cell plate adjacent
to a smaller diameter hole in the next cell plate, is so that an
interconnecting shaft will pass through the larger diameter hole,
and not make an electrical connection (i.e. insulated with PVC
tubing) rather only forming an electrical connection between
alternate (common) cell plates.  
  
The cell unit 125 shown in Fig. 4 arrangement is an exploded view.
When fully constructed, all the elements are stacked to be in
intimate contact. Mechanical fastening is achieved by use of one
of two adhesives such as (a) "PUR-FECT LOK" (TM) 34-9002, which is
a Urethane Reactive Hot Melt adhesive with a main'ingredient of
Methylene Bispheny/Dirsocynate (MDI), and (b) "MY-T-BOND" (TM)
which is a PVC solvent based adhesive. Both adhesives are Sodium
Hyroxide (20% present in the electrolyte) resistant. In that case
the water/electrolyte only resides within the area proscribed by
the cell plate sleeve 94. Thus the only path for the inlet of
water/electrolyte is by bottom channels 118,122 and the only
outlet for the gases is by the top channels 112,120.In a system
constructed and tested by the inventor, the thickness of the cell
plates 90,98 is 1 mm (2 mm on the rim because of the PVC sleeve
94), with a diameter of 336 mm. The cell unit 125 is segmented
from the next cell by an insulating PVC segmentation disc 114. A
segmentation disc 114 also is placed at the beginning and end of
the entire cell bank.  
  
If there is to be no control over separation of the liberated
gases, then the PTFE membranes 116 are not provided, nor is the
sleeve 94 required.The PTFE membrane 116 is fibrous and has 0.2 to
1.0 micron interstices. A suitable type is type Catalogue Code J,
supplied by Tokyo Roshi International Inc (Advantec).   
  
The water/electrolyte fills the interstices and ionic current
flows only via the water - there is no contribution of ionic flow
through the PTFE material itself. This leads to a reduction in the
resistance to ionic flow. The PTFE material also has a 'bubble
point' that is a function of pressure, hence by controlling the
relative pressures at either side of the PTFE separation sheets,
the gases can be 'forced' through the interstices to form an
admixture, or otherwise kept separate. Other advantages of this
arrangement include a lesser cost of construction, improved
operational efficiency and greater resistance to faults.  
  
Fig. 5a is a stylised, and exploded, schematic view of a linear
array of three series-connected cell units 125. For clarity, only
six interconnecting shafts 126-131 are shown. The shafts 126-131
pass through the respective shaft holes 102,100 in the various
cell plates 90,98 in the stacked arrangement. The polarity
attached to each of the exposed end shafts, to which the DC supply
is connected also is indicated. The shafts 126-131 do not run the
full length of the three cell banks 125. The representation is
similar to the arrangement shown in Figs. 7a and 8. One third the
full DC source voltage appears across each anode/cathode cell
plate pair 90,98.  
  
Further, the gas conduits 132,133, respectively for hydrogen and
oxygen, that pass through the port holes 104,106 in the cell
plates 90,98 also are shown. In a similar way, water/electrolyte
conduits 134,135, passing through the water port holes 108,110 in
the cell plates also are shown.  
  
Fig. 5b particularly shows how the relative potential difference
in the middle cell bank 125 changes. That is, the plate electrode
90a now functions as a cathode (i.e.relatively more negative) to
generate hydrogen, and the plate electrode 98a now functions as an
anode (i.e. relatively more positive) to generate oxygen. This is
the case for every alternate cell unit. The arrowheads shown in
Fig. 5b indicate the electron and ionic current circuit. Fig. Sc
is an electrical equivalent circuit representation of Fig. 5b,
where the resistive elements represent the ionic resistance
between adjacent anode/cathode plates. Thus it can be seen that
the cell units are connected in series.  
  
Because of the change of function of the cell plates 90a and 98a,
the complementary gases are liberated at each, hence the
respective channels 112 are connected to the opposite gas conduit
132,133. Practically, this can be achieved by the simple reversal
of the cell plates 90,98.  
  
Fig. 6 shows the three cell units 125 of Fig. 5a connected to a
gas collection arrangement. The cell units 125 are located within
a tank 140 that is filled with water/electrolyte to the level h
indicated. The water is consumed as the electrolysis process
proceeds, and replenishing supply is provided via the inlet 152.
The water/electrolyte level h can be viewed via the sight glass
154. In normal operation, the different streams of hydrogen and
oxygen are produced and passed from the cell units 125 to
respective rising columns 142,144. That is, the pressure of
electrolyte on opposed sides of the PTFE membranes 116 is
equalised, thus the gases cannot admix.  
  
The columns 142, 144 also are filled with the water/electrolyte,
and as it is consumed at the electrode plates, replenishing supply
of electrolyte is provided by way of circulation through the
water/electrolyte conduits 134,135. The circulation is caused by
entrainment by the liberated gases, and by the circulatory
inducing nature of the conduits and columns.  
  
The upper extent of the tank 140 forms two scrubbing towers
156,158, respectively for the collection of oxygen and hydrogen
gases. The gases pass up a respective column 142,144, and out from
the columns via openings therein at a point within the interleaved
baffles 146. The point where the gases exit the columns 142,144 is
  
  
beneath the water level h, which serves to settle any turbulent
flow and entrained electrolyte. The baffles 146 located above the
level h scrub the gas of any entrained electrolyte, and the
scrubbed gas then exits by respective gas outlet columns 148,150
and so to a gas receiver. The level h within the tank 140 can be
regulated by any convenient means, including a float switch, again
with the replenishing water being supplied by the inlet pipe 152.  
  
The liberated gases will always separate from the
water/electrolyte solution by virtue of the difference in
densities. Because of the relative height of the respective set of
baffles, and due to the density differential between the gases and
the water/electrolyte, it is not possible for the liberated
hydrogen and oxygen gases to mix.  
  
The presence of the full volume of water within the tank 140
maintains the cell plates in an immersed state, and further serves
to absorb the shock of any internal detonations should they occur.  
  
In the event that a gas admixture is required, then firstly the
two flow valves 136,137 respectively located in the oxygen gas
outlet conduit 132 and water/electrolyte inlet port 134 are
closed. This blocks the outlet path for the oxygen gas and forces
the inlet water/electrolyte to pass to the inlet conduit 134 via a
one-way check valve 139 and pump 138. The water/electrolyte within
the tank 140 is under pressure by virtue of its depth (volume),
and the pump 138 operates to increase the pressure of
water/electrolyte occurring about the anode cell plates 90,98a to
be at an increased pressure with respect to the water/electrolyte
on the other side of the membrane 116.  
  
This pressure differential is sufficient to cause the oxygen gas
to migrate through the membrane, thus admixed oxygen and hydrogen
are liberated via the gas output conduit 133 and column 144. Since
there is no return path for the water/electrolyte supplied by the
pump 138, the pressure about the cell plates 90,98a will increase
further, and to a point where the difference is sufficient such
that the water/electrolyte also can pass through the membrane 116.
Typically, pressure differential in the range of 1.5 - 10 psi is
required to allow passage of gas, and a pressure differential in
the range of 10 - 40 psi for water/electrolyte.  
  
While only three cell units 125 are shown, clearly any number,
connected in series, can be implemented.  
  
Embodiments of the present invention now will be described. Where
applicable, like reference numerals have been used.  
  
Figs. 7a and 7b show a first type of cell plate 190 respectively
as an end view and as an enlarged cross-sectional view along line
VIIb-VIIb. The cell plate 190 differs from the previous cell plate
90 shown in Figs. la and 1b in a number of important aspects. The
region of the electrode disc 192 received within the sleeve 194
now is perforated. The function of these perforations is to
further reduce the weight of the cell plate 190. The shaft holes
200,202 again pass through the electrode disc 192, but so too do
the upper holes 204,206 through which the conduits for the
out-flow of liberated hydrogen and oxygen gases pass. The bottom
holes 208,210, provided for the inlet of water and electrolyte,
now also are located in the region of the sleeve 194 coincident
with the perforated edge margin of the electrode disc 192.The
channels 212,218 respectively communicating with the port hole 204
and the supply hole 210 also are shown.  
  
Figs. 8a and 8b show a second type of cell plate 198 as a
companion to the first cell plate 190, and as the same respective
views. The second cell plate 198 is somewhat similar to the cell
plate 98 previously shown in Figs. 2a and 2b. The differences
therebetween are the same as the respective differences between
the cell plate shown in Figs. la and 1b and the one shown in Figs.
7a and 7b. The arrangement of the respective channels 220,222 with
respect to the port 206 and the water supply hole 208 also are
shown.  
  
In the fabrication of the cell plates 190,198, the sleeve 94 is
injection moulded from PVC plastics material formed about the edge
margin of the electrode disc 192.  
  
The injection moulding process results in the advantageous forming
of interconnecting sprues forming within the perforations 196 in
the region of the disc 192 held within the sleeve 194, thus firmly
anchoring the sleeve 194 to the disc 192.  
  
Fig. 9 is a view similar to Fig. 3, but for the modified porting
arrangement and perforations (shown in phantom where covered by
the sleeve) of the region of the disc 192 within and immediately
outside of the sleeve 194.  
  
Fig. 10 shows a cell unit 225 in the form of an exploded
alternating stacking of first and second cell plates 190,198, much
in the same manner as Fig. 4. Only two pairs of anode/cathode cell
plates are shown, however the number of such plates can be greatly
increased per cell unit 225. The membrane 216 preferably is type
QR-HE silica fibre with the alternative being PTFE. Both are
available from Tokyo Roshi International Inc. (Advantec) of Japan.
Type QR-HE is a hydrophobic material having 0.2 to 1.0 micron
interstices, and is capable of operation at temperatures up to
10000C.  
  
The cell unit 225 can be combined with other such cell units 225
to form an interconnected cell bank in the same manner as shown in
Figs. 5a, 5b and 5c.  
  
Furthermore, the cell units can be put to use in a gas collection
arrangement such as that shown in Fig. 6. Operation of the gas
separation system utilising the new cell plates 190,198 is in the
same manner as previously described.  
  
Fig. 11 is an enlarged cross-sectional view of three cell plates
in the vicinity of the oxygen port 204. The cell plates comprise
two of the first type of plate 190 shown in Fig. 7a constituting a
positive plate, and a single one of the second type of plate 198
shown in Fig. 8a representing a negative plate. The location of
the respective channels 212 for each of the positive cell plates
190 is shown as a dashed representation. The respective sleeves
194 of the three cell plates are formed from moulded PVC plastics
as previously described, and in the region that forms the
perimeter of the port 204 have a configuration particular to
whether a cell plate is positive or negative. In the present case,
the positive cell plates 190 have a flanged foot 230 that, in the
assembled construction, form the contiguous boundary of the gas
port 204.Each foot 230 has two circumferential ribs 232 that
engage corresponding circumferential grooves 234 in the sleeve 194
of the negative plate 198.  
  
The result of this arrangement is that the exposed metal area of
the negative cell plates 198 always are insulated from the flow of
oxygen gas liberated from the positive cell plates 190, thus
avoiding the possibility of spontaneous explosion by the mixing of
the separated hydrogen and oxygen gases. This arrangement also
obviates the unwanted production of either oxygen gas or hydrogen
gas in the gas port.  
  
For the case of the gas port 206 carrying the hydrogen gas, the
relative arrangement of the cell plates is reversed such that a
flanged footing now is formed on the sleeve 194 of the other type
of cell plate 198. This represents the converse arrangement to
that shown in Fig. 11.  
  
Figs. 12a and 12b show perspective side views of adjacent cell
plates, with Fig. 12a representing a positive cell plate 190 and
Fig. 12b representing a negative cell plate 198. The gas port 206
thus formed is to carry hydrogen gas. The mating relationship
between the flanged foot 230 and the end margin of the sleeve 194
of the positive cell plate 192 can be seen, particularly the
interaction between the ribs 232 and the grooves 234.  
  
Fig. 13 is a cross-sectional view of four cell plates formed into
a stacked arrangement delimited by two segmentation plates 240,
together forming a cell unit 242.   
  
Thus there are two positive cell plates 190 and two negative cell
plates 198 in alternating arrangement. The cross-section is taken
in the vicinity of a shaft hole 202 through which a negative
conductive shaft 244 passes. The shaft 244 therefore is in
intimate contact with the electrode discs 192 of the negative cell
plates 198. The electrodes discs 192 of the positive cell plates
190 do not extend to contact the shaft 244. The sleeve 194 of the
alternating negative cell plates 198 again have a form of flanged
foot 246, although in this case the complementarily shaped ribs
and grooves are formed only on the sleeve of the negative cell
plates 198, and not on the sleeve 194 of the positive cell plates
190.The segmentation plates 240 serve to delimit the stacked
plates forming a single cell unit 242, with ones of the cell units
242 being stacked in a linear array to form a cell bank such as
has been shown in Fig. Sa.  
  
A threaded shaft nut 250 acts as a spacer between adjacent
electrodes connecting with the shaft 244. Fig. 14 is a perspective
view of the shaft nut 250 showing the thread 252 and three
recesses 254 for fastening nuts, screws or the like.  
  
In all of Figs. 11 to 13, the separation membrane material 216 is
not shown, but is located in the spaces 248 between adjacent cell
plates 190,198, extending to the margins of the electrode disks
192 in the vicinity of the gas ports 204,206 or the shaft holes
200,202.  
  
An electrolysis hydrogen and oxygen gas system incorporating a gas
separation system, such as has been described above, can therefore
be operated to establish respective high pressure stores of gas.
That is, the separated hydrogen and oxygen gases liberated by the
electrolysis process are stored in separate gas receivers or
pressure vessels. The pressure in each will increase with the
continuing inflow of gas.  
  
Fig. 15 shows an idealised electrolysis system, comprising an
electrolysis cell 150 that receives a supply of water to be
consumed. The electrolysis process is driven by a DC potential
(Es) 152. The potential difference applied to the cell 150
therefore must be sufficient to electrolyse the water into
hydrogen and oxygen gas dependent upon, inter alia, the water
pressure PC and the back pressure of gas PB acting on the surface
of the water, together with the water temperature Tc. The separate
liberated hydrogen and oxygen gases, by a priming function, are
pressurised to a high value by storage in respective pressure
vessels 158,160, being carried by gas lines 154,156.  
  
The pressurised store of gases then are passed to an energy
conversion device that converts the flow of gas under pressure to
mechanical energy (e.g. a pressure drop device 162). This
mechanical energy recovered WM is available to be utilised to
provide useful work. The mechanical energy WM also can be
converted into electrical form, again to be available for use.  
  
The resultant exhausted gases are passed via lines 164,166 to a
combustion chamber 168. Here the gases are combusted to generate
heat QR, with the waste product being water vapour. The recovered
heat QR can be recycled to the electrolysis cell to assist in
maintaining the advantageous operating temperature of the cell.  
  
The previously described combustion chamber 168 can alternatively
be a fuel cell. The type of fuel cell can vary from phosphoric
acid fuel cells through to molten carbonate fuel cells and solid
oxide cells. A fuel cell generates both heat (QR) and electrical
energy (WE), and thus can supply both heat to the cell 150 or to
supplement or replace the DC supply (Es) 152.  
  
Typically, these fuel cells can be of the type LaserCellTM as
developed by Dr Roger Billings, the PEM Cell as available from
Ballard Power Systems Inc. Canada or the Ceramic Fuel Cell (solid
oxide) as developed by Ceramic Fuel Cells Ltd. Melbourne,
Australia.  
  
It is, of course, necessary to replenish the pressurised store of
gases, thus requiring the continuing consumption of electrical
energy. The recovered electrical energy WE is in excess of the
energy required to drive electrolysis at the elevated temperature
and is used to replace the external electrical energy source 152,
thereby completing the energy loop after the system is initially
primed and started.  
  
The present inventor has determined that there are some
combinations of pressure and temperature where the efficiency of
the electrolysis process becomes advantageous in terms of the
total energy recovered, either as mechanical energy by virtue of a
flow of gas at high pressure or as thermal energy by virtue of
combustion (or by means of a fuel cell), with respect to the
electrical energy consumed, to the extent of the recovered energy
exceeding the energy required to sustain electrolysis at the
operational pressure and temperature. This has been substantiated
by experimentation. This notion has been termed "over-unity".  
  
"Over-unity" systems can be categorised as broadly falling into
three types of physical phenomena:  
  
(i) An electrical device which produces 100 Watts of electrical
energy as output after 10 Watts of electrical energy is input
thereby providing 90 Watts of overunity (electrical) energy.  
  
(ii) An electro-chemical device such as an electrolysis device
where 10 Watts of electrical energy is input and 8 Watts is output
being the thermal value of the hydrogen and oxygen gas output.
During this process, 2 Watts of electrical energy converted to
thermal energy is lost due to specific inefficiencies of the
electrolysis system. Pressure - as the over-unity energy - is
irrefutably produced during the process of hydrogen and oxygen gas
generation during electrolysis.   
  
Pressure is a product of the containment of the two separated
gases. The Law of Conservation of Energy (as referenced in
"Chemistry Experimental Foundations", edited by Parry, R.W.;
Steiner, L.E.; Tellefsen, R.L.; Dietz, P.M. Chap. 9, pp. 199-200,
Prentice-Hall, New Jersey" and "An Experimental Science", edited
by Pimentel, G.C., Chap. 7, pp. 115-117, W.H. & Freeman Co.
San Francisco) is in equilibrium where the 10 watts of input
equals the 8 watts thermal energy output plus the 2 watts of
losses. However, this Law ends at this point. The present
invention utilises the apparent additional energy being the
pressure which is a by-product of the electrolysis process to
achieve over-unity.  
  
(iii) An electro-chemical device which produces an excess of
thermal energy after an input of electrical energy in such devices
utilised in "cold fusion" e.g.10 watts of electrical energy as
input and 50 watts of thermal energy as output.  
  
The present invention represents the discovery of means by which
the abovementioned second phenomenon can be embodied to result in
"over-unity" and the realisation of 'free' energy. As previously
noted, this is the process of liberating latent molecular energy.
The following sequence of events describes the basis of the
availability of over-unity energy.  
  
In a simple two plate (anode/cathode) electrolysis cell, an
applied voltage differential of 1.57 DC Volts draws 0.034 Amps per
cm2 and results in the liberation of hydrogen and oxygen gas from
the relevant electrode plate. The electrolyte is kept at a
constant temperature of 40"C, and is open to atmospheric pressure.  
  
The inefficiency of an electrolytic cell is due to its ionic
resistance (approximately 20%), and produces a by-product of
thermal energy. The resistance reduces, as does the minimum DC
voltage required to drive electrolysis, as the temperature
increases. The overall energy required to dissociate the bonding
electrons from the water molecule also decreases as the
temperature increases. In effect, thermal energy acts as a
catalyst to reduce the energy requirements in the production of
hydrogen and oxygen gases from the water molecule.  
  
Improvements in efficiency are obtainable by way of a combination
of thermal energy itself and the NaOH electrolyte both acting to
reduce the resistance of the ionic flow of current.  
  
Thermal 'cracking' of the water molecule is known to occur at 1
5000C, whereby the bonding electrons are dissociated and
subsequently 'separate' the water molecule into its constituent
elements in gaseous form. This thermal cracking then allows the
thermal energy to become a consumable. Insulation can be
introduced to conserve thermal energy, however there will always
be some thermal energy losses.  
   
