U.S. patent application number 14/821256 was filed with the patent office on 2016-01-07 for outboard motor including one or more of cowling, water pump, fuel vaporization supression, and oil tank features.
The applicant listed for this patent is SEVEN MARINE, LLC. Invention is credited to Eric A. Davis, Richard A. Davis.
Application Number | 20160001864 14/821256 |
Document ID | / |
Family ID | 50190788 |
Filed Date | 2016-01-07 |
United States Patent
Application |
20160001864 |
Kind Code |
A1 |
Davis; Eric A. ; et
al. |
January 7, 2016 |
OUTBOARD MOTOR INCLUDING ONE OR MORE OF COWLING, WATER PUMP, FUEL
VAPORIZATION SUPRESSION, AND OIL TANK FEATURES
Abstract
Embodiments of outboard motors and related systems and
components thereof, as well as arrangements of marine vessels
implementing same, as well as related methods of operation, use,
assembly, and manufacture, and related improvements, are disclosed
herein. In at least some embodiments, the outboard motor includes a
cowling system in which at least one divider portion separates an
interior region into first and second portion, with the
transmission and engine respectively being situated in the first
and second portions, respectively. Additionally, in at least some
embodiments, the outboard motor includes a water pump system in
which a water pump is integrated with the transmission. Further, in
at least some embodiments, the outboard motor includes a fuel
vaporization suppression feature, or an oil tank feature that
allows for desirable oil drainage from the engine of the outboard
motor particularly when the outboard motor is in particular (e.g.,
storage) positions.
Inventors: |
Davis; Eric A.; (Mequon,
WI) ; Davis; Richard A.; (Mequon, WI) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
SEVEN MARINE, LLC |
Germantown |
WI |
US |
|
|
Family ID: |
50190788 |
Appl. No.: |
14/821256 |
Filed: |
August 7, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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PCT/US2014/016089 |
Feb 12, 2014 |
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14821256 |
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61840013 |
Jun 27, 2013 |
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61764529 |
Feb 13, 2013 |
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Current U.S.
Class: |
440/53 ;
440/77 |
Current CPC
Class: |
F02B 75/22 20130101;
B63H 20/002 20130101; B63H 20/106 20130101; B63H 20/245 20130101;
B63H 20/32 20130101; F01P 2060/16 20130101; B63H 20/02 20130101;
B63H 20/28 20130101; B63H 2020/006 20130101; B63H 20/10 20130101;
F02B 61/045 20130101; B63H 20/24 20130101; B63H 20/08 20130101;
F02B 2075/1832 20130101; F01P 2005/105 20130101; F01P 2060/02
20130101; F01P 3/205 20130101; F01P 2050/12 20130101; F01P 2060/04
20130101; B63H 20/12 20130101 |
International
Class: |
B63H 20/10 20060101
B63H020/10; B63H 20/00 20060101 B63H020/00; B63H 20/12 20060101
B63H020/12; B63H 20/32 20060101 B63H020/32 |
Claims
1. An outboard motor having a front surface and an aft surface and
configured to be mounted on a marine vessel having a front to rear
axis, such that the front surface would face the marine vessel and
the aft surface would face away from the marine vessel when in a
standard operational position, the outboard motor comprising: a
housing having an upper and a lower portions and having an
interior; an internal combustion engine disposed within the housing
interior and that provides rotational power output via a crankshaft
that extends horizontally or substantially horizontally in a
front-to-rear direction when the outboard motor is in the standard
operational position and the engine is further disposed
substantially or entirely above a trimming axis and is steerable
about a steering axis, the trimming axis being perpendicular to or
substantially perpendicular to the steering axis, and the steering
axis and trimming axis both being perpendicular to or substantially
perpendicular to the front-to-rear axis of the marine vessel; a
tank positioned within the housing and connected to a crankcase of
the engine; wherein the tank is configured such that little, if
any, of an amount of the lubricant is in or provided to the tank
when the engine is in the standard operational position.
2. The outboard motor of claim 1, wherein the tank is positioned
along or on a front of the engine, nearer the front surface of the
outboard motor than the aft surface thereof.
3. The outboard motor of claim 1, wherein, the outboard motor
configured to be tilted about the trimming axis away from the
standard operating position to at least one additional operating
position and at least one additional position suitable for storing,
transporting and/or limited operation of the outboard motor.
4. The outboard motor of claim 1, wherein the standard operating
position is a position in which the trimming axis is at least
substantially horizontal and the steering axis is at least
substantially vertical, and with the steering axis being at least
substantially parallel to and/or in line with a vertical plane
passing through a center of the engine, and wherein the outboard
motor is configured to be tilted from the standard operating
position to at least one of: (i) a second operating position that
corresponds to a position in which the outboard motor is tilted,
rotated or otherwise moved about the trimming axis such that a
steering axis of the outboard motor as rotated is at an angle
.beta. relative to at least one of a vertical axis and to the
steering axis of the outboard motor when in the standard operating
position; (ii) a third operating position that corresponds to a
position in which the outboard motor is tilted, rotated or
otherwise moved about the trimming axis such that a steering axis
of the outboard motor as rotated is greater than the angle .beta.
up to a maximum angle of .psi.+.beta. relative to the vertical
axis, and rotated at an angle from .beta. up to a maximum angle
.psi.+.beta. relative to the steering axis of the outboard motor
when in the standard operating position; (iii) a first storage
position that corresponds to a position in which the outboard motor
is tilted, rotated or otherwise moved about the trimming axis such
that a steering axis of the outboard motor as rotated is greater
than the angle .psi.+.beta. up to a maximum angle of
.OMEGA.+.psi.+.beta. relative to the vertical axis, and rotated at
an angle from .psi.+.beta. up to a maximum angle
.OMEGA.+.psi.+.beta. relative to the steering axis of the outboard
motor when in the standard operating position; and (iv) a second
storage position that corresponds to a position in which the
outboard motor is tilted, rotated or otherwise moved about the
trimming axis and is also further tilted, rotated or otherwise
moved about the steering axis.
5. The outboard motor of claim 4, wherein the angle .beta. is
fifteen (15) degrees off of the vertical axis.
6. The outboard motor of claim 4, wherein the angle .beta. is the
maximum rotational position of the outboard motor away from the
vertical axis at which the outboard motor is in the second
operating position, and wherein the outboard motor is in the second
operating position if it is rotated a lesser amount less than the
angle .beta..
7. The outboard motor of claim 4 wherein the second operating
position encompasses positions of the outboard motor suited for
shallow water drive operation of the outboard motor in which the
outboard motor can be operated at, or substantially at, full
propulsion or full power.
8. The outboard motor of claim 7, wherein the tank is configured or
structured so that the lubricant/oil utilized by the engine remains
in the crankcase during shallow water drive operation, and very
little or none of the engine lubricant/oil enters or remains within
the tank.
9. The outboard motor of claim 8, wherein the tank is connected to
the engine via one or more oil lines that having a relatively low
positioning relative to the remainder of the tank and the
relatively high positioning of at least most of the tank relative
to the one or more oil lines as well as relative to large sections
of the internal combustion engine.
10. The outboard motor of claim 4, wherein the angle .psi. is ten
(10) degrees off of the steering axis, and the angle .psi.+.beta.
is twenty-five (25) degrees off of the vertical axis.
11. The outboard motor of claim 4, wherein the angle .psi.+.beta.
is the maximum rotational position of the outboard motor away from
the vertical axis at which the outboard motor can still be
considered to be in the third operating position in this
embodiment, and wherein the outboard motor is in the third
operating position if it is rotated a lesser amount less than the
angle .psi.+.beta. down to the angle .beta..
12. The outboard motor of claim 4, wherein the third operating
position encompasses positions of the outboard motor in which the
outboard motor can be operated at limited propulsion or limited
power, and wherein the tank is configured or structured so that all
or substantially all of the lubricant/oil in the crankcase remains
in the crankcase during such shallow water drive operation.
13. The outboard motor of claim 12, wherein the tank is connected
to the engine via one or more oil lines having a relatively low
positioning relative to the remainder of the tank and to the
relatively high positioning of at least most of the tank relative
to the one or more oil lines as well as relative to large sections
of the internal combustion engine.
14. The outboard motor of claim 4, wherein the angle .OMEGA. is
forty-five (45) degrees off of the steering axis, and
.OMEGA.+.psi.+.beta. is seventy (70) degrees off of the vertical
axis.
15. The outboard motor of claim 4, wherein the angle .OMEGA. is the
maximum rotational position of the outboard motor away from the
vertical axis at which the outboard motor can still be considered
to be in the first storage position, and wherein the outboard motor
is in the first storage position if it is rotated a lesser amount
less than the angle .OMEGA.+.psi.+.beta. down to the angle
.psi.+.beta..
16. The outboard motor of claim 4, wherein the first storage
position corresponds to a position of the outboard motor in which
the outboard motor is serviced, or transported, from one location
to another, and wherein the second storage position corresponds to
a position of the outboard motor that is particularly suitable when
the outboard motor is being stored, serviced, or transported from
one location to another.
17. The outboard motor of claim 4, wherein the tank is configured
to receive some or all of the lubricant from the crankcase when the
outboard motor is positioned in one or both of the first and second
storage positions, or wherein the tank is sized to hold a quantity
of oil or other lubricant needed to prevent one or more of the
cylinders from filling up with oil/lubricant, when the outboard
motor is positioned in one or both of the first and second storage
positions.
18. The outboard motor of claim 4 wherein the tank is configured
such that an amount of lubricant can flow into the tank when the
engine is tilted to the one or both of the first and the second
storage positions and the amount of lubricant can flow out of the
tank when the engine is repositioned to at least one of the
standard, second and third operating positions.
19. The outboard motor of claim 1, wherein the internal combustion
engine is an automotive engine suitable for use in an automotive
application.
20. The outboard motor of claim 19, wherein at least one of: (a)
the internal combustion engine is one of an 8-cylinder V-type
internal combustion engine; (b) the internal combustion engine is
operated in combination with an electric motor so as to form a
hybrid motor; (c) the rotational power output from the internal
combustion engine exceeds 550 horsepower; and (d) the rotational
power output from the internal combustion engine is within a range
from at least 557 horsepower to at least 707 horsepower.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application is based upon, and claims priority
to each of, U.S. provisional patent application No. 61/764,529
filed on Feb. 13, 2013 and entitled "Cowling and Water Pump for
Outboard Motor", and also U.S. provisional patent application No.
61/840,013 filed on Jun. 27, 2013 and entitled "OUTBOARD MOTOR
INCLUDING ONE OR MORE OF COWLING, WATER PUMP, FUEL VAPORIZATION
SUPPRESSION, AND OIL TANK FEATURES", and the contents of each of
those two provisional patent applications is hereby incorporated by
reference herein.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable
FIELD OF THE INVENTION
[0003] The present invention relates to marine propulsion systems
and/or related methods of making and/or operating such systems, and
more particularly to outboard motors used as marine propulsion
systems (and/or systems or components thereof), alone and/or in
combination with marine vessels with respect to which those motors
are implemented, and/or methods of making and/or operating same,
and/or methods of manufacturing such systems, motors, and
components.
BACKGROUND OF THE INVENTION
[0004] Current outboard motors or engines employed in relation to
marine vessels typically employ an engine coupled to a leg system
that mounts the engine and constrains the engine above the water's
surface and a 90.degree. gear case below the water surface. The
engine shafting transmits torque that is downwardly directed to the
90.degree. gear case which in turn supports a propeller for the
creation of horizontal thrust to propel the attached watercraft. As
such current outboard motors have a cowling system that surrounds
the engine on all sides thus encasing it and protecting it from the
environment. One of the significant functions of an outboard motor
(or engine) cowl is to provide or facilitate airflow to the
enclosed engine and throttle at relatively low restriction to allow
for engine operation and prevent/minimize loss of horsepower due to
inadequate air flow.
[0005] Although the cowling system of an outboard motor must be
capable of allowing the passage of air to the engine in order to
support combustion, this airflow into the cowling can be
challenging as the air can be carrying large amounts of entrapped
moisture and or liquid water into the engine compartment. Indeed, a
complication associated with providing air to the engine is that
typically the air provided to the engine is from the outside
environment of the motor, which is in direct proximity to water of
a body of water in which the motor is operating, such that the air
entering the motor usually (if not always) includes along with it
some amount of water that is entrapped/entrained with the air.
Indeed, an outboard motor can be subjected to following waves of
water that can cover the cowling system with water and result in
significant water entering into the outboard motor and, regardless
of wave levels, rain water or splashing from the ocean can present
liquid water to the cowl air inlet system. As the engine is
enclosed by the cowl system, once water enters the cowl it is
important that the water be prevented/hindered from entering the
engine intake system to avoid negative effects upon the engine by
the ingress of water.
[0006] In view of the above, outboard cowling systems such as a
cowling system 5200 shown in FIG. 52 (Prior Art) are typically
carefully designed to minimize inbound water while at the same
encouraging airflow to the engine less power losses occur due to
intake air restrictions. Thus an air entrance area (air intake)
5202 is normally located high on the cowling system along an upper
cowling portion 5206, far from the water's surface (and above a
lower cowling portion 5208), as determined in part by an
arrangement of an upper cover section 5210 along the upper cowling
portion 5206. With such an arrangement, the cowling system 5200 is
fashioned in a manner to accept air via an air flow path (or paths)
5212 that particular involves passage of air but discourages the
entrance of liquid water. Further, normally upwardly-looking air
passages 5204 are projecting above an internal surface 5214 and are
covered from above by the upper cover section 5210 to
prevent/hinder direct ingress of water into the outboard motor, as
shown. A further development in conventional cowl systems is the
inclusion of an inner liner system that controls entering air and
directs it downwardly to the bottom cowl (lower cowling portion
5208, which is located above a leg system 5218 of the outboard
motor) where the air/moisture is then released into the cowling
system. In this manner the downward path of the air inside the
liner is done to direct extra water down to the lower cowl where
drains are included to release the water to the body of water
(e.g., ocean) while air is allowed to rise thru the engine
compartment (inside space for the engine) 5216 for the engine air
intake.
[0007] Both of the above-described systems have proven to be
effective for various sizes of outboard motors with engines up to
and including 350 horsepower (hp) engines. However, as increased
power is accompanied by increased airflow, these types of intake
systems become spatially inadequate to provide large amounts of
airflow within the compact space of the cowling system without
creating large airflow restrictions in order to accomplish the
necessary separation of air from water.
[0008] In addition to the above concerns, in today's current
inboard and stern drive marine propulsion systems, two types of
water pumps are used. First a sea pump lifts water from the ocean
and provides it to the engine where a circulation pump then in turn
circulates water continuously thru the engine block and heat
system. The sea pump is normally rubber belt driven from the
crankshaft with external water hoses connecting to the drive
apparatus where water is picked up and returned to. The sea pump is
typically (if not always) composed of a multivane flexible polymer
impeller which has a positive displacement feature at low speed and
starting for priming functions and transitions to a centrifugal
pump at speed as the polymer vanes loose contact with the liner at
higher speeds. The circulation pump is typically (if not always) of
rigid centrifugal impeller construction and is attached to the
engine and also rubber belt driven from the crankshaft.
[0009] Such sea and circulation pumps operate efficiently together
and as such are widely used both in open cooling systems where sea
water is the only coolant utilized and in closed coolant systems
where sea water is circulated by the sea pump thru heat exchangers
while the circulation pump circulates coolant (glycol types) thru
the engine and heat exchanger (much like an automotive system if
the radiator were replaced with a water to water heat exchanger for
the sea pump to push sea water through).
[0010] Notwithstanding the practicality of such existing
arrangements, such water pump arrangements in outboard motors
nevertheless have some disadvantages. In particular, given the
complexity of such arrangements, such arrangements lack
compactness. For example, portions of the water pumps or associated
components (e.g., manifolds associated therewith) can protrude out
of the side of the outboard motor/engine or otherwise extend or be
arranged in inconvenient manners. Also, the parts count of such
water pump arrangements can be high. Further, durability of such
arrangements can be limited, due to the use of fan belts and other
components.
[0011] In addition to the above considerations, in contrast to many
fuel systems developed for fuel injected engines in non-marine
applications, where fuel is managed so as to be largely or mostly
consumed by the engine but yet a portion of the fuel can be
returned back to the fuel tank, conventional outboard motors
typically have fuel systems that have been uniquely developed to
pull fuel from a boat's fuel tank system and consume the fuel
within the outboard motor's engine without returning fuel to the
boat. In many fuel systems, there is a desire to be able to return
fuel to a fuel tank particularly to allow for "excess" fuel output
by a pressure regulator of the fuel system (serving to regulate
fuel pressure) to return to the fuel tank. However the return of
fuel to a fuel tank is viewed as problematic in marine applications
in the case of an undetected leakage of fuel (e.g., because of
disconnection of a fuel line) in the return circuit since, if such
a leakage were to occur, the engine could continue to make power
and propel the craft in spite of the fact that fuel is being lost
into the boat without being delivered to the fuel tank. Indeed,
such a problem can be difficult to detect as it does not
immediately affect boat operation. Further, it has also been found
that if leakage occurs on the supply side where fuel is being drawn
into the engine, air or water is most likely entrained in the fuel
line as the pressure in the fuel line on the supply side is
depressed below atmospheric pressure, thereby enabling flow into
the line, which can soon affect engine performance. Therefore,
outboard motors that are mounted outside the rear of the vessel
(i.e., mounted on the transom) have been developed with fuel
systems that draw fuel into the engine, but without returning the
fuel back across the transom into the boat.
[0012] Further in regard to fuel systems, it is also known to
employ a vapor separator device or vapor separating tank ("VST")
within a fuel injected engine for drawing fuel into the engine
without returning fuel to the fuel tank. Such VSTs are equipped
with fuel pump(s), fuel filter(s), and a working volume of fuel
that is required to supply fuel to the pump(s). This working volume
of fuel is either vented or unvented to atmospheric pressure. VSTs
separate air from fuel in the working volume of fuel, thus
supplying liquid fuel to the fuel pump and venting the vapor or air
(that occurs due to pressure depression in the supply line) out of
the working volume of fuel. If air (vapor) is entrained in the
fuel, to measurable extents, the fuel pump cannot maintain fuel
flow or pressure. Fuel temperature can also cause vapor creation
and, for at least this reason, many cooling devices have been
incorporated into vapor separating tanks ("VSTs") as fuel
temperature now causes vapor according to the vapor pressure of the
fuel. Aside from the use of such VSTs, the other known method of
eliminating vapor, other than venting it out to atmosphere,
involves pressurizing the working volume of fuel. In general,
therefore, conventional VSTs either vent air out of the system or
pressurize the fuel in the system in order to reliably deliver
pressurized fuel to the engine.
[0013] Existing types of VSTs more particularly include (1) VSTs
that are mechanically-switched (float-needle seat system), (2) VSTs
that are electrically-switched, and (3) VSTs that are
proximity-switched. A mechanically-switched VST often includes the
following operational features or characteristics: (a) a high
vacuum lift pump draws fuel from the onboard tank to the outboard;
(b) fuel is delivered into a float chamber; (c) a float is lifted
when there is a sufficient level of fuel in the float chamber; (d)
the float acts upon a needle and seat which shuts off the incoming
fuel; (e) the high pressure pump draws fuel from the float chamber
and delivers it to a regulator; (f) the regulator allows a set
pressure of fuel to pass and returns the excess to the float
chamber; and (g) pressurized fuel exiting the high pressure pump is
ready to be consumed by the engine. By comparison, an
electrically-switched VST typically includes many of the
aforementioned features of a mechanically-switched VST, but differs
in that a diaphragm lift pump of the mechanically-switched VST will
typically be replaced with an electric pump in the
electrically-switched VST and, additionally, the float actuates an
electrical switch opening the power circuit stopping the lift pump
when the float chamber is full. This type of system can be made to
operate without venting the float chamber to atmosphere, as the
float and switch do not need an atmospheric reference. Lastly,
proximity-switched VSTs typically include many of the same features
or characteristics of mechanically-switched and
electrically-switched VSTs, but further include a proximity switch
on the float valve, or an ultrasonic device that indicates fluid
level in the "float chamber" thereby interrupting the flow of the
low pressure pump to halt the overfilling of the float chamber or
working fuel volume.
[0014] Additionally, outboard motors have classically been designed
to incorporate two cycle engine technology in a number of aspects.
As two cycle engines did not require a captive lubricant
compartment from which to draw lubricant or to which to return
lubricant (from and to locations within the engine), in such
engines the lubricant (typically oil) was added to the fuel in
prescribed ratios and consumed through the course of normal
operation. Yet as emissions regulations have become more stringent,
the two-cycle engine, with its inherent disadvantage of
hydro-carbon emissions, has given way to the four-cycle engine.
With this transition in engine technology came the need for an oil
sump from which the engine could pump and return lubricant. As
outboard engines have historically been constructed with the engine
being vertical in orientation, that is, with the crankshaft
extending vertically, the oil sump has been mounted below the
engine in a compartment not common to the crankcase. The sump
additionally has been configured so that the oil will not flood
into the engine as the engine is trimmed, that is, rotated about a
horizontal axis perpendicular to the axis of propulsion. Thus, for
many conventional outboard motors with such a vertical
configuration (vertically oriented such that the crankshaft is
vertically mounted) traditionally have included these additional
characteristics: (1) sump mounted below the engine; (2) the engine
crankcase communicates to the sump, but is not integral with the
sump; (3) the sump has a geometry that is tall and thin; (4) the
sump will not allow the engine to fill with oil when trimmed to an
extent, such as approximately 70 degrees from horizontal; and (5)
cylinders face aft and are tilted toward vertical when trimmed,
preventing them from filling with oil should any oil be left in the
engine during or after tilting.
[0015] Notwithstanding the traditional prevalence of
vertically-configured outboard motors, horizontally-configured
outboard motors (that is, outboard motors having a
horizontally-oriented engine with a horizontally-extending
crankshaft) have arisen that have somewhat different features,
including: (1) an oil sump which is integral with the crankcase;
(2) cylinders that are generally vertically oriented (or in the
case of a V-type engine, oriented between 30 to 60 degrees from
vertical); and an (3) an oil sump that is long, narrow, and
shallow. Given this arrangement, when the engine is mounted in an
outboard configuration and tilted (as described above in relation
to vertically oriented engine), the engine oil pours out of the oil
sump and into the crankcase of the engine. Consequently, oil that
enters the crankcase can run into the cylinders as one or more of
the cylinders have rotated to a near horizontal position. Yet oil
that enters a cylinder can potentially be detrimental to the
engine, as it can result in bending of the connecting rods due to
hydraulic locking the engine, particularly if enough oil enters the
combustion chamber and is acted upon by the piston.
[0016] Therefore, in view of the above, it would be advantageous if
an improved outboard motor for use with marine vessels, and/or
systems or components thereof, and/or methods or processes for
operating or using same (and/or related methods or processes for
manufacturing such an outboard motor, or systems or components
thereof), could be developed that addressed one or more of the
above concerns and/or provided one or more other or additional
advantages.
BRIEF SUMMARY OF THE INVENTION
[0017] The present inventors have recognized these concerns, and
further have recognized that an improved outboard motor can be
developed that alleviates one or more of these concerns. In at
least some example embodiments, the present invention relates to an
outboard motor for use with a marine vessel comprising and outboard
motor. The outboard motor includes a transmission, an engine
positioned adjacent to the transmission, and a cowling assembly.
The cowling assembly includes at least one outer formation
extending around the transmission and the engine so as to provide a
housing therefore, and a wall formation extending within the outer
formation between the transmission and the engine so as to form a
barrier therebetween, so that an interior within the at least one
outer formation is divided into a plurality of portions including a
first portion and a second portion. The transmission is positioned
at least partly within the first portion and the engine is
positioned at least partly within the second portion.
[0018] There exists a space beneath the wall formation so that the
first portion is in fluid communication with the second portion,
and the at least one outer formation includes at least one inlet
positioned at or proximate to a top of the at least one outer
formation along the first portion so as to allow the first portion
to be in fluid communication with a region outside of the outboard
motor. The outboard motor is configured to allow air to enter the
first portion via the at least one outer formation and to pass from
the first portion into the second portion via the space, whereby,
due to the wall formation, the air entering the outboard motor via
the at least one inlet must pass downward within the first portion
to the space in order for the air to enter into the second portion,
and due to the downward movement of the air, at least some water
entering the at least one inlet along with the air proceeds
downward past the space and does not enter the second portion.
[0019] Additionally in at least some example embodiments, the
present invention relates to a water pump assembly. The water pump
assembly includes a pump housing having an inlet and an outlet, a
first impeller located within the pump housing and configured to
rotate in a rotational plane, about a first axis of rotation, in a
first rotating direction, and a second impeller located within the
pump housing and configured to rotate in the rotational plane,
about a second axis of rotation, in a second rotating direction
that is opposite the first rotating direction.
[0020] Further in at least some example embodiments, the present
invention relates to a vapor separating tank (VST) system. The VST
system includes a first pump configured to receive fuel at a first
pressure from a fuel source and to output the fuel at a second
pressure that is higher than the first pressure, and also includes
a fuel reservoir coupled to the first pump via at least one first
linkage so that the fuel at the second pressure output by the first
pump is received at the fuel reservoir. Further, the VST system
also includes a second pump coupled to the fuel reservoir via at
least one second linkage, where the second pump is configured to
receive the fuel at the second pressure from the fuel reservoir and
to output the fuel at a third pressure that is higher than the
second pressure, and additionally includes an output port by which
at least some of the fuel at the third pressure can be communicated
from the VST system to an internal combustion engine. Also, the VST
system further includes a first pressure regulator at least
indirectly coupled between the output port and the fuel reservoir
by way of at least one third linkage so that, if a first pressure
differential across the first pressure regulator exceeds a first
predetermined threshold, a first fluid communication path is at
least temporarily established between the output port and the fuel
reservoir via the first pressure regulator.
[0021] Additionally in at least some example embodiments, the
present invention relates to an outboard motor having a front
surface and an aft surface and configured to be mounted on a marine
vessel having a front to rear axis, such that the front surface
would face the marine vessel and the aft surface would face away
from the marine vessel when in a standard operational position. The
outboard motor includes a housing having an upper portion and a
lower portion and having an interior, and an internal combustion
engine disposed within the housing interior and that provides
rotational power output via a crankshaft that extends horizontally
or substantially horizontally in a front-to-rear direction when the
outboard motor is in the standard operational position, where the
engine is further disposed substantially or entirely above a
trimming axis and is steerable about a steering axis, the trimming
axis being perpendicular to or substantially perpendicular to the
steering axis, and the steering axis and trimming axis both being
perpendicular to or substantially perpendicular to the
front-to-rear axis of the marine vessel. The outboard motor further
includes a tank positioned within the housing and connected to a
crankcase of the engine, wherein the tank is configured such that
little, if any, of an amount of the lubricant is in or provided to
the tank when the engine is in the standard operational
position.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] FIG. 1 is a schematic view of an example marine vessel
assembly including an example outboard motor;
[0023] FIG. 2 is a right side elevation view of the outboard motor
of FIG. 1;
[0024] FIG. 3 is a rear elevation view of the outboard motor of
FIG. 1;
[0025] FIGS. 4A and 4B are right side elevation views of alternate
embodiments of the outboard motor of FIG. 1;
[0026] FIG. 5 is a further right side elevation view of the
outboard motor of FIG. 1, showing in more detail several example
internal components of the outboard motor particularly revealed
when cowling portion(s) of the outboard motor are removed;
[0027] FIG. 6A is a schematic diagram illustrating in additional
detail several example internal components of the outboard motor of
FIGS. 1 and 5;
[0028] FIG. 6B is a further diagram showing an upper portion of the
outboard motor of FIG. 6 an illustrating an example manner of
configuring the cowling of the outboard motor to allow for opening
and closing of a portion of the cowling so as to reveal internal
components;
[0029] FIGS. 6C-6E illustrate schematically sealing pan features
associated with the engine.
[0030] FIGS. 7A and 7B are schematic diagrams showing in more
detail two example embodiments of a first transmission of the
outboard motor of FIG. 6A;
[0031] FIG. 7C is a cross-sectional view of an alternate embodiment
of a first transmission (transfer case) of the outboard motor of
FIG. 6A that is configured to allow for gear ratio variation, the
cross-section being taken a long a central plane extending through
the central axes of the input and output shafts of the transfer
case;
[0032] FIG. 7D is an additional, partially-cutaway, cross-sectional
view of an upper portion of the first transmission (transfer case)
shown in FIG. 7C, the cross-section being taken along a plane
extending through the central axis of the input shaft of the
transfer case but extending askew of the output shaft central
axis;
[0033] FIG. 7E is a front elevation view of a further alternate
embodiment of a first transmission (transfer case) of the outboard
motor of FIG. 6A that is configured to allow for gear ratio
variation and that also includes an integrated oil pump;
[0034] FIG. 7F is a cross-sectional view of the further alternate
embodiment of the first transmission (transfer case) shown in FIG.
7E, taken along line F-F of FIG. 7E;
[0035] FIGS. 7G, 7H, 7I, 7J, and 7K respectively are left side
perspective, right side perspective, rear elevation, right side,
and front elevation views of the oil pump that is integrated in the
further alternate embodiment of the first transmission (transfer
case) of FIGS. 7E and 7F;
[0036] FIG. 8 is a schematic diagram showing in more detail an
example embodiment of a second transmission of the outboard motor
of FIG. 6A;
[0037] FIGS. 9A-9C are schematic diagrams showing in more detail
three example embodiments of a third transmission of the outboard
motor of FIG. 6A (or a modified version thereof having two
counterrotating propellers);
[0038] FIG. 10A is a cross-sectional view of a lower portion of the
outboard motor of FIGS. 1-3, 5, and 6A, taken along line 10-10 of
FIG. 3, shown cutaway from mid and upper portions of that outboard
motor;
[0039] FIG. 10B is a rear elevation view a gear casing of the lower
portion of the outboard motor of FIG. 1 OA, shown cutaway from the
remainder of the lower portion;
[0040] FIG. 11A is a rear elevation view of upper and mid portions
of the outboard motor of FIGS. 1-3, 5, 6A and 10A-10B, shown with
the cowling of the outboard motor removed to reveal internal
components of the outboard motor including exhaust system
components;
[0041] FIG. 11B illustrates various exhaust system components of
the outboard motor in additional detail;
[0042] FIG. 12 is an enlarged perspective view of the exemplary
mounting system in accordance with embodiments of the present
disclosure;
[0043] FIG. 13 is an enlarged right side elevational view of the
mounting system of FIG. 12;
[0044] FIG. 14 is an enlarged front view of the mounting system of
FIG. 12;
[0045] FIG. 15 is a schematic view of the mounting system of FIG.
12 generally illustrating convergence between the upper mounts and
the lower mounts;
[0046] FIG. 16 is an enlarged top view of the mounting system of
FIG. 12;
[0047] FIG. 17 is a cross sectional view taken along line 17-17 of
FIG. 13 and/or through a tilt tube structure of the mounting system
of FIG. 12;
[0048] FIG. 18 is a right side view of the outboard motor showing
an illustrative outboard motor water cooling system in accordance
with embodiments of the present disclosure;
[0049] FIG. 19 is a schematic illustration of an alternative
arrangement for an outboard motor water cooling system, in
accordance with embodiments of the present disclosure;
[0050] FIG. 20 is a right side view of the outboard motor including
a rigid connection of multiple motor components or structures to
create a rigid structure in accordance with embodiments of the
present disclosure;
[0051] FIG. 21 is a reduced right side view of the outboard motor
and a mounting system for mounting the outboard motor to a marine
vessel;
[0052] FIG. 22 is a schematic cross sectional view, taken along
line 22-22 of FIG. 21, showing a progressive mounting assembly;
[0053] FIGS. 23A-C are schematic illustrations depicting a portion
of the progressive mounting structure of FIG. 21 in operation;
and
[0054] FIG. 24 is a rear elevation view of example structural
support components and other components of an alternate embodiment
of the outboard motor.
[0055] FIG. 25 is a right side elevation view of an example
outboard motor having a cowling system in accordance with at least
some embodiments herein;
[0056] FIG. 26 is a right side elevation cutaway view of a top (or
powerhead) portion of the outboard motor of FIG. 1, with a portion
of the cowling system removed or sectioned so as to reveal at least
some internal components of the outboard motor.
[0057] FIGS. 27 and 28 respectively are rear perspective (3/4) and
front perspective (3/4) cutaway views of the top (or powerhead)
portion of the outboard motor already shown in FIG. 2 (or
substantially the same as that shown in FIG. 2); and
[0058] FIG. 29 is a further top view of the top (or powerhead)
portion of the outboard motor of FIG. 1, with a portion of the
cowling system removed so as to reveal at least some internal
components of the outboard motor;
[0059] FIG. 30 shows an example side elevation view of a
transmission assembly with an integrated water pump;
[0060] FIG. 31 shows an example rear elevation view of the
transmission assembly and integrated water pump of FIG. 30;
[0061] FIG. 32 is a right side cross-sectional cutaway view showing
portions of the transmission assembly and integrated water pump of
FIGS. 30 and 31, particularly, the water pump and lower portions of
the transmission assembly with which the water pump is
integrated;
[0062] FIG. 33 is a rear cross-sectional view of the water pump of
FIGS. 30, 31, and 32;
[0063] FIG. 34 is an exploded view of the water pump of FIGS. 30,
31, 32, and 33; and
[0064] FIGS. 35A and 35B are side perspective views of an example
vapor separating tank (VST) system that can be employed in an
outboard motor in accordance with an embodiment encompassed
herein;
[0065] FIG. 36 is an exploded view of components of the VST system
of FIGS. 35A and 35B;
[0066] FIGS. 37A-37E are cross-sectional views of the VST system of
FIGS. 35A and 35B, with FIGS. 37A-37D showing cross-sectional views
taken along different respective vertical planes extending through
various portions of the VST system and FIG. 37E showing a
cross-sectional view taken along a horizontal plane extending
through a cylindrical axis of a second (high-pressure) regulator of
the VST system;
[0067] FIG. 38 is a schematic view of the VST system of FIGS. 35A
and 35B in relation to an internal combustion engine and fuel
cooler of an outboard motor on which the VST system is implemented,
and additionally in relation to a fuel source (e.g., fuel tank)
from which the outboard motor draws fuel, such as a fuel source
located on a marine vessel to which the outboard motor is
attached;
[0068] FIG. 39 is a schematic view of an alternate embodiment of a
VST system differing from that of FIG. 38;
[0069] FIGS. 40A, 40B, and 40C are end, left side, and right side
elevation views of an alternate embodiment of a VST system
differing form that of FIGS. 35A and 35B;
[0070] FIG. 41 is a further right side elevation view of the
outboard motor of FIG. 25, showing in more detail several example
internal components of the outboard motor particularly revealed
when cowling portion(s) of the outboard motor are removed (with the
outboard motor being shown in a first or standard operating or
operational position), showing in detail several example internal
components of the outboard motor (again particularly revealed when
cowling portion(s) of the outboard motor are removed) such as the
VST system of FIGS. 35A and 35B and a tank for holding oil, or
other lubricant(s), in accordance with embodiments of the present
disclosure;
[0071] FIG. 42 is a front elevation view of the outboard motor of
FIG. 41;
[0072] FIG. 43 is a rear elevation view of the outboard motor of
FIG. 41;
[0073] FIG. 44 is a right side elevation view of the outboard motor
of FIG. 41, with the outboard motor now shown such that it has been
tilted, rotated and/or otherwise moved and is positioned in a
second operating or operational position;
[0074] FIG. 45 is a front elevation view of the outboard motor of
FIG. 44, that is with the outboard motor again shown in the second
operating or operational position;
[0075] FIG. 46 is a right side elevation view of the outboard motor
of FIG. 41, with the outboard motor now shown such that it has been
further tilted, rotated and/or otherwise moved so that it is
positioned a third operating or operational position;
[0076] FIG. 47 is a front elevation view of the outboard motor of
FIG. 46, that is with the outboard motor again shown in the third
operating or operational position;
[0077] FIG. 48 is a right side elevation view of the outboard motor
of FIG. 41, with the outboard motor now shown such that it has been
still further tilted, rotated and/or otherwise moved so that it is
positioned in a first storage position, such as a position in which
the outboard motor can be serviced or transported from one location
to another;
[0078] FIG. 49 is a front elevation view of the outboard motor of
FIG. 48, that is with the outboard motor again shown in the first
storage position;
[0079] FIG. 50 is a right side elevation view of the outboard motor
of FIG. 41, with the outboard motor now shown such that it has been
yet still further tilted, rotated and/or otherwise moved so that it
is positioned in a second storage position;
[0080] FIG. 51 is a front elevation view of the outboard motor of
FIG. 48, that is with the outboard motor again shown in the second
storage position; and
[0081] FIG. 52 is an illustration of a right side elevation cutaway
of view of upper portions of a Prior Art outboard motor.
