Orbital engine

The present disclosure includes an engine having a torodial piston chamber, at least one piston positioned in the torodial piston chamber, and at least one engine valve positioned to interact with the torodial piston chamber.

BACKGROUND AND SUMMARY

This invention generally relates to internal combustion engines. More specifically the present invention relates to internal combustion engines having an orbital piston movement in which the pistons move in a toroidal path.

In an exemplary embodiment of the present disclosure, an engine is provided. The engine comprising: an engine block including a toroidal piston chamber, at least a first piston disposed for orbital rotation within the piston chamber, the first piston having a piston ring, and at least a first engine valve and a second engine valve. Each engine valve being rotatable to a first open position permitting the first piston to pass thereby and a second closed position wherein the first piston may not pass thereby. The first engine valve being positionable in a first opening of the toroidal piston chamber and the second engine valve being positionable in a second opening of the toroidal piston chamber. The engine further comprising at least one intake conduit for allowing a fuel mixture to be positioned within the piston chamber. The intake conduit being located between the first engine valve and the second engine valve. The engine further comprising at least one ignition member capable to ignite the fuel mixture resulting in the combustion of the fuel mixture and the creation of combustion gases and at least one exhaust conduit for allowing the combustion gases to exit the piston chamber. As a first piston passes by the first engine valve, the first engine valve moves to the second position forming an ignition chamber area within the piston chamber behind the first piston and between the first piston and the first engine valve. The piston ring of the first piston extending across the first opening of the toroidal piston chamber as the first piston passes by the first engine valve.

In another exemplary embodiment of the present disclosure, a method of operating an engine is provided. The method comprising the steps of providing an orbital engine having a plurality of pistons which orbit through a toroidal piston chamber and a plurality of engine valves which move between an open position and a closed position forming ignition chamber areas in the toroidal piston chamber and exhaust chamber areas in the toroidal piston chamber; controlling a plurality of injectors which provide fuel and air to the ignition chamber areas of the toroidal piston chamber; controlling a plurality of ignition members to ignite a fuel mixture in the toroidal piston chamber; and selecting between at least two operating modes.

In a further exemplary embodiment of the present disclosure, a method of forming a toroidal piston chamber for an engine is provided. The method comprising the steps of:

making the toroidal piston chamber having a first cross-sectional area smaller than a desired final cross sectional area of the toroidal piston chamber; and rotating a cutting tool through the toroidal piston chamber to achieve a second cross-sectional area generally equal to the desired final cross sectional area.

In yet another exemplary embodiment of the present disclosure, an engine is provided. The engine comprising: an engine block including a toroidal piston chamber; at least a first piston disposed for orbital rotation within the piston chamber; an output shaft coupled to the first piston through a connecting member; and at least a first seal positioned between the toroidal piston chamber and the output shaft and contacting the connecting member. The first seal including a biasing member. The engine further comprising at least a first engine valve and a second engine valve. Each engine valve being rotatable to a first open position permitting the first piston to pass thereby and a second closed position wherein the first piston may not pass thereby. The engine further comprising at least one intake conduit for allowing a fuel mixture to be positioned within the piston chamber. The intake conduit being located between the first engine valve and the second engine valve. The engine further comprising at least one ignition member capable to ignite the fuel mixture resulting in the combustion of the fuel mixture and the creation of combustion gases; and at least one exhaust conduit for allowing the combustion gases to exit the piston chamber. As a first piston passes by the first engine valve, the first engine valve moves to the second closed position forming an ignition chamber area within the piston chamber behind the first piston and between the first piston and the first engine valve.

In still another exemplary embodiment of the present disclosure, a method of operating an engine is provided. The method comprising the steps of providing an orbital engine having a first piston which orbit through a toroidal piston chamber and a first rotatable engine valve which moves between an open position wherein an opening of the first rotatable engine valve aligns with the toroidal piston chamber and a closed position wherein a tab of the first rotatable engine valve aligns with the toroidal piston chamber; aligning the opening of the first rotatable engine valve with the toroidal piston chamber; passing the first piston through the opening; and aligning the opening of the first rotatable engine valve with an air inlet to provide pressurized air to an area of toroidal piston chamber behind the first piston.

Features and advantages of the present invention will become apparent to those of ordinary skill in the relevant art when the following detailed description of the illustrated embodiments is read in conjunction with the appended drawings in which like reference numerals represent like components throughout the several views.

The drawings are proportional unless otherwise indicated.

DETAILED DESCRIPTION OF THE DRAWINGS

Referring now to the drawings,FIGS. 1-12show an illustrated embodiment of an orbital engine10of the present invention. The engine10includes first and second engine block assemblies12and14and a cover plate16. Illustratively, the blocks12and14and cover plate16are made from aluminum. Each block half12and14is illustratively a two-piece design. As best shown inFIGS. 5 and 6, block half12includes a first block18and a block insert20. Second block half14includes a second block22and a block insert24. Although the engine10illustratively includes an engine block formed in two halves12,14, more or fewer sections (halves, thirds, quarters, etc.) may be used depending on the methods of manufacturing or the manufacturer's desires. For example, for a smaller engine, two halves should be suitable, while for a larger engine, the engine block may need to be formed from many sections.

