Fluidic-piston engine

BACKGROUND

[0002] Stirling engines refer to a specific class of external combustion heat engines that convert heat differentials into mechanical energy with relatively high conversion efficiencies. Such efficiencies for a class of optimized Stirling engines can surpass most known air-breathing internal combustion engines, and utilize a regenerator to store or release fluid heat during the engine cycle. Such Stirling engines can approach the efficiency of an ideal Carnot cycle.

[0003] External combustion engines can be used in a variety of applications. For example, as prime movers, cooling systems, cryogenic coolers, heat pumps or pressure generators in a variety of design forms and operating sizes. Current applications range in size from large power generators to miniature engines for artificial hearts. Stirling engines thus far developed vary in output power from as little as a few watts to as much as 1 MW (1 MW=1341 hp). High temperature Stirling engines may operate at temperatures exceeding 1000 K, with mean working fluid pressures in the range of one atmosphere to as high as 20 MPa (1 MPa≈10 atmospheres).

[0004] Conventional Stirling engines utilize the roughly steady-state expansion of a highly compressed fixed number of light molecular mass working fluid, such as helium, hydrogen or air, in contact with a heat source at a substantially fixed temperature for their power stroke; followed by forced convection heat transfer or gas cooling by contact with a heat sink to generate engine speeds ranging from low to high frequency, typically measured in revolutions per minute.

[0005] Since the essential ingredient needed to operate a Stirling engine is an appropriate external heat source such as, for example, solar, natural gas, fossil fuel, oil, coal, waste heat or geothermal energy; this makes the Stirling engine well suited for not only terrestrial applications but also for large scale space and underwater applications, including spacecraft and submarines.

[0006] Any conventional (non-rotary) type Stirling engine requires simple components for its operation. It requires internal pistons as the means for displacing and compressing the working fluid therein and to generate output power. The pistons receive work during their up-stroke (compression), and generate greater work during their down-stroke (expansion), followed by a transfer of heat at some temperature by the working fluid to the surrounding heat sink. The power pistons are usually equipped with high performance fluid rings to assure and maintain a high pressure differential between their upper and lower faces.

[0007] Regenerators, which are placed between the hot and cold heat exchangers, optimally recycle the heat supply and transfer process by acting as thermodynamic sponges. Their function is to receive heat from the working fluid during the fluid passage from the high to low temperature space, and to release heat to the working fluid during the fluid passage back from the low to high temperature space.

[0008] Generally, the system efficiency and the cyclic work output are functions of both thermodynamic variables, such as pressure, and the internal volumetric compression ratio. From a thermodynamic standpoint, an ideal reversible four-path Stirling cycle when depicted in the pressure (P) versus volume (V) diagram consists of two isothermal (constant temperature) and two isochoric (constant volume) processes in sequence. When depicted in the temperature (T) versus entropy (S) diagram, the heat energy transfer in the process is proportional to the area enclosed in the T-S diagram (SdT). Likewise, the work done by the engine is proportional to the area enclosed on the P-V diagram (PdV).

[0009] Disadvantages of conventional Stirling engines include the use of relatively expensive and heavy materials, such as Inconel® and other alloy steels, for the high temperature structural components (e.g., pistons, cylinders and regenerators). In addition, the use of seals at the piston connecting rod is a serious factor for limiting the useful life of the engine and is a well-known cause for downgrading the engine's overall efficiency. Further, these seals are specialized designs and are correspondingly expensive to produce, and typically do not perform an adequate function in preventing leakage of high-pressure working fluid.

[0010] Conventional high temperature Stirling engines generally operate at high rotational velocities of typically about 3000 RPM. This is one prime reason for the reduction of the regenerator efficiency, and causes a marked increase in frictional losses from the high velocity motion of the working fluid. Other adverse effects due to high temperatures, typically about 720° C., include the high heat losses due to the blackbody radiation. Although the low to middle temperature types of Stirling engines (<450° C.) can alleviate some of these losses, the price to pay is a lower Carnot efficiency. There also remain numerous other drawbacks, deficiencies, and disadvantages associated with conventional Stirling engines. One disadvantage is the premature failure of the seal between the connecting rod, which exhibits complex translational and rotational motions, and the mechanical drive linkage, despite expensive seal designs. A further disadvantage is the mechanical coupling of all adjacent pistons that results in a fixed phase angle relationship, which prevents optimization of the engine.

[0011] Since a Stirling engine is a device based on an oscillatory and forced convection of the working fluid, parasitic losses of the engine are related to the frequency of the operation. The higher the frequency the worse are certain performance losses. For a fixed target power, the lower frequency engine may be preferable. Reduction of unnecessary dead space volumes that do not participate in power generation and overall operation is desirable in the design of an optimized Stirling engine.