DETAILED DESCRIPTION OF THE INVENTION
[0082] The present inventors have recognized that vertical
crankshaft engines, which are naturally suited for outboard motor
applications insofar as the crankshafts naturally are configured to
deliver rotational power downward from the engines to the
propellers situated at the bottoms of the outboard motors for
interaction with the water, nevertheless impose serious limits on
the development of higher power systems, because the development of
vertical crankshaft engines capable of achieving substantial
increases in power output in outboard motor marine propulsion
systems has proven to be very time-consuming, complicated, and
costly. Additionally, the present inventors have recognized that it
is possible to implement horizontal crankshaft engines in outboard
motor marine propulsion systems, and that the use of horizontal
crankshaft engines opens up the possibility of using a wide variety
of high quality, relatively inexpensive engines (including, for
example, many automotive engines) in outboard motor marine
propulsion systems that can yield dramatic improvements in the
levels of power output by outboard motor marine propulsion systems
as well as one or more other types of improvements as well.
[0083] Relatedly, the present inventors have recognized one or more
features that, depending upon the embodiment, can be employed in
the design of outboard motor marine propulsion systems utilizing
horizontal crankshaft engines that can enhance the performance of
such systems and allow for more streamlined, more efficient, and
otherwise more effective integration of horizontal crankshaft
engines in relation to other system components. For example, in
some embodiments, a three-part transmission (including, further for
example, a forward-neutral-reverse transmission) can be utilized so
as to deliver and allow for the delivery of rotational power from
the engine to the propeller(s). Also for example, in some
embodiments, exhaust from the engine can be delivered by way of
exhaust conduit(s) to the gear assembly and out a rear hub
proximate a propeller of the assembly. Further for example, in at
least some embodiments, some of the water within which the marine
vessel is situated can be utilized for cooling of gear portions
and/or for cooling the engine itself, via a heat exchanger. Also
for example, the mounting system by which the outboard motor is
attached to the marine vessel itself can have one or more
particular attributes that reflect, and take advantage of, the use
of a horizontal crankshaft engine.
[0084] Further, the present inventors have recognized that a
variety of implementations and embodiments of transmission devices
can be implemented in one or more such outboard motors. For
example, transmission devices can be employed in which one or more
internal power train components such as one or more gears can be
accessed and replaced so as to modify operational parameter(s) of
the transmission devices, for example, a gear ratio of a
transmission device. This can be achieved, in at least some
embodiments for example, by providing a cover portion on the
transmission device that can be removed to allow access of the one
or more internal power train components. Further, in some such
transmission devices, an oil pump can be integrated with the
transmission device and particularly mounted upon a rotating shaft
associated with the transmission device such that, when the
transmission is operating such that the rotating shaft is
experiencing rotation, the oil pump pressurizes and outputs oil for
use by any one or more of a variety of components that can benefit
from such oil.
[0085] Additionally, the present inventors have also recognized
that one or more other features can be provided in an outboard
motor so as to achieve enhanced performance in one or more
respects. Among other things, such features can include an enhanced
cowling system having a configuration that minimizes or reduces the
amount of water that can reach water-sensitive internal components
of the outboard motor (e.g., the engine or throttle) and/or,
relatedly, facilitates the elimination or discharge of such water
from the outboard motor. More particularly, in one such enhanced
cowling system encompassed herein, the cowling system (or cowling)
is divided into first and second portions. A first portion is
implemented around the transmission, which is insensitive to water
submersion, and air enters the outboard motor via the first
portion. A second portion is enclosed around the engine. Airflow
passages connect the two portions in such a manner as to allow
passage of air but discourage passage of water toward the
engine.
[0086] Also, such features for allowing an outboard motor to
achieve enhanced performance in at least some embodiments can
include a water pump configuration that improved upon existing
water pump configurations in terms of any one or more of enhancing
compactness, reducing part count, improving durability, or
enhancing other aspects of the outboard motor. In at least some
such embodiments, an outboard motor includes an engine mounted
circulation pump that is provided with automotive type engines but
integrates the sea pump into the transmission of the outboard
motor. Also, in at least some such embodiments, such an arrangement
enhances compactness, reduces parts count, and/or enhances
durability of the water pumping arrangement by the elimination of
external plumbing and rubber belt drive systems.
[0087] Additionally, in some embodiments, the outboard motor
includes a vapor separating tank (VST) feature that prevents (or
substantially limits) vaporized fuel from reaching the engine or
engine combustion chambers. In at least some such embodiments, the
VST feature includes a low pressure pump that pumps fuel received
from a fuel source to a fuel mixer or filter, where the fuel
exiting the low pressure pump is at a low (or medium) pressure
level, and then additionally includes a high pressure pump that
receives fuel from the fuel mixer or filter and further pressurizes
the fuel to a high (or higher) pressure level suitable for the
engine. Further, in at least some embodiments, the outboard motor
includes an additional oil tank that is positioned proximate the
front of the engine and serves to receive oil that will drain from
the engine when the outboard motor is tilted (trimmed) to a
non-operating orientation, so as to collect oil and prevent oil
from collecting (or limit the extent to which oil collects) in any
cylinders of the engine during engine storage in the non-operating
orientation.
[0088] Therefore, numerous embodiments of outboard motors and
related systems and components thereof, as well as arrangements of
marine vessels implementing same, as well as related methods of
operation, use, assembly, and manufacture, and related
improvements, are disclosed herein. In at least some embodiments,
the outboard motor includes a cowling system in which at least one
divider portion separates an interior region into first and second
portion, with the transmission and engine respectively being
situated in the first and second portions, respectively. Air for
use by the engine enters the outboard motor via air inlets in the
first portion, proceeds downward within that portion to a space in
the at least one divider portion, and then proceeds through the
space and upward into the second portion. Additionally, in at least
some embodiments, the outboard motor includes a water pump system
in which a water pump is integrated with the transmission. The
water pump includes a single inlet for water that is then driven by
two counterrotating impellers and can ultimately be driven through
each of higher and lower velocity outlets. Further, in at least
some embodiments, the outboard motor includes a fuel vaporization
suppression feature. Additionally, in at least some embodiments,
the outboard motor includes an oil tank feature that allows for
desirable oil drainage from the engine of the outboard motor
particularly when the outboard motor is in particular (e.g.,
storage) positions.
[0089] Notwithstanding the above comments, it should be understood
that, depending upon the embodiment, one or more of these types of
features can be present and/or one or more of these various
features need not be present. Further, the present inventors have
additionally realized that one or more of these features can
potentially be advantageously implemented in embodiments of
outboard motor marine propulsion systems even though other(s) of
these features are not present, and even potentially where other
types of engines other than horizontal crankshaft engines are being
utilized (or even possibly in some sterndrive or other marine
propulsion systems where the engine is not integrated with the
outboard assembly).
[0090] Referring to FIG. 1, an example marine vessel assembly 100
is shown to be floating in water 101 (shown in cut-away) that
includes, in addition to an example marine vessel 102, an example
outboard motor marine propulsion system 104, which for simplicity
is referred to below more simply as an outboard motor 104. As
shown, the outboard motor 104 is coupled to a stern (rear) edge or
transom 106 of the marine vessel 102 by way of a mounting system
108, which is described in further detail below. Also described
below, the mounting system 108 will be considered, for purposes of
the present discussion, to be part of the outboard motor 104
although one or more components of the mounting system can
technically be assembled directly to the stern edge (transom) 106
and thus could also be viewed as constituting part of the marine
vessel 102 itself. In the present embodiment shown, the marine
vessel 102 is shown to be a speed boat although, depending upon the
embodiment, the marine vessel can take a variety of other forms,
including a variety of yachts, other pleasure craft, as well as
other types of boats, marine vehicles and marine vessels.
[0091] As will be discussed in further detail below, the mounting
system 108 allows the outboard motor 104 to be steered about a
steering (vertical or substantially vertical) axis 110 relative to
the marine vessel 102, and further allows the outboard motor 104 to
be rotated about a tilt or trimming axis 112 that is perpendicular
to (or substantially perpendicular to) the steering axis 110. As
shown, the steering axis 110 and trimming axis 112 are both
perpendicular to (or substantially perpendicular to) a
front-to-rear axis 114 generally extending from the stern edge 106
of the marine vessel toward a bow 116 of the marine vessel.
[0092] The outboard motor 104 can be viewed as having an upper
portion 118, a mid portion 120 and a lower portion 122, with the
upper and mid portions being separated conceptually by a plane 124
and the mid and lower portions being separated conceptually by a
plane 126 (the planes being shown in dashed lines). Although for
the present description purposes the upper, mid and lower portions
118, 120 and 122 can be viewed as being above or below the planes
124, 126, these planes are merely provided for convenience to
distinguish between general sections of the outboard motor, and
thus in certain cases it may be appropriate to refer to a section
of the outboard motor that is positioned above the plane 126 (or
plane 124) as still being part of the lower portion 122 (or mid
portion 120) of the outboard motor view, or to refer to a section
of the outboard motor that is positioned below the plane 126 (or
plane 124) as still being part of the mid portion 120 (or upper
portion 118). This is the case, for example, in the discussion with
respect to FIG. 10A.
[0093] Nevertheless, generally speaking, the upper portion 118 and
mid portion 120 can be understood as generally being positioned
above and below the plane 124, while the mid portion 120 and lower
portion 122 can be understood as generally being positioned above
and below the plane 126. Further, each of the upper, mid, and lower
portions 118, 120, and 122 can be understood as generally being
associated with particular components of the outboard motor 104. In
particular, the upper portion 118 is the portion of the outboard
motor 104 in which the engine or motor of the outboard motor
assembly is entirely (or primarily) located. In the present
embodiment, given the positioning of the upper portion 118, the
engine therewithin (e.g., internal combustion engine 504 discussed
below with respect to FIG. 5) particularly can be considered to be
substantially above (or even entirely above) the trimming axis 112
mentioned above. Given such positioning, the engine essentially is
not in contact with the water 101 during operation of the marine
vessel 102 and outboard motor 104, and advantageously the outside
water 101 does not tend to enter cylinder ports of the engine or
otherwise deleteriously affect engine operation. Such positioning
further is desirable since, by positioning the engine above the
trimming axis 112, the mounting system 108 and the transom 106 to
which it is attached can be at a convenient (e.g.,
not-excessively-elevated) location along the marine vessel 102.
[0094] By comparison, the lower portion 122 is the portion that is
typically within the water during operation of the outboard motor
104 (that is, beneath a water level or line 128 of the water 101),
and among other things includes a gear casing (or torpedo section),
as well as a propeller 130 as shown (or possibly multiple
propellers) associated with the outboard motor. The mid portion 120
positioned between the upper and lower portions 118, 122 as will be
discussed further below can include a variety of components and,
among other things in the present embodiment, will include
transmission, oil reservoir, cooling and exhaust components, among
others.
[0095] Turning next to FIGS. 2 and 3, a further side elevation view
(right side elevation view) and rear view of the outboard motor 104
of FIG. 1 are provided. It will be understood that the left side
view of the outboard motor 104 is in at least some embodiments a
mirror image of the right side view provided in FIG. 2. In
particular, FIGS. 2 and 3 again show the outboard motor 104 as
having the upper portion 118, mid portion 120 and lower portion 122
separated by the planes 124 and 126, respectively. Further, the
steering axis 110 and trimming (or tilt) axis 112 are also shown.
The mounting system 108 is particularly evident from FIG. 2, as is
the propeller 130 (which is not shown in FIG. 3). FIGS. 2 and 3
particularly show several features associated with an outer housing
or cowling 200 of the outboard motor 104. Among other things, the
cowling 200 includes air inlet scoops (or simply air inlet) 202
along upper side surfaces of the upper portion 118 of the outboard
motor 104, one of which is shown in the right side elevation view
provided in FIG. 2 (it being understood that a complimentary air
inlet is provided on the left side of the cowling 200). In the
present embodiment, the air inlet scoops 202 extend in a
rearward-facing direction and serve as an entry for air to be used
in the engine of the outboard motor 104 (see FIG. 5). The high
positioning of the air inlet scoops 202 reduces the extent to which
seawater can enter into the air inlets.
[0096] Additionally as shown, also formed within the cowling 200
are exhaust bypass outlets 204, which are shown in further detail
in FIG. 3 to be rearward-facing oval orifices in the upper portion
118 of the outboard motor 104 extending into the cowling 200. As
discussed further below, the exhaust bypass outlets 204 in the
present embodiment serve as auxiliary (or secondary) outlets for
exhaust generated by the engine of the outboard motor 104. As such,
exhaust need not always (or ever) flow out of the exhaust bypass
outlets 204, albeit in the present embodiment it is envisioned that
under at least some operational circumstances the exhaust will be
directed to flow out of those outlets.
[0097] Further as evident from FIG. 2, the lower portion 122 of the
outboard motor 104 includes a gear casing (or torpedo) 206
extending along an elongated axis 208 about which the propeller 130
spins when driven. Downwardly-extending from the gear casing 206 is
a downwardly-extending fin 210. Referring particularly to FIG. 3,
it should further be understood that an orifice (actually multiple
orifices as discussed further with respect to FIGS. 10A and 10B)
302 is formed at a rearward-most end or hub 212 of the gear casing
206 that surrounds a propeller driving output shaft 212 extending
along the axis 208. As will be discussed further below, this
orifice 302 forms a primary exhaust outlet for the outboard motor
104 that is the usual passage out of which exhaust is directed from
the engine of the outboard motor (as opposed to the exhaust bypass
outlets 204).
[0098] Referring additionally to FIGS. 4A and 4B, first and second
alternate embodiments 402 and 404, respectively, of the outboard
motor 104 are shown. Each of these alternate embodiments 402, 404
is substantially identical to the outboard motor 104 shown in FIG.
2, except insofar as the mid portion 120 of the outboard motor 104
is changed in its dimensions in each of these other alternate
embodiments. More particularly, a leg lengthening section 408 of a
mid portion 410 of the first alternate embodiment 402 of FIG. 4A is
shortened relative to the corresponding leg lengthening section of
the mid portion 120 of the outboard motor 104, while a leg
lengthening section 412 of a mid portion 414 of the second
alternate embodiment 404 of FIG. 4B is elongated relative to the
corresponding section of the mid portion 120 of the outboard motor
104. Thus, with such variations, the positioning of the lower
portion 122 can be raised or lowered relative to the upper portion
118 depending upon the embodiment and particularly the leg
lengthening section of the mid portion.
[0099] Turning to FIG. 5, a further right side elevation view of
the outboard motor 104 is provided that differs from that of FIG. 2
at least insofar as the cowling 200 (or, portions thereof) is
removed from the outboard motor to reveal various internal
components of the outboard motor, particularly within the upper
portion 118 and mid portion 120 of the outboard motor. At the same
time, the lower portion 122 of the outboard motor 104 is viewed
from outside the cowling 200 of the outboard motor, as is a lower
section of the middle portion 120 that can be termed a midsection
502 of the middle portion 200. Again though, above the midsection
502, various internal components of the outboard motor 104 are
revealed. As with the views provided in FIG. 2 and FIG. 4, the view
in FIG. 5 is the mirror image (or substantially a mirror image) of
the left side elevation view that would be obtained if the outboard
motor were viewed from its opposite side (with the cowling
removed).
[0100] More particularly as shown in FIG. 5, an engine 504 of the
outboard motor 104 is positioned within the upper portion 118 of
the outboard motor, entirely or at least substantially above the
trimming axis 112 as mentioned earlier. In at least some
embodiments, and in the present embodiment, the engine 504 is a
horizontal crankshaft internal combustion engine having a
horizontal crankshaft arranged along a horizontal crankshaft axis
506 (shown as a dashed line). Further, in at least some embodiments
and in the present embodiment, the engine 504 not only is a
horizontal crankshaft engine, but also is a conventional automotive
engine capable of being used in automotive applications and having
multiple cylinders and other standard components found in
automotive engines. More particularly, in the present embodiment,
the engine 504 particularly is an eight-cylinder V-type internal
combustion engine such as available from the General Motors Company
of Detroit, Mich. for implementation in Cadillac (or alternatively
Chevrolet) automobiles. Further, the engine 504 in at least some
embodiments is capable of outputting power at levels of 550
horsepower or above, and/or power within the range of at least 557
horsepower to at least 707 horsepower.
[0101] As an eight-cylinder engine, the engine 504 has eight
exhaust ports 508, four of which are evident in FIG. 5, emanating
from the left and right sides of the engine. The four exhaust ports
508 emanating from the right side of the engine 504 particularly
are shown to be in communication with an exhaust manifold 510 that
merges the exhaust output from these exhaust ports into an exhaust
channel 512 that leads downward from the exhaust manifold 510 to
the midsection 502. It will be understood that a complimentary
exhaust manifold and exhaust channel are provided on the left side
of the engine to receive the exhaust from the corresponding exhaust
ports on that side of the engine. As will be described in further
detail below, both of the exhaust channels (including the exhaust
channel 512) upon reaching the midsection 502 further are coupled
to the lower portion 122 at which the exhaust is ultimately
directed through the gear casing 206 and out the orifice 302
serving as the primary exhaust outlet. It should further be noted
that, given the use of the horizontal crankshaft engine 504, all of
the steam relief ports associated with the various engine cylinders
are at a shared, high level, above the crankshaft (all or
substantially all steam in the engine therefore rises to a shared
engine level). Also the accessory drive and heat exchanger system
are accessible at the front of the engine 504 (particularly when
the lid portion of the cowling 200 is raised as discussed further
below). In addition to showing the aforementioned components, FIG.
5 additionally shows a transfer case 514 within which is provided a
first transmission as discussed further below, and a second
transmission 516 that is located below the engine 504.
[0102] Further, FIG. 5 shows the mounting system 108, including a
lower mounting bracket structure 518 of the mounting system 108 by
which the midsection 502 of the mid portion 120 of the outboard
motor 504 is linked to the mounting system, and also an upper
mounting bracket 520 by which the mounting system is attached to an
upper section of the mid portion 120. An elastic axis of mounting
519 is provided and passes through the upper mounting bracket 520
and the lower mounting bracket 518. In at least some embodiments,
the center of gravity of the engine 504 is in line with the elastic
axis of mounting. Also FIG. 5 shows a lower water inlet 522
positioned along a front bottom section of the gear casing 206
forward of the fin 210, as well as an upper water inlet 524 and
associated cover plate 526 provided near the front of the lower
portion 122, about midway between the top and bottom of the lower
portion. The lower and upper water inlets 522, 524 and associated
cover plates 526 (there is also a corresponding upper water inlet
and associated cover plate on the left side of the lower portion
122) are discussed further with respect to FIG. 10A. All of these
components, and additional components of the outboard motor 104,
are discussed and described in further detail below.
[0103] Turning to FIG. 6A, a further right side elevation view of
the outboard motor 104 is provided in which the relationship of
certain internal components of the outboard motor are figuratively
illustrated in phantom. More particularly as shown, the outboard
motor 104 again is shown to include the engine 504 (this time as
represented by a dashed outline in phantom) within the upper
portion 118 of the outboard motor. Further as illustrated,
rotational power output from the engine 504 is delivered from the
engine and to the propeller 130 of the outboard motor by way of
three distinct transmissions. More particularly as shown,
rotational output power is first transmitted outward from a rear
face 602 of the engine 504, along the crankshaft axis 506 as
represented by an arrow 604, to a first transmission 606 shown in
dashed lines (the power being transmitted by the crankshaft, not
shown). A flywheel 607 of the outboard motor 104 is further
positioned between the rear of the engine 504 and the first
transmission 606, on the crankshaft, for rotation about the
crankshaft axis 506.
[0104] Referring additionally to FIG. 6B, an additional cutaway
view of the upper portion 118 of the outboard motor 104 shown in
FIG. 6A is provided so as to particularly illustrate a portion of
the cowling 200, shown as a cowling portion 650, that is hinged
relative to the remainder of the cowling by way of a hinge 652. As
a result of the particular manner in which the cowling portion 650
is hingedly coupled to the remainder of the cowling 200, the
cowling portion 650 is able to be opened in a manner by which the
cowling swings upward and aftward relative to the remainder of the
cowling, in a direction represented by an arrow 654. Thus, the
cowling portion 650 can take on both a closed position (shown in
FIG. 6B in solid lines) and an open position (shown in dashed
lines), as well as positions intermediate therebetween. Further,
because the cowling portion 650 includes a front side 656 that
extends all or almost all of (or a large portion of) the height of
the upper portion 118 of the outboard motor 104, opening of the
cowling portion in this manner allows the engine 504 to be largely
exposed and particularly for a front portion 658 of the engine 504
and/or a top portion 660 of the engine to be easily accessed, and
particularly easily accessed by a service technician or operator
standing at the stern of the marine vessel 102 to which the
outboard motor 104 is attached. In embodiments where the engine 504
is a horizontal crankshaft engine, particularly an automotive
engine as mentioned above, servicing of the engine (and
particularly those portions or accessories of the engine that most
commonly are serviced, such as oil level, spark plugs, belts,
and/or various electrical components) can be particularly
facilitated by this arrangement. Also, an accessory drive,
extending from the front of the engine 504, along with an
associated accessory drive belt, can be accessed in this
manner.
[0105] Referring again to FIG. 6A, the purpose of the first
transmission 606 is first of all to transmit the rotational power
from the crankshaft axis 506 level within the upper portion 118 of
the engine 104 to a lower level corresponding to a second
transmission 608 (also shown in dashed lines) within the mid
portion 120 of the outboard motor 104 (the upper portion 118 and
middle portion 120 again being separated by the plane 124). Thus,
an arrow 610 is shown connecting the arrow 604 with a further arrow
612 at a set level 611 of the second transmission 608. The arrow
612, which links the arrow 610 with the second transmission 608, is
representative of a shaft or axle (see FIG. 7) linking the first
transmission 606 with the second transmission 608, by which
rotational power is communicated in a forward direction within the
outboard motor 104 from the first transmission to the second
transmission. Additionally, a further arrow 614 then represents
communication of the rotational power downward again from the level
of the second transmission 608 within the mid portion 120 to a
third transmission 616 within the gear casing 206 of the lower
portion 122. In accordance with at least one aspect, the gear
casing 206 has a center of pressure 207 that is aft of the elastic
axis of mounting (FIG. 5). Finally, as indicated by an arrow 618,
rotational power is communicated from the third transmission 616
aftward (rearward) from that transmission to the propeller 130
along the axis 208. It can further be noted that, given this
arrangement, the flywheel 607 mentioned above is aft of the engine
504, forward of the first transmission 606, and above each of the
second and third transmissions 608 and 616. In at least some
embodiments, an oil pump is provided that is concentrically driven
by the engine crankshaft.
[0106] Thus, in the outboard motor 104, power output from the
engine 504 follows an S-shaped route, namely, first aftward as
represented by the arrow 604, then downward as represented by the
arrow 610, then forward as represented by the arrow 612, then
downward again as represented by the arrow 614 and then finally
aftward again as represented by the arrow 618. By virtue of such
routing, rotational power from the horizontal crankshaft can be
communicated downward to the propeller 130 even though the power
take off (that is, the rotational output shaft) of the engine is
proximate the rear of the outboard motor 104/cowling 200. Although
it is possible that, in alternate embodiments, rotational power
need not be communicated in this type of manner, as will be
described further below, this particular manner of communicating
the rotational power via the three transmissions 606, 608, 616 is
consistent with, and makes possible, a number of advantages.
Additionally, it should further be noted that in FIG. 6A, a center
of gravity 617 of the engine 504 is shown to be above the
crankshaft axis 506, and a position of the mounting pad for the
engine block 620 is also shown (in phantom) to be located
substantially at the level of the crankshaft axis 506.
[0107] In addition to showing the above features of the outboard
motor 104 particularly relating to the transmission of power within
the outboard motor, FIG. 6A also shows certain aspects of an oil
system of the outboard motor 104. In particular, in the present
embodiment, it should be understood that each of the engine 504,
the first transmission 606, the second transmission 608, and the
third transmission 616 includes its own dedicated oil reservoir,
such that the respective oil sources for each of these respective
engine components (each respective transmission and the engine
itself) are distinct. In this regard, the oil reservoirs for the
first transmission 606 and third transmission 616 can be considered
part of those transmissions (e.g., the reservoirs can be the bottom
portions/floors of the transmission housings). As for the engine
504, an engine oil reservoir 622 extends below the engine itself,
and in this example extends partly into the mid portion 120 of the
outboard motor 104 from the upper portion 118. Notwithstanding the
present description, the engine oil reservoir 622 can also be
considered to be part of the engine itself (in such case, the
engine 504 is substantially albeit possibly not entirely above the
trimming axis 112; alternatively, the engine oil reservoir 622 can
be considered distinct from the engine per se, in which case the
engine is entirely above the trimming axis). In accordance with
other embodiments of the present disclosure, a dry sump (not shown)
can be provided, separate and apart from the engine oil reservoir
622. And in accordance with embodiments of the present disclosure,
a circulation pump is provided, for example, as part of the engine
to circulate glycol, or a like fluid.
[0108] Further, FIG. 6A particularly shows that a second
transmission oil reservoir 624 is positioned within the mid portion
120 of the outboard motor 104, beneath the second transmission 608.
This positioning is advantageous for several reasons. First, as
will be discussed further below, the positioning of the second oil
transmission reservoir 624 at this location allows cooling water
channels to pass in proximity to the reservoir and thus facilitates
cooling of the oil within that reservoir. Additionally, the
positioning of the second oil transmission reservoir 624 at this
location is advantageous in that it makes use of interior space
within the mid portion 120 which otherwise would serve little or no
purpose (other than as a housing for the shaft connecting the
second and third transmissions and for cooling and exhaust pathways
as discussed below), as a site for storing oil that otherwise would
be difficult to store elsewhere in the outboard motor. Indeed,
because as discussed below the second transmission 608 is a
forward-neutral-reverse (FNR) transmission, that transmission
utilizes a significant amount of oil (e.g., 10 quarts or 5 Liters)
and storage of this amount of oil requires a significant amount of
space, which fortunately is found at the mid portion 120 (within
which is positioned the second oil transmission reservoir 624
capable of holding such amounts of oil).
[0109] Turning next to FIGS. 6C-6D, additional features of the
outboard motor 104 are shown, particularly in relation to the cowl
200 and a watertight sealing pan beneath the engine 104. As
illustrated particularly in FIG. 6C (which shows a cutaway view of
the upper portion 118), the cowl 200 particularly serves to house
the engine 504 and serves to separate the engine compartment from
other remaining portions of the outboard motor 104 to provide a
clean and dry environment for the engine. For this purpose, in
combination with the cowl 200, the outboard motor 104 additionally
includes a substantially watertight sealing pan 680 that is
positioned beneath the engine 504. Referring additionally to FIG.
6D, which schematically provides a top view of the watertight
sealing pan 680. In particular as shown, the watertight sealing pan
680 includes valves 682 that allow water that resides in the
watertight sealing pan to exit the watertight sealing pan, but that
preclude water from reentering the watertight sealing pan. As for
FIG. 6E, a further schematic view illustrates a rights side view of
the upper portion 118 and a section of the mid portion 120 to
illustrate how the exhaust conduits 512 pass through holes separate
from the first transmission 606 through the sealing pan.
[0110] Turning next to FIGS. 7A-9C, internal components of the
first, second and third transmissions 606, 608 and 616 are shown.
It should be understood that, notwithstanding the particular
components shown in FIGS. 7A-9C, it is envisioned that the first,
second and third transmissions can take other forms (with other
internal components) in other embodiments as well. Particularly
referring to FIG. 7A, both a rear elevation view and also a right
side elevation view (corresponding respectively to the views
provided in FIG. 3 and FIG. 2) of internal components 702 of the
first transmission 606 are shown. In this embodiment, the first
transmission 606 is a parallel shaft transmission that includes a
series of first, second and third gears 704, 706 and 708,
respectively, that are each of equal diameter and are arranged to
engage/interlock with one another in line between the crankshaft
axis 506 and the level 611 previously discussed with reference to
FIG. 6A. All three of the first, second and third gears 704, 706
and 708 are housed within an outer case 710 of the first
transmission 606. An axis of rotation 712 of the second gear 706
positioned in between the first gear 704 and the third gear 708 is
parallel to the first axis 506 and level 611, and all of the first
axis 506, level 611 and axis of rotation 712 are within a shared
vertically-extending or substantially vertically-extending
plane.
[0111] As will be understood, because there are three gears,
rotation of the first gear 704 in a first direction represented by
an arrow 714 (in this case, being counterclockwise as shown in the
rear view) produces identical counterclockwise rotation in
accordance with an arrow 716 of the third gear 708, due to
intermediary operation of the second gear 706, which rotates in the
exact opposite (clockwise) direction represented by an arrow 718.
Thus, in this embodiment, rotation of a crankshaft 720 of the
engine (as shown in cutaway in the side elevation view) about the
crankshaft axis 506 produces identical rotation of an intermediate
axle 722 rotating about the level 611, the intermediary axle 722
linking the third gear 708 with the second transmission 608.
[0112] Although in the present embodiment of FIG. 7A, each of the
first, second and third gears 704, 706 and 708 are of equal
diameter, in other embodiments the gears can have different
diameters such that particular rotation of the crankshaft 720
produces a different amount of rotation of the intermediary axle
722 in accordance with stepping up or stepping down of gear ratios.
In addition, depending upon the embodiment, the number of gears
linking the crankshaft 720 with the intermediary axle 722 need not
be three. If an even number of gears is used, it will be understood
that the intermediary axle will rotate in a direction opposite that
of the crankshaft. Further, in at least some embodiments, the
particular gears employed in the first transmission can be varied
depending upon the application or circumstance, such that the
outboard motor 104 can be varied in its operation in real time or
substantially real time. For example, a 3-gear arrangement can be
replaced with a 5-gear arrangement, or a 3 to 2 step down gear
ratio can be modified to a 2 to 3 step up ratio.
[0113] Notwithstanding the embodiment of the first transmission 606
shown in FIG. 7A, in an alternate embodiment of the first
transmission shown in FIG. 7B as a transmission arrangement 730,
internal components 732 of the transmission include a chain 734
that links a first sprocket 736 with a second sprocket 738, where
the first sprocket 736 is driven by a crankshaft 740 and the second
sprocket 738 drives an intermediary axle 742 (intended to link the
second sprocket 738 to the second transmission 608). Due to
operation of the chain 734, rotation of the crankshaft 740 in a
particular direction produces identical rotation of the
intermediary axle 742. Also as shown, the chain 734 and sprockets
736, 738 are housed within an outer case 744.
[0114] Notwithstanding the embodiments shown in FIGS. 7A-7B, it
should be understood that a variety of other transmission types can
be employed in other embodiments to serve as (or in place of) the
first transmission 606. For example, in some embodiments, a first
wheel (or pulley) driven by the crankshaft (power take off from the
engine 504) can be coupled to a second wheel (or pulley) for
driving the intermediate axle (for driving the second transmission
608) by way of a belt (rather than a chain such as the chain 734).
In still another embodiment, a 90 degree type gear driven by the
crankshaft can drive another 90 degree type gear in contact with
that first 90 degree gear, and that second 90 degree gear can drive
a further shaft extending downward (e.g., along the arrow 610 of
FIG. 6A) so as to link that second gear with a third 90 degree gear
that is located proximate the level 611. The third 90 degree gear
can turn a fourth 90 degree gear that is coupled to the
intermediary axle and thus provides driving power to the second
transmission 608.
[0115] Additionally, as already noted, in at least some
embodiments, the particular gears (or other components) employed in
the first transmission can be varied depending upon the application
or circumstance, such that the gear ratio between the input and
output of that first transmission can be varied and such that the
outboard motor 104 can consequently be varied in its operation in
real time or substantially real time. One further example of a
first transmission that particularly allows for such gear ratio
variation is shown to be a transfer case 751 in FIGS. 7C and 7D,
where the transfer case 751 is configured to be coupled (and
mounted in relation) to the engine 504 to receive input power
therefrom, and also to the second transmission 608 (to which output
power from the transfer case is provided).
[0116] As shown, in this embodiment, the transfer case 751 includes
an input shaft 758, a first change gear 760, a second change gear
765, an intermediate shaft 771, a further gear 766, an additional
gear 772, a lay shaft 773, a final output gear 774, and an output
shaft 775. The first change gear 760 is particularly mounted upon
the input shaft 758 by way of a splined coupling, and the second
change gear 765 is mounted upon the intermediate shaft 771 also via
a splined coupling. During normal operation, the transfer case 751
operates by transmitting power received from the engine 504 via the
input shaft 758. Rotation of the input shaft 758 drives rotation of
the first change gear 760, which meshes with and consequently
drives the second change gear 765. Power is then transmitted from
the second change gear 765 by way of the intermediate shaft 771 to
the further gear 766, which is also mounted upon the intermediate
shaft 771. The further gear 766 drives the additional gear 772 that
is mounted to the lay shaft 773. The additional gear 772 in turn
meshes with and drives the final output gear 774, which is mounted
to the output shaft 775, thus allowing for the delivery of output
power from the output shaft that can be provided to the second
transmission 608.
[0117] Further as shown, the transfer case 751 has particular
features that facilitate modification of gear/power train
components within the transfer case. The transfer case 751 has a
primary cover 752 that serves as a housing that surrounds and
encloses the transfer case and the gears/power train components
therewithin (including the aforementioned first change gear 760,
second change gear 765, intermediate shaft 771, further gear 766,
additional gear 772, lay shaft 773, final output gear 774, and at
least portions of the input shaft 758 and output shaft 775).
However, as should be particularly evident from FIG. 7D, the
primary cover 752 does not entirely enclose all of the gears/power
train components but rather has an orifice 790 at an upper
rear-facing region of the primary cover by way of which the first
and second change gears 760, 765 are accessible from outside of the
primary cover to allow for modifications to the gears/power train
components so as to result in gear ratio modifications. So that the
gears/power train components can be fully enclosed (and protected
from the outside environment) once a desired arrangement and gear
ratio have been achieved, the transfer case 751 additionally
includes a change gear (or simply gear) cover 753, which can be
assembled to the primary cover 752 (e.g., by way of bolts or other
fastening structures) so as to cover over the orifice 790. The gear
cover 753 in the present embodiments additionally serves to support
some of the gear/power train components of the transfer case 751
when it is assembled to the primary cover 752.