Accordingly, thermal energy is both a catalyst and a consumable
(in the sense that the thermal energy exites bonding electrons to
a higher energetic state) in the electrolysis process. A net
result from the foregoing process is that hydrogen is being
produced from thermal energy because thermal energy reduces the
overall energy requirements of the electrolysis system.  
  
Referring to the graph titled "Flow Rate At A Given Temperature"
shown in Fig. 16, it has been calculated that at a temperature of
20000C, 693 litres of hydrogen/oxygen admixed gas (2:1) will be
produced. The hydrogen content of this volume is 462 litres. At an
energy content of 11 BTUs per litre of hydrogen, this then gives
an energy amount of 5082 BTUs (11 x 462). Using the BTU:kilowatt
conversion factor of 3413:1, 5082 BTUs of the hydrogen gas equate
to 1.49 kW. Compare this with lkW to produce the 693 litres of
hydrogen/oxygen (including 463 litres of hydrogen). The usage of
this apparatus therefore identifies that thermal energy, through
the process of electrolysis, is being converted into
hydrogen.These inefficiencies, i.e. increased temperature and NaOH
electrolyte, reduce with temperature to a point at approximately
1000"C where the ionic resistance reduces to zero, and the
volumetric amount of gases produced per kWh increases.  
  
The lowering of DC voltage necessary to drive electrolysis by way
of higher temperatures is demonstrated in the graph in Fig. 17
titled "The Effect of temperature on Cell Voltage".  
  
The data in Figs. 16 and 17 has two sources. Cell voltages
obtained from 0 C up to and including 100"C were those obtained by
an electrolysis system as described hereinbefore. Cell voltages
obtained from 1500C up to 2000"C are theoretical calculations
presented by an acknowledged authority in this field, Prof. J.
O'M. Bockris. Specifically, these findings were presented in
"Hydrogen Energy, Part A, Hydrogen Economy Miami Energy
Conference, Miami Beach, Florida, 1974, edited by T. Nejat
Veziroglu, Plenum Press" pp. 371-379. These calculations appear on
page 374.  
  
By inspection of Fig. 17 and Fig. 18 (titled "Flow Rate of
Hydrogen and Oxygen at 2:1"), it can be seen that as temperature
increases in the cell, the voltage necessary to dissociate the
water molecule is reduced, as is the overall energy requirement.
This then results in a higher gas flow per kWh.  
  
As constrained by the limitation of the materials within the
system, the operationally acceptable temperature of the system is
1000"C. This temperature level should not, however, be considered
as a restriction. This temperature is based on the limitations of
the currently commercially available materials. Specifically, this
system can utilise material such as compressed Silica Fibre for
the sleeve around the electrolysis plate and hydrophobic Silica
Fibre (part no. QR-100HE supplied by Tokyo Roshi International
Inc., also known as "Advantec") for the diaphragm (as previously
discussed) which separates the electrolysis disc plates.In the
process of assembling the cells, the diaphragm material and
sleeved electrolysis plates 190,198 are adhered to one another by
using high-temperature-resistant silica adhesive (e.g. the
"Aremco" product "Ceramabond 618" which has an operational
tolerance specification of 1000 C).  
  
For the above-described electrolysis cell, for the electrolyte at
10000C and utilising electrical energy at the rate of 1kWh, 167
litres of oxygen and 334 litres of hydrogen per hour will be
produced.  
  
The silica fibre diaphragm 116 previously discussed separates the
oxygen and hydrogen gas streams by the mechanism of density
separation, and produce a separate store of oxygen and hydrogen at
pressure. Pressure from the produced gases can range from 0 to
150,000 Atmospheres. At higher pressures, density separation may
not occur. In this instance, the gas molecules can be magnetically
separated from the electrolyte if required.  
  
In reference to the experiments conducted by Messrs Hamann and
Linton (S.D. Hamann and M. Linton, Trans. Faraday Soc.
62,2234-2241. Specifically, page 2240), this research has proven
that higher pressures can produce the same effect as higher
temperatures in that the conductivity increases as temperature
and/or pressure increases. At very high pressures, the water
molecule at low temperatures dissociates.  
  
The reason for this is that the bonding electron is more readily
removed when under high pressure. The same phenomenon occurs when
the bonding electrons are at a high temperature (e.g. 1500"C) but
at low pressures.  
  
As shown in Fig. 15, hydrogen and oxygen gases are separated into
independent gas streams flowing into separate pressure vessels
158,160 capable of withstanding pressures up to 150,000
Atmospheres. Separation of the two gases thereby eliminates the
possibility of detonation. It should also be noted that high
pressures can facilitate the use of high temperatures within the
electrolyte because the higher pressure elevates the boiling point
of water.  
  
Experimentation shows that 1 litre of water can yield 1,850 litres
of hydrogen/oxygen (in a ratio of 2: 1) gas mix after
discomposition, this significant differential (1:1,850) is the
source of the pressure. Stripping the bonding electrons from the
water molecule, which subsequently converts liquid into a gaseous
state, releases energy which can be utilised as pressure when this
occurs in a confined space.  
  
A discussion of experimental work in relation to the effects of
pressure in electrolysis processes can be obtained from "Hydrogen
Energy, Part A, Hydrogen Economy Miami Energy Conference, Miami
Beach, Florida, 1974, edited by T. Nejat Veziroglu, Plenum Press".
The papers presented by F.C. Jensen and F.H. Schubert on pages 425
to 439 and by John B. Pangborn and John C. Sharer on pages 499 to
508 are of particular relevance.  
  
Attention must be drawn to the above published material;
specifically on page 434, third paragraph, where reference is made
to "Fig. 7 shows the effect of pressure on cell voltage...". Fig.
7 on page 436 ("Effect of Pressure on SFWES Single Cell")
indicates that if pressure is increased, then so too does the
minimum DC voltage.  
  
These quotes were provided for familiarisation purposes only and
not as demonstrable and empirical fact. Experimentation by the
inventor factually indicates that increased pressure (up to 2,450
psi) in fact lowers the minimum DC voltage.  
  
This now demonstrable fact, whereby increased pressure actually
lowers minimum DC voltage, is further exemplified by the findings
of Messrs. Nayar, Ragunathan and Mitra in 1979 which can be
referenced in their paper: "Development and operation of a high
current density high pressure advanced electrolysis cell".  
  
Nayar, M.G.; Ragunathan, P. and Mitra, S.K. International Journal
of Hydrogen Energy (Pergamon Press Ltd.), 1980, Vol. 5, pp. 65-74.
Their Table 2 on page 72 expressly highlights this as follows: "At
a Current density (ASM) of 7,000 and at a temperature of 80"C, the
table shows identical Cell voltages at both pressures of 7.6
kg/cm2 and 11.0 kg/cm2. But at Current densities of 5,000, 6,000,
8,000, 9,000 and 10,000 (at a temperature of 80"C), the Cell
voltages were lower at a pressure of 11.0 kg/cm2 than at a
pressure of 7.6 kg/cm2. "The present invention thus significantly
improves on the apparatus employed by Mr. M.G. Nayar et al at
least in the areas of cell plate materials, current density and
cell configuration.  
  
In the preferred form the electrode discs 192 are perforated mild
steel, conductive polymer or perforated resin bonded carbon cell
plates. The diameter of the perforated holes 196 is chosen to be
twice the thickness of the plate in order to maintain the same
total surface area prior to perforation. Nickel was utilised in
the noted prior art system. That material has a higher electrical
resistance than mild steel or carbon, providing the present
invention with a lower voltage capability per cell.  
  
The aforementioned prior art system quotes a minimum current
density (after conversion from ASM to Amps per square cm.) at 0.5
Amps per cm2. The present invention operates at the ideal current
density, established by experimentation, to minimise cell voltage
which is .034 Amps per cm2.  
  
When compared with the aforementioned system, an embodiment of the
present invention operates more efficiently due to a current
density improvement by a factor of 14.7, the utilisation of better
conducting cell plate material which additionally lowers cell
voltage, a lower cellivoltage of 1.49 at 800C as opposed to 1.8
volts at 800 C, and a compact and efficient cell configuration.  
  
In order to further investigate the findings of Messrs. M.G. Nayer
et al, the inventor conducted experiments utilising much higher
pressures. For Nayer et al the pressures were 7.6 kg/cm2 to 11.0
kg/cm2, whereas inventor's pressures were 0 psi to 2450 psi in an
hydrogen/oxygen admixture electrolysis system.  
  
This electrolysis system was run from the secondary coil of a
transformer set approximately at maximum 50 Amps and with an
opencircuit voltage of 60 Volts. In addition, this electrolysis
system is designed with reduced surface area in order that it can
be housed in an hydraulic container for testing purposes. The
reduced surface area subsequently caused the gas production
efficiency to drop when compared with previous (i.e. more
efficient) prototypes. The gas flow rate was observed to be
approximately 90 litres per hour at 70"C in this system as opposed
to 310 litres per hour at 700C obtained from previous prototypes.  
  
All of the following data and graphs have been taken from the
table shown in Fig. 19.  
  
Referring to Fig. 20 (titled "Volts Per Pressure Increase"), it
can be seen that at a pressure of 14.7 psi (i.e. 1 Atmosphere),
the voltage measured as 38.5V and at a pressure of 2450 psi, the
voltage measured as 29.4V. This confirms the findings of Nayar et
al that increased pressure lowers the system's voltage.
Furthermore, these experiments contradict the conclusion drawn by
F.C. Jensen and F.H. Schubert ("Hydrogen Energy, Part A, Hydrogen
Economy Miami Energy Conference, Miami Beach, Florida, 1974,
edited by T. Nejat Veziroglu, Plenum Press", pp 425 to 439,
specifically Fig. 7 on page 434) being that "... as the pressure
of the water being electrolysed increases, then so too does the
minimum DC Voltage".As the.inventor's experiments are current and
demonstrable, the inventor now presents his findings as the
current state of the art and not the previously accepted findings
of Schubert and Jensen.  
  
Referring to Fig. 21 (titled "Amps Per Pressure Increase"), it can
be seen that at a pressure of 14.7 psi (i.e. 1 Atmosphere being
Test Run No. 1), the current was measured as 47.2A and at a
pressure of 2450 psi (Test Run No. 20), the current was measured
as 63A.  
  
Referring to Fig. 22 (titled "Kilowatts Per Pressure Increase"),
examination of the power from Test Run No. 1 (1.82 kW) through to
Test Run No. 20 (1.85 kW) indicates that there was no major
increase in energy input required at higher pressures in order to
maintain adequate gas flow.  
  
Referring to Fig. 23 (titled "Resistance (Ohms) Per Pressure
Increase"), the resistance was calculated from Test Run No. 1
(0.82 ohms) to Test Run No. 20 (0.47 ohms). This data indicates
that the losses due to resistance in the electrolysis system at
high pressures are negligible.  
  
Currently accepted convention has it that dissolved hydrogen, due
to high pressures within the electrolyte, would cause an increase
in resistance because hydrogen and oxygen are bad conductors of
ionic flow. The net result of which would be that this would
decrease the production of gases.  
  
These tests indicate that the ions find their way around the H2
and 2 molecules within the solution and that at higher pressures,
density separation will always cause the gases to separate from
the water and facilitate the movement of the gases from the
electrolysis plates. A very descriptive analogy of this phenomenon
is where the ion is about the size of a football and the gas
molecules are each about the size of a football field thereby
allowing the ion a large manoeuvring area in which to skirt the
molecule.  
  
Referring to Fig. 24 (titled "Pressure Differential (Increase)"),
it can be seen that the hydrogen/oxygen admixture caused a
significant pressure increase on each successive test run from
Test Run No. 1 to Test Run No. 11. Test Runs thereafter indicated
that the hydrogen/oxygen admixture within the electrolyte solution
imploded at the point of conception (being on the surface of the
plate).  
  
Referring again to the table of Fig. 19, it can be noted the time
taken from the initial temperature to the final temperature in
Test Run No. 12 was approximately half the time taken in Test Run
No. 10. The halved elapsed time (from 40"C to 700C) was due to the
higher pressure causing the hydrogen/oxygen admixture to detonate
which subsequently imploded within the system thereby releasing
thermal energy.  
  
Referring to the table shown in Fig. 25 (titled "Flow Rate
Analysis Per Pressure Increase"), these findings were brought
about from flow rate tests up to 200 psi and data from Fig. 24.
These findings result in the data of Fig. 25 concerning gas flow
rate per pressure increase. Referring to Fig. 25, it can be seen
that at a pressure of 14.7 psi (1 Atmosphere) a gas production
rate of 88 litres per kWh is being achieved. At 1890 psi, the
system produces 100 litres per kWh. These findings point to the
conclusion that higher pressures do not affect the gas production
rate of the system, the gas production rate remains constant
between pressures of 14.7 psi (1Atmosphere) and 1890 psi.  
  
Inferring from all of the foregoing data, increased pressure will
not adversely affect cell performance (gas production rate) in
separation systems where hydrogen and oxygen gases are produced
separately, nor as a combined admixture. Therefore, in an enclosed
electrolysis system embodying the invention, the pressure can be
allowed to build up to a predetermined level and remain at this
level through continuous (ondemand) replenishment. This pressure
is the over-unity energy because it has been obtained during the
normal course of electrolysis operation without additional energy
input.  
  
This over-unity energy (i.e. the produced pressure) can be
utilised to maintain the requisite electrical energy supply to the
electrolysis system as well as provide useful work.  
  
The following formulae and subsequent data do not take into
account the apparent efficiencies gained by pressure increase in
this electrolysis system such as the gained efficiency factors
highlighted by the previously quoted Hamann and Linton research.
Accordingly, the over-unity energy should therefore be considered
as conservative claims and that such claimed over-unity energy
would in fact occur at much lower pressures.  
  
This over-unity energy can be formalised by way of utilising a
pressure formula as follows: E = (P - PO) V which is the energy
(E) in Joules per second that can be extracted from a volume (V)
which is cubic meters of gas per second at a pressure (P) measured
in Pascals and where P0 is the ambient pressure (i.e. 1
Atmosphere).  
  
In order to formulate total available over-unity energy, we will
first use the above formula but will not take into account
efficiency losses. The formula is based on a flow rate of 500
litres per kWh at 10000C. When the gases are produced in the
electrolysis system, they are allowed to self-compress up to
150,000 Atmospheres which will then produce a volume (V) of 5.07 x
10-8 m3/sec.  
  
Work [Joules/sec] = ((150-1) x 108) 5.07 x 10-8 m3/sec = 760.4
Watts  
  
The graphs in Figs. 27-29 (Over-Unity in Watt-Hours) indicate
over-unity energy available excluding efficiency losses. However,
in a normal work environment, inefficiencies are encountered as
energy is converted from one form to another.  
  
The results of these calculations will indicate the amount of
surplus- over-unity energy after the electrolysis system has been
supplied with its required 1 kWh to maintain its operation of
producing the 500 Iph of hydrogen and oxygen (separately in a
ratio of 2:1).  
  
The following calculations utilise the abovestated formula
including the efficiency factor. The losses which we will
incorporate will be 10% loss due to the energy conversion device
(converting pressure to mechanical energy, which is represented by
device 162 in Fig. 15) and 5% loss due to the DC generator We
providing a total of 650 Watt-Hours which results from the
pressurised gases.  
  
Returning to the 1 kWh, which is required for electrolysis
operation, this 1 kWh is converted (during electrolysis) to
hydrogen and oxygen. The 1 kWh of hydrogen and oxygen is fed into
a fuel cell. After conversion to electrical energy in the fuel
cell, we are left with 585 Watt-Hours due to a 65 % efficiency
factor in the fuel cell (35 % thermal losses are fed back into
electrolysis unit 150 via Qr in Fig. 15)  
  
Fig. 30 graphically indicates the total over-unity energy
available combining a fuel cell with the pressure in this
electrolysis system in a range from 0 kAtmospheres to 150
kAtmospheres. The data in Fig. 30 has been compiled utilising the
previously quoted formulae where the Watt-Hours findings are based
on incorporating the 1 kWh required to drive the electrolysis
system, taking into account all inefficiencies in the idealised
electrolysis system (complete the loop) and then adding the output
energy from the pressurised electrolysis system with the output of
the fuel cell. This graph thereby indicates the energy break-even
point (at approximately 66 k Atmospheres) where the idealised
electrolysis system becomes self-sustaining.  
  
In order to scale up this system for practical applications, such
as power stations that will produce 50 MW of available electrical
energy (as an example), the required input energy to the
electrolysis system will be 170 MW (which is continually looped).  
  
The stores of high pressure gases can be used with a
hydrogen/oxygen internal combustion engine, as shown in Figs. 31a
to 31e. The stores of high pressure gases can be used with either
forms of combustion engines having an expansion stroke, including
turbines, rotary, wankel and orbital engines. One cylinder of an
internal combustion engine is represented, however it is usually,
but not necessarily always the case, that there will be other
cylinders in the engine offset from each other in the timing of
their stroke. The cylinder 320 houses a piston head 322 and crank
324, with the lower end of the crank 324 being connected with a
shaft 326. The piston head 322 has conventional rings 328 sealing
the periphery of the piston head 322 to the bore of the cylinder
320.  
  
A chamber 330, located above the top of the piston head 322,
receives a supply of regulated separated hydrogen gas and oxygen
gas via respective inlet ports 332,334.   
  
There is also an exhaust port 336 venting gas from the chamber
330.  
  
The engine's operational cycle commences as shown in Fig. 31a,
with the injection of pressurised hydrogen gas, typically at a
pressure of 5,000 psi to 30,000 psi, sourced from a reservoir of
that gas (not shown). The oxygen gas port 334 is closed at this
stage, as is the exhaust port 336. Therefore, as shown in Fig.
31b, the pressure of gas forces the piston head 322 downward, thus
driving the shaft 326. The stroke is shown as distance "A".  
  
At this point, the oxygen inlet 334 is opened to a flow of
pressurised oxygen, again typically at a pressure of 5000 psi to
30,000 psi, the volumetric flow rate being one half of the
hydrogen already injected, so that the hydrogen and oxygen gas
within the chamber 330 are the proportion 2:1.  
  
Conventional expectations when injecting a gas into a confined
space (e.g. such as a closed cylinder) are that gases will have a
cooling effect on itself and subsequently its immediate
environment (e.g. cooling systems/refrigeration). This is not the
case with hydrogen. The inverse applies where hydrogen, as it is
being injected, heats itself up and subsequently heats up its
immediate surroundings. This effect, being the inverse of other
gases, adds to the efficiency of the overall energy equation when
producing over-unity energy.  
  
As shown in Fig. 31c, the piston head 322 has moved a further
stroke, shown as distance "B", at which time there is
self-detonation of the hydrogen and oxygen mixture.   
  
The hydrogen and oxygen inlets 332,334 are closed at this point,
as is the exhaust 336.  
  
As shown in Fig. 31d, the piston head is driven further downwardly
by an additional stroke, shown as distance "C", to an overall
stroke represented by distance "D".  The added piston
displacement occurs by virtue of the detonation.  
  
As shown in Fig. 31e, the exhaust port 336 is now opened, and by
virtue of the kinetic energy of the shaft 326 (or due to the
action of others of the pistons connected with the shaft), the
piston head 322 is driven upwardly, thus exhausting the waste
steam by the exhaust port 336 until such time as the situation of
Fig. 31e is achieved so that the cycle can repeat.  
  