[0012] One example of a Stirling engine is provided by U.S. Pat. No. 4,199,945 to Finkelstein, which describes a four cylinder, double acting engine in which the four cylinders are oriented at least partially horizontal with the four hot heat exchangers separated. For large engines of the design provided by Finkelstein, separation of the heat exchangers can be several meters apart and thus require four separate burner systems. Moreover, the horizontal configuration taught by Finkelstein places lateral loads on piston shaft bearings, rings and seals all reducing life of the engine. This condition is further aggravated when high power is desired as the size and weight of the piston can be significant. Finkelstein also describes an eight cylinder embodiment in FIG. 5, which is basically two four cylinder engines which are opposed to each other. In this case, he has linked the acting power piston of one engine to the displacement piston of the opposed, different, engine thereby achieving the necessary input. Problematically, the heat input on both ends has to be perfectly balanced for the engine to have an equal stroke length in both directions. Thus, the eight cylinder embodiment of Finkelstein would require the use of control system to balance the piston motion in both directions.

SUMMARY

[0013] The above-described and other drawbacks and deficiencies are overcome or alleviated by an external combustion engine comprising: a plurality of cavities; a compressible working fluid in fluid communication between each pair of adjacent cavities; and a plurality of hydraulic linkages in reciprocal phase communication between each pair of alternate cavities.

[0014] In an alternative embodiment an external combustion engine includes: a plurality of cavities; a compressible working fluid in fluid communication between each pair of adjacent cavities; and a plurality of articulated mechanical linkages in reciprocal phase communication between each pair of alternate cavities.

[0015] In another alternative embodiment an external combustion engine includes: at least four upright cavities disposed substantially equidistant from a central upright axis; a compressible working fluid in fluid communication between each pair of adjacent cavities; and at least one linkage in reciprocal phase communication between each pair of alternate cavities. The at least one linkage may comprise a hydraulic linkage. Alternatively, the at least one linkage may comprise an articulated mechanical linkage.

BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Referring now to the drawings wherein like elements are numbered alike in the several Figures:

[0017]
FIG. 1 is a schematic representation of a prior art Stirling engine;

[0018]
FIG. 2 is a schematic representation of a first exemplary embodiment Fluidic-Piston engine;

[0019]
FIG. 3 is a schematic representation of a second exemplary embodiment Fluidic-Piston engine;

[0020]
FIG. 4 is a schematic representation of a third exemplary embodiment Fluidic-Piston engine; and

[0021]
FIG. 5 is a schematic representation of a fourth exemplary embodiment Fluidic-Piston engine.

DESCRIPTION OF PREFERRED EMBODIMENTS

[0022] As shown in FIG. 1, a prior art double-acting multi-cylinder Stirling engine is indicated generally by the reference numeral 10. The engine 10 has one reciprocating element 12a-12d per cylinder 14a-14d, respectively, and is generally designed such that the compression space 16a-16d of each cylinder 14a-14d, respectively, is connected through an associated heat exchanger 18a-18d, respectively, to the expansion space 20a-20d in an adjacent cylinder 14a-14b, respectively, via associated passageways 22a-22d, 24a-24d. As used herein, the term heat exchanger shall include a cooler, a regenerator or a heater, or any combination thereof.

[0023] Compression space 16a of cylinder 14a is connected through regenerator 18a via passageways 22a and 24a to the expansion space 20b of the adjacent cylinder 14b. The three adjacent cylinders 14b-14d are similarly connected. Here, each piston 12a-12d has two functions: (1) to transmit the power to the output shafts 26a-26d, respectively; and (2) to cause fluid motion to and from the two sets of variable spaces 16a-16d, and 20a-20d. This configuration is known in the art as the Rider configuration. The connecting rods 28a-28d, which are coupled to the output shafts 26a-26d, respectively, are sealed from the environment, which tends to decrease the engine's efficiency as will be further described. Conventional Rider configuration Stirling engines depend on some mechanical linkage or crankshaft 30 to transmit power from the connecting rods 28a-28d. Such linkages include crankshafts, rhombic drives, swash plates and slider-cranks. Because the pistons 12a-12d are mechanically linked via the crankshaft 30, for example, the thermodynamic state of one cylinder may not be optimized relative to an adjacent cylinder.