[0118] In addition to the above, FIGS. 7C and 7D show further
features of the transfer case 751 and gears/power train components
therewithin. More particularly, the respective first change gear
760 can be securely fastened to the input shaft 758 via a first nut
761 (see FIG. 7D) and the second change gear 765 can be securely
fastened to the intermediate shaft 771 by way of a second nut
(which is not shown, but should be understood to be of the same
type as the first nut and at a location in relation to the second
change gear that corresponds to the location of the first nut
relative to the first change gear). Additionally as shown, each of
the input shaft 758 and the intermediate shaft 771 is
suspended/supported within (or relative to) the transfer case 751
by way of a respective pair of roller bearing assemblies 791
respectively positioned at opposite ends of the respective shaft
within the transfer case (at opposite ends proximate the front and
rear of the transfer case 751). More particularly, the input shaft
758 is supported by a first roller bearing assembly 792 located
proximate the front of the transfer case 751 that includes an outer
cup 755 and a cone 756 on the shaft 758, plus a shim 754, and a
second roller bearing assembly 793 located proximate the rear of
the transfer case 751 that includes an outer cup 763 and a cone 762
on the shaft 758, plus a shim 764. Similarly, the intermediate
shaft 771 is supported by a third roller bearing assembly 794
located proximate the front of the transfer case 751 that includes
an outer cup 767 and a cone 797 on the shaft 771, plus a shim 768,
and a fourth roller bearing assembly 795 located proximate the rear
of the transfer case 751 that includes an outer cup 770 and a cone
798 on the shaft 771, plus a shim 769.
[0119] The bearing assemblies 791 (792, 793,794, and 795) are
particularly set to the appropriate pre-load level by way of the
shims 754, 764, 768, and 769 (in other words, the bearings
partiality to the appropriate pre-load level with the shims). It
can be further noted that, in the present embodiment, the first
change gear 760 is spaced apart from the first bearing assembly 792
by way of a cylindrical spacer 759, but is spaced (kept) apart from
the second bearing assembly 793 by way of the nut 761. By
comparison, the second change gear 765 is spaced part from the
third bearing assembly 794 by way of the further gear 766, and
spaced (kept) part from the fourth bearing assembly 795 by way of
the second nut mentioned above (not shown). Finally, it should be
appreciated from FIG. 7C that each of the lay shaft 773 and output
shaft 775 also are supported by way of respective pairs of bearing
assemblies As shown, the lay shaft 773 is particularly supported by
a fifth bearing assembly 776 proximate the front of the transfer
case 751 and a sixth bearing assembly 777 proximate the rear of the
transfer case, and that the output shaft 775 is supported by a
seventh bearing assembly 779 proximate the front of the transfer
case and an eighth bearing assembly 778 proximate the rear of the
transfer case. In this embodiment, each of the bearing assemblies
includes a respective shim 780 (although the same reference numeral
780 is used for simplicity in referring to each of these shims, it
should be appreciated that the respective shims used for each
bearing can be different from the others), and also each of the
bearing assemblies includes a respective outer cup and respective
cone.
[0120] Given the design shown in FIGS. 7C and 7D, with the gear
cover 753 removed from the primary cover 752, the first and second
change gears 760 and 765 can be selected and modified to vary the
gear ratio as required depending on the application. In particular,
the first change gear 760 can be removed and replaced as desired
without changing the shimming of the roller bearing assemblies 792,
793 (or bearing set) on the input shaft 758. Also, the same method
of shimming and changing of the second change gear 765 can be
performed in relation to the intermediate shaft 771 without
changing the shimming of the roller bearing assemblies 794, 795
(bearing set) associated with that shaft. For example, although in
the present example embodiment of the transfer case 751 shown in
FIGS. 7C and 7D the first and second change gears 760 and 765 have
the same (or substantially the same) diameter as one another, the
first change gear 760 can be replaced with a first replacement
change gear (not shown) having a larger (or smaller) diameter than
the first change gear 760 and the second change gear 765 can be
replaced with a second replacement change gear (not shown) having a
smaller (or larger) diameter than the second change gear 765 so as
to vary the gear ratio between the input shaft 758 and the
intermediate shaft 771 from a 1:1 (or substantially 1:1) ratio to a
ratio substantially less than (or greater than) a 1:1 ratio. Also
for example, if the transfer case 751 initially has a first change
gear that is larger (or smaller) in diameter than the second change
gear, the first and second change gears can be replaced so that the
first change gear is smaller (or larger) in diameter than the
second change gear (or so that the first and second change gears
share the same diameter), so as effect additional changes in gear
ratio.
[0121] Using this approach, therefore, variations in the gear ratio
of the transfer case 751 can be accomplished simply by removing the
gear cover 753, removing the two retaining nuts (one of which is
shown as the nut 761) from the shafts 758, 771, changing/replacing
of one or both of the change gears 760, 765, placing the retaining
nuts (or possibly other nuts or other fasteners differing from the
original ones) back onto the shafts to retain the
changed/replacement gears, and reassembling the gear cover 753 onto
the remainder of the transfer case 751 (e.g., onto the primary
cover 752). The gears 760, 765 and thus the associated gear ratio
of the transfer case 751 can consequently be changed without
affecting the pre-load torque of the shafts 758, 771. An advantage
of this design is that, in contrast to many conventional transfer
case designs, which require that the transfer case be separated
completely from the engine and transmission in order to check a
preload shaft, the present embodiment of FIGS. 7C and 7D
particularly eliminates this disassembly requirement.
[0122] Notwithstanding the particular discussion provided with
respect to FIGS. 7C and 7D, a variety of alternate embodiments are
also possible. For example, in some alternate embodiments, the
respective shims on one or the other of the ends of one or both of
the input and intermediate shafts 758, 771 can be eliminated from
the roller bearing assemblies 791 at those respective end(s). That
is, in one such alternate embodiment, the shim 754 can be present
while the shim 764 is absent, or vice-versa. Likewise, in alternate
embodiments shims can be absent from one or the other of the
bearing assemblies used to support one or both of the shafts 773
and 775. Also, although in the embodiment of FIGS. 7C and 7D
removal of the gear cover 753 allows for access and
modification/replacement of the first and second change gears 760,
765 (as well as possibly one or more of the associated components,
such as one or more components of the bearing assemblies 791 such
as one or more of the shims 754, 764, 768, 769), in other
embodiments the gear cover 753 and primary cover 752 (e.g., in
terms of the size of the orifice 790) can be modified to allow for
accessing and modification/replacement of one or more of the other
gears 766, 772, 774 and associated power train components (again
such as one or more of the associated bearing assemblies and
components thereof such as one or more shims). Also, in other
embodiments, the numbers and/or types of gears and associated power
train components in the transfer case can be varied.
[0123] Referring to FIGS. 7E and 7F, in still an additional
alternate embodiment of the first transmission 606, the first
transmission can be (or include) a transfer case 1751 that includes
an integrated oil pump 1780. FIG. 7E particularly shows a front
elevation view of the transfer case 1751 and FIG. 7F shows a
cross-sectional view of the transfer case 1751 taken along line F-F
of FIG. 7E (with the view directed so as to allow for viewing of
portions of a right half of the transfer case). As is evident from
FIG. 7F in particular, the transfer case 1751 includes a number of
components that correspond to the same or substantially the same
components of the transfer case 751 of FIGS. 7C and 7D. Among other
things, the transfer case 1751 includes a first change gear 1760,
second change gear 1765, intermediate shaft 1771, further gear
1766, additional gear 1772, lay shaft 1773, final output gear 1774,
and at least portions of an input shaft 1758 and output shaft 1775
that respectively correspond to (and are identical to or
substantially similar to) the first change gear 760, second change
gear 765, intermediate shaft 771, further gear 766, additional gear
772, lay shaft 773, final output gear 774, and the input shaft 1758
and output shaft 1775 (or portions of those shafts),
respectively.
[0124] Further, the transfer case 1751 includes two pairs of roller
bearing assemblies 1791 for supporting the input shaft 1758 and
intermediate shaft 1771, which correspond respectively to the
roller bearing assemblies 791 of the transfer case 751 (in which
each roller bearing assembly includes a respective cup, cone, and
shim), as well as roller bearing assemblies 1776, 1777, 1778, and
1779 respectively corresponding to the respective roller bearing
assemblies 776, 777, 7778, and 7779 of the transfer case 751 (and
again which each include a respective cup, cone, and shim), and
also includes nuts (or other spacers) corresponding to the nuts of
the transfer case 751 (e.g., the first nut 761 discussed above) for
maintaining relative positioning of the gears. Additionally, the
transfer case 1751 also includes a primary housing 1752 and gear
cover 1753 that is attachable to and removable from the primary
housing, so as to reveal and allow for changing/replacement of the
first and second change gears 1760 and 1761 so as to allow for
variation of the gear ratio provided by the transfer case. Thus, in
terms of allowing for the transfer of rotational power from the
input shaft 1758 and the output shaft 1775, and facilitating
variation of the gear ratio provided by the transfer case 1751 by
the changing/replacement of one or more of the change gears 1760
and 1761, the transfer case 1751 operates in a manner that is the
same as or substantially the same as the transfer case 751 of FIGS.
7C and 7D.
[0125] Notwithstanding these similarities, the transfer case 1751
includes additional features different from those of the transfer
case 751 particularly insofar as the transfer case 1751 includes
the oil pump 1780 integrated within the transfer case. As shown, in
the present embodiment, the oil pump 1780 particularly is mounted
on the output shaft 1775 as it extends forward from the final
output gear 1774, toward the location at which is positioned the
second transmission 608 (not shown) below the engine 504. More
particularly as shown in additional FIGS. 7G, 7H, 7I, 7J, and 7K,
which respectively are left side perspective, right side
perspective, rear elevation, right side, and front elevation views
of the oil pump 1780 independent of the remainder of the transfer
case 1751, the oil pump 1780 is a substantially annular structure
having an inner orifice 1781 (as particularly is evident from FIGS.
7G, 7H, 7I, and 7K), an oil output port 1786 (see particularly FIG.
7K), and an oil input port 1783 (below the oil output port), where
the oil input port 1783 is positioned along a front-facing face
1784 of the oil pump (as is visible in FIGS. 7G, 7H, 7I, and 7J)
and the oil output port 1786 is formed along a rear-facing face
1785 of the oil pump (as shown in FIGS. 7J and 7K). The oil output
port 1786 is shown particularly as including an orifice surrounded
by an O-ring. Further as shown, the oil pump 1780 additionally
includes an oil pressure relief valve 1782 that extends outward
(forward) from the front-facing face 1784 of the oil pump, which is
located above the oil input port 1783, and which serves to prevent
oil pressure from going beyond predetermined level(s).
[0126] As is evident particularly from the FIG. 7F, when the oil
pump 1780 is mounted on the output shaft 1775, the output shaft
1775 passes through the inner orifice 1781. Due to coupling of an
exterior splined surface of the output shaft with an inner splined
surface within the oil pump that forms the inner orifice 1781,
rotation of the output shaft causes rotation of the oil pump. Since
the output shaft 1775 turns when the engine 504 causes rotation of
the input shaft 1758 (that is, when transfer case 1751/first
transmission operates or turns), engine operation and consequent
rotation of the output shaft drives the oil pump and causes the oil
pump to deliver oil. Although operation can vary depending upon the
embodiment, in the present embodiment, the oil pump only operates
to deliver oil when the when the transfer case (first transmission)
1751 is operating and the output shaft 1775 is rotating. When the
oil pump is operating due to rotation of the output shaft 1775, the
pump pressurizes incoming oil received via the oil input port 1783
and delivers (outputs) the pressurized oil via the output port 1786
to an oil filter 1798 (see FIG. 7E), which removes debris from the
oil. The filtered, pressurized oil exiting the oil filter 1798 then
is ready to be used, and is supplied from the oil filter to any of
a variety of components of the outboard motor (e.g., in this case,
the outboard motor 104 equipped with the transfer case 1751) that
can utilize that oil, by way of any of a variety of, or a series of
(or a variety of series of), of interconnected passages, galleries,
tubes, and/or holes.
[0127] In the present embodiment, the oil pump 1780 can be a
conventional gerotor pump suitable for pumping oil suitable for use
in an engine such as the engine 504 or in relation to components of
transmission devices such as the first, second, and third
transmissions 606, 608, and 616. A gerotor pump can be suitable as
the oil pump 1780 particularly because the output shaft 1775 passes
through the center of the pump on a spline that allows radial
driving torque for the pump but also allows free axial motion of
the pump driver (thus not affecting the free axial motion of the
pump inner member that is typically required for the correct
functioning of a gerotor pump). Nevertheless, in other embodiments,
the oil pump 1780 can be another type of oil pump including, for
example, a vane type oil pump or a geared oil pump.
[0128] Also, in the present embodiment, the oil pump 1780 is
positioned on the output shaft 1775 because an oil sump or
reservoir 1799 from which the oil pump draws oil is located at the
bottom of (or below) the transfer case 1751 and the output shaft
1775 is the lowermost shaft of the transfer case that is closest to
that oil sump. More particularly as illustrated, the oil input port
1783 (oil pump inlet tube or pickup tube) in the present embodiment
extends into the oil sump 1799 such that, as the outboard motor
changes angle during operation of the outboard motor or the marine
vessel on which the outboard motor is implemented (in terms of any
of fore and aft or aft angle referred to as "trim" or boat roll
angles), the oil input port allows oil to be accessed and delivered
even despite such movements of the outboard motor/marine
vessel.
[0129] Nevertheless, in alternate embodiments, the oil pump can
instead be mounted on any other of the shafts of the transfer case
1751 (e.g., any of the input shaft 1758, the intermediate shaft
1771, the lay shaft 1773), and/or can be mounted in other manners.
Indeed, the present disclosure is intended to encompass any of a
variety of embodiments in which any of a variety of oil pumps is
formed as part of, and/or integrated with, a transmission device
(or transfer case), and is driven to pump oil when the transmission
device (or transfer case) is operating to communicate rotational
power. And the present disclosure is further intended to encompass
any of a variety of such embodiments involving an oil pump formed
as part of or integrated with a transmission device, where the
pumped oil can be utilized to lubricate any of a variety of
component(s) of that transmission device (e.g., power train
components such as gears or shafts or bearings thereof), and/or of
other transmission devices, the engine, or other structures or
devices (e.g., other components of the outboard motor).
[0130] Providing of the oil pump 1780 in the transfer case 1751 in
the manner shown in FIGS. 7E and 7F is advantageous in the present
embodiment of an outboard motor in which a horizontal crankshaft
engine is employed. To begin, providing of the oil pump 1780 in an
integrated manner along the output shaft 1775 (or another shaft of
the transfer case), is a convenient and elegant manner of
implementing an engine-driven oil pump. Although the oil pump 1780
can provide oil to any of a variety of components of the outboard
motor, including components of the engine 504 and/or any of the
transmissions 606, 608, 616, in the present embodiment a primary
purpose of the oil pump 1780 is to lift oil from the oil sump 1799,
drive the oil through the oil filter 1798, and cause delivery of
the filtered oil to the backside(s) of the tapered roller bearings
(e.g., the roller bearing assemblies 1791, 1776, 1777, 1778, 1779)
of the transfer case 1751 via interconnecting passages. This
augments the natural flow of oil thru each bearing.
[0131] The particular interconnecting passages used to communicate
oil from the oil pump (and oil filter 1798) to the bearings can
vary depending upon the embodiment. In the present embodiment, in
which the transfer case 1751 includes eight of the bearings (four
bearing assemblies 1791, plus the bearing assemblies 1776, 1777,
1778, and 1779), the oil pump (or oil pump via the oil filter 1798)
can deliver oil to the uppermost six (6) of the bearings (the
bearing assemblies 1791, 1776, and 1777) via transmission internal
drill ways. Also, as shown in FIG. 7K, in the present embodiment
oil can be delivered from the oil pump 1780 to a seventh of the
bearings (the bearing assembly 1779) by way of an orifice 1787
included in the oil pump body itself, so as to feed oil to that
bearing, which is the bearing that is closest to the oil pump. The
eighth of the bearings (the bearing assembly 1778) can be directly
exposed to the oil sump 1799. With such an arrangement, oil returns
to the oil sump 1799 from the bearings by cascading downwardly,
thereby lubricating the gears 1760, 1765, 1766, 1772, and 1774 of
the transfer case 1751 (first transmission).
[0132] In addition, placement of the oil pump 1780 in the location
shown in FIGS. 7E and 7F not only allows for filtered, pressurized
oil to be directly supplied to components of the transfer case
1751, but also allows for such oil to be provided to any of a
number of other components of the outboard motor that can benefit
from such oil. Indeed, in the present embodiment of the outboard
motor, in which first, second, and third transmissions are employed
(e.g., in this example, the transfer case 1751, the second
transmission 608, and the third transmission 616, respectively) to
connect the engine 504 to the propeller mounted at the gear casing
206 and to communicate engine torque and driving power to the
propeller, there are numerous components that require or can
benefit from lubrication provided by the oil delivered from the oil
pump 1780.
[0133] Further in this regard, it should be appreciated that,
depending upon the embodiment of outboard motor, there are a
variety of different types of transmissions and transmission
components that can be employed as well as a variety of manners of
assembling and/or coupling those transmissions and transmission
components, and the present disclosure is intended to encompass
numerous such embodiments including, further for example (and
without limitation), embodiments involving any one or more of gear,
belt, shaft, electric generator and/or motor, hydraulic pump and/or
motor, and/or other components. Regardless of which of such
implementations are provided in any given embodiment, in all or
substantially all of such implementations, an oil pump providing
lubrication can beneficially supply oil to one or more components
of such implementations.
[0134] Turning next to FIG. 8, in the present embodiment the second
transmission 608 is a wet plate transmission (or multi-plate wet
disk clutch transmission) that receives rotational power via the
intermediary axle 722 (previously shown in FIG. 7A) rotating about
the level 611 and provides output power by way of an output shaft
802, which extends downwardly in the direction of the arrow 614 and
links the second transmission to the third transmission 616 within
the gear casing 206. The internal components of the wet disk clutch
transmission constituting the second transmission 608 can be
designed to operate in a conventional manner. Thus, operation of
the second transmission 608 is controlled by controlling
positioning of a clutch 804 positioned between a reverse gear 806
on the left and a forward gear 808 on the right of the clutch,
where each of the reverse gear, clutch and forward gear are
co-aligned along the axis established by the level 611. Movement of
a control block 810 located to the right of the forward gear 808,
to the right or to the left, causes engagement of the reverse gear
806 or forward gear 808 by the clutch 804 such that either the
reverse gear 806 or the forward gear 808 is ultimately driven by
the rotating intermediary axle 722.
[0135] Further as shown, each of the reverse gear 806 and forward
gear 808 are in contact with a driven gear 812, with the reverse
gear engaging a left side of the driven gear and the forward gear
engaging a right side of the driven gear, the reverse and forward
gears being oriented at 90 degrees relative to the driven gear. The
driven gear 812 itself is coupled to the output shaft 802 and is
configured to drive that shaft. Thus, depending upon whether the
reverse gear 806 or forward gear 808 is engaged, the driven gear
812 connected to the output shaft 802 is either driven in a
counterclockwise or clockwise manner when rotational power is
received via the intermediate axle 722. Also, a neutral position of
the clutch 804 disengages the output shaft 802 from the
intermediary axle 722, that is, the driven gear 812 in such
circumstances is not driven by either the forward gear 808 or the
reverse gear 806 and consequently any rotational power received via
the intermediary axle 722 is not provided to the output shaft
802.
[0136] It should be noted that the use of a wet disk clutch
transmission in the present embodiment is made possible since the
wet disk clutch transmission can serve as the second transmission
608 rather than the third transmission 616 in the gear casing (and
since the wet disk clutch transmission need not bear as large of
torques, particularly when the twin pinion arrangement is employed
in the third transmission). Nevertheless, it can further be noted
that, in additional alternate embodiments, the second transmission
608 need not be a wet disk clutch transmission but rather can be
another type of transmission such as a dog clutch transmission or a
cone transmission. That is, although in the present embodiment the
wet disk clutch transmission serves as the second transmission 608,
in other embodiments, other transmission devices can be employed.
For example, in other embodiments, the second transmission 608 can
instead be a cone clutch transmission or a drop clutch
transmission. Further, in other embodiments, the third transmission
(gear casing) 616 can itself employ a dog clutch transmission or
other type of transmission. Also, in other embodiments, the first
transmission 606 can serve as the transmission providing
forward-neutral-reverse functionality instead of the second
transmission providing that capability, in which case the second
transmission can simply employ a pair of bevel gears to change the
direction of torque flow from a horizontal direction (between the
first and second transmissions) to a downward direction (to the
third transmission/gear case).
[0137] Turning next to FIG. 9A, internal components of the third
transmission 616 are shown within a cutaway section of the lower
portion 122 of the outboard motor 104 (plus part of the mid portion
120). In the present embodiment the third transmission 616 is a
twin pinion transmission. Given this configuration, the output
shaft 802 extending from the second transmission 608 reaches the
plane 126 at which are located a pair of first and second gears 902
and 904, respectively, that are of equal diameter and engage one
another. In the present embodiment, the second gear 904 is forward
of the first gear 902, with both gears having axes parallel to (or
substantially parallel to) the steering axis 110 (see FIG. 1) of
the outboard motor 104. First and second additional downward shafts
906 and 908, respectively, extend downward from the first and
second gears 902 and 904, respectively, toward first and second
pinions 910 and 912, respectively, which are located within the
gear casing 206 with the first pinion 910 being aft of the second
pinion 912. Due to the interaction of the first and second gears
902 and 904, while rotation of the first additional downward shaft
906 proceeds in the same direction as that of the output shaft 802,
the rotation of the second additional downward shaft 908 is in the
opposite direction relative to the rotation of the output shaft
802. Thus, the pinions 910 and 912, respectively, rotate in
opposite directions.
[0138] Further as shown, each of the first and second pinions 910
and 912 engages a respective 90 degree type gear that is coupled to
the propeller driving output shaft 212 that is coupled to the
propeller 130 (not shown). The power provided via both of the
pinions 910, 912 is communicated to the propeller driving output
shaft 212 by way of a pair of first and second 90 degree type gears
916 and 918 or, alternatively, 920 and 922. Only the gears 916, 918
or the gears 920, 922 are present in any given embodiment (hence,
the second set of gears 920, 922 in FIG. 9A are shown in phantom to
indicate that those gears would not be present if the gears 916,
918 were present). As shown, the gears of each pair 916, 918 or
920, 922 are arranged relative to their respective pinions 910, 912
along opposite sides of the pinions such that the opposite rotation
of the respective pinions will ultimately cause the respective
gears of either pair to rotate the propeller driving output shaft
212 in the same direction. That is, the first 90 degree type gear
916 is towards the aft side of the first pinion 910 while the
second 90 degree type gear 918 is to the forward side of the pinion
912. Likewise, while the first 90 degree type gear 920 (shown in
phantom) is to the forward side of the first pinion 910, the second
90 degree type gear 922 is (also shown in phantom) to the aft side
of the second pinion 912.
[0139] Notwithstanding the above discussion, in alternate
embodiments the third transmission 616 can take other forms. For
example, as shown in FIG. 9B, in one alternate embodiment of the
third transmission shown as a transmission 901, there is only a
single pinion 924 within the gear case 206 that is directly coupled
to the output shaft 802 (elongated as appropriate), and that pinion
drives a single 90 degree type gear 926 coupled to the propeller
driving output shaft 914. In yet a further alternate embodiment of
the third transmission 616, shown as a transmission 903 in FIG. 9C,
gears within the gear casing 206 are configured to drive a pair of
counter-rotating propellers (not shown). More particularly, in this
embodiment, a single pinion 928 within the gear casing 206 is
driven by the output shaft 802 (again as appropriately elongated)
and that pinion drives both rear and forward 90 degree type gears
930 and 932, respectively. As shown, the forward 90 degree type
gear 932 drives an inner axle 934 that provides power to a rearmost
propeller (not shown) of the counter-rotating pair of propellers,
while the rear 90 degree type gear 930 drives a concentric tubular
axle 936 that is coaxially aligned around the first axle 934. The
tubular axle 936 is connected to the forward one of the propellers
of the pair of counter-rotating propellers (not shown) and drives
that propeller.
[0140] Referring further to FIG. 10A, an additional cross-sectional
view is provided of the lower portion 122 of the outboard motor
104, taken along line 10-10 of FIG. 3. Among other things, this
cross-sectional view again shows components of the third
transmission 616 of the outboard motor 104. The view provided in
FIG. 10A particularly also is a cutaway view with portions of the
outboard motor 104 above the plane 126 cutaway, aside from a
section 1002 of the lower portion 122 receiving the output shaft
802 from the second transmission 608 and housing the first and
second gears 902, 904 (contrary to the schematic view of FIG. 9A,
in FIG. 10A the section 1002 actually extends slightly above the
plane 126 serving as the general conceptual dividing line between
the lower portion 122 and the mid portion 120, but nevertheless can
still be considered part of the lower portion 122 of the outboard
motor 104). In addition to the section 1002, FIG. 10A also shows
the first and second additional downward shafts 906 and 908, which
link the respective first and second gears 902 and 904 with the
first and second pinions 910 and 912, respectively. In turn, the
first and second pinions 910 and 912, respectively, are also shown
to engage the first and second 90 degree type gears 916 and 918,
respectively, which drive the propeller driving output shaft 212
(as with FIG. 3, the propeller 130 is not shown in FIG. 10A)
extending along the elongated axis 208 of the gear casing 206 above
the fin 210. Tapered roller bearings 1003 are further shown in FIG.
10A to support the first and second 90 degree type gears 916, 918
and the propeller driving output shaft 212 relative to the walls of
the third transmission 616.
[0141] In addition to showing some of the same components of the
third transmission 616 shown schematically in FIG. 9A, FIG. 10A is
also intended to illustrate oil flow within the third transmission,
and further to illustrate several components/portions of a cooling
system of the outboard motor 104 and also several
components/portions of an exhaust system of the outboard motor that
are situated within the lower portion 122 (additional
components/portions of the cooling system and exhaust system of the
outboard motor 104 are discussed further below with respect to
subsequent FIGS.). With respect to oil flow within the third
transmission 616, it should be noted that oil congregates in a
reservoir portion 1004 near the bottom of the gear casing 206. By
virtue of rotation of the first and second 90 degree type gears 916
and 918, not only is oil provided to lubricate those gears but also
oil is directed to the first and second pinions 910 and 912,
respectively. Flow in this direction, particularly from the
reservoir portion 1004 via the first 90 degree type gear 916 to the
first pinion 910 and a space 1005 above the first pinion is
indicated by an arrow 1006 (it will be understood that oil proceeds
in a complementary manner via the second 90 degree type gear 918 to
the second pinion 910).
[0142] Upon reaching the space 1005 above the first pinion 910,
some of that oil is directed to the tapered roller bearings 1003
supporting the 90 degree type gears 916, 918 and the propeller
driving output shaft 212 (as well as aft of those components) via a
channel 1007. Further, additional amounts of the oil reaching the
space 1005 is directed upward to the first gear 902 by way of
rotation of the first additional downward shaft 906, due to
operation of an Archimedes spiral mechanism 1008 formed between the
outer surface of the first additional downward shaft and the inner
surface of the passage within which that downward shaft extends, as
represented by arrows 1010. Ultimately, due to operation of the
Archimedes spiral mechanism 1008, oil is directed upward through
the channel of the Archimedes spiral mechanism up to additional
channels 1012 linking a region near the top of the Archimedes
spiral mechanism with the first gear 902 as represented by arrows
1014. Upon reaching the first gear 902, the oil lubricates that
gear and also further lubricates the second gear 904 due to its
engagement with the first gear as represented by arrows 1016. Then,
some of the oil reaching the first and second gears 902, 904,
proceeds downward back to the reservoir portion 1004 by way of
further channels 1018 extending downward between the first and
second additional downward shafts 906, 908 to the reservoir portion
1004, as represented by arrows 1020.
[0143] Although in this example oil reaches the top of the third
transmission 616 and particularly both of the first and second
gears 902, 904 via the Archimedes spiral mechanism 1008 associated
with the first additional downward shaft 906, such operation
presumes that the first additional downward shaft is rotating in a
first direction tending to cause such upward movement of the oil.
However, this need not always be the case, since the outboard motor
104 can potentially be operated in reverse. Given this to the be
the case, an additional Archimedes spiral mechanism 1022 is also
formed between the outer surface of the second additional downward
shaft 908 and the inner surface of the passage within which that
downward shaft extends. Also, additional channels 1024
corresponding to the additional channels 1012 are also formed
linking the top of the additional Archimedes spiral mechanism 1022
with the second gear 904. Given the existence of the additional
Archimedes spiral mechanism 1022 and the additional channels 1024,
when the direction of operation of the outboard motor 104 is
reversed from the manner of operation shown in FIG. 10A, oil
proceeds upward from the reservoir portion 1004 via the second 90
degree type gear 918, the second pinion 912, an additional space
1023 above the second pinion 912 (corresponding to the space 1005),
the additional Archimedes spiral mechanism 1022, and the additional
channels 1024 to the second gear 904 and ultimately the first gear
902 as well (after which the oil then again proceeds back down to
the reservoir portion via the further channels 1018). Thus, oil
reaches the first and second gears 902 and 904 and the entire third
transmission 616 is lubricated regardless of the direction of
operation of the outboard motor 104.
[0144] Finally, it should also be noted that, assuming a given
direction of operation of the outboard motor 104, while oil
proceeds upward to the first and second gears 102, 104 via one of
the Archimedes spiral mechanism 1008, 1022, it should not be
assumed that the other of the Archimedes spiral mechanism 1022,
1008 is not operating in any manner. Rather, whenever one of the
Archimedes spiral mechanisms 1008, 1022 is tending to direct oil
upward, the other of the Archimedes spiral mechanisms 1022, 1008 is
tending to direct at least some of the oil reaching it back down to
that one of the pinions 910, 912 and then ultimately to the
reservoir portion 1004 as well (via the corresponding one of the 90
degree type gears 916, 918). Thus, in the example of FIG. 10A
showing oil to be provided upward due to operation of the
Archimedes spiral mechanism 1008, it should also be understood that
at least some of the oil reaching the second gear 904, rather than
being direct downward back to the reservoir portion 1004 via the
further channels 1018, instead proceeds back down to the reservoir
portion via the additional Archimedes spiral mechanism 1022, which
in this case would tend to be directing oil downward.
Alternatively, if the outboard motor 104 was operating in the
reverse manner and oil was directed upward via the additional
Archimedes spiral mechanism 1022, then the Archimedes spiral
mechanism 1008 would tend to direct at least some of the oil
reaching it via the first gear 902 back down to the reservoir
portion 1004 as well.
[0145] As already noted, FIG. 10A also shows several cooling system
components of the lower portion 122 of the outboard motor 104. In
the present embodiment, coolant for the outboard motor 104 and
particularly the engine 504 is provided in the form of some of the
water 101 within which the marine vessel assembly 100 is situated.
More particularly, FIG. 10A shows that the outboard motor 104
receives/intakes into a coolant chamber 1028 within the lower
portion 122 some of the water 101 (see FIG. 1) via multiple water
inlets, namely, the lower water inlet 522 and two of the upper
water inlets 524 already mentioned with respect to FIG. 5. As
earlier noted, the lower water inlet 522 is positioned along the
bottom of the gear casing 206, near the front of that casing
forward of the fin 210, and the water 101 proceeds into the coolant
chamber 1028 via the lower water inlet generally in a direction
indicated by a dashed arrow 1030.
[0146] It should further be noted from FIG. 10A that an oil drain
screw 1031 allowing for draining of oil from the reservoir portion
1004/third transmission 616 extends forward from the third
transmission toward the lower water inlet 522, from which it can be
accessed and removed so as to allow oil to drain from the third
transmission even though the oil drain screw is still located
interiorly within the outer housing wall of the outboard motor 104.
Such positioning of the oil drain screw 1031 is advantageous
because, in contrast to some conventional arrangements, the oil
drain screw does not protrude outward beyond the outer housing wall
of the outboard motor 104 and thus does not create turbulence or
drag as the outboard motor passes through the water and also does
not as easily corrode over time due to water exposure.
[0147] In contrast to the lower water inlet 522, the upper water
inlets 524 are respectively positioned midway along the left and
right sides of the lower portion 122 (particularly along the sides
of a strut portion of the lower portion linking the top of the
lower portion with the torpedo-shaped gear casing portion at the
bottom), and the water 101 proceeds into the coolant chamber 1028
via these inlets in a direction generally indicated by a dashed
arrow 1032. It should be understood that, as a cross-sectional view
from the right side of the lower portion 122, FIG. 10A particularly
shows the left one of the upper water inlets 524, while the right
one of the upper water inlets (along the right side of the lower
portion 122) is shown instead in FIG. 5. More particularly, in the
present embodiment, each of the respective left and right ones of
the upper water inlets 524 is formed by the combination of a
respective one of the cover plates 526 (previously mentioned in
FIG. 5) and a respective orifice 528 within the respective left or
right sidewalls (housing or cowling walls) of the lower portion
122. The respective cover plate 526 of each of the upper water
inlets 524 serves to partly, but not entirely, cover over the
corresponding one of the respective orifices 528, so as to direct
water flow into the coolant chamber 1028 via the respective one of
the upper water inlets in a front-to-rear manner as illustrated by
the dashed arrow 1032. The cover plates 526 can be attached to the
sidewalls of the lower portion 122 in a variety of manners,
including by way of bolts or other fasteners, or by way of a snap
fit.
[0148] Upon water being received into the coolant chamber 1028 via
the lower and upper water inlets 522, 524, water then proceeds in a
generally upward direction as indicated by an arrow 1029 toward the
mid portion 120 (and ultimately to the upper portion 118) of the
outboard motor 104 for cooling of other components of the outboard
motor including the engine 504 as discussed further below. It
should be further noted that, given the proximity of the coolant
chamber 1028 adjacent to (forward of) the third transmission 616,
cooling of the oil and third transmission components (including
even the gears 902, 904) can be achieved due to the entry of
coolant into the coolant chamber. Eventually, after being used to
cool engine components in the mid portion 120 and upper portion 118
of the outboard motor 104, the cooling water is returned back down
to the lower portion 122 at the rear of the lower portion, where it
is received within a cavity 1033 within a cavitation plate 1034
along the top of the lower portion, and is directed out of the
outboard motor via one or more orifices leading to the outside (not
shown). It should be further noted that FIG. 10A, in addition to
showing the cavity 1033, also shows the cavitation plate 1034 to
support thereon a sacrificial anode 1036 that operates to alleviate
corrosion occurring due to the proximity of the propeller 130 (not
shown), which can be made of brass or stainless steel, to the lower
portion 122/gear casing 206, which can be made of Aluminum.
[0149] Although in the present embodiment the cover plates 526
allow water flow in through the respective orifices 528 into the
coolant chamber 1028, and additionally water flow is allowed in
through the lower water inlet 522 as well, this need not be the
case in all embodiments or circumstances. Indeed, it is envisioned
that, in at least some embodiments, a manufacturer or operator can
adjust whether any one or more of these water inlets do in fact
allow water to enter the outboard motor 104 as well as the
manner(s) in which water flow into the coolant chamber 1028 is
allowed. This can be achieved in a variety of manners. For example,
rather than employing the cover plates 526, in other embodiments or
circumstances other cover plates can be used to achieve a different
manner of water flow into the orifices 528 of the upper water
inlets 524, or to entirely preclude water flow into the coolant
chamber 1028 via the orifices (e.g., by entirely blocking over
covering over the orifices). Likewise, a cover plate can be placed
over the lower water inlet 522 (or the orifice formed thereby) that
would partly or entirely block, or otherwise alter the manner of,
water flow into the coolant chamber 1028.
