U.S. patent application number 13/622293 was filed with the patent office on 2013-01-17 for internal combustion engine.
This patent application is currently assigned to RICH IDEAS CREATED - HOLDING COMPANY, INC.. The applicant listed for this patent is Rich Ideas Created - Holding Company, Inc.. Invention is credited to Richard F. Chipperfield.
Application Number | 20130014725 13/622293 |
Document ID | / |
Family ID | 38328066 |
Filed Date | 2013-01-17 |
United States Patent
Application |
20130014725 |
Kind Code |
A1 |
Chipperfield; Richard F. |
January 17, 2013 |
Internal Combustion Engine
Abstract
In an engine, blow-by is substantially eliminated and friction
is significantly reduced using one or more combinations of
non-metallic rings. By substantially eliminating blow-by and by
reducing friction, certain engine parameters may be changed. In
addition, by substantially eliminating blow-by and by reducing
friction, pollution may be reduced, fuel economy may be increased
and power may be increased.
Inventors: |
Chipperfield; Richard F.;
(Westerly, RI) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Rich Ideas Created - Holding Company, Inc.; |
Cranston |
RI |
US |
|
|
Assignee: |
RICH IDEAS CREATED - HOLDING
COMPANY, INC.
Cranston
RI
|
Family ID: |
38328066 |
Appl. No.: |
13/622293 |
Filed: |
September 18, 2012 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
11702033 |
Feb 1, 2007 |
8267062 |
|
|
13622293 |
|
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|
60764429 |
Feb 1, 2006 |
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Current U.S.
Class: |
123/193.6 |
Current CPC
Class: |
F16J 9/14 20130101; F02F
3/00 20130101; F16J 9/28 20130101; Y02T 10/62 20130101; F16J 9/06
20130101; F02F 5/00 20130101; B60T 1/10 20130101; B60K 6/24
20130101; Y02T 10/6295 20130101 |
Class at
Publication: |
123/193.6 |
International
Class: |
F02F 3/00 20060101
F02F003/00; F02F 3/26 20060101 F02F003/26 |
Claims
1. A piston for use in an internal combustion engine, the piston
comprising: a piston body having a first ring groove for receiving
a first ring assembly, wherein the first ring assembly includes a
first non-metallic ring and a second non-metallic ring; the piston
body having a second ring groove for receiving a second ring
assembly, wherein the second ring assembly includes a third
non-metallic ring and a fourth non-metallic ring.
2. The piston of claim 1, wherein the piston is designed to be
received by a cylinder having a cylinder wall and wherein the first
non-metallic ring biases the second non-metallic ring towards the
cylinder wall when the piston is received in the cylinder.
3. The piston of claim 2, wherein the third non-metallic ring
biases the fourth non-metallic ring towards the cylinder wall when
the piston is received in the cylinder.
4. The piston of claim 1, wherein the second non-metallic ring
includes a split.
5. The piston of claim 4, wherein the fourth non-metallic ring
includes a split.
6. The piston of claim 1, wherein the piston includes a piston head
that is recessed to form a combustion chamber.
7. The piston of claim 6, wherein the piston head is coated with a
catalyst for oxygen.
8. The piston of claim 6, wherein the piston head has a top and the
top is oval-shaped.
9. The piston of claim 7, wherein the piston head has a top and the
top is oval-shaped.
10. The piston of claim 2, wherein the piston includes a piston
head that is recessed to form a combustion chamber.
11. The piston of claim 10, wherein the piston head is coated with
a catalyst for oxygen.
12. The piston of claim 10, wherein the piston head has a top and
the top is oval-shaped.
13. The piston of claim 11, wherein the piston head has a top and
the top is oval-shaped.
14. The piston of claim 3, wherein the piston includes a piston
head that is recessed to form a combustion chamber.
15. The piston of claim 14, wherein the piston head is coated with
a catalyst for oxygen.
16. The piston of claim 14, wherein the piston head has a top and
the top is oval-shaped.
17. The piston of claim 15, wherein the piston head has a top and
the top is oval-shaped.
18. The piston of claim 4, wherein the piston includes a piston
head that is recessed to form a combustion chamber.
19. The piston of claim 18, wherein the piston head is coated with
a catalyst for oxygen.
20. The piston of claim 18, wherein the piston head has a top and
the top is oval-shaped.
21. The piston of claim 19, wherein the piston head has a top and
the top is oval-shaped.
22. The piston of claim 5, wherein the piston includes a piston
head that is recessed to form a combustion chamber.
23. The piston of claim 22, wherein the piston head is coated with
a catalyst for oxygen.
24. The piston of claim 22, wherein the piston head has a top and
the top is oval-shaped.
25. The piston of claim 23, wherein the piston head has a top and
the top is oval-shaped.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This is a continuation of U.S. patent application Ser. No.
11/702,033 (now U.S. Pat. No. 8,267,062), which claims the benefit
of U.S. Provisional Application No. 60/764,429, filed Feb. 1, 2006,
both of which are incorporated herein by reference in their
entireties.
FIELD OF THE INVENTION
[0002] The present invention relates generally to engines
including, for example, internal combustion engines used in
automobiles.
BACKGROUND OF THE INVENTION
[0003] Environmental pollution is one of the most-discussed issues
in the world today. Pollution and greenhouse gases have been blamed
for causing climate change, health problems and natural disasters,
such as hurricanes and flooding.
[0004] Two of the largest causes of environmental pollution and
greenhouse gases are the automotive industry and the power
industry, both of which burn fossil fuels in internal combustion
engines. Engines for cars, trucks, airplanes, trains, ships, boats,
buses, motorcycles, mopeds, snowmobiles, chainsaws and lawnmowers
(among others) spew pollution and greenhouse gases into the
environment. Power plants use engines that burn fossil fuels such
as natural gas, diesel and coal, which produce additional pollution
and greenhouse gases.
[0005] The concerns relating to pollution and greenhouse gases are
expected to increase as emerging countries, such as China and
India, continue their economic development. The total number of
internal combustion engines that burn fossil fuels is only expected
to increase. The manner in which pollution and greenhouse gases is
regulated, generally, varies from country-to-country. The degree of
enforcement, of such regulations also, generally, varies from
country-to-country. However, there are no strict boundaries
associated with the spreading of pollution and greenhouse gases.
Accordingly, at present, there is no practical solution to solve
this global problem.
[0006] Alternative fuels, such as hydrogen and ethanol, have been
proposed to reduce pollution and/or greenhouse gases. Automobiles
powered by hydrogen-based fuel cell technology are expected to be
completely pollution free. However, with respect to hydrogen, the
infrastructure for a so-called hydrogen-based economy is not yet
available. For example, hydrogen-based filling stations are not
widely-available. Furthermore, there is no low-cost method for
producing and storing hydrogen in large volumes.
[0007] If automobile engines used only ethanol as their fuel,
pollution would be reduced, since ethanol is a clean-burning fuel.
However, carbon dioxide, which is a greenhouse gas, would still be
produced. Depending upon the design of an ethanol-burning engine
(e.g., the compression ratio and, correspondingly, the temperature
inside the engine), other greenhouse gases (e.g., oxides of
nitrogen) might still be produced.
[0008] Furthermore, techniques are not available to supply enough
ethanol to sustain an ethanol-based fuel economy. In fact, there is
an insufficient capacity to produce ethanol to supply the world
with a mixture of more than 10% of ethanol with other engine
fuels.
[0009] Efforts have been made to reduce pollution caused by
internal combustion engines that use fossil fuels. For example,
catalytic converters have been used in combination with internal
combustion engines in an attempt to burn-away hydrocarbons that
remain unburned in the internal combustion engine. To explain
certain problems associated with engines that use catalytic
converters, reference is made to FIG. 1.
[0010] FIG. 1 is a simplified block diagram of a system 100 that
includes an internal combustion engine 110, an air supply 120, a
fuel supply 130, a carburetor/fuel injector 140, a drive shaft 150,
a catalytic converter 160, an air blower 170 and a PCV valve 180.
Ambient air is drawn from the environment through the air supply
120 and is mixed with fuel supplied by the fuel supply 130. The
air-fuel mixture is then delivered to the internal combustion
engine 110 via a carburetor or fuel injector 140.
[0011] Through well-known techniques, a combustion process occurs,
whereby chemical energy is converted over a number of steps to
mechanical energy that is used to turn the drive shaft (e.g.,
chemical energy to heat energy, heat energy into kinetic energy,
and kinetic energy to mechanical energy and, in the case of power
plants, mechanical energy to electrical energy). Because of
incomplete combustion, unburned hydrocarbons and carbon monoxide
are present in the engine 110. Instead of expelling these
pollutants into the environment, the unburned hydrocarbons and
carbon monoxide are delivered to a catalytic converter 160 (in some
cases, multiple catalytic converters), so a large portion of such
unburned hydrocarbons and carbon monoxide are burned before
exhausting the remainder into the environment.
[0012] In order to burn such unburned hydrocarbons, an air blower
170 is used to introduce ambient air, which has not been subjected
to the combustion process in the internal combustion engine. The
ambient air includes two major gases, nitrogen and oxygen. The
oxygen from the ambient air is used as a catalyst to burn the
unburned hydrocarbons. However, because (in part) of the inhibiting
affects of nitrogen (which is itself a fire retardant, often used
in fire extinguishers), platinum is used in the catalytic converter
as a catalyst for oxygen. Platinum increases the catalytic affect
of oxygen to increase the temperature in the catalytic converter
160 to sufficient levels to complete the burning of most unburned
hydrocarbons and carbon monoxide.
[0013] A significant problem with raising the temperature to such
levels (e.g., above about 1850 degrees Fahrenheit) is that
compounds of oxygen unite with various compounds of nitrogen to
form various oxides of nitrogen, collectively known as NOx. NOx is
thought to include greenhouse gases, which are believed to
contribute to global warming. In fact, some believe that NOx is
three hundred times more potent a greenhouse gas than carbon
dioxide.
[0014] The inventor has recognized that NOx could be significantly
reduced if a technique were available to reduce or eliminate the
nitrogen being introduced into the catalytic converter 160 by the
air blower 170. The inventor has also recognized that the amount of
unburned hydrocarbons could be significantly reduced if a technique
were available to reduce or eliminate the nitrogen being introduced
into the internal combustion chamber of the internal combustion
engine 110.
[0015] As can be seen from FIG. 1, the unburned hydrocarbons
exiting the internal combustion engine 110 represent chemical
energy that has been unconverted into heat energy. Once the
unburned hydrocarbons are delivered to the catalytic converter,
they are converted into heat energy. However, such heat energy is
not converted into kinetic energy and, therefore, cannot be
converted into mechanical energy (or, ultimately, electric energy
in the case of a power plant). In other words, no useful work is
performed by the unburned hydrocarbons with respect to powering the
drive shaft 150. The inventor has recognized that the amount of
useful work associated with powering the drive shaft 150 can be
increased if a technique were available to more completely burn a
higher percentage of the fuel in the combustion chamber of the
internal combustion engine 110, so that significantly less unburned
hydrocarbons were expelled from the combustion chamber of the
internal combustion engine 110.
[0016] Referring still to FIG. 1, unused heat energy is also
delivered from the combustion chamber of the internal combustion
engine 110 to the catalytic converter 160--the greater the
percentage of unburned hydrocarbons, the greater the percentage of
waste heat (i.e., heat that is not converted into mechanical
energy). The inventor has recognized that the amount of useful work
associated with powering the drive shaft 150 can be increased if a
technique were available to more completely burn a higher
percentage of the fuel in the combustion chamber of the internal
combustion engine 110, thereby reducing the amount, of waste heat
expelled from the combustion chamber of the internal combustion
engine 110.
[0017] In addition, waste heat is absorbed by the internal
components of the combustion chamber (e.g., the heads, the pistons,
the exhaust valve, the intake valve, the cylinder walls, etc.) of
the internal combustion engine. The inventor has recognized that
the amount of useful work associated with powering the drive shaft
150 can be increased if a technique were available to recover the
potential energy associated with the waste heat absorbed by the
internal components of the combustion chamber of the internal
combustion engine 110.