[0024] Turning now to FIG. 2, an exemplary embodiment multi-cylinder engine is indicated generally by the reference numeral 100. Engine 100 is an external combustion engine that includes a plurality of rigid pistons 141a-141d disposed upright in a plurality of corresponding chambers, cavities or cylinders 140a-140d, respectively. The cylinders 140a-140d are formed in a cylinder block (not shown), which may include cylinder heads 146d or 146a-146cd that are also known as heater heads. As used herein, “cylinder block” shall include a single block or a multi-component structure, which, when coupled together, functions as the cylinder block of the engine 100. Each rigid piston 141a-141d is in contact along its bottom surface with a fixed mass of compressible working gasfluidic pistons 142a-142d, which in-turn are in contact with a fixed mass of compressible working gas in a compression space 143a-143d. The cylinders 140a-140d are physically arranged in a two-by-two matrix with each other such that each cylinder is vertically oriented and equidistant from each of two adjacent cylinders.

[0025] Each cylinder 140a-140d defines a compression space 143a-143d, respectively, defined by the volume below piston 141a-141d, respectively, and below each cold heat exchanger 150a-150d, respectively; and an expansion space 145d or 145a-145cd defined by the volume above each rigid piston 141a-141d, respectively, and above each regenerator 144d or 144a-144cd, respectively. The compression space 143a-143d of each cylinder 140a-140d, respectively, is thermodynamically coupled to a corresponding heat exchanger or regenerator 144a-144d, respectively, and connected to the expansion space 145a-145d, respectively, of an adjacent cylinder 140ba-140d or 140a, respectively, via associated passageways or tubes 147a-147d, respectively. For example, the compression space 143a of cylinder 140a is connected through passageways or tubes 148a to the regenerator 144a, and, in turn, through the tubes 147a to the expansion space 145a of the adjacent cylinder 140b.

[0026] The compression 143a-143d and expansion spaces 145d or 145a-145cd are occupied during the engine cycle by a substantially fixed mass of working fluid, such as, for example, air, hydrogen, helium, or other working fluids having suitable heat-transfer and thermodynamic properties for serving the functions of the working fluid described herein.

[0027] The exemplary engine 100 includes a second set of pistons 149a-149d, which are directly and rigidly connected to pistons 141a-141d, respectively, in an axial relationship. Pistons 149a-149d are connected to pistons 141a-141d, respectively, via shafts 142a-142d150a-150d, respectively, passing through shaft ports 151a-151d, respectively, which may be formed entirely within the cylinder block to effectively seal the shaft. The second set of pistons 149a-149d are housed within chambers or cylinders 152a-152d, respectively.

[0028] Each cylinder 152a-152d includes a volumetric space 153a-153d, for hydraulic fluid to ingress and egress during each stroke. For example, piston 141a in the expansion mode is rigidly connected to piston 149a, which, in turn, transfers part of the force to the hydraulic fluid 153a and part of the force of expansion through an articulated mechanical linkage 155a to piston 149c. Thus, the pistons 141a and 141c are maintained in an opposite phase relationship of 180 degrees. A second linkage (not shown) similarly transfers expansion forces between pistons 149b and 149d and thus maintains the pistons 141b and 141d in an opposite phase relationship.

[0029] Each cylinder 152a-152d includes a volumetric space 153a-153d, for hydraulic fluid to ingress and egress during each stroke. For example, piston 141a in the expansion mode is rigidly connected to piston 149a, which, in turn, transfers the force of expansion through an articulated mechanical linkage 155a to piston 149c. Thus, the pistons 141a and 141c are maintained in an opposite phase relationship of 180 degrees. A second linkage (not shown) similarly transfers expansion forces between pistons 149b and 149d and thus maintains the pistons 141b and 141d in an opposite phase relationship.

[0030] Although alternate pistons such as 141a and 141c are maintained in a phase relationship of 180 degrees, the phase relationship between adjacent pistons such as between pistons 141a and 141b is not fixed at 90 degrees, and is gas dynamically variable between about 0 to about 180 degrees during portions of an engine cycle. It shall be recognized that the instantaneous phase relationship between one pair of adjacent pistons is equal to the instantaneous phase relationship between the other pair of adjacent pistons. Thus, if piston 141a leads piston 141b by 135 degrees, for example, at a point in its expansion stroke; then piston 141c leads piston 141d by 135 degrees at an opposite point in its compression stroke. These phase differentials between adjacent pistons will tend towards 90 degrees or ¼ engine cycle at about a mid-point of the travel of each piston 141a-141d due to the balancing effect of the linkages 155a and 155b.

[0031] Unlike with crankshafts, the linkage 155a need not make a full rotation to guide the pistons 141a, 141c through a complete cycle. Thus, the stroke length and corresponding compression ratio for each piston 141a-141d is not fixed by the linkage 155a, but may automatically vary from a relatively small stroke up to the limits of travel of the pistons 141a-141d according to the thermodynamic conditions in the working fluid.

