1. Field of the Invention
This invention relates to an engine, and more particularly, an engine construction and lubrication method for a small four-cycle internal combustion engine which is particularly suitable for the use with portable or transportable power tools.
2. Description of the Related Art
U.S. Pat. No. 7,287,508 to Kurihara and U.S. Pat. No. 7,624,714 to Kurihara et al., which are incorporated herein by reference, disclose a light weight and compact prior art small four-cycle engine construction.
Portable power tools such as line trimmers, blower/vacuums, chain saws are mostly powered by two-cycle internal combustion engines or electric motors. Some transportable power tools such as tiller/cultivators, generators are currently powered by two-cycle or four-cycle internal combustion engines. With the growing concern regarding air pollution, there is increasing pressure to reduce the emissions of both portable and transportable power equipment. Electric motors unfortunately have limited applications due to power availability for corded products, and battery life and power availability for cordless devices. In instances where weight is not an overriding factor such as lawn mowers, emissions can be dramatically reduced by utilizing heavier four-cycle engines. When it comes to power tools such as line trimmers, chain saws and blower/vacuums, four-cycle engines pose a very difficult problem. Four-cycle engines tend to be too heavy for a given horsepower output and lubrication becomes a very serious problem since portable or transportable power tools must be able to run in a very wide range of orientations except generators or tiller/cultivators. For some tiller/cultivators powered by four-cycle engines with vertical power shafts, lubrication also becomes a serious problem since it is difficult to use the same lubrication system as engines with horizontal power shafts.
Therefore, it is an object of the present invention to provide a small four-cycle internal combustion engine having low emissions that is sufficiently light weight to be carried and/or transported by an operator, which is especially suitable for a hand-held or transportable power tool.
It is a further object of the present invention to provide a small four-cycle internal combustion engine having an internal lubrication system enabling the engine to be run at a wide variety of orientations typically encountered during normal operation, which is especially suitable for a portable or transportable power tool.
It is a further object of the present invention to provide a small lightweight four-cycle engine having an engine block, an overhead valve train and a lubrication system to splash oil mist to lubricate the crankshaft chamber throughout the normal range of operating positions, which is especially suitable for a portable or transportable power tool.
It is a further object of the invention to provide a lubricant return system to return lubrication oil into oil reservoir after lubricating parts in the crankshaft chamber and the overhead valve chamber.
In the prior art previously referred, circular and scroll-type walls play important roles in the inventions. However, the construction to make these walls are not so cost effective and not so compact. Thus, it is a further object of the present invention to provide a more cost effective and more compact construction.
These and other objects, features, and advantages of the present invention will become apparent upon further review of the remainder of the specification and the accompanying drawings.
In order to achieve the above objects, a four-cycle, internal combustion engine is provided which is suitable for use with portable or transportable power tools. The four-cycle engine is provided with an engine block having at least one cylindrical bore oriented in a normally upright orientation having an enclosed combustion chamber.
A lower case is attached to the said cylinder block with a horizontal mating plane. The cylinder block and said lower case form a crankshaft chamber. A crankshaft is pivotably mounted within the crankshaft chamber. An enclosed oil reservoir is located below the crankshaft chamber separated from the crankshaft chamber by a substantially circular wall.
A pump is connected drivably to cam gear-cam assembly, and said pump inhales lubrication oil from the oil reservoir to splash oil into the cylinder.
When lubrication oil is properly filled, the engine is able to rotate or to be stored without oil flowing into combustion chamber at any inclination posture.
A lower case 3 and said cylinder block 1 mate with each other at the horizontal interface and form a crankshaft chamber 5.
A crankshaft 4 is pivotably mounted within the crankshaft chamber 5 in a conventional manner. The axis of said crankshaft 4 is contained at the horizontal interface to mate cylinder block 1 and lower case 3.
A piston 6 slides within the cylindrical bore 2 and is connected to the crankshaft 4 by a connecting rod 7. A cylinder head 8 is integrated to the engine block 1 to define an enclosed combustion chamber 9.
The cylinder head 8 is provided with an intake port 10 coupled to an insulator 11 and a carburetor 100 and selectively connected to the combustion chamber 9 by an intake valve 12. A filter element of air cleaner 101 eliminates dust from the intake air into the engine. The cylinder head 8 is also provided with an exhaust port 13 connected to a muffler 14 and selectively connected to the combustion chamber 9 by an exhaust valve 15.