[0018] FIG. 2 is a simplified and enlarged cross-sectional view of
a portion of a conventional internal combustion engine 200
illustrating an engine block 210, a cylinder 212, a head assembly
214, a combustion chamber 216, a piston 218 (including a head
portion 220 and a skirt 222), a rod 224, a wrist pin 226, a first
metallic compression ring 230, a second metallic compression ring
238, a metallic oil ring 239, an intake manifold 242, an exhaust
manifold 244, an intake valve 246, an exhaust valve 248 and a spark
plug 250. FIG. 3 is a cross-sectional view taken along line 3-3 of
FIG. 2, which illustrates a cross-section of the piston 218, wrist
pin 226 and rod 224. FIG. 4 is a magnified view of a portion of
FIG. 3, which illustrates the first metallic compression ring 230
and the second metallic compression ring 238, without showing its
metallic oil ring 239. FIG. 5 is a diagrammatic representation of
piston positions inside a cylinder of a conventional four-stroke
engine and associated valve positions.
[0019] The operation of internal combustion engine 200 is
well-known and, therefore, will only be briefly described. With
reference to FIGS. 2-5, the piston 218 starts at top dead center.
Top dead center is the position of the piston shown in FIG. 2,
without regard to the opening or closing of the intake valve 246 or
the exhaust valve 248.
[0020] The suction stroke begins when the piston 218 moves
downwardly as a cam (not shown) simultaneously opens the intake
valve 246 (with the exhaust valve 248 closed), so that the air/fuel
mixture is drawn into the cylinder 212 by the suction created by
movement of the piston 218 (see FIG. 5). Once the piston 218
reaches bottom dead center, the intake valve 246 is closed and the
exhaust valve 248 remains closed, thereby ending the suction stroke
and beginning the compression stroke.
[0021] During the compression stroke, the piston 218 moves
upwardly, thereby compressing the air/fuel mixture. The compression
stroke ends and the power stroke begins when the piston 218 reaches
top dead center, again with both the intake valve 246 and the
exhaust valve 248 closed.
[0022] During the power stroke, the spark plug 250 fires, which
ignites the fuel and creates the energy sufficient to thrust the
piston 218 downward. The power stroke ends and the exhaust stroke
begins when the piston 218 reaches bottom dead center.
[0023] During the exhaust stroke, a cam (not shown) is used to open
the exhaust valve 248, when the piston 218 is at bottom dead
center. As the piston 218 moves upwardly, products of combustion
are pushed out of the cylinder (past the exhaust valve 248) and
into the exhaust manifold 244. Ultimately, after the piston has
reached top dead center (i.e., the end of the exhaust stroke), most
of the products of combustion are delivered to a catalytic
converter 160 (see FIG. 1), where a second combustion takes place,
during which attempts are made to burn the unburned
hydrocarbons.
[0024] The exhaust stroke ends when the piston 218 is at top dead
center and the exhaust valve 248 is closed and the intake valve 246
is simultaneously opened. The 4-cycle process is complete and the
process begins again with the next suction stroke.
[0025] As seen in FIG. 4, the first metallic compression ring 230
is located in first annular groove 228 in the piston 218 and the
second, metallic compression ring 238 is located in second annular
groove 236 in the piston 218. The first and second metallic
compression rings 230, 238 each extend beyond the outer diameter of
the piston and are designed to contact the cylinder wall 212 (see
FIG. 2).
[0026] Because of temperature changes in cylinder 212, the first
and second metallic rings 230, 238 are made of spring steel that is
designed to expand and contract. The first and second metallic
rings 230, 238 each include a gap 252, as shown in FIG. 6. The gap
252 closes as the temperature inside the cylinder 212 increases.
Conversely, the gap 252 opens as the temperature inside the
cylinder 212 decreases. More specifically, when the piston 218 is
heated and expands, the first and second metallic rings 230, 238
are forced against the cylinder wall 212, which, squeezes the
spring steel, thereby reducing the size of the gap 252.
[0027] The first and second metallic rings 230, 238 each have a
height 254, 256 (respectively). Because the height, of the first
metallic ring 230 expands due to the heat, in the cylinder 212, the
first metallic ring 230 is not tightly seated in the first annular
groove 228. (Likewise, the second metallic ring 238 is not tightly
seated in the second annular groove 236.) Accordingly, some
tolerance (not shown) is provided between the height of the first
annular groove 228 and the height of the first metallic ring 230.
If sufficient tolerance were not provided, the friction between the
upper/lower surfaces of the first metallic ring 230 and the
corresponding surfaces of the first annular groove 228 would
prevent the gap 252 of the first metallic ring 230 from closing at
higher temperatures. Therefore, the friction between the metallic
ring 230 and the cylinder wall 212 would increase, causing the
engine to cease (not unlike what would occur if the engine lost its
engine coolant or engine oil).
[0028] The tolerance between the first metallic ring 230 and the
first annular groove 228 (and, likewise, the tolerance between the
second metallic ring 238 and the second annular groove 236) allows
for blow-by, which causes a number of problems each of which damage
the engine. For example, during the suction stroke, blow-by of the
air/fuel mixture through the gap between the piston 218 and the
cylinder wall 212 into the crankcase (not shown, but below the
piston 218) both reduces the volumetric efficiency of the engine
(thereby reducing fuel economy) and gives rise to the need of a PCV
valve 180 (see FIG. 1) to extract oil and fuel vapors from the
crankcase.
[0029] During the compression stroke, hydrocarbons (such as oil
vapors and fuel vapors) are drawn up from the crankcase into the
combustion chamber after blowing-by the first metallic compression
ring and the second metallic compression ring 230, 238. The oil in
the crankcase is designed to lubricate the cylinder wall 212, while
resisting combustion. Accordingly, oil vapors similarly are
designed to resist combustion, whereas fuel vapors are designed to
burn. Unfortunately, the oil vapors are mixed with the air/fuel
mixture that is being prepared for combustion during the
compression stroke. Some of the oil vapors become attached to the
internal components of the combustion chamber (e.g., the piston
head 220, bottom of the intake valve 246, the bottom of the exhaust
valve 248, the spark plug 250, etc.). In addition, some of the oil
vapors become affixed to the first and second compression rings
230, 238.
[0030] During the power stroke, the oil vapors that are mixed with
the air/fuel mixture result in incomplete combustion. Specifically,
the portion of the air/fuel mixture that does not burn leads to the
production of unburned hydrocarbons, among other things. Similarly,
the portion of the oil vapors that does not burn also leads to the
production of unburned hydrocarbons, among other things. Because
the oil vapors are not designed to burn, they interfere with the
efficient movement of the flame front, which leads to further
incomplete combustion of the air/fuel mixture causing even more
unburned hydrocarbons and a reduction in kinetic energy.
[0031] Still during the power stroke, some unburned hydrocarbons
and unburned air/fuel mixture are, blown-by the rings into the
crankcase causing additional oil vapors, while other unburned
hydrocarbons become attached to the first and second metallic rings
230, 238 before they can reach the crankcase. Because the
temperature of the unburned hydrocarbons and the air/fuel mixture
is high relative to the temperature during the suction stroke, the
amount of oil vapors that is produced during the power stroke is
generally greater than the amount of oil vapors produced during the
suction stroke. This gives rise to a greater need for a PCV valve
180. It should also be noted that unburned hydrocarbons can also
become attached to the piston head 220 and the cylinder walls 212
during the power stroke.
[0032] During the exhaust stroke, oil vapors and fuel vapors are
drawn up from the crankcase by the rising piston 218. Some of the
oil vapors attach themselves to the first and second metallic
compression rings 230, 238 and to the first and second annular
grooves 228, 236. Other oil vapors blow-by the rings on their way
into the combustion chamber 216 and, along with unburned
hydrocarbons (i.e., those hydrocarbons that have been exposed to
the combustion process), become attached to the internal components
of the engine including the cylinder wall 212, the piston head 220,
bottom of the intake valve 246, the bottom of the exhaust valve
248, the bottom of the head assembly 214, the spark plug 250, the
valve seat of the exhaust valve and the exhaust manifold 244 (and,
if present, fuel injectors). Because the oil vapors and unburned
hydrocarbons are not evenly distributed on the seat of the exhaust
valve, the exhaust valve 248 may leak.
[0033] As a result of the oil vapors and unburned hydrocarbons
sticking to the internal components of the engine, along with heat
radiating from the exhaust valve 248, problems may be caused such
as pre-ignition, dieseling, knock, ping, and shockwaves, resulting
in additional blow-by and damage to the engine. Ultimately, this
results in reduced fuel economy, reduced power, increased
pollution, increased engine wear and the need for increased
maintenance.
[0034] Blow-by also causes other problems in the engine. Because
the chemistry of the unburned hydrocarbons is equal to sand and
glass in its abrasiveness, when the unburned hydrocarbons mix with
the oil in the crank case, the viscosity of the oil is broken down.
Instead of the oil lubricating moving parts of the engine, the oil
becomes a medium for transporting the unburned hydrocarbons to the
moving parts, thereby creating excessive wear of such moving
parts.
[0035] The unburned hydrocarbons in the oil and the unburned
hydrocarbons on the cylinder wall 212 may also plug-up the orifices
of the oil ring 239 (see FIG. 3), thereby rendering the oil ring
239 inoperable. Therefore, the oil ring 239 is unable to deliver a
sufficient amount of oil through at least some of its orifices to
locations along the cylinder wall 212. At such locations, the
metal-to-metal contact between the skirt 222 of the piston 218 may
cause scoring of the cylinder wall 212 or cause wear of the skirt
222 of the piston 218 (resulting, for example, in piston slap).
Furthermore, the metal-to-metal contact between the first and
second metallic compression rings 230, 238 and the cylinder wall
212 at such locations may cause wearing of the first and second
metallic compression rings 230, 238, scoring of the cylinder wall
212 or ceasing of the engine. The scoring of the cylinder wall 212,
the wearing of the skirt 222 of the piston 218 and the wearing of
the first and second metallic compression rings 230, 238, all
result in further blow-by.
[0036] Furthermore, the unburned hydrocarbons that are attached to
the first and second metallic compression rings 230, 238 and that
are lodged in the first and second annular grooves 228, 236, reduce
the effectiveness of the first and second metallic compression
rings 230, 238 (e.g., requiring a ring job), since they cannot open
and close their gaps 252 properly. Therefore, the first and second,
metallic compression rings 230, 238 may break, wear, or cause
scoring of the cylinder wall 212. Accordingly, blow-by is
increased, thereby further exacerbating the problem and
accelerating the demise of the engine.
[0037] The inventor of the present invention has recognized that
fuel efficiency will be increased, power will be increased,
pollution will be reduced, engine life will be lengthened,
maintenance costs will be reduced, and superfluous parts can be
eliminated (e.g., catalytic converter 160, air blower 170, PCV
valve 180 and the sensors and computing power associated with the
regulation of such items, thereby reducing the cost and the weight
of the engine and saving space), if a technique were available to
reduce or eliminate blow-by.
[0038] Because engines similar to the one shown in FIGS. 2-6 use
first and second metallic compression rings which engage the
cylinder wall, the design of such engines is limited due to the
contact area between the metal rings and the cylinder wall. For
example, friction is exponentially increased as the diameter of the
cylinder is increased, since the contact area between the metal
rings and the cylinder wall is exponentially increased. Also, the
likelihood and amount of blow-by will increase (as will the
likelihood of the problems associated with blow-by, discussed
above), since the area in which blow-by may occur is also
exponentially increased when the diameter of the cylinder is
increased. Furthermore, as the length of the stroke of the piston
inside the cylinder is increased, the friction between the metal
rings and the cylinder wall will exponentially increase, since the
contact area between the metal rings and cylinder wall
exponentially increases.