[0032] At the same time that piston 141a compresses and displaces the working fluid in the compression space 143a, piston 149c displaces the hydraulic fluid from the volume space 153c through valve 154c that controls the flow of hydraulic fluid into and out of the cylinder 152c. This hydraulic fluid can then be used to drive a conventional hydraulic motor (not shown) for production of rotational motion.

[0033] Each fluidic piston 142a-142d is substantially incompressible and at least partially disposed in the corresponding cylinder 144d or 144a-144c, respectively, which is formed in the cylinder block (not shown). Each fluidic piston 142a-142d also extends into the tube set 148a-148d, respectively, during a portion of each thermodynamic cycle, thereby displacing substantially all of the working fluid from the tube set 148a-148d into the corresponding heat-exchanger 144a-144d, respectively, when the corresponding rigid piston 141a-141d, respectively, is at the bottom of its travel.

[0034] Engine 100 may further include conventional features such as piston rings connected to the rigid pistons 141a-141d and/or 149a-149d, a cooling system coupled to the cylinder block and/or cylinder heads 146d or 146a-146c, and magnetic couplings coupled to the pistons 149a-149d for generating power. These items have not been shown in the drawings for the sake of clarity.

[0035] According to this exemplary multi-cylinder engine embodiment, since the non-adjacent pistons of opposite phase are linked to each other via the linkages 155a, the effect is that any piston in the power or expansion mode belonging to a given cylinder becomes, during a given half-cycle time, the complementing driving means for the compression or displacement mode of the oppositely disposed piston. Thus, as specifically shown in FIG. 1, pistons 141a and 141c are in the power and displacement mode, while pistons 141b and 141d temporarily not in motion until power piston 141a has nearly finished its stroke. The arrows on the pistons 141a-141d indicate the directional motion of each oppositely disposed piston at this particular phase in the engine cycle. Due to the inherent operational symmetry of the engine 100, the reversing of this process occurs during the second half-cycle time for the engine. As such, any pair of linked pistons belonging to two opposite phase cylinders will oscillate substantially in reciprocal register with one another.

[0036] Accordingly, the engine 100 provides a continuously gas dynamically variable inter-cylinder phase relationship as well as a dynamically variable stroke length and compression ratio, each of which are either actively controlled or inherently varied by the thermodynamic conditions in the working fluid to optimize the efficiency of the thermodynamic cycle.

[0037] Engine 100 incorporates the use of intermediate zone between the piston shaft seal 151a-151d, and the hydraulic piston 149a-149d. This area is a pressurized zone which functions as a collection port for leaking working gas and hydraulic fluid. Pressurizing this zone reduces the differential pressure thereby reducing frictional losses and leakage rates. Pressure control is provided by valves 157a-157d and can be dynamically controlled via a pressure sensor control loop. Recycled gas can be compressed and put back into the engine to maintain proper gas quantity.

[0038] Engine 100 is an external combustion engine that includes a plurality of rigid pistons 141a-141d disposed upright in a plurality of corresponding chambers, cavities or cylinders 140a-140d, respectively. The cylinders 140a-140d are formed in a cylinder block (not shown), which may include cylinder heads 146d or 146a-146c that are also known as heater heads. As used herein, “cylinder block” shall include a single block or a multi-component structure, which, when coupled together, functions as the cylinder block of the engine 100. Each rigid piston 141a-141d is in contact along its bottom surface with a corresponding substantially incompressible fluidic piston 142a-142d, respectively. The cylinders 140a-140d are physically arranged in a two-by-two matrix with each other such that each cylinder is vertically oriented and equidistant from each of two adjacent cylinders.

[0039] Although the fluidic pistons 142a-142d are preferably liquid, other relatively incompressible fluids, including gels, may be used. The material of the fluidic piston may be chosen from water, glycols (such as ethylene glycol, propylene glycol or other glycols), DOWTHERM®, aromatics, silicones, and similar substantially incompressible fluids for serving the function of the fluidic piston described herein. In general, the material of the fluidic piston will preferably exhibit substantial incompressibility relative to a working fluid, high boiling point, high breakdown temperature (including auto-ignition and/or dissociation temperatures), low density, low viscosity change under design conditions, low viscosity at lower temperatures, low vapor pressure and immiscibility with the chosen working fluid. Functions of the fluidic piston may include displacing a volume of working fluid, lubricating piston and engine seals, and preventing high-pressure gaseous working fluid from leaking between the internal passageways of the engine and an external environment by means of a gas to liquid barrier.