As illustrated in
The lower case 3 is connected to a bottom cover 17 that provides an enclosed oil reservoir 18.
The crankshaft 4 is provided with an axial shaft member 19 having an output end 20 adapted to be coupled to a flywheel 21 which has an implement input member 22. An input end 23 of axial shaft member 19 is coupled to a counterweight web 24. A crankpin 25 is affixed to counterweight webs 24, 26 and is parallel to and radially offset from the axial shaft 19. The crankpin 25 pivotally cooperates with a roller bearing 27 (
The axial shafts 19 and 28 of crankshaft 4 are pivotably attached to between the cylinder block 1 and the lower case 3 by a pair of bearings 29 and 30. At the side of bearing 30, a crank gear 31 is mounted on the crankshaft 4 in a cam chamber 53.
A camshaft drive and valve lifter mechanism is best illustrated in
Push rods 38 and 39 extend between camshaft followers 35 and 36 and rocker arms 40 and 41 located within the cylinder head 8. The cam 34, push rods 38, 39 and rocker arms 40, 41 are part of a valve train assembly. Affixed to the cylinder head 8 is a valve cover 42 which defines therebetween an enclosed valve chamber 43.
A wall 44 surrounds the intake and exhaust push rods 38 and 39 in a conventional manner in order to prevent the entry of dirt into the engine.
The cam chamber 53 and the valve chamber 43 are in communication with each other.
In order to lubricate the engine, a pump 45 such as a trochoid pump is placed at the side of cam gear 32. As illustrated in
The inner rotor 46 formed on the outer surface of the camshaft 33 is driven by the cam gear 32, and the outer rotor 47 formed on the inner surface of the outer portion 123 is rotated following the rotation of the inner rotor 46. Lubrication oil is inhaled from the passage 48. One end of the passage 48 leads to an oil entrance of the pump. The other end of passage 48 is connected to one end of a flexible tube 49. The other end of flexible tube 49 is connected to a filter with weight 50. By means of the weight 50, an entrance of the flexible tube 49 is dipped in the oil in the oil reservoir 18 at any orientation of the engine.
The oil pushed out by the pump 45 is lead in parallel to a hole 52 formed in the cylinder wall and a hole 125 formed in the outer wall of the cam shaft 33 through an inner through hole 51 of the cam shaft as illustrated in
As illustrated in
At the bottom of circular arc wall 55, a drain hole 56 is provided. As illustrated in
At the side of the cylinder block 1, a drilled oil passage 104 is provided. One end of the passage 104 leads to the oil entrance of the pump together with the passage 48. The other end of passage 104 leads to upper portion in the valve chamber 43 as illustrated in
A small hole 109 is opened from the valve chamber to the passage 104 near the bottom surface of the valve chamber.
In other embodiments of the present application, a flexible tube may be used to provide passage 104. An oil inlet 107 is provided at said other end of the passage 104.
As best illustrated in
Between the first inlet cavity 200 and the second inlet cavity 201, a wall 202 is provided to separate the cavities 200 and 201. An outlet cavity 203 provides a passage for oil to the cylinder bore through the inner hole 51. A relief oil passage is formed in the outer portion 123 of the pump body 122. One end of the relief oil passage 204 opens to the outlet cavity 203. The other end of the relief oil passage 204 opens to the oil reservoir 18 through a drilled hole (not shown).
In the valve chamber 43, a breather pipe 61 is opened through the valve cover 42. One end of the breather pipe 61 is connected to an air cleaner case 62 through a breather tube 63. At said one end of breather pipe 61, a check valve 60 is installed. The valve chamber 43 opens when the pressure in the valve chamber 43 is higher than the pressure in the breather tube 63, and the valve chamber 43 closes when the pressure in the valve chamber is lower than the pressure in the breather tube 63. In the air cleaner case 62, an oil separating deflector 102 is provided. The breathing oil mist provided through the breather tube 63 is separated into oil-lean gas and oil-rich gas by the deflector 102.
A return tube 64 interconnects the air cleaner case 62 and a return hole 65 formed in the cylinder wall. The return hole 65 opens and closes with a reciprocating motion of the piston 6 and the oil-rich mist returns into the crankshaft chamber 5 only when the pressure in the crankcase is negative. The oil-lean mist is inhaled to the carburetor 100 through the filter element 101.