[0039] In order to reduce the friction and blow-by in each
individual cylinder, cylinder sizes and stroke lengths are designed
to be relatively small. However, in order to increase the amount of
power associated with each individual cylinder, the average
velocity of the piston (per stroke) inside of the cylinder must be
correspondingly increased. As a consequence of increasing the
average velocity of the piston, the amount of friction per unit
time increases and the temperature increases (giving rise to
possibility of the formation of oxides of nitrogen, which forces
the engine designer to reduce the compression ratio by engine
redesign).
[0040] Furthermore, in order to provide sufficient power for the
engine as a whole, a larger number of cylinders is required,
thereby increasing the number of component parts, increasing the
space required for such parts, increasing the weight (which reduces
fuel economy), increasing the maintenance and increasing the cost.
Even further, the increased number of cylinders increases the
collective amount of friction, the collective amount of heat loss
and the collective amount of blow-by (and their associated
problems, discussed above).
[0041] The inventor of the present invention has recognized that it
would be beneficial to provide an engine that maintained or
increased the amount of power per cylinder while decreasing the
average velocity of the piston (per stroke) inside of the cylinder,
so that the total number of cylinders could be reduced, the number
of component parts could be reduced, the collective space required
could, be reduced, the weight could be reduced, the fuel economy
could be increased, the collective amount of maintenance could be
reduced, the relative cost could be reduced, the collective amount
of friction could be reduced, the collective amount of heat loss
could be reduced, the collective amount of blow-by (and its
associated problems, discussed above) could be reduced and the
collective amount of pollution could be reduced.
[0042] In the 1970's and 1980's, in an effort to reduce blow-by,
the inventor of the present invention researched, developed and
tested an internal combustion engine. More specifically, the
inventor modified an existing Chevrolet V-8 engine and incorporated
his technology. Although features of the inventor's modified engine
are described below, the inventor does not necessarily admit that
such engine is "prior art," as such term is legally defined.
[0043] The inventor's modified engine differed from the internal
combustion engine discussed in FIGS. 2-6. Specifically, instead of
having a second metallic compression ring 238 of FIGS. 2-4, a
non-metallic ring assembly 738 (shown in FIG. 7) was used. Neither
the first metallic compression ring 230, nor the oil ring 239 was
replaced. In addition, the cylinder was slightly bored-out
(approximately 0.060 inch) and had a smooth, mirror-like
finish.
[0044] FIG. 7 is a simplified, enlarged and exaggerated
diagrammatic representation of a portion of a cylinder wall 712, a
portion of a piston 218, a gap 232 between the cylinder wall 712
and the piston 218, an annular groove 736 and a non-metallic ring
assembly 738. The non-metallic ring assembly 738 includes a
generally T-shaped (in cross-section) Rulon ring 740 and a Viton
O-Ring 742.
[0045] The Rulon ring 740 has a front 744, which contacts the
cylinder wall 712 as the bearing area, and a back 746 which is that
surface furthest from the cylinder wall 712. The height of the back
746 of the Rulon ring 740 is approximately twice the height of the
front 744 of the Rulon ring 740.
[0046] The Viton O-Ring 742 operates as a spring against the Rulon
ring 740 and pre-loads the Rulon ring 740 against the cylinder wall
712. The Viton O-Ring 742 sits in the area between the back 746 of
the Rulon ring 740 and the back 748 of the annular groove 736. When
heated and under pressure, the Viton O-Ring 742 acts
hydrostatically.
[0047] A system pressure (either positive or negative, depending on
the stroke of the engine) is created in the gap 232 between the
cylinder wall 712 and the piston 218. The bearing pressure
associated with the pre-load is sufficient to direct the system
pressure between the back 746 of the Rulon ring 740 and the back
748 of the annular groove 736, taking the path of least
resistance.
[0048] The Viton O-Ring 742, acting hydrostatically, moves to the
top or bottom of the Rulon ring (depending on whether the system
pressure is positive or negative) and operates as a check valve to
prevent the system pressure from flowing thereby. Thus, the Viton
O-Ring 742 prevents any blow-by behind the non-metallic ring
assembly 738 (through the annular groove 736) into the crankcase or
the combustion chamber 216, depending upon whether the system
pressure is positive or negative.
[0049] The moments of force associated with the system pressure are
directed (perpendicularly) from the back 746 of the Rulon ring 740
toward the front 744 of the Rulon ring 740. Since the back 746 of
the Rulon ring 740 is approximately twice the height of the front
744 of the Rulon ring 740, the force against the cylinder wall 712
is amplified and is approximately twice the force of the system
pressure, which prevents any blow-by between the Rulon ring 740 and
the cylinder wall 712. In view of the above, it can be seen that
the non-metallic ring assembly 738 prevents blow-by, either at the
bearing area or at the back the non-metallic ring assembly,
regardless of whether the system pressure is from the combustion
chamber 216 towards the crankcase or from the crankcase towards the
combustion chamber 216, completing a universal seal.
[0050] The force in the bearing area is dependent upon the system
pressure, since the system pressure is directed behind the Rulon
ring 740. Accordingly, the force in the bearing area will change
depending upon the system pressure. Thus, the greater the system
pressure, the higher the bearing pressure (and visa-versa).
Therefore, the non-metallic ring assembly 738 forms a dynamic
seal.
[0051] One of the problems with the non-metallic ring assembly 738
shown in FIG. 7 is that oil vapors (from the oil on the cylinder
walls 712 and the oil from the crankcase) and unburned hydrocarbons
(from the fossil fuels) find their way to the back 746 of the Rulon
ring 740. This can cause the Viton O-Ring 742 to become dirty and
can cause the Viton O-Ring 742 to lose its ability to perform as a
check valve. Furthermore, the Viton O-Ring 742 can lose its elastic
spring-like qualities, thus not providing an adequate pre-load.
Accordingly, over time, the non-metallic ring assembly may allow
blow-by both near the front 744 of the Rulon ring 740 (i.e., the
front of the non-metallic ring assembly 738) and near the Viton
O-Ring 742 (i.e., the back of the non-metallic ring assembly
738).
[0052] In addition to the changes described above, the inventor's
modified engine also used a larger flywheel (not shown) that the
flywheel used in the unmodified Chevrolet V-8 engine. Furthermore,
the flywheel had a greater amount of weight concentrated near its
periphery than the flywheel of the unmodified Chevrolet V-8
engine.
[0053] The inventor's modified engine was subjected to an emissions
test and the modified engine passed such test. However, more
impressively, the inventor's modified engine passed the emissions
test without a catalytic converter or an air blower.
[0054] On Jan. 4, 2005, the inventor of the present invention was
awarded U.S. Pat. No. 6,837,205, which is entitled "Internal
Combustion Engine" and which was filed on Oct. 28, 2002. U.S. Pat.
No. 6,837,205 is incorporated herein, by reference.
[0055] In an effort to reduce the potential for blow-by described
in connection with the non-metallic ring assembly of FIG. 7, U.S.
Pat. No. 6,837,205 discloses a first, compression ring assembly 800
(although the aforementioned term is not used in the patent) and a
non-metallic compression ring 838. No change was made to the oil
ring.
[0056] As shown in FIG. 8, the first compression ring assembly 800
is received in first annular groove 828 of piston 818 and includes
first and second outer metallic rings 830, 832, with gaps (like gap
252 in FIG. 6) that are oriented 180 degrees apart to reduce
blow-by through the gaps. In addition, the first compression ring
assembly 800 includes a non-metallic O-ring 834, which positively
urges the first and second outer metallic rings 830, 832 into
contact with the cylinder wall 812. The O-ring 834 also operates as
a check valve in an effort to reduce blow-by.
[0057] The non-metallic compression ring 838 is non-gapped, so as
to provide for the preloading thereof, and essentially prevents any
blow-by. The height of non-metallic compression ring 838 is the
same as the height of the annular groove 836 in which it is seated,
so as to prevent any foreign materials from getting between the
non-metallic compression ring 838 and the annular groove 836.
[0058] There can be problems associated with both the first
compression ring assembly 800 and the non-metallic compression ring
838 shown in FIG. 8. For example, one of the problems with, the
first compression ring assembly 800 is that there is metal-to-metal
contact between the outer metallic rings 830, 832 and the cylinder
wall 812. This creates friction and heat, and requires oil as a
lubricant. Furthermore, friction from the oil ring (not shown in
FIG. 8) and the piston skirt (not shown in FIG. 8) exacerbate the
problem.
[0059] In addition, one of the problems with the non-metallic
compression ring 838 is that the inherent characteristics of the
non-metallic compression ring 838 are the sole provider of the
pre-load of the non-metallic compression ring 838 against the
cylinder wall 812. Because of the friction from the metal cylinder
walls, the non-metallic compression ring 838 will begin to wear,
thereby reducing the pre-load. Once the pre-load has been
sufficiently reduced, it becomes difficult to stop blow-by.
[0060] Accordingly, there is a need for a revolutionary engine that
can solve some or all of the problems described above.
SUMMARY OF THE INVENTION
[0061] The present invention is designed to solve at least one or
more of the above-mentioned problems.
[0062] In an engine, blow-by is substantially eliminated and
friction is significantly reduced using one or more combinations of
non-metallic rings. By substantially eliminating blow-by and by
reducing friction, certain engine parameters may be changed. In
addition, by substantially eliminating blow-by and by reducing
friction, pollution may be reduced, fuel economy may be increased
and power may be increased.
[0063] Embodiments of the present invention enhance existing hybrid
technologies, such as fuel-electric hybrid technologies.
Embodiments of the present invention enable new hybrid (or
"tribrid") technologies to be used, such as fuel-steam hybrid
technologies or fuel-steam-electric "tribrid" technologies.
[0064] Engines described in one or more of the various embodiments
can be used in a large number of environments including, for
example, cars, trucks, airplanes, power plants, trains, ships,
boats, buses, motorcycles, mopeds, snowmobiles, chainsaws and
lawnmowers, among others.
[0065] Other embodiments, objects, features and advantages of the
invention will be apparent from the following specification taken
in conjunction with the following drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0066] FIG. 1 is a simplified block diagram of a system that
includes an internal combustion engine, a catalytic converter and
certain associated components;
[0067] FIG. 2 is a simplified and enlarged cross-sectional view of
a portion of a conventional internal combustion engine;
[0068] FIG. 3 is a cross-sectional view taken along line 3-3 of
FIG. 2;
[0069] FIG. 4 is a magnified view of a portion of FIG. 3;
[0070] FIG. 5 is a diagrammatic representation of piston positions
inside a cylinder of a conventional four-stroke engine and,
associated valve positions;
[0071] FIG. 6 is an enlarged diagrammatic representation of a
metallic compression ring having a gap;
[0072] FIG. 7 is an enlarged and exaggerated diagrammatic
representation, in cross-section, of a non-metallic ring assembly,
along with a portion of a piston and a portion of a cylinder;
[0073] FIG. 8 is a magnified view (somewhat similar to FIG. 4) of a
cross-sectional view of a portion of a piston and a portion of a
cylinder;
[0074] FIG. 9 is an enlarged and exaggerated diagrammatic
representation, in cross-section, of a non-metallic ring assembly,
a portion of a piston and a portion of a cylinder in accordance
with an embodiment of the present invention;
[0075] FIG. 10A is an enlarged diagrammatic representation of a
cross-section of a second non-metallic ring;
[0076] FIG. 10B is a diagrammatic representation of a top view of a
second non-metallic ring showing a split in, the second
non-metallic ring;
[0077] FIG. 10C is an, enlarged, three dimensional, diagrammatic
representation of a portion of a second non-metallic ring having a
split;
[0078] FIG. 11 is a simplified and enlarged cross-sectional view of
a portion of an internal combustion engine in accordance with an
embodiment of the present invention;
[0079] FIG. 12 is an enlarged and exaggerated diagrammatic
representation, in cross-section, of a non-metallic guide ring, a
portion of a piston and a portion of a cylinder in accordance with
an embodiment of the present invention;
[0080] FIG. 13A is an enlarged diagrammatic representation of a
cross-section of a non-metallic guide ring;
[0081] FIG. 13B is a diagammatic representation of a top view of a
non-metallic guide ring showing a split in the non-metallic guide
ring;
[0082] FIG. 13C is an enlarged, three dimensional, diagrammatic
representation of a portion of a non-metallic guide ring having a
split;
[0083] FIG. 14 is an enlarged and exaggerated diagrammatic
representation, in cross-section, of a non-metallic guide button, a
portion of a cylinder wall and a portion of a piston in accordance
with an embodiment of the present invention;
[0084] FIG. 15 is an enlarged and exaggerated diagrammatic
representation of a non-metallic ring assembly, a portion of a
cylinder wall and a portion of a piston in accordance with an
embodiment of the present invention;
[0085] FIG. 16A is an enlarged and exaggerated diagrammatic
representation, in cross-section, of a portion of a piston, a
portion of a cylinder, and a pair of non-metallic guide rings and a
non-metallic ring assembly in the same ring groove in accordance
with an embodiment of the present invention;
[0086] FIG. 16B is an enlarged and exaggerated diagrammatic
representation, in cross-section, of a portion of a piston, a
portion of a cylinder, and a pair of non-metallic guide rings and
anon-metallic ring assembly in a channeled ring groove in
accordance with an embodiment of the present invention;
[0087] FIG. 17 is an enlarged and exaggerated diagrammatic
representation, in cross-section, of a portion of a piston, a
portion of a cylinder, a first non-metallic guide ring and a first
non-metallic ring assembly in a first ring groove, and a second
non-metallic guide ring and a second non-metallic ring assembly in
a second ring groove in accordance with an embodiment of the
present invention; and,
[0088] FIG. 18 is a diagrammatic representation of a cross-section
of a cylinder wall that is coated with anon-metallic coating in
accordance with one embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0089] While this invention is susceptible of embodiments in, many
different forms, there are shown in the drawings and will herein be
described in detail, preferred embodiments of the invention with
the understanding that the present disclosure is to, be considered
as an exemplification of the principles of the invention and is not
intended to limit the broad aspects of the invention to the
embodiments illustrated.