A particular advantage of an internal combustion motor constructed
in accordance with the arrangement shown in Figs. 3 1a to 3 1e is
that no compression stroke is required, and neither is an ignition
system required to ignite the working gases, rather the
pressurised gases spontaneously combust when provided in the
correction proportion and under conditions of high pressure.  
  
Useful mechanical energy can be extracted from the internal
combustion engine, and be utilised to do work. Clearly the supply
of pressurised gas must be replenished by the electrolysis process
in order to allow the mechanical work to continue to be done.
Nevertheless, the inventor believes that it should be possible to
power a vehicle with an internal combustion engine of the type
described in Figs. 31a to 31 e, with that vehicle having a store
of the gases generated by the electrolysis process, and still be
possible to undertake regular length journeys with the vehicle
carrying a supply of the gases in pressure vessels (somewhat in a
similar way to,  and the size of, petrol tanks in
conventional internal combustion engines).  
  
When applying over-unity energy in the form of pressurised
hydrogen and oxygen gases to this internal combustion engine for
the purpose of providing acceptable ranging (i.e. distance
travelled), pressurised stored gases as mentioned above may be
necessary to overcome the problem of mass inertia (e.g. stop-start
driving). Inclusion of the stored pressurised gases also
facilitates the ranging (i.e. distance travelled) of the vehicle.  
  
Over-unity energy (as claimed in this submission) for an average
sized passenger vehicle will be supplied at a continual rate of
between 20 kW and 40 kW. In the case of an over-unity energy
supplied vehicle, a supply of water (e.g. similar to a petrol tank
in function) must be carried in the vehicle.  
  
Clearly electrical energy is consumed in generating the gases.
However it is also claimed by the inventor that an over-unity
energy system can provide the requisite energy thereby overcoming
the problem of the consumption of fossil fuels either in
conventional internal combustion engines or in the generation of
the electricity to drive the electrolysis process by coal, oil or
natural gas generators.  
  
Experimentation by the inventor shows that if 1,850 litres of
hydrogen/oxygen gas mix (in a ratio of 2:1) is detonated, the
resultant product is 1 litre of water and 1,850 litres of vacuum
if the thermal value of the hydrogen and oxygen gas mix is
dissipated. At atmospheric pressure, 1 litre of admixed
hydrogen/oxygen (2:1) contains 11 BTUs of thermal energy. Upon
detonation, this amount of heat is readily dissipated at a rate
measured in microseconds which subsequently causes an implosion
(inverse differential of 1,850:1). Tests conducted by the inventor
at 3 atmospheres (hydrogen/oxygen gas at a pressure of 50 psi)
have proven that complete implosion does not occur. However, even
if the implosion container is heated (or becomes heated) to 400C,
total implosion will still occur.  
  
This now available function of idiosyncratic implosion can be
utilised by a pump taking advantage of this action. Such a pump
necessarily requires an electrolysis gas system such as that
described above, and particularly shown in Fig. 6.  
  
Figs. 32a-32c show the use of implosion and its cycles in a
pumping device 400. The pump 400 is initially primed from a water
inlet 406. The water inlet 406 then is closed-off and the
hydrogen/oxygen gas inlet 408 is opened.  
  
As shown in Fig. 32b, the admixed hydrogen/oxygen gas forces the
water upward through the one-way check valve 410 and outlet tube
412 into the top reservoir 414. The one-way check valves 410,416
will not allow the water to drop back into the cylinder 404 or the
first reservoir 402. This force equates to lifting the water over
a distance. The gas inlet valve 408 then is closed, and the spark
plug 418 detonates the gas mixture which causes an implosion
(vacuum). Atmospheric pressure forces the water in reservoir 402
up through tube 420.  
  
Fig. 32c shows the water having been transferred into the pump
cylinder 404 by the previous action. The implosion therefore is
able to 'lift' the water from the bottom reservoir 402 over a
distance which is approximately the length of tube 420.  
  
The lifting capacity of the implosion pump is therefore
approximately the total of the two distances mentioned. This
completes the pumping cycle, which can then be repeated after the
reservoir 402 has been refilled.  
  
Significant advantages of this pump are that it does not have any
diaphragms, impellers nor pistons thereby essentially not having
any moving parts (other than solenoids and one-way check valves).
As such, the pump is significantly maintenancefree when compared
to current pump technology.  
  
It is envisaged that this pump with the obvious foregoing positive
attributes and advantages in pumping fluids, semi-fluids and gases
can replace all currently known general pumps and vacuum pumps
with significant benefits to the end-user of this pump.  
   


---

  

**Electrolysis systems**  
**US5843292**

  
**Also published as: WO9507373 // US5997283 // SG52487 //
PL313328**  
A cell arrangement for the electrolysis of water to liberate
hydrogen and oxygen gases is described. A cell unit (125) has a
stacked arrangement of segmentation disks   
  
(114), a first type of (anode) cell plates (90), a second type of
(cathode) cell plates (98) and separation membranes (116).
Interconnecting conductive shafts (126-131) pass through holes
(100, 102) of the cell plates (90,98) to have selective electrical
interconnection therewith. Water and electrolyte are supplied by
inlet ports (108, 110) to immerse the cell plates (90, 98). The
membranes (116) normally isolate adjacent cathode and anode plates
(90, 98) from the mixing of liberated oxygen and hydrogen gases
while allowing ionic current to flow. By selective adjustment of
the water/electrolyte pressure differential on the respective
sides of the separation membranes (116), the admixture of the
liberated gases can be produced. The liberated gases discharge
through outlet ports (104,106).  
  
A cell arrangement for the electrolysis of water to liberate
hydrogen and oxygen gases is described. A cell unit (125) has a
stacked arrangement of segmentation disks (114), a first type of
(anode) cell plates (90), a second type of (cathode) cell plates
(98) and separation membranes (116). Interconnecting conductive
shafts (126-131) pass through holes (100, 102) of the cell plates
(90,98) to have selective electrical interconnection therewith.
Water and electrolyte are supplied by inlet ports (108, 110) to
immerse the cell plates (90, 98). The membranes (116) normally
isolate adjacent cathode and anode plates (90, 98) from the mixing
of liberated oxygen and hydrogen gases while allowing ionic
current to flow. By selective adjustment of the water/electrolyte
pressure differential on the respective sides of the separation
membranes (116), the admixture of the liberated gases can be
produced. The liberated gases discharge through outlet ports
(104,106).  
  
**TECHNICAL FIELD OF THE INVENTION**  
The present invention relates to the generation of hydrogen gas
and oxygen gas from water, either as an admixture or as separated
gases, by the process of electrolysis, and relates further to
applications for the use of the liberated gas. Embodiments of the
invention particularly relate to an apparatus for the efficient
generation of these gases, and to the use of the gases as a
thermal source in atomic welding or cutting, and in gaseous waste
disposal.  
  
**BACKGROUND ART**  
The technique of electrolysing water in the presence of an
electrolyte such as sodium hydroxide (NaOH) or potassium hydroxide
(KOH) to liberate hydrogen and oxygen gas (H2, O2) is well known.
The process involves applying a DC potential difference between
two or more anode/cathode electrode pairs and delivering the
minimum energy required to break the H--O bonds (i.e. 68.3 kcal
per mole @STP). The gases are produced in the stoichiometric
proportions for O2 :H2 of 1:2 liberated respectively from the
anode (+) and cathode (-).  
  
Reference can be made to the following texts: "Modern
Electrochemistry, Volume 2, by John O'M. Bockris and Amulya K. N.
Reddy, (Plenum Publishing Corporation)", "Electro-Chemical
Science," by J. O'M. Bockris and D. M. Drazic, (Taylor and Francis
Limited) and "Fuel Cells, Their Electrochemistry," by J. O'M.
Bockris and S. Srinivasan, (McGraw-Hill Book Company).  
  
A discussion of experimental work in relation to electrolysis
processes can be obtained from "Hydrogen Energy, Part A, Hydrogen
Economy Miami Energy Conference," Miami Beach, Fla., 1974, edited
by T. Nejat Veziroglu, Plenum Press. The papers presented by J.
O'M. Bockris on pages 371 to 379, by F. C. Jensen and F. H.
Schubert on pages 425 to 439 and by John B. Pangborn and John C.
Sharer on pages 499 to 508 are of particular relevance.  
  
On a macro-scale, the amount of gas produced depends upon a number
of variables, including the type and concentration of the
electrolytic solution used, the anode/cathode electrode pair
surface area, the electrolytic resistance (equating to ionic
conductivity, which is a function of temperature), the achievable
current density and anode/cathode potential difference. The total
energy delivered must be sufficient to disassociate the water ions
to generate hydrogen and oxygen gases, yet avoid plating
(oxidation/reduction) of the metallic or conductive non-metallic
materials from which the electrodes are constructed.  
  
Reference also is made to prior art Australian Patent No. 487062
to Yull Brown, that discloses an electrolysis cell arrangement to
produce hydrogen and oxygen on demand, together with a safety
device preventing the generation of excess pressure of the
liberated gases. FIG. 2 of the Brown patent shows a number of
electrodes (20a,20b) in a series electrical arrangement between
two terminals (22), across which a voltage is applied. The cell
(20) produces a gas volumetric flow rate output, and if that
output is insufficient for a particular application, then a larger
number of individual cell units must be provided which are all
electrically connected in series.  
  
The end result is a large structure to be supported.  
  
It is also not possible to produce high gas flow rates (of the
order of 10,000 liters per hour) on demand from the prior art
apparatus without the use of expensive and complicated equipment,
and even then the equipment suffers from low efficiencies in the
conversion of electrical energy to generate the hydrogen and
oxygen gases. Thus, the large scale commercial implementation of
such apparatus is not economically viable.  
  
Admixed hydrogen and oxygen gases (or hydroxy gas) are used as a
thermal source when burnt in a stream, for example, in furnaces.
Hydrogen alone is used for atomic cutting and often for atomic
welding, although the device described in the Brown patent
performed atomic welding with admixed hydrogen and oxygen. Recent
industry practice clearly exemplifies that the presence of oxygen
in a plasma arc causes severe oxidation of the tungsten
electrodes.  
  
One of the problems experienced in implementing these applications
is the need to incorporate electrical switchgear to transform main
supply voltages to a level suitable for a bank of electrolysis
cells (i.e. by step-down transformers). The resulting completed
arrangement is electrically inefficient and cumbersome, and also
can be expensive if precise voltage and current regulation (hence
gas flow regulation) is required.  
  
Combusted hydrogen and oxygen gases mixed into a single stream
burn at a very high temperature, typically of the order of 6000
DEG C. Hydrogen/oxygen welding sets are generally known to
comprise of a welding tip or hand piece connected by a dual gas
hose to separate supplies of oxygen and hydrogen.  
  
There are four other common types of welding apparatus and
techniques in use. These are oxy-acetylene welding, electric arc
welding, MIG (metal-inert-gas)/TIG (tungsten-inert-gas) systems
and plasma cutting.  
  
It is estimated that more than 100,000 oxy-acetylene sets are used
in Australia. Of those, approximately 70% are used primarily for
cutting metals, with the remainder being used as a heat source,
for fusion welding of sheet metal, brazing, silver soldering and
the like. Typically, oxy-acetylene sets can weld thicknesses of
metal between 0.5 mm to 2 mm. Further, thicknesses up to 140 mm
can be cut, but only where the steel contains a high percentage of
iron. The reason for this is that the iron and the oxygen are
required to support the oxidation process which induces the
cutting effect. The acetylene gas provides the initial temperature
to start the oxidation reaction, being typically 850 DEG C.
Oxy-acetylene sets require a bottled supply of both acetylene and
oxygen gas. Hence, the bottles must be bought or rented, then
continually maintained and refilled with use.  
  
Electric arc welding is a method used for welding metals of
greater than 1.5 mm in thickness. The principle of operation is
that a hand piece is supplied with a consumable electrode, and the
work piece forms the other electrode. An AC or DC potential
difference is created between the electrodes, thus causing an arc
to be struck when the hand piece is brought into proximity of the
work piece. The arc can be used to fuse or weld metal pieces
together.  
  
MIG systems are based around a continuous wire feed system. In one
known arrangement, the consumable wire is shrouded by argon gas
(or a plasma) which typically is provided from a bottled supply.
TIG systems, on the other hand, require the filler wire to be
hand-fed into the weld pool. MIG/TIG systems can weld metals from
between 1 mm to 20 mm in thickness. These metals, typically
include stainless steel, aluminium, mild steel and the like.
Reference can be made to a text "The Science and Practice of
Welding, Volume 2, A. C. Davies, Cambridge University Press" with
respect to a plasma MIG processes.  
  
Plasma cutting is a method of cutting by introducing compressed
air (comprising predominantly nitrogen) to a DC electric arc,
thereby producing very high temperatures (about 15,000 DEG C.) and
so stripping electrons from the nitrogen nucleus to form a high
temperature plasma. This plasma can be utilized to cut ferrous and
non-ferrous materials such as mild steel, stainless steel, copper,
brass and aluminium. Available plasma cutters can cut up to a 25
mm thickness and have the advantage of not requiring bottled gas,
but rather utilize free air. Reference can be made to the text
"Gas Shielded Arc Welding," by N. J. Henthome and R. W. Chadwick,
(Newnes Technical Books.) with respect to plasma cutting.  
  
As can be seen from the discussion of the prior art, no one unit
or system has the capability of performing all welding and cutting
functions, and typically, one of the systems already described
would be chosen over another for any particular job. This then
requires that metal workers or other metal trade industry
manufacturers must purchase and maintain a number of different
types of welding units in order to have the capability to handle
any job on demand. The costs associated with the purchase of
replacement bottled gas also are very high.  
  
**DISCLOSURE OF THE INVENTION**  
It is a preferred object of the present invention to provide an
arrangement whereby hydrogen and oxygen gases can be produced by
electrolysis in a manner that avoids one or more of the foregoing
disadvantages. In that sense, the electrolysis apparatus is
compact and offers greater efficiencies than the prior art for
comparative gas flow rates.  
  
It is a further preferred object of the invention to provide an
improved structure for an electrolysis cell for use in the
generation of hydrogen and oxygen gas. The electrolysis cell can
be used in hydrogen/oxygen welding or hydrogen plasma cutting.
Other applications may relate to industrial processes where a
combustible source of fuel is required, such as incinerators, and
to the incineration of intractable wastes.  
  
It is a yet further preferred object to provide an electrolysis
cell arrangement that allows the selective separation or admixture
of hydrogen and oxygen gas into individual gas streams.  
  
The present invention further preferably is directed to provision
of a unitary welding unit which can provide all the welding or
cutting requirements of a user. Advantageously, no bottled supply
of hydrogen or oxygen is required. A bottled supply of any other
gas also required is not. For example, argon is not required in
shrouded MIG/TIG applications.  
  
It is a yet further preferred object of the invention to provide a
flashback arrester for a hydrogen/oxygen welding or hydrogen
plasma cutting tip.  
  
Therefore, the invention discloses a cell arrangement for the
electrolysis of water to liberate hydrogen and oxygen gases, the
arrangement comprising:  
  
a plurality of anode-forming electrodes in a stacked relation,
each anode electrode comprising a flat plate through which passes
one or more common first conductive interconnecting members; and  
  
a plurality of cathode-forming electrodes in a stacked relation,
each cathode electrode comprising a flat plate through which
passes one or more common second conductive interconnecting
members;  
  
and wherein the anode electrodes and the cathode electrodes are
interleaved.  
  
The invention further discloses a cell arrangement for the
electrolysis of water to liberate hydrogen and oxygen gases, the
arrangement comprising:  
  
a plurality of anode-forming electrodes interconnected by one or
more first common conductive members to be electrically in
parallel, the anode electrodes being interleaved with a plurality
of cathode forming electrodes interconnected by one or more second
conductive members to be electrically in parallel, the anode
electrodes and cathode electrodes forming a cell unit; and a
plurality of the cell units being electrically connected in
series.  
  
The invention further discloses a cell arrangement for the
electrolysis of water to liberate separated or admixed hydrogen
and oxygen gases, the arrangement comprising:  
  
a plurality of anode-forming electrodes arranged in a stacked
relation, each anode electrode comprising a flat plate through
which passes one or more first conductive interconnecting members;  
  
a plurality of cathode-forming electrodes arranged in a spaced
linear stacked relation, each cathode electrode comprising a flat
plate through which passes one or more second conducting
interconnecting members; wherein the anode electrodes and the
cathode electrodes are interleaved; and  
  
a plurality of membranes, each membrane located between an
adjacent anode electrode and cathode electrode, the membranes
allowing the passage of ionic current between adjacent anode and
cathode electrodes, but selectively blocking the flow of gas
therethrough dependant upon a pressure differential between
opposite sides of a membrane.  
  
The invention yet further discloses an electrolysis unit for the
liberation of oxygen and hydrogen gases, the unit comprising:  
  
a plurality of anode-forming electrodes interleaved with a
plurality of cathode forming electrodes;  
  
a plurality of separation membranes between each adjacent cathode
and anode electrode; and  
  
means for supplying at least water to the anode and cathode
electrodes, the supply means being operable to control pressure
differential of the at least the water on opposed sides of each
membrane to selectively maintain separation or admixture of
liberated oxygen and hydrogen gases.  
  
The invention further discloses a burner arrangement for use in
the thermal destruction of gaseous pollutants, the burner
comprising:  
  
a hemispherical burner chamber;  
  
a supply of hydrogen and oxygen gases in communication with the
burner chamber via a tortuous path exiting by a plurality of
concentrically arranged nozzles directed towards the epicenter of
the hemispherical chamber; and  
  
an inlet for the supply of the gaseous pollutants;  
  
and wherein the gaseous pollutants are combusted together with the
hydrogen and oxygen gases.  
  
The invention yet further discloses a multi-modal welding and
cutting generator, comprising:  
  
a power supply controllable to produce a plurality of AC and DC
output voltage sources; and  
  
an electrolysis unit coupled to the power supply, and operable to
selectively produce hydrogen and oxygen separately or as admixed
hydrogen and oxygen from a supply of water by electrolysis due to
a DC voltage source of the power supply; the hydrogen, oxygen and
admixed hydrogen and oxygen, together with the output voltage
sources, being available for connection to a welding and/or
cutting apparatus.  
  
The invention yet further discloses a flashback arrester for a
welding tip having use with combusted gases, the arrester
comprising a meshed barrier in the stream of a passage for the
gases to be combusted, the meshed barrier having an opening with a
size to allow free passage of the gases, and to impede passage of
a flashback by the flashback flame so that it is unable to pass
the barrier and is extinguished.  
  
