The present invention is in the field of internal combustion (IC) engines, and more particularly high efficiency IC engines.
In a conventional Otto cycle internal combustion (IC) engine, the gasoline fuel is injected into the intake manifold to mix with the air and is drawn into the cylinder through the intake valve during the intake stroke. The fuel flow is metered to produce fuel-air ratios that are very close to stoichiometric for all operating conditions. Conventional IC engines are limited in compression ratio by the requirement that the fuel must be burned at stoicheometric premixed fuel-air ratios with no detonation or pre-ignition, which limits the thermal efficiency that can be achieved with these engines. Diesel engines with direct fuel injection can operate at much higher compression ratios and leaner fuel-air ratios with higher efficiency. However, diesel engines use compression ignition of fuel that is not well mixed, resulting in a significant combustion delay time and reduced release of energy at the beginning of the power stroke, which results in reduced efficiency.
The present invention provides a cylinder for an IC engine having co-annular dual pistons, the cylinder including: i) a main cylinder including a main cylinder wall and a cylinder head, and having at least one exhaust port, an exhaust valve disposed in the exhaust port, and at least one inlet air port, and an inlet air valve disposed in the inlet air port; ii) an outer piston having an annular crown, an inner cylinder wall defining an inner cylinder, and an annular outer sidewall extending from the periphery of the crown, the outer piston configured for reciprocating movement within the main cylinder; iii) an inner piston having a crown, and an annular inner sidewall extending from the periphery of the crown, the inner piston configured for reciprocating movement within the inner cylinder; iv) a securement means for securing selectively the outer piston with the main cylinder; and v) an optional coupling means for engaging selectively the inner piston with the outer piston for cooperative reciprocating movement within the main cylinder.
The present invention further provides a method for operating an internal combustion (IC) engine, the method comprising repeating a four-stroke cylinder cycle, the cycle comprising the steps of: a) providing the cylinder provided herein above, b) drawing in a combustion air into the inner cylinder while driving the inner piston within the inner cylinder, from proximate top dead center to proximate bottom dead center; c) compressing the combustion air by driving the inner piston within the inner cylinder, from proximate bottom dead center to proximate top dead center; d) injecting a fuel into the compressed combustion air; e) igniting the fuel; f) powering, by combustion of the ignited fuel in the fuel-air mixture, the inner piston and the outer piston simultaneously within the main cylinder from proximate top dead center, to bottom dead center; and g) exhausting the combustion gases by driving the inner piston and the outer piston simultaneously within the main cylinder, from proximate bottom dead center to proximate top dead center.
The present invention further provides a method for operating an internal combustion (IC) engine, the method comprising repeating a cylinder cycle, the cycle comprising the steps of: a) providing the cylinder provided herein above, b) drawing in a fuel-combustion air mixture into the inner cylinder while driving the inner piston within the inner cylinder, from proximate top dead center to proximate bottom dead center; c) compressing the fuel-combustion air mixture by driving the inner piston within the inner cylinder, from proximate bottom dead center to proximate top dead center; d) igniting the compressed fuel-combustion air mixture; e) powering, by combustion of the ignited fuel of the fuel-air mixture, the inner piston and the outer piston simultaneously within the main cylinder from proximate top dead center, to bottom dead center; and f) exhausting the combustion gases by driving the inner piston and the outer piston simultaneously within the main cylinder, from proximate bottom dead center to proximate top dead center.
The present invention further provides a method for operating an internal combustion (IC) engine, the method comprising repeating a cylinder cycle, the cycle comprising the steps of: a) providing the cylinder provided herein above, b) drawing in a fuel-combustion air mixture through an opened inlet port and a closed exhaust port, into the inner cylinder by driving the inner piston within the inner cylinder, from proximate top dead center to proximate bottom dead center; c) compressing the fuel-combustion air mixture by driving the inner piston within the inner cylinder, from proximate bottom dead center to proximate top dead center, with a closed inlet port and a closed exhaust port; d) igniting the compressed fuel-combustion air mixture; e) powering, by combustion of the ignited fuel of the fuel-air mixture, the inner piston and the outer piston simultaneously within the main cylinder from proximate top dead center, to bottom dead center, with a closed inlet port and a closed exhaust port; and f) exhausting the combustion gases through an opened exhaust port, by driving the inner piston and the outer piston simultaneously within the main cylinder, from proximate bottom dead center to proximate top dead center.
The co-annular dual piston cylinder can be operated at conventional compression ratios with a significant power output, particularly when operated with high velocity inlet air swirl flow, a stratified charge fuel injector spray, and a high energy ignition source. The operation of the co-annular dual piston cylinder delivers large reductions in the heat energy that is normally lost to the cooling system, and in the energy normally lost in the engine exhaust system.