[0090] FIG. 9 is an enlarged and exaggerated diagrammatic
representation of a portion of a cylinder wall 912, a portion of a
piston 918, a ring groove 928, a gap 932 between the cylinder wall
912 and the piston 918, and a non-metallic ring assembly 960. The
piston 918 is designed to reciprocate within a cylinder formed by
cylinder wall 912.
[0091] The non-metallic ring assembly 960 includes a first
non-metallic ring 962 and a second non-metallic ring 964 that are
received in the ring groove 928. The first non-metallic ring 962
biases the second non-metallic ring 964 towards the cylinder wall
912. The second non-metallic ring 964 contacts the cylinder wall
912 and a static force (as opposed to a dynamic force like that
described in connection with FIG. 7) is applied at a bearing area
between the second non-metallic ring 964 and the cylinder wall 912
in cooperation with the first non-metallic ring 962.
[0092] That is, in contrast to FIG. 7, the first non-metallic ring
962 and the second non-metallic ring 964 are not designed to
purposely allow the system pressure in the gap 932 to be directed
behind the second non-metallic ring 964 to change the force between
the second non-metallic ring 964 and the cylinder wall 912
depending upon the system pressure. Accordingly, in the embodiment
shown in FIG. 9, the force at the bearing area between the second
non-metallic ring 964 and the cylinder wall 912 does not increase
as the system pressure increases. Therefore, the non-metallic ring,
assembly 960 forms a static, as opposed to a dynamic, seal in
cooperation with the cylinder wall 912.
[0093] FIG. 10A is an enlarged diagrammatic representation of a
cross-section of the second non-metallic ring 964. As shown in FIG.
10A, the second non-metallic ring 964 has a front 966 having a
height 968 and has a back 970 having a height 972. In contrast to
the Rulon ring 740 shown in FIG. 7, the height 968 of the front 966
of the second non-metallic ring 964 is approximately equal to the
height 972 of the back 970 of the second non-metallic ring 964.
Furthermore, as shown in FIG. 9, the ring groove 928 has a height
974 that is designed to snugly receive the second non-metallic ring
964, which reduces the likelihood of the first non-metallic ring
962 from becoming dirty (e.g., by being contacted with oil vapors
and unburned hydrocarbons).
[0094] It should be understood that the ring groove 928 does not
necessarily have to have a substantially constant height 974.
Accordingly, in one embodiment, if the ring groove 928 did not have
a substantially constant height, the second non-metallic ring 964
would have at least one height which would cause at least a portion
of the second non-metallic ring 964 to be snugly received by the
ring groove 928.
[0095] It should be understood that the height 968 of the front 966
of the second non-metallic ring 964 does not have to be
substantially equal to the height 972 of the back 970 of the second
non-metallic ring 964. In one embodiment, the height 972 of the
back 970 of the second non-metallic ring 964 is greater than the
height 968 of the front 966 of the second non-metallic ring 964. In
another embodiment, the height 972 of the back 970 of the second
non-metallic ring 964 is less than the height 968 of the front 966
of the second non-metallic ring 964.
[0096] Returning to FIG. 9, the first non-metallic ring 962
provides a pre-load for the second non-metallic ring 964 to
compensate for wear of the second non-metallic ring 964, which
increases the useful life of the second non-metallic ring 964. This
is to be contrasted to the non-metallic compression ring 838 of
FIG. 8, which does not have any other mechanism to compensate for
wear other than by using its inherent characteristics.
[0097] Furthermore, the first non-metallic ring 962 operates as a
check valve when under pressure. For example, if system pressure
makes its way from the front 966 of the second non-metallic ring
964 to the back 970 of the second non-metallic ring 964 along the
top 976 of the second non-metallic ring 964, the first non-metallic
ring 962 prevents such system pressure from returning to the front
966 of the second non-metallic ring 964 along the bottom 978 of the
second non-metallic ring 964. Of course, if system pressure makes
its way from the front 966 of the second non-metallic ring 964 to
the back 970 of the second non-metallic ring 964 along the bottom
978 of the second non-metallic ring 964, the first non-metallic
ring 962 prevents such system pressure from returning to the front
966 of the second non-metallic ring 964 along the top 976 of the
second non-metallic ring 964.
[0098] Preferably, the first non-metallic ring 962 is a gapless
(i.e., continuous) ring which is made of a rubber or rubber-like
material, has spring-like qualities and can act as a check valve
when under pressure. (It should be understood, however, that the
first non-metallic ring does not have to have the shape of an "O"
in cross-section and can take a variety of different shapes
including, e.g., a "D-shape" in cross-section or a rectangular
shape in cross-section, among others.) In addition, the first
non-metallic ring 962 can, preferably, operate efficiently at
temperatures of up to about 550 degrees Fahrenheit and, preferably,
can withstand temperatures of about 600 degrees Fahrenheit. It
should be understood that the above temperatures are not
necessarily limiting, as other temperatures are possible.
Furthermore, the first non-metallic ring 962 is preferably soft
(e.g., capable of being stretched over the piston 918) and has
memory (i.e., will return to its original shape when cooled or when
pressure is reduced). The first non-metallic ring 962, for example,
can be made of a high-temperature fluoroelastomer, such as
Viton.
[0099] The second non-metallic ring 964 is, in one embodiment, a
gapless (i.e., continuous) ring that can operate efficiently at
temperatures of up to about 550 degrees Fahrenheit and preferably,
can withstand temperatures of about 600 degrees Fahrenheit. It
should be understood that the above temperatures are not
necessarily limiting, as other temperatures are possible. In
addition, the second non-metallic ring 964, preferably, has a
relatively low coefficient of friction. Furthermore, in one
embodiment, the second non-metallic ring 964 should be capable of
being stretched when heated (e.g., when it is being stretched over
piston 918 for installation) but should also have memory, so that
when it is cooled it returns to its original shape.
[0100] Preferably, the second non-metallic ring 964 is made of a
fluoroplastic or fluoropolymer material. For example, the second
non-metallic ring may be a rubber-like plastic material such as, or
similar to, the materials in the fluoroplastic and fluoropolymer
families that include products such as Poly Tetra Fluoro Ethylene
(PTFE), Teflon (a DuPont product) and Rulon (a St. Gobain
product).
[0101] Instead of providing one non-metallic ring assembly 960, a
plurality of non-metallic ring assemblies 960 may be provided,
e.g., in a corresponding plurality of ring grooves 928.
Furthermore, instead of being gapless rings, it should be
understood that one or both of the first and second non-metallic
rings 962, 964 may include a gap or may include a split.
[0102] As alluded to above, in order to install the (gapless)
second non-metallic ring 964, it may be heated, so that it can be
stretched over the piston 918. In one example, if the second
non-metallic ring 964 is made of Rulon, it may be heated to about
200 degrees Fahrenheit. (Of course, if the second non-metallic ring
964 was made of another material, it may require heating to a
different temperature.) Then, it is stretched over the piston 918
(e.g., by hand) and into its ring groove 928. The second
non-metallic ring 964 is placed in front (i.e., closer to the
cylinder wall 912) of the first non-metallic ring 962, which will
already have been placed in the ring groove 928. Alternatively, the
(gapless) first non-metallic ring 962 and the (gapless) second
non-metallic ring 964 can be stretched over the piston and
installed into the ring groove 928 together. The second
non-metallic ring 964 is allowed to cool, so that it can return to
its normal size and shape. A standard ring cylinder (not shown) is
used, to compress the second non-metallic ring 964, so that the
piston 918 can be installed in its cylinder.
[0103] As another alternative, a generally frustoconically-shaped
jig (not shown) can be used to install one or both of the first and
second non-metallic rings 962, 964 into the ring groove 928, if
they are gapless. One or both of the first and second non-metallic
rings 962, 964 are heated. Then, the first and second non-metallic
rings 962, 964 are stretched, using the jig, to an adequate size
and are slid over the piston 918 into the ring groove 928. The
second non-metallic ring 964 is allowed to cool, so that it can
return to its normal size and shape. A standard ring cylinder is
used to compress the second non-metallic ring 964, so that the
piston 918 can be installed in its cylinder.
[0104] In another embodiment, one or both of the first and second
non-metallic rings 962, 964 may include a split. FIG. 10B is a
diagrammatic representation of a top view of a second non-metallic
ring 964A that includes a split 1000. FIG. 10C is an enlarged,
three-dimensional, diagrammatic representation of a portion a
second non-metallic ring 964A that includes a split 1000. Using a
second non-metallic ring 964A that has a split 1000 makes the
second non-metallic ring 964A more sensitive to pressure being
applied by the first non-metallic ring 962 (relative to a gapless,
second non-metallic ring 964). Thus, the split second non-metallic
ring 964A is more capable of remaining in contact with the cylinder
wall 912, especially if it needs to follow any irregularities in
the cylinder wall 912 (due to, e.g., changes in shape of the
cylinder wall 912 or scoring in the cylinder wall 912). In
addition, including a split 1000 in the second non-metallic ring
964A can make installation of the second non-metallic ring 964A
easier.
[0105] As shown in FIG. 10C, in one embodiment, the split 1000
extends from the top 976 to the bottom 978 of the second
non-metallic ring 964A (or visa-versa) at an angle that is
different from 90 degrees relative to the top 976 of the second
non-metallic ring 964A. When installed inside the ring groove 928,
the snug fit of the second non-metallic ring 964A effectively seals
the split 1000.
[0106] In one embodiment, the angle of the split 1000 is about 22
degrees relative to the top 976 of the second non-metallic ring
964A. In another embodiment, the angle of the split 1000 is about
45 degrees relative to the top 976 of the second non-metallic ring
964A. Of course, other angles are possible and anticipated.
[0107] The split 1000 may be made, for example, using a
computer-controlled cutting tool. Alternatively, the second
non-metallic ring 964A may be manufactured with a split 1000.
[0108] In one embodiment, one or more gapless non-metallic rings,
like second non-metallic ring 964, can be placed adjacent to a
split second non-metallic ring 964A in the same ring groove 928.