**BRIEF DESCRIPTION OF THE DRAWINGS****FIGS. 1a and 1b show a single cell plate respectively as a
plan view and side view;****FIG. 2 shows a stacked array of cell plates;****FIG. 3 shows, as a vertical cross-sectional view, an
electrolysis cell bank;****FIG. 4 is a vertical cross-sectional view showing an
arrangement of electrodes of part of another electrolysis cell
bank embodying the invention;****FIG. 5 is a perspective view of part of one electrode shown
in FIG. 4;****FIG. 6 is a simplified representation of a series
arrangement of the electrodes shown in FIG. 4;****FIGS. 7a and 7b show the mechanical arrangement of a single
cell stack in another embodiment;****FIG. 8 shows the arrangement of a number of the cells shown
in FIGS. 7a and 7b;****FIG. 9 shows the series electrical configuration of a
number of cells in a cell bank;****FIGS. 10a and 10b show the mechanical configuration of a
cell bank assembly;****FIGS. 11a and 11b show a yet further embodiment of a cell
plate;****FIGS. 12a and 12b show a complementary cell plate to that
of FIGS. 11a and 11b;****FIG. 13 shows detail of the perforations and porting of the
cell plates of FIGS. 11a, 11b, 12a and 12b;****FIG. 14 shows an exploded stacked arrangement of the cell
plates of FIGS. 11a, 11b, 12a and 12b;****FIG. 15a shows a schematic view of the gas separation
system of FIG. 14;****FIG. 15b shows a stylised representation of FIG. 15a;****FIG. 15c shows an electrical equivalent circuit of FIG.
15a;****FIG. 16 shows a gas collection system for use with the cell
bank separation system of FIGS. 14 and 15a;****FIG. 17 shows, as a cross-sectional view, a hydraulic
scrubber and check valve;****FIG. 18 shows, as a cross-sectional view, a welding tip of
FIG. 10 including a flashback arrester;****FIGS. 19a and 19b show a burner for the destructive
combustion of pollutants;****FIG. 20 shows a block diagram of a multi modal welding and
cutting apparatus; and****FIG. 21 shows a schematic diagram of the apparatus of FIG.
20.** **![](us1.jpg) ![](us2.jpg)   
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![](us23.jpg)****DETAILED DESCRIPTION AND BEST MODE OF PERFORMANCE**An electrolysis cell bank embodying the invention is
constructed of a number of hexagonally shaped electrolysis cell
plates 10, one of which is shown in plan a in FIG. 1a and as a
side view in FIG. 1b. Each plate 10 has three slots 12, each one
arranged in alternating side edges of the plate 10. The other
sides of the cell plate 10 each are provided with a conductive
bridge or flange 14. Typically twenty individual cell plates 10
are stacked to form one complete cell 16 as shown as a side view
in FIG. 2. The total number of plates can vary in accordance with
the required surface area, and thus, also is a function of plate
diameter.  
  
The stacking of adjacent individual cell plates 10 is in a
reversed order, so that the conductive bridges 12 of adjacent
plates extend in opposed directions and with a relative rotational
offset of 60 DEG . This rotational offset is provided so that
adjacent plates 10 are to bear opposite polarity. The conductive
bridges 14 are long enough to pass through a corresponding slot 12
in an adjacent plate 10, without contacting that plate, and
contact the next subsequent plate to form a conductive path
between each alternate plate. In this way, the completed cell
structure 16 has three positive end terminals and three negative
end terminals, although FIG. 2 shows only two of the positive
terminals and one of the negative terminals. The cell stack 16 is
enveloped by an insulating case 18 (shown in cut-away form). The
cell plates 10 shown in FIGS. 1a, 1b and 2 are suited to form in a
parallel electrical arrangement, with each adjacent two cell
plates 10 forming either the anode or the cathode.  
  
Parallel stacked flat cell plates are described in Australian
Patent No. 487062. In that patent, a stack of twenty cell plates
typically requires a potential difference across the individual
electrodes of each cell plate in the range of 1.55-2.0 volts to
liberate hydrogen and oxygen gas from the water containing an
electrolyte of typically 15% sodium hydroxide solution.  
  
FIG. 3 shows, as a vertical cross-sectional view, seven complete
cell stacks 16 arranged in a hexagonal matrix and enclosed by a
steel casing 20, thereby to provide an electrolysis cell bank 25.
The cell stacks 16 are insulated from the steel casing 20 by nylon
insulating bushes 22. The electrical interconnection of the
individual cell stacks 16 is not shown, but typically the cells
are connected between their respective positive (+) and negative
(-) terminals by straps to form a series connection.  
  
It sometimes can be the case that a parallel interconnection of
the cell stacks 16 is implemented. The actual electrical
interconnection will depend upon the number of individual cell
plates 10 comprising each cell stack 16, the supply voltage and
the current that can be drawn from the supply.  
  
Water is consumed as the hydrogen and oxygen gas is liberated
during the electrolysis reaction. One liter of water generates
1860 liters of admixed oxygen and hydrogen at STP, in the
volumetric proportion noted above. In the arrangement shown water
is continually supplied through the inlet port 24.  
  
The nylon covers 18 separating adjacent stacks have the benefit of
directing the liberated gas upwardly to be collected by, for
example, a gas outlet 26 located at the top of the electrolysis
cell bank 25. By virtue of volumetric displacement in a ratio of
1:1860, the liberated gases are self-pressurizing as they pass
from the outlet port 26 into the interconnecting pipe work (not
shown), which has a far narrower cross-sectional area than that of
the cell bank.  
  
FIG. 4 is a vertical cross-sectional view showing the mechanical
configuration of an electrolysis cell in accordance with a further
embodiment. The basic cell unit 30 is constituted by respective
halves of a pair of interdigitated electrodes 32, 34 arranged much
in the nature of interleaved combs. Each electrode is formed by a
conductive spine 36, 38, typically constructed of resin bonded
carbon material, mild steel or conductive polymers, from which
extend eleven finger-like plates 40, 42, also constructed of
carbon, steel or conductive polymer.  
  
FIG. 5 is a perspective view of one of the electrodes 32 in which
the spine 36 and plates 40 are rectangular in shape. The
electrodes need not necessarily be of the shape shown, but rather
can take on many other forms, one example of which will presently
be described. The common requirement for all such configurations
is that the plates be parallel and interconnected by a common
member usually arranged orthogonally to the plates.  
  
Each pair of electrodes 32, 34 are in a staggered arrangement so
that the respective outermost plates 40a, 42a are offset by
approximately one half of the total length of each electrode 32,
34. The respective mid-point plates are identified by the
reference numerals 40b and 42b.  
  
FIG. 6 shows the staggering arrangement in a simplified form.
Every sixth plate is located in the space formed between the first
and eleventh plate of the respective opposed adjacent electrodes.  
  
Referring to FIG. 4 again, two complete cell units 30 and a part
of the next respective adjacent cell units are shown. The total
number of cell units is governed by the DC supply voltage, since a
minimum anode/cathode voltage is required to derive the
electrolysis process, and each adjacent cell unit is in a series
electrical connection of the parallel-arranged plates 40, 42. In
the electrolysis process, the cells 30 are immersed in water and
electrolyte and a DC voltage is applied between the end-most
plates 40c, 42c causing elemental ionic currents (some of which
are represented by the dashed arrows) to flow between the adjacent
plates 40, 42, and some current-wise along the respective spines
36, 38 and plates 40, 42 (shown by the solid arrows). A different
current path is followed at each mid-plate. For example, the DC
current travels from one end cell plate 42a, through the
electrolyte, passing through the mid cell plate 40b and again
through the electrolyte to the next end cell plate 42a. This
process causes the accumulation of net positive charge on one side
of the mid-plate 40b, and a negative charge on the other side.  
  
The ionic current flow is accompanied by disassociation of the
water molecules such that oxygen and hydrogen gas is produced
respectively at the anode plate and cathode plate surfaces. The
cathode plate surfaces are those surfaces towards which ionic
current flows. The converse applies for the anode plate surfaces.  
  
The voltage applied across the end-most plates 40c is divided
equally between the constituent cell units 30, with that fraction
of the supplied voltage appearing between the respective
outer-most plates and mid-point plates 40a & 42b, 40b &
42a.  
  
The achievable current density is limited, in part, by the
effective electrical resistance of the electrolytic solution. The
smaller the gap between adjacent plates 40, 42 the less is the
resistance. The interdigitated nature of the electrodes 32, 34
means that there is a large surface area available per unit
volume, and there is a minimum separation between electrode plates
in all instances. In that case, the resistance of the electrolyte
is kept low, hence efficiency of the conversion of electrical
energy to generate the hydrogen and oxygen gases is greater than
in the prior art.  
  
By virtue of the specific arrangement shown, it is not necessary
to isolate each individual cell unit 30 from adjacent ones
thereof. The ionic flow naturally will take the path of least
resistance, hence short-circuits between cell units 30, being a
path otherwise of greater resistance, are avoided. A large number
of cells therefore can be arranged to extend longitudinally, and
allow direct connection to a rectified mains power supply, thus
obviating the need to electrically interconnect groups of cell
units by strapping, as has been done in the prior art.  
  
Each individual cell unit 30 satisfies the operational criteria
regarding voltage, the surface area of the plates and so on, to
successfully electrolyze water, and thereby operates essentially
independently of the adjacent cell units 30.  
  
Testing has established that for a temperature range of 90 DEG C.
to 50 DEG C., a DC voltage in the range 1.47-1.56 V applied across
one cell unit 30 (i.e. across one half of a complete electrode 32
or 34) a minimum (and the optimum) anode current density of 0.034
A/cm@2 is required to generate a gas flow rate of about 340-300
l/h per kWh respectively. The discovery that the minimum plate
surface area corresponds to the optimum gas flow rate means that
the total volume occupied can be kept to a minimum. By way of
specific example, a rectified 240 Vrms main voltage nominally
results in an average DC voltage of 215 V, hence for direct
connection to the main supply via a rectifier (i.e. without
requiring a step-down transformer), a total of about one hundred
and forty cells are required. It is particularly advantageous not
to require voltage transformation equipment in terms of equipment
cost, technical simplicity and the avoidance of losses.  
  
FIG. 7a shows a partial cut-away side view of a cell unit 50 in
accordance with another embodiment. The cell unit 50 is similar in
configuration to that of FIG. 4 except for the number and shape of
interconnecting spine members and the shape of the electrode
plates.  
  
FIG. 7b shows an end view of the cell unit 50, and in particular
the end-most plate 52c. The plate electrodes 52, 54 are hexagonal
in shape. Each plate 52, 54 has six interconnecting rod-like
spines 56, 58 passing therethrough, one near each vertice. Each
alternate one of the spines 56 represents a common positive
conductor and the other set of alternate spines 58 represents
negative conductors. Each adjacent plate 52, 54 is electrically
connected either to the positive conductors or the negative
conductors. Spacing bushes 60 are provided between adjacent plates
52, 54 to provide electrical isolation and to provide a space in
which the water and electrolyte circulates. Connection of each
spine conductor 56, 58 to the respective plate electrode 52, 54
typically is by a threaded nut or interference fit. The reason for
connecting each plate 52, 54 to three common spine conductors 56,
58 is to achieve a uniform current distribution across the whole
surface area of a plate 52, 54.  
  
As can be seen in FIG. 7b, the positive spine conductors 56 extend
away from one end of the assembly for series interconnection with
other arrangements of cells, as do three negative spine conductors
58 from the other end. All unconnected ends of the conductors are
blanked-off with a non-conductive end cap 62.  
  
FIG. 8 shows a stylized form of three cell units 50 electrically
connected in series (arranged longitudinally), and particularly
the passage of the spine conductors 56, 58. The cell units 50 are
enclosed within an insulating tube 64, typically made of PVC,
which has an access for the communication of water to envelope the
plates 52, 54 and for the generated gases to escape.  
  
FIG. 9 shows the series electrical interconnection of a number of
cell units 50 directly connected with the DC output side of an
AC/DC converter 66 (such as a simple diode bridge rectifier)
without requiring a step-down transformer.  
  
FIG. 10a shows an end view of the mechanical arrangement of seven
assemblies (designated A-G), each consisting of three series
connected cell units 50 (as shown in FIG. 8), forming a total cell
arrangement 70. The cell assemblies 50 are located within a steel
cylinder 72 containing the water and electrolyte required for the
generation of the hydrogen and oxygen gases. Each group (A-G) of
three cell units 50 is interconnected by means of a first group of
steel connecting straps 74 at one end and a second group of steel
connecting straps 76 (not shown) at the other end, arranged to be
offset between the groups. While the first straps 74 alone are
shown in FIG. 10a, both sets of the straps 74,76 are more clearly
shown in FIG. 10b, which is a side view of the groups A-G when
`unravelled`.  
  
The PVC tubes 64 shown in FIG. 10a insulate adjacent groups to
avoid "short-circuiting" effects between one another. The cell
arrangement 70 is very compact, and in a comparison with the prior
art Brown arrangement is only one third of the physical size for a
comparable gas volumetric flow rate. Moreover, there also being a
similar reduction in total mass. The supply of water for the
electrolysis process is provided by an inlet 78 located at the
bottom of the cylinder 72, with the gases produced exit the
cylinder 72 by an outlet 80 located at the top of the cylinder.  
  
Electrical connection to a DC power supply is across the totality
of the cells, and in the arrangement is at a central terminal 82
on the underside of cell A and a central terminal 84 on the top
side of cell G, respectively.  
  
FIGS. 11a and 12a show further embodiments of a first and second
type of cell plate 90, 98 as an end view. FIGS. 11b and 12b are
partial cross-sectional views along the respective mid-lines as
shown. Common reference numerals have been used where appropriate.
The plates 90, 98 can have the function of either an anode (+) or
a cathode (-), as will become apparent. Each comprises an
electrode disc 92 that is perforated with hexagonally shaped holes
96. The disc 92 is made from steel or resin-bonded carbon or
conductive polymer material. The disc 92 is housed in a circular
rim or sleeve 94. The function of the perforations 96 is to
maximize the surface area of the electrode disc 92 and minimize
the weight over solid constructions by 45%.  
  
By way of example, for a disc having diameter of 280 mm, the
thickness of the disc must be 1 mm in order to allow the current
density (which ranges from 90 A/2,650 cm@2 -100 A/2,940 cm@2 of
the anode or cathode) to be optimal. If the diameter of the plate
is increased, which consequently increases the surface area, it is
necessary to increase the thickness of the plate in order to
maintain uniformity of conductance for the desired current
density.  
  
The hexagonal perforations in a 1 mm thick disc have a distance of
2 mm between the flat portions of the plates and are 1 mm away
from the next adjacent perforation, in order to maintain the same
total surface area prior to perforation, and to allow the current
density to be optimal. A 1 mm (plate to plate) distance between
the adjacent hexagonal perforations is required because a smaller
distance will result in thermal (resistive) losses and a larger
distance will add to the overall weight of the plate.  
  
The sleeve 94 is constructed of PVC material and incorporates a
number of equally spaced shaft holes 100, 102. The holes are for
the passage of interconnecting shafts provided in a stacked
arrangement of the plates 90, 98 forming the common conductor for
the respective anode and cathode plates, much in the nature of the
arrangement shown in FIGS. 7a and 7b. The additional two upper
holes 104, 106 each support a conduit respectively for the
out-flow of oxygen and hydrogen gases, respectively. The
additional holes 108, 110 at the bottom of the sleeve 94 are
provided for the inlet of water and electrolyte to the respective
cell plates 90, 98.  
  
FIG. 13 shows an enlarged view of a portion of the cell plate 90
shown in FIG. 11a. The port hole 104 is connected to the hexagonal
perforations 96 within the sleeve 94 by an internal channel 112. A
similar arrangement is in place for the other port hole 106, and
for the water/electrolyte supply holes 108, 110.  
  
If the hydrogen and oxygen gases liberated are to be kept separate
(i.e. not to be formed as an admixture), then it is necessary to
separate those gases as they are produced. In the prior art, this
is achieved by use of diaphragms that block the passage of gases
and effectively isolate the water/electrolyte on each side of the
diaphragm. Ionic transfer thus is facilitated by the ionically
conductive nature of the diaphragm material (i.e. a
water--diaphragm--water path). This results in an increase in the
ionic resistance, and hence, a reduction in efficiency. Prior art
patent No. 487062 describes another arrangement (see FIG. 6
thereof) that utilizes magnets to cause the separation of the
gases.  
  
FIG. 14 shows an exploded stacked arrangement of four cell plates,
being an alternative stacking of two (anode) cell plates 90 and
two (cathode) cell plates 98. The two ends of the stacked
arrangement of cell plates delineates a single cell unit 125.
Interposed between each adjacent cell plate 90, 98 is a PTFE
separation 116. Although not shown in FIG. 14, the cell unit
includes separate hydrogen and oxygen gas conduits that
respectively pass through the stacked arrangement of cell plates
via the port holes 106, 104 respectively. In a similar way,
conduits are provided for the supply of water/electrolyte,
respectively passing through the holes 108, 110 at the bottom of
the respective plates 90, 98.  
  
Only two pairs of anode/cathode cell plates are shown. The number
of such plates can be greatly increased per cell unit 125.  
  
Also not shown are the interconnecting conductive shafts that
electrically interconnect alternate common cell plates. The reason
for having a large diameter hole in one cell plate adjacent to a
smaller diameter hole in the next cell plate, is so that an
interconnecting shaft will pass through the larger diameter hole,
and not make an electrical connection (i.e. insulated with PVC
tubing) but rather only form an electrical connection between
alternate (common) cell plates.  
  
The cell unit 125 shown in FIG. 14 arrangement is an exploded
view. When fully constructed, all the elements are stacked to be
in intimate contact. Mechanical fastening is achieved by use of
one of two adhesives such as (a) "PUR-FECT LOK" (TM) 34-9002,
which is a Urethane Reactive Hot Melt adhesive with a main
ingredient of Methylene Bispheny/Dirsocynate (MDI), and (b)
"MY-T-BOND" (TM) which is a PVC solvent based adhesive. Both
adhesives are Sodium Hyroxide (20% present in the electrolyte)
resistant. In that case, the water/electrolyte only resides within
the area proscribed by the cell plate sleeve 94. Thus the only
path for the inlet of water/electrolyte is by bottom channels 118,
122 and the only outlet for the gases is the top channels 112,120.
In a system constructed and tested by the inventor, the thickness
of the cell plates 90, 98 is 1 mm (2 mm on the rim because of the
PVC sleeve 94), with a diameter of 336 mm. The cell unit 125 is
segmented from the next cell by an insulating PVC segmentation
disc 114. A segmentation disc 114 is also placed at the beginning
and end of the entire cell bank.  
  
If there is to be no control over separation of the liberated
gases, then the PTFE membranes 116 are not needed.  
  
The PTFE membrane 116 is fibrous and has 0.2 to 1.0 micron
interstices. A suitable type is type Catalogue Code J, supplied by
Tokyo Roshi International Inc (Advantec). The water/electrolyte
fills the interstices and ionic current flows only via the
water--there is no contribution of ionic flow through the PTFE
material itself. This leads to a reduction in the resistance to
ionic flow. The PTFE material also has a "bubble point" that is a
function of pressure. Hence by controlling the relative pressures
at either side of the PTFE separation sheets, the gases can be
"forced" through the interstices to form an admixture, or
otherwise kept separate. Other advantages of this arrangement
include a cheaper cost of construction, improved operational
efficiency and greater resistance to faults.  
  
FIG. 15a is a stylized and exploded, schematic view of a linear
array of three series-connected cell units 125. For clarity, only
six interconnecting shafts 126-131 are shown. The shafts 126-131
pass through the respective shaft holes 102, 100 in the various
cell plates 90, 98 in the stacked arrangement. The polarity
attached to each of the exposed end shafts, to which the DC supply
is connected also is indicated. The shafts 126-131 do not run the
full length of the three cell banks 125. The representation is
similar to the arrangement shown in FIGS. 7a and 8. One third of
the full DC source voltage appears across each anode/cathode cell
plate pair 90, 98.  
  