[0150] Adjustment of the lower and upper water flow inlets 522, 524
in these types of manners can be advantageous in a variety of
respects. For example, in some implementations or operational
circumstances, the outboard motor 104 will not extend very deeply
into the water 101 (e.g., because the water is shallow) and, in
such cases, it can be desirable to close off the upper water flow
inlets 524 so that air cannot enter into coolant chamber 1028 if
the upper water flow inlets happen to be positioned continuously
above or occasionally exposed above the water line 128, for
example, if the water line is only at about a mid strut level 1038
as shown in FIG. 5 or even lower, further for example, at a level
1040 (which can be considered the water line or water surface for
on plane speed for surfacing propellers). Alternatively, in some
implementations or operational circumstances, the outboard motor
104 will extend deeply into the water, such that the water line
could be at a high level 1042 (which can be considered the water
line or water surface for on plane speeds for submerged propellers)
above the upper water flow inlets 524. In such cases, it would
potentially be desirable to have all of the lower and upper water
flow inlets 522, 524 configured to allow for entry of the water 101
into the coolant chamber 1028.
[0151] Yet in still other circumstances, even with the outboard
motor 104 extending deeply into the water, it can be desirable for
the upper water flow inlets 524 to be configured to allow water
entry therethrough and yet to block water entry via the lower water
flow inlet 522, for example, if the bottom of the lower portion 122
is nearing the bottom of the body of water in which the marine
vessel assembly 100 is traveling, such that dirt or other
contaminants are likely to enter into the coolant chamber 1028
along with water entering via the lower water flow inlet 522 (but
such dirt/contaminants are less likely to be present at the higher
level of the upper water flow inlets 524). It is often, if not
typically, the case that one or more of the lower and upper water
flow inlets 522, 524 will be partly or completely blocked or
modified by the influence of one or more cover plates, to adjust
for operational circumstances or for other reasons.
[0152] Referring still to FIG. 1 OA, in addition to the
aforementioned cooling system components, also shown are several
components of the outboard motor 104 that are associated with the
exhaust system. In particular, as discussed above and discussed
further below, exhaust produced by the engine and delivered via the
exhaust channels 512 (as shown in FIG. 5), depending upon the
circumstance or embodiment, primarily or entirely directed to the
lower portion 122 and into an exhaust cavity 1044 that is
positioned generally aft relative to the components of the third
transmission 616 (e.g., aft of the first and second gears 902, 904
and first and second pinions 910, 912), generally in a direction
indicated by an arrow 1048. The exhaust cavity 1044 opens directly
to the rear gear casing 206. To show more clearly the manner in
which the exhaust cavity 1044 is in communication with the exterior
of the outboard motor 104 (e.g., to the water 101), further FIG.
10B is provided that shows a rear elevation view 1050 of the gear
casing 206 of the lower portion 122, cutaway from the remainder of
the lower portion. For comparison purposes, a diameter 1052 of the
gear casing 206 of FIG. 10B corresponds to a distance 1054 between
lines 1056 and 1058 of FIG. 10A.
[0153] More particularly as shown in FIG. 10B, exhaust from the
exhaust cavity 1044 particularly is able to exit the outboard motor
104 via any and all of four quarter section orifices 1060 (which
together make up the orifice 302 of FIG. 3) surrounding the
propeller driving output shaft 212 and respectively extending
circumferentially around that output shaft between respective pairs
of webs 1062 extending radially inward toward the crankshaft from a
surrounding wall 1064 of the lower portion 122. Given the
particular relationship between the cross-sectional view of FIG.
10A and the rear elevation view of FIG. 10B, two of the webs 1062
are also shown in FIG. 10A extending radially upward and downward
from the propeller driving output shaft 212 to the surrounding wall
1064 of the lower portion 122. As shown, the webs 1062 also extend
axially along the propeller driving output shaft 212 and along the
surrounding wall 1064. It can further be noted that, in the present
embodiment, a bore 1066 extends between the cavity 1033 that
receives cooling water and the exhaust cavity 1044, which allows
some amount of excess cooling water within the cavity 1033 to drain
out of outboard motor 104 via the exhaust cavity 1044 and quarter
section orifices 1060/orifice 302 (although this manner of draining
coolant is not at all the primary manner by which coolant exits the
outboard motor). It should be noted that such interaction with
coolant, and in other locations where the coolant system interacts
with the exhaust system, helps to cool the exhaust in a desirable
manner.
[0154] Turning next to FIG. 11A, several other components of the
exhaust system of the outboard motor 104 are shown in additional
detail by way of an additional rear elevation view of the upper
portion 118 and mid portion 120 of the outboard motor, shown with
the cowling 200 removed, and shown in cutaway so as to exclude the
lower portion 122 of the outboard motor. In particular as shown,
the exhaust conduits 512 receiving exhaust from the exhaust
manifolds 510 along the right and left sides of the engine 504 (see
also FIG. 5) are shown extending downward toward the lower portion
122 and the exhaust cavity 1044 described with respect to FIG.
10A.
[0155] As illustrated, the exhaust conduits 512 particularly direct
hot exhaust along the port and starboard sides of the outboard
motor 104, so as to reduce or minimize heat transfer from the hot
exhaust to internal components or materials (e.g., oil) that
desirably should be or remain cool.
[0156] Exhaust from the engine 504 is primarily directed by the
exhaust conduits 512 to the exhaust cavity 1044 since exhaust
directed out of the outboard motor 104 via the orifice 302
proximate the propeller 130 (not shown) is typically (or at least
often) innocuous during operation of the outboard motor 104 and the
marine vessel assembly 100 of which it is a part. Nevertheless,
there are circumstances (or marine vessel applications or
embodiments) in which it is desirable to allow some exhaust (or
even possibly much or all of the engine exhaust) to exit the
outboard motor 104 to the air/atmosphere. In this regard, and as
already noted with respect to FIGS. 2 and 3, in the present
embodiment the outboard motor 104 is equipped to allow at least
some exhaust to exit the outboard motor via the exhaust bypass
outlets 204. More particularly, in the present embodiment, at least
some exhaust from the engine 504 proceeding through the exhaust
conduits 512 is able to leave the exhaust conduits and proceed out
via the exhaust bypass outlets 204. So that exhaust exiting the
outboard motor 104 in this manner is not overly noisy, further in
the present embodiment such exhaust proceeds only indirectly from
the exhaust conduits to the exhaust bypass outlets 204, by way of a
pair of left side and right side mufflers 1102 and 1104,
respectively, which are arranged on opposite sides of the transfer
case 514 aft of the engine 504 within which is positioned the first
transmission 606. Further as shown in FIG. 11A, each of the left
side muffler 1102 and right side muffler is coupled to a respective
one of the exhaust conduits 512 by way of a respective input
channel 1106. Each of the mufflers 1102, 1104 then
muffles/diminishes the sound associated with the received exhaust,
by way of any of a variety of conventional muffler internal chamber
arrangements. Further, in the present embodiment, the left and
right side mufflers 1102, 1104 are coupled to one another by way of
a crossover passage 1108, by which the sound/air patterns occurring
within the two mufflers are blended so as to further diminish the
noisiness (and improve the harmoniousness) of those sound/air
patterns. As a result of the operations of the mufflers 1102, 1104
individually and in combination (by way of the crossover passage
1108), exhaust output provided from the respective mufflers at
respective output ports 1110 is considerably less noisy and less
objectionable than it would otherwise be. The exhaust output from
the output ports 1110 thus can be provided to the exhaust bypass
outlets 204 (again see FIGS. 2 and 3) so as to exit the outboard
motor 104.
[0157] Turning to FIG. 11B, features of an alternate exhaust bypass
outlet system are illustrated, which can also (or alternatively) be
implemented in the outboard motor 104. In this arrangement, again
the exhaust conduits 512 are shown through which exhaust flows
downward to the lower portion 122 of the outboard motor.
Additionally, portions of the input channels 1156 are shown that
link the exhaust conduits 512 with bypass outlet orifices 1158 in
the cowl 200 of outboard motor. Further as shown, an idle relief
muffler 1160 is coupled to each of the input channels 1156 by way
of respective intermediate channels 1162 extending between the idle
relief muffler and intermediate regions 1164 of the input channels.
Exhaust as processed by the idle relief muffler 1160 eventually is
returned to the input channels 1156 prior to those input channels
1156 reaching the bypass outlet orifices 1158 by way of respective
return channels 1166. Further, to govern the amount of exhaust
passing through the input channels 1156 from the exhaust conduits
512 to the bypass outlet orifices 1158, respective rotatable (and
controllable) throttle plates 1168 are positioned within the input
channels 1156 in between the locations at which the respective
intermediate channels 1162 encounter the respective input channels
(that is, at the respective intermediate regions 1164) and the
locations at which the respective return channels 1166 encounter
the respective input channels. As result, the amount of exhaust
that leaves the outboard motor via the orifices 1158 can be
controlled, and exhaust flow can be permitted, limited, and/or
completely precluded.
[0158] FIGS. 12, 13, and 14 are enlarged perspective, right side
elevational, and front views, respectively, of a mounting system
108 in accordance with embodiments of the instant disclosure.
Mounting system 108 generally links, or otherwise connects, an
outboard motor to a marine vessel (for example, the exemplary
outboard motor 104 and the exemplary marine vessel 102 shown and
described in FIG. 1). More particularly, the mounting system 108
connects the outboard motor to the rear or transom area of the
marine vessel and, in this way, the mounting system can also be
termed a "transom mounting system". In accordance with at least
some embodiments, mounting system 108 generally includes a swivel
bracket structure 1202, which is cast or otherwise formed.
Extending from the swivel bracket structure 1202 is a pair of clamp
bracket structures 1204, 1206, respectively. In at least some
embodiments, the clamp bracket structures 1204, 1206 are generally
mirror images of, and thus are symmetric with respect to, one
another and in this respect can be said to extend equally, or be
equally disposed, with respect to the swivel bracket structure
1202. The clamp bracket structures 1204, 1206 are generally used to
secure the mounting system to the marine vessel transom. In
accordance with various embodiments, clamp bracket structures 1204,
1206 include respective upper regions 1208, 1210, a plurality of
holes 1212, 1214 for receiving connectors or fasteners 1216, 1218.
In addition, the clamp bracket structures 1204, 1206 include,
respective lower regions 1220, 1222, and slots 1224, 1226, for
receiving connectors or fasteners 1228, 1230. Connectors 1216,
1218, 1228, and 1230 are used to affix the clamp bracket structures
1204, 1206, and more generally the mounting system 108 to the
marine vessel. Slots 1224 and 1226 provide for additional
variability and/or adjustability such mounting by permitting the
fasteners to be located in a variety of locations (e.g., higher or
lower). Connectors 1216 and 1218 (only a few of which are shown)
and 1228 and 1230 can, as shown, take the form of nut-bolt
arrangements, but it should be understood that other fasteners are
contemplated and can be used. Similarly, with regard to the holes
1212 and 1214, and slots 1224 and 1226, it should be understood
that the size, shape, number and precise placement, among other
items, can vary.
[0159] The swivel bracket structure 1202 further includes a first
or upper steering yoke structure 1240, as well as a second or lower
steering yoke structure 1242 that are joined by way of a tubular or
substantially tubular structure 1246 (also called a steering tube
structure). The first yoke structure 1240 includes a first or upper
crosspiece mounting structure 1248 that is, in at least some
embodiments, centered or substantially centered about the steering
tube structure 1246, and the crosspiece mounting structure
terminates in a pair of mount portions 1250, 1252 having passages
1254, 1256, respectively, which are used to couple the swivel
bracket structure, typically via bolts or other fasteners (not
shown), to the outboard engine via upper mounting brackets or motor
mounts 520 (FIG. 5). The second or lower yoke structure 1242
similarly includes a pair of mount portions 1258, 1260 having
passages 1262, 1264, respectively, which further couple, again
typically via bolts or other fasteners (not shown), to the outboard
engine, typically via lower mounting brackets or motor mounts 518
(FIG. 5) and as well be described below. A steering axis 1266
extends longitudinally along the center of steering tube structure
1246 and thereby provides an axis of rotation, which in use is
typically a vertical or substantially vertical axis of rotation,
for the upper and lower steering yoke structures 1240, 1242 and the
swivel bracket structure 1202 to which they are joined. Swivel
bracket structure 1202 is rotatable about a tilt tube structure
1243 having a tilt axis 1245 and thus also relative clamp bracket
structures 1206 and 1208. The tilt axis 1245 generally is an axis
of rotation or axis of pivot (e.g., permitting tiling and/or
trimming about the axis), but for simplicity the axis is generally
referred to simply as a tilt axis. When the outboard motor is in
use, the tilt axis 1245 is typically a horizontal, or substantially
horizontal, axis of rotation.
[0160] FIG. 15 is a schematic illustration of the mounting system
108 having the swivel bracket structure 1202 and clamp bracket
structures 1206 and 1208. With reference to FIGS. 12 and 15.
Passages 1254 and 1256 are separated by a distance "d1" and
passages 1262 and 1264 are separated by a distance "d2". Similarly,
passages 1254 and 1262 are separated by a distance "d3" and
passages 1256 and 1264 are separated by a distance "d4". As can be
seen, distance d1 is longer or greater than distance d2. It should
be understood that distances d1-d4 referenced here are generally
taken from centers of the respective passages which, as shown, are
typically cylindrical or substantially cylindrical in shape. More
generally, it should be understood that the distance separating the
respective upper mounting portions is greater than the distance
separating the lower mounting portions. In addition, other shapes
for the passages are contemplated and the relative position for
establishing the respective distances can vary to convenience. And
more generally, connections can be accomplished using other
structures besides passages, or external fastening mechanisms, and
such modifications are contemplated and considered within the scope
of the present disclosure.
[0161] An axis 1266 is illustrated to extend between passages 1264
and 1266 and further, and axis 1268, is depicted to extend between
passages 1256 and 1264. For illustrative purposes, a center axis
1270 is provided bisecting the distances d1 and d2. As can be seen,
by axes 1266 and 1268 converge on axis 1270, as shown, at a point
of convergence1272 located below or beyond yoke structure 1242 and
an angle theta is established between these axes. Advantageously,
having a distance d1 larger than d2 increases steering stability.
More particularly, when the swivel bracket structure 1202 is
coupled to a horizontal crankshaft engine of the kind described
herein, resultant roll torque is reduced or minimized.
[0162] It is noted that while in the instant embodiment both the
upper and lower yoke structures include a pair of passages, it
should be understood that this can vary but yet still provide for
the aforementioned convergence. For example, the lower yoke
structure could include only a single mounting portion, with the
single mounting portion (which again can include a passage) for
mounting the yoke structure to swivel bracket structure located
below and between the pair of upper mounting portions of the first
or upper steering yoke structure such that the there is a similar
convergence from the upper mounting portions to the lower mounting
portion. In at least one embodiment the single mount portion would
be generally situated, and in at least some instances centered
about, the steering axis.
[0163] Referring to FIG. 16, an enlarged top view of the mounting
system 108 of FIG. 12 is shown. FIG. 17 illustrates a cross
sectional view of the mounting system of FIG. 12 along or through
tilt tube structure 1243. The tilt tube 1243 further provides a
housing for a power steering cylinder 1280 having a central axis
1282 that coincides, or substantially coincides, with the tilt axis
1245. The power steering cylinder includes a power steering piston
1284 that translates or otherwise moves within the steering
cylinder 1280 in response to power steering fluid (e.g., hydraulic
fluid) movement. Actuation of the steering cylinder 1280 provides
translation of a steering arm mechanism 1286 to actuate steering of
the swivel bracket structure 1202 about the steering axis 1266.
Positioning the power steering cylinder inside the tilt tube, the
need for additional mounting space for the power steering
components is eliminated. Further, such positioning accommodates
the scaling of the structures, with the relative trim tube and
power steering tube structure size typically related (e.g., based
on engine size, vessel sized, etc.).
[0164] Several other considerations can be noted in relation to the
power steering operation of the outboard motor 104. For example, in
accordance with the present embodiment, a tilt tube structure (or,
more generally a "tilt structure") surrounds a power steering
actuator, the actuator comprising a hydraulic piston. However, it
should be understood that, in accordance with alternative
embodiments, a variety of actuators can be used, including by way
of example, an electronic linear actuator, a ball screw actuator, a
gear motor actuator, and a pneumatic actuator, among others.
Various actuators can also be employed to control tilting/trimming
operation of the outboard motor 104.
[0165] It should further be noted that the degree of rotation
(e.g., pivoting, trimming, tilting) that can take place about a
tilt tube structure axis of rotation (or more generally a "tilt
structure axis of rotation") can vary depending upon the embodiment
or circumstance. For example, in accordance with at least some
embodiments, trimming can typically comprise a rotation of from
about -5 degrees from horizontal to 15 degrees from horizontal,
while tilting can comprise a greater degree of rotation, for
example, from about 15 degrees from horizontal to about 70 degrees
from horizontal. Further, it can be noted that, as the power
steering structure (or other actuator) size is increased, the tilt
tube structure that at least partially surrounds or houses the
power steering structure is increased. Such increase in size of the
tilt tube structure generally increases the strength of the tilt
tube structure. The tilt tube structure can be constructed from
steel or other similarly robust material.
[0166] FIG. 18 is a right side view of outboard motor 104 showing
an illustrative outboard motor water cooling system 1300 in
accordance with various embodiments of the present disclosure.
Cooling water flows throughout the motor to cool various components
as shown and described, and such cooling water flow is generally
represented by various arrows. As previously described in detail
with respect to FIG. 10A, the outboard motor 104 receives/intakes,
indicated by arrows 1301, 1302 into the lower portion 122 some of
the water 101 (see FIG. 1) via multiple water inlets 522, 524,
respectively. Cooling water then proceeds generally upwardly, as
indicated by an arrow 1029, toward and into the mid portion 120 of
the outboard motor 104 to provide a cooling affect. In accordance
with at least some embodiments and as shown, cooling water proceeds
generally rearwardly and then generally upwardly (e.g., vertically
or substantially vertically) as indicated by an arrows 1306 and
1308, respectively, in the mid portion 120 past the second
transmission oil reservoir 624 (shown in phantom) and gears 902 and
904 (which can be considered part of the lower portion 122) and
thereby cools the oil in the reservoir and the gears.
[0167] Cooling water traverses generally upwardly, as indicated by
arrow 1310, past, and in so doing cools, the second transmission
608, and into the upper portion 118, which includes the engine 504.
More specifically, and in accordance with at least some
embodiments, cooling water traverses forwardly, as indicated by
arrow 1312 to a water pump 1315 where it proceeds, in the
embodiment shown, upwardly, as indicated by arrow 1316. Water that
is pumped by the water pump 1315 exits the water pump, after doing
so, flows, as indicated by arrow 1318, into and through, so as to
cool, an engine heat exchanger and an engine oil cooler, which are
generally collectively referenced by numeral 1320. The engine heat
exchanger and engine oil cooler 1320 serve to cool a heat exchanger
fluid (e.g., glycol, or other fluid) and oil, respectively, within
or associated with the engine 504 and at least in these ways
accomplish cooling of the engine. A circulation pump circulates the
cooled glycol (or other fluid) within the engine 504.
[0168] After exiting the engine heat exchanger and engine oil
cooler 1320, water flows generally downwardly, toward and into a
chamber surrounding the exhaust channels 512 (one of which is
shown), as indicated by arrow 1322, where it then flows back
upwardly, as indicated by arrows 1324, 1326, into the exhaust
manifold 510. It is noted that, while in the chamber (not shown)
surrounding the exhaust channels 512, cooling water runs in a
direction counter to the direction of exhaust flow so as to cool
the exhaust, with such counter flow offering improved cooling
(e.g., due to the temperature gradient involved). From the exhaust
manifold 510, cooling water flows downwardly, as indicated by arrow
1328, through the mufflers 1102, 1104 and past the first
transmission 514 and, in so doing, cools the mufflers and the
transmission. Cooling water continues to proceed out of the
outboard motor 104 and into the sea, typically via the cavitation
plate 1034 along the top of the lower portion 122.
[0169] From the above description, it should be apparent that the
cooling system in at least some embodiments actually includes
multiple cooling systems/subsystems that are particularly (though
not necessarily exclusively) suited for use with outboard motors
having horizontal crankshaft engines such as the outboard motor 104
with the engine 504. In particular, in at least some embodiments,
the outboard motor includes a cooling system having both a
closed-loop cooling system (subsystem), for example, a
glycol-cooling system of the engine where the glycol is cooled by
the heat exchanger. This can be beneficial on several counts, for
example, in that the engine need not be as expensive in its design
in order to accommodate externally-supplied water (seawater) for
its internal cooling (e.g., to limit corrosion, etc.). At the same
time, the outboard motor also can include a self-draining cooling
system (subsystem) in terms of its intake and use of water
(seawater) to provide coolant to the heat exchanger (for cooling
the glycol of the closed-loop cooling system) and otherwise, where
this cooling system is self-draining in that the water (seawater)
eventually passes out of/drains out of the outboard motor 104.
Insofar as the engine 504 includes both a closed-cooling system and
a self-draining cooling system, the engine includes both a
circulation pump for circulating glycol in the former (distinctive
for an outboard motor) and a water (e.g., seawater) pump for
circulating water in the latter. High circulation velocity is
achievable even at low engine speeds. Further by virtue of these
cooling systems (subsystems), enhanced engine operation is
achievable, for example, in terms of better thermally-optimized
combustion chamber operation/better combustion, lower emission
signatures, and relative avoidance of hot spots and cold spots.
[0170] Many modifications to the above cooling system 1300 (and
associated cooling water flow circuit) are contemplated and
considered within the scope of the present disclosure. For example,
the water pump 135, or an additional water pump, can be provided in
the lower portion 122 (e.g., in a lower portion gear case) to pump
water from a different location. In addition, and as already noted,
various modifications can be made engine components and structures
already described herein, including their placement, size, and the
like and the above-described cooling system can be modified account
for such changes.
[0171] FIG. 19 is a schematic illustration of an alternative
arrangement for an outboard motor water cooling system 1900, in
accordance with various embodiments of the present disclosure. In
the present illustration, cooling water flow is again represented
by various arrows. As shown, cooling water flows, as indicated by
arrow 1902, into the water inlets 522, 524. In the instant
exemplary embodiment, cooling water flows, as indicated by arrow
1904 and arrows 1906 and 1908, to first and second water pumps
1907, 1909 and, in so doing, cools the pumps. Water that is pumped
by the water pump 1907 exits the water pump and, after doing so,
flows, as indicated by arrow 1910, into and through an engine heat
exchanger 1912 and then an engine oil cooler 1914. While shown as
separate coolers, it is understood that the engine heat exchanger
1912 and the engine oil cooler 1914 can be integrated as a
collective unit (e.g., as described with regard to FIG. 18). The
engine heat exchanger 1912 serves to cool engine coolant (e.g.,
glycol, or similar fluid), and the engine oil cooler 1914 serves to
cool oil, and at least in these ways cooling of the engine 504 is
accomplished. After exiting the engine heat exchanger 1912 and
engine oil cooler 1914, cooling water flows, as indicated by arrows
1916 and 1918 out to the sea, via a cavity 1033, which can be
located within the cavitation plate in the lower portion 122.
[0172] In addition to, or in parallel with the cooling of the
engine heat exchanger 1912 and the engine oil cooler 1914 as just
described, water is pumped by the water pump 1907 and proceeds into
a chamber (not shown) surrounding the exhaust channels 512. In so
doing cools exhaust flowing within the channels. In at least some
embodiments, the cooling water generally traverses, as indicated by
1920, the engine 504, and it is noted that such water flow may, but
need not necessarily, serve to provide a cooling effect for the
engine. Cooling water then flows to and cools the intercooler 1922
(or charge cooler) as indicated by arrow 1924, 1926. As indicated
by arrows 1930, 1932, cooling water flows through the mufflers
1102, 1104, as well as past the first transmission 514, and in so
doing, the mufflers and the first transmission are cooled. Finally
water proceeds, as indicated by arrows 1934, 1936 from the mufflers
1102, 1104, as well as from the first transmission 514, as
indicated by arrow 1938, out of the outboard motor to the sea, for
example, via a cavity 1033.
[0173] Again, it is noted that many modifications to the above
cooling systems are contemplated and considered within the scope of
the present disclosure. For example, cooling of the intercooler
1922 can be separated from the cooling of the exhaust channels, the
mufflers and the first transmission. An additional water pump and
an additional heat exchanger (e.g., a dedicated heat exchanger) can
be provided to accomplish such separated cooling of the intercooler
1922 (and associated cooling passages), allowing for the
intercooler utilize a lighter fluid, such as glycol. Again, various
modifications can be made engine components and structures already
described herein, including respective placement, size, and the
like and the above-described cooling system 1900 can be modified
account for such changes.
[0174] FIG. 20 is a right side view of the outboard motor 104
including a rigid connection of multiple motor components or
structures to create a rigid structure or rigid body structure,
indicated by dashed line 2000, and related method of assembly of
the rigid structure, is shown in accordance with embodiments of the
invention. The outboard motor can include a horizontal crankshaft
engine 504. The engine 504 (or a surface or portion of the engine),
can be bolted or otherwise connected to the first transmission 514
(or a surface or portion of the first transmission). The engine 504
is oriented horizontally, or substantially horizontally, and a
horizontal plane representative of such orientation is indicated
illustratively by horizontal dashed line 2002. The first
transmission 514 is oriented vertically, or substantially
vertically, and a vertical plane representative of such orientation
is indicated illustratively by vertical dashed line 2004. The first
transmission 514 (or a surface or portion of the first
transmission) can be bolted or otherwise connected to the second
transmission 608 (or a surface or portion of the second
transmission). The second transmission 608 is oriented
horizontally, or substantially horizontally, and a horizontal plane
representative of such orientation is indicated illustratively by
horizontal dashed line 2006. And the second transmission 608 (or a
surface or portion of the second transmission, such as a cover
portion) can be bolted or otherwise connected to the engine 504 (or
a surface or portion of the engine) by way of a vertically oriented
additional structure 2007, which can take the form of, for example,
a cast motor structure or frame portion. A vertical, or
substantially vertical, plane representative of such orientation is
indicated illustratively by vertical dashed line 2008.
[0175] Rigid body structure 2000 thus is created by the interaction
of these four structures engaged with one another. In accordance
with at least one aspect and in the present illustrated embodiment,
rigid body structure 2000 is rectangular or substantially
rectangular in shape. Fastener 2010 is provided. Fastener 2010
permits adjustability needed (e.g., due to manufacturing tolerances
and other variations) in the assembly of rigid body structure 2000
and particularly allows for variation in the spacing between the
forwardmost portion of the engine and the forward most portion of
the second transmission, that is, the spacing afforded by the
additional structure 2007. In accordance with at least some
embodiments, the center of gravity 2012 of the outboard motor 504
is located between the vertical (or substantially vertical) planes
2008 and 2004 of the rigid body structure 2000 and substantially at
the plane 2002 of the engine 504. Creation and position of the
rigid body structure 2000 in accordance with embodiments of the
invention, including those which are illustrated, is particularly
beneficial in that it offers resistance to bending and torsional
moments (or similar stresses) which may result during operation of
the outboard motor 504.
[0176] FIG. 21 is a reduced right side view of the outboard motor
104 and a mounting system 108, the mounting system being used to
mount the outboard motor to a marine vessel as previously
described. FIG. 22 is a schematic cross sectional view, taken along
line 22-22 of FIG. 21, showing a progressive mounting assembly
2200. FIG. 22 shows the lower steering yoke structure 1242 mounted
or otherwise connected to the lower mounting bracket structure 518
by way of bolts or other fasteners 2201 so that the mid portion 120
of the outboard motor 104 is linked to the mounting system 108.
Also shown is steering tube structure 1246 which provides, as
already described, for rotation of the mounting system 108 about
the steering axis. A thrust mount structure 2202 is further
provided between the mid portion 120 and the lower steering yoke
structure 1246. Taken together, it can be seen that the progressive
mounting assembly includes the lower steering yoke structure 1242,
the lower mounting bracket structure 518, and the thrust mount
structure 2202,
[0177] FIGS. 23A-C are schematic illustrations depicting the
progressive nature of the progressive mounting structure 2200 of
FIG. 21 at various levels of operation. With references to FIG. 23A
in particular, along with FIGS. 21 and 22, the progressive mounting
structure 2200 is shown at an operational level having a low load
(e.g., the motor 504 powers the marine vessel 102 at a slow or very
slow speed) powering a watercraft. Accordingly, thrust mount
structure 2202, which is disposed relative to, and possibly
directly contacting motor mid portion 120, but with a space or air
gap separating the thrust mount structure 2202 from the lower yoke
assembly 1242.
[0178] With references to FIG. 23B in particular, along with FIGS.
21 and 22, the progressive mounting structure 2200 is shown at an
operational level having a medium load (e.g., the motor 504 powers
the marine vessel 102 at a medium or mid level speed). Accordingly,
thrust mount structure 2202, which is disposed relative to, and
possibly directly contacting motor mid portion 120, now contacts
the lower yoke assembly 1242. That is, the thrust mount structure
2202 has moved relative the lower yoke assembly 1242 (e.g., such
relative movement is permitted by way of the fasteners 2201), and
the space or air gap previously separating the thrust mount
structure 2202 from the lower yoke assembly 1242 is eliminated.
[0179] With references to FIG. 23C in particular, along with FIGS.
21 and 22, the progressive mounting structure 2200 is shown at an
operational level having a high load (e.g., the motor 504 powers
the marine vessel 102 at a high speed). Accordingly, thrust mount
structure 2202, which is disposed relative to, and possibly
directly contacting motor mid portion 120. The space or air gap
previously separating the thrust mount structure 2202 from the
lower yoke assembly 1242 is eliminated and the thrust mount
structure 2202 contacts the lower yoke assembly 1242. The thrust
mount structure 2202 is shown in a deformed state because it now
serves to transfer force created by the high level of
operation.
[0180] It should be understood that the aforementioned progressive
mounting system previously described is illustrative in nature and
various alternatives and modifications to the progressive mounting
system can be made. Also, the progressive mounting structure
facilitates changes to the thrust mount structure. For example, a
thrust mount structure can, with relative ease, be removed and
replaced with another thrust mount having different
characteristics, such as a different size, shape or stiffness.
Advantageously, the progressive mounting system is capable of being
tuned or changed to accommodate a wide range (from very low to very
high) of thrust placed on the system in a manner that is compact
and suitable for a wide variety of outboard motor mounting
applications.
[0181] From the above discussion, it should be apparent that
numerous embodiments, configurations, arrangements, manners of
operation, and other aspects and features of outboard motors and
marine vessels employing outboard motors are intended to be
encompassed within the present invention. Referring particularly to
FIG. 24, a rear elevation view is provided of internal components
one alternate embodiment of an outboard motor 2404. In this
embodiment, as with the outboard motor 104, there is a horizontal
crankshaft engine 2406 with a rearwardly-extending crankshaft
extending along a crankshaft axis 2408 at an upper portion 2409 of
the outboard motor, a first transmission having an outer perimeter
2410, a second transmission 2412 within a mid portion 2413 of the
outboard motor, and a third transmission 2414 at a lower portion
2415 of the outboard motor. Also, there is an intake manifold 2416
atop the engine 2406, exhaust manifold ports 2418 extending outward
from port and starboard sides of the engine, and both cylinder
heads 2420 of the engine and an engine block 2422 of the engine are
visible, as is a flywheel 2424 mounted adjacent the rear of the
engine. A gearcase mounting flange 2425 is further illustrated that
can be understood as dividing the lower portion 2415 from the mid
portion 2413, albeit it can also be understood as within the lower
portion only. Further, in this embodiment, a supercharger 2426 is
positioned above the engine block 2422 between the cylinder heads
2420. Although not shown, in still another embodiment a
turbocharger can instead be positioned at the location of the
supercharger 2426 or, further alternatively, one or more
turbochargers can be positioned at locations 2429 beneath the
manifold ports 2418.
[0182] Although in the embodiment of FIG. 24, port and starboard
tubular exhaust conduits 2428 and 2430 extend downward (similar to
the exhaust conduits of the engine 104) from the exhaust manifold
ports 2418 to the lower portion 2415. However, in the embodiment of
FIG. 24, the tubular exhaust conduits serve as more than merely
conduits for exhaust. Rather, in the embodiment of FIG. 24, the
tubular exhaust conduits collectively serve as a tubular mounting
frame 2432 for the outboard motor 2404. In particular, the tubular
mounting frame 2432 is capable of connecting the upper portion
2409, the mid portion 2413, and lower portion 2415 of the outboard
motor 2404 with one another. Further, in still other embodiments,
in addition to or instead of conducting exhaust, one or more tubes
of such a tubular mounting frame can conduct coolant or other
fluids as well.
[0183] From the above discussion, it should be understood therefore
that the present invention is intended to encompass numerous
features, components, characteristics, and outboard motor designs.
Among other things, in at least some embodiments, the outboard
motors encompassed herein are designed to be fastened to the aft
end of a boat or other marine vessel (e.g., the transom) and to
power or thrust the marine vessel through the use of a horizontal
crankshaft engine. Further, in at least some embodiments, the
outboard motors employ an engine that is coupled to a first
transmission, a second transmission, and a third transmission,
and/or is capable of steering about a steering axis and/or being
rotatably trimmed about a trim axis. Further, in at least some
embodiments, the outboard motor includes three portions, namely,
upper, middle, and lower portions.
[0184] Also, in at least some embodiments, the engine is mounted
above the transom with the crankshaft centerline substantially
horizontal and substantially parallel to a keel longitudinal axis
of the boat (parallel to the keel line or other bow-to stern axis)
when trimmed to a nominal angle of 0 degrees (the steering axis can
be perpendicular a sea level surface). The engine power take off
(PTO) faces aft and rotatably drives a first transmission that
transfers torque downwardly to a second transmission, which
transmits torque through and 90 degree corner and then into a
vertical output shaft than can be also be termed a driveshaft. The
driveshaft transmits the torque to a third transmission, typically
within a gearcase, which directs the torque into a horizontal
propeller shaft where a propeller transfers the torque into thrust.
The horizontal propeller shaft is typically located at or below the
surface of the water so as to enable single or counter-rotating
twin propellers. In at least some embodiments, the architecture of
the outboard motor is intended to achieve good balance on the
transom of the boat/marine vessel, good vibration isolation, and
good steering stability across a wide operating speed range.
[0185] Additionally, in at least some embodiments, a pivot axis for
trimming and tilting the outboard motor is located at the top of
the transom, below the crankshaft centerline ahead of the steering
axis (as noted above, the engine also is entirely or substantially
above the trimming axis). A vertical steering axis is created by
the swivel bracket which is constrained at the pivot axis for the
trim system by the clamp brackets which are equally disposed to
either side of the swivel bracket for securing the outboard to the
transom. The outboard motor can be mounted to the swivel bracket
with a plurality (e.g., four) rubber mounts attached by the
steering head shafting which is rotatably mounted to the swivel
bracket. The four rubber mounts create an elastic mounting axis
which is designed to be aft of the vertical steering axis.
Mountings as described are in the center portion of the outboard,
or midsection. Extending the mounting axis upward to the upper
portion where the engine is located, the elastic axis will be
substantially proximal to the engine mounting positions which are
located on opposite sides of the engine block proximal the midline
of the crankshaft which is also proximate the vertical plane which
contains the center of gravity of the engine whereby the discrete
engine center of gravity as a separate component is mounted to the
outboard's elastic mounting axis proximate the engines center of
gravity. Extending the elastic axis downward to the lower portion,
the gearcase, to the intersection of the propshaft centerline, the
steering axis will be forward of the elastic axis and the elastic
axis will be forward of the gearcase plan view center of pressure.