Using such a configuration can reduce the amount of system pressure
experienced by the split 1000. One or more first non-metallic rings
962 may be provided to bias the continuous and split second
non-metallic rings 964, 964A. In one embodiment, a first
non-metallic ring 962 may not be provided.
[0109] In one embodiment, one split second non-metallic ring 964A
is located in a first ring groove that is proximate the head (e.g.,
head 214) and another split second non-metallic ring 964A is
located in a second ring groove distal the head. In such case, a
gapless second non-metallic ring 964 is placed in the first ring
groove in a position closer to the head relative to the split
second non-metallic ring 964A in such ring groove. Another gapless
second non-metallic ring 964 can be placed in the second ring
groove in a position farther from the head relative, to other split
second non-metallic ring 964.
[0110] In one embodiment, two split second non-metallic rings 964A
are placed in the same ring groove with their splits 1000 offset
from one another. In one embodiment, the splits 1000 are offset 180
degrees from one another.
[0111] FIG. 11 is used to describe some other embodiments of the
present invention. FIG. 11 is a simplified and enlarged
cross-sectional view of a portion of an internal combustion engine
1100 illustrating an engine block 1110, a cylinder 1112, a head
assembly 1114, a combustion chamber 1116, a piston 1118 (including
a head portion 1120 and a skirt 1122), a rod 1124, a wrist pin
1126, an intake manifold 1142, an exhaust manifold 1144, an intake
valve 1146, an exhaust valve 1148, a spark plug 1150, a first ring
groove 928, a non-metallic ring assembly 960, a second ring groove
1180, a non-metallic guide ring 1182, a third ring groove 1184, an
oil ring 1186, a first guide-button recess 1188, a first
non-metallic guide button 1190, a second guide-button recess 1192
and a second non-metallic guide button 1194.
[0112] In contrast to the conventional internal combustion engine
shown in FIG. 2, the internal combustion engine 1100 of FIG. 11
does not, include first and second metallic compression rings 230,
238. Furthermore, unlike the internal combustion engines described
in connection with FIGS. 7 and 8, no metallic compression rings are
used in the internal combustion engine 1100 of FIG. 11.
[0113] Instead, the engine 1100 includes a non-metallic ring
assembly 960, a non-metallic guide ring 1182, a first non-metallic
guide button 1190 and second non-metallic guide button 1194. The
latter three of which are primarily used to guide the piston 1118
as reciprocates in the cylinder 1112, thereby reducing (and,
preferably, eliminating) most significant metal-to-metal contact
between the piston 1118 and the cylinder 1112.
[0114] The non-metallic guide ring 1182, first non-metallic guide
button 1190 and second non-metallic guide button 1194 are
preferably made of a hard plastic material, such as from the
fluoroplastic and fluoropolymer families that include products such
as Meldin (a St. Gobain product) or Vespel (a DuPont product).
Meldin and Vespel are pure poly plastics that can be modified to
operate in special environments, such as steam.
[0115] It should be understood that the number and position of both
the non-metallic guide rings and the non-metallic guide buttons are
not restricted to the embodiment shown in FIG. 11. More or less
than one non-metallic guide ring may be provided. Also, more or
less than two non-metallic guide buttons may be provided.
Furthermore, one or more non-metallic guide buttons may be used in
place of a guide ring (or even guide rings). In addition, the
position of the non-metallic guide rings and/or non-metallic guide
buttons relative to the non-metallic ring assembly 960 may also be
varied. For example, the non-metallic ring assembly 960 may be
located at a position between two non-metallic guide rings. In one
embodiment, if no piston skirt 1122 is provided, (one or both of)
the first and second non-metallic guide buttons 1190, 1194 (and
their corresponding recesses 1188, 1192) may be eliminated or
relocated.
[0116] FIG. 12 is an, enlarged and exaggerated diagrammatic
representation of a portion of a cylinder wall 1112, a portion of a
piston 1118, a gap 1132 between the cylinder wall 1112 and the
piston 1118, a second ring groove 1180 (see FIG. 11) and a
non-metallic guide ring 1182. The piston 1118 is designed to
reciprocate within a cylinder formed by cylinder wall 1112.
[0117] FIG. 13 is an enlarged diagrammatic representation of a
cross-section of the non-metallic guide ring 1182. As shown in FIG.
13, the non-metallic guide ring 1182 has a front 1166 having a
height 1168 and has a back 1170 having a height 1172. Furthermore,
as shown in FIG. 12, the second ring groove 1180 has a height 1174
that is designed to snugly receive the non-metallic guide ring
1182.
[0118] It should be understood that the second ring groove 1180
does not necessarily have to have a substantially constant height
1174. In one embodiment, if the ring groove 1180 did not have a
substantially constant height, the non-metallic guide ring 1182
would have at least one height which would cause at least a portion
of the non-metallic guide ring 1182 to be snugly received by the
second ring groove 1180.
[0119] It should be understood that the height 1168 of the front
1166 of the non-metallic guide ring 1182 does not have to be
substantially equal to the height 1172 of the back 1170 of the
non-metallic guide ring 1182. In one embodiment, the height 1172 of
the back 1170 of the non-metallic guide ring 1182 is greater than
the height 1168 of the front 1166 of the non-metallic guide ring
1182. In another embodiment, the height 1172 of the back 1170 of
the non-metallic guide ring 1182 is less than the height 1168 of
the front 1166 of the non-metallic guide ring 1182.
[0120] The non-metallic guide ring 1182 can, preferably, operate
efficiently at temperatures of up to about 550 degrees Fahrenheit
and, preferably, can withstand temperatures of about 600 degrees
Fahrenheit. It should be understood that the above temperatures are
not necessarily limiting, as other temperatures are possible. In
addition, the non-metallic guide ring 1182, preferably, has a
relatively low coefficient of friction.
[0121] Because the non-metallic guide ring 1182 is made of a hard
plastic material, it includes a split 1300 (see FIGS. 13B and 13C)
to allow for easier installation. FIG. 13B is a diagrammatic
representation of a top view of anon-metallic guide ring 1182 which
shows split 1300. FIG. 13C is an enlarged, three-dimensional,
diagrammatic representation of a portion of a non-metallic guide
ring 1182 that includes a split 1300.
[0122] As shown in FIG. 13C, in one embodiment, the split 1300
extends from the top 1176 to the bottom 1178 of the non-metallic
guide ring 1182 at an angle that is different from 90 degrees
relative to the top 1176 of the non-metallic guide ring 1182. When
installed inside the ring groove 1180, the snug fit of the
non-metallic guide ring 1182 substantially seals the split
1300.
[0123] In one embodiment, the angle of the split 1300 is about 22
degrees relative to the top 1176 of the non-metallic guide ring
1182. In another embodiment, the angle of the split 1300 is about
45 degrees relative to the top 976 of the non-metallic guide ring
1182. Of course, other angles are possible and anticipated.
[0124] The split 1300 may be made, for example, using a
computer-controlled cutting tool. Alternatively, the non-metallic
guide ring 1182 may be manufactured with a split 1300.
[0125] FIG. 14 is an enlarged and exaggerated diagrammatic
representation of a portion of a cylinder wall 1112, a portion of a
piston 1118 (e.g., a piston skirt 1122 like that shown in FIG. 11),
a gap 1132 between the cylinder wall 1112 and the piston 1118, a
first guide-button recess 1188 (see also FIG. 11) and a first
non-metallic guide button 1190. The first non-metallic guide button
1190 can have various shapes and the use of the term button is not
intended to limit those shapes to circular shapes, although
circular shapes are possible and anticipated. Rather, the term
button is used for the purpose of indicating that the first
non-metallic guide button 1190 does not extend around substantially
the entirety of the circumference of the piston 1118. For example,
in one embodiment, the first non-metallic guide button 1190 can
take the shape of a segment of a ring. In another embodiment, the
first non-metallic guide button 1190 can have a front 1466 that is
generally circular or oval.
[0126] The size and shape of the first guide-button recess 1188
will depend on the size and shape of the first non-metallic guide
button 1190. Preferably, the first non-metallic guide button 1190
is designed to be snugly received by the first guide-button recess
1188.
[0127] The first non-metallic guide button 1190 can, preferably,
operate efficiently at temperatures of up to about 550 degrees
Fahrenheit and, preferably, can withstand temperatures of about 600
degrees Fahrenheit. It should be understood that the above
temperatures are not necessarily limiting, as other temperatures
are possible. In addition, the first non-metallic guide button
1190, preferably, has a relatively low coefficient of friction.
[0128] The discussion above, with respect to the first non-metallic
guide button 1190 is equally-applicable to the second non-metallic
guide button 1194. Accordingly, such discussion will not be
repeated below.
[0129] Returning to FIG. 11, the oil ring 1186 is a conventional
metal oil ring, like the oil ring 239 shown in FIGS. 2 and 3.
However, to further reduce metal-to-metal contact, at least the
portion of the oil ring 1186 that contacts the cylinder wall 1112
may be made of a hard plastic material, such as from the
fluoroplastic and fluoropolymer families that include products such
as Meldin (a St. Gobain product) or Vespel (a DuPont product). In
another embodiment, substantially the entire oil ring 1186 may be
made of a hard plastic material, such as from the fluoroplastic and
fluoropolymer families that include products such as Meldin (a St.
Gobain product) or Vespel (a DuPont product).
[0130] In one embodiment, the internal combustion engine 1100 does
not require oil to lubricate its cylinder walls 1112. Accordingly,
in such embodiment, the oil ring 1186 is removed altogether.
[0131] By itself, the non-metallic guide ring 1182 cannot stop
blow-by through the gap 1132 between the piston 1118 and the
cylinder wall 1112 (although, in some cases, it can help to reduce
it) because the non-metallic guide ring 1182 is made of a hard
plastic, which is not completely capable of following changes in
shape of the piston 1118 and/or the cylinder 1112. In contrast, the
non-metallic ring assembly 960 (see FIG. 9) is made of one or more
soft plastics that are capable of following such changes in shape.
Accordingly, the non-metallic guide ring 1182, along with the first
and, second non-metallic guide buttons 1190, 1194, are designed to
reduce (and, more preferably, prevent) contact of the piston 1118
with the cylinder wall 1112.
[0132] Because oil is not necessary to lubricate the cylinder walls
1112 due to the guide rings and/or guide buttons, certain problems
associated with the non-metallic ring assembly 738 (described in
the background of the invention section of the present application
in connection with FIG. 7) can be overcome (or, at least, reduced).
Accordingly, in one embodiment, when no oil (or even a reduced
amount of oil) is used to lubricate the cylinder walls 1112, a
non-metallic ring assembly 1560 (see FIG. 15) having dynamic
sealing capabilities may be used.
[0133] FIG. 15 is an enlarged and exaggerated diagrammatic
representation of a portion of a cylinder wall 1112, a portion of a
piston 1118, a gap 1132 between the cylinder wall 1112 and the
piston 1118, a ring groove 1528 and a non-metallic ring assembly
1560. The non-metallic ring assembly 1560 includes a first
non-metallic ring 1562 and a second non-metallic ring 1564.
[0134] Preferably, the first non-metallic ring 1562 is a gapless
(i.e., continuous) ring which is made of a rubber or rubber-like
material, has spring-like qualities and can act as a check valve
when under pressure. (It should be understood, however, that the
first non-metallic ring does not have to have the shape of an "O"
in cross-section and can take a variety of different shapes.) In
addition, the first non-metallic ring 1562 can, preferably, operate
efficiently at temperatures of up to about 550 degrees Fahrenheit
and, preferably, can withstand temperatures of about 600 degrees
Fahrenheit. It should be understood that the above temperatures are
not necessarily limiting, as other temperatures are possible.
Furthermore, the first non-metallic ring 1562 is preferably soft
(e.g., capable of being stretched over the piston 1118) and has
memory (i.e., will return to its original shape when cooled or when
pressure is reduced). The first non-metallic ring 1562, for
example, can be made of a high-temperature fluoroelastomer, such as
Viton.