Block inserts20and24include notches34which are configured to be aligned with projections36formed on blocks18and22, respectively. The first and second blocks18and22cooperate to define a piston chamber26therebetween as best shown inFIG. 6. First and second blocks18and22illustratively include arcuate surfaces28A,28B, respectively, which cooperate to define the piston chamber26when the blocks18and22are coupled together as show inFIG. 6. In other words, block halves12,14are bolted together to form an engine block which defines a toroid shaped piston chamber26. Pistons46travel in a circular or orbital manner through and around piston chamber26.

Blocks18and22further include cooling channels30A,30B located adjacent the arcuate surfaces28A,28B, respectively, which define the piston chamber26as best shown inFIGS. 5,6, and12. Cooling channels30A,30B of blocks18and22, respectively, cooperate with cooling channels32A,32B formed in block inserts20and24, respectively. Cooling channels32A,32B are best shown inFIGS. 5,6and23. Cooling channels are therefore defined on opposite sides of the piston chamber26by channels30A and32A and channels30B and32B, respectively. Liquid or air is circulated in the cooling channels to cool engine10.

Engine10can be air-cooled, dissipative-cooled, or liquid-cooled. Various known and conventional cooling systems (not shown) can be applied to engine10by those of ordinary skill in the art without undue experimentation. An exemplary dissipative-cooled system can comprise heat sinks or vanes to pull heat from the various components of engine10. An exemplary liquid-cooled system can comprise liquid circulatory pipes or ducts much like the liquid cooling systems of conventional internal combustion engines.

An exemplary air-cooled system can comprise directional vanes for directing cooling air towards the various components of engine10. An example is shown inFIG. 19Afor the engine200shown inFIG. 13. Referring toFIG. 19Aan impellar fan380is coupled to engine200. Impellar fan380is connected to one of connecting disc334or output shaft121through a gear system381. Gear system381connects impellar fan380to one of connecting disc334and output shaft121and multiples the rotation rate of the one of connecting disc334and output shaft121such that impellar fan380has a higher rate of rotation. In one embodiment, a ring gear is supported by output shaft121. Impellar fan380rotates with connecting disc334and directs air382toward and into fluid conduits384in block member233. In one embodiment, the air pressure in conduits384is about 30 pound per square inch (psi). In one embodiment, a check valve is provided in fluid conduits384to permit the flow of fluid into piston chamber206, but not out of piston chamber206. The embodiment shown inFIG. 19Amay be used in any size engine, but may be well suited for small applications wherein a liquid coolant is not practical, such as a weed eater.

In one embodiment, the number of pistons208is increased. A first subset of the pistons208operates as discussed herein to rotate connecting disc334and expel exhaust gas. A second subset of the pistons208operates to compress a charge of air introduced into the piston chamber206or a second piston chamber. The compressed air is then recycled back to be used by one of the pistons208in the first subset for combustion. In one embodiment, the compressed air is passed through a chamber outside of piston chamber206and reintroduced into piston chamber206. In one embodiment, the compressed air is compressed in a second separate piston chamber (the second set of pistons are carried by a separate connecting disc) and initially introduced into piston chamber206to be combusted by one of the first subset of pistons208.

Returning to engine10, block cover16illustratively covers a belt drive system38best shown inFIGS. 9 and 10and discussed in more detail below. Cover16also provides a solid foundation for another engine module10to be mounted in an embodiment in which multiple engine modules10are stacked together as discussed in detail in U.S. patent application Ser. No. 11/451,120, filed Jun. 12, 2006 and U.S. Pat. No. 7,059,294, the disclosures of which are expressly incorporated herein by reference. The multiple engine modules10may be connected serially to a common crankshaft or output shaft121to create a single engine with more power. Any desired number of engine units10may be connected together to create engines of more or less power.

A connecting disc40for coupling pistons46to an output shaft121is made from anodized aluminum. Disc40includes a plate42having mounting portions44for a plurality of pistons46. Connecting disc40further includes a center mounting portion48for connecting to an output shaft121to transmit power from the engine10to another device. Connecting disc flanges50are coupled to opposite sides of connecting disc40. Illustratively, flanges50are steel parts made by Grob, Inc. Flanges50have internal splines which match up with the output shaft121that extends through the center of the engine10and outward axially. The flanges50are illustratively bolted to the connecting disc40. As shown inFIG. 5, two identical flanges50are coupled to opposite sides of the disc40. Flanges50extend into central bearing portions52A and52B of blocks18and22, respectively. The output shaft121is illustratively a steel shaft which connects the disc40and flanges50to an external device.

The blocks18and20also include housing portions60A and60B which define housings for receiving four identical chambering discs or valves62. The chambering valves62are illustratively formed from a steel plate. In one embodiment, the chambering valves are made of magnesium. A steel bushing64is illustratively mounted to one side of each chambering valve62to provide more contact area for a splined shaft66which extends through the chambering valve62. It is understood that components62,64and66may be made as one piece, if desired. The chambering valves62each have notches or openings68and70formed on opposite sides to permit the pistons46to pass through the valves62. It is understood that a single opening may be provided in chambering valves62, if desired.