Further, the gas conduits 132, 133, respectively for oxygen and
hydrogen, that pass through the port holes 104, 106 in the cell
plates 90, 98 also are shown. In a similar way, water/electrolyte
conduits 134, 135, passing through the water port holes 108, 110
in the cell plates also are shown.  
  
FIG. 15b particularly shows how the relative potential difference
in the middle cell bank 125a changes. That is, the plate electrode
90a now functions as a cathode (i.e. relatively more negative) to
generate hydrogen, and the plate electrode 98a now functions as an
anode (i.e. relatively more positive) to generate oxygen. This is
the case for every alternate cell unit. The arrowheads shown in
FIG. 15b indicate the electron and ionic current circuit. FIG. 15c
is an electrical equivalent circuit representation of FIG. 15b,
where the resistive elements represent the ionic resistance
between adjacent anode/cathode plates. Thus, it can be seen that
the cell units are connected in series.  
  
Because of the change of function of the cell plates 90a and 98a,
the complementary gases are liberated at each. Hence, the
respective channels 112 are connected to the opposite gas conduit
132,133. Practically, this can be achieved by the simple reversal
of the cell plates 90, 98.  
  
FIG. 16 shows the three cell units 125 of FIG. 15a connected to a
gas collection arrangement. The cell units 125 are located within
a tank 140 that is filled with water/electrolyte to the level h
indicated. The water is consumed as the electrolysis process
proceeds, and replenishing supply is provided via the inlet 152.
The water/electrolyte level h can be viewed via the sight glass
154. In normal operation, the different streams of oxygen and
hydrogen are produced and passed from the cell units 125 to
respective rising columns 142,144. That is, the pressure of
electrolyte on opposed sides of the PTFE membranes 116 is
equalized. Thus, the gases cannot admix.  
  
The columns 142, 144 also are filled with the water/electrolyte,
and as it is consumed at the electrode plates, replenishing supply
of electrolyte is provided by way of circulation through the
water/electrolyte conduits 134, 135. The circulation is caused by
entrainment by the liberated gases, and by the circulatory
inducing nature of the conduits and columns.  
  
The upper extent of the tank 140 forms two scrubbing towers 156,
158, respectively for the collection of oxygen and hydrogen gases.
The gases pass up respective columns 142, 144, and out from the
columns via openings therein at a point within the interleaved
baffles 146. The point where the gases exit the columns 142, 144
is beneath the water level h, which serves to settle any turbulent
flow and entrained electrolyte. The baffles 146 located above the
level h scrub the gas of any entrained electrolyte, and the
scrubbed gas then exits by respective gas outlet columns 148, 150
and so to a gas receiver. The level h within the tank 140 can be
regulated by any convenient means, including a float switch, and
with the replenishing water supplied by the inlet pipe 152.  
  
The liberated gases will always separate from the
water/electrolyte solution by virtue of the difference in
densities. Because of the relative height of the respective set of
baffles, and due to the density differential between the gases and
the water/electrolyte, it is not possible for the liberated
hydrogen and oxygen gases to mix. The presence of the full volume
of water within the tank 140 maintains the cell plates in an
immersed state, and further serves to absorb the shock of any
internal detonations should they occur.  
  
In the event that a gas admixture is required, then, firstly, the
two flow valves 136, 137 respectively located in the oxygen gas
outlet conduit 132 and water/electrolyte inlet port 134 are
closed. This blocks the outlet path for the oxygen gas and forces
the inlet water/electrolyte to pass to the inlet conduit 134 via a
one-way check valve 139 and pump 138. The water/electrolyte within
the tank 140 is under pressure by virtue of its depth (volume),
and the pump 138 operates to increase the pressure of
water/electrolyte occurring about the anode cell plates 90, 98a to
be at an increased pressure with respect to the water/electrolyte
on the other side of the membrane 116. This pressure differential
is sufficient to cause the oxygen gas to migrate through the
membrane. Thus, admixed oxygen and hydrogen are liberated via the
gas output conduit 133 and column 144. Since there is no return
path for the water/electrolyte supplied by the pump 138, the
pressure about the cell plates 90, 98a will increase further, and
to a point where the difference is sufficient such that the
water/electrolyte also can pass through the membrane 116.
Typically, pressure differential in the range of 1.5-10 psi is
required to allow passage of gas, and a pressure differential in
the range of 10-40 psi for water/electrolyte.  
  
While only three cell units 125 are shown, clearly any number,
connected in series, can be implemented.  
  
FIG. 17 shows another embodiment of a check valve and scrubber
unit 160 for scrubbing liberated gas(es) before subsequent use.
The unit 160 is filled with water, typically to a level being
about half the full height of the unit. The level is regulated by
a float switch 162. Water is supplied by means of the inlet 164. A
sight column 166 is also provided, which serves to give a visual
indication of the water level.  
  
The hydrogen and/or oxygen gases from the gas receiver, now under
pressure, enter by an entry tube 168 having an opening 170 at the
bottom end thereof. The gases travel down the tube 168 and out of
the opening 170 to bubble upwardly on the inside of the inner
column 172, which also is filled with the supplied water, thus
performing a first scrubbing action to remove the sodium hydroxide
electrolyte. The gas then enters another downwardly directed tube
174 and out the opened end thereof, passing again through the
water in the outer chamber 176 to be further scrubbed. The gas is
to be stored under pressure within the space above the water level
and be available for supply from the outlet 178.  
  
Admixed hydrogen and oxygen gases supplied from the output 178 to,
for example, a welding tip (not shown) are in the correct
stoichiometric proportions as a result of the electrolysis
process, and ensures that, on combustion, a neutral flame is
produced. The only products of the combustion process are heat and
water vapour.  
  
If the gases are produced separately, two check-valve scrubbers
160 are employed, the gases can then be mixed in a mixing chamber
which also will produce the correct stoichiometric mix.  
  
If there is an explosion which backs-up through the outlet 178
from a welding tip, it will be quenched by the water within the
unit 160. The energy of the explosion will be absorbed by
displacing the water in both the outer chamber 176 and the inner
column 172. This displacement also cuts off the flow of inlet gas
to the tube 168. In this way, there will be no possibility of the
explosion further propagating towards an electrolysis cell bank
producing the gases. The water within the unit 160 therefore acts
both as a gas scrubber and also as a check valve.  
  
FIG. 18 shows a welding tip 180 in cross-sectional detail. The
hydrogen and oxygen gases are received along an inlet tube 182,
passing by a needle valve 184 and into an expansion chamber 186.
The expansion chamber 186 includes a flashback control apparatus,
which comprises a cylindrically arranged flashback arrester 188,
typically formed of 5 micrometer stainless steel meshing. In
normal operation, the gases flow through the flashback arrester
188 and to the outlet or nozzle 190, where combustion, or gas
ionisation during the production of plasma, takes place.  
  
In the event that flashback occurs, the flashback arrester 188
disallows further rearward passage of the flame, which cannot
physically pass through openings as small as, for example, 5
micrometers. This is coupled with a heat sink effect of the
material from which the arrester 188 is constructed which operates
to dissipate the energy of the flame, and thus, assist in
extinguishing the flame.  
  
The use of hydrogen and/or oxygen in welding and cutting by
electrolysis allows temperatures of the order of 6000 DEG C. to be
achieved with the ability to produce gas on demand. No gas stored
in bottle form is required. It is further possible to conduct fine
flame welding with a high purity of gas, and also to be able to
fuse ceramic materials.  
  
All of the following materials can be welded: carbon steel, cast
iron, stainless steel, aluminium, brazing, silver soldering,
copper and ceramics. The following ferrous and non-ferrous
materials, due to the available production of pure hydrogen
subsequently passed through a DC arc providing a hydrogen plasma
stream (H2 .fwdarw.H1), can be readily cut: carbon steel, cast
iron, stainless steel, aluminium, brazing and copper.  
  
The embodiment of the invention can provide a continuous supply of
hydrogen gas at large flow rates. As such, it is well disposed to
applications that consume large quantities of hydrogen. An example
of one such process is the Plascon (TM) waste destruction process
developed by the Australian CSIRO's Division of Manufacturing
Technology. A summary of the Plascon process can be found in the
CSIRO Journal "Ecos, Volume 68, Winter 1991".  
  
One application of the hydrogen and oxygen gases produced by the
apparatus described above is in the thermal destruction of waste,
and without the consumption of atmospheric oxygen. This procedure
requires an on-demand supply of hydrogen and oxygen gas. The
electrolysis apparatus described above can, in a scaled-up
version, produce the requisite gas flow rates in order to combust
waste gases on a commercial scale.  
  
FIGS. 19a and 19b show a configuration for a burner used in the
destruction of such gaseous polluting emissions. FIG. 19a shows a
cross-sectional view of a burner 200. The cross-sectional view
along the mid-line is shown in FIG. 19b. The burner 200 has a
combustion chamber 202 that is hemispherical in shape. The
emissions, which may include a mixture of fumes containing
hydrocarbons and other volatile pollutants as a waste product of
industrial processes, are injected to the combustion chamber by an
inlet path 206. There are two sources of an admixture of gaseous
hydrogen and oxygen in stoichiometric proportions of 2:1, one each
to an upper and lower quadrant of the combustion chamber 202.
These gases are supplied by the two gas inlets 208 at points
diametrically opposed on the sides of the burner 200. The mixture
of hydrogen and oxygen and emissions formed within the combustion
chamber 202 is ignited by means of a spark plug 210, or the like,
and burns at a temperature of not less than 4000 DEG C., thus
providing energy for molecular disassociation of all the
pollutants into harmless compounds that can be discharged to the
atmosphere. No atmospheric oxygen is consumed in the burning
process. Complete combustion of the pollutants is aided by the
"focusing" effect of the combustion chamber 202, which further
improves the mixing of the gas streams.  
  
A thermocouple 212 measures the temperature within the silicone
fiber refractory heat insulatory material 214 surrounding the
combustion chamber 202. The cladding 216 applied to the burner 200
is typically made of stainless steel.  
  
The burner configuration is formed by seven (only four are shown)
concentrically arranged sets of nozzles 212, as is clearly shown
in FIG. 19b. The nozzles 222 are directed to commonly intersect at
the epicenter 204 of the combustion chamber 202. The cooling
water, supplied by an inlet 218 and exiting by an outlet 220, is
intended to maintain the nozzles 222 at a temperature of less than
300 DEG C. Above 300 DEG C., hydroxy gas has the tendency to "back
burn".  
  
The flow path of hydrogen and oxygen gases to the nozzles 222 from
the inlets 208 has four 90 DEG (minimum) correction changes. This
is intended to slow the linear momentum of the hydroxy flame in
the event of a flashback, and so cause the flame to
self-extinguish. This is particularly advantageous, as hydrogen
burns at a rate of 3,600 m/s.  
  
FIG. 20 shows in block diagram form a multi-modal cutting and
welding apparatus 230. The apparatus receives a supply of DC power
provided to an AC/DC converter 232. An AC supply is available for
connection to AC electric arc welding apparatus 234, while the
converted DC output voltage is provided for connection with a DC
electric arc welding or cutting apparatus 236. The DC output
supply voltage also is provided to an electrolysis cell unit 238
for the generation of, in this case, separated hydrogen and oxygen
gases. The hydrogen and oxygen gases both are provided to a
hydroxy gas welding apparatus 240. The hydrogen (and oxygen for
secondary injection) is made available for connection with plasma
cutting apparatus 242. The hydrogen is passed through a DC arc to
produce a plasma stream, and on a secondary injection, the oxygen
is introduced into the plasma stream to produce an oxidizing
plasma cutting effect which increases cutting efficiency.
Thicknesses of up to 150 mm can be cut with this process. It
should be noted that introducing oxygen downstream from the
tungsten electrodes eliminates any oxidation of the electrodes.  
  
The hydrogen gas alone also is provided to a MIG/TIG apparatus
244, with the hydrogen in plasma form otherwise taking the place
of the conventional inert gas. An AC or DC supply also is required
to form the plasma.  
  
The converter 232 can be of any conventional design, typically
having a multi-tapped transformer for the selection of appropriate
rectified DC voltages. The electrolysis unit 238 can be of any of
the embodiments previously described, and including the scrubber
and check valve arrangements. The various cutting and welding
apparatus 234, 236, 240, 242, 244, described also are
conventional.  
  
The multi-modal apparatus 230 thus provides greater flexibility
for the user in being able to select from the one unit the
particular mode of cutting or welding required. Clearly, an
apparatus comprised of any single or combination of
welding/cutting apparatus is contemplated by the present
invention.  
  
FIG. 21 shows the multi-modal apparatus 230 in greater detail. As
previously described, the electrolysis generator 238 separately
produces gaseous hydrogen and oxygen and can also produce gaseous
hydrogen and oxygen as an admixture.  
  
The power supply unit 232 comprises a multi-tapped transformer
246. The reduced voltage is rectified by a bridge rectifier 247.
The output rectified voltage is then connected by terminals 248 to
the cell bank 238 containing 30 cells via a contactor 249 which is
activated by a pressure switch 250. The switch 250 is, in turn,
activated by a pressure sensor 251 which measures the gas pressure
levels within the cell bank 238. Thus the contactor 249 is
operable to remove the supply of power to the cell bank 238 on the
establishment of an operational pressure. The contactor 249
operates on demand with use of the gas.  
  
Thus, gas is produced as required, and typically for a total of 15
liters at any one time. This 15 liters of gasses comprises 10
liters of hydrogen and 5 liters of oxygen.  
  
The gases are provided from the scrubbing towers 156, 158 of the
cell bank 238. As a closed loop system, the pressure in each tower
will compensate for the other, thereby maintaining constant
desired gas production levels. If, however, the water level is too
high due to excessive use of either gas, the respective float
switch 254, 255 in the respective tower 156, 158 will disallow gas
flow by shutting the respective solenoid valve 256, 257.  
  
The float switches 254, 255 activate the solenoid valves 256, 257
from an AC supply 258 tapped from the transformer 246. Other float
switches located in the check valve and scrubber units 160 and the
pressuring pump 138, also receive the AC supply 258.  
  
Two flow regulators 261, 262 are incorporated for the purpose of
maintaining the desired back-pressure in the towers 156, 158 in
order that the system will always have pressure even if the system
is switched off and/or should the gases be exhausted through gas
outlets, the gas outlets 263, 264 of the check valves/scrubber
units 160 or by the welding tip 265.  
  
As opposed to separated generation in the cell bank 238, method of
obtaining an admixture is once the hydrogen and oxygen have passed
through the check valve and scrubber units 160, a selection valve
266 allows the gases to mix and pass to the welding tip 265 where
they are ignited and combusted to be used for the purposes of
hydrogen/oxygen welding.  
  
If the hydrogen and oxygen gases are produced separately and
required for hydrogen plasma cutting 242 and/or hydrogen plasma
MIG/TIG welding 244, the selection valve 266 disallows the
admixture of the two gases.  
  
The power supply unit 232 is a conventional arrangement of a
multi-tapped transformer 246, including a reactor winding 267 and
a range selector switch 268 which allows a selection of a chosen
output voltage level. The generated secondary AC voltage also can
be rectified by the rectifier 247 to produce a DC voltage output.
All these output voltages pass another polarity selector 269
allowing the user to select between an AC or DC output and to
select the appropriate polarity for the DC output.  
  
The output 248 from the power supply unit 232 is shown connected
to the electrolysis cell bank 238. However, the power supply also
can connect with other forms of welding and cutting such as
indicated in FIG. 20.  
  
Another output 271 supplies the necessary DC power for hydrogen
plasma shroud MIG/TIG welding 244 and hydrogen plasma oxidising
cutting applications 242. Yet another AC output 272 and DC output
273 supply the necessary current to produce an arc for the MIG and
TIG processes.  
  
Output voltages in the range of 20-60 Volts are required for the
cell bank unit 238 and the electric arc units 234, 263, whereas
the MIG/TIG welding 244 operates, typically, on an output voltage
of 30-60 Volts (AC or DC). Plasma cutting and plasma shrouding, as
provided by the plasma unit 242, typically requires the supply of
120 Volts DC.  
   


---

  

**UPDATING OF ELECTROLYSIS SYSTEMS**  
**RU2149921**

  
**FIELD:** chemistry.   
**SUBSTANCE:** cellular device has complex structure composed
of separating discs, cellular plates of first type ( anode ),
cellular plates of second type ( cathode ) and separating
membranes. Joining conductive rods pass through holes in cellular
plates to perform selective electric connection. Water and
electrolyte for submersion of cellular plates are supplied through
inlets holes. Normally membranes isolate adjacent plates-cathodes
and plates-anodes from mixing released gaseous oxygen and hydrogen
and provide for flow of ion current.   
**EFFECT:** enhanced efficiency of conversion of electric
energy.  
  
**DESCRIPTION**  
  
The present invention relates to the formation of hydrogen gas and
oxygen gas from water, either as mixtures or as separated gases
using an electrolysis process, and also relates to applications
associated with the released gas.  
  
Embodiments of the invention, in particular, to an apparatus for
the efficient production of these gases and to use these gases as
a heat source in atomic welding or cutting, and to eliminate
gaseous losses.  
  
Well known water electrolysis method in the presence of an
electrolyte such as sodium hydroxide (NaOH) or potassium hydroxide
(KOH) with the release of hydrogen and oxygen gases (H, O).  
  
The process involves application of the potential difference Vdc
between two or more anode / cathode electrode pairs and supplying
the minimum energy required to break bonds HO (ie  
68.3 kcal / mol at normal conditions).  
  
Gases produced in the stoichiometric proportions for O: Hb 1:2
respectively allocated at the anode (+) and the cathode (-).  
  
You can refer to the following articles: "Modern Electrochemistry,
v.2, John O'M. Bockris and Amulya KN Reddy, Plenum Publishing
Corporation "," Electro-Chemical Science, J. O'M Bockris and DM
Drazik, Taylor and Francis Limited "and" Fuel Cells, Their
Electrochemistry, J. O'M. Bockris and S. Srinivasan, McGraw-Hill
Book Company ".  
  
Discussion of the experimental work in relation to the
electrolysis process can be found in the "Hydrogen Energy, Part A,
Hydrogen Economy Miami Energy Conference, Miami Beach, Florida,
1974, edited by T. Nejat Veziroglu, Plenum Press".  
  
Particularly relevant is the article submitted J. O'M. Bockris on
p.371-379, FC Lensen and FH Schubert on p. 425-439 and B. Pangborn
and John C. Sharer on p.  
499-508.  
  
By and large, the quantity of gas dependent on a number of
variables, including the type and concentration of the
electrolytic solution, the surface area of ??the anode-cathode
electrode pair, the electrolytic resistance (equal to the ion
conductivity which is a function of temperature), the achievable
current density and the potential difference between the anode and
cathode.  
  
The total energy supplied shall be sufficient for the dissociation
of water and ions formation of hydrogen and oxygen gases, but it
is necessary to avoid coating (oxidation / reduction) metallic or
non-metallic conductive materials making up the electrodes.  
  
One can refer to the prior Australian Patent N 487062 website Yull
Brown, which discloses construction of an electrolytic cell for
producing hydrogen and oxygen as needed, together with a safety
device to prevent pressurisation of evolved gases.  
  
FIG. 2 Brown patent shows a plurality of electrodes (20a, 20b)
electrically connected in series between two terminals (22) to
which a potential difference is applied.  
  