[0135] The second non-metallic ring 1564 is, preferably, a gapless
(i.e., continuous) ring that can operate efficiently at
temperatures of up to about 550 degrees Fahrenheit and, preferably,
can withstand temperatures of about 600 degrees Fahrenheit. It
should be understood that the above temperatures are not
necessarily limiting, as, other temperatures are possible. In
addition, the second non-metallic ring 1564, preferably, has a
relatively low coefficient of friction. Furthermore, the second
non-metallic ring 1564 should be capable of being stretched when
heated (e.g., when it is being stretched over piston 1118 for
installation) but should also have memory, so that when it is
cooled it returns to its original shape.
[0136] Preferably, the second non-metallic ring 1564 is made of a
fluoroplastic or fluoropolymer material. For example, the second
non-metallic ring may be a rubber-like plastic material such as, or
similar to, the materials in the fluoroplastic and fluoropolymer
families that include products such as Poly Tetra Fluoro Ethylene
(PTFE), Teflon (a DuPont product) and Rulon (a St. Gobain
product).
[0137] The non-metallic ring assembly 1564 can be used in
conjunction with, or in place of, the non-metallic ring assembly
960 described in connection with FIG. 9. In addition, instead of
providing one non-metallic ring assembly 1564, a plurality of non
metallic ring assemblies 1564 may be provided in a corresponding
plurality of ring grooves 1528. Furthermore, instead of being
continuous rings, it should be understood that one or both of the
first and, second non-metallic rings 1562, 1564 may be
non-continuous (e.g., split).
[0138] The non-metallic ring assembly 1560 can be installed using
techniques like those described in connection with the non-metallic
ring assembly 960.
[0139] With respect to the operation of the non-metallic ring
assembly 1560, reference is made to FIG. 15. In one embodiment, the
second non-metallic ring 1562 is generally T-shaped in
cross-section (although other shapes are possible and are
anticipated) and has a front 1544, which contacts the cylinder wall
1112 as the bearing area, and a back 1546 which is that surface
furthest from the cylinder wall 1112. The height of the back 1546
of the second non-metallic ring 1564 is approximately twice the
height of the front 1544 of the second non-metallic ring 1564
(although other differences in height are possible and
anticipated).
[0140] The first non-metallic ring 1562 operates as a spring
against the second non-metallic ring 1564 and pre-loads the second
non-metallic ring 1564 against the cylinder wall 1112. The first
non-metallic ring 1562 sits in the area between the back 1546 of
the second non-metallic ring 1546 and the back 1548 of the ring
groove 1528. When heated and under pressure, the first non-metallic
ring 1562 acts hydrostatically.
[0141] A system pressure (either positive or negative, depending on
the stroke of the engine) is created in the gap 1132 between the
cylinder wall 1112 and the piston 1118. The bearing pressure
associated with the pre-load is sufficient to direct the system
pressure between the back 1546 of the second non-metallic ring 1564
and the back 1548 of the ring groove 1528, taking the path of least
resistance.
[0142] The first non-metallic ring 1562, acting hydrostatically,
moves to the top 1568 or bottom 1570 of the second non-metallic
ring 1564 (depending on whether the system pressure is positive or
negative) and operates as a check valve to prevent the system
pressure from flowing thereby. Thus, the first non-metallic ring
1564 prevents any blow-by behind the non-metallic ring assembly
1560 through the ring groove 1528.
[0143] The moments of force associated with the system pressure are
directed (perpendicularly) from the back 1546 of the second
non-metallic ring 1564 toward the front 1544 of the second
non-metallic ring 1564. Since the back 1546 of the second
non-metallic ring 1546 is approximately twice the height of the
front 1544 of the second non-metallic ring 1564, the force against
the cylinder wall 1112 is amplified and is approximately twice the
force of the system pressure, which prevents any blow-by between
the second non-metallic ring 1564 and the cylinder wall 1112. In
view of the above, it can be, seen that the non-metallic ring
assembly 1560 prevents blow-by.
[0144] The force in the bearing area is dependent upon the system
pressure, since the system pressure is directed behind the second
non-metallic ring 1564. Accordingly, the force in the bearing area
will change depending upon the system pressure. Thus, the greater
the system pressure, the higher the bearing pressure (and
visa-versa). Therefore, the non-metallic ring assembly 1560 forms a
dynamic seal.
[0145] It should be understood that the back 1546 of the second
non-metallic ring 1546 is not limited to being approximately twice
the height of the front 1544 of the second non-metallic ring 1564.
Other relationships between such heights are possible and
anticipated.
[0146] Returning to FIG. 11, it should be understood that, in some
embodiments, the non-metallic ring assembly 960 and the
non-metallic guide ring 1182 do not have to be in different ring
grooves.
[0147] For example, FIG. 16A illustrates a ring groove 928A that
receives a first non-metallic ring 962B, a second non-metallic ring
964B, a first non-metallic guide ring 1182A and a second
non-metallic guide ring 1182B. As shown in FIG. 16A, the second
non-metallic ring 964B is interposed between first non-metallic
guide ring 1182A and second non-metallic guide ring 1182B.
Furthermore, the first non-metallic ring 962B biases the first
non-metallic guide ring 1182A, the second non-metallic guide ring
1182B and the second non-metallic ring 964B towards the cylinder
wall 1112.
[0148] FIG. 16B illustrates a ring groove 928B that receives a
first non-metallic ring 962C, a second non-metallic ring 964C, a
first non-metallic guide ring 1182A and a second non-metallic guide
ring 1182B. As shown in FIG. 16B, the second non-metallic ring 964C
is interposed between first non-metallic guide ring 1182A and
second non-metallic guide ring 1182B. The ring groove 928B includes
a channel 1600 which receives at least a portion of first
non-metallic ring 962C. Accordingly, in contrast to FIG. 16A, the
first non-metallic ring 962C only biases the second non-metallic
ring 964C (not first and second non-metallic guide rings 1182A,
1182B) towards the cylinder wall 1112.
[0149] FIG. 17 illustrates a first ring groove 928D that receives
first non-metallic ring 962D, first non-metallic guide ring 1182D
and second non-metallic ring 964D. FIG. 17 also illustrates a
second ring groove 1180E that receives first non-metallic ring
962E, second non-metallic guide ring 1182E and second non-metallic
ring 964E. The first non-metallic ring 962D biases the first
non-metallic guide ring 1182D and the second non-metallic ring 964D
towards cylinder wall 1112. Similarly, the first, non-metallic ring
962E biases the second non-metallic guide ring 1182E and second
non-metallic ring 964E towards cylinder wall 1112.
[0150] As will be appreciated, the composition of and various
features associated with first non-metallic rings 962B, 962C, 962D
and 962E correspond with first non-metallic ring 962 (e.g., may be
made of a fluoroelastomer (such as Viton), may be continuous, and
may have a variety of shapes in cross-section--O-shaped, D-shaped
or rectangular, among others). Similarly, the composition of and
various features associated with second non-metallic rings 964A,
964B, 964C, 964D and 964E correspond with second non-metallic ring
964 (e.g., may be made of a soft plastic and may be continuous or
split). In addition, the composition of and various features
associated with (first and second) non-metallic guide rings 1182A,
1182B, 1182D and 1182E correspond with non-metallic guide ring 1182
(e.g., may be made of a hard plastic material and may be continuous
or split).
[0151] It should be understood that more than one first
non-metallic ring 962 can be provided in a single ring groove with
one or more second non-metallic rings 964 and/or one or more
non-metallic guide rings 1182. Furthermore, it should be understood
that, in some ring grooves, a first non-metallic ring 962 may not
be provided, even though such ring grooves include one or more
second non-metallic rings 964 and/or one or more non-metallic guide
rings 1182. In addition, it should be understood that when one or
more first non-metallic rings 962 are provided, the amount of
preload exerted on one non-metallic ring (e.g., second non-metallic
964) may be different than the amount of preload exerted on another
non-metallic ring (e.g., non-metallic guide ring 1182).
[0152] In addition, it should be understood that none, one or more
of the second non-metallic rings 964 may include a split and/or
none, one or more of the non-metallic guide rings 1182 may include
a split. It should also be understood that, in embodiments where
two or more non-metallic rings (e.g., one second non-metallic ring
964 and one non-metallic guide ring 1182) include a split and are
in the same (or different) ring groove, the splits may be offset
from one another. In one embodiment, if N non-metallic rings in the
same ring groove include a split, the splits are offset
360.degree./N from one another.
[0153] It should be understood that there are many other ring
combinations other than those shown in the embodiments of FIGS.
16A, 16B and 17. Thus, such embodiments should only be considered
as representative embodiments.
[0154] In conventional engines, the cylinder walls (like cylinder
wall 212 in FIG. 2) include cross-hatching (not shown), which is
used to file down the first metallic compression ring 230 and the
second metallic compression ring 238 to compensate for the
out-of-roundness of the cylinder 212. In contrast to conventional
engines, in one embodiment, the cylinder walls (see, e.g., cylinder
wall 1112 in FIG. 11) have a smooth, mirror-like finish (not
shown). Among other things, this reduces friction between the
cylinder wall 1112 and the non-metallic ring(s) that contact the
cylinder wall 1112. Furthermore, this reduces wear of the
non-metallic ring(s) that contact the cylinder wall 1112. In the
case of implementing one or more features of the present invention
into an existing engine (i.e., retrofitting), the mirror finish may
be obtained by boring, reaming and/or honing the cylinder.
[0155] FIG. 18 is a diagrammatic representation of a cross-section
of a cylinder wall 1112 that is coated with a non-metallic coating
1894 to reduce friction. The non-metallic coating 1894 on the
cylinder wall 1112 may be a rubber-like plastic material such as,
or similar to, the materials in the fluoroplastic and fluoropolymer
families that include products such as PTFE, Teflon or Rulon. In
one embodiment, the non-metallic coating 1894 extends along those
portions of the cylinder wall 1112 that are likely to come into
contact with the non-metallic ring assembly 960 (or non-metallic
ring assembly 1560), the first non-metallic guide ring 1182, the
second non-metallic guide ring 1186, the first non-metallic guide
button 1190 and/or the second non-metallic guide button 1194 (see
FIG. 11). Use of the non-metallic coating 1894 will further ensure
that metal-to-metal contact between the piston 1118 and the
cylinder wall 1112 will be reduced (and, in some embodiments, be
eliminated).
[0156] In one embodiment, the non-metallic coating 1894 is baked
onto the cylinder wall 1112. In one embodiment, the thickness of
the non-metallic coating 1984 is about 0.001 inch. In, one
embodiment, the thickness of the non-metallic coating 1894 is less
than 0.001 inch. In one embodiment, the cylinder wall 1112 is made
of titanium or one or more titanium alloys.
[0157] It should be understood that some of the soft and hard
plastic materials described above can be enhanced with various
fillers such as graphite, fiberglass, Teflon and many other
substances to operate with unique qualities with respect to
temperature, rigidity, compression, friction, elasticity, memory
and use in special environments such as steam.
[0158] With reference again to FIG. 11, the internal combustion
engine 1100 includes a combustion chamber 1116 that is formed in
the piston 1118 (more specifically, in the head portion 1120 of the
piston 1118). Furthermore, the head assembly 1114 is flat (i.e.,
not curved along its inside). This is to be contrasted to the
combustion chamber 216 (shown in FIG. 2) that is formed in the
curved head assembly 214 (i.e., curved along its inside).
[0159] As shown in FIG. 11, the head portion 1120 of the piston
1118 is dish-shaped (i.e., has a continuous, smooth curve). It
should be understood, however, that the head portion 1120 of the
piston 1118 can take many different shapes. For example, in one
embodiment, the head portion 1120 of the piston 1118 can be
generally frustoconically shaped. In another embodiment, the head
portion 1120 of the piston 1118 can be frustoconically shaped with
a flat portion at its bottom. Explained generically, in all of such
embodiments, the head portion 1120 of the piston 1118 is
recessed.