A cross-sectional view of the co-annular cylinder design is shown in
The cylinder head 12 has at least one exhaust port 4, an exhaust valve 6 disposed in the exhaust port for opening and closing fluid communication therethrough, and at least one inlet air port 2, and an inlet air valve 8 disposed in the inlet air port for opening and closing fluid communication therethrough. The cylinder head 12 includes an annular flange 13 that confronts and is secured sealingly to the annular flange 15 of the main cylinder 10, using bolts or similar fasteners.
The co-annular cylinder also includes an outer piston 20 that is configured for reciprocating movement within the main cylinder 10. The outer piston 20 includes an annular crown 22 , an inner cylindrical wall 24 extending axially from the inner rim of the crown 22 and defining an inner cylinder 25 having a volume, and an annular outer sidewall 26 extending axially from the outer periphery of the crown 22. The inner cylindrical wall 24 and the outer sidewall 26 are co-annular and co-axial. The flange 13 of the cylinder head 12 can extend radially inward of the cylinder wall 14, and can cover the area of the crown 22 of the outer piston 20. In another embodiments, a portion of the crown 22 of the outer piston 20 is uncovered by the flange 13, and is exposed to the air space within the cylinder head 12.
The co-annular cylinder also includes an inner piston 30 having a crown 32, and an annular inner sidewall 34 extending from the periphery of the piston crown 32, and configured for reciprocating movement within the inner cylinder 25.
The co-annular cylinder also includes a securement means for securing selectively the outer piston 20 to the main cylinder 10, with the upper portion of the outer piston 20 proximate the cylinder head 12, during a portion of the engine cycle. The engagement means prevents the outer piston 20 from reciprocal movement away from the cylinder head 12 when the inner piston 30 reciprocates between a top-dead position, shown in
A first embodiment of an engagement means includes a mechanical securement of the outer cylinder 10 to the outer piston 20.
An electrically powered and controlled solenoid 66 actuates the pin 62 between the first position and the second position. The solenoid can be dual-actuating, wherein the direction of the current flow through the solenoid is reversible, to drive the pin in both axial directions. The solenoid can also be single actuating, actuating and holding the pin in a single direction against the bias of a biasing means, which drives the pin in the opposite direction when actuating current is removed. The biased position is either the first or second position of the pin, and the biasing means can be a mechanical spring.
A second embodiment of an engagement means includes a magnet coupling, including a first magnetic member 52 disposed on the underside of the cylinder head 12, and a second magnetic member 54 disposed on the annular crown 22 of the outer piston 20. The first and second magnetic members have magnetically attractive forces when activated which assist to hold the outer piston 20 to the cylinder head 12. The magnetic members can be permanent magnets which exert attractive forces whenever the two magnetic members are in proximity. The magnetic members can also be selectively magnetic, and can include an electromagnetic coupling. Either one of the first or second magnetic members can be the magnetically active member, and the other is the magnetic-attracting member. In the illustrated embodiment, a plurality of the first magnetic members 52 are distributed annularly within the flange of the cylinder head 12, and a corresponding and registering plurality of the second magnetic members 54 are distributed annularly within the upper flange of the main cylinder head 10. Any number of the first and second magnetic members can be employed.
The co-annular cylinder also optionally includes a coupling means for engaging selectively the inner piston 30 with the outer piston 20 for cooperative reciprocating movement within the main cylinder 10. It is noted that the inner piston 30 is driven reciprocally by the crankshaft. In the configuration wherein the inner piston 30 and the inner cylinder 30 are both at top-dead center, against the cylinder head 12, and with the pin 62 out of engagement with the outer piston 20, the outer piston 20 is free to reciprocate within the main cylinder, and the coupling means engages the outer piston 20 for travel with the inner piston 30 from the top-dead position during the power stroke (as will be discussed below), as shown in
To assist in moving the outer piston 20 away from the cylinder head 12 at the start of the power stroke (the outer piston is disengaged from the main cylinder 10), pressurized gases within the cylinder head 12 exert a downward force upon the crown 22 of the outer piston 20. In an embodiment wherein the flange 13 covers substantially the area of the crown 22, air cavities can be provide communication between the interior of the cylinder head airspace and at least a portion of the area of the crown 22 of the outer piston 20.
The outer or main cylinder 10 and the cylinder head 12 are air-cooled. The inner piston 30 is a conventional IC engine piston that has a connecting rod 36 attached to the engine crankshaft 38. The outer piston 20 has an annular crown 22 of about the same crown area as that of the crown 32 of the inner piston 30, which provides a power stroke volume that is about double the compression stroke volume provided by the inner piston 30 alone. The increased volume through the power stroke results in full expansion of the combustion gasses, toward and almost down to atmospheric pressure. For the intake stroke of the inner piston 30, airflow inters the cylinder volume through an inlet port 2 in the cylinder head 12, arranged for tangential inflow entry, along an inlet centerline tangential to the axial centerline of the cylinder, to provide turbulent, high velocity swirl flow of combustion air. This swirling airflow is then compressed to a high compression ratio, at the top of the cylinder with only the inner piston 30, where a fuel injector 80 injects a fuel 82 in a spray pattern in the downstream direction of the swirling, compressed combustion air, and a closely-spaced high-energy spark plug 84 ignites the rich center part of the stratified-charge fuel spray. For the power stroke, the co-annular outer piston 20 is secured selectively to the inner piston 30. A large exhaust valve 6 in the cylinder head 12 is used to exhaust the burned combustion gases, with both of the pistons 20 and 30, through the cylinder 10 during the exhaust stroke.