With this architecture steering and vibration stability can be
achieved.
[0186] Further, a mounting system that generally connects an
outboard motor to a marine vessel is described in connection with a
wide variety of embodiments. The mounting system accommodates
significant thrust resulting from, for example, high power output
by the engine during operation. As disclosed and in accordance with
a variety of embodiments, the distance separating upper mounts or
mounting portions is greater than the distance separating the lower
mounts or mounting portions (or in the case of a single lower
mount, the single lower mount or mounting portion is between and
below the upper mounting portions). Such upper mount structure
"spread" results in increased steering stability. In at least some
further embodiments, an additional mounting structure (e.g., a
thrust mount) can be included below the upper mount structure
(e.g., yoke structure) for additional engagement with the outboard
motor under at least some operating conditions. In such
embodiments, there are five (or possibly four, if there is only one
lower mount) mounts in the mounting assembly.
[0187] Further, in at least some embodiments, the engine is mounted
to a tubular assembly which provides mountings for the engine,
first, second and third transmissions, and the elastic mounts. The
tubular structure can be constructed in such a way as to utilize
the rear tubular segments as exhaust passages thus eliminating
extra plumbing within the outboard system. The upper portion of the
tubular structure provides a pair of mounting pads, disposed on
opposite sides of the longitudinal centerline, which are designed
to receive the engine mounts. Further, the upper portion provides a
rear engine mounting surface designed to mount to the rear face of
the engine to which the first transmission will also fasten. Thus,
the rear mounting surface of the tubular structure is a plate that
mounts the engine on one side and the first transmission on the
other side. This method of mounting located the engines center of
gravity as described above as well as providing a third rear mount
for additional stability while under operating conditions.
Additionally, the middle section of the tubular midsection provides
a mounting surface for the second transmission. Below the mounting
surface for the second transmission, the midsection provides for an
oil sump for the transmission as well as a fuel sump and location
for a high pressure fuel pump. Further, the lower section of the
midsection provides for the mounting of the third transmission, the
gearcase.
[0188] Additionally, it least some embodiments, the present
invention concerns an outboard motor and/or marine vessel assembly
having any one or more of the following features:
[0189] the center of gravity of the engine is vertically above the
crankshaft center line;
[0190] torque flow: horizontal through engine, downward thru first
transmission, forward and downward thru second transmission,
downward and rearward thru third transmission;
[0191] wet clutch mounted in the midsection with a horizontal input
and a vertical output;
[0192] tubular midsection construction;
[0193] separate oil pumps--dual engine pumps, transmission pump,
and gearcase pump;
[0194] horizontal crankshaft with propeller below and engine
vertically above;
[0195] dry sump with horizontal crankshaft;
[0196] engine oil proximate the transmission oil, and cooled by sea
water;
[0197] outboard engine with integrated circulation pump and a
separate remote circulation pump drive by an accessory belt for raw
seawater;
[0198] air to glycol water cooling of an aluminum intercooler;
[0199] horizontal crankshaft outboard w/supercharger located in the
vee of a vee type engine with the supercharger located below the
intake manifold;
[0200] a horizontal crankshaft outboard engine with at least a
turbo charger located in the V of a V-type engine with exhaust
manifold also in the V;
[0201] a horizontal crankshaft engine with turbo chargers disposed
on either side of the crankcase;
[0202] a horizontal crankshaft outboard with a supercharger above
crankshaft centerline with an intercooler above crankshaft center
line, with an intake manifold inlet above the supercharger;
[0203] a tubular midsection construction with exhaust conduit
integrated as a structural member with the midsection;
[0204] the above including the combination of a water outlet tube
with an exhaust tube;
outboard motor with exhaust downwardly toward the propeller and
upwardly toward a throttled outlet located above the waterline;
[0205] closure of exhaust throttle valves opens a third passage for
idle relief through an exhaust attenuation circuit;
[0206] an exhaust throttle valve that actuates a water control
circuit for an idle relief muffler;
[0207] horizontally disposed inlet to an exhaust system, without a
riser, that flows downwardly toward the propeller;
[0208] outboard engine with accessory drive ahead of the driveshaft
centerline;
[0209] an outboard with accessory drive in front of driveshaft
centerline and a transmission behind the driveshaft centerline;
[0210] an outboard with a flywheel behind driveshaft
centerline;
[0211] flywheel behind an engine, in front of a transmission, above
a second transmission, above a third transmission;
[0212] a horizontal crankshaft outboard in combination with a wet
clutch in the second transmission and a counter rotating propeller
set;
[0213] a 90 degree transmission above the gearcase allowing torque
to be evenly split between front and rear gears in both forward and
reverse rotations to minimize torpedo diameter by eliminating
shifting in the gearcase;
[0214] the above feature where the 90 degree transmission drives a
third transmission with 2 input pinions and a single output shaft,
and/or the above feature in combination with actively managed
exhaust bypass to allow increased reverse thrust;
[0215] water cooling flow path where the water induced by vacuum
water the gearcase, then passes the first transmission, then the
second transmission, then the engine oil, to the inlet of a sea
pump, where it is pressurized to pass through a heat exchanger,
then up to the exhaust manifolds, then downwardly, then mixed with
the exhaust and discharged, some with the exhaust and some
without;
[0216] provision for the metering of water into the exhaust stream
of the engine for the purpose of cooling but limiting and
controlled to reduce the back pressure with the balance of water
discharged outside of the exhaust path;
[0217] idle relief discharge to be common w/exhaust bypass where
the discharge is located downstream of the throttle plate;
[0218] a hinged cowl system allowing the cowl to be hinged up out
of the way without being removed that can also be alternately
removed without being hinged up first;
[0219] a hinged cowl with a mechanical tether to prevent cowl
ejection in the event of a strike of an underwater object while at
operating speeds;
[0220] the above feature with the mechanical tether disposed
opposite the service access points of the engine.
[0221] Among other things, in at least some embodiments, the
present invention relates to an outboard motor configured to be
mounted on a marine vessel. The outboard motor includes a housing
including an upper portion and a lower portion, where at least one
output shaft extends outward from the lower portion upon which at
least one propeller is supported, and an engine configured to
provide first torque at a first shaft extending outward from the
engine, the engine being substantially situated within the housing.
The outboard motor also includes a first transmission device that
is in communication with the first shaft so as to receive the
output torque and configured to cause second torque including at
least some of the first torque to be communicated to a first
location beneath the engine, a second transmission device
configured to receive the second torque and to cause third torque
including at least some of the second torque to be communicated to
a second location beneath the first location within or proximate to
the lower portion, a third transmission device positioned within or
proximate to the lower portion that is configured to receive the
third torque and cause at least some at least some of the third
torque to be provided to the at least one output shaft.
[0222] Also, in at least some such embodiments, the first shaft is
a crankshaft of the engine and extends aftward from the engine
along a horizontal or substantially horizontal crankshaft axis, and
a center of gravity of the engine is positioned above the
horizontal crankshaft axis. Further, in at least some such
embodiments, the third transmission device is situated at least
partly within a gear casing of the lower portion, the gear casing
having at least a portion that is substantially torpedo-shaped.
Also in at least some such embodiments, the at least one output
shaft includes a first output shaft and the at least one propeller
includes a first propeller. Further, in at least some such
embodiments, the third transmission device is situated at least
partly within a gear casing of the lower portion, where the gear
casing houses therewithin first and second pinions, where each of
the first and second pinions is configured to receive a respective
portion of the third torque, where the first and second pinions are
respectively configured to rotate in opposite directions, where the
gear casing further houses first and second additional gears are
both axially aligned with the first output shaft, where the first
and second additional gears respectively engage the first and
second pinions in a manner such that opposite rotation of the first
and second pinions relative to one another causes both of the first
and second additional gears to rotate in a shared direction, and
where such operation allows for the gear casing to have a reduced
cross-sectional area. Additionally, in at least some such
embodiments, the third transmission device additionally has third
and fourth gears respectively situated above and coupled to the
first and second pinions, respectively, where the third gear is
coupled at least indirectly to the second transmission device so as
to receive the third torque and drives the fourth gear. Further, in
at least some such embodiments, the third transmission device is
either a twin pinion transmission device or a single pinion
transmission device, or the at least one output shaft additionally
includes a second output shaft and the at least one propeller
includes a second propeller, where the third transmission device is
configured to cause the first and second output shafts to rotate in
respectively opposite directions upon receiving the third torque
such that the first and second propellers rotate in respectively
opposite directions.
[0223] Additionally, in at least some such embodiments, the second
transmission device includes, or is configured to receive the
second torque via, an intermediate shaft, where the intermediate
shaft is below and substantially parallel to the first shaft, and
further in at least some such embodiments, the second transmission
device is a multi-plate wet disk clutch transmission, and the third
torque is communicated from the second transmission device to the
third transmission device via an additional shaft that is
substantially vertical in orientation, or the second transmission
device is capable of being controlled to achieve forward, neutral,
and reverse states, where in the forward state the second
transmission device is configured to communicate the third torque
in a first rotational direction, where in the reverse state the
second transmission device is configured to communicate the third
torque in a second rotational direction, and where the third
transmission device is a twin pinion transmission device.
[0224] Further, in at least some such embodiments, the first
transmission device includes one of (a) a series of gears each
having a respective axis extending parallel to a first axis of the
first shaft extending outward from the engine; (b) a first wheel or
gear driven by the first shaft in combination with a second wheel
or gear that drives a secondary shaft for providing the second
torque further in combination with a belt or chain for linking the
respective wheels or gears; or (c) first and second 90 degree type
gear arrangements that interact such that the first torque provided
via the first shaft is communicated from the first 90 degree type
gear arrangement downward via an intermediary shaft to the second
90 degree type gear arrangement, which in turn outputs the second
torque. Also, in at least some such embodiments, either (a) the
first transmission device includes a transfer case that includes an
arrangement of gears or other components that interact so that
first rotational movement received from the first shaft is
converted into second rotational movement accompanying the second
torque, the second rotational movement differing in speed or
magnitude from the first rotational movement, or (b) the second
torque includes substantially all of the first torque, the third
torque includes substantially all of the second torque, and the
output shaft receives substantially all of the third torque.
[0225] Additionally, in at least some such embodiments, an oil
reservoir for holding oil for the second transmission device is
located within a mid portion of the outboard motor, between the
second transmission device and the third transmission device, or
the oil reservoir is either (a) cooled by water coolant arriving
from the lower portion of the outboard motor, or (b) is capable of
holding substantially 5 Liters or more of oil; and in addition to
the oil reservoir for the second transmission device, each of the
engine, the first transmission device, and third transmission
device additionally has a further respective dedicated oil
reservoir or repository of its own, so as to enhance operational
robustness of the outboard motor. Also, in at least some such
embodiments, a flow of rotational power from the engine to a
propeller located at an aft end of a first propeller shaft of the
at least one output shaft follows an S-shaped route from the engine
to the first transmission device to the second transmission device
to the third transmission device and finally to the propeller.
Further, in at least some such embodiments, a gear ratio achieved
between the output shaft and a first propeller shaft of the at
least one propeller shaft can be varied by an operator by modifying
at least one characteristic of at least one of the first, second,
and third transmission devices.
[0226] Additionally, in at least some such embodiments, an aft
surface of the engine is rigidly attached to the first transmission
device, where the first transmission device is further rigidly
attached to the second transmission device, and where the second
transmission device is further rigidly attached, at least
indirectly by an additional rigid member, to the internal
combustion engine, whereby in combination the engine, first and
second transmission devices, and additional rigid member form a
rigid combination structure. Also, in at least some such
embodiments, the outboard motor further includes a tubular assembly
that provides mountings for the engine and each of the transmission
devices, where a first of the mountings provided by the tubular
assembly is located at a midsection of the tubular assembly, where
proximate the midsection is further provided at least one of an oil
sump, a fuel sump and a fuel pump, and where the tubular assembly
includes at least a first tube that serves as a conduit for exhaust
produced by the engine.
[0227] Further, in at least some additional embodiments, the
present invention relates to a method of operating an outboard
engine. The method includes providing first torque from the engine
at a first shaft extending aftward from the engine, causing second
torque including at least some of the first torque to be provided
to a first location below the engine at least in part by way of a
first transmission device, and causing third torque including at
least some of the second torque to be provided to a second location
below the first location at least in part by way of a second
transmission device. The method additionally includes causing
fourth torque including at least some of the third torque to be
provided to a propeller supported in relation to a torpedo portion
of the outboard engine.
[0228] Additionally, in at least some embodiments, the present
invention relates to an outboard motor configured for attachment to
and use with a marine vessel. The outboard motor comprises an
internal combustion engine that is positioned substantially (or
entirely) above a trimming axis and that provides rotational power
output via a crankshaft that extends horizontally or substantially
horizontally, a propeller rotatable about a propeller axis and
positioned vertically below the internal combustion engine when the
outboard motor is in a standard operational position, and at least
one transmission component that allows for transmission of at least
some of the rotational power output to the propeller. Further, in
at least some such embodiments of the outboard motor, the outboard
motor includes a front surface and an aft surface, the outboard
motor being configured to be attached to the marine vessel such
that the front surface would face the marine vessel and the aft
surface would face away from the marine vessel when in the standard
operational position, and the crankshaft of the engine extends in a
front-to-rear direction substantially parallel to a line linking
the front surface and aft surface. Also, in at least some such
embodiments of the outboard motor, the internal combustion engine
is an automotive engine suitable for use in an automotive
application and further, in at least some additional embodiments,
one or more of the following are true: (a) the internal combustion
engine is one of an 8-cylinder V-type internal combustion engine;
(b) the internal combustion engine is operated in combination with
an electric motor so as to form a hybrid motor; (c) the rotational
power output from the internal combustion engine exceeds 550
horsepower; and (d) the rotational power output from the internal
combustion engine is within a range from at least 557 horsepower to
at least 707 horsepower.
[0229] Further, in at least some such embodiments of the outboard
motor, the at least one transmission component is positioned
substantially below the internal combustion engine, between the
internal combustion engine and the propeller axis. Also, in at
least some such embodiments of the outboard motor, all cylinders of
the internal combustion engine are positioned substantially at or
above a center of gravity of the internal combustion engine.
Additionally, in at least some such embodiments of the outboard
motor, the engine includes (or is operated in conjunction with) at
least one of a supercharger and a turbocharger, at least one of a
plurality of spark plugs, one or more electrical engine components,
the supercharger, and the turbocharger is positioned above one or
both of the center of gravity of the internal combustion engine and
the crankshaft of the engine, and the outboard motor includes at
least one of an intercooler, a heat exchanger, and a circulation
pump. Further, in at least some such embodiments of the outboard
motor, all of the cylinders of the internal combustion engine have
respective cylinder axes that are oriented so as to be either
vertical or to have vertical components, and all of the cylinders
of the internal combustion engine have exhaust ports that are above
the crankshaft of the engine. Additionally, in at least some
embodiments of the outboard motor, the outboard motor is configured
to be attached to the marine vessel such that a front surface of
the outboard motor would face the marine vessel and the aft surface
would face away from the marine vessel when in the standard
operational position, the internal combustion engine has front and
aft sides, the front and aft sides respectively being proximate the
front and aft surfaces, respectively, and a power take off of the
internal combustion engine extends from the aft side of the
internal combustion engine.
[0230] Also, in at least some such embodiments of the outboard
motor, either (a) one or more of a heat exchanger and an accessory
drive output are positioned at or extend from the front side of the
internal combustion engine at or proximate to the front surface, or
(b) one or more of an accessory drive, a belt, one or more spark
plugs, one or more electrical engine components, and one or more
other serviceable components are positioned at or proximate to a
top side of the internal combustion engine or proximate to the
front side of the internal combustion engine opposite the aft side
of the internal combustion engine from which the power take off
extends. Additionally, in at least some embodiments of the outboard
motor, (a) a flywheel is positioned aft of the internal combustion
engine, between an aft surface of the internal combustion engine
and a first transmission component adjacent thereto, or (b) a
center of gravity of the internal combustion engine is above an
axis of the crankshaft of the internal combustion engine. Also, in
at least some such embodiments of the outboard motor, an aft
surface of the internal combustion engine is rigidly attached to a
first transmission component of the at least one transmission
component, the first transmission component is further rigidly
attached to a second transmission component positioned below the
internal combustion engine, and the second transmission components
is further rigidly attached (at least indirectly by an additional
rigid member) to the internal combustion engine, whereby in
combination the internal combustion engine, first and second
transmission components, and additional rigid member form a rigid
combination structure.
[0231] Further, in at least some such embodiments of the outboard
motor, the outboard motor further comprises a cowling that extends
around at least a portion of the outboard motor so as to form a
housing therefore. Additionally, in at least some such embodiments
of the outboard motor, at least one portion of the cowling extends
around an upper portion of the outboard motor at which is located
the internal combustion engine. Also, in at least some such
embodiments of the outboard motor, a first portion of the cowling
is hingedly coupled to a second portion of the cowling by way of a
hinge, and the hinge allows for rotation of the first portion of
the cowling upward and aftward so that the one or more serviceable
components of the internal combustion proximate a top surface or a
front surface of the internal combustion engine are accessible.
Further, in at least some embodiments, the present invention also
relates to a boat comprising such an outboard motor, the boat being
a marine vessel, the outboard motor being attached to a transom of
the boat associated with a stern of the boat or a fishing deck of
the boat. Additionally, in at least some such embodiments of the
boat, an operator standing proximate the stern of the boat is able
to access one or more components of the internal combustion engine
proximate one or more of a front surface and a top surface of the
internal combustion engine that are exposed when a cowling portion
of the outboard motor is opened upward and aftward away from the
stern of the boat. Also, in at least some such embodiments of the
boat, the boat further comprises at least one additional motor also
attached to the transom or another portion of the boat, and each of
the at least one additional motor is identical or substantially
identical to the outboard motor.
[0232] Also, in at least some embodiments, the present invention
relates to an outboard motor configured for use with a marine
vessel. The outboard motor comprises a horizontal crankshaft
automotive engine and means for communicating at least some
rotational power output from the horizontal crankshaft automotive
engine to an output thrust device positioned below the horizontal
crankshaft engine and configured to interact with water within
which the outboard motor is situated. Further, in at least some
such embodiments of the outboard motor, the output thrust device
includes either a single propeller or two counterrotating
propellers, the means for communicating includes a plurality of
transmission devices, and a crankcase of the horizontal crankshaft
automotive engine is made substantially or entirely from
Aluminum.
[0233] Additionally, in at least some embodiments, the present
invention relates to an outboard motor configured to be mounted on
a marine vessel. The outboard motor comprises a housing including
an upper portion and a lower portion, where at least one output
shaft extends outward from the lower portion upon which at least
one propeller is supported, and an engine configured to provide
first torque at a first shaft extending outward from the engine,
the engine being substantially situated within the housing. The
outboard motor further comprises a first transmission device that
is in communication with the first shaft so as to receive the
output torque and configured to cause second torque including at
least some of the first torque to be communicated to a first
location beneath the engine, a second transmission device
configured to receive the second torque and to cause third torque
including at least some of the second torque to be communicated to
a second location beneath the first location within or proximate to
the lower portion, and a third transmission device positioned
within or proximate to the lower portion that is configured to
receive the third torque and cause at least some at least some of
the third torque to be provided to the at least one output
shaft.
[0234] In at least some such embodiments of the outboard motor, the
first shaft is a crankshaft of the engine and extends aftward from
the engine along a horizontal or substantially horizontal
crankshaft axis, and a center of gravity of the engine is
positioned above the horizontal crankshaft axis. Further, in at
least some such embodiments of the outboard motor, the third
transmission device is situated at least partly within a gear
casing of the lower portion, the gear casing having at least a
portion that is substantially torpedo-shaped. Also, in at least
some such embodiments of the outboard motor, the at least one
output shaft includes a first output shaft and the at least one
propeller includes a first propeller. Additionally, in at least
some such embodiments of the outboard motor, the third transmission
device is situated at least partly within a gear casing of the
lower portion, the gear casing houses therewithin first and second
pinions, each of the first and second pinions is configured to
receive a respective portion of the third torque, the first and
second pinions are respectively configured to rotate in opposite
directions, the gear casing further houses first and second
additional gears are both axially aligned with the first output
shaft, the first and second additional gears respectively engage
the first and second pinions in a manner such that opposite
rotation of the first and second pinions relative to one another
causes both of the first and second additional gears to rotate in a
shared direction, and wherein such operation allows for the gear
casing to have a reduced cross-sectional area.
[0235] Additionally in at least some such embodiments of the
outboard motor, the third transmission device additionally has
third and fourth gears respectively situated above and coupled to
the first and second pinions, respectively, and the third gear is
coupled at least indirectly to the second transmission device so as
to receive the third torque and drives the fourth gear. Also, in at
least some such embodiments of the outboard motor, the third
transmission device is either a twin pinion transmission device or
a single pinion transmission device. Further, in at least some such
embodiments of the outboard motor, the at least one output shaft
additionally includes a second output shaft and the at least one
propeller includes a second propeller, and the third transmission
device is configured to cause the first and second output shafts to
rotate in respectively opposite directions upon receiving the third
torque such that the first and second propellers rotate in
respectively opposite directions. Also, in at least some such
embodiments of the outboard motor, the second transmission device
includes (or is configured to receive the second torque via) an
intermediate shaft, where the intermediate shaft is below and
substantially parallel to the first shaft. Further, in at least
some such embodiments of the outboard motor, the second
transmission device is a multi-plate wet disk clutch transmission,
and the third torque is communicated from the second transmission
device to the third transmission device via an additional shaft
that is substantially vertical in orientation. Also, in at least
some such embodiments of the outboard motor, the second
transmission device is capable of being controlled to achieve
forward, neutral, and reverse states, where in the forward state
the second transmission device is configured to communicate the
third torque in a first rotational direction, where in the reverse
state the second transmission device is configured to communicate
the third torque in a second rotational direction, and where the
third transmission device is a twin pinion transmission device.
[0236] Further, in at least some such embodiments of the outboard
motor, the first transmission device includes one of (a) a series
of gears each having a respective axis extending parallel to a
first axis of the first shaft extending outward from the engine,
(b) a first wheel or gear driven by the first shaft in combination
with a second wheel or gear that drives a secondary shaft for
providing the second torque further in combination with a belt or
chain for linking the respective wheels or gears, or (c) first and
second 90 degree type gear arrangements that interact such that the
first torque provided via the first shaft is communicated from the
first 90 degree type gear arrangement downward via an intermediary
shaft to the second 90 degree type gear arrangement, which in turn
outputs the second torque. Also, in at least some such embodiments
of the outboard motor, either (a) the first transmission device
includes a transfer case that includes an arrangement of gears or
other components that interact so that first rotational movement
received from the first shaft is converted into second rotational
movement accompanying the second torque, the second rotational
movement differing in speed or magnitude from the first rotational
movement, or (b) the second torque includes substantially all of
the first torque, the third torque includes substantially all of
the second torque, and the output shaft receives substantially all
of the third torque.
[0237] Further, in at least some such embodiments of the outboard
motor, an oil reservoir for holding oil for the second transmission
device is located within a mid portion of the outboard motor,
between the second transmission device and the third transmission
device. Also, in at least some such embodiments of the outboard
motor, the oil reservoir is either (a) cooled by water coolant
arriving from the lower portion of the outboard motor, or (b) is
capable of holding substantially 5 Liters or more of oil. Further,
in at least some such embodiments of the outboard motor, in
addition to the oil reservoir for the second transmission device,
each of the engine, the first transmission device, and third
transmission device additionally has a further respective dedicated
oil reservoir or repository of its own, so as to enhance
operational robustness of the outboard motor.
[0238] Also, in at least some such embodiments of the outboard
motor, a flow of rotational power from the engine to a propeller
located at an aft end of a first propeller shaft of the at least
one output shaft follows an S-shaped route from the engine to the
first transmission device to the second transmission device to the
third transmission device and finally to the propeller.
Additionally, in at least some such embodiments of the outboard
motor, a gear ratio achieved between the output shaft and a first
propeller shaft of the at least one propeller shaft can be varied
by an operator by modifying at least one characteristic of at least
one of the first, second, and third transmission devices. Further,
in at least some such embodiments of the outboard motor, an aft
surface of the engine is rigidly attached to the first transmission
device, the first transmission device is further rigidly attached
to the second transmission device, and the second transmission
device is further rigidly attached (at least indirectly by an
additional rigid member) to the internal combustion engine, whereby
in combination the engine, first and second transmission devices,
and additional rigid member form a rigid combination structure.
Also, in at least some such embodiments of the outboard motor, the
outboard motor further comprises a tubular assembly that provides
mountings for the engine and each of the transmission devices,
where a first of the mountings provided by the tubular assembly is
located at a midsection of the tubular assembly, where proximate
the midsection is further provided at least one of an oil sump, a
fuel sump and a fuel pump, and where the tubular assembly includes
at least a first tube that serves as a conduit for exhaust produced
by the engine.
[0239] Additionally, in at least some embodiments, the present
invention relates to a method of operating an outboard engine. The
method includes providing first torque from the engine at a first
shaft extending aftward from the engine, causing second torque
including at least some of the first torque to be provided to a
first location below the engine at least in part by way of a first
transmission device, causing third torque including at least some
of the second torque to be provided to a second location below the
first location at least in part by way of a second transmission
device, and causing fourth torque including at least some of the
third torque to be provided to a propeller supported in relation to
a torpedo portion of the outboard engine.
[0240] Further, in at least some embodiments, the present invention
relates to an outboard motor for a marine application comprising an
upper portion within which is situated an engine that generates
torque, and a lower portion including a gear casing, where a
propeller output shaft extends aftward from the gear casing along
an axis drives rotation of a propeller. Additionally, the gear
casing includes each of: (a) first and second pinions, where each
of the first and second pinions is configured to receive a
respective portion of the torque generated by the engine via at
least one transmission device, and where the first and second
pinions are respectively configured to rotate in opposite
directions; (b) first and second additional gears that are both
axially aligned with the axis and coupled to or integrally formed
with the propeller output shaft, where the first and second
additional gears respectively engage the first and second pinions
in a manner such that opposite rotation of the first and second
pinions relative to one another causes both of the first and second
additional gears to rotate in a shared direction; and (c) an
exhaust port formed at or proximate an aft end of the gear casing,
the exhaust port allowing exhaust provided thereto via at least one
channel within the lower portion to exit the outboard motor.
[0241] Additionally, in at least some such embodiments of the
outboard motor, at least one water inlet is formed along the lower
portion by which water coolant is able to enter the outboard motor
from an external water source. Further, in at least some such
embodiments, the at least one water inlet includes a lower water
inlet formed along a bottom front surface of the gear casing and at
least one upper water inlet formed along at least one side surface
of the lower portion at a location substantially midway between a
top of the lower portion and the bottom front surface. Also, in at
least some such embodiments of the outboard motor, the at least one
upper water inlet includes port and starboard upper water inlets
formed along port and starboard side surfaces of the lower portion.
Further, in at least some such embodiments of the outboard motor,
operation of the upper water inlets can be tuned by placing or
modifying one or more cover plates over the upper water inlets so
as to partly or entirely cover over one or more orifices formed
within the port and starboard side surfaces in various manners,
further operation of the lower water inlet can be tuned by placing
an additional cover plate over or in relation to the lower water
inlet, and all of the water inlets are positioned forward of the
first and second pinions toward a forward side of the outboard
motor, the outboard motor being configured so that the forward side
faces a marine vessel when the outboard motor is attached to the
marine vessel.
[0242] Additionally, in at least some such embodiments of the
outboard motor, (a) at least one of the orifices is entirely
covered over by way of at least one of the cover plates, so as to
preclude any of the water coolant from entering the at least one
orifice, or (b) the additional cover plate is added so as to block
the lower water inlet and thereby preclude any of the water coolant
from entering the lower water inlet. Further, in at least some such
embodiments of the outboard motor, an oil drain screw associated
with an oil reservoir for the gear casing extends, from within the
lower portion, toward the lower water inlet without protruding out
of the lower portion, whereby the oil drain screw can be accessed
to allow draining of oil from the gear casing, and whereby a
positioning of the oil drain screw is such that no portion of the
oil drain screw protrudes out beyond an exterior surface of the
gear casing. Also, in at least some such embodiments of the
outboard motor, the lower housing includes a front coolant chamber
configured to receive the water coolant able to enter the outboard
motor via the at least one water inlet. Additionally, in at least
some such embodiments of the outboard motor, the outboard motor
further comprises first and second transfer gears respectively
coupled to the first and second pinions by way of first and second
additional downward shafts extending respectively from the first
and second transfer gears to the first and second pinions,
respectively, where the first and second transfer gears engage one
another and the first transfer gear receives at least some of the
torque generated by the engine from a transmission device
positioned above the first and second transfer gears by way of an
intermediate shaft extending from the transmission device to the
first transfer gear.
[0243] Also, in at least some such embodiments of the outboard
motor, the outboard motor further comprises a mid portion in
between the upper portion and the lower portion, where the mid
portion and lower portion are configured so that at least a first
portion of the water coolant received by the front coolant chamber
passes by the first and second transfer gears so as to cool the
first and second transfer gears. Additionally, in at least some
such embodiments of the outboard motor, the outboard motor further
comprises an oil reservoir for the transmission device, the oil
reservoir being positioned below the transmission device and above
the first and second transfer gears within the mid portion, where
the mid portion and lower portion are configured so that at least
the first portion or a second portion of the water coolant received
by the front coolant chamber passes by the oil reservoir so as to
cool oil within the oil reservoir. Further, in at least some such
embodiments of the outboard motor, Archimedes spiral mechanisms are
formed in relation to each of the first and second additional
downward shafts, such that oil is conducted upwards from a
reservoir portion within the gear casing to the first and second
transfer gears regardless of whether the outboard motor is
operating a forward or reverse direction. Also, in at least some
such embodiments of the outboard motor, the outboard motor further
comprises a mid portion in between the upper portion and the lower
portion, where a transmission device capable of
forward-neutral-reverse operation is positioned within the mid
portion above the first and second pinions, and where the
respective portions of the torque are supplied to the first and
second pinions at least indirectly from the transmission
device.
[0244] Additionally, in at least some such embodiments of the
outboard motor, the lower portion includes an exhaust cavity
positioned aftward of the first and second pinions, the exhaust
cavity being configured to receive exhaust provided thereto from
the engine and being coupled by way of or constituting the at least
one channel by which the exhaust is provided to the exhaust port.
Further, in at least some such embodiments of the outboard motor,
the exhaust port includes a plurality of exhaust port sections
positioned around the propeller output shaft and separated from one
another by a plurality of axially extending vanes. Also, in at
least some such embodiments of the outboard motor, the lower
portion includes a cavitation plate extending aftward along a top
portion of the lower portion above the propeller, and the
cavitation plate includes at least one of a (a) cavity within which
water coolant circulating within the outboard motor arrives after
performing cooling within the outboard motor and prior to exiting
the outboard motor, the cavity at least partly in communication
with the exhaust cavity and (b) a sacrificial anode.
[0245] Further, in at least some embodiments, the present invention
relates to an outboard motor for a marine application that
comprises an upper portion within which is situated an engine that
generates torque, and a lower portion including a gear casing,
where a propeller output shaft extends aftward from the gear casing
along an axis drives rotation of a propeller. The gear casing has:
(a) first and second pinions coupled respectively to first and
second gears by way of first and second downwardly-extending
shafts, respectively, where each of the first and second gears is
configured to receive a respective portion of the torque generated
by the engine via at least one transmission device, and where the
first and second pinions are configured to rotate in opposite
directions; (b) first and second additional gears that are both
axially aligned with the axis and coupled to or integrally formed
with the propeller output shaft, where the first and second
additional gears respectively engage the first and second pinions
in a manner such that opposite rotation of the first and second
pinions relative to one another causes both of the first and second
additional gears to rotate in a shared direction; and (c) a
plurality of tunable water inlets formed along one or more forward
surfaces of the lower portion, the tunable water inlets being
configurable to allow or preclude entry of water coolant from an
external water source to enter into the lower portion, wherein the
lower portion is configured so that at least some of the water
coolant entering the lower portion passes by the first and second
gears so as to cool the first and second gears.
[0246] Additionally, in at least some such embodiments of the
outboard motor, at least one of the lower portion, upper portion
and a mid portion between the lower and upper portions is
configured to direct at least some of the water coolant toward or
by at least one of: (a) an oil reservoir for a transmission device;
(b) a heat exchanger configured to cool glycol engine coolant upon
receiving the water coolant; and (c) an exhaust conduit receiving
exhaust from the engine. Further, in at least some such embodiments
of the outboard motor, the engine is a horizontal crankshaft
engine, and the at least one transmission device includes a wet
disk clutch transmission. Also, the present invention also relates
in at least some embodiments to a marine vessel comprising such
embodiments of the outboard motor.
[0247] Further, in at least some embodiments, an outboard motor
includes a lower portion having one or more tunable water inlets.
In some such embodiments, there are one or two upper water inlets
located substantially midway between top and bottom regions of the
lower portion. In other embodiments, there is at least one tunable
water inlet along a bottom surface of a gear case. In at least some
such embodiments, one or more water inlets are tunable by placement
of one or more covers (e.g., cover plates, clamshell-type
structures, etc.) that entirely or partly block entry of water into
an interior of the lower portion via the one or more water inlets.
Water entering via the inlets can proceed into the outboard motor
for use for cooling.
[0248] Additionally, in at least some embodiments, the present
invention relates to a mounting system for connecting an outboard
motor to a marine vessel. The mounting system comprises a swivel
bracket structure having a steering tube structure and providing a
steering axis about which the swivel bracket structure is capable
of rotating, and a pair of clamp bracket structures extending from
the swivel bracket structure. The mounting system also comprises a
first steering yoke structure connected to the swivel bracket
structure by way of the steering tube structure, and including a
first crosspiece mounting structure that includes a pair of first
steering yoke structure mount portions which can be used to couple
the swivel bracket structure to the outboard engine, the pair of
first steering yoke structure mount portions separated by a first
distance. The mounting system further comprises a second steering
yoke structure connected to the swivel bracket structure by way of
the steering tube structure, and including a second steering yoke
structure mount portion which can be used to couple the swivel
bracket structure to the outboard engine, the second steering yoke
structure mount portion positioned between the pair of first
steering yoke structure mount portions.
[0249] Further, in at least some such embodiments of the mounting
system, each of the pair of first steering yoke structure mount
portions includes a respective first passage and the second
steering yoke structure mount portion includes a second passage.
Also, in at least some such embodiments of the mounting system, the
second steering yoke structure mount portion passage is below and
between the pair of first steering yoke structure mount portions.
Additionally, in at least some such embodiments of the mounting
system, the outboard motor includes a horizontal crankshaft
engine.
[0250] Also, in at least some embodiments, the present invention
relates to a mounting system for connecting an outboard motor to a
marine vessel. The mounting system includes a swivel bracket
structure having a steering tube structure and providing a steering
axis about which the swivel bracket structure is capable of
rotating, and a pair of clamp bracket structures extending from the
swivel bracket structure. The mounting system further includes a
first steering yoke structure connected to the swivel bracket
structure about a steering tube structure, and including a first
crosspiece mounting structure that includes a pair of first
steering yoke structure mount portions which can be used to couple
the swivel bracket structure to the outboard engine, the pair of
first steering yoke structure mount portions separated by a first
distance. The mounting system additionally includes a second
steering yoke structure connected to the swivel bracket structure
about the steering tube structure, and including a pair of second
steering yoke structure mount portions which can be used to couple
the swivel bracket structure to the outboard engine, the pair of
second steering yoke structure mount portions separated by a second
distance, where the first distance is greater than the second
distance, thereby providing convergence from the pair of first
steering yoke structure mount portions to the pair of second
steering yoke structure mount portions.