Box (20) provides a flow rate of gas at the outlet, and when this
capacity is insufficient for a particular application, then a
larger number of individual cellular devices that are electrically
connected in series.  
  
The end result is a great design that you want to maintain.  
  
Also it is not possible to achieve the required high volumetric
gas flow velocities (about 10,000 l / h) from the previously known
devices without the use of expensive and sophisticated equipment,
but even then the equipment has a low conversion efficiency of
electrical energy to produce hydrogen and oxygen gases.  
  
Thus, the commercial application of such devices High resolution
is not economically feasible.  
  
Mixed gas of hydrogen and oxygen (or hydroxy gas) are used as heat
source in the combustion in the stream, such as furnaces.  
  
For cutting atomic hydrogen is only one and often - for atomic
welding, although disclosed in Brown apparatus performs welding in
the presence of atomic hydrogen and oxygen mixed.  
  
Modern industrial practice clearly confirmed that the presence of
oxygen in the plasma arc causes intense oxidation of tungsten
electrodes.  
  
One of the problems that occur during the use of these
applications is the need to combine the electrical switchgear to
transform the voltage to a suitable level for a block of
electrolytic cells (i.e. by step-down transformers).  
  
Completed final design is inefficient, from an electrical point of
view, and cumbersome and can be expensive if fine adjustment of
voltage and current (and hence, the regulation of the gas flow).  
  
Combustible gaseous hydrogen and oxygen mixed into a single
stream, burn at very high temperatures, typically of the order
6000C. Hydrogen / oxygen welding devices are well known and
consist of a welding tip or hand portion connected to the dual gas
hose to separate feeding of oxygen and hydrogen.  
  
There are four other known types of welding apparatus and methods
of their application - it is the oxygen-acetylene welding,
electric arc welding system MIG (metal inert gas) / TIG
(tungsten-inert gas) and plasma cutting.  
  
It is estimated that in use in Australia are more than 100,000
oxy-acetylene units.  
  
Of these, approximately 70% are used primarily for cutting, and
the remaining are used as heat sources for welding fusing sheet
metal, brazing, silver soldering, etc.  
  
Usually oxygen-acetylene welding metal settings can thickness from
0.5 to 2 mm.  
  
Additionally, metal can be cut up to 140 mm thick, but only if the
steel contains a high percentage of iron.  
  
The reason for this is that the iron and oxygen required to
sustain the process of oxidation, which causes the effect of
cutting.  
  
Acetylene gas creates an initial temperature to start the
oxidation reaction is usually equal to 850C. Oxy-acetylene
cylinders require installation of gases (oxygen and acetylene),
and hence the cylinders shall be purchased or rented, and then
constantly maintained in good condition and using refilled.  
  
Arc welding is a method used for welding metals more than 1.5 mm
thick.  
  
The principle is that the hand piece is supplied with a consumable
electrode and the working electrode forms the other part.  
  
Between the electrodes creates a potential difference of AC or DC,
thereby causing arcing that manual portion is brought into an area
close to the working part.  
  
The arc can be used for melting or welding together of metal
parts.  
  
Systems MIG (metal inert gas) based on the continuous wire feed
system.  
  
In one known construction the consumable wire is surrounded by
argon gas (or plasma), which is usually fed from a cylinder.  
  
TIG (tungsten inert-gas) systems, on the other hand, require a
weld wire that has to be entered manually into the welding area.  
  
MIG / TIG-welding of the metal thickness can be from 1 to 20 mm, a
typical stainless steel, aluminum, mild steel, etc.  
  
References concerning plasma MIG-process can be made to the text
of "The Science and Practice of Welding, v.2, AC Davies, Cambridge
University Press ".  
  
Plasma cutting is a cutting manner by means of compressed air
(comprising predominantly nitrogen) to a DC electric arc, thereby
creating a very high temperature (about 15000C), and thus taking
the electrons from the nitrogen nucleus to form a high temperature
plasma.  
  
This plasma can be used for cutting iron and
zhelezonesoderzhaschih materials such as mild steel, stainless
steel, copper, brass and aluminum.  
  
Applied plasma cutters can cut the material to 25 mm thickness and
have the advantage that they require no use of a gas cylinder, and
the normal air.  
  
Reference to a plasma cutting can be done on the text "Gas
Shielded Arc Welding, NJ Henthorne and RW Chadwick Newnes
Technical Books".  
  
As follows from the discussion of the prior art, no one unit or
system is unable to perform all welding and cutting functions, and
typically one of the systems described above must be given
preference to any other particular operation.  
  
This in turn requires that workers on metal or other metal
industries industrial manufacturers bought and maintained in many
different types of welding machines, in order to be able to do any
work required.  
  
Costs associated with the purchase of gas in cylinders for
replacement, are also very high.  
  
A preferred aim of the present invention is to provide a
construction whereby the hydrogen and oxygen gases can be produced
electrolytically, which lacks one or more of the aforementioned
disadvantages.  
  
In this sense, the electrolytic apparatus is compact and offers
greater efficiencies than the prior art devices, the gas at
comparable costs.  
  
Another preferred object of the present invention is to provide an
improved structure of an electrolytic cell for use in the
production of hydrogen and oxygen.  
  
The electrolytic cell can be used in a hydrogen / oxygen hydrogen
welding or plasma cutting.  
  
Other applications may include industrial processes that require
sources from burning fuels such as furnaces for calcining and
burning intractable wastes.  
  
Another preferred object of the present invention is to provide an
electrolytic cell structure which provides a selectable division
or mixing gases of hydrogen and oxygen in a single gas stream.  
  
The present invention is further directed to a predominantly
single welder that can satisfy all user requirements for welding
or cutting.  
  
The advantage is that the cylinders do not require the presence of
hydrogen or oxygen.  
  
Cylinders is also not required by any other gas such as argon, in
the systems of MIG / TIG immersion in an inert gas.  
  
Another preferred object of the present invention is to provide a
damper for a reverse flame hydrogen / oxygen welding or cutting
tip hydrogen plasma.  
  
Therefore, the invention discloses a honeycomb structure for the
electrolysis of water to liberate hydrogen and oxygen gas.  
  
Said structure comprises a plurality of electrodes, anodes in a
folded state, each anode electrode comprises a flat plate through
which pass one or more common first current conducting connecting
elements   
and a plurality of electrodes, the cathode in folded condition,
each cathode electrode comprises a flat plate, through which
undergo one or more common second conductive interconnecting
current elements; in   
the above structure, the electrodes and the electrodes are anodes,
cathodes overlap.  
  
The invention further discloses a cell structure for the
electrolysis of water to liberate hydrogen and oxygen gas.  
  
Said structure comprises a plurality of electrodes-anodes
interconnected via one or more common first current conducting
elements connected electrically in parallel; electrodes, anodes, a
plurality of electrodes overlapped cathodes interconnected via one
or more common second current conducting elements connected
electrically in parallel; said electrodes, anodes and cathodes
electrodes forming a cellular device, and a plurality of cellular
devices connected electrically in series.  
  
The invention further discloses a cell structure for the
electrolysis of water to liberate hydrogen and oxygen gas.  
  
Said structure comprises a plurality of anode electrodes, united
in the folded structure, each anode electrode comprises a flat
plate through which passes one or more common first conductive
interconnecting element current; a plurality of cathode
electrodes, united in a linear folded spatial structure, each
cathode electrode comprises a flat plate through which pass one or
more common second conductive interconnecting element current; in
the above structure, the electrodes and the electrodes are anodes,
cathodes overlap; and a plurality of membranes, each membrane
located between adjacent anode electrode and cathode electrode,
the membranes allow the passage of ionic current between adjacent
electrodes, the anodes and cathodes, electrodes, but selectively
blocking the flow of gas passing in dependence on the pressure
difference between opposite sides of the membrane  
  
The invention further discloses a device for releasing
electrolytically gaseous pollutants.  
  
The apparatus comprises a plurality of electrodes, anodes,
overlapping a plurality of electrodes, cathodes; many separation
membranes between each adjacent anode electrode and cathode
electrode; means for supplying at least water to the anode
electrodes and the cathode electrodes; said supply means to be
operable to control the differential pressure of water at least on
opposite sides of each membrane to provide a separation or
selection of mixing the released gaseous oxygen and hydrogen.  
  
The invention further discloses a structure of an apparatus for
combustion thermal decomposition of gaseous pollutants.  
  
The device comprises a hemispherical combustion chamber; supplying
hydrogen gas and oxygen into the combustion chamber via a tortuous
path, exiting through a plurality of concentrically arranged
nozzles directed towards the epicenter of the hemispherical
chamber; an inlet for the supply of gaseous pollutants; Combustion
apparatus in the gaseous pollutants are burned with the gases
(hydrogen and oxygen).  
  
The invention also discloses a multimodular cutting and welding
generator comprising a power source adapted for providing a
plurality of output voltages AC and DC; electrolytic device
connected to a power source for production of hydrogen and
optionally oxygen alone or as a mixture of hydrogen and oxygen by
water electrolysis using the constant voltage supplied from the
power source; Hydrogen, oxygen, and hydrogen and oxygen mixed with
an output voltage source suitable for connection to the welding
apparatus and / or cutting.  
  
The invention also discloses a damper for a reverse flame welding
tip, is used when the combustion gas contains a quencher mesh
barrier to the flow of gases to be incinerated, has a grid barrier
clearances for ensuring the free passage of gases but prevent the
reverse passage of flame, flame converse without being able to
pass through the barrier, thus extinguished.  
  
**FIG. 1a and 1b depict a honeycomb plates in plan and side view
respectively.****FIG. 2 shows a set of cellular folded plates.****FIG. 3 is a vertical sectional view of an electrolytic cell
unit.****FIG. 4 is a vertical section showing arrangement of
electrodes of part of another electrolysis cell block embodying
the invention.****FIG. 5 shows a perspective view of part of one electrode
shown in FIG. 4.****FIG. 6 shows a simplified representation of a sequence of
electrode structure shown in FIG. 4.****FIG. 7a and 7b show the mechanical connection of one group
of cells in another embodiment.****FIG. 8 illustrates the interconnection of several groups of
cells as shown in FIG. 7a and 7b.****FIG. 9 shows a sequential electrical connection of several
cells in a block of groups of cells.****FIG. 10a and 10b show the mechanical construction of the
device unit cell.****FIG. 11a and 11b depict another embodiment of the honeycomb
plate.****FIG. 12a and 12b illustrate the plate complementary to the
cells of FIGS. Cells 11a and 11b.****FIG. 13 shows details of the perforation plate and part of
the honeycomb shown in FIG. 11a, 11b, 12a and 12b.****FIG. 14 shows a discontinuity in the folded honeycomb
plates of FIGS. 11a, 11b, 12a and 12b.****FIG. 15a schematic view of a gas separation system of FIG.
14.****FIG. 15b shows a stylized representation of FIG. 15a.****FIG. 15c shows an electrical equivalent circuit of FIG.
15a.****FIG. 16 shows a gas collection system for use with a unit
cell separation system shown in FIG. 14 and 15a.****FIG. 17 depicts a cross-sectional hydraulic scrubber
(scrubber) and the valve stopper.****FIG. 18 depicts a cross-sectional welding tip used with the
equipment shown in FIG. 10 including the quencher reverse flame.****FIG. 19a and 19b shows a decomposition furnace combustion
of polluting gases.****FIG. 20 shows a block diagram of multimodular welding and
cutting device.****FIG. 21 is a schematic diagram of the apparatus shown in
FIG. 20.** **![](ru1.jpg) ![](ru2.jpg)  
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  ![](ru16.jpg)![](ru17.jpg)****Detailed description of the invention.**Block electrolytic cell embodying the invention consists of
several electrolytic honeycomb hexagonal plates 10, one of which
is shown in plan in FIG. 1a and in side view in FIG. 1b.  
  
Each plate 10 has three slots 12, each of which is located on the
end sides of alternating plate 10.  
  
Other side of each mesh plate 10 provided with a conductive bridge
or flange 14.  
  
Typically twenty individual cell plates 10 are combined into one
set to form a completed cell 16 is shown in side view in FIG.  
  
2. Total number of plates can vary in accordance with the desired
surface area and is therefore also a function of the diameter of
the wafer.  
  
Combining a set of adjacent mesh plates 10 is carried out in a
different order so that the conductive bridges 12 of adjacent
plates extending in opposite directions and with a relative
rotation of 60.  
  
Said rotation is due to the fact that adjacent the plate 10 must
be of opposite polarity.  
  
The conductive bridges 14 are long enough to pass through a
corresponding slot 12 in the adjacent plate 10, without contact
with this plate and so as to contact with the next successive
plate, forming a conductive path between each alternate plate.  
  
Thus, filled cellular structure 16 has three positive and three
negative output output, although FIG. 2 shows only two positive
and one negative output conclusion.  
  
Cellular set 16 surrounded by an insulating housing 18 (shown in
cracked form).  
  
Mesh plate 10 shown in FIG. 1a, 1b and 2 are suitable for forming
a parallel electrical connection with each adjacent two cell
plates 10 forming either the anode or cathode.  
  
Parallel folded flat cell plates are described in Australian
Patent N 487062.  
  
It set of twenty cell plates typically requires a potential
difference between the electrodes of each individual mesh plates
in the range of 1.55-2.0 V for release of gaseous hydrogen and
oxygen from water containing an electrolyte of typically 15%
sodium hydroxide solution.  
  
FIG. 3 depicts a vertical sectional seven completed honeycomb 16
sets collected in a hexagonal matrix and enclosed by the housing
20 of steel, thus forming a block of electrolytic cells 25.  
  
Cellular sets 16 are isolated from the steel hull 20 nylon
insulating sleeve 22.  
  
Electrical interconnection of individual cellular sets 16 are not
shown, but usually the cells are interconnected by their
respective positive (+) and negative (-) lead by straps to form a
serial connection.  
  
Sometimes it happens that make parallel interconnect cellular sets
16.  
  
Real electrical interconnection will depend on the number of
individual cellular plates 10, set up each cellular 16, the
applied voltage and current that would flow from the source.  
  
During the electrolysis reaction when released gaseous hydrogen
and oxygen, water is consumed. 1 liter of water produces 1860
liters of mixed oxygen and hydrogen at standard conditions (STP)
per volume proportions indicated above.  
  
In the illustrated construction, water is supplied continuously
through the inlet 24.  
  
Nylon 18 separating adjacent sets contributes toward upward rising
released gases to be collected via a gas outlet 26 located at the
top of the electrolytic cell unit 25.  
  
Due to volume expansion ratio of 1: 1860 released gases are
self-contracting when they emerge from the outlet 26 into the
connection pipe (not shown), which has a much narrower
cross-section than the unit cell.  
  
FIG. 4 is a vertical sectional view showing the mechanical design
of the electrolytic cell according to another embodiment.  
  
Main cellular device 30 is formed corresponding pair of
overlapping halves of the electrodes 32, 34, arranged in a similar
overlapping ridges.  
  
Each electrode is formed by conductive holders 36, 38 are
typically made of resin-bonded graphite, mild steel or conductive
polymers, from waste holder eleven plates 40, 42 in the form of
fingers, also made from graphite, steel or conductive polymer.  
  
FIG. 5 is a perspective view of one of the electrodes 32 in the
holder 36 and the plate 40 have a rectangular shape.  
  
Optionally, the electrodes have a specified shape, but rather can
take on many other forms, one example of which will be described.  
  
A common requirement for all such designs is that the plates are
parallel and are connected through a common structural member
disposed orthogonally plates.  
  
Each pair of electrodes 32, 34 are located in an alternating
structure so that the respective outermost plates 40a, 42a are
offset by approximately half the total length of each electrode
32, 34.  
  
Corresponding average plate reference numerals 40b and 42b.  
  
FIG. 6 illustrates a folded structure in a simplified form.  
  
Every sixth plate is located in a space formed by the first and
eleventh plate adjacent respective opposite electrodes.  
  
Referring again to FIGS. 4, which depicts two-filled cellular
device 30 and the respective adjacent portion of the subsequent
cellular devices.  
  
Total cellular units defined by the source of DC voltage, since
the beginning of the electrolytic process requires a minimum anode
/ cathode voltage, and each adjacent honeycomb unit is
electrically connected in serial parallel spaced plates 40, 42.  
  
When the process of the electric cell 30 are immersed and an
electrolyte, a constant voltage is applied between the end plates
40c and 42c, causing elemental ionic currents (some of which are
represented by dashed arrows) to flow between the adjacent plates
40, 42 and the total current - along the respective holders 36, 38
and plates 40, 42 (shown by solid arrows).  
  
In each middle plate currents caused by different directions.  
  
For example, a constant current flows from one end mesh plate 42a
through the electrolyte flowing through the middle plate 40b, and
again through the electrolyte to the next terminal mesh plate 42a.  
  
This process causes the accumulation of the positive charge of the
grid on one side of the middle plate 40b, and a negative charge -
on the other side.  
  
Leakage of ionic current flow is accompanied by dissociation of
water molecules, so that oxygen and hydrogen gases are produced
respectively on the surfaces of the anode plates and cathode
plates.  
  
Surfaces of the cathode plates are those plates, which are
directed ionic currents.  
  
The reverse is true for surfaces of anode plates.  
  
The voltage applied to the outermost plates 40c, is divided
equally between the constituent devices honeycomb 30, and as the
applied voltage is divided equally between the respective
outermost plates and the middle plate 40a and 42b, 40b and 42a.  
  
The achievable current density is limited, in particular, the
effective electrical resistance of the electrolytic solution.  
  
The smaller the distance between the adjacent plates 40, 42, the
less resistance.  
  
Overlapping design of electrodes 32, 34 means that there is a
large surface area per unit volume, and there is a minimum
distance between the electrodes, plates throughout the device.  
  
In this case, the resistance of the electrolyte is kept low, hence
efficiency of the conversion of electric energy into hydrogen and
oxygen production than in previous designs.  
  
Due to the specific design shown is not necessary to isolate each
individual honeycomb unit 30 from the same neighboring devices.  
  
Ionic current flows naturally along the path of least resistance,
hence short-circuit between a honeycomb units 30, but having a
greater resistance, are avoided.  
  
Therefore, a large number of cells can be combined into an
extended linear structure and allowed direct connection to the
source of the rectified voltage, thus avoiding the need to
electrically connect a group of cellular devices through a
contraction, as was done in previous developments.  
  
Each single honeycomb unit 30 satisfies the conditions from the
viewpoint of operability supply voltage, the surface area of ??the
plates and so on, for successful electrolysis of water, and
thereby operates essentially independently of the adjacent
honeycomb units 30.  
  
Testing has established that for a temperature range of from 90 to
50C at a DC voltage in the range 1.47-1.56, applied to one
honeycomb unit 30 (ie, one half of the entire electrode 32 or 34)
requires a minimum (and the optimum) anode current density 0.034 A
/ cm for receiving gas flow of about 340-300 l / h per 1 kW acent h,
respectively.  
  
The discovery that the minimum plate surface area corresponds to
the optimum gas flow rate means that the total volume occupied can
be kept to a minimum.  
  
For example, the rectified mains voltage is 240 V (rms) results in
an average nominal DC voltage 215 V, therefore, for direct
connection to the device through a rectifier (ie, without the
required step-down transformer) is required total of 140 cells.  
  
It is particularly advantageous that the equipment is not required
for voltage conversion in terms of equipment cost, technical
simplicity and the avoidance of losses.  
  