Chambering valves62are mechanically connected to the output shaft121by the belt drive assembly38or an equivalent mechanism such that the chambering valves62rotate in a coordinated manner with output shaft121as discussed below. Those of ordinary skill in the art may design the appropriate mechanical and gearing linkages, or other types of linkages, between the output shaft121and chambering valves62such that notches68,70rotate through piston chamber26as a piston46approaches and passes by chambering valve62within piston chamber26.

The pistons46are illustratively coupled to mounting flanges44of connecting disc42by two roll pins. Pistons46are illustratively formed from aluminum. Piston46illustratively includes two faces which are mounted to a piston body with roll pins. The piston ring assemblies is made from a carbon/graphite composite material and has three ring contact areas. The center contact area is located radially outward further since it has an arch further from the inside edge of the piston. Details of the pistons46are best shown inFIG. 11. The piston ring assembly45maintains at least two contact areas47(illustratively three contact areas separated by lower regions49) in contact with the surface of the piston chamber as the piston46rotates over a gap in the piston chamber corresponding to the location of the chambering valve.

The illustrated embodiment includes four pistons46and four chambering valves62. It is understood that in an alternative embodiment, multiple chambering valves62may be provided per piston46. In another alternative embodiment, multiple pistons46may be provided per chambering valve62. Further, in a multiple module configuration, each module can have one or more pistons46and one or more chambering valves62, as long as the piston locations are staggered to create a balanced force. Likewise, depending on size, weight and other factors, a single piston46, single chambering valve62engine may be used.

Seals are provided to seal the connecting disc42to the first and second blocks18and22. A first seal located between the connecting disc42and block18is illustratively a carbon/graphite seal. This seal helps keep the connecting disc42straight as well as provide a secondary sealing area for any outer seal blow by. A second seal located between the connecting disc42and block22is illustratively a large carbon/graphite seal. This seal has two sealing contact rings and has notches to receive the chambering disc seal. There are two chambering carbon/graphite seals per chambering disc42. Seals have a center hole for bearing and seal locations. Additionally there is a hole with a slot that allows the piston to pass through.

Blocks18and22are each formed to include first and second coolant openings80and82. Illustratively, four such openings80,82are provided on each block18,22. Block inserts20and24also each include four sets of coolant openings84and86aligned with coolant openings80and82and blocks18and22, respectively. In other illustrated embodiments, fewer coolant openings may be provided to circulate coolant within the engine10. Coolant is illustratively circulated using conventional pumps and cooled using conventional radiators or other heat transfer mechanisms.

As shown inFIG. 3, the chambering valves62are located in slots90A formed in housings60A of block18. Valve drive shafts92extend generally perpendicularly to shafts66of chambering valves62. Valve drive shafts92have a gear portion94. Gear portion94is preferably a bevel gear which meshes with a bevel gear65on shaft66. Drive shafts92illustratively extend through apertures96formed in second block22as best shown inFIG. 2.

A belt drive system38best shown inFIGS. 9 and 10is used to rotate the shafts92which in turn rotate the chambering valves62within the housings60A and60B. As shown inFIGS. 9 and 10, gears98are coupled to each of the shafts92. A central gear100is located on the main output shaft121. An idler wheel102is also provided. A drive belt105having a plurality of teeth engages gears98,102. Location of idler wheel102is adjustable by a plate104having a first end pivotably coupled to the block insert24by fastener106. As opposite of end plate104includes a slot108which receives a fastener109. Therefore, the plate104may be pivoted about fastener106to adjust the tension of belt105using idler wheel102. Cover16is located over the belt drive system38. It is understood that any suitable gear drive or belt drive system may be used to rotate the chambering disc62as long the system provides accurate and reliable timing.

Various components are provided with locating pin holes. This makes initial timing of the connecting disc40with the chambering valves62easier and more accurate. It is understood that housings60A,60B including the seals, gearing, and the like may be separate pieces bolted on to the remainder of the blocks18,22. Such separate pieces may facilitate assembly and repair of the engine10.

FIG. 8illustrates an air injector110coupled to an inlet port formed in the second block22. A spark plug112and a fuel injector114are coupled to respective ports formed in first block18. Air injector110, spark plug112and fuel injector114are in communication with the piston chamber26. It is understood that the positions of the fuel injector114and air injector110can be reversed. In an illustrated embodiment, a direct fuel injector is used to inject fuel and a standard fuel injector is used to inject air. In addition, a single injector for fuel and air may be used to deliver an air/fuel mixture directly into the piston chamber26.

An air injector110, spark plug112and fuel injector114set is provided adjacent each chambering valve. Therefore, in the illustrated embodiment, four such sets are provided.

The air/fuel mixture is illustratively injected into ignition chamber area of the piston chamber26by air injector110and fuel injector114. The air/fuel injection system is timed or connected with the rotation of the output shaft121and/or chambering valves62by mechanical, electrical, electronic, or optical means, or the equivalent.

Block18is formed to include exhaust ports116adjacent each chambering valve62as shown inFIGS. 1-3and8. Exhaust gases emitted from exhaust ports116is preferably directed through an exhaust system (not shown) to the atmosphere or to an exhaust remediation system. Conventional exhaust components such as catalytic converters and mufflers can be incorporated as desired or necessary.