[0040] As may be recognized by those of ordinary skill in the pertinent art, the pistons 141a-141d and/or 149a-149d may be substituted with other displacement devices, such as, for example, rotors in a Wankel type rotary engine chamber, for fulfilling the functions of the pistons described herein without departing from the teachings of this disclosure.

[0041] As shown in FIG. 3, an alternate exemplary embodiment Fluidic-Piston engine is indicated generally by the reference numeral 200. Engine 200 is an external combustion engine similar to engine 100 of FIG. 2, and therefore like reference numerals preceded by the numeral “2” are used to indicate like elements having like functionality. Engine 200 includes a plurality of rigid pistons 241a-241d disposed in a plurality of corresponding cylinders 240a-240d, respectively. The cylinders 240a-240d are formed in a cylinder block (not shown), which may include cylinder heads 246d or 246a-246c. Each rigid piston 241a-241d is in contact along its bottom surface with a corresponding fluidic piston 242a-242d, respectively.

[0042] Each cylinder 240a-240d defines a compression space 243a-243d, respectively, defined by the volume above each fluidic piston 242a-242d, respectively, and below each regenerator 244a-244d, respectively; and an expansion space 245d or 245a-245c defined by the volume above each rigid piston 241a-241d, respectively, and above each regenerator 244d or 244a-244c, respectively. The compression space 243a-243d of each cylinder 240a-240d, respectively, is thermodynamically coupled to a corresponding heat exchanger or regenerator 244a-244d, respectively, and connected to the expansion space 245a-245d, respectively, of an adjacent cylinder 240b-240d or 240a, respectively, via associated passageways 247a-247d, respectively. For example, the compression space 243a of cylinder 240a is connected through passageways 248a to the regenerator 244a, and, in turn, through the passageways 247a to the expansion space 245a of the adjacent cylinder 240b.

[0043] The exemplary engine 200 includes a second set of pistons 249a-249d, which are directly connected to pistons 241a-241d, respectively, in an axial relationship. Pistons 249a-249d are connected to pistons 241a-241d, respectively, via shafts 250a-250d, respectively, passing through shaft ports 251a-251d, respectively, which may be formed entirely within the cylinder block to effectively seal the shaft. The second set of pistons 249a-249d are housed within cylinders 252a-252d, respectively. Each cylinder 252a-252d includes a volumetric space 253a-253d, for hydraulic fluid to ingress and egress during each stroke.

[0044] The compressive force is transferred to each piston 249a-249d by the expansive force applied to the oppositely phased piston 249c-249d and 249a-249b, respectively, acting on a hydraulic fluid circuit 255a-255d, respectively. Thus, the fixed phase relationship is maintained between oppositely phased cylinders 240a and 240c, as well as between 240b and 240d, while using a portion of the kinetic energy produced by the expansion cycle of one cylinder to produce the work required by the compression cycle of an oppositely phased cylinder 240c-240d or 240a-240b, respectively. Due to the inherent operational symmetry of the engine 200, the reversing of this process occurs during the second half-cycle time for the engine. Therefore, any pair of linked pistons belonging to two oppositely phased cylinders will oscillate substantially in reciprocal register with one another.

[0045] Turning now to FIG. 4, an alternate exemplary embodiment Fluidic-Piston engine is indicated generally by the reference numeral 300. The Fluidic-Piston engine 300 primarily differs from engine 200 in that the power valve 254 of FIG. 3 has been relocated from the expansion side of paired power piston 249 of FIG. 3 to the compression side of power piston 241 of FIG. 3. However, new reference numerals will be used for clarity.

[0046] Engine 300 includes a plurality of rigid pistons 361a-361d disposed in a plurality of corresponding cavities or cylinders 360a-360d, respectively. The cylinders 360a-360d are formed in a cylinder block (not shown), which may include cylinder heads 371a-371d. Each rigid piston 361a-361d is in contact along its bottom surface with an hydraulic fluid in a volumetric space 362a-362d. The volumetric spaces 362a-362d are open to hydraulic valves 363a-363d, respectively, for hydraulic fluid to ingress and egress by pumping action during each stroke. This pumped hydraulic fluid is used by a hydraulic motor (not shown) to generate rotary or other designed output motion.