[0160] Using a recessed head portion 1120 of the piston 1118
increases engine efficiency and provides advantages with respect to
using non-metallic rings. For example, the recessed head portion
1120 of the piston 1118 directs (e.g., by refraction) the moments
of force to the center of the bottom of the recessed head portion
1120, which keeps the heat in the center of the cylinder, thereby
reducing the potential for heat loss. When the moments of force are
directed to, and along the axis of, the center of the piston 1118,
the transfer of energy to the piston 1118 (and, thus, to the
connecting rod 1124) is improved. When the heat does not come into
contact with the cool cylinder walls 1112, it is able to complete
combustion in a shorter period of time allowing less time for heat
loss. Further, heat that does radiate towards the perimeter does
not reach the cylinder walls 1112; rather, it hits the walls of the
recessed piston head 1120. Even further, because the combustion is
taking place in the center of the recessed piston 1118, radiated
heat is directed away from the cylinder walls 1112 and the rings
(e.g., non-metallic ring assembly 960 and non-metallic guide ring
1182), thereby protecting the non-metallic rings. The bowl-shape of
the piston head 1120 causes gases, once they reach the bottom of
the piston head 1120, to collide and form a spout in the center of
the piston head 1120, which results in more proper atomization,
homogenization, gasification and vaporization. As such, the
combustion process takes place more efficiently and in less time.
Accordingly, heat loss is reduced. Finally, the increased surface
area (due to the recessed shape of the piston head 1120) allows the
molecules to be spread out, which improves the combustion process
and allows it to occur in less time.
[0161] In some embodiments, a pressurized radiator having coolant
with an operating temperature above 180 degrees Fahrenheit may be
provided. In one embodiment, the operating temperature of the
coolant is at least 200 degrees Fahrenheit. In one embodiment, the
operating temperature of the coolant is at least 225 degrees
Fahrenheit. In one embodiment, the operating temperature of the
coolant is at least 250 degrees Fahrenheit. In one embodiment, the
operating temperature of the coolant is above 300 degrees
Fahrenheit. In one embodiment, the operating temperature of the
coolant is above 350 degrees Fahrenheit. In one embodiment, the
operating temperature of the coolant is about 400 degrees
Fahrenheit.
[0162] Accordingly, to the extent that some of the heat rises above
the top of the recessed piston head 1120 and comes into contact
with the cylinder walls 1112, the cylinder walls 1112 will have a
substantially higher temperature than prior engines, due to the
pressurized radiator. Therefore, heat loss will be further
diminished.
[0163] As shown in FIG. 11, the flat head assembly 1114 includes an
intake valve 1146 that moves in a direction that is substantially
parallel to the direction of movement of the piston 1118.
Similarly, the flat head assembly 1114 includes an exhaust valve
1148 that moves in a direction that is substantially parallel to
the direction of the movement of the piston 1118.
[0164] Using a flat head assembly 1114 provides several advantages.
For example, in conventional engines (see, e.g., FIG. 2), when a
required torque is applied to seal the head gasket (not shown)
between the head assembly 214 and the cylinders 212 of the engine
block 210, such torque tends to cause the cylinders 212 to go
slightly out-of-round. This problem is exacerbated when the engine
is heated, causing the cylinders 212 to even go more
out-of-round.
[0165] By using a flat head assembly 1114 (see FIG. 11), the
effects of torque used to seal the head gasket (not shown) between
the head assembly 1114 and the engine block 1110 can be less per
square inch, without sacrificing the sealability. Thus, the
out-of-roundness of the cylinders is substantially reduced, which
also reduces the amount of out-of-roundness that occurs when the
engine is heated.
[0166] By substantially eliminating blow-by and by decreasing
friction using one or more combinations of the non-metallic rings
described above, a plethora of changes can be made to existing
engine designs. One major design change that can be made is that
engines no longer have to be made "in-square." A brief explanation
is provided below.
[0167] Vehicle engine designers have faced a number of obstacles in
attempting to increase power, while both limiting the amount of
pollution and achieving required fuel economy. For example, power
could be increased by increasing the piston stroke length inside
the cylinder, by increasing the diameter of the piston, or by
increasing the revolutions per minute of the engine. However, each
of these design changes, in traditional engines, causes increased
blow-by, increased friction and increased temperature, resulting in
increased pollution and decreased, fuel economy. Furthermore, it is
a generally well-accepted principle in engine design that between
the parameters of increasing power, decreasing pollution and
increasing fuel economy, not more than two of three parameters may
experience a gain, and at least one of the parameters must
experience a loss.
[0168] In order to ensure that both the amount of pollution is not
increased beyond acceptable levels and the fuel economy is not
decreased beyond required levels, vehicle engine designers have
"learned" that engines cannot be built "out-of-square." That is,
the stroke length of a piston cannot be greater than approximately
70% of the diameter of the piston. Accordingly, in order to
increase power, some vehicle engine designers have reduced the
diameter of the pistons, reduced the stroke length, increased the
number of cylinders and increased the revolutions per minute of the
engine.
[0169] Because embodiments of the present invention substantially
eliminate blow-by and reduce friction, certain constraints placed
on vehicle engine designers can now be lifted. For example, in
contrast to prior teachings, engines can be built that increase
power, decrease pollution and increase fuel economy. Furthermore,
such engines can either be built "in square" or "out-of-square." In
addition, in order to not overload an existing engine, one or more
embodiments of the present invention can be used to modify the
existing engine such that power is maintained, while pollution is
decreased and fuel economy is increased.
[0170] In one embodiment, the diameter of the piston 1118 is
significantly increased as compared to prior pistons (like piston
218). By using a larger diameter piston 1118, additional engine
design changes can be made, since there is more room to add and/or
move components. In one embodiment, a larger diameter piston 1118
is used in combination with a flat head assembly 1114. It should be
understood that some benefits may also be achieved by using a
larger diameter piston with a conventional head assembly.
[0171] In one embodiment, the flat head assembly 1114 includes one
or more oxygen injectors. Instead, or in addition, the flat head
assembly may also include one or more combination oxygen/fuel
injectors. In one embodiment, one or more spark plugs are provided,
wherein, for example, one spark plug fires one spark and another
spark plug fires multiple sparks. In one embodiment, the flat head
assembly 1114 includes a fuel injector, which delivers fuel to an
upper portion of the head portion 1120 of the piston 1118 (e.g.,
near the top of the combustion chamber 1116).
[0172] In one embodiment, the piston 1118 (more specifically, the
top of the head 1120 of the piston 1118) may be coated with a
catalyst for oxygen, such as platinum, rhodium or palladium (or
combination thereof). It should be understood that other catalysts
for oxygen may be used and, furthermore, more than one catalyst for
oxygen may be used.
[0173] In one embodiment, one or more parts of the engine that are
exposed to the combustion process are coated with one or more
catalysts for oxygen. For example, a portion of the head assembly
1114, the bottom of intake valve 1146, the bottom of exhaust valve
1148, and/or one or more spark plugs 1150 are coated with one or
more catalysts for oxygen. It should be understood that such parts
may be coated with one or more catalysts for oxygen in addition to,
or in place of, the head 1120 of the piston 1118.
[0174] The inventor has observed that, when a catalyst for oxygen
(e.g., platinum) is used inside the combustion chamber, as opposed
to externally as in a conventional engine, the heat energy can be
converted to mechanical energy for useful work. Also, in some
embodiments, a large portion of the remaining heat energy inside
the combustion chamber can be converted into kinetic energy by way
of one or more steam strokes.
[0175] In one embodiment, due to the decreased friction obtained by
using the non-metallic rings, a more efficient flywheel may be
used, which allows the engine to idle at significantly lower
revolutions per minute. Specifically, flywheel has a weight or mass
at its perimeter that is increased relative to the rest of the
flywheel. For example, a metallic flywheel made primarily of a
relatively lighter-weight metal can include a relatively
heavier-weight metal at its perimeter. In one embodiment, the
diameter of the flywheel may also be increased, as compared to a
conventional flywheel, which increases the delivered torque.
[0176] In one embodiment, the flywheel has a shaft that is made out
of titanium (or one or more titanium alloys), and the bearing
associated with the flywheel can be modified to further reduce
friction and to further decrease the revolutions per minute. More
specifically, in one embodiment, the bearing is made of (or may be
coated with) a hard plastic material (i.e., a non-metallic
material), such as from the fluoroplastic and fluoropolymer
families the include products such as Meldin (a St. Gobain product)
or Vespel (a DuPont product). In another embodiment, the bearing is
made of (or may be coated with) a soft plastic material (i.e., a
non-metallic material), such as from the fluoroplastic and
fluoropolymer materials that include products such as Poly Tetra
Fluoro Ethylene (PTFE), Teflon (a DuPont product) and Rulon (a St.
Gobain product). Because the engine is able to idle at lower
revolutions per minute, fuel economy is increased, pollution is
decreased, noise is decreased and engine wear is decreased. The
flywheel is, thus, made a more effective component to store
mechanical energy.
[0177] In one embodiment, the idling speed can be less than 500
rpm. In one embodiment, the idling speed can be less than 200 rpm.
In one embodiment, the idling speed can be less than 100 rpm. In
yet a further embodiment, the idling speed can be about 60 rpm.
[0178] Some may observe that operating an engine at lower
revolutions per minute makes use of a catalytic converter
impractical. However, like the inventor's prior engine described in
connection with FIG. 7, embodiments of the present invention are
believed to be able to meet emissions requirements without a
catalytic converter or air blower. Furthermore, in embodiments of
the present invention, the PCV valve may also be eliminated.
[0179] By increasing the surface area of the top of the piston 1118
(e.g., by recessing the piston and/or by increasing its diameter),
the time it takes for the piston 1118 to complete a power stroke
may be increased, while still maintaining the same amount power. By
increasing the time to complete a power stroke, fuel and oxygen may
be delivered at precise times associated with the travel of the
piston 1118, which can increase efficiency, as will be understood
after the following description.
[0180] As the crankshaft (not shown) turns, the piston 1118 is
traveling at different speeds. Timely combustion of fuel based upon
piston location 1118 allows the piston to do more useful work based
upon the principle of leverage, whereby the crank is used as a
lever arm. In an engine having its top dead center at 12 o'clock (0
degrees), the potential for the maximum torque that may be exerted
on the crankshaft is when crank is at 3 o'clock (90 degrees), which
is at a point about mid-way along the travel of the piston during
its power stroke.
[0181] In one example engine, when the piston is at top dead
center, the piston is not moving. A 5 degree turn of the crankshaft
results in a 0.003 inch movement of the piston, as measured by a
dial indicator. The next 5 degree turn of the crankshaft results in
a 0.015 inch movement of the piston. Shortly, thereafter, when the
crankshaft is at around 3 o'clock, a 5 degree turn of the
crankshaft results in a 0.250 inch movement of the piston, which is
about 83 times longer than it was traveling at the first 5 degree
turn of the crankshaft (therefore, 83 times faster). Unfortunately,
in a conventional engine, by the time the piston has reached its
fast-moving location, a significant amount of the fuel has already
been consumed. The Environmental Protection Agency (EPA) has also
recognized some of these engineering facts and, in March 2005,
published grant applications for not-for-profit organizations to
take advantage of such facts.
[0182] According to Newton's Law of Motion, kinetic energy is equal
to the force times the velocity squared, all divided by two. The
inventor has recognized that about 80 percent of the work done by
the piston is performed during about 40 percent of the piston's
travel (which the inventor has termed the power-efficiency sweet
spot). In order for combustion to take place at the right location
along the stroke of the piston (i.e., when the crank is at about 3
o'clock), the amount of time required to complete the power stroke
should be made longer, while still maintaining the same amount of
power. Furthermore, combustion should take place faster and be more
complete.
[0183] In one embodiment, the surface area of the top of the piston
1118 is increased by increasing the diameter of the piston. In one
embodiment, the surface area of the top of the piston 1118 is
increased by making the piston oval-shaped. In one embodiment, the
surface area of the piston 1118 is increased by recessing the
piston 1118 (or recessing the piston 1118 further). It should be
understood that the surface area of the top of the piston can be
increased by combining two or more of the above.