The volume of the piston chamber26located between a closed chambering valve62and a rear side of a piston46is illustratively an ignition chamber area, which incorporates the intake ports111,115,113of injectors110,114and the spark plug112, respectively. At the moment (or slightly after) the chambering valves62rotate to close off piston chamber26, the spark plug112causes the air/fuel injected into piston chamber26by injectors110,114to explode (burn) in ignition chamber area causing a rapid expansion of the combustion gases, as in conventional internal combustion engines, imparting power to pistons46. This forces pistons46to continue traveling in the same direction of rotation, which in turn is transmitted via connecting disc40to the output shaft121. Chambering valves62still are closing off piston chamber26during this step.

As the pistons46continue their powered travel through piston chamber26, exhaust gases from a preceding combustion ahead of them are forced from the piston chamber out of exhaust ports116. Chambering valves62still are closing off piston chamber26during this step. The volume of the piston chamber26located between the closed chambering valve62and the front side of a piston46is illustratively an exhaustion chamber area, which incorporates an exhaust port116. As pistons46move closer to chambering valves62(that is, each piston46is moving closer to the next sequential chambering valve62), a notch68or70of chambering valve62rotates into piston chamber26allowing pistons46to pass through notch68or70.

During assembly of the connecting disc40assembly, the connecting disc flanges50are mounted to the connecting disc plate42with six screws. Next, the piston bodies are mounted to the connecting disc mounting tabs44with two roll pins each. One piston face is mounted to the piston body, or alternatively, it can be mounted just prior to mounting the body to the connecting disc. A piston ring seal is then positioned onto the piston body. The opposite piston face is then installed.

The chambering valve assembly is illustratively constructed as follows: Start by installing the bevel gears onto the horizontal and vertical splined shafts66,92with roll pins. Press a small bearing onto the horizontal shaft end, and medium bearings onto the vertical shaft, separated with a spacer. Press the vertical shaft assembly into the block. Press oil seal into chambering valve seal nearest the small bearing. Insert the bevel gear on the horizontal shaft into the oil seal. Slide the chambering valve62into place, with the flange away from the miter gear. Put the opposite chambering disc seal on and then press a medium bearing onto the end of the horizontal splined shaft.

Engine block assembly is illustratively constructed as follows: Press the large bearings into the block and block insert locations. Install the connecting disc seals into the block22. Next, take the chambering valve assemblies and slide them onto the connecting disc at the same time. Then lower the entire rotating assembly into the block22, ensuring the center shaft presses into the large (flange) bearing. Once the block22is ready, stand it on an edge, along with the block18. Install the block seals into the block18, being careful to not let them fall out. Slide the two block halves18,22together. Bolt the two halves together. Install the spark plugs112and injectors110,114.

An Electromotive TEC3r programmable fuel injector and ignition control module111is illustratively used to control injectors110,114and spark plugs112. The module111independently controls both the fuel and air injectors114,110, as well as the spark plugs112.

The engine may be operated in multiple modes depending on required power. In a High power mode, all pistons are fired simultaneously at each chamber location. The illustrated embodiment has four pistons46and four chamber areas. Therefore, in this illustrated embodiment, there are up to sixteen ignitions per revolution of the connecting disc40.

In a Moderate power mode all pistons are illustratively fired at every other piston chamber location. In a Light power mode, alternate pistons46are illustratively fired at alternate piston chamber locations. In an Idle mode, two pistons46are illustratively fired every other revolution.

It is understood that there are many variations of power output combinations. When a piston does not fire at every chamber location, it could skip any number of chambers. For example, in an illustrated embodiment, a piston46may be fired at 90°, 180°, 270°, 360°, 450°, etc. The fuel and air injectors114,110may have the possibility of firing multiple times per combustion cycle. For example, if there is more time/piston travel available, a second dose of fuel air could be injected as the initial combustion is diminishing to revitalize the combustion.

For production, a cutting tool that fits where the piston46is located is preferred. This cutter is coupled to a drive mechanism; either mechanical or hydraulic that rotates cutting tips where the piston rings would be located. Then, during casting of the engine block or machining of the engine block, the piston chamber is slightly smaller in diameter than desired. The engine would be assembled with the cutting/finishing ‘pistons’. These cutting/finishing ‘pistons’ would complete the final boring/honing of the ‘cylinder’ area of the piston chamber. In one embodiment, a power source includes a connection to the cutting tools of cutting/finishing ‘pistons’ through a bore in the connecting disc. Once the final boring is completed. The block members would be disassembled and cleaned. The block members would then be assembled again along with working pistons46positioned in the piston chamber.

This engine10has increased horsepower and torque. The torque increase is a result of a longer torque arm. This engine can turn at higher revolutions per minute without detrimental changes of direction of the pistons, and therefore is less self-destructing. There is no reciprocating mass and the valve train is not restricted by the revolutions per minute of the engine. This engine also has a decreased level of complexity when compared to current engines, has fewer moving parts, and easier maintenance. This engine further has less internal friction and, as a result, can utilize needle, roller, or ball bearings rather than plain bearings found in conventional engines.