[0047] Each cavity 360a-360d defines a compression space 366a-366d, respectively, defined by the volume above a fluidic piston 365a-365d, respectively, and below a regenerator 367b-367d or 367a, respectively; and an expansion space 368a-368d defined by the volume above each rigid piston 361a-361d, respectively, and above each regenerator 367a-367d, respectively. The compression space 366a-366d of each cavity 360a-360d, respectively, is thermodynamically coupled to the corresponding heat exchanger or regenerator 367a-367d, respectively, and open to the expansion space 368a-368d, respectively, of an adjacent cylinder 360d or 360a-360c, respectively, via associated passageways 370a-370d, respectively. For example, the compression space 366a of cavity 360a is open through passageways 370a to the regenerator 367a, and, in turn, to the expansion space 368a of the adjacent cylinder 360d.

[0048] The exemplary engine 300 includes a second set of pistons 364a-364d, which are directly rigidly connected to pistons 361a-361d, respectively, in an axial relationship. Pistons 364a-364d are connected to pistons 361a-361d, respectively, via shafts 373a-373d, respectively, passing through shaft ports 372a-372d, respectively, which may be formed entirely within the cylinder block to effectively seal the shaft. The second set of pistons 364a-364d is housed within cavities or cylinders 369a-369d, respectively. Each cylinder 369a-369d includes a volumetric space spanned by the fluidic piston 365a-365d, respectively, for the fluidic piston to ingress and egress therefrom during each stroke. The compressive force is transferred to each piston 365a-365d by the expansive force applied to the corresponding piston 364a-364d, respectively.

[0049] The compressive force is transferred to each piston 364a-364d by the expansive force applied by the corresponding piston 364c-364d or 364a-364b, respectively, acting through a hydraulic fluid circuit 375a-375b, respectively. Thus, the fixed phase relationship is maintained between oppositely phased pistons 361a-361d while using a portion of the kinetic energy produced by the expansion cycle of one cylinder to produce the work required by the compression cycle of an oppositely phased cylinder 360c-360d or 360a-360b, respectively. Due to the inherent operational symmetry of the engine 300, the reversing of this process occurs during the second half-cycle time for the engine. Therefore, any pair of linked pistons belonging to two oppositely phased cylinders will oscillate substantially in reciprocal register with one another.

[0050] Thus, in the engine 300, the piston 364a-364d is acted on by both the direct expansive force of 361a-361d in the expansion mode, and the hydraulic fluid from the hydraulic passageways 375a-375b resulting from the expansive force of pistons 361c-361d or 361a-361b, respectively.

[0051] This embodiment exhibits improved efficiency because the power output to the hydraulic motor is not first transferred to the coupled piston while incurring frictional losses as in engine 200, but is received directly from the compression side of piston 364a-364d while the lesser power required to compress the oppositely phased piston is transferred indirectly via hydraulic passageways 375a-375b, thereby incurring reduced frictional losses due to the reduced mass flow or power transfer. Alternate embodiments based on engine 300 may also utilize the articulated mechanical linkage 155a as described for engine 100.

[0052] As shown in FIG. 5, an alternate exemplary embodiment Fluidic-Piston engine is indicated generally by the reference numeral 400. Engine 400 is an external combustion engine similar to engine 100 of FIG. 2, and therefore like reference numerals preceded by the numeral “4” are used to indicate like elements having similar functionality. Engine 400 includes a rigid power piston 441 disposed in a first cylinder 440, and a rigid compression piston 464 disposed in a second cylinder 478. The cylinders 440, 478 are formed in a cylinder block (not shown), which is connected at its upper surface to a cylinder head 446. Alternatively, the cylinder head 446 may be formed as an integral part of the cylinder block (not shown). The rigid power piston 441 is connected at its lower end to the upper end of a first connecting rod 480, which, in turn, is connected at its lower end to a crankshaft 482. The crankshaft 482 is connected to the lower end of a second connection rod 484 having a fixed rotational phase delay of about 90 degrees relative to the first connection rod 480. The second connection rod 484 is connected at its upper end to the lower end of the rigid compression piston 464. The rigid compression piston 464 is adjacent at its upper surface to a fluidic piston 442.

[0053] The cylinder 478 defines a compression space 443 in the volume above the fluidic piston 442 and below a regenerator 444, which is located at the upper end of the cylinder 478 in this exemplary embodiment. The volume above the rigid piston 441 and above the regenerator 444 defines an expansion space 445. The expansion space includes the volumes within the elongated hot heat exchanger 447, which are open at their first ends to the portion of the expansion space immediately above the rigid power piston 441, and at their second ends to the upper end of the regenerator 444. The compression space 443 of the cylinder 478 is thermodynamically coupled to the regenerator 444 via a cold heat exchanger 448. The hot heat exchanger 447 includes three elongated tubes in this embodiment, although any number of shaped passageways may be used in alternate embodiments for fulfilling the functions of the hot heat exchanger described herein. The cold heat exchanger 448 includes five elongated tubes in this embodiment, although any number of shaped passageways may be used in alternate embodiments for fulfilling the functions of the cold heat exchanger described herein.