[0251] Further, in at least some such embodiments of the mounting
system, each of the pair of first steering yoke structure mount
portions includes a passageway and the first distance is at least
about the distance between respective centers of the passageways.
Additionally, in at least some such embodiments of the mounting
system, each of the pair of second steering yoke structure mount
portions includes a passageway and the second distance is at least
about the distance between respective centers of the passageways.
Also, in at least some such embodiments of the mounting system, the
first crosspiece mounting structure is centered or substantially
centered about the steering tube structure, and the crosspiece
mounting structure terminates in the pair of mount portions.
Additionally, in at least some such embodiments of the mounting
system, the clamp bracket structures are symmetric with respect to
one another. Further, in at least some such embodiments of the
mounting system, the clamp bracket structures are capable of being
affixed rigidly or substantially rigidly to the marine vessel.
Also, in at least some such embodiments of the mounting system, the
crosspiece mounting structure terminates in the pair of mount
portions.
[0252] Additionally, in at least some such embodiments of the
mounting system, a steering axis extends longitudinally along the
center of steering tube structure and provides an axis of rotation.
Also, in at least some such embodiments of the mounting system, the
axis of rotation is vertical or substantially vertical. Further, in
at least some such embodiments of the mounting system, the mounting
system further includes a tilt tube structure having an axis of
rotation that permits at least one of tilting and trimming about
the axis of rotation, and the axis of rotation of the tilt tube
structure further coincides with an axis of actuation of a power
steering actuator that is generally housed within the tilt tube
structure. Also, in at least some such embodiments of the mounting
system, the mounting system further includes a tilt tube structure
having an axis of rotation. Further, in at least some such
embodiments of the mounting system, the swivel bracket structure is
rotatable about the tilt tube axis of rotation. Additionally, in at
least some such embodiments of the mounting system, the swivel
bracket structure is at least one of tiltable and trimmable about
the tilt tube axis of rotation. Also, in at least some such
embodiments of the mounting system, the tilt tube axis of rotation
is horizontal or substantially horizontal and, by virtue of
swiveling around the tilt tube axis of rotation, it is possible to
rotate the outboard motor in relation to a transom of the marine
vessel so as to bring a lower portion of the marine vessel out of
the water within which it would ordinarily be situated.
[0253] Also, in at least some embodiment, the present invention
relates to a mounting system for connecting an outboard motor to a
marine vessel. The mounting system comprises a swivel bracket
structure having a steering tube structure and providing a steering
axis about which the swivel bracket structure is capable of
rotating, and a pair of clamp bracket structures extending from the
swivel bracket structure. The mounting system further comprises a
tilt tube structure having an axis of rotation, the tilt tube
structure housing (at least in part) a power steering cylinder
having a central axis that coincides, or substantially coincides,
with the tilt tube structure axis of rotation. Further, in at least
some such embodiments of the mounting system, the power steering
cylinder includes a power steering piston that is capable of moving
within the steering cylinder in response to power steering fluid
movement. Additionally, in at least some such embodiments of the
mounting system, the swivel bracket structure is rotatable about
the tilt tube axis of rotation. Further, in at least some such
embodiments of the mounting system, the swivel bracket structure is
at least one of tiltable and trimmable about the tilt tube axis of
rotation. Also, in at least some such embodiments of the mounting
system, the tilt tube axis of rotation is horizontal.
[0254] Additionally, in at least some such embodiments of the
mounting system, the mounting system further comprises a first
steering yoke structure connected to the swivel bracket structure
by way the steering tube structure, and including a first
crosspiece mounting structure that includes a pair of first
steering yoke structure mount portions which can be used to couple
the swivel bracket structure to the outboard engine, the pair of
first steering yoke structure mount portions separated by a first
distance, and a second steering yoke structure connected to the
swivel bracket structure by way of the steering tube structure, and
including a second steering yoke structure mount portion which can
be used to couple the swivel bracket structure to the outboard
engine, the second steering yoke structure mount portion positioned
between the pair of first steering yoke structure mount portions.
Also, in at least some such embodiments of the mounting system, the
mounting system further comprises a first steering yoke structure
connected to the swivel bracket structure about a steering tube
structure, and including a first crosspiece mounting structure that
includes a pair of first steering yoke structure mount portions
which can be used to couple the swivel bracket structure to the
outboard engine, the pair of first steering yoke structure mount
portions separated by a first distance, and a second steering yoke
structure connected to the swivel bracket structure about the
steering tube structure, and including a pair of second steering
yoke structure mount portions which can be used to couple the
swivel bracket structure to the outboard engine, the pair of second
steering yoke structure mount portions separated by a second
distance, wherein the first distance is greater than the second
distance, thereby providing convergence from the pair of first
steering yoke structure mount portions to the pair of second
steering yoke structure mount portions.
[0255] Further, in at least some embodiments, the present invention
relates to a method of cooling an outboard motor having a lower
portion, a mid portion, an upper portion, a first transmission
disposed in the upper portion and a second transmission disposed in
the mid portion. The method includes receiving, into the lower
portion of the outboard motor, an amount of cooling water, and
flowing the amount of cooling water generally upwardly into the mid
portion of the outboard motor and past the second transmission. In
at least some such embodiments of the method, the amount of cooling
water is received into the lower portion of the outboard motor via
a plurality of water inlets, and/or the cooling water cools at
least in part the second transmission. Also, in at least some such
embodiments of the method, the amount of cooling water that is
flowing upwardly in the mid portion of the outboard motor flows
vertically or substantially vertically. Further, in at least some
such embodiments of the method, the amount of cooling water flowing
into the mid portion of the outboard motor also flows generally
rearwardly in the mid portion past at least one of a pair of
transfer gears and a second transmission oil reservoir to cool any
oil in the reservoir. Also, in at least some such embodiments of
the method, an engine is disposed in the upper portion of the
outboard motor and the amount of cooling water flows from the mid
portion generally upwardly into the upper portion.
[0256] Additionally, in at least some such embodiments of the
method, the method further comprises flowing the amount of cooling
water forwardly to a water pump. Also, in at least some such
embodiments of the method, the method further comprises pumping,
using the water pump, the amount of cooling water into and through,
so as to cool, an engine heat exchanger and an engine oil cooler.
Further, in at least some such embodiments of the method, the
method further comprises cooling a heat exchanger fluid at the heat
exchanger using the amount of cooling water and further cooling an
amount of oil at the engine oil cooler using the amount of water.
Additionally, in at least some such embodiments of the method, the
method further comprises, after exiting the engine heat exchanger
and engine oil cooler, flowing the amount of water generally
downwardly, toward and into at least one chamber surrounding a
plurality of exhaust channels, and further flowing the amount of
water back upwardly into at least one exhaust manifold, so as to
cool exhaust. Also, in at least some such embodiments of the
method, cooling water flows in a direction counter to a direction
of exhaust flow so as to cool the exhaust (while in the at least
one chamber surrounding the exhaust channels). Further, in at least
some such embodiments of the method, after exiting the at least one
exhaust manifold, the amount of cooling water flows downwardly,
through one or more mufflers, and past the first transmission and,
in so doing, cools the one or more mufflers and the first
transmission. Also, in at least some such embodiments of the
method, the method further comprises flowing the amount of cooling
water out of the outboard motor, by way of the lower portion.
[0257] Further, in at least some embodiments, the present invention
relates to a method of cooling an outboard motor having a lower
portion, a mid portion, and an upper portion. The method comprises
receiving, into the lower portion of the outboard motor, an amount
of cooling water, and flowing the amount of water upwardly from the
lower portion to and through the mid portion and into the upper
portion. The method also includes flowing a first portion of the
amount of water into a first water pump and pumping the water from
the first pump into and through one or more engine heat exchangers
(e.g., and engine coolant heat exchanger and/or an engine oil
cooler) and, after exiting the engine heat exchanger(s), flowing
the first portion of the cooling water out of the outboard motor by
way of the lower portion. The method further includes flowing a
second portion of the amount of water into a second water pump and
pumping the second portion into chambers surrounding respective
exhaust channels to cool exhaust flowing within the channels, and
flowing the second portion of the amount of cooling water through a
plurality of mufflers and past a first transmission disposed in the
upper portion, and in so doing, cooling the mufflers and the first
transmission. The method additionally includes flowing the second
portion of the amount of cooling water from the mufflers and the
first transmission, out of the outboard motor.
[0258] Additionally, in at least some such embodiments of the
method, the method further comprises flowing the amount of cooling
water generally upwardly into the mid portion of the outboard motor
and past, so as to cool, the second transmission disposed in the
mid portion. Further, in at least some such embodiments of the
method, the method further comprises cooling the engine in the
upper portion by cooling engine coolant using a heat exchanger and
cooling engine oil using an engine oil cooler. Also, in at least
some such embodiments of the method, the method further comprises
at least one of: (a) flowing the second portion of the amount of
cooling water to, so as to cool, an intercooler, and (b) flowing a
third portion of the amount of water into a third water pump and
pumping the third portion of the amount of cooling water to, so as
to cool, an intercooler. Further, in at least some such embodiments
of the method, the intercooler is an aluminum intercooler, and air
to glycol water cooling is performed at the intercooler.
[0259] Further, in at least some embodiments, the present invention
relates to a rigid body structure for use with outboard motor
comprising an internal combustion engine that is rigidly attached
to a first a first transmission assembly, a second transmission
assembly positioned below the internal combustion engine and
connected the first transmission assembly, and an additional rigid
member connected to the second transmission assembly and to the
internal combustion engine, whereby in combination the internal
combustion engine, first and second transmission assemblies, and
the additional rigid member form a rigid body structure.
Additionally, in at least some such embodiments of the rigid body
structure, the internal combustion engine is a horizontal
crankshaft engine. Further, in at least some such embodiments of
the rigid body structure, the rigid body structure is rectangular
or substantially rectangular in shape. Also, in at least some such
embodiments of the rigid body structure, the rigid body structure
includes a fastener which permits adjustability in the assembly of
the rigid body structure.
[0260] Additionally, in at least some embodiments, the present
invention relates to a progressive mounting assembly of an outboard
motor also having a transom mounting assembly, the progressive
mounting assembly for use in allowing connection of the outboard
motor to a transom of a marine vessel by way of the transom
mounting assembly. The progressive mounting assembly includes a
steering yoke structure capable of being used with the transom
mounting assembly, a mounting bracket structure connected to the
steering yoke structure and mountable to a remainder of the
outboard motor, and a thrust mount structure in operable
association with the steering yoke structure and the mounting
bracket structure such that the thrust mount structure is capable
of transferring force in during an operational range of the
outboard motor. Further, in at least some such embodiments of the
progressive mounting assembly, the thrust mount structure contacts
the lower yoke assembly and is deformed transferring a moderate to
substantial force.
[0261] Also, in at least some embodiments, the present invention
relates to an outboard motor adapted for use with a marine vessel.
The outboard motor comprises an internal combustion engine
positioned substantially within an upper portion of the outboard
motor, where the internal combustion engine is configured to output
rotational power at a crankshaft and further output exhaust from at
least one engine cylinder during operation of the engine, and a
first exhaust conduit that is configured to communicate at least
some of the exhaust downward from the engine to a gear casing at a
lower portion of the outboard motor, where the exhaust is able to
exit the lower portion by way of at least one orifice formed in an
aft surface of the gear casing positioned in front of a propeller
attached to the gear casing. The outboard motor further comprises
at least one water inlet positioned proximate a front surface of
the lower portion by which water coolant is able to enter into the
lower portion from an exterior water source, and at least one
channel leading from the at least one water inlet to a portion of
the exhaust conduit, the least one channel being configured to
direct at least some of the water coolant to pass in proximity to
the exhaust conduit so as to cool the exhaust communicated by the
exhaust conduit.
[0262] Further, in at least some such embodiments of the outboard
motor, the at least one engine cylinder includes a plurality of
engine cylinders, where the first exhaust conduit is configured to
receive the exhaust from a first cylinder along a first side of the
engine, and the outboard motor further comprises a second exhaust
conduit that is configured to receive additional exhaust from a
second cylinder along a second side of the engine and to
communicate at least some of the additional exhaust downward from
the engine to the gear casing. Also, in at least some such
embodiments of the outboard motor, the first and second exhaust
conduits run along port and starboard sides of the outboard motor
so as to minimize heat transfer from the exhaust conduits to one or
both of oil or other internal engine components. Additionally, in
at least some such embodiments of the outboard motor, the outboard
motor further comprises third and fourth exhaust conduits that link
the first and second exhaust conduits, respectively, with first and
second mufflers, respectively, the first and second mufflers being
positioned aftward of the internal combustion engine substantially
along first and second sides of a first transmission. Also, in at
least some such embodiments of the outboard motor, the first and
second mufflers are coupled in a manner tending to reduce or
ameliorate noise associated with the exhaust and additional exhaust
communicated from the engine.
[0263] Further, in at least some such embodiments of the outboard
motor, output ports of the first and second mufflers are coupled to
output orifices formed within an upper portion of a cowling of the
outboard motor, where positioning of the orifices within the upper
portion minimizes water entry into the orifices, and where the
upper portion of the cowling further includes at least one air
intake port. Additionally, in at least some embodiments, the engine
is a horizontal crankshaft engine that outputs the exhaust
communicated by the exhaust conduits. Also, in at least some
embodiments, coolant for cooling exhaust flows in a direct opposite
or counter a direction of flow of the exhaust leaving the
engine.
[0264] Additional alternate embodiments are also possible. For
example, in some other embodiments, more than one (e.g., two) of
the outboard motors such as the outboard motor 104 are positioned
on a single marine vessel such as the marine vessel 102 to form a
marine vessel assembly.
[0265] Further, numerous additional features can be provided in one
or more additional embodiments of outboard motors encompassed
herein. Among these additional features are (a) a cowling system
with one or more features that are in addition to or in place of
one or more for cowling system features already discussed above;
(b) a water pump system as described below; (c) a vapor separating
tank (VST) system as described below; and (d) an oil tank system as
described below. It should be understood that, notwithstanding the
discussion below, the present disclosure is intended to encompass
numerous different embodiments of outboard motors having any one or
more of the features described above and/or below, including any
one or more of the cowling, water pump, VST, and oil tank systems
specifically described below, and/or modified versions of any one
or more of those features or systems. Further, the present
disclosure is intended to encompass any one or more of such
features or systems as those features or systems can be implemented
in a variety of outboard motors, as well as intended to encompass
any of a variety of marine vessels that employ any one or more of
such outboard motors and/or features and/or systems. Additionally,
the present disclosure is intended to encompass numerous different
embodiments of methods and processes of operation, use,
manufacturing, and assembly suited for any one or more of such
features or systems, outboard motors employing any such features or
systems, and/or marine vessels employing any such outboard motors,
features, and/or systems.
[0266] Cowling System
[0267] The present invention in at least some embodiments relates
to an outboard motor that includes a cowling system in which the
cowling is divided into first and second portions and serves to
divide an interior region within the upper portion of the motor
into two subcavities. A first portion of the cowling is implemented
around the transmission, which is insensitive to water submersion,
and air enters the outboard motor via the first portion.
Additionally, a second portion of the cowling is enclosed around
the engine. Airflow passages connect the two portions in such a
manner as to allow passage of air but discourage passage of
water.
[0268] In at least some such embodiments, the first portion is
separated from the second portion by way of a substantially
vertical interior wall formation, and the first portion and second
portions are in fluid communication with one another by way of an
opening proximate a bottom of the wall formation. Air entering the
outboard motor enters at inlet(s) positioned at or proximate to a
top of the motor and a top of the wall formation such that, for the
air to reach the engine, the air must pass downward through the
first portion to the opening and then upward into the second
portion toward the engine. Further in at least some such
embodiments, air is delivered to the engine in the second portion
while entrapped/entrained water is separated in the first portion
and allowed to drain through passages provided in the lowermost
portion of the first portion of the cowling system. Also, in at
least some such embodiments, the cross-sectional sizes of the first
and second portions are different from one another such that air
flow downward through the first portion is at a higher flow rate
and air flow upward into/through the second portion is at a lower
flow rate.
[0269] At least some embodiments of the improved cowling system are
appropriate especially for large outboard motors that require high
airflow rates due to elevated power levels. By dividing the cowling
system into two separate compartments where a first compartment is
partitioned from a second compartment and a relatively low
restriction passage is provided between the first and second
compartment. Then the first compartment can be utilized to create
an airflow reversing effect where air velocity is utilized to
separate water from air due to the reversal effect. Here airflow is
introduced to the cowling and immediately directed downwardly in
the first compartment then turned upwardly causing water to "fall
out" to the bottom of the first compartment and thereby be drained.
Then the upwardly rising air passes into the second and larger
compartment causing a slowing of the airflow which in turn causes
the remainder of entrapped water to be drained through a second set
of drain orifices in the lower portion of the second cowl
chamber.
[0270] Hence, in such embodiments, the first chamber is designed to
be smaller than the second chamber as higher airflow velocity
better serve the reversal effect than the larger chamber utilizes
lower velocity for further water removal as the larger second
chamber has a longer horizontal path that allows more time for
gravity to pull the heavier entrapped water from the slowly rising
airflow. In this way, low airflow restriction is accomplished for
better engine breathing efficiency while water is efficiently
removed sequentially in each of two chambers each equipped with
independent drain orifices and enabled by both high velocity
reversal effects and low velocity gravitational effects.
[0271] In view of these features, the outboard motor serves to one
or more of (1) minimize the ingress of water into the motor (e.g.,
due to the high placement of the air inlets), (2) minimize
proceeding of water toward water-sensitive components such as the
engine due to one or more of (a) the required flow path for air
involving forward movement of the air, (b) successive downward and
then upward movement of the air within the motor, and/or (c) high
velocity air flow downward followed by low velocity upward air
flow, and/or (3) enhanced drainage of water from the outboard
motor, so as to keep water-sensitive components such as the engine
as dry as possible, by way of water outlets at two distinct regions
of the outboard motor.
[0272] Referring to FIG. 25, a right side elevation view of an
example outboard marine propulsion system or outboard motor (or
outboard engine or outboard machine) 2500 is shown. The outboard
motor 2500 can be an alternate embodiment of the outboard motor 104
already discussed above. In the present embodiment, the outboard
motor 2500 is configured to be coupled to a stern (rear) edge or
transom of a marine vessel (not shown, but which can be for example
the marine vessel 100 discussed above) by way of a mounting system
2502 positioned along a front edge or region 2503 of the outboard
motor. As already discussed above, it will be appreciated that the
marine vessel in relation to which the outboard motor 2500 can be
utilized can take any of a variety of forms including a variety of
speed boats, yachts, other pleasure craft, as well as other types
of boats, marine vehicles and marine vessels.
[0273] Further with respect to FIG. 25, the outboard motor 2500
particularly includes a cowling system or simply cowling (or cowl)
2504 surrounding and forming a housing for an upper portion 2506
and a mid portion 2508 of the outboard motor. A lower portion 2510
of the outboard motor 2500 includes a propeller 2512 that is
located along a rear edge or region 2513 of the outboard motor and
that is rotated by operation of the outboard motor 2500 and, by
virtue of such rotation, drives the outboard motor and any marine
vessel to which the motor is attached. With respect to the cowling
2504 in particular, the cowling can generally be considered to have
an upper cowl 2514 and a lower cowl 2516, where the upper cowl is
generally the portion of the cowl corresponding to the upper
portion 2506 of the outboard motor 2500, and the lower cowl
generally encompasses the portion of the cowl positioned within the
mid portion 2508 of the outboard motor (albeit the lower cowl can
also be considered to be partly or entirely within a lower portion
of the upper portion 2506 of the outboard motor). FIG. 25
additionally shows the cowling 2504 to include air inlet(s) (in the
Helmut as discussed below) 2518 and optional side air inlets 2520
and associated covers 2522.
[0274] Turning to FIGS. 26, 27, and 28, a side elevation cutaway
view, rear perspective cutaway view (or rear 3/4 view), and front
perspective cutaway view (or front 3/4 view), respectively, of a
portion of the outboard motor 2500 of FIG. 25 generally
corresponding to the upper portion 2506 of the outboard motor and
also referred to as a "powerhead" of the outboard motor are shown.
For simplicity of discussion, FIG. 26 will be particularly referred
to in the discussion below except where particular details of
interest are particularly evident from one or more of FIGS. 27 and
28 as mentioned below, and it should be understood that the
discussion below is equally pertinent to FIGS. 27 and 28. Further
in addition to FIGS. 26, 27, and 28, an additional top view of the
upper portion 2506 of the outboard motor 2500 is provided in FIG.
29, which differs from the views of FIGS. 26, 27, and 28 insofar as
the upper portion 2506 is shown with the upper cowl 2514 (or a
Helmut of the cowling 2504) removed.
[0275] FIG. 26 particularly shows portions of the cowling 2504,
particularly portions of the upper cowl 2514, to be removed
(sectioned off) so as to reveal several internal components of the
outboard motor 2500 (that is, FIG. 26 can be considered a view of
the powerhead with section cowl). Among other things, FIG. 26 shows
that the cowling 2504 includes an outer (exterior) cowling 2600
that forms the outer housing of the upper portion 2506 of the
outboard motor 2500. An upper portion 2602 of the outer cowling
2600 extends upward and over an internal combustion engine 2604 of
the outboard motor 2500 and corresponds to (or forms part of) the
upper cowl 2514. Further, a lower portion 2606 of the outer cowling
2600 extends underneath the engine 2604 and corresponds to (or
forms part of) the lower cowl 2516.
[0276] In addition to the outer cowling 2600, the cowling 2504
further includes several interior cowling portions that are
positioned/extend within the interior of the outer cowling. More
particularly as shown, the interior cowling portions include an
upper divider plate 2608 that extends within the interior of the
outer cowling 2600, rearward of the engine 2604, downward from the
upper portion 2602, to a location 2609 beneath (in this example,
just beneath) the engine 2604 (and behind the engine). Further, the
interior cowling portions also include a lower divider plate 2610
that is located beneath (and behind) the engine 2604. As shown in
FIG. 26, the lower divider plate 2610 has a first section 2612 that
extends horizontally inwardly (forwardly) from a rear surface of
the upper cowl 2514, and then a second section 2614 that extends
vertically upward from a front end of the first section 2612, up to
a location beneath the location 2609 and beneath the engine 2604.
By virtue of the upper and lower divider plates 2608 and 2610,
respectively, an interior cavity within the cowling 2504 (and
particularly within the upper cowl 2514) is substantially divided
into two major subcavities, namely, a first cowling section 2618
and a second cowling section 2620. As shown, the second cowling
section 2620 is located frontward of the first cowling section
2618, and the engine 2604 is situated within the second cowling
section 2620. By contrast, a transmission 2622 is situated within
the first cowling section 2618.
[0277] Although the upper and lower divider plates 2608 and 2610
serve to substantially divide the interior cavity of the cowling
2504 into the first and second cowling sections 2618 and 2620,
those subcavities are still in fluid communication with one another
by way of one or more intermediate air flow passages or spaces or
openings 2624 that exist between the bottom edges of the upper
divider plate 2608 at the location 2609 and an upper edge of the
lower divider plate 2610, which is shown to be located at a
location 2625. As will be discussed further below, the openings
2624 allow for air entering the first cowling section 2618 to
proceed into the second cowling section 2620, so that the air can
be received and utilized by the engine 2604 (or throttle) within
that second cowling section. That is, the openings 2624 are air
transfer openings from the first cowling section 2618 into the
second cowling section 2620 allow for airflow to the engine
2604.
[0278] It should further be noted that, in relation to the openings
2624, in the present embodiment there are two such openings as is
evident particularly from FIG. 29. More particularly as shown, the
openings 2624 are located toward each of the left and rights sides
of the cowling 2504. Further, as is evident particularly from FIG.
27, the openings 2624 in the present embodiment are actually formed
at least partly between bottom edges (at the location 2609) of flap
portions 2627 of the upper divider plate 2608 that extend at least
partly in the rearward direction and upper edges of the lower
divider plate 2610. In alternate embodiments, however, only one of
the openings 2624 (e.g., one side only) or more than two of the
openings can be present.
[0279] In addition to the above, the cowling 2504 further includes
an additional lower cowl plate 2626 that extends forward from the
lower divider plate 210. More particularly as shown, the lower cowl
plate 2626 is generally at the same level (albeit somewhat
vertically higher than) the first section 2612, and extends
generally beneath the engine 2604 and forms a floor of the second
cowling section 2620. Because the first section 2612 of the lower
divider plate 2610 and the lower cowl plate 2626 respectively form
the floors of the first and second cowling sections 2618 and 2620,
respectively, any water entering the first and second cowling
sections naturally due to gravity will eventually tend to fall to
those structures. So that water reaching those structures can exit
the outboard motor, the first section 2612 includes water outlet
passages 2628 and the lower cowl plate 2626 also includes a water
outlet passage 2630.
[0280] Referring still to FIG. 26, a path of the airflow thru the
first and second cowling sections 2618 and 2620 is such that water
entrained/entrapped in the air entering the outboard motor is
substantially or entirely eliminated prior the air reaching the
engine 2604 (or throttle associated therewith). As shown by arrows
2632, first the airflow enters thru the air inlets 2518 provided at
the uppermost portion of the upper cowl 2514 of the cowling 2504,
which can also be referred to as the Helmut (in at least some
embodiments, the Helmut can be a removable portion of the cowling,
and can correspond, for example, the upper portion 2602 of the
cowling). The air inlets 2518 particularly are positioned as high
as possible from the anticipated surface of the ocean or other body
of water in which the outboard motor will be operated, so as to
minimize the amount of water that will likely enter into the air
inlets. By virtue of the positioning and orientation of the air
inlets 2518 (which again are air passages that are downwardly
directed into the first cowling section 2618), air particularly
enters the cowling 2504 in a downwardly manner. In at least some
embodiments, the air inlets 2518 are configured so that air
entering air inlets needs to flow not only downward but also
forward so as to enter the air inlets.
[0281] Further as shown by arrows 2634, the air entering the air
inlets 2518 is directed downwardly by the steeply vertical surface
of the upper (air) divider plate 2608, which as discussed above
separates the first cowling section 2618 and the second cowling
section 2620 (the upper divider plate 2608 can also be considered
to form part of the first cowling section). The downwardly directed
air then reaches the lower divider plate 2610 (which also serves to
divide the first and second cowling sections 2618, 2620, and which
can also be considered as part of the first cowl section), and that
air is turned upwardly in order to escape into the second cowling
section 2620 by way of the opening(s) 2624, as represented by
arrows 2636.
[0282] As discussed, the air passing through the first cowling
section 2618 will often if not typically include
entrained/entrapped water. Due to the downward direction of the air
flow within the first cowling section 2618, the heavier water
droplets continue downwardly thereby are collected at the first
section 2612 of the lower divider plate 2610 are drained from the
first cowling section as indicated by arrows 2638 and ultimately
out of the outboard motor via the water outlet passages 2628
provided thereon (the water outlet passages provided in the lower
portion of the first cowling section 2618). Since the first cowling
section 2618 encloses the transmission 2622, and since exposure to
water is not a problem for the transmission (particularly water
flowing around it), this water flow through and out of the first
cowling section 2618 is an acceptable and satisfactory manner of
handling the water.
[0283] As mentioned, the air entering the first cowling section
2618 eventually flows into the second cowling section 2620 via the
openings 2624. In the present embodiment, two of the openings 2624
are provided, one on each side of the cowling 2504 (again see FIG.
29), albeit in other embodiments there could be more than two such
openings or there could only be a single opening (e.g., one opening
at only one side of the cowling). Upon entering the second cowling
section 2620 where the engine 2604 resides, the air then flows
forward and upward over and around the engine 2604 as represented
by arrows 2640 toward a throttle 2642 (or air entrance into the
engine), where it is then ingested into the engine.
[0284] Although much (if not largely or substantially all) of any
water entrapped/entrained in the air entering the first cowling
section 2618 leaves the engine via the water outlet passages 2628,
some remaining water droplets can succeed in passing thru the first
cowling section 2618. Even though this can occur, these water
droplets nevertheless tend to exit out of the second cowling
section 2620 by falling to the lower cowl plate 2626 and exiting
from the water outlet passage 2630 before those water droplets pass
by the engine 2604, or at least before those water droplets reach
the throttle 2642. This process of the water droplets tending to
exit the second cowling section 2620 before reaching the engine
2604 (or the throttle 2642) occurs partly because the water, in
order to proceed from the openings 2624 to the throttle 2642, not
only must pass over a relatively long distance between the openings
2624 and the throttle 2642, but also must do so even though the air
is moving generally upward at this time over this distance.
[0285] Although water is eliminated from the outboard motor 2500
for the reasons discussed above, in the present embodiment there
are other reasons as well. In particular, the cross-sectional areas
of the first and second cowling sections 2618 and 2620 (as well as
the openings 2624) are set in a manner that causes variations in
the velocity of the air flow within the first and second cowling
sections, which further aids in water elimination. More
particularly, in the present embodiment, a first cross-sectional
area of the flow path within the first cowling section 2618 (e.g.,
a first cross-sectional area taken normal to one of the
downwardly-directed arrows 2634) is smaller than a second
cross-sectional area of the flow path within the second cowling
section 2620 (e.g., a second cross-sectional area taken normal to a
first arrow 2644 of the arrows 2640). The openings 2624 can, in
combination with one another, also have a total cross-sectional
area equal or similar in size to that of the first cross-sectional
area of the first cowling section (or alternatively some other size
can be chosen). Given such dimensions, the air flow downward
through the first cowling section 2618 occurs at a substantially
higher velocity than the air flow forward and upward through the
second cowling section 2620. This facilitates water elimination
since, in the first cowling section, the water droplets in the
downwardly-flowing air have a relatively high momentum such that,
even though the air ultimately changes direction so as to proceed
through the openings 2624, the water droplets tend to continue on
downward toward the water outlet passages 2628.
[0286] Further, in the second cowling section 2620, the lower
velocity of the air flow due to the larger cross-sectional area
constitutes a further reason as to why the water drops are
encouraged to fall out of the slower moving airstream, since this
better allows the water to fall to the bottom of the second cowling
section 2620 and thereby be drained through the water outlet
passage (or passages) 2630 in the lower cowl plate 2626. The
throttle 2642 in the second cowling section 2620 (within which is
situated the engine 2604) is positioned high and as far (as far
forward) as practical, away from the first cowling section 2618, so
as to allow as much time and distance as possible for water to fall
out of suspension with the air. By way of these features of the
two-section cowling system, air and water are separated to the
greatest extent possible to provide dry air to the engine and
return liquid water to the ocean or other body of water.
[0287] In addition to the above-discussed features, as mentioned in
relation to FIG. 25 in at least some embodiments the outboard motor
2500 also includes optional side air inlets 2520 and associated
covers 2522. The side air inlets 2520 and covers 2522 particularly
are configured so that air flowing in through the side air inlets
necessarily flows in a forward direction as indicated by arrow 2524
in FIG. 25. Further, given the location of the side air inlets
2520, the side air inlets connect (open) directly into the second
cowling section 2620 (as shown in FIG. 26) and, to reach the
throttle 2642, the air flow must also be upwardly directed within
the second cowling section 2620.
[0288] The side air inlets 2520 can be used to govern air flow
entry for various purposes, depending upon the embodiment or
circumstance (in some cases, there is electronic control of the
opening or closing of the side air inlets, for example, by
controlled opening or closing of the covers). Among other things,
the flow of air via the side air inlets 2520 is used to control
temperature or to control air inflow losses (or to provide
additional air for use by the engine 2604). Because air flowing in
via the side air inlets 2520 can only reach the throttle 2642 if
the air is moving forward and upward, water entrained/entrapped in
(or otherwise associated with) that air again tends not to reach
the throttle. This is particularly true since, during operation of
the outboard motor 2500 in connection with a marine vessel, the
motor and vessel are already moving forward such that air is
passing rearward in relation to the motor, and thus the air
entering the side air inlets 2520 essentially has to completely
change direction for it to enter in via the side air inlets.
[0289] Water Pump System
[0290] In at least some embodiments encompassed herein, and
particularly in the outboard motor 2500 of FIG. 25, the outboard
motor also employs an improved water pump system or arrangement, in
which a water pump assembly is integrated with the transmission
2622 of the outboard motor. In particular, in the present
embodiment, although an engine mounted circulation pump (such as
that provided with automotive type engines) is used, the outboard
motor 2500 also has a sea pump that is integrated into the
transmission 2622 for compactness and durability by the elimination
of external plumbing and rubber belt drive systems. As described in
further detail below, FIGS. 30 and 31 show a water (sea) pump
assembly (which can also generally be considered a water pump) 3000
integrated into the transmission 2622 (which can also be considered
a transmission assembly) without any external plumbing. The
combination of the transmission 2622 and water pump assembly 3000
shown in FIGS. 30 and 31 can be considered overall as forming a
transmission and water pump assembly. Further, FIG. 32 shows a
cross-sectional cutaway view through the transmission 2622 in
proximity to the water pump assembly 3000, and further depicts a
gear train 3200 and a shaft system 3202 that drives the twin
counter rotating impellers. FIG. 33 further reveals the details of
the counter-rotating impellers acting in conjunction with each
other, and FIG. 34 is an exploded view of the water pump assembly
to reveal the components of the water pump assembly that allow the
water pump assembly to operate.
[0291] As already noted, FIGS. 30 and 31 illustrate the water pump
assembly 3000 and transmission 2622 in accordance with the present
embodiment. As shown, the water pump assembly 3000 is integrated
into the transmission 2622 without any external plumbing (e.g.,
pipes, fixtures, etc.). The water pump assembly 3000 includes a
water pump body or housing 3002 which generally houses (e.g.,
within its interior) components or structure of, or associated
with, the water pump assembly as described and illustrated further
herein. The water pump assembly 3000, and more particularly the
housing 3002, includes an inlet or inlet port 3004 and an outlet or
outlet port 3006 as well as an additional outlet port 3008, all of
which are discussed further below. Additionally referring to FIG.
32, the cross-sectional cutaway view shown therein is particularly
a cross-sectional view taken along a center vertical axis extending
through the transmission 2622 (which therefore proceeds through the
centers of the shafts within the transmission) in proximity to the
water pump assembly 3000. FIG. 32 further depicts the gear train
3200 and shaft system 3202 that drives the water pump assembly
3000, and particularly its twin counter rotating impellers, as
shown and described further herein, in accordance with embodiments
of the present disclosure. As shown, in one orientation, the water
pump assembly 3000 includes an upper water pump 3005 comprising an
upper one of the twin impellers, and a lower water pump 3007
comprising a lower one of the twin impellers. Further, the shaft
system 3002 is shown to comprise a first or driven shaft 3204 and a
second or output shaft 3206. The transmission 2622 is housed by a
transmission housing 3208.
[0292] Turning to FIGS. 33 and 34, structural and functional
details of the water pump assembly 3000 are revealed and
illustrated. As illustrated in FIG. 33, the upper water pump 3005
of the water pump assembly 3000 particularly includes an impeller
structure (or simply impeller) 3300 and the lower water pump 3007
of the water pump assembly 3000 particularly includes an impeller
structure (or impeller) 3302. As already noted above, in accordance
with the present embodiment, the impellers 3300 and 3302 are
counter-rotating impellers acting in conjunction with each other.