This engine has a higher power to weight ratio, meaning it can be smaller and have a decreased weight for the amount of power generated. The structure of this engine can be less rigid and use less material. As a result, this engine can be scaled up or down in size for use in a variety of devices, from small-sized gardening equipment such as weed trimmers and lawn mowers, to medium-sized engines such as motorcycle engines and electrical generators, to large-size automotive engines, to even larger-sized locomotive, ship, and power plant engines.

Further, this engine is modular in design in that several engine units can be stacked together to create a multi-unit design, analogous to multi-cylinder conventional engines. This modular design makes it easier to add performance by simply adding additional units, decreases the cost of manufacturing as each unit can be identical, and makes it easier maintain as individual units can be replaced upon malfunction.

Referring toFIGS. 13-31, another exemplary embodiment of an orbital engine200is shown. Engine200may operate in the same manner as engine10and/or as disclosed in U.S. patent application Ser. No. 11/451,120, filed Jun. 12, 2006 and U.S. Pat. No. 7,059,294, the disclosures of which are expressly incorporated herein by reference.

Engine200includes an first block assembly202and a second block assembly204. As described herein first block assembly202and second block assembly204cooperate to define a piston chamber206(seeFIG. 19) through which a plurality of pistons208(seeFIG. 19) move. Engine200further includes a plurality of modular engine valve assemblies210. Each of the modular engine valve assemblies210support an engine valve212(seeFIG. 16) which cooperates with piston chamber206and plurality of pistons208to form one or more ignition chamber areas and exhaust chambers. Illustratively, four modular engine valve assemblies210are shown. In one embodiment of engine200, at least one engine valve212are provided for one or more of plurality of pistons208. In one embodiment of engine200, at least one plurality of pistons208are provided for one or more of engine valve212. In one embodiment, an equal number of pistons208and engine valves212are provided. In one embodiment, a greater number of pistons208are provided than engine valves212. In one embodiment, a greater number of engine valves212are provided than pistons208.

Modular engine valve assemblies210each support a fuel injector216and an ignition member218. The modular engine valve assemblies210and one or both of first block assembly202and second block assembly204cooperate to bring fuel injector216and ignition member218into communication with piston chamber206. One of first block assembly202and second block assembly204includes an air inlet220(block member232of block assembly202) through which pressurized air is introduced into piston chamber206. One of first block assembly202and second block assembly204includes an exhaust outlet222(illustratively block member233of block assembly204) through which exhaust gases are removed from piston chamber206. Although various components of first block assembly202, second block assembly204, and the plurality of modular engine valve assemblies210are shown including fuel injector216, ignition member218, air inlet220, and exhaust outlet222, any arrangement is permissible as long as fuel and air are provided between plurality of pistons208and valves212to be combusted.

In one embodiment, first block assembly202and second block assembly204are each divided into four quadrants. In this embodiment, the engine valve assemblies210are formed integral with the first block assembly202and the second block assembly204, such as engine10.

First block assembly202includes a first block member230and a second block member232. Second block member232includes a surface234(seeFIG. 19) which forms a portion of piston chamber206. Surface234is a generally semicircular shape and forms a toroidal recess about a longitudinal axis236of engine200. Block member233includes a surface305(seeFIG. 19) which also forms a portion of piston chamber206. Surface305is a generally semicircular shape and forms a toroidal recess about a longitudinal axis236of engine200. Pistons208rotate through piston chamber206.

First block member230further includes a plurality of recesses238. Second block member232also includes a plurality of recesses240. Recesses238and recesses240cooperate to form cooling channels242through which a fluid is passed to remove heat from piston chamber206. Exemplary fluids include air and liquid. First block member230includes a fluid inlet244(seeFIG. 13) and a fluid outlet246(seeFIG. 13) through which a cooling fluid is introduced to cooling channels242and is removed from cooling channels242, respectively.

Referring toFIG. 23A, four instances of plurality of recesses238are shown. A corresponding number of plurality of recesses240are provided in second block member232. A corresponding seal249is provided for each pair of plurality of recesses238and plurality of recesses240. Seal249is illustratively an o-ring. Seals249are received in grooves307in respective block members230and235(illustrated for block member230inFIG. 29and shown inFIG. 19).

Referring toFIG. 16, one of the modular engine valve assemblies210is shown. Plurality of modular engine valve assemblies210includes a first base member250and a second base member252. First base member250includes a recess251for receiving engine valve212. First base member250further includes a first bore254sized to receive an engine valve support assembly256and a second bore258sized to receive a valve to drive system coupling assembly260.

Engine valve support assembly256includes a first bearing262, a first gear264, a seal266, engine valve212, a bushing268, a shaft270, a second bearing272, and a plurality of couplers274. Bushing268is coupled to engine valve212through plurality of couplers274. Bushing268is coupled to shaft270so that engine valve212rotates with shaft270. In one embodiment, bushing268and shaft270have interlocking spline features. In one embodiment, shaft270and valve212are a single component. Seal266is positioned adjacent engine valve212on the opposite side of bushing268. First gear264is positioned adjacent seal266and is supported by shaft270. First gear264is coupled to shaft270so that shaft270rotates with first gear264. First bearing262and second bearing272support opposite ends of shaft270.