[0054] In operation, an external combustion heat source is applied to the hot heat exchanger 447 to cause heating of a substantially isochoric volume of working fluid as the power piston 441 travels from about the top of its travel down to about the mid-point of its travel while the fluidic piston travels from about the half-displacement point of its travel to the top of its travel. Next, substantially isothermal expansion of the working fluid takes place as the power piston 441 travels from about the mid-point of its travel to about the bottom of its travel while the fluidic piston 442 travels from about the top of its travel to about the half-displacement point of its travel. Following this expansion, substantially isochoric cooling of this volume of working fluid takes place as the power piston 441 travels from about the bottom of its travel to about the mid-point of its travel while the fluidic piston 442 travels from about the half-displacement point of its travel to about the bottom of its travel, thereby cooling a substantial portion of the working fluid by heat conduction and convection with the cold heat exchanger 448. Finally, substantially isothermal compression takes place as the power piston 441 travels from about the mid-point of its travel to about the top of its travel while the fluidic piston 442 travels from about the bottom of its travel to about the half-displacement point of its travel, thereby completing the cycle.

[0055] Thus, the fluidic piston 442 substantially increases the thermodynamic efficiency of practical embodiments of Fluidic-Piston Stirling engines by expelling the working fluid from the internal passages of the cold heat exchanger during the substantially isochoric heating phase of the cycle. In alternate embodiments, such as, for example, those utilizing fluidic pistons having very low thermal conductivity and density, the fluidic pistons may also displace working fluid from the regenerators. The fluidic piston 442 is maintained separate from the working fluid by means of gravity. Thus, the fluidic piston has a specific density greater than that of the working fluid, and the cylinder 478 is oriented vertically with the fluidic piston 442 disposed below the working fluid.

[0056] When the expanding working fluid forces the power piston 441 downwards, it causes the connecting rod 480 to apply positive work to the crankshaft 482. The crankshaft 482 has a finite rotational inertia resulting in storage of kinetic energy in the crankshaft 482. Once the power piston 411 reaches the bottom of its travel, it begins moving upward by means of an upward force applied by the crankshaft 482 through the connecting rod 480. At the same time, the fluidic piston begins moving downwards by means of a downward force applied by the high-pressure working fluid through the connecting rod 484 and the compression piston 464. Once, the compression piston 464 reaches the bottom of its travel, it begins to move upward by means of an upward force applied by the crankshaft 482 through the connecting rod 484. This combination of the upward motion of the power piston 441 and the downward motion of the fluidic piston 442 results in a substantially isochoric phase wherein the volume of the working fluid remains substantially constant while its temperature is reduced via thermodynamic transfer of heat to the regenerator 444 and the cold heat exchanger 448.

[0057] Although the fluidic piston is a compression piston in the above-described exemplary embodiment, it is contemplated that the fluidic piston may serve as an expansion piston in alternate embodiments. As may be recognized by those of ordinary skill in the pertinent art, other possible configurations of the fluidic piston 442 are contemplated as new fluids are encountered for serving the purposes of the working fluid and/or the fluidic piston. For example, a magnetorheological fluid may be used as the fluidic piston 442 in combination with a magnetic compression piston 464 in order to substantially eliminate the reliance on gravity to keep the fluidic piston intact as shown in this exemplary embodiment. Other fluids may also be substituted for the fluidic piston 442 that would generally exhibit substantial incompressibility, low viscosity, and low thermal conductivity in order to fulfill the functions of the exemplary fluidic piston described herein.

[0058] As may also be recognized by those of ordinary skill in the pertinent art, an alternate fluidic piston may be added directly above the power piston 441 along the geometrical or other minor modifications, if necessary, to prevent the alternate fluidic piston from substantially mixing with the working fluid and/or substantially entering the regenerator 444. However, the type of fluid used for the alternate piston would have more stringent thermal breakdown requirements than that of the fluidic piston 442 due to its direct contact with the hot heat exchanger 447 and the heated working fluidic therein.

[0059] A balancing of the overall engine torque for a four-cycle engine constrains the “optimal” minimum number of like cylinders to four. However, a lesser total number of cylinders is also realizable in alternate embodiment engines if the dynamic balancing requirement is relaxed, as is permissible for lower speed engines. In addition, although the exemplary engine 100 shows piston sets that are substantially identical, the coupling of two un-identical pistons (such as, for example, having different diameters and/or temperature ranges) that share a common linkage is possible and contemplated as part of this disclosure. In addition, those of ordinary skill in the pertinent art will recognize, based on the teachings herein, that an Ericsson type engine may be provided by incorporating associated pressure valves between the individual passageways 147a-147d and 148a-148d.