The present invention provides a method for operating an internal combustion (IC) engine having full-expansion, co-annular, dual-piston cylinders, comprising repeating a four-stroke cylinder cycle that includes air intake, air compression, fuel injection, ignition, combustion, power and exhaust. The objective of the co-annular, dual piston cylinder is to operate with only the inner piston during the two strokes of air intake and air compression, and with both co-annular pistons during the two strokes of fuel combustion, power and exhaust
At this point, the engaging pin 62 remains within the bore 27 to secure the outer piston 20 to the outer housing 10. Fuel is then injected into the compressed combustion air as the crank angle continues moving toward top dead center, crank angle 360 degrees). Near top dead center, the engaging means is disengaged; as shown in
As the pistons progress past bottom dead center, the exhaust valve 6 is opened so that the spent combustion gases can be exhausted during the exhaust stroke (
In another aspect of the invention, the four-stroke cylinder cycle of the invention can include the steps of: drawing in a fuel-combustion air mixture into the inner cylinder while driving the inner piston within the inner cylinder, from proximate top dead center to proximate bottom dead center; compressing the fuel-combustion air mixture by driving the inner piston within the inner cylinder, from proximate bottom dead center to proximate top dead center, with the inlet and exhaust valves closed; igniting the compressed fuel-combustion air mixture; powering, by combustion of the ignited fuel of the fuel-air mixture, both the inner piston and the outer piston simultaneously within the main cylinder from proximate top dead center, to bottom dead center, to a pressure approaching atmospheric; and exhausting the combustion gases by driving the inner piston and the outer piston simultaneously within the main cylinder, from proximate bottom dead center to proximate top dead center.
In another aspect of the invention, the four-stroke cylinder cycle of the invention can include the steps of: drawing in a fuel-combustion air mixture through an opened inlet port and a closed exhaust port, into the inner cylinder by driving the inner piston within the inner cylinder, from proximate top dead center to proximate bottom dead center; compressing the fuel-combustion air mixture by driving the inner piston within the inner cylinder, from proximate bottom dead center to proximate top dead center, with a closed inlet port and a closed exhaust port; igniting the compressed fuel-combustion air mixture; powering, by combustion of the ignited fuel of the fuel-air mixture, the inner piston and the outer piston simultaneously within the main cylinder from proximate top dead center, to bottom dead center, with a closed inlet port and a closed exhaust port; and exhausting the combustion gases through an opened exhaust port, by driving the inner piston and the outer piston simultaneously within the main cylinder, from proximate bottom dead center to proximate top dead center.
Alternatively, the illustrated conventional poppet-type exhaust valve can be replaced with a sliding plate or rotary valve.
The present invention also provides a stratified fuel charge and rapid ignition with high velocity air swirl flow, which provides a very short combustion delay time with more energy released at the top of the stroke, resulting in high thermal efficiency. With no premixed fuel, there is no region in the cylinder where the high compression ratio can cause detonation or pre-ignition. Also, with stratified charge and high energy spark ignition, many different kinds of fuel can be used. U.S. Pat. No. 8,051,830 and U.S. Patent Application Publication 2012-0174881, the disclosures of which are incorporated by reference in their entireties, disclose a stratified fuel charge and combustion. With this combustion concept, the engine power output is controlled by the fuel flow. To reduce combustion temperatures, the fuel is burned at reduced fuel-air ratios at the design power output. With TBC coatings on the inside of the cylinder head and on the piston crowns, the reduced temperatures result in large reductions of heat losses from the cylinders, especially at low power cruise conditions. Also, NOx, HC and CO emissions are reduced, and there are no smoke or soot emissions with Diesel fuel. Nearly all of the available energy that is normally lost in the exhaust system is recovered with the full expansion concept, and with the engine power controlled by the fuel flow, airflow restrictions are eliminated and pressure losses in the air intake system are reduced. Thermodynamic cycle studies for this engine concept show that the fuel consumption will be reduced to about 55% of conventional IC engines with the same power output and the cost of this full expansion engine will be considerably less than for turbo-charged engines with exhaust driven power turbines that have the same efficiency.
This application claims the benefit of U.S. Provisional application 61/691,908, filed Aug. 8, 2012, the disclosure of which is incorporated by reference in its entirety.
Number | Date | Country | |
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61691908 | Aug 2012 | US |