Referring toFIG. 17, first bearing262s received adjacent surface276of first bore254and second bearing272is received adjacent a surface278of a bore277in second base member252when first base member250and second base member252are assembled together through couplers253.

Referring back toFIG. 16, drive system coupling assembly260includes a second gear280, a first bearing282, a second bearing284, a retainer286, a shaft288, and a drive gear290. Second gear280is coupled to shaft288so that second gear280rotates with shaft288. Drive gear290is coupled to shaft288so that gear290rotates with shaft288. First bearing282and second bearing support opposite ends of shaft288.

Referring toFIG. 17, first bearing282is received adjacent surface294of second bore258and second bearing272is received adjacent a surface296of second bore258. Second gear280is received in region292of second bore258. Second gear280includes teeth which first gear264. Second gear280is maintained in engagement with first gear264by retaining shaft288in second bore258through retainer286. Retainer286is received in a groove298of second bore258.

A rotation of drive gear290is transferred to second gear280through shaft288. Second gear280transfers the rotation to first gear264. The rotation of first gear264is transferred to engine valve212through shaft270. Drive gear290is coupled to an output shaft121positioned along longitudinal axis236. In one embodiment, drive system38ofFIG. 9is used to couple drive gear290to the main output shaft121. The drive system38is mounted to a surface297of block member230.

Surface297of block member230may serve as a mounting location for drive system38, a mounting location for another instance of engine200, or the mounting of an accessory drive. Exemplary accessory drives include power steering system, an alternator, a fuel pump, and an air conditioner system.

Each of the modular valve assemblies210is assembled to upper block assembly202and lower block assembly204through couplers299. As shown inFIGS. 20A and 22A, respective slots300and302of second block member232and block member233are angled at an angle303relative to a radial normal304of piston chamber206. Pistons208travel in direction207through piston chamber206. In one embodiment, slots300and302are angled at about 12 degrees from radial normal304. By angling slots300and302individual piston rings318,320, and322may be used in place of the single piston rib of engine10. The angling makes sure that each of piston rings318,320, and322are not aligned with slots300and302. In one embodiment, an angling of slots300and302of from about 5 degrees up to about 12 degrees is used. In one embodiment, an angling of slots300and302of from about 12 degrees up to about 30 degrees. In one embodiment, angle303is 12.5 degrees. In one embodiment, angle303is selected such that at least half of the piston ring remains in contact with wall of piston chamber206as the piston passes by slots300and302. Further, the smaller the angle303is the more uniform the air pressure is on valve212. In one embodiment, piston rings318,320, and322are made from carbon graphite, the block is anodized with a TEFLON brand coating, and the valves212are made of magnesium.

Referring toFIGS. 20B and 22B, another embodiment is shown wherein slots300and302are angled the other direction about the respective radial normals. Corresponding changes in the shape of members250and252and block assemblies202and204should be made. Pistons208still travel in the same direction207.

In one embodiment, slots300and302are angled about radial normal304either alone or in combination with angling relative to radial normal304. In one embodiment, slots300and302are generally aligned with radial normal304and piston rings318,320, and322are angled relative to radial normal304. The angling of piston rings318,320, and322may be any of the ranges provided above for slots300and302. In one embodiment, both slots300and302and piston rings318,320, and322are angled in opposite directions relative to radial normal304.

Referring toFIGS. 24A and 25B, piston208includes a piston base member308, a first piston face310, and a second piston face312. Each of first piston face310and second piston face312have recesses which are received on protrusions314and316, respectively, and are secured thereto with roll pins. Each of piston base member308, first piston face310, and second piston face312include a circumferential slot324,326, and328, respectively, which receives a respective one of piston rings318,320, and322. In one embodiment, piston base308, piston face310, and piston face312are combined into a single integral component.

In one embodiment, the end of piston face310and the end of piston face312are parallel to a radial normal line304of engine200as shown inFIG. 26. In one embodiment, the end of piston face310and piston face312is other than parallel to a radial normal line304of engine200.

Referring toFIG. 25, piston base member308includes a recess330which receives a tab332(seeFIG. 23B) on connecting disc334. Piston base member308is coupled to tab332through a pair of roll pins received in apertures336. In one embodiment, shown inFIG. 27, a removable tab338is coupled to connecting disc334. Removable tab338is received in an opening340of connecting disc334. Tab338may be secured to connecting disc334by fasteners, shear pins, interlocking members, or any other suitable means.

In one embodiment, tab338breaks away from connecting disc334if engine200malfunctions and piston assembly208runs into valve212. By permitting tab338to break away, connecting disc334is able to continue to spin with the main output shaft121. This permits in a multi-module engine (having multiple instances of engine200mounted to a common output shaft121) for the engine to continue to operate even if one of the modules has malfunctioned. The malfunctioning module would simply have a connecting disc334spinning with less than all of its pistons operating.