[0060] According to these exemplary embodiments of the Fluidic-Piston engine, the components of engines 100, 200, 300 and 400, such as the heat exchanges and regenerators, may be formed of a high temperature conductive material to increase the overall efficiency by allowing faster and more complete heat transfer to occur between the various critical components. A current example of such a high temperature conductive material is Inconel® or nickel-based alloy steel. In addition, the Fluidic-Piston engine operates at a relatively low frequency in order to reduce viscous losses and enhance the heat exchanger efficiency; typically from an upper frequency of about 50 Hz, with an upper frequency of about 35 Hz desired, and an upper frequency of about 20 Hz more desired; to a lower frequency of about 0.5 Hz, with a lower frequency of about 2.5 Hz desired, and a lower frequency of about 5 Hz more desired.

[0061] Thus, a Fluidic-Piston engine is configured for increased efficiency and useful life. The engine includes mechanically and/or hydraulically coupled piston pairs. A first set of pistons is disposed in a first set of cylinders and a second set of pistons is disposed in a second set of cylinders. A piston in the second set of pistons is mechanically and/or hydraulically connected to a piston in the first set of pistons in an opposing relation, thereby defining a pair of connected pistons. The pair of pistons is thus adapted to oscillate in reciprocal register with one another. Thus, a piston in an expansion mode drives an oppositely disposed piston in a displacement mode. Because adjacent pistons operate independently in that no direct mechanical or hydraulic coupling exists, adjacent pistons are driven based on substantially optimized operating parameters.

[0062] In the external combustion engine of the present invention, use of an articulated linkage instead of a rigid connection allows for a co-axial vertical orientation of the cylinders. That is, each cylinder in a single engine can be oriented vertically in a common direction. This orientation is preferred over the at least partially horizontal orientation of the prior art because the vertical orientation described herein reduces lateral loads on the piston components, such as shaft bearings, rings and seals, which increases engine life over that possible with engines of the prior art. Also, the vertically oriented configuration of the external combustion engine described herein allows the cylinders to be grouped together such that they use the same burner system, regardless of the size of the engine. For large engines of the prior art, separation of the heat exchangers can be several meters apart and thus require multiple burner systems.

[0063] In prior art external combustion engines having greater than four cylinders, multiple four cylinder engines are opposed to each other to provide power output. With this prior art design, the acting power piston of one engine is linked to the displacement piston of the opposed, different, engine thereby achieving the necessary input. Problematically, the heat input on both ends has to be balanced for the engine to have an equal stroke length in both directions, thus requiring the use of a control system to balance the piston motion in both directions. In the external combustion engine of the present invention, an articulated linkage links the power and displacement pistons of the same side thereby eliminating the need for any control device.

[0064] Other advantages of embodiments of the Fluidic-Piston engine described herein is the reduced leakage of working fluid at the engine seals due to the additional sealing provided by the liquid to gas barrier of the fluidic piston to working fluid interface. Another advantage of embodiments of the Fluidic-Piston engine is reduced packaging requirements due to the similar vertical orientation of all power pistons made possible by the provision of the non-rigid interconnections between cylinders. Yet another advantage of the Fluidic-Piston engine is increased engine efficiency due to the optimization of the instantaneous phase angle difference permissible between a power piston and an adjacent compression piston action on the same mass of working fluid. Another, more specific, advantage of the Fluidic-Piston engine is increased kinetic energy output of the engine due to substantially complete evacuation of the working fluid from the cold heat exchanger during the compression and heating phases of the engine cycle. Another more specific advantage of the Fluidic-Piston engine is reduced frictional losses and wear of the seals due to lubrication from the fluid.

[0065] While the invention has been described with reference to exemplary embodiments, it will be understood by those of ordinary skill in the pertinent art that various changes may be made and equivalents may be substituted for the elements thereof without departing from the scope of the disclosure. In addition, numerous modifications may be made to adapt the teachings of the disclosure to a particular object, material or situation without departing from the essential scope thereof. Therefore, it is intended that the Claims not be limited to the particular embodiments disclosed as the currently preferred best modes contemplated for carrying out the teachings herein, but that the Claims shall cover all embodiments falling within the true scope and spirit of the disclosure.

	Number	Date	Country
Parent	09847141	May 2001	US
Child	10420640	Apr 2003	US

Fluidic-piston engine

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