As illustrated in
As illustrated in
By the same way, in the boss to support bearing 30, slits 80 and 81 are provided to communicate between the crankshaft chamber 5 and cam chamber 53.
By the reciprocating motion of the piston 6, pressure in the crankshaft chamber 5 changes up and down and oil mist in the crankshaft chamber 5 is pushed out to the cam chamber 53 and lubricate the valve actuating parts in the cam chamber 53.
As illustrated in
The axes of intake valve 12 and exhaust valve 15 are inclined to each other. Therefore, a corner 82 of a deck 84 of the cylinder head 8 near the inlet valve spring 83 in the valve chamber 43 is lower than the top of the deck 84. So, in the normal operation posture of the engine in which the cylinder head 8 is upright, lubricating oil in the valve chamber 43 flows easily to the corner 82 of the deck 84 after lubricating the parts in the valve chamber.
A passage 85 is provided between the corner 82 of the deck 84 and the oil reservoir 18. At one end of the passage 85, a pipe 86 is provided in the oil reservoir 18 with a small distance from the wall of the bottom cover 17. Since intake and exhaust valves 12, 15 are inclined to each other, cooling performance of the engine in accordance with the present invention is better than that of the prior art because a cooling air passage 124 between valves is wide.
Other parts not specifically referenced in the foregoing relate to conventional four-cycle engines. As illustrated in
A fuel tank 72 is provided below the oil reservoir 18, adequately spaced apart therefrom. As illustrated in
In order to achieve high power output and relatively low exhaust emissions, the four-cycle engine in accordance with the present invention is provided with a very compact combustion chamber 9. When the engine is started by pulling the winding rope 69 illustrated in
The excess oil after lubricating parts in the valve chamber 43 returns into oil reservoir 18 through the passage 85 shown in
As illustrated in
After lubricating the engine parts, as the webs 24, 26 rotate, the oil returns into the oil reservoir 18 through the drain hole 56.
The excess oil in the cam chamber 53 returns into the oil reservoir 18 through the pipe 54.
Portable or transportable power tools are operated with various orientations. For instance, a typical brush cutter, which installs an engine at an upper end of the boom and a cutter at the lower opposite end of the boom, is usually operated with 25-40 degrees inclination of the boom relative to the ground.
In the present invention, the circular arc wall 55 is funnel shaped with a 20-45 degree conical angle. Therefore, lubricating oil is not agitated excessively by rotation of web 24 and drops into the oil reservoir 18 when a brush cutter is operated in normal operation posture.
As illustrated in
As illustrated in
As illustrated in
It is necessary to be sure that portable or transportable power tools are safely stored. For instance, even if a brush cutter is stored with a posture with the vertical boom side up and the engine side down, lubrication oil should not flow into the combustion chamber 9. On the contrary, even if the same brush cutter is stored with a posture with the vertical boom side down and the engine side up, lubrication oil should not flow into the combustion chamber 9 also.
5
The function of the relief passage 204 the pump 45 is as follows: Assuming that the sectional area of oil passage of the hole to splash oil into cylinder bore is S1, the sectional area of relief passage is s2, and the discharge volume by pump is Q. Then, the discharge volume in to the cylinder bore is Q*S1/(S1+S2). Return volume of oil to the oil reservoir is Q*S2/(S1+S2). So, by adequate design, in accordance with the present invention, some part of the oil discharged by the pump 45 always returns into the oil reservoir 18. In the prior arts, on the other hand, because there is provided no relief passage, in some operation condition, all of the oil in the oil reservoir 18 is sucked and sent into the cylinder bore, and no oil returns into the oil reservoir 18. This means that there may be a rare instance where the crankshaft chamber 5 is filled by a lot of oil. The present invention solves this problem.
It is believed that small light weight four cycle engines made in accordance with the present invention will be particularly suitable for the use with hand-held or transportable power tools having low emissions and will be sufficiently light to be carried and/or transported by an operator. In the prior art, effective lubricating methods for hand-held or transportable power tools have been presented. However, they require complicated arc and scroll shaped wall to control flow of lubricating oil in the engines and to prevent oil from flowing into cylinder head when engine is positioned upside down or vertical.
In the present invention, however, more simple and economic construction is provided to solve the problem in the prior arts.
Further, construction such as the pump in the prior art is basically followed, so that specific feature and advantage of the prior art are maintained in the present invention.