More particularly as shown in FIG. 34, the water pump assembly 3000
includes the water pump housing 3002, along with a cover plate
structure 3400 (e.g., a cover plate), a wear plate structure 3402
(e.g., an outer wear plate), a plurality of ported liner structures
3404a and 3404b, inner wear plates 3406a and 3406b, and a seal
structure 3408 (e.g., an o-ring seal), which are fastened or
otherwise secured by way of fasteners 3410, which in this example
include eight assembly screws. With respect to water pump
orientation and operation, as seen in FIGS. 33 and 34 (and
particularly FIG. 33), both of the two counter-rotating impellers
3300 and 3302 are utilized for the water pump assembly 3000 (which
again is a sea pump) in the outboard motor 2500. In contrast to
conventional outboard motors, the outboard motor 2500 (which for
example can be, but is not limited to being, a large outboard motor
capable of high levels of power output, such as 557 horsepower)
includes both a sea pump and a circulation pump (albeit in other
embodiments of outboard motors, the outboard motors only have sea
pumps in the gear case or elsewhere that push water through the
outboard motor power head).
[0293] Further with respect to FIG. 33, as indicated by an arrow
3303, in the present embodiment the impeller 3300 rotates in a
counterclockwise rotating direction and additionally, as indicated
by an arrow 3305, the impeller 3302 rotates in a clockwise rotating
direction. Also in accordance with the present embodiment, each of
the impellers 3300, 3302 is eccentrically offset from a respective
center axis by a distance 3350. Further, as is normally done with
an impeller, each of the impellers 3300 and 3302 is operated in a
respective ported liner. More particularly, the impeller 3300 is
operated in the ported liner 3404b and the impeller 3302 is
operated in the ported liner 3404a, and each of the ported liners
serves to allow water into and out of a respective pump chamber of
the respective impeller. More specifically, the ported liner 3404a
includes inlet and outlet ports 3310a and 3310b, respectively, and
the ported liner 3404b includes inlet and outlet ports 3312a and
3312b, respectively. Both of the inlet ports 3310a and 3312a are
connected to an intake tube (or port) 3004 of the water pump
assembly 3000, which serves as a common water intake passage in
order to consolidate intake plumbing.
[0294] More particularly, inlet port 3310a is connected to the
intake tube 3004 by a channel 3304a extending within the water pump
3000, and inlet port 3312a is connected to the intake tube 3004 by
a channel 3304b also formed within the water pump assembly 3000. By
virtue of the channels 3304a and 3304b and inlet ports 3310a and
3312a (that is, both inlet ports), both of the two impellers 3300
and 3302 serve to pull sea water into the water pump (water pump
system or assembly) 3000. Some water arriving via the intake tube
3004 proceeds via a water inlet path 3351a via the channel 3304a to
the lower water pump 3007 and some water proceeds via a water inlet
path 3351b via the channel 3304b to the upper water pump 3005.
Thus, the upper and lower water pumps 3005 and 3007 operate,
respectively by virtue of rotation of the respective impellers 3300
and 3302, to receive sea water via the same shared inlet
arrangement (albeit there are two distinct water inlet paths 3351
and 3351b corresponding to the respective channels 3304a and 3304b)
and particularly the same intake duct (intake tube 3004).
[0295] In contrast to the shared water input for each of the water
pumps 3005 and 3007, the outlet sides of the water pump assembly
3000 are generally divided from one another. The lower water pump
3007 with the impeller 3302 particularly drives water into and
through a low pressure passage 3306 that leads to the outlet port
(or tube or passage) 3006, which is particularly suited for
providing high volume--low pressure flow through a heat exchanger
of the outboard motor 2500 (e.g., such as the heat exchanger 1912
already discussed above), so as to maximize mass flow of sea water
thru the heat exchanger and thereby enhance its efficiency.
Although not shown, it should be appreciated that the outboard
motor 2500 will include suitable connector(s) linking the outlet
port 3006 to the heat exchanger to communicate high volume--lower
pressure water 3354 from the water pump assembly 3000 to the heat
exchanger.
[0296] By contrast, the upper water pump 3005 with the impeller
3300 particularly drives water into a high pressure passage 3308
that leads to the outlet port (or tube or passage) 3008, which is
particularly suited for providing higher pressure (and lower
volume) water flow output. In particular, higher pressure--lower
volume water 3356 that is output at the outlet port 3008 in the
present embodiment is directed so as to force water flow through
the exhaust headers (left and right) and also to force water flow
through an intercooler (e.g., such as the intercooler 1922 already
discussed above) of the outboard motor 2500 so as to cool the
intake air charge. Again, although not shown, it should be
appreciated that the outboard motor 2500 will include suitable
connector(s) linking the outlet port 3008 to the exhaust headers
and intercooler for this purpose. Therefore, in the present
embodiment, the water pump assembly 3000 serves to provide both
functions of outputting the high volume--lower pressure (high
flow--low pressure) water 3354 and outputting the higher
pressure--lower volume (low flow--high pressure) water 3356, by way
of the two counter-rotating impellers 3300 and 3302 joined on the
intake side but separated on the outlet side for distinctly
different purposes.
[0297] Although in the present embodiment the outlet sides of the
water pump assembly 3000 (corresponding to the upper and lower
water pumps 3005 and 3007) are generally separate, it should
further be appreciated from FIG. 33 that the two outlet sides are
not entirely separate. In particular, a connective passing
structure or passage 3318 is included that allows communication of
water between the low pressure passage 3306 and the high pressure
passage 3308 (and thus effectively between the outlet port 3006 and
the outlet port 3008). The connective passage 3318 is provided so
as to allow the higher pressure water exiting the outlet port 3008
to spill into outlet port 3006, thereby adding to the flow through
the heat exchanger if required. Also if either of impellers 3300 or
3302 happen to stop working normally or provide less than desired
amounts of water flow, the connective passage 3318 would or can
allow water flow between the passages 3306 and 3308. Thus, the
connective passage 3318 allows for water cooling of each of the
devices cooled by water flow from each of the outlet ports 3006,
3008 (e.g., all of the heat exchanger, exhaust headers, and
intercoolers) to continue, at least at reduced rates, since water
can continue to keep flowing out of each of the outlet ports 3006,
3008, and the connective passage accordingly allows for a "return
home" feature due to the two impeller redundancy (that is, either
of the impellers is to redundant with respect to the other, at
least to some extent, and can direct water to all of the devices
being cooled via water flow through both of the outlet ports 3006
and 3008).
[0298] In addition to the above features, it should be appreciated
that the arrangement of the impellers 3300 and 3302 and other
components of the water pump assembly 3000 includes several
structural features that are noteworthy and advantageous in various
respects. First, the arrangement of the impellers 3300 and 3302
relative to one another is advantageous insofar as the impellers
are coplanar in their arrangement. That is, a single plane
perpendicular to each of the central axes of rotation of each of
the impellers 3300 and 3302 is a plane along which each of the
impellers is located. Thus, the impellers 3300, 3302 are compactly
positioned, in contrast to a design in which the impellers would be
at different positions along their axes of rotation (that is, a
design in which the impellers would be "stacked").
[0299] Additionally as shown in FIG. 33, it can be noted that the
impellers 3300, 3302 are separated from one another by an
intermediate structure 3319, and also that the inlet port 3004 and
outlet port 3006 are separated from one another by the intermediate
structure 3319. Accordingly, the inlet port 3004, outlet port 3006,
upper water pump 3005 (with the impeller 3300), and lower water
pump 3007 (with the impeller 3302) are arranged generally in the
shape of a diamond, with each of those structure positioned at a
respective vertex of the diamond (albeit the outlet port 3008 is
positioned in between the two positions occupied by the outlet port
3006 and the upper water pump 3005).
[0300] It should be appreciated that the present embodiment of
water pump assembly 3000 with the above-described design features
results in a very compact, durable, redundant, sea water pump to
facilitate high water flows and high pressure flows thru multiple
devices simultaneously. Also, among other things, absence of a
rubber belt to drive the pump particularly can improve durability,
and the arrangement also is advantageous in terms of affording a
lower parts count. That said, the present invention is intended to
encompass numerous variations and alternate embodiments in addition
to the water pump assembly 3000. For example, although the
intermediate structure 3319 (and water pump assembly 3000 more
generally) is shown to take one particular form in this embodiment,
in other embodiments the intermediate structure (and water pump
assembly overall) can take on numerous other shapes. For example,
in the present embodiment a curved surface 3321 of the intermediate
structure 3319 is elongated so as to extend up to and from the
connective passage 3318, in another embodiment, the curved surface
can be shortened so that the overall intermediate structure 3319 is
substantially symmetrical. In such an embodiment, it would be
possible for all water directed by each of the impellers to flow
out the outlet port 3306 (and the outlet port 3308 would no longer
be present).
[0301] Vapor Separating Tank (VST)
[0302] Turning now to FIG. 35, in at least some embodiments
encompassed herein, including that of the outboard motor 2500 of
FIG. 25, the outboard motor includes a fuel vapor suppression
mechanism or VST system that eliminates (or substantially or
largely eliminates) the need to control the volume of the working
fuel chamber of the internal combustion engine 2604 by pressurizing
the working fuel to a pressure above the "vapor pressure" of the
fuel that can be reached during the operation of the engine. In at
least some such embodiments, the VST system includes a primary pump
that is utilized to lift fuel and then pressurize the fuel to a
primary pressure (e.g., about 10 psi) so as to supply a secondary,
high pressure, pump with liquid fuel that has been pressurized in
order to prevent fuel vaporization. Additionally, in at least some
such embodiments, a working volume internal to the VST system is
maintained at the primary pressure as controlled with a pressure
regulator valve which discharges fuel back to the fuel inlet in the
event that the pressure at the output of the primary pump becomes
too high. Also, in at least some such embodiments, the working
volume is provided by a fuel filter and mixer. Thus, fuel is
obtained from a fuel source (e.g., a fuel tank located on a marine
vessel such as the marine vessel 100 to which the outboard motor
2500 is attached), pressurized to a regulated valve, circulated
through the fuel filter and thereby supplied to the high pressure
pump (secondary circuit).
[0303] Additionally, in at least some such embodiments, upon
reaching the high pressure pump, the high pressure pump in turn
pressurizes the filtered fuel to a higher, regulated pressure
(e.g., regulated at 65 psi) that is suitable for the internal
combustion engine 2604 (e.g., suitable for a fuel rail thereof).
The high pressure pump also includes at its output (or at a
location at the same pressure as its output) a fuel regulator
relief valve that allows fuel flow to be directed through a fuel
cooler and returned back to the pressurized fuel filter, in the
event fuel pressure at the output of the high pressure pump becomes
too high. Thus, the function of drawing fuel from the marine vessel
(e.g., boat) fuel tank, and filtering the fuel, and pressurizing of
the fuel to prevent the formation of air vapors is accomplished
with a low pressure primary circuit. Then the supplying of the fuel
under elevated pressure regulated to a high or higher level (e.g.,
65 psi) that is supplied to the engine fuel rail is accomplished
with a high pressure secondary circuit.
[0304] Embodiments with VST systems such as those discussed above
are advantageous in several respects. First, in such embodiments,
both the low pressure primary circuit and the high pressure
secondary circuit are contained within the same device (e.g.,
within a single integrated structure) in order to minimize size and
loss. Also, containment of the working fuel volume within the fuel
filter (or region in which the filter is present) serves to enhance
the simplicity of the VST system. Additionally, in such embodiments
in which the high pressure regulator is connected on its discharge
side to the control pressure of the primary fuel working volume
(e.g., the location of the fuel filter), advantageous operation can
result. In particular, such an arrangement does affect the high
pressure fuel supply pressure by slight amounts during low fuel
flow experienced at idle speeds of the engine 2604. This pressure
drift is accounted for by the electronic control unit (ECU) of the
engine 2604 at idle operation. Additionally, cooling of the fuel is
required at sustained idle in hot environments and is accomplished
with a remote fuel cooler that is connected to sea water flowing
through the engine cooling heat exchangers. This fuel is
pressurized to the primary fuel pressure to enhance the fuel
cooling effect and prevent the formation of vapor in the fuel.
[0305] Referring now to FIGS. 35A and 35B, first and second (e.g.,
respectively right and left) side perspective views are provided of
a VST system 3500 that is employed in the outboard motor 2500 of
FIG. 25, and that can also be employed in other outboard motors
such as the outboard motor 104 of FIG. 1. Additionally referring to
FIG. 36, an exploded view is provided of the VST system 3500 to
highlight various components thereof. As shown, the VST system 3500
includes a low pressure fuel pump 3600 having an input port 3602
and an output port 3604 and also a cylindrical fuel filter 3606.
The cylindrical fuel filter 3606 has a cylindrical container 3608,
within which (when the cylindrical fuel filter is fully assembled)
is provided a cylindrical fuel filter element 3610, and a cap
structure 3612 having an input port region 3614 by which the output
port 3604 of the low pressure fuel pump 3600 can be in fluid
communication with the interior of the cylindrical fuel filter 3606
and the cylindrical fuel filter element 3610 therewithin (when the
VST system is fully assembled). Also, the cap structure 3612
includes a pressure regulator extension 3616 by which the cap
structure 3612 can be coupled to a pressure regulator extension
3617 of a fuel regulator assembly 3618 when the VST system is fully
assembled.
[0306] Further, the VST system 3500 also includes a high pressure
fuel pump 3620 having an input end 3622 and an output end 3624. The
cap structure 3612 includes output port region 3626 by which the
cylindrical fuel filter 3606 can be in fluid communication with an
input port associated with the input end 3622 of the high pressure
fuel pump 3620 when the VST system 3500 is fully assembled.
Additionally when the VST system 3500 is fully assembled, the high
pressure fuel pump 3620 is positioned within an orifice 3619 within
the fuel regulator assembly 3618 so that the output end 3624 of the
high pressure fuel pump is also coupled at least indirectly with
the internal combustion engine 2604 (or engine rails) for providing
fuel thereto, as discussed in further detail below. Also in the
present embodiment, when the VST system 3500 is fully assembled,
the fuel regulator assembly 3618 includes first and second pressure
regulators 3628 and 3630 that respectively serve as low and high
pressure regulators (or vice-versa, depending upon the embodiment).
The interior of the cylindrical container 3608 of the cylindrical
fuel filter 3606 is coupled to the first pressure regulator 3628 by
way of the pressure regulator extensions 3616 and 3617, and the
output end 3624 of the high pressure fuel pump 3620 is coupled to
the second pressure regulator 3630 in addition to being coupled at
least indirectly with the internal combustion engine 2604 (the link
between the output end 3624 and the second pressure regulator 3630
is indirect and passes by way of a fuel cooler described
below).
[0307] Although the VST system 3500 includes, as its primary
components, the low pressure fuel pump 3600, cylindrical fuel
filter 3606 (having both the cylindrical container 3608 and the cap
structure 3612), the high pressure fuel pump 3620, and the fuel
regulator assembly 3618, it will be appreciated from FIG. 36 that
numerous additional components such as bolts 3632, fuel regulator
cover structures (or cover regulators) 3634, plugs 3636, O-rings
3638, sealing rings 3640, fittings 3642, and support fittings 3644,
which are configured to fit within complementary support orifices
3646 on the fuel regulator assembly 3618, are also employed to
couple the components together and/or provide sealed connections
and allow fluid communication between various ones of the input and
output ports of the various components. The particular
configurations, numbers, and types of components used for such
purposes can vary depending upon the embodiment. That said, in the
present embodiment, the VST system 3500 is generally intended to be
compact and to provide an arrangement that minimizes hoses or
coupling links and other parts used for coupling or fastening
purposes, and uses many off the shelf components.
[0308] Turning now to FIGS. 37A, 37B, 37C, 37D, and 37E, first,
second, third, fourth, and fifth cross-sectional views 3700, 3720,
3740, 3760, and 3780, respectively, of the VST system 3500 are
provided in order to show various interrelationships among
components of the VST system in more detail as well as to show
portions of internal communication channels linking those
components. Additionally, FIG. 18 is provided to illustrate in
schematic form the interrelationships among the components of the
VST system 3500 relative to one another as well as with respect to
a fuel source 3800 (which would be located separate from the
outboard motor 2500, e.g., on the marine vessel 100) and the
internal combustion engine 2604, to show how fuel proceeds to,
through, and out of the VST system 3500. Particularly as
illustrated in FIG. 38, fuel is drawn into the VST system 3500 from
a fuel tank 3800 via a filter 3802, both of which typically are
provided on a marine vessel (e.g., the marine vessel 100 of FIG. 1)
to which the outboard motor 2500 is coupled, that is, provided
separate from the outboard motor (as represented by region 3804).
As shown, link 3801 links the fuel tank 3800 with the filter 3802
and an additional link 3803 links the filter 3802 with the VST
system 3500. The links 3801 and 3803 can be hoses or tubes or any
of a variety of other linkages allowing for fluid
communication.
[0309] Fuel enters the VST system 3500 particularly via a check
valve 3806 (an input port of which can be considered the fuel input
port of the VST system overall) that prevents the fuel from
returning back into the fuel tank 3800 after it has been drawn to
the VST system 3500. This is significant particularly insofar as
the VST system 3500 typically is at a vertical elevation that is
above that of the fuel tank 3800, e.g., forty inches higher than
the fuel tank. After passing through the check valve 3806, the fuel
is drawn to the low pressure fuel pump 3600, which can also be
considered a lift pump since operation of that fuel pump serves to
lift the fuel from the fuel tank 3800 to the level of the lift pump
within the VST system 3500. The fuel is communicated from the check
valve 3806 by way of a channel 3807 within the VST system 3500,
which leads to the input port 3602 of the low pressure fuel pump
3600, which in the present embodiment is an electrically-driven
fuel pump mechanism.
[0310] Additionally, by virtue of operation of the low pressure
fuel pump 3600 the fuel is pressurized to a low (or mid-level)
pressure level and driven out of the output port 3604 of that fuel
pump, via a channel 3809, to the cylindrical fuel filter 3606 via
the input port region 3614 thereof. FIG. 37A shows a
cross-sectional view taken along a vertical plane extending through
the low pressure fuel pump 3600 and the cylindrical fuel filter
3606 that particularly illustrates portions of the channels 3807
and 3809 (but not the channels in their entirety). Further due to
operation of the low pressure fuel pump 3600 and pressurization of
the fuel as a result, a reed vapor pressure (RVP) of the fuel
(e.g., the fuel within the cylindrical fuel filter) is driven up so
that the fuel is no longer likely to vaporize and so that fuel at a
steady fuel pressure can be delivered, even if heat generated by
the internal combustion engine 2604 (or for other reasons) becomes
elevated, for example, during idling of the engine. Indeed,
vaporization is eliminated or reduced by the VST system 3500 even
when only relatively modest fuel cooling is provided by way of the
fuel cooler (described further below). In the present embodiment,
the low (or mid-level) pressure of the fuel output by the low
pressure fuel pump 3600 can be 10 psi albeit, in other embodiments,
the pressure can be at other levels such as 12 psi, 15 psi, or 18
psi.
[0311] Additionally, as already noted, the cylindrical fuel filter
3606 includes a cylindrical fuel filter element 3610, such that the
cylindrical fuel filter 3606 serves both as a filter to remove
impurities (e.g., water) from the fuel and also serves as a mixer.
Further, the cylindrical fuel filter 3606 also serves as a fuel
reservoir, from which the high pressure fuel pump 3620 can draw
fuel as described further below. As shown in FIG. 38, the
cylindrical fuel filter 3606 not only is coupled to the low
pressure fuel pump 3600 and to the high pressure fuel pump 3620
(and coupled between those two fuel pumps), but also the
cylindrical fuel filter is coupled to the first pressure regulator
3628 by way of a channel 3811, and the first pressure regulator is
coupled between the channel 3811 and the channel 3807. A portion of
the channel 3811 is also shown in the cross-sectional view of FIG.
37A, and it can be appreciated that the channel 3811 generally
extends within the pressure regulator extensions 3617 and 3616 of
the fuel regulator assembly 3618 and the cap structure 3612,
respectively. The first pressure regulator 3628 in this embodiment
serves as a low pressure regulator that allows fuel to return from
the channel 3811 back to the channel 3807 if the pressure at the
channel 3811 (which is the pressure within the cylindrical fuel
filter 3606 and at the output port 3604 of low pressure fuel pump
3600) exceeds a predetermined value, e.g., if the pressure exceeds
10 psi or exceeds 10 psi by more than a preset margin.
[0312] With respect to the high pressure fuel pump 3620, as shown
in FIG. 38, that pump draws fuel from the cylindrical fuel filter
3606 by way of a channel 3813. In addition to being shown in FIG.
38, it will be appreciated that the channel 3813 extends generally
from the output region 3626 of the cap structure 3612 as shown in
FIG. 36. Also, FIG. 37B, which shows a cross-sectional view of the
VST system 3500 taken along a vertical plane extending through an
end portion of the VST system and particularly through the
cylindrical fuel filter 3606, also shows a portion of the channel
3813. Further FIG. 37D, which provides an additional
cross-sectional view of the VST system 3500 taken along another
vertical plane extending through the cylindrical fuel filter 3606
and the high pressure fuel pump 3620, illustrates the channel 3813
as well. As is the case with the low pressure fuel pump 3600, the
high pressure fuel pump 3620 in the present embodiment is
electrically driven, and in the present embodiment both of the
pumps 3600 and 3620 are operated to run continuously and therefore
no switching circuits are employed to turn on and off the pumps
(albeit in alternate embodiments, such switching circuits can be
employed). In contrast to the low pressure fuel pump 3600, which in
the present embodiment is a cylindrical structure having a
generally vertical cylinder axis, the high pressure fuel pump 3602
is a cylindrical structure having a generally horizontal cylinder
axis.
[0313] In the present example, the high pressure fuel pump 3620
particularly operates to draw in the fuel from the cylindrical fuel
filter 3606, which is at 10 psi (or other pressure level as
established by the low pressure fuel pump 3600), and further
operates to pressurize that fuel so that the fuel reaches a higher
pressure suitable for use by the internal combustion engine 2604.
In the present embodiment, the higher pressure is 65 psi albeit, in
other embodiments, that pressure can be at other levels. The fuel
output by the high pressure fuel pump 3620 is particularly
delivered at an output port 3814 of the high pressure fuel pump
(corresponding to the output end 3624 of FIG. 36), is then driven
from the output port 3814 through a check valve 3816, and then is
output from a VST system output port 3818, which is connected by
way of one or more links (e.g., tubes, pipes, or channels) 3820 to
left hand and right hand rails 3822 and 3824, respectively, of the
internal combustion engine 2604, at which the fuel is consumed
(e.g., by way of fuel injectors). Additionally in this regard, FIG.
37C provides a further cross-sectional view of the VST system 3500
taken along a vertical plane extending through the cylindrical fuel
filter 3606 and the high pressure fuel pump 3620, and particularly
shows the output port 3814, check valve 3816, and VST system output
port 3818 allowing for the fuel to proceed from the high pressure
fuel pump 3620 out of the VST system for use by the internal
combustion engine 2604.
[0314] In addition to being coupled to the check valve 3816, the
VST output port 3818 (and downstream end of the check valve 3816)
is also coupled by way of a channel 3826 to the second pressure
regulator 3630, which in the present embodiment is a high pressure
regulator. The second pressure regulator 3630 in turn is coupled in
between the channel 3826 and an additional channel 3828, which in
turn extends to a fuel cooler output port 3829 of the VST system
3500. In the present embodiment, the fuel cooler 3890 is separate
from the VST system 3500 but is coupled to the fuel cooler output
port 3829 of the VST system by way of a channel 3891, and also is
coupled to a fuel cooler input port 3831 of the VST system by way
of an additional channel 3892, where the fuel cooler input port
3831 is in turn coupled to the cylindrical fuel tank 3606 by way of
a further channel 3830. Thus, the fuel cooler 3890 is coupled for
fluid communication between the second pressure regulator 3630 and
the cylindrical fuel filter 3606 by way of the channels 3828, 2891,
3892, and 3830 such that fuel passing through the second pressure
regulator 3630 into the channel 3828 is cooled at the fuel cooler
3890 and then returned to the cylindrical fuel filter 3606. Further
in this regard, FIG. 37E shows a cross-sectional view taken along a
horizontal plane extending through the VST system 3500 generally
along the central axis of the high pressure fuel pump 3620 that
shows not only the output port 3814, check valve 3816, and VST
system output port 3818 (as already shown in FIG. 37C), but also
shows the second pressure regulator 3630 and the additional channel
3828 linking the second pressure regulator to the fuel cooler
output port 3829.
[0315] With respect to the fuel cooler 3890, referring additionally
to FIGS. 41 and 42, this component in the present embodiment is
positioned proximate to (but not directly adjacent to) the VST
system 3500, proximate a side of the internal combustion engine
2604 generally at or near the front end of the engine. Although not
shown in FIGS. 41 and 42, from FIG. 38 it should be understood
that, when fully assembled, the VST system 3500 (and particularly
the fuel cooler input and output ports 3831 and 3829) is coupled to
the fuel cooler 3890 by way of the channels 3892 and 3891,
respectively. More particularly, the fuel cooler 3890 includes
first and second connection ports 3894 and 3896 (see FIG. 42) that
are respectively ports at which the channels 3891 and 3892 are
coupled when those channels are implemented, so as to allow fuel to
proceed to the fuel cooler 3890 from the VST system 3500 and to be
returned to the VST system 3500 from the fuel cooler,
respectively.
[0316] Although the fuel cooler can take various forms depending
upon the embodiment, in one example embodiment the fuel cooler
includes a mesh of tubes that surround a coolant channel 3898 (see
FIG. 41) by which coolant (e.g., seawater) is being directed to the
internal combustion engine 2604 for engine cooling purposes. That
is, fuel entering the fuel cooler 3890 at the first connection port
3894 passes through the mesh of tubes such that heat transfer
occurs between that fuel and the coolant flowing through the
coolant channel, and then passes out of the mesh of tubes via the
second connection port 3894 for return to the VST system 3500. In
the present embodiment, the coolant provided to the fuel cooler
section is the same coolant that is used to cool the internal
combustion engine 2604 and can be water, such that all of the water
going through the engine cooler passes also through the fuel cooler
3890. The fuel cooler 3890 in the present embodiment can use the
engine coolant for cooling of the fuel because that engine coolant
has not yet reached the engine, at which coolant ultimately becomes
sufficiently warm that it would not serve well as fuel coolant.
[0317] Although the present embodiment of the VST system 3500
includes the fuel cooler 3890, it should be understood that, by
comparison with many conventional fuel pump mechanisms associated
with outboard motors, the VST system 3500 does not require as much
coolant or fuel cooling operation to eliminate or reduce the
possibility of fuel vaporization in or at the output of the fuel
pump mechanism (or particularly in terms of vaporization present in
the fuel delivered to the internal combustion engine 2604). This is
true even during engine idling operation, when the engine can still
impart significant heat to the fuel in the VST system and even when
the amount of coolant delivered to the fuel cooler section 3890 is
reduced by comparison with times at which the engine is fully
operating. Rather, thanks to the pressurization achieved by the low
pressure fuel pump 3600, fuel vaporization still does not occur, or
occurs to a much lesser degree, under most or all engine operating
conditions, including idling operation. Also, such elimination or
minimization of fuel vaporization is still achieved without any
need for vents to allow for fuel vapors to escape into the
atmosphere.
[0318] Although the VST system 3500 of FIGS. 35-38 is one example
of a VST system encompassed herein, the present invention is
intended to encompass numerous variations on the VST system 3500
and alternate embodiments of VST systems or fuel vaporization
suppression systems. For example, as shown in FIG. 39, in an
example alternate embodiment VST system 3900, a diaphragm pump
(mechanical pump) is employed as a low pressure fuel pump 3901
instead of the low pressure fuel pump 3600. In such embodiment,
fuel is drawn from the fuel tank 3800 (via the same filter 3802,
links 3801 and 3803, and region 3804 as in FIG. 38) into an input
port of the VST system by way of the low pressure fuel pump 3901,
and an output port 3902 at which high pressure fuel is output by
the VST system 3900 is coupled to the same internal combustion
engine 2604 and associated rails 3822, 3824 as shown in FIG. 39,
via one or more links 3904. The VST system 3900 can operate by
employing the same high pressure fuel pump 3620 and operate in
conjunction with the fuel cooler 3890 as in the VST system 3500,
where the fuel cooler is again coupled to the fuel cooler input and
output ports 3831 and 3832 by way of the channels 3892 and 3891,
respectively. However, due to the incorporation of the low pressure
fuel pump 3901, the interconnection of other components is
different in the VST system 3900 by comparison with that of the VST
system 3500.
[0319] More particularly, an output port 3906 of the low pressure
fuel pump 3901, at which the low pressure fuel pump outputs fuel at
a low (or mid-level) pressure that is elevated relative to the
pressure in the fuel tank 3800, is coupled by way of a link 3908
directly to the input port of the high pressure fuel pump 3620. The
output port 3814 of the high pressure fuel pump 3620 is coupled to
the output port 3902 of the VST system 3900 by way of the check
valve 3816 and also by way of a high pressure regulator 3910 (which
can be, but need not be, the same as the pressure regulator 3630),
which in this embodiment is shown to be connected in series between
the output port 3902 and a link 3912 by which it is additionally
connected to the output (downstream) port of the check valve 3816.
The high pressure regulator 3910 is coupled to the fuel cooler
output port 3832 by way of a channel 3928 and governs whether
pressurized fuel output by the high pressure fuel pump 3620 is
allowed to proceed to the fuel cooler 3980 by way of the channels
3928 and 3891. Additionally, in the VST system 3900, the fuel
cooler 3890 is coupled to the fuel cooler input port 3831 by way of
the channel 3891, and the fuel cooler input port 3831 is coupled to
the link 3908 by way of a channel 3930. Thus, the fuel cooler 3890
is coupled in between the high pressure regulator 3910 and the link
3908 such that the fuel cooler section can serve (at least partly)
as a fuel reservoir from which fuel is drawn by the high pressure
fuel pump 3620.
[0320] Further, it should also be appreciated that the arrangement
of components of the VST system 3500 can be varied and that the
present invention is intended to encompass numerous such
variations. FIGS. 40A, 40B, and 40C for example show an end
elevation view, a left side elevation view, and a right side
elevation view (partly in phantom) of a further embodiment VST
system 4000. Also depending upon the embodiment, a VST system can
be employed in combination with other types of engines and/or
engine components other than or in addition to those discussed
above. For example, in some embodiments, a fuel rail pressure
sensor can be integrated into the outlet of the high pressure pump
from the VST housing. Also, although the engine 2604 in the present
embodiment is a fuel injected engine, it should be appreciated that
in other embodiments the engine can take other forms such as a
carbureted engine.
[0321] Thus, in at least some embodiments encompassed herein such
as the present embodiment of the VST system 3500 of FIGS. 35-38, a
VST system on an outboard motor includes a primary fuel pump that
is capable of lifting fuel up to the level of the internal
combustion engine from a fuel source (e.g., a fuel tank within a
marine vessel to which the outboard motor is attached), for
example, a distance of approximately forty inches, at a flow rate
that is required by the engine. The primary pump is capable of
pressurizing the working fuel volume to regulated pressure levels
at sufficient flow rate for the engine. Additionally, the discharge
side of the primary regulator is connected to the inlet side of the
primary pump thereby completing the primary circuit. With such an
arrangement, no venting of the working fuel that is maintained at a
regulated primary pressure is required in order to prevent vapor
formation, and thus fuel is not lost to the outside environment due
to evaporation (and, relatedly, there are no fuel fumes that pass
out into the environment due to such venting). Further, in such
arrangements, an inlet side of a secondary pump is coupled to the
primary pressure thereby supercharging the secondary pump enhancing
its efficiency. The discharge of the high pressure pump is
connected with minimal effect upon the control of secondary fuel
pressure supplied to the engine fuel rail. Also, the fuel cooler is
connected to the discharge of secondary regulator thereby creating
flow at primary fuel pressure through the fuel cooler thus
enhancing its function and preventing vapor formation.
[0322] Oil Tank
[0323] With reference to FIGS. 41-43, FIG. 41 is a further right
side elevation view of the outboard motor 2500 of FIG. 25, showing
in more detail several example internal components of the outboard
motor particularly revealed when cowling portion(s) of the outboard
motor are removed. The outboard motor 2500 comprises the engine
2604 which, as described with respect to previous embodiments, is
positioned entirely, or at least substantially, above a trimming
axis 4104 (which is shown as a dashed line in FIGS. 42 and 43) and
which is steerable about a steering axis that in this position
coincides with a vertical axis 4106 (which is shown in FIG. 41).
The vertical axis 4106 (which again is the same as the steering
axis in this position) is shown in relation to a mounting structure
4108 which, as previously described (e.g., with reference to FIGS.
12, 13, and 14), is a structure that generally links, or otherwise
connects, the outboard motor 2500 to a marine vessel (for example,
the exemplary outboard motor 104 and the exemplary marine vessel
102 shown and described in FIG. 1).
[0324] More particularly, and again as noted earlier, the mounting
system 4108 connects (or is configured to connect) the outboard
motor 2500 to the rear or transom area of the marine vessel and, in
this way, the mounting system can also be termed a "transom
mounting system". In accordance with at least some embodiments, the
mounting system 4108 generally includes a swivel bracket structure
4110, which is cast or otherwise formed and which provides for
rotation of the motor about the steering axis (which again in this
view corresponds to the vertical axis 4106). In accordance with
embodiments of the present disclosure, the outboard motor 2500 is
configured, by virtue of the mounting system 4108, to be steered
about its steering axis, which again in this view corresponds to
the vertical axis 4106 (that is, the steering axis is vertical or
substantially vertical), relative to the marine vessel, and further
allows the outboard motor 2500 to be rotated about the tilt or
trimming axis 4104 that is perpendicular to (or substantially
perpendicular to) the vertical axis 4106. The steering axis (in
this case, corresponding to the vertical axis 4106) and trimming
axis 4104 can both be perpendicular to (or substantially
perpendicular to) a front-to-rear axis, such as the front-to-rear
axis 114 illustrated in FIG. 1 that generally extending from the
stern edge 106 of the marine vessel 102 toward a bow 116 of the
marine vessel.
[0325] In accordance with at least some embodiments, the engine
2604 is a horizontal crankshaft internal combustion engine having a
horizontal crankshaft arranged along a horizontal crankshaft axis
4116 (shown as a dashed line in FIG. 41). Further, in at least some
embodiments the engine 2604 not only is a horizontal crankshaft
engine, but also is a conventional automotive engine capable of
being used in automotive applications and having multiple
cylinders, two of which are referenced generally by the numeral
4118 in FIG. 43, and other standard components found in automotive
engines. More particularly, in the present embodiment, the engine
2604 particularly is an eight-cylinder V-type internal combustion
engine such as available from the General Motors Company of
Detroit, Mich. for implementation in Cadillac (or alternatively
Chevrolet) automobiles.
[0326] With continuing reference to FIGS. 41-43, the cylinders 4118
are symmetrically oriented about a vertical plane 4120 passing
through and coinciding with the crankshaft axis 4116. That is, each
of the cylinders 4118 (again two of which are referenced by the
numeral 4118) is positioned at an angle +.theta. or -.theta.,
respectively, where each respective angle is measured from the
vertical plane 4120 that passes through center of the V-type engine
to a respective cylinder axis generally centered within a
respective cylinder. More generally, in V-type engines, each of the
cylinders is oriented such that the angle .theta. is typically
between about 30 degrees and about 60 degrees as measured from (and
on either side of) the vertical plane 4120. Additionally, each of
the respective cylinders on a respective side of the engine 2604
(in this case four of the eight cylinders of the eight cylinder
V-type engine) is oriented such that the cylinder axes of all of
those cylinders on the same side of the engine are parallel with
one another. It will be appreciated that, in other embodiments, the
cylinders can have other orientations, including that the cylinders
can be oriented generally in straight-line fashion, such as
vertically oriented (e.g., so that the cylinder axes are, in the
present view, along or coincident with the vertical plane 4120). As
shown in FIGS. 41-43, the outboard engine 2604 is positioned in
what will be termed a first operating or operational position
corresponding to a standard operating or operational position, that
is, a an operating position in which the trimming axis 4104 is at
least substantially horizontal and the steering axis 4106 is at
least substantially vertical, with the steering axis 4106
particularly being at least substantially parallel to and/or in
line with the vertical plane 4120.