FIG. 7a shows a side view of a torn private cellular device 50, in
accordance with another embodiment.  
  
Honeycomb apparatus 50 is similar in configuration to the
apparatus shown in FIG. 4 except for the number and shape of the
overlapping protruding elements and electrode plates form.  
  
FIG. 7b shows a rear view of the cellular device 50 and, in
particular, the most recent card 52c.  
  
Plate electrodes 52, 54 have the shape of a hexagon.  
  
Through each plate 52, 54 are six connecting rods 56, 58, one near
each vertex.  
  
Each of the rods 56 alternating represents a common positive
conductor and the other set of alternating rods 58 are negative
conductors.  
  
Each adjacent plate 52 or 54 is electrically connected to the
positive conductors or the negative conductors.  
  
The intermediate inserts 60 are inserted between the adjacent
plates 52, 54 for electrical isolation and for the formation of a
space in which the water and electrolyte circulates.  
  
Connecting each conductor 56, 58 to the respective plate electrode
52, 54 is typically performed by screwing a nut or tight fitting.  
  
The reason for connecting each plate 52, 54 common to the three
conductors 56, 58 is to achieve a uniform current distribution
over the entire surface area of ??the plates 52, 54.  
  
As can be seen in FIG. 7b, the positive conductor 56 extends
outwardly from one end of the apparatus for serial connection with
the other set of cells, as well as projecting three negative
conductor 58 - the other end of.  
  
All unconnected ends of the conductors are closed nonconductive
plugs 62.  
  
FIG. 8 shows a stylized form of three cellular devices 50,
electrically connected in series (connected in the longitudinal
direction), and in particular - the passage of the protruding
wires 56, 58.  
  
Fusing device 50 are placed in an insulating tube 64, typically
constructed of polyvinylchloride (PVC), which has access to water
immersion exchange plates 52, 54 and for the removal of gases
produced.  
  
FIG. 9 shows a sequence of electrical connection of several
cellular devices 50 connected directly to the output DC converter
AC to DC (such as a simple rectifier using the diode bridge)
without the use of step-down transformer.  
  
FIG. 10a shows a rear view of the mechanical construction of the
seven devices (denoted AG), each consisting of three
series-connected cellular devices 50 (as shown in FIG. 8), forming
a general honeycomb structure 70.  
  
Fusing device 50 are in a steel cylinder 72 containing the water
and electrolyte required for the production of hydrogen and oxygen
gases.  
  
Each group (AG) of the three cellular devices 50 connected via a
first group of steel connecting couplers 74 on one end and a
second group of steel connecting ties 76 (not shown) at the other
end to form bridges between groups.  
  
Although in FIG. 10a shows only the first coupler 74, both sets of
ties more clearly shown in FIG. 10b, which is an expanded side
view of the groups AG.  
  
PVC tubes 64 shown in FIG. 10a, insulate adjacent groups to avoid
the effect of short-circuiting therebetween.  
  
The mesh structure 70 is a very compact, as compared with the
known construction Brown occupies only one third of its volume
with a comparable gas volumetric flow, while also reducing about
the same total weight ratio.  
  
Feed water for the electrolytic process is carried out through the
inlet opening 78 at the bottom raspolozhennoe cylinder 72, with a
yield of the product gas through an outlet opening 80 at the top
raspolozhennoe cylinder 72.  
  
Electrical connection to the conclusion that a DC source via a set
of cells of said structure and connecting to a central terminal 82
on the lower side of the cell A and the center pin 84 to the upper
side of the cell G respectively.  
  
FIG. 11a and 12a depict a rear view of a further embodiment of the
cellular inserts 90, 98 of first and second type.  
  
FIG. 11b and 12b are partial cross-sectional views along the
respective mid-lines as shown in FIG.  
  
General numbering used where reference is required.  
  
Plates 90, 98 can function as the anode or the (+) or a cathode
(-), as will become apparent hereinafter.  
  
Each electrode plate 92 comprises a disc which has holes
(perforations) 96 hexagonal shape.  
  
Disk 92 is made from steel or graphite or tarred conductive
polymeric material.  
  
Disc 92 is an annular rim or sleeve 94.  
  
The function of the holes 96 is to maximize the surface area of
??the electrode disc 92 and minimize the weight of the solid
structures 45%.  
  
For example, for a 280 mm diameter disc plate thickness must be 1
mm in order that the current density (which ranges from 100 cm
90A/2650 A/2940 smanoda or cathode) was optimal.  
  
If the diameter of the plate is increased, which accordingly
increases the surface area, it is necessary to increase the
thickness of the plate, in order to maintain the same conductivity
for the desired current density.  
  
Between the planes of the hexagonal holes (perforations) in the
disc thickness 1 mm spacing of 2 mm, and the holes are spaced 1 mm
from the next adjacent hole in order to maintain the same total
surface area as that of the prior art, and optimizing the current
density .  
  
Between adjacent hexagonal holes required distance of 1 mm (plane
to plane) because shorter distance leads to thermal (resistive)
losses, and greater distance will increase the total weight of the
plate.  
  
An annular ring 94 is made of PVC material and combines a
plurality of holes 100, 102 equally spaced axes.  
  
The openings intended for the passage of connecting axles, present
in the assembled structure of plates 90 and 98 forming the common
conductor for the respective anode and cathode plates, as well as
the design of the device shown in FIG. 7a and 7b.  
  
The following two upper openings 104, 106, respectively, each
support pipe for flowing hydrogen and oxygen.  
  
The openings 108, 110 in the lower portion of the annular rim 94
are intended to intake water and electrolyte to the respective
cell plates 90, 98.  
  
FIG. 13 is an enlarged view of the mesh plate 90 of FIG. 11a.  
  
Hole 104 is connected to the hexagonal holes 96 within the annular
inner rim 94 through the channel 112.  
  
A similar construction is to place another hole 106 and holes 108,
110, water feed / electrolyte.  
  
In the case where the released hydrogen and oxygen gases must be
kept separate (i.e. not to be obtained as a mixture), it is
necessary to separate them on delivery.  
  
In previous designs is achieved by the use of diaphragms that
block the passage of gases and effectively isolate the water /
electrolyte on each side of the diaphragm.  
  
Ion transfer thus is facilitated by the ion permeability of the
diaphragm material (i.e. the water path - diaphragm - water).  
  
This leads to an increase in ionic resistance, and hence reduced
efficiency.  
  
BACKGROUND Patent N 487062 describes another construction (see
FIG. 6 therein), which uses a magnet for the separation of gases.  
  
FIG. 14 shows, in the form of a torn assembled structure of the
four cellular plates, which constitute its two alternate (anode)
cell plates 90 and two (cathode cell plates 98.  
  
Two extreme disk assembled structure of cellular plates complete
the formation of one cellular device 125.  
  
Between each adjacent plates 90, 98 are located spacers 116 of
polytetrafluoroethylene (PTFE).  
  
Although not shown in FIG. 14, the honeycomb unit contains a
separate gas pipes for hydrogen and oxygen respectively, which
pass through the assembled structure of cellular plates through
holes 106, 104 respectively.  
  
Similarly, the gas supply pipes are arranged for the supply of
water / electrolyte, respectively passing through holes 108, 110
in the lower portions of the respective plates 90, 98.  
  
Shown, only two pairs of anode / cathode cell plates.  
  
Number of plates in such a device a cellular 125 may be
significantly increased.  
  
Also not shown conductive connection axis that electrically
connect the common striped cell plates.  
  
The reason for producing a large diameter hole in one plate and a
mesh manufacturing smaller diameter holes in the next adjacent
plate mesh is that the connecting axis will pass through the holes
of a larger diameter, without an electrical connection (i.e.
insulated with PVC tubing) while only forming electrical
connection between the alternating (general) cell plates.  
  
Honeycomb apparatus 125 shown in FIG. 14 in the form of torn.  
  
The assembled all elements are assembled to obtain intimate
contact.  
  
Mechanical fastening is achieved by using one of two binders
(adhesives) such as (a) "PUR-FECT LOK" (TM) 34-9002, which is a
urethane reactive hot melt adhesive having a main component
Methylene Bispheny / Dirsocynate (MDI) and b ) "MY-T-BOND" (TM)
which is a binder based on PVC solvent.  
  
Both binding substances are resistant to sodium hydroxide (a 20%
availability in the electrolyte).  
  
In this case, the water / electrolyte are only in areas not
occupied by the annular rim 94 mesh plate.  
  
Thus, by the water / electrolyte only a path from the inlet
through the lower channels 118, 122 which serves to remove gases
only by way of the upper channels 112, 120.  
  
In a system constructed and tested by the inventor, the thickness
of the mesh plate 90, 98 is equal to 1 mm (2 mm from the edge of
the annular rim 94 PVC), and the diameter - 336 mm.  
  
Honeycomb device 125 is separated from the next cell by separating
the insulating disc 114 PVC. Separating disk 114 is also available
at the beginning and end of the whole cellular bank.  
  
If you do not want to manage the division of released gases, the
PTFE membrane 116 missing.  
  
PTFE membrane 116 is fibrous and has a lumen size of from 0.2 to
1.0 microns.  
  
A suitable type is the Catalogue Code J., delivered Tokio Roshi
International Inc.(Advantec).  
  
The water / electrolyte fills the interstices and ionic current
flows only via the water - there is no compensation for the flow
of ions through the PTFE material itself. This reduces the
resistance to ion flow.  
PTFE material also has a "point of foaming", which is a function
of pressure, thus controlling the relative pressure on either side
of the dividing sheets of PTFE, the gases may be "pushed through"
through the holes to form a mixture or, alternatively, to maintain
separation.  
  
Other advantages of this design are significantly lower
construction costs, improved efficiency and significantly greater
fault tolerance.  
  
FIG. 15a is stylized and ripped a schematic view of a linear
connection of three series-connected cellular devices 125.  
  
For clarity, only six axes connecting 126-131.  
  
Axles 126-131 pass through corresponding axial holes 102, 100 in
different cellular plates 90, 98 in the folded structure.  
  
Also contains the polarity power supply connected to each terminal
uncovered axes, which connects DC power source.  
  
126-131 axis does not pass along the entire length of three units
of 125 mesh.  
  
This design is similar to the structure shown in FIG. 7a and 8.  
  
One third of the total voltage DC source is present on each pair
(anode-cathode) cellular plates 90, 98.  
  
Further, the gas conduits are shown as 132, 133, respectively, for
hydrogen and oxygen, which pass through holes 104, 106 in the cell
plates 90, 98.  
  
Similarly, conduits 134 are shown, 135 for water / electrolyte,
passing through the openings 108, 110 in the cell plates.  
  
FIG. Separately 15b shows how the relative potential difference in
average honeycomb block 125.  
  
That is, the plate electrode 90a is functioning as a cathode (i.e.
relatively more negative) to generate hydrogen, and a plate
electrode 98a is functioning as an anode (i.e. relatively more
positive) for the production of oxygen.  
  
This occurs for each alternating cellular device.  
  
FIGS. 15b arrows indicate the chain of electron and ion currents.  
  
FIG. 15c is an electrical equivalent circuit of FIG. 15b, where
the resistive elements represent the ionic resistance between
adjacent anode-cathode plates.  
  
Thus it can be seen that the honeycomb units are connected in
series.  
  
Due to changes in the function of cellular plates 90a and 98a on
each of the additional gases are released, hence the respective
channels 112 are connected to the opposite gas conduits 132, 133.  
  
In particular, this may be achieved by simple permutation of the
plates 90, 98.  
  
FIG. 16 shows three cellular device 125 shown in FIG. 15a,
connected to a gas collection device.  
  
The honeycomb unit 125 is located within the reservoir 140 which
is filled with water / electrolyte to the level indicated by h.  
  
Water consumed in the electrolytic process, and new feed it
through the inlet 152.  
  
Level of water / electrolyte h can be seen through the transparent
glass 154.  
  
In normal operation, produced a variety of streams of hydrogen and
oxygen and tested by cellular device 125 to the corresponding
towering columns 142, 144.  
  
That is, the pressure of electrolyte on opposed sides of the PTFE
membranes 116 are aligned so that the gases can not be mixed.  
  
Columns 142, 144 are also filled with water / electrolyte, and a
flow rate at the electrode plates is performed again by feeding
the electrolyte circulating through the ducts 134, 135 for water /
electrolyte.  
  
Circulation caused by entrainment of released gases and circulates
konstruktsiey pipes and columns.  
  
The upper part of the tank 140 forms two gazoochistitelnye columns
156, 158, respectively, for collecting hydrogen and oxygen gases.  
  
Gases rise up the corresponding columns 142, 144 and exits the
column through hole at a point within the overlapping baffles 146.  
  
Eta point where the gases exit the columns 142, 144 is below the
water level h, which serves to eliminate any turbulent flow and
entrained electrolyte.  
  
Partitions 146 located above the level h, purified gas from any
gas entrained electrolyte, and the purified gas is then eviscerate
the column via respective outlet 148, 150 and, thus, - the gas in
the receiver.  
  
The level h within the tank 140 may be adjusted by any of
conventional methods using a float switch to the newly incoming
water supplied through inlet pipe 152.  
  
Released gases will always be separated from the solution of water
/ electrolyte due to the difference in densities.  
  
Because of the relative height of the respective set of baffles,
and due to the difference in density between water and gas /
electrolyte mixing impossible liberated hydrogen and oxygen gases.  
  
Having full volume of water within the tank 140 maintains the cell
plates in a submerged condition and also serves to absorb the
shock of any internal detonations when they occur.  
  
In the case where the mixed gas is required, primarily closed two
valves 136, 137 respectively located in the conduit 132 to exit
and the oxygen gas inlet 134 for water / electrolyte.  
  
IT'S inhibits the output path for the gaseous oxygen and causes
the intake water / electrolyte held in the inlet conduit 134
through unidirectional retaining valve 139 and pump 138.  
  
The water / electrolyte within the tank 140 is pressurized due to
its depth (volume), and the pump 138 operates to increase the
pressure of water / electrolyte around the anode cell plates 90,
98a, which leads to an increased pressure relative to the pressure
of water / electrolyte on the other side of the membrane 116.  
  
Eta is a sufficient pressure difference to cause movement of the
oxygen gas through the membrane, thus the mixed oxygen and
hydrogen are liberated via the gas output conduit 133 and column
144.  
  
Since there is no return path for the feed pump 138 water /
electrolyte, the pressure about the cell plates 90, 98a will
continue to increase to a value at which the difference is
sufficient to keep the water / electrolyte also can pass through
the membrane 116.  
  
Usually it takes the pressure difference between 1.5-10 lbs /
inch, to permit passage of a gas pressure difference and in the
range of 10-40 lbs / dyuymdlya water / electrolyte.  
  
Although depicted only three honeycomb unit 125, it is clear that
there may be any number of them are formed connected in series.  
  
FIG. 17 depicts another embodiment of a valve locking device 160
and gazoochischayuschego purification released (s), gas (es)
before subsequent use.  
  
Device 160 is typically filled with water to a level of half of
the total height of the device.  
  
The level is controlled by a float switch 162.  
  
Water is supplied through inlet 164.  
  
Built as a transparent tube 166, which serves as a visual
indication of water level.  
  
Gaseous hydrogen and / or oxygen from the pressurized gas receiver
receives at input conduit 168 having a bottom exit 170.  
  
The gases pass down the tube 168 and out of holes 170, in the form
of bubbles rising up inside the inner column 172, which is also
filed filled with water, thereby performing an initial
purification to remove the sodium hydroxide electrolyte.  
  
The gas then flows into the down tube 174, and emerges from the
open end thereof, passing again through the water in the outer
chamber 176 to further purify, and so is the pressure in the
volume above the water level for subsequent exit from outlet 176.  
  
Mixed gas of hydrogen and oxygen exiting from the outlet 178, for
example, the welding tip (not shown) in the correct stoichiometric
proportions as a result of the electrolytic process, and can be
sure that the neutral formed by the combustion flame. The products
of combustion are only heat and water vapor.  
  
If the gases are produced separately, the scrubbers 160 using the
two valves lock, then the gases are mixed in a mixing chamber
which also will produce the correct stoichiometric mix ratio.  
  
If there is an explosion that "back" through the outlet 178 of the
welding tip, it must be repaid with water in the device 160, and
the explosion energy is absorbed by water displacement and 176 in
the outer chamber and the inner column 172, and also for the
offset cuts incoming gas flow into the tube 168.  
  
In this case there should be the possibility of explosion
propagation in the direction of the electrolytic cell bank
producing the gases. Water device 160 acts so as cleaning gas and
the valve stopper.  
  
FIG. 18 shows a welding tip 180 in cross section.  
  
Hydrogen and oxygen gas coming from the inlet tube 182, needle
valve 184 are omitted, and thus, enter into the expansion chamber
186.  
  
Expansion chamber 186 comprises a control device reverse flame
quenching, which consists of a cylindrical absorber 188 Reverse
flame are usually made of a 5-micron stainless steel mesh.  
  
During normal operation gas flows through the damper 188 and the
reverse flame so - to the outlet or nozzle 190, where combustion
occurs or during ionization of the gas plasma formation.  
  
If the reverse flame damper 188 reverse flame prevents further
spread of the flame in the opposite direction, which can not
physically pass through the holes of such a small size as, say, 5
microns.  
  
This is related to the heat absorption effect of the material of
the absorber 188 is made, which leads to dissipation of the flame,
and that, consequently, contributes to the destruction of the
flame.  
  
The use of hydrogen and / or oxygen in welding and cutting by
electrolysis allows temperatures of the order of 6000C to achieve
the ability to produce a desired amount of gas.  
  
Not required gas stored in the tank.  
  
It is also possible to carry out high-quality welding flame with
high purity gas, and can be melted ceramic materials.  
  
All of the following materials can be welded carbon steel, cast
iron, stainless steel, aluminum, brass, silver solder, copper and
ceramic.  
  
Following iron and *zhelezonesoderzhaschie* materials due to
the possibility of production of pure hydrogen flowing through the
DC electric arc, forming a stream of hydrogen plasma (H --->
H), can be easily cut carbon steel, cast iron, stainless steel,
aluminum, brass and copper.  
  
Embodiment of the invention can provide a continuous supply of
hydrogen gas at a greater rate.  
  
If so, then the invention is well suited for applications that
consume large amounts of hydrogen.  
  
An example of such a process is Plascon (TM) process waste
decomposition developed Australian CSIBO's Division of
Manufacturing Technology.  
  
Overview-Plascon process can be found in CS1BO Journal "Ecos,
Volume 68, Winter 1991."  
  
One application of hydrogen and oxygen gases produced by the
above-described apparatus, the waste is thermally decomposed
without burning atmospheric oxygen.  
  
This procedure requires on-demand supply of hydrogen and oxygen.  
  
The above-described electrolysis apparatus may produce an increase
in the size of the desired gas flow, in order to burn the waste
gas in a commercial scale.  
  
FIG. 19a and 19b show the configuration of the furnace used for
the decomposition of gaseous pollutant emissions.  
  
FIG. 19a shows a cross section of the furnace 200.  
  
The cross section along the center line shown in FIG. 19b.  
  
The furnace 200 is combustion chamber 202 of the hemispherical
shape.  
  
Separation, which may comprise a mixture of fumes containing
hydrocarbons and other volatile contaminants in a waste product
from industrial processes, are injected into the combustion
chamber through an inlet 206.  
  