Referring toFIG. 19, piston chamber206is sealed along an outer edge through the contact of block members232and233. Piston chamber206along an inner edge includes a gap through which connecting disc334extends. Piston chamber206may be sealed along this inner edge relative to connecting disc334in multiple ways. As shown inFIG. 19, two instances of a first seal352are received in corresponding recesses353of block members232and233, respectively. Each of seals352include multiple contact areas which contact connecting disc334. Illustratively, each of seals352includes two contact areas which contact connecting disc334. Seals352each include openings358which receive fasteners to secure seals352to the respective block members232and233.

Two instances of a second seal354in the same manner are received in corresponding recesses355of block members232and233, respectively. Second seal354operates as a secondary seal. Each of seals354include multiple contact areas which contact connecting disc334. Illustratively, each of seals354includes two contact areas which contact connecting disc334. Seals354each include openings360which receive fasteners to secure seals354to the respective block members232and233. In one embodiment, connecting disc334carries one or both of the two instances of seals352and354such that the seals rotate with connecting disc334.

By having spaced apart seals352and354the vibration of connecting disc334may be reduced. Further, the spaced apart seals352and354keep the connecting disc334flat and centered.

Referring toFIG. 30, a seal360is shown. Seal360is shown replacing seal352in recess353. Seal360may also or in the alternative replace seal354. Seal360is able to accommodate different spacings between connecting disc334and block members232and233. This reduces the tolerance needed when machining block members232and233, such as a depth of recess353. Seal360is expandable to ensure contact with both recess353and connecting disc334.

Seal360includes a first seal member362and a second seal member364. Seal member362includes a plurality of contact areas366which contact connecting disc334. Illustratively three contact areas366are shown. Seal360further includes a downwardly extending leg portion368. Leg portion368contacts second seal member364. The spacing between a surface370of first seal member362and a surface372of second seal member364is biased by a biasing member374. In one embodiment, biasing member374is a spring. In one embodiment, biasing member374is a wave spring. Exemplary wave springs include Model No. CRR-0950-0.156 available from Smalley Steel Rings located at 555 Oakwood Road, Lake Zurich, Ill. 60047. Biasing member374maintains contact areas366of first seal member362in contact with connecting disc334. This automatically adjusts seal360to account for machining irregularities and to make up for any wear.

Air from piston chamber206is blocked by seal360. In order to pass between connecting disc334and seal360, the air has to pass between each of the three contact areas366and connecting disc334. Alternatively, the air has to travel down a wall of recess353and pass between first seal member362and second seal member364. Seal360functions to prevent the flow of air in either direction resulting in more pressure being used to urge piston208further along its orbit about piston chamber206. Seals352and354also function to prevent the flow of air in either direction resulting in more pressure being used to urge piston208further along its orbit about piston chamber206.

Referring toFIG. 31, a knife edge seal375is formed between block member233and connecting disc334. Knife edge seal375, in one embodiment, is located between recess353and piston chamber206. Knife edge seal375includes a plurality of protrusions376which reduce the gap between block member233and connecting disc334. This in effect increases the resistance of travel of air from piston chamber206between connecting disc334and block member233. Knife edge seal375may be used in concert with one or more of seals352,354, and360.

In one embodiment, connecting disc334includes a layer of a sealing coating. The sealing coating may be applied by either dipping connecting disc334into the coating material or spray applying the sealing coating layer. Exemplary sealing coatings include carbon graphite, ceramic, and other materials which will wear to an appropriate fit with minimal friction. In one embodiment, the layer is about 0.005 of an inch to about 0.010 of an inch thick.

Once block assemblies202and204are assembled with connecting disc334assembled thereto, connecting disc334is rotated and the sealing coating is worn to adjust to the shape of the gap between block members232and233. In one embodiment, the sealing coating on connecting disc334is used in combination with any of seals352,354,360, and375.

Referring toFIG. 32, in one embodiment, either engine10or engine200generates electrical power. Engine200is represented inFIG. 32. A conductive wire390is wrapped around a base member391. The conductive wire is positioned proximate to wall of the piston chamber206. In one embodiment, the wall of the piston chamber is made of an insulating material at least in the region corresponding to the location of the conductive wire390.

The conductive wire390is connected to a power supply392through a wire394. Piston208carries a magnetic member396, such as a permanent magnet. In one embodiment, the magnetic member396is an insert in a side of piston208proximate to wire390. As piston208with magnet member396passes by the wound wire390an electrical field is induced in wound wire390. This causes a current to flow in wire394and the electrical energy is stored in power supply392. This power may be used to operate various application devices. Exemplary application devices include the ignition system. In one embodiment, the power generated eliminates the need for a conventional alternator.

In operation, valve212rotates in direction209(FIG. 28). Valve212includes a plurality of openings211. As shown inFIG. 28, openings211are sized to align valve212relative to piston chamber206in a non-interfering position. As opening211rotate in direction209tabs213of valve212overlap piston chamber206forming a ignition chamber area between a just passing piston208and tab213of valve212and an exhaust chamber between the next piston208and tab213of valve212, as explained in U.S. patent application Ser. No. 11/451,120, filed Jun. 12, 2006 and U.S. Pat. No. 7,059,294, the disclosures of which are expressly incorporated herein by reference.