[0184] In one embodiment, a flame front is created by introducing a
small amount of fuel, in order to get the piston past its blind
spot. Oxygen is injected (e.g., at the speed of sound), via an
oxygen injector, directly perpendicular to the center (or centroid,
if the piston is oval-shaped) of the top of the piston 1118. At
about the same time, fuel (e.g., preheated, homogenized and
atomized fuel) is injected via a 360 degree spray, using one or
more fuel injectors, just inside the uppermost region of the
recessed piston 1118. The fuel spray is forced, via refraction,
down the wall of the recessed piston head 1120 meeting the oxygen
being refracted up the wall of the recessed piston head 1120. Since
atomization is a function of the relative velocity squared, this
violent explosive condition will be met by the flame front coming
down from above to create a tornadic action for complete and rapid
combustion, which is a major goal of engine efficiency. Preferably,
combustion takes place during the power-efficiency sweet spot.
[0185] In one embodiment, ambient air is presented to a sieve,
which separates at least a portion of the nitrogen contained in the
air from at least a portion of the oxygen in the air. Thus, in one
embodiment, instead of injecting pure oxygen toward the top of
piston 1118, a mixture of oxygen and nitrogen (wherein the mixture
has less nitrogen content than ambient air) is directed toward the
top of the piston 1118.
[0186] In one embodiment, oxygen can be obtained via electrolysis
through a sieve carried in the vehicle. In one embodiment, the
water obtained from the by-product of combusting fuel can be
delivered to a sieve, which takes oxygen from the water. In one
embodiment, water is carried on-board and the water is delivered to
the sieve.
[0187] In one embodiment, a sieve can be powered by electric power
from the battery associated with the engine. In embodiment, a sieve
can be powered by a steam jenny using the waste heat from the
engine.
[0188] In one embodiment, oxygen is carried on-board in an oxygen
tank. However, the inventor recognizes that storage of oxygen in a
tank may be dangerous. Accordingly, using a sieve is considered to
be a better alternative.
[0189] In one embodiment, some parts of the engine may be made out
of titanium or one or more titanium alloys. These parts may include
the engine block 1110, the cylinder walls 1112, the pistons 1118,
the head assembly 1114, the intake and exhaust valves 1146, 1148
(with hollow valve stems), the cams (if present), the connecting
rods 1124, the wrist pin 1126, the crankshaft, the drive shaft,
gears, the fuel injectors, the oxygen injectors, among other
possible parts. Using titanium allows for many advantages,
including being lighter-weight, which saves energy when lifting
against gravity and when turning. Another advantage of titanium is
that shafts and rods will not bend, especially when made hollow,
during the power stroke. Also, since less cylinders and connecting
rods can be used (e.g., when increasing the surface area of the top
of the piston), the length of the crankshaft can be reduced,
thereby preventing bending further.
[0190] Since titanium will not easily bend, non-metallic bearings
may be used. For example, in one embodiment, one or more
non-metallic bearings can be made of or coated with, a rubber-like
plastic material such as, or similar to, the materials in the
fluoroplastic and fluoropolymer families that include products such
as Poly Tetra Fluoro Ethylene (PTFE), Teflon (a DuPont product) and
Rulon (a St. Gobain Product). In one embodiment, one or more
non-metallic bearings can be made of a hard plastic material, such
as from the fluoroplastic and fluoropolymer families that include
products such as Meldin (a St. Gobain Product) or Vespel (a DuPont
product). In one embodiment, one or more non-metallic bearings are
used as oil pump bearings and as the main bearing. In addition,
non-metallic bearing materials may be used to decrease friction
associated with the wrist pin, cam, lifters, valves--both intake
and exhaust, timing gear and assembly, flywheel shaft and
distributor shaft, among other components.
[0191] A major advantage of using a titanium piston 1118 and
titanium cylinder is that the tolerance between the cylinder wall
1112 and the piston 1118 can be reduced. This is possible because
of the reduced amount of expansion of the piston 1118 when made of
titanium, especially when the piston 1118 is thin. The cylinder,
because it is made stronger, also do not go out-of-round. All of
these factors can be used to reduce the gap 1132 between the
cylinder wall 1112 and the piston 1118. Therefore, there is less
opportunity for system pressure to get into the gap 1132. If some
system pressure does get into the gap 1132, it will be reduced due
to the size of the gap 1132. Thus, using a titanium piston 1118 and
a titanium cylinder wall 1112 can assist in protecting the
non-metallic rings.
[0192] Furthermore, because the titanium cylinder walls 1112 can be
made thin, the temperature gradient is such that any heat reaching
the cylinder walls 1112 can quickly be dissipated into the water
jacket without harming the non-metallic rings. Furthermore, heat
transferred to the non-metallic rings through the piston 1118 will
also be dissipated into the water jacket without harming the
non-metallic rings.
[0193] In one embodiment, titanium sleeves may be used to retrofit
existing engines. Specifically, conventional cylinders can be
bored-out and titanium sleeves can be inserted therein. In
addition, the curved head assembly in the existing engine may be
replaced with a flat head assembly made of titanium. In one
embodiment, one or more titanium sleeves and at least a portion of
the flat head assembly may be constructed as one piece.
[0194] One problem encountered when boring out the cylinders in
prior engines is that the first and second metallic compression
rings would wear through the bored-out cylinder walls and reach the
water jacket, which would ruin the engine. However, by using
titanium sleeves, the engine will actually have stronger walls
after such sleeves inserted as compared to the original engine,
which will allow the engine to last longer. Furthermore, the first
and second metallic compression rings would be eliminated, as
described in various embodiments above.
[0195] In one embodiment, the titanium sleeves have a smooth,
mirror-like finish. In one embodiment, the titanium sleeves are
coated with a non-metallic coating to reduce friction. The
non-metallic coating may be a rubber-like plastic material such as,
or similar to, the materials in the fluoroplastic and fluoropolymer
families that include products such as PTFE, Teflon or Rulon.
[0196] Titanium can be forged, drawn or fabricated. Some of the
above parts may be made using one or more of such techniques.
[0197] In one embodiment, the closing of the intake valve 1146 may
be delayed during the compression stroke, thereby causing a portion
of the air-fuel mixture (or oxygen-fuel mixture, etc.) that has
been introduced into the combustion chamber to be pushed back into
the intake manifold. This causes pre-heating and premixing of the
air-fuel mixture before it is delivered to the next combustion
chamber, which enhances the likelihood of complete combustion.
[0198] When using pure (or nearly pure) oxygen in combination with
fuel, the oxygen-fuel mixture is only compressed about 2 to 1 (as
compared to compressing the air-fuel mixture about 8 to 1 in a
regular engine). Accordingly, the closing of the intake valve
during the compression stroke may be delayed even further, which
saves energy.
[0199] In one embodiment, the intake valve is not closed until the
piston has traveled at least about 50% of the length of its
compression stroke. In one embodiment, the intake valve is not,
closed until the piston has traveled at least about 55% of the
length of its compression stroke. In one embodiment, the intake
valve is not closed until the piston has traveled at least about
60% of the length of its compression stroke. In one embodiment, the
intake valve is not closed until the piston has traveled at least
about 65% of the length of its compression stroke.
[0200] Using a combination of non-metallic rings (which stop
blow-by and reduce friction), as described above, along with making
parts of the engine out of titanium (or titanium alloys) enable a
steam-fuel hybrid engine. In one embodiment, steam is introduced
into a combustion chamber (e.g., via a steam injector in the flat
head) in which, on a previous stroke, fuel was burned. Because
steam is a solvent, in one embodiment, the steam-fuel hybrid engine
does not use oil to lubricate its cylinder walls.
[0201] It should be understood that the steam-fuel hybrid engine
may also be combined with fuel-electric hybrid technologies to
provide a steam-fuel-electric hybrid engine. Furthermore, such
technologies may also be combined with hydrogen fuel cells and
solar power. Furthermore, embodiments of the engine can be used
without, steam, but still be used as part of a fuel-electric hybrid
engine or other hybrid technologies.
[0202] For example, because embodiments of the engine provide space
and weight savings due to the reduction of certain engine
components, a larger battery may be used for a fuel-electric hybrid
engine. The battery can be used to store excess energy when the
fuel portion of the engine is operating, so that the fuel portion
of the engine may be turned-off at low speeds and the battery can
provide electric power. Furthermore, energy can be stored in the
battery using regenerative braking techniques that are known to
those skilled in the art. In one embodiment, a direct drive
connection, is made between the battery and the drive shaft, such
that electric power is provided without any gearing, pistons,
connecting rods, etc. In one embodiment, when the battery level is
low, the fuel portion of the engine is used to provide power.
[0203] In one embodiment, a "sidewinder" engine configuration is
used. That is, the piston(s) reciprocate along an axis that is
substantially parallel to the ground. In one embodiment, a
dual-headed piston is provided, wherein each piston head is
recessed and forms a combustion chamber. In such embodiment, two
flat head assemblies are provided. A piston rod is connected to the
piston and passes through the center (or centroid) of one of the
piston heads. In addition, the piston has no skirt.
[0204] In one embodiment, the piston heads have oval-shaped tops.
In one embodiment, the length of the oval-shaped tops of the piston
heads is about 8 inches (about twice the diameter of a piston used
in a Chevrolet 350 V-8 engine) and the width of the oval-shaped top
of each of the piston heads is about 6 inches. The piston uses at
least one of the combination of non-metallic rings described above
to reduce (or substantially eliminate) blow-by.
[0205] In one embodiment, the sidewinder engine has parts that, as
described above, are made of titanium or titanium alloys. In one
embodiment, the cylinder walls are coated with a non-metallic
material, which will be baked-on and less than 0.001 inch
thick.
[0206] In one embodiment, one piston head is recessed more than the
other piston head, due to the area taken up by a piston rod. In one
embodiment, the wrist pin is located outside of the cylinder.
[0207] Engines made in accordance with embodiments of the present
invention can use the following fuels: diesel fuel and/or a mixture
thereof, gasoline and/or a mixture thereof, methanol and/or a
mixture thereof, ethanol and/or a mixture thereof, and/or natural
gas and/or a mixture thereof. It is anticipated that other fuels
may also be used.
[0208] Although the present invention has been described in
connection with an engine having pistons which reciprocate within
their cylinders, certain features of the present invention may also
be used in connection with rotary engines, including pistons
designed for rotary engines.
[0209] The present invention, in various embodiments, includes
components, methods, processes, systems and/or apparatuses
substantially as depicted and described herein, including various
embodiments, sub-combinations, and subsets thereof. Those with
skill in the art will understand how to make and use the present
invention after understanding the present disclosure. The present
invention, and various embodiments, includes providing the devices
and processes in the absence of items not depicted and/or described
herein or in various embodiments hereof, including in the absence
of such items as may have been used in previous devices or
processes, e.g., for improving performance, achieving ease of
and/or reducing cost of implementation. The present invention
includes items which are novel, and terminology adapted from
previous and/or analogous technologies, for convenience in,
describing novel items or processes, do not necessarily retain all
aspects of conventional usage of such terminology.
[0210] The foregoing discussion of the invention has been presented
for purposes of illustration and description. The foregoing is not
intended to limit the invention to the forms or form disclosed
herein. Although the description of the invention has included
description of one or more embodiments and certain variations and
modifications, other variations and modifications are within the
scope of the invention, e.g., as may be within the skill and
knowledge of those in the art, after understanding the present
disclosure. It is intended to obtain rights which include
alternative embodiments to the extent permitted, including
alternate, interchangeable and/or equivalent structures, functions,
ranges or steps to those claimed, whether or not such alternate,
interchangeable and/or equivalent structures, functions, ranges or
steps are disclosed herein, and without intending to publicly
dedicate any patentable subject matter.
[0211] While an effort has been made to describe some alternatives
to the preferred embodiment, other alternatives will readily come
to mind to those skilled in the art. Therefore, it should be
understood that the invention may be embodied in other specific
forms without departing from the spirit or central characteristics
thereof. The present examples and embodiments, therefore, are to be
considered in all respects as illustrative and not restrictive, and
the invention is not intended to be limited to the details given
herein.
* * * * *