[0327] It should be appreciated that the outboard motor 2500
employs a lubricant sump (not visible) for containing a lubricant
(e.g., oil). The lubricant sump is typically long, narrow, and
shallow and, moreover, is typically integral with, or otherwise
integrated with respect to, a crankcase. The crankcase is generally
understood to include a volume or space within the engine 2604 in
which are positioned the crankshaft, connecting rods, and sometimes
camshafts and lubricant (e.g., oil) pumps of the engine and, is
generally referenced in FIGS. 41-43 by the numeral 4122. In
accordance with embodiments of the present disclosure, additionally
a tank or tank structure 4124 (not visible in FIG. 43) is provided
on the outboard motor 2500 for storing and providing lubricant
(e.g., oil) for use by the engine 2604. As is evident from FIGS. 41
and 43, in the present embodiment, the tank 4124 is provided at the
front of the engine 2604. Also, the tank 4124 is connected to the
crankcase 4122 by a plurality of lubricant (e.g., oil) lines, which
in the present embodiment include first and second lubricant lines
4126a and 4126b at locations that are at or near the bottom of the
crankcase 4122 and that are visible in FIG. 42, and that are also
at or near the bottom of the oil tank 4124, which is configured to
extend generally upwardly from the locations at which those oil
lines extend from the oil tank. Additionally, the tank 4124 is
further connected to the crankcase by way of a vent line at or near
the top of the crankcase (not shown). In accordance with at least
some embodiments of the present disclosure, the tank 4214 is also
connected to the oil sump of the outboard motor 2500.
[0328] FIGS. 44 and 45 are right side and front elevation views,
respectively, of the outboard motor 2500 of FIG. 41, with the
outboard motor now shown such that it has been tilted, rotated
and/or otherwise moved so that the outboard motor and particularly
the engine 2604 is positioned at a second operating or operational
position. More specifically, the second operating position
corresponds to a position in which the outboard motor 2500 is
tilted, rotated or otherwise moved about the trimming axis 4104
such that a steering axis 4106' of the outboard motor as rotated is
at an angle up to (and including) a maximum angle .beta. relative
to the vertical axis, that is, rotated at an angle up to a maximum
angle .beta. relative to the steering axis of the outboard motor
when in the standard operating position (FIGS. 41-43). In the
present embodiment, the angle .beta. is fifteen (15) degrees off of
the vertical axis 4106, albeit this can vary depending upon the
embodiment. Thus, it should be appreciated that the particular
rotational position of the outboard motor 2500 shown in FIG. 46
illustrates the maximum rotational position of the outboard motor
away from the vertical axis 4106 at which the outboard motor can
still be considered to be in the second operating position in this
embodiment, and the outboard motor 2500 would also be considered to
be in the second operating position if it was rotated a lesser
amount less than the angle .beta. (e.g., rotated an amount less
than 15 degrees but greater than, or substantially greater than,
zero degrees).
[0329] It additionally should be appreciated that the rotational
range (up to a maximum of (3) corresponding to the second operating
position is intended generally to encompass positions of the
outboard motor 2500 suited for shallow water drive operation of the
outboard motor 2500 in which the outboard motor can be operated at,
or substantially at, full propulsion or full power. In accordance
with embodiments of the present disclosure, the tank 4124 is
configured or structured so that the lubricant/oil utilized by the
engine 2604 remains in (that is, the lubricant/oil is kept or
retained in) the crankcase 4122 during such shallow water drive
operation, rather than enters into the tank 4124. That is, very
little (or none) of the engine oil enters or remains within the
tank 4124, due to the position of the lines 4126a and 4126b and the
structure of the tank (which extends generally above those lines).
Notwithstanding the above description, it should be understood that
the second operating position can comprise many other positions
depending upon the design and intended use of the outboard motor
2500.
[0330] Turning next to FIGS. 46 and 47, there are provided right
side and front elevation views, respectively, of the outboard motor
2500 of FIG. 41 that are similar to those of FIGS. 44 and 45,
except insofar as the outboard motor is now shown such that it has
been tilted, rotated and/or otherwise moved so that the outboard
motor (and particularly the engine 2604 thereof) is positioned in a
third operating or operational position. More specifically, the
third operating position corresponds to a position in which the
outboard motor 2500 is tilted, rotated or otherwise moved about the
trimming axis 4104 such that a steering axis 4106'' of the outboard
motor as rotated is greater than the angle .beta. up to a maximum
angle of .psi.+.beta. relative to the vertical axis 4106, that is,
rotated at an angle from .beta. up to a maximum angle .psi.+.beta.
relative to the steering axis of the outboard motor when in the
standard operating position (FIGS. 41-43). In the present
embodiment, the angle .psi. is ten (10) degrees off of the steering
axis 4106', and.ir the angle .omega.+.beta. is twenty-five (25)
degrees off of the vertical axis 4106, albeit these amounts can
vary depending upon the embodiment. Thus, it should be appreciated
that the particular rotational position of the outboard motor 2500
shown in FIG. 46 illustrates the maximum rotational position of the
outboard motor away from the vertical axis 4106 at which the
outboard motor can still be considered to be in the third operating
position in this embodiment, and the outboard motor 2500 would also
be considered to be in the third operating position if it was
rotated a lesser amount less than the angle .psi.+.beta. down to
the angle .beta. (e.g., rotated an amount less than 25 degrees off
of the vertical axis 4106 but greater than, or substantially
greater than, 15 degrees off of the vertical axis).
[0331] The range of rotational positions corresponding to the third
operating position is intended generally to correspond to a shallow
water drive operation of the outboard motor 2500 in which the
outboard motor can be operated at limited propulsion or limited
power. Here again, in accordance with embodiments of the present
disclosure, the tank 4124 is configured or structured so that all
or substantially all of the lubricant/oil in the crankcase 4122
remains in (or is kept or retained in) the crankcase during such
shallow water drive operation. Again, such operation is
particularly achieved again by virtue of the relatively low
positioning of the lines 4126a and 4126b relative to the remainder
of the tank 4124 and the relatively high positioning of most of the
tank relative to both of those lines as well as relative to large
sections of the internal combustion engine 2604. Notwithstanding
the above description, it should be appreciated that the third
operating position can comprise many other positions depending the
embodiment, design, and/or intended use of the outboard motor
2500.
[0332] Next turning to FIGS. 48 and 49, there are provided right
side and front elevation views, respectively, of the outboard motor
2500 of FIG. 41 that are similar to those of FIGS. 46 and 47,
except insofar as the outboard motor is now shown such that it has
been tilted, rotated and/or otherwise moved so that the outboard
motor (and particularly the engine 2604 thereof) is positioned in
fourth position that is a first storage position. More
specifically, the first storage position corresponds to a position
in which the outboard motor 2500 is tilted, rotated or otherwise
moved about the trimming axis 4104 such that a steering axis
4106''' of the outboard motor as rotated is greater than the angle
.psi.+.beta. up to a maximum angle of .OMEGA.+.psi.+.beta. relative
to the vertical axis 4106, that is, rotated at an angle from
.psi.+.beta. up to a maximum angle .OMEGA.+.psi.+.beta. relative to
the steering axis of the outboard motor when in the standard
operating position (FIGS. 41-43). In the present embodiment, the
angle S2 is forty-five (45) degrees off of the steering axis
4106'', and .OMEGA.+.psi.+.beta. seventy (70) degrees off of the
vertical axis 4106, albeit these amounts can vary depending upon
the embodiment. Thus, it should be appreciated that the particular
rotational position of the outboard motor 2500 shown in FIG. 48
illustrates the maximum rotational position of the outboard motor
away from the vertical axis 4106 at which the outboard motor can
still be considered to be in the first storage position in this
embodiment, and the outboard motor 2500 would also be considered to
be in the first storage position if it was rotated a lesser amount
less than the angle .OMEGA.+.psi.+.beta. down to the angle
.psi.+.beta. (e.g., rotated an amount less than 70 degrees off of
the vertical axis 4106 but greater than, or substantially greater
than, 25 degrees off of the vertical axis).
[0333] More particularly, the first storage position is intended
generally correspond to a position of the outboard motor 2500 in
which the outboard motor is typically serviced or transported from
one location to another. As such, the first storage position is a
position taken on by the outboard motor 2500 when the outboard
motor is typically not operational or operating, and is thus
typically static. Such a storage position is one that is
particularly suitable when the outboard motor is being stored,
serviced, or transported from one location to another. However, it
is contemplated that the outboard motor 2500 can operate when
positioned in the first storage position in at least some
embodiments under at least some circumstances, and/or for at least
a limited period of time, and so the use of the term first storage
position, while generally indicative of a status in which the
outboard motor is not operating, should not in all cases be viewed
as excluding all outboard motor/engine operation. That said, for
ease of understanding, and notwithstanding the possibility of at
least some limited operation of the outboard motor 2500, the
position of the outboard motor illustrated in exemplary fashion by
FIG. 48 is referred to herein as the first storage position.
[0334] Additionally, FIGS. 50 and 51 are a right side elevation and
front elevation view, respectively, of the outboard motor of FIG.
41, with the outboard motor now shown such that it has been still
further tilted, rotated and/or otherwise moved so that it is
positioned in a second storage position. More particularly, the
outboard motor 2500 is shown in a position in which the outboard
motor is tilted, rotated or otherwise moved about the trimming axis
4104, as previously described with respect to FIGS. 48-49 (the
details of which are not repeated here), but additionally the
outboard motor 2500 is also further tilted, rotated or otherwise
moved (e.g., steered) about the steering axis 4106'''. The second
storage position, as with the first storage position illustrated in
FIGS. 48-49, is intended to generally correspond to a position of
the outboard motor 2500 that is particularly suitable when the
outboard motor is being stored, serviced, or transported from one
location to another and, as such, corresponds to a position in
which the outboard motor is typically not operational or operating.
However, it is again contemplated that the outboard motor 2500 can
operate when positioned in the first storage position under at
least some circumstances, and/or for at least a limited period of
time. That said, for ease of understanding, and notwithstanding the
possibility of at least some limited operation of the outboard
motor 2500, the position of the outboard motor illustrated in
exemplary fashion by FIGS. 50 and 51 is referred to herein as the
second storage position. It should also appreciated that, although
FIG. 51 shows the outboard motor 2500 to be steered to certain
steering orientation, in one direction (e.g., toward the starboard
side of a marine vessel to which the outboard motor would be
attached), it is intended that FIG. 51 be representative of the
outboard motor 2500 taking on other steered positions that can
involve turning the outboard motor to a lesser or greater degree
than that shown, as well as turning the outboard motor to any such
variety of degrees in the opposite direction (e.g., to toward the
port side of the marine vessel).
[0335] As shown in FIGS. 40-51, the outboard motor 2500 is
configured so that the tank 4124 is positioned in front of the
engine 2604 and sized to have sufficient capacity or at least
enough volume to hold a desired quantity of oil (or other engine
lubricant). In particular, in the present embodiment, the tank 4124
particularly is configured to be able to hold a sufficient quantity
of oil so that oil does not tend to congregate at or near one or
more of the cylinders 4118 of the engine 2604. Such operation is
desirable for the purpose of preventing one or more of the
cylinders 4118 from filling up or otherwise becoming flooded with
oil (or at least substantially limiting the extent to which, or
chance that, one or more of the cylinders become filled with oil),
particularly when the outboard motor 2500 is positioned in a
storage and/or non-operating position such as the first or second
storage positions depicted respectively in FIGS. 48-49 and FIGS.
50-51, respectively. Additionally, the tank 4124 is configured in
such a manner that an amount of oil (or other lubricant) can flow
into the tank from the engine 2604 (particularly from the crankcase
4122 thereof) when the engine is tilted to a storage position
(again, FIGS. 48-49 and FIGS. 50-51), and additionally, oil (or
other lubricant) can flow out of the tank back into the engine (and
particularly into the crankcase 4122 thereof) when the outboard
motor is returned to any of the first (normal), second, or third
operating positions shown in FIGS. 41-47.
[0336] In accordance with at least some embodiments of the present
disclosure, the tank 4124 can be sized to hold all, or
substantially all, of the engine oil contained within the crankcase
4122 for use in operating the engine 2604 of the outboard motor
2500. Also in accordance with at least some embodiments of the
present disclosure, an amount of oil will enter the tank 4124 when
the outboard motor 2500 is moved (e.g., tilted) to one of the first
and second storage positions, such as above 25 degrees of tilt, as
shown by way of example in FIGS. 48 and 49. Similarly, an amount of
oil will enter, or re-enter so as to be returned (and ultimately
fully returned) to the crankcase 4122 (such operation being
referred to as "drain back"), when the outboard motor 2500 is
positioned (or re-positioned as the case may be) in one of the
operating positions, e.g., a position at which the tilt of the
outboard motor is at or less than twenty-five degrees off of the
vertical axis 4106 as shown by way of example in FIGS. 41-47. In
general, the rate of oil return (during drain back) from the tank
4124 will, in at least some embodiments of the present disclosure,
match or substantially match or correspond to the time required to
tilt the engine 2604 from a given storage position back into a
given operating position, so as to ensure or increase the
likelihood that a minimum amount or level of oil is returned to the
crankcase 4122 by time an operator of the outboard motor 2500 may
decide to attempt to start the engine.
[0337] The particular arrangement or structural details of the tank
4124 can vary depending upon the embodiment, and the particular
structural details of the tank 4124 shown in FIGS. 41-51 are only
intended to be exemplary. As noted previously, in accordance with
at least some embodiments of the present disclosure, the tank 2012
is connected by the plurality of lubricant lines 4126a and 4126b
(see FIG. 42) located at or near the bottom of the engine crankcase
4122 and a vent line (not shown). The actual numbers of the
lubricant and vent lines can vary depending upon the embodiment, as
can the structural characteristics of those lines (e.g., the inner
diameters of the channels within those lines establishing flow
paths) and their particular locations along the tank 4124 and/or
the engine 2604. It should be understood that connection of the
tank 4124 to the crankcase 4122 by way of the vent line provides a
closed system that creates a constant, or at least substantially
constant, crankcase volume (where the crankcase volume includes the
volume of the tank 4124 as well as the crankcase 4122), thereby
allowing for the free exchange of volume, that is, oil (or other
lubricant) for air and air for oil, particularly when tilting of
the outboard motor 2500 from an operating position (e.g., from the
first or standard operating opposition of FIGS. 41-43) to a storage
position (e.g., the first storage position of FIGS. 48-49) occurs.
Moreover, a closed system desirably avoids the venting of vapors
(or at least substantially limits the extent to which there is
venting of vapors) from the crankcase 4122 to the outside
environment and thus is advantageous from an emissions standpoint.
The rate of oil exchange between the crankcase 4122 to the tank
4124 is generally limited or otherwise governed by the size of the
connecting lubricant lines 4126a-b and the vent line, which as
noted above can vary depending upon the embodiment (and can vary to
convenience). Similarly, the angle at which oil is transferred from
the crankcase to the tank (and back) can vary to convenience and is
generally governed by the geometry and relative positioning of the
tank and the connecting lines.
[0338] Depending upon the embodiment, the use of the tank 4124 or a
similar tank in an outboard motor such as the outboard motor 2500
can provide various advantages. The embodiment of the outboard
motor 2500 and tank 4124 shown in FIGS. 41-51 is particularly
advantageous in that, when the outboard motor 2500 (and engine 2604
thereof) is mounted in an outboard configuration and tilted or
otherwise positioned into a storage position, an amount (up to and
including all or substantially all) of the engine oil does not pour
out of the oil sump of the outboard motor 2500 and into the
crankcase 4122, even as the cylinders 4118 of the engine reach a
near horizontal position (e.g., tilted up to an angle of 70
degrees), instead of running into one or more of the cylinders (and
particularly combustion chambers acted upon by respective pistons
within those cylinders) which could potentially be undesirable in
terms of adversely affecting engine operational performance or
leading to hydraulic locking or stressing upon various engine
components such as connecting rods of the engine. Indeed, in the
present embodiment, the tank 4124 is configured so that oil enters
the tank so as to avoid reaching or entering (or so as to avoid
substantially reaching or entering) even that one of the cylinders
4118 of the engine 2604 that may be at a lowest position due to the
particular storage position of the engine (e.g., that one of the
cylinders that is most forward in the V-type engine 2604 and on the
starboard side of that engine when in the second storage position
shown in FIG. 51, where in such case that one cylinder could
potentially be arranged such that its cylinder axis was
substantially horizontal). In at least some embodiments, no more
than 10% of the total engine oil can proceed from the engine into
the tank 4124 until the outboard motor 2500 has been trimmed to an
angle of more 30 degrees off of the vertical axis 4106 (so that the
tank does not "steal" oil). The tank 4124 is helpful for storing
oil when the outboard motor is in a storage position, and also due
to its configuration oil flows into and out of the tank due to the
influence of gravity. Also in accordance with at least some
embodiments of the present disclosure, the tank 4124 can be
configured or structured to mount or be mounted to other components
of the outboard motor 2500, such as heat exchangers and/or the tank
4124 can be configured or structured to receive hot oil (e.g., oil
that is heated to approximately 300 degrees Fahrenheit).
[0339] Although numerous embodiments are disclosed above, it is
envisioned that numerous variations to the disclosed embodiments
above are possible and encompassed herein. Among other things,
although embodiments of the outboard motor 100 above envision use
of an internal combustion engine (the engine 204) that is a
horizontal crankshaft engine and that, in at least some such
embodiments, can be an automotive engine, in alternate embodiments
the engine can be another engine including, for example, a vertical
crankshaft engine. Also for example, although the water pump
assembly 600 shown above is "diamond-shaped" in that it has
generally four corners, with the impellers located at two of those
corners and the inlet and one of the outlets located at the other
two corners, in other embodiments the water pump assembly could
take on a different shape such as a pentagon (e.g., where two of
the vertices of the pentagon were locations at which each of the
two outlets were positioned). Additionally, it should be
appreciated that any use of terms pertaining to orientation, such
as with respect to a vertical and horizontal axes as described
above, is for purposes of reference and understanding of the
embodiments described above, and that such teachings are not
intended to limit the scope of the present disclosure to encompass
embodiments having other orientations.
[0340] Additionally, at least some example embodiments encompassed
herein relate to an outboard motor for use with a marine vessel.
The outboard motor includes a transmission, and an engine
positioned adjacent to the transmission. The outboard motor further
includes a cowling assembly including at least one outer formation
extending around the transmission and the engine so as to provide a
housing therefore, and a wall formation extending within the outer
formation between the transmission and the engine so as to form a
barrier therebetween, so that an interior within the at least one
outer formation is divided into a plurality of portions including a
first portion and a second portion. The transmission is positioned
at least partly within the first portion and the engine is
positioned at least partly within the second portion, there exists
a space beneath the wall formation so that the first portion is in
fluid communication with the second portion, and the at least one
outer formation includes at least one inlet positioned at or
proximate to a top of the at least one outer formation along the
first portion so as to allow the first portion to be in fluid
communication with a region outside of the outboard motor. The
outboard motor is configured to allow air to enter the first
portion via the at least one outer formation and to pass from the
first portion into the second portion via the space, whereby, due
to the wall formation, the air entering the outboard motor via the
at least one inlet must pass downward within the first portion to
the space in order for the air to enter into the second portion,
and due to the downward movement of the air, at least some water
entering the at least one inlet along with the air proceeds
downward past the space and does not enter the second portion.
[0341] In at least some such embodiments, the cowling assembly
includes at least one outlet opening at or below a vertical level
of the space, where the at least some water that does not enter the
second portion exits the outboard motor by way of the at least one
outlet opening. Further, in at least some such embodiments, the
first portion and the transmission are positioned aftward of the
wall formation, and the second portion and the engine are
positioned forward of the wall formation. Additionally, in at least
some such embodiments, a throttle assembly is positioned also
within the second portion, and an additional outlet opening is
formed along a floor of the second portion. Further, in least some
such embodiments, the throttle assembly is positioned at or
proximate to a frontmost portion of the second portion, whereby the
throttle assembly is positioned away from the space, and/or the
engine is a horizontal crankshaft engine.
[0342] Also, in at least some such embodiments, the air entering
the second portion via the space must proceed at least partly
upward in order to reach one or both of the engine or another
component of the outboard motor. Further, in at least some such
embodiments, at least some additional water that enters the second
portion along with the air ceases to move upward along with the air
and fails to reach the engine or another component of the outboard
motor but rather then proceeds downward within the outboard motor
and exits the outboard motor by way of the at least one outlet
opening or an additional outlet opening. Additionally, in at least
some embodiments, a first cross-sectional area of the first portion
through which the air proceeds downward from the at least one inlet
to the space is smaller than a second cross-sectional area of one
or both of the space and a region within the second portion through
which the air proceeds at least partly upward, so that a first
velocity of the air as it proceeds downward is greater than a
second velocity of the air as it proceeds into or at least partly
upward within the second portion. Also, in at least some
embodiments, the at least one outer formation includes a rear wall
formation, a front wall formation, a left wall formation, a right
wall formation, and a roof formation, where each of the rear,
front, left, and right wall formations extend downward from the
roof formation.
[0343] Further, at least some example embodiments encompassed
herein relate to a water pump assembly. The water pump assembly
includes a pump housing having an inlet and an outlet, a first
impeller located within the pump housing and configured to rotate
in a rotational plane, about a first axis of rotation, in a first
rotating direction, and a second impeller located within the pump
housing and configured to rotate in the rotational plane, about a
second axis of rotation, in a second rotating direction that is
opposite the first rotating direction.
[0344] In at least some such embodiments, the first rotating
direction is clockwise and the second rotating direction is
counter-clockwise and the first impeller and the second impeller
are counter-rotating impellers. Also, in at least some such
embodiments, the first impeller and the second impeller both rotate
to draw or pull water from the pump housing inlet. Further, in at
least some embodiments, the first impeller rotates to draw a first
amount of water flowing from the inlet and the second impeller
rotates to draw a second amount of water from the inlet. Also, in
at least some embodiments, the first and second impellers each are
eccentrically offset. Additionally, in at least some embodiments,
the pump housing outlet includes a first outlet area and a second
outlet area. Also, in at least some embodiments, the first outlet
area and the second outlet area are connected by way of a
connective or connecting passage.
[0345] Further, in at least some embodiments, the pump housing
outlet includes a first outlet area and a second outlet area, where
all or substantially all of an amount of water from the first
impeller and at least some of another amount of water from the
second impeller are discharged via the first outlet area, and
further where all or substantially all of a remaining amount of the
other amount of water from the second impeller is discharged via
the second outlet area. Also, in at least some embodiments, (i) the
first impeller rotates to draw a first amount of water flowing from
the inlet and the second impeller rotates to draw a second amount
of water from the inlet, and/or (ii) the pump housing outlet
includes a first outlet area and a second outlet area, where all or
substantially all of the first amount of water from the first
impeller and at least some of the second amount of water from the
second impeller are discharged via the first outlet area, and
further where all or substantially all of a remaining amount of the
second amount of water from the second impeller is discharged via
the second outlet area. Further, in at least some embodiments, the
pump housing outlet includes a first outlet area and a second
outlet area, the second outlet area structured to discharge a
volume of water that is less than, and at a higher pressure than,
another volume of water that is discharged from the first outlet
area.
[0346] Also, in at least some such embodiments, the water pump
assembly further includes a first liner structure and a second
liner structure, where the first impeller is positioned within, or
substantially within, the first liner structure and the second
impeller is positioned in, or substantially in, the second liner
structure. Additionally, in at least some embodiments, each of the
first and second liner structure include one or more water ports.
Also, in at least some embodiments, the pump housing includes an
inlet side and an outlet side. Further, in at least some
embodiments, the water pump assembly further includes one or more
wear plates structures, a cover plate structure, at least one seal
structure, and a plurality of assembly fasteners for securing the
one or more wear plate structures, the cover plate structure, the
seal structure and the housing together. Additionally, in at least
some embodiments, the at least one seal structure includes an
O-ring type seal and the plurality of assembly fasteners comprises
one or more screws.
[0347] Further, at least some example embodiments encompassed
herein relate to an outboard motor (or outboard engine) that
includes a water pump assembly as described above. In at least some
such embodiments, the outboard motor includes a transmission
assembly and the water pump assembly is integrated with or into, or
in proximity to, the transmission assembly. Also, in at least some
embodiments, the water pump assembly is operably connected to the
transmission assembly by a geartrain. Further, in at least some
embodiments, the transmission drives at least one of the first and
the second impellers. Additionally, in at least some embodiments,
one of the first impeller and the second impeller is located above,
and spaced apart from the other of the first impeller and second
impeller.
[0348] At least some additional example embodiments encompassed
herein relate to a vapor separating tank (VST) system. The VST
system includes a first pump configured to receive fuel at a first
pressure from a fuel source and to output the fuel at a second
pressure that is higher than the first pressure, and also includes
a fuel reservoir coupled to the first pump via at least one first
linkage so that the fuel at the second pressure output by the first
pump is received at the fuel reservoir. Further, the VST system
also includes a second pump coupled to the fuel reservoir via at
least one second linkage, where the second pump is configured to
receive the fuel at the second pressure from the fuel reservoir and
to output the fuel at a third pressure that is higher than the
second pressure, and additionally includes an output port by which
at least some of the fuel at the third pressure can be communicated
from the VST system to an internal combustion engine. Also, the VST
system further includes a first pressure regulator at least
indirectly coupled between the output port and the fuel reservoir
by way of at least one third linkage so that, if a first pressure
differential across the first pressure regulator exceeds a first
predetermined threshold, a first fluid communication path is at
least temporarily established between the output port and the fuel
reservoir via the first pressure regulator.
[0349] Additionally, in at least some such embodiments, the fuel
reservoir includes a filter by which the fuel received from the
first pump is filtered, and the fuel reservoir additionally is
configured to operate as a mixer. Further, in at least some
embodiments, the second pump is a high pressure pump and the first
pump is a low pressure pump. Also, in at least some embodiments,
each of the first pump and second pump is an electrically-driven
pump. Additionally, in at least some embodiments, the VST system
further includes a second pressure regulator at least indirectly
coupled between the fuel reservoir and an input port of the first
pump by way of at least one fourth linkage so that, if a second
pressure differential across the second pressure regulator exceeds
a second predetermined threshold, then a second fluid communication
path is at least temporarily established between the fuel reservoir
and the input port via the second pressure regulator. Also, in at
least some embodiments, the first and second pressure regulators,
the first and second fuel pumps, and the fuel reservoir are
assembled in a unitary component, with the first fuel pump having a
first cylindrical axis and the second fuel pump having a second
cylindrical axis, the first and second cylindrical axes being
substantially perpendicular to one another. Additionally, in at
least some embodiments, the VST system includes a fuel cooler
output port and a fuel cooler input port by which the VST system is
capable of being coupled to a fuel cooler so that at least one
amount of the fuel that exits the fuel cooler output port returns
via the fuel cooler input port after being cooled by way of the
fuel cooler, and the fuel cooler output port is at least indirectly
coupled to the first pressure regulator and the fuel cooler input
port is at least indirectly coupled to the fuel reservoir. Further,
in at least some embodiments, the first pump is a diaphragm pump
and the second pump is an electrically-driven pump.
[0350] Also, at least some example embodiments encompassed herein
relate to an outboard motor that includes a VST system as described
above, where the outboard motor includes an internal combustion
engine that is a fuel injected engine. Also, in at least some such
embodiments, the outboard motor comprises a coolant channel by
which coolant is directed to the internal combustion engine, and
further comprises a fuel cooler that extends proximate a portion of
the coolant channel, where the fuel cooler is coupled between the
first pressure regulator and the fuel reservoir so that a portion
of the fuel passing through the first pressure regulator in turn
passes through the fuel cooler before returning to the fuel
reservoir.
[0351] Additionally, at least some example embodiments encompassed
herein relate to an outboard motor having a front surface and an
aft surface and configured to be mounted on a marine vessel having
a front to rear axis, such that the front surface would face the
marine vessel and the aft surface would face away from the marine
vessel when in a standard operational position. The outboard motor
includes a housing having an upper and a lower portions and having
an interior, and an internal combustion engine disposed within the
housing interior and that provides rotational power output via a
crankshaft that extends horizontally or substantially horizontally
in a front-to-rear direction when the outboard motor is in the
standard operational position, where the engine is further disposed
substantially or entirely above a trimming axis and is steerable
about a steering axis, the trimming axis being perpendicular to or
substantially perpendicular to the steering axis, and the steering
axis and trimming axis both being perpendicular to or substantially
perpendicular to the front-to-rear axis of the marine vessel. The
outboard motor further includes a tank positioned within the
housing and connected to a crankcase of the engine, where the tank
is configured such that little, if any, of an amount of the
lubricant is in or provided to the tank when the engine is in the
standard operational position.
[0352] Further, in at least some such embodiments, the tank is
positioned along or on a front of the engine, nearer the front
surface of the outboard motor than the aft surface thereof. Also,
in at least some embodiments, the outboard motor is configured to
be tilted about the trimming axis away from the standard operating
position to at least one additional operating position and at least
one additional position suitable for storing, transporting and/or
limited operation of the outboard motor. Additionally, in at least
some embodiments, the standard operating position is a position in
which the trimming axis is at least substantially horizontal and
the steering axis is at least substantially vertical, with the
steering axis being at least substantially parallel to and/or in
line with a vertical plane passing through a center of the engine,
where the outboard motor is configured to be tilted from the
standard operating position to at least one of: (i) a second
operating position that corresponds to a position in which the
outboard motor is tilted, rotated or otherwise moved about the
trimming axis such that a steering axis of the outboard motor as
rotated is at an angle .beta. relative to at least one of a
vertical axis and to the steering axis of the outboard motor when
in the standard operating position; (ii) a third operating position
that corresponds to a position in which the outboard motor is
tilted, rotated or otherwise moved about the trimming axis such
that a steering axis of the outboard motor as rotated is greater
than the angle .beta. up to a maximum angle of .psi.+.beta.
relative to the vertical axis, and rotated at an angle from .beta.
up to a maximum angle .psi.+.beta. relative to the steering axis of
the outboard motor when in the standard operating position; (iii) a
first storage position that corresponds to a position in which the
outboard motor is tilted, rotated or otherwise moved about the
trimming axis such that a steering axis of the outboard motor as
rotated is greater than the angle .psi.+.beta. up to a maximum
angle of .OMEGA.+.psi.+.beta. relative to the vertical axis, and
rotated at an angle from .psi.+.beta. up to a maximum angle
.OMEGA.+.psi.+.beta. relative to the steering axis of the outboard
motor when in the standard operating position; and (iv) a second
storage position that corresponds to a position in which the
outboard motor is tilted, rotated or otherwise moved about the
trimming axis and is also further tilted, rotated or otherwise
moved about the steering axis.
[0353] In at least some such embodiments, the angle .beta. is
fifteen (15) degrees off of the vertical axis. Also, in at least
some embodiments, the angle .beta. is the maximum rotational
position of the outboard motor away from the vertical axis at which
the outboard motor is in the second operating position, and the
outboard motor is in the second operating position if it is rotated
a lesser amount less than the angle .beta.. Further, in at least
some embodiments, the second operating position encompasses
positions of the outboard motor suited for shallow water drive
operation of the outboard motor in which the outboard motor can be
operated at, or substantially at, full propulsion or full power.
Also, in at least some embodiments, the tank is configured or
structured so that the lubricant/oil utilized by the engine remains
in the crankcase during shallow water drive operation, and very
little or none of the engine lubricant/oil enters or remains within
the tank. Further, in at least some embodiments, the tank is
connected to the engine via one or more oil lines that having a
relatively low positioning relative to the remainder of the tank
and the relatively high positioning of at least most of the tank
relative to the one or more oil lines as well as relative to large
sections of the internal combustion engine. Also, in at least some
embodiments, the angle .psi. is ten (10) degrees off of the
steering axis, and the angle .psi.+.beta. is twenty-five (25)
degrees off of the vertical axis. Additionally, in at least some
embodiments, the angle .psi.+.beta. is the maximum rotational
position of the outboard motor away from the vertical axis at which
the outboard motor can still be considered to be in the third
operating position in this embodiment, and the outboard motor is in
the third operating position if it is rotated a lesser amount less
than the angle .psi.+.beta. down to the angle .beta.. Further, in
at least some embodiments, the third operating position encompasses
positions of the outboard motor in which the outboard motor can be
operated at limited propulsion or limited power.
[0354] Also, in at least some embodiments, the tank is configured
or structured so that all or substantially all of the lubricant/oil
in the crankcase remains in the crankcase during such shallow water
drive operation. Further, in at least some embodiments, the tank is
connected to the engine via one or more oil lines having a
relatively low positioning relative to the remainder of the tank
and to the relatively high positioning of at least most of the tank
relative to the one or more oil lines as well as relative to large
sections of the internal combustion engine. Additionally, in at
least some embodiments, the angle .OMEGA. is forty-five (45)
degrees off of the steering axis, and .OMEGA.+.psi.+.beta. is
seventy (70) degrees off of the vertical axis. Further, in at least
some embodiments, the angle .OMEGA. is the maximum rotational
position of the outboard motor away from the vertical axis at which
the outboard motor can still be considered to be in the first
storage position, and the outboard motor is in the first storage
position if it is rotated a lesser amount less than the angle
.OMEGA.+.psi.+.beta. down to the angle .psi.+.beta..
[0355] Also, in at least some embodiments, the first storage
position corresponds to a position of the outboard motor in which
the outboard motor is serviced, or transported, from one location
to another. Further, in at least some embodiments, the second
storage position corresponds to a position of the outboard motor
that is particularly suitable when the outboard motor is being
stored, serviced, or transported from one location to another.
Additionally, in at least some embodiments, the tank is configured
to receive some or all of the lubricant from the crankcase when the
outboard motor is positioned in one or both of the first and second
storage positions. Further, in at least some embodiments, the tank
is sized to hold a quantity of oil or other lubricant needed to
prevent one or more of the cylinders from filling up with
oil/lubricant, when the outboard motor is positioned in one or both
of the first and second storage positions. Additionally, in at
least some embodiments, the tank is configured such that an amount
of lubricant can flow into the tank when the engine is tilted to
the one or both of the first and the second storage positions and
the amount of lubricant can flow out of the tank when the engine is
repositioned to at least one of the standard, second and third
operating positions. Further, in at least some embodiments, the
internal combustion engine is an automotive engine suitable for use
in an automotive application. Also, in at least some embodiments,
one or more of the following is/are true: (a) the internal
combustion engine is one of an 8-cylinder V-type internal
combustion engine; (b) the internal combustion engine is operated
in combination with an electric motor so as to form a hybrid motor;
(c) the rotational power output from the internal combustion engine
exceeds 550 horsepower; and (d) the rotational power output from
the internal combustion engine is within a range from at least 557
horsepower to at least 707 horsepower.
[0356] It is further specifically intended that the present
invention not be limited to the embodiments and illustrations
contained herein and in the addenda attached hereto, but include
modified forms of those embodiments including portions of the
embodiments and combinations of elements of different embodiments
as come within the scope of the following claims.
* * * * *