There are two sources of mixing hydrogen and oxygen in a
stoichiometric proportion of 2:1, which are the upper and lower
quadrants of the combustion chamber 202.  
  
These gases are fed via two gas inlets 208 are located at points
on opposite sides of furnace 200.  
  
The mixture of hydrogen and oxygen precipitates formed within the
combustion chamber is ignited by a spark from spark plug 210 or
the like, and is burned at a temperature not less than 4000C,
thereby providing energy for dissociation of contaminants into
harmless components which can be released into the atmosphere .  
  
During combustion the atmospheric oxygen is not consumed.  
  
Completion of combustion pollution contributes effect "focus" of
the combustion chamber 202, which also improves the mixing of the
gas streams.  
  
Thermocouple 212 measures the temperature inside the silicone
fibrous refractory insulating material 214 surrounding combustor
202.  
  
Cladding 216, applied to the furnace 200, typically made of
stainless steel.  
  
The furnace is made of seven (only four shown) are concentrically
arranged sets of nozzles 212, as clearly shown in FIG. 19b.  
  
Nozzles 222 are directed to a common point of intersection in the
midst of 204 of the combustion chamber 202.  
  
Cooling water is supplied through inlet 218 and exiting through
outlet 220, is designed to maintain a temperature of less than 222
nozzles 300C. Over 300C hydrogen gas has a tendency to
"burn-back."  
  
The flow path of gaseous hydrogen and oxygen to the nozzles 222
from the inlet openings 208 has four (minimum) changes direction
at 90C. This is intended to reduce the linear inertia
hydroxy-flame combustion in the case of reverse, and thus make the
flame extinguish itself.  
  
This is particularly advantageous when the hydrogen burns with a
speed of 3600 m / s.  
  
FIG. 20 shows in block diagram form and multimodule machine 230.  
  
To the device is supplied DC power coming from the converter 232
AC to DC.  
  
Commercially available AC voltage source is intended for
connection to the device 234, a welding arc AC voltage, while the
converted DC output voltage is designed for connection to an
apparatus, a welding arc voltage constant, or a cutting device
236.  
  
The voltage applied to the output DC voltage is applied to the
electrolytic cellular device 238 to obtain in this case separated
hydrogen and oxygen gases. Hydrogen and oxygen gas are fed to the
welding apparatus 240.  
  
Hydrogen (and oxygen for secondary injection) Secondary power
supply available for connection to a plasma cutting device 242.
Hydrogen passes through the DC arc for plasma flow and the
secondary injection of oxygen introduced into the plasma stream to
produce an oxidizing plasma cutting effect, which increases the
cutting efficiency.  
  
With this process it is possible to cut the material to a
thickness of 150 mm.  
  
It should be noted that the introduction of oxygen from the
downflow of tungsten electrodes eliminates any oxidation of the
electrodes.  
  
Device for MIG / TIG 244 manufactured in a hydrogen gas plasma to
form Unlike conventional inert gas occurring.  
  
For plasma formation also requires a source of AC or DC.  
  
Transducer 232 may be of any conventional design, typically
multiterminal imeyuschey transformer to select an appropriate
rectified voltage.  
  
The electrolytic device 238 may be any of the previously described
embodiments and may include a scrubber and the valve stopper.  
  
Various described cutting and welding devices 234, 236, 240, 242,
244 are also conventional.  
  
Multimodular device 230 thus provides greater flexibility for the
user with the ability to select one device of a particular mode
desired cutting or welding.  
  
Clearly, the device comprising any single device or combination
welding / cutting provided by the present invention.  
  
FIG. 21 is a multimodular device 230 with a high degree of detail.  
  
As described above, an electrolytic generator 238 separately
generates hydrogen and oxygen gases, and may also produce hydrogen
and oxygen as a mixture.  
  
Power supply device 232 includes a transformer 246 mnogovyvodnyh.  
  
Reduced voltage is rectified by a bridge rectifier 247.  
  
Rectified voltage output pin 248 is then connected to the unit
cell 238 containing 30 cells, a contactor 249, which is driven by
a pressure switch 250. Switch 250 in turn operates a pressure
sensor 251 which senses the level of gas pressure within the cell
block 238.  
  
Thus, the contactor 249 is controlled to remove supply voltage to
the unit cells 238 in setting the working pressure.  
  
Contactor 249 runs on demand using gas.  
  
Thus, gas produced in sufficient quantities, and typically 15
liters at a time.  
  
These gases contained 15 l 10 l 5 l of hydrogen and oxygen.  
  
Gases come from gas... columns 156, 158, 238 block of cells.  
  
Since the ring system is closed, the pressure in each column will
be compensated by the pressure in the other, thereby maintaining a
constant level of production of a desired gas.  
  
If, however, the water level is too high due to an excessive use
of gas, the corresponding float switch 254, 255 in the
corresponding column 156, 158 will obstruct the flow of gas,
corresponding to closing the solenoid valve 256, 257.  
  
Float switches 254, 255 actuated solenoid valves 256, 257 of the
AC voltage source 258, the exhaust from the transformer 246.  
  
Other float switches located in the stop valve and the scrubber
160 and forcing pump 138 also powered from AC voltage source 258.  
  
Two flow controller 261, 262 are combined in order to maintain a
desired back pressure in the columns 156, 158, in order that said
system is always under pressure, even if the system is disabled
and / or gases are exhausted through the gas discharge holes, gas
outlets 263, the stopper 264 valves / devices ... welding tip 160
or 265.  
  
Another method is to produce a mixture that, when hydrogen and
oxygen gases as opposed to the separation of cells in the block
238 have passed through the locking valve and the cleaning device
160, then select valve 266 allows gases to be mixed and supplied
to the welding tip, where they are ignited and combusted, for to
be used for hydrogen / oxygen welding.  
  
If hydrogen and oxygen are fed separately and are required for the
hydrogen plasma cutting device 242 and / or hydrogen plasma device
MIG / TIG-welding 244, the valve 266 does not allow the selection
mix two gases.  
  
Feeder voltage 232 is a conventional device with transformer 246
containing reactive winding 267 and 268 range selection switch
that allows selection of the output voltage level.  
  
Generated secondary alternating voltage can also be rectified
rectifier 247 for DC voltage at the output.  
All said output voltage is then applied to the selector 269
polarity, allowing the user to choose between AC or DC output
voltage and select the appropriate polarity for DC output voltage.  
  
Output 248 232 shows a power source connected to the electrolytic
cell unit 238, however, the power source may also be coupled with
other types of cutting or welding equipment such as those shown in
FIG.20.  
  
Next Exit 271 supplies the necessary DC power to the power source
244 MIG / TIG-immersion in hydrogen plasma and hydrogen oxidizing
plasma cutting device 242.  
  
Next Exit 272 VAC and 273 VDC output give the required current for
the arc for MTG-or TIG-processes.  
  
For a block of cells 238 and 234 devices arcing, 263 required
output voltages in the range of 20-60 V, while welding MIG /
TIG-devices operate normally when the output voltage of 30-60 V
(AC or DC).  
  
Plasma cutting and plasma immersion, which is carried Plasma
device 242 typically requires supply 120 VDC.  
  


---

  

**Improvements in electrolysis systems**  
**CN1133619**

**AU7647894**

---

**Compound power plant**  
**AU2897000**  
**WO0053918**

The exhaust gases from an internal combustion
engine (12) are provided to a turbo fan/alternator unit (20)
and the electrical output therefrom passes a rectifier (22) to
a battery storage unit (24). The stored electrical energy is
controlled by a power controller (26) as it is provided to an
electrolysis gas generator (16). The liberated admixed
hydrogen and oxygen gases are provided to the engine (12) as a
substitute for, or an additive to hydrocarbon fuel. The
otherwise waste energy of exhaust gases is recovered, in part.
Such a compound power plant can be utilised in a motor vehicle
or a marine vessel.  
  
**Field of the Invention**  
This invention relates to a compound power plant that utilises
an internal combustion engine for the production of motive
power. The power plant can be used in all forms of land
vehicles, marine engines and stationary motor-driven generator
sets.  
  
**Background of the Invention**  
Internal combustion engines utilise hydrocarbon fuels as a
power source, the chemical energy of which is converted to
motive power by the engine (as is well known) with varying
degrees of efficiency. Common forms of hydrocarbon fuel are
gasoline, liquid petroleum gas. dieseline, marine diesel oil
and natural gas. All forms of internal combustion engine have
the problem of the undesirable waste combustion products such
as non-combusted hydrocarbon, carbon, oxides of sulphur and
nitrogen, and (in some circumstances) heavy metals.  
  
Considerable effort is being expended, particularly in the
motor vehicle industry, in the reduction of polluants and
greenhouse gas emissions in response to environmental laws.
Another area of research associated with internal combustion
engines is the imperfect nature of energy conversion from the
latent chemical energy of the fuel to energy that can be
mechanically harnessed.  
  
It is an object of the present invention to ameliorate one or
more such disadvantages in the prior art.  
  
**Disclosure of the Invention**  
The invention discloses a compound power plant comprising: an
internal combustion engine receiving a supply of hydrocarbon
fuel; a gas generation electrolysis unit supplying admixed
hydrogen and oxygen gases to be combusted with said
hydrocarbon fuel by said internal combustion engine; and a
turbo fan/alternator unit receiving the exhaust gases from
said internal combustion engine and providing a DC power
output therefrom coupled to the electrolvsis unit.  
  
Advantageously, a battery unit receives and stores the DC
power and provides a source of stored DC power to a power
controller that controls, by way of chopping, the supply of
power to the electrolysis unit. Additionally, there is a
battery charge detector sensing the charged state of the
battery unit and providing a signal representative thereof to
the power controller.  
  
Preferably there is further a water reservoir providing a
supply of water to the gas generator. There iurther can be a
fuel tank for supply of fuel to the internal combustion
engine.  
  
The compound power plant can further include a wind generator
providing a further supply of DC power to said battery unit.  
  
Yet further. for a motor vehicle embodiment, rotational
(kinetic) energy of the drive chain, includillg a tail shaft
and axles, can be recovered by an electrical generator to
provide a yet further supply of DC energy to the battery unit.  
  
The invention further provides a motor vehicle or marine
vessel having a compound power plant as described above, in
which said internal combustion engine provides a source of
motive power.  
  
The invention furthel discloses a method for recovering waste
energy from an internal combustion engine ! the method
comprising: converting volumetric flow of exhaust gases to
electrical energy;  
utilising said stored electrical energy to electrolyse water
to produce admixed hydrogen and oxygen gases; and utilising
said admixed ganses in the combustion process.  
  
Preferably. the method comprises the further steps of storing
the electrical energy and controlling tue amont of stored
electrical energy used for electrolysis in accordance with
internal combustion engine demand.  
**Brief Description of the Drawings****A number of preferred embodiments of the invention will
now be described with reference to the accompanying
drawings, in which :****Fig. 1 is a schematic block diagram of a compound power
plant;****Figs. 2a and b show characteristics of the power
controller of Fig. 1;****Fig. 3 is a schematic block diagram of a compound power
plant of a second embodiment;****Fig. 4 shows a schematic block diagram of a compound
power plant of a third embodiment; and****Fig. 5 shows the relative physical location of elements
of the compound power plant in a motor vehicle.****Detailed Description and Best Mode**  
  
The compound power plant 10 shown at Fig. 1 has an internal
combustion benzine 12 that receives a supply of hydrocarbon
fuel from a fuel tank 14. The encrine provides motive force
for a motor vehicle or marine vessel in which it is installe
by a drive chain (not shown). The drive chais in the
embodiment of a motor vehicle, inclues the tail shaft from the
gear box or automatic transmission and the front and rear
wheel axles, either or both of which axles may be driven bu
tue tail shaft.  
  
In addition to the hydrocarbon fuel from the fuel tank 14, the
engane 12 also receives a supply of admixed hvdrogell and
oxygen gases (H2 and 0,,) provided by a gas generator 16, in
the form of an electrolysis unit. A suitable form of
electrolysis unit. havinc, the characteristics of being
lightweight. compact and efficient. is disclosed in commonly
owned International Publication  
No. WO 95/07373 and US Patent No. 5,843,292, the contents of
which are incorporated lzerein by wav of cross-reference. The
gas generator 16 receives a supply of water from a water
reservoir 18. Of course. the supply of water could be from a
town main supply, and in that sense. be relatively unlimited
with respect to a single engine.  
  
The admixed hydrogen and oxygen gases supplie to the engine 12
are combusted in the engaine as an alternative, or as a
supplement to the hydrocarbon fuel. In the latter case, the
admixed gases act as a catalyst for the hydrocarbon fuel,
providing for more efficient combustion. The use of both
admixed hydrogen and oxygen gases and hydrocarbon fuel results
in a significant decrease in undesirable combustion products,
including carbon.  
  
For example, a 5% additive of hydrogen gas to a gasoline/air
mix can reduce nitrous oxide emissions by 30-40%. Tests
conducted by the inventor on a 3. 3 litre internal combustion
engin. where 28 litre/min of admixed gas is mixed with 4,000
litre/min of an air/fuel mix, reduced hydrocarbon emissions by
40%. Also, tests conducted on diesel emissions recorde a
reduction of 25% carbon black at flow rates of 6. 6 litres peu
minute of admixed gas with air/fuel mix 2,200 litres per
minute.  
  
Further tests carried out proved that the high pressure and
temperature produced in the combustion chambrer of a diesel
engine, in particular, did not cause the admixed gas to
pre-ignite before the top dead centre of the combustion stroke
and overall cycle, which would have caused pre-ignition. The
reason for this is due to the admixed gases'unique gaseous
properties, where the calorific value is low. therefore the
detonation temperature is high. In this test it proved to be
higher than the diesel fuel's ignition temperature.  
  
Internal combustion engines are known to be inefficient, in
that up to 2/3 of the energy liberated during combustion is
wasted: typically 40% as heat and 25% as exhaust pressure
(also known as iblow down energy'). It would be useful to
harness some of this otherwise wasted energy.  
  
In this reard. tlie exhaust gases from the engine 12 are
provided to a turbo fan/alternator unit 20. The fonction of
the turbo fan/alternator unit 16 is to induce rotation of a
shaft-mounted fan which, in turn, causes rotation of an
alternator mounted on the shaft from which electrical energy
is generated. A suitable form of turbo fan/alternator unit 20
is the"TurboGenerators"model manulactured by the company  
AlliedSignal Inc. of 101 Columbia Road, Morristown, NJ 07862,
USA. An AlliedSignalTM TurboGenerator of 25 ka rating (up to
120, 000 rpm) would be suitable for matching with a 100 kW
internal combustion engine. such as found in trucks and small
marine vesses.  
  
The AC output from the unit 20 is passed to a rectifier unit
22, and a regulated DC output then provided to a battery unit
24. The battery unit 24 has a function of storing electrical
charge, tao be supplie on demand. Battery unit 24 supplies DC
power to an electronic power controller 26 that includes a
conventional controlled chopper circuit.  
  
The power controller has an output characteristic shown in
Fig. 2a: chopped waveform shaving controlled tl, and t,, I-f
periods. This is sometimes known also as the mark-to-space
ratio. The output voltage level during tolu must be arrange to
be sufficiently high to promote electrolysis of the water,
including tlie necessary overvoltage, as is well known.  
  
By supplying the waveform of the nature shown in Fig. 2a to
the gas generator 16, an average gas flow will be achieved.
That is, strictly electrolysis ceases during the period
however because of inertia, there is an averaging of gas flow
with time.  
  
The volume of gas supply must be regulated to match engine
demand. These is an empirical relationship between a volume of
admixed hydrogen and oxygen gases generated by the gas
generator 16 and the volume of hydrocarbon fuel supply to the
engine 12. This relationship has been determined to be
approximately linear with respect to engine revolutions, in
the manner shown generally in Fig. 2b. The period tofi-reduces
as the gas demand increases.  
  
Of course. a limiting factor on the a rage volume of gas that
can be provided by the gas generator 16 is the power available
to be source from the battery unit 24. To account for this, a
battery charge detector 28 senses tlie energy storage level of
the battery unit 24, and provides a signal representative of
this state to the power controller 26. If the power controller
also receives a signal representative of the engine
revolutions it can sense demande Las load and control the DC
power provided to the gas generator 16 accordingly, subject to
the electrical energy being available from the battery unit
24. If the gas flow that which can be achieved by the
electrical energy exceeds available from the battery unit 24,
then the power controller 26 will clamp the volumetric slow-in
a manner shown by the dashed line in Fig. 2b.  
  
It is also possible for tlle energy recovered by the turbo
fan/alternator unit 20 simply to be stored in the battery unit
24, rather than being instantly consume by the gas generator
16.  
  
In another broader form, the DC output from the rectifier 22
can be provided directly to the gas generator 16 in an
unregulated manner.  
  
Considering then the energy balance aspect of the embodiment
of Fig. 1.  
  
A 30 kW internal combustion engine 12 produces approximately
7.5 kW of exhaust gas or blow down energy. The turbo
fanalternator 20 recovers typically 70% of the available
energy, being 5.25 kW. 5. 25 kW of electrical energy produces
1470 1/h of admixed hydrogen and oxygen gases. This volumetric
flow rate, when combusted by the engine 12, produces an
additional 3. 8 kW of energy, which is a 12% recovery of the
total energy available from the engine.  
  
For a compound power plant mounted on a motor vehicle, it is
possible also to take avantage of other available recoverable
forms of energy. In a further embodiment, shown in Fig. 3. the
power plant 10'further inclues a wind generator 30 that
supplies a further source of DC electrical energy to the
battery unit 24. Any suitable wind generator can be chosen.  
  
A yet further embodiment of the compound power plant, again
suitable for use with a motor vehicle, is shown in Fig. 4. The
compound power plant 10"shows a representative drive cliain 32
extending from the engine 12, (e. g. tail shaft or wheel
axles) by which motive power is transmitted. Mounted
concentrically around the drive chan 32 is an alternator 34.
The drive shaft acts as the rotor of the alternator, having
permanent magnets mounted to it. The interaction of the
magnetic field generated by the shaft with the stator windings
produces an alternating electrical output which acts to load
the shaft and cause it to slow. Tous, the rotational kinetic
energy can be recovered. The electrical output is from the
stator rectifie and provided to the battery unit 24.  
  
It is desirable for tlle alternator 34 to be controlled in a
switched manner to load the shaft when the vehicle's braking
system is activated by the driver. An example of sucez a
regenerative braking system is that implemented in the
ToyotaTM PriusTM motor vehicle,  
  
The increased electrical energy recovered from the exhaust gas
means that other electrical lods 36 in a motor vehicle can be
accommodated. For example, an electrical air conditioning unit
can be implemented, removing the conventional belt-driven
compressor and unburdening the engine to provide greater
available power (when the airconditioner is being operated).
Of course, the use of electrical energy for other loads (sucs
as airconditioning) may reduce the energy available for the
generation of admixed hydrogen and oxygen gases. There is an
engineering compromise to be made. Other examples of
electrical loads are lights and instrumentation.  
  
Fig. 5 shows a side view of a vehicle, and the relative
physical location of the elements of the compound power unit
10'of Fig. 3. It will be readily understood that the
consumable fuels. water and hydrocarbon are required to be
replenished.  
  
![](wo1.jpg) ![](wo2.jpg) ![](wo3.jpg)  
![](wo4.jpg) ![](wo5.jpg)



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