Fuel is introduced into a ignition chamber area of piston chamber206through a fuel inlet402and is supplied through a fuel injector404. In one embodiment, fuel injector404is replaced with a carburetor. In one embodiment, fuel injector404is replaced with a throttle body. Air is introduced into an ignition chamber area of piston chamber206through an air inlet220. In one embodiment, the air is provided through an injector. In one embodiment, the air is provided through an impellar fan380. In one embodiment, air and fuel are injected together with an injector. A spark to ignite the fuel and air mixture is provided through inlet406(FIG. 22) with an ignition member408. An exemplary ignition member is a sparkplug. The combustion gases are expelled from piston chamber206through an exhaust outlet222(seeFIG. 22).

In the illustrated embodiment inFIG. 28, air inlet220is either blocked by a tab213of valve212or unblocked when aligned with one of openings211. The location of air inlet220relative to openings211in valve212and relative to piston chamber206is chosen such that air inlet is unblocked at least when tab213blocks piston chamber206prior to the ignition of the air with ignition member408. In one embodiment, a separate opening is provided in valve212to control the provisional of air to a ignition chamber area of piston chamber206. In one embodiment, the separate opening is inward of openings211. In one embodiment, wherein a throttle body or carburetor is used, valve212controls the provision of air and fuel to a ignition chamber area of piston chamber.

In one embodiment, the air and fuel injected into piston chamber206is first introduced into the ignition chamber area. In one embodiment, at least the air is introduced into the piston chamber206prior to being introduced into the ignition chamber area.

Engine200may be assembled in the following manner. Piston body members308are coupled to tabs332(seeFIG. 23B) of connecting disc334. In one embodiment, the piston body members are coupled to tabs332through roll pins. Piston ring318is received by groove324. Piston face members310and312are coupled to piston body member308. In one embodiment, piston face members310and312are coupled to piston body member308through roll pins. Seals279are coupled to connecting disc334between pistons208.

TurnEngine valve assemblies210are assembled. Gear264is coupled to shaft270. In one embodiment, each of gear264and shaft270include interlocking spline features. In one embodiment, gear264is coupled to shaft270with a roll pin. Couple bushing268to valve212with couplers274. Position seal266on shaft270adjacent gear264. Seal266abuts surface281. Couple the combination of bushing268and valve212to shaft270. In one embodiment, bushing268and shaft270include interlocking spline features. Position bearing262onto shaft270and position the assembly into bore254in first base member250. Position bearing272onto shaft270and position the assembly in bore277of second base member252. First base member250and second base member252are coupled together. In one embodiment, first base member250and second base member252are coupled together through fasteners253.

Turning to assembly263of engine valve assembly210, bearings282and284are assembled to shaft288. Gear280is coupled to shaft288. In one embodiment, each of gear280and shaft288have interlocking spline features. This assembly is positioned in bore258of first base member250such that the teeth of gear280engage the teeth of gear264. The assembly is retained in bore258by coupling retainer286to first base member250. In one embodiment, retainer286is a clip retainer which is received in groove298of first base member250. Finally, gear290is coupled to shaft288such that shaft288rotates with gear290.

Turning toFIG. 23B, flanges221are coupled to connecting disc334. In one embodiment, flanges221are connected to connecting disc334through a plurality of couplers. Referring toFIG. 23C, bearing223, seal352, and seal354are received in recesses225,353, and355of block member233, respectively. Seals352and354in one embodiment are coupled to block member233with a plurality of fasteners. One of the flanges221coupled to connecting disc334may then be received within bearing233and positioned such that connecting disc334contacts seals352and354. In the same manner, seals352and354and bearing228many be assembled to block member232. Block member232may then receive the other of flanges221such that connecting disc334contacts the seals352and354of block member232.

Block member232is aligned with block member233. As shown inFIG. 20A, block member232includes a plurality of locators227which are received by locators226on block member233. In one embodiment, locators227are pins received in openings (locators226). Block member232is coupled to block member233through a plurality of fasteners, such as screws or bolts. Similar locators are used to align block member230and block member232and block member235with block member233. Block member230is coupled to block member233through a plurality of fasteners, such as screws or bolts.

Turning toFIG. 23A, seals249are positioned in grooves on block member230(seeFIG. 29). Block member232is aligned with block member230. Similar seals are positioned between block member233and block member235.

An output shaft121is coupled to flanges221of connecting disc334. In one embodiment, the output shaft121and the flanges have interlocking spline features. Also, the engine valve assemblies210are coupled to the block assemblies202and204. The drive system38is installed. Ignition members408are coupled to valve assemblies210along with fuel injectors. An air supply and an exhaust system are also coupled to the one of the block assemblies or the valve assemblies.

By having engine valve assemblies210as a modular component, easily removed from block assemblies202and204, repair or inspection of a given valve212is greatly simplified. The respective engine valve assembly210is removed and the valve is repaired or inspected without the need to disassemble the block assemblies202and204.

The above detailed description of the illustrated embodiments, examples, and the appended figures are for illustrative purposes only and are not intended to limit the scope and spirit of the invention, and its equivalents. One skilled in the art will recognize that many variations can be made to the invention disclosed in this specification without departing from the scope and spirit of the invention.