Heat-insulating engine with swirl chambers

Abstract: This invention relates to a heat-insulating engine with swirl chambers which reduces a throttle loss due to the communication ports and increases the speed of a vortex flow within swirl chambers (2). The heat-insulating engine with swirl chambers comprises small communication ports (8) each with a small passage area and large communication ports (9) each with a large passage area formed at the lower portions of the swirl chamber blocks (3) constituting heat-insulating swirl chambers (2), and control valves (11) provided to large communication ports (9). During the compression stroke, the control valves close the large communication ports, and open the same ports during the expansion stroke after fuel injection and on rise in pressure in the swirl chambers (2). Accordingly, during the compression stroke, air is sent into the swirl chambers (2) at high speed via small communication ports (8) to increase a vortex flow speed within the swirl chambers (2). During the expansion stroke, the large communication ports being open, combustion gas and flame are forced into the main combustion chambers (1) from the swirl chambers (2) to reduce a throttle loss.

Description: This invention relates to a heat-insulating engine with swirl chambers which includes main chambers at piston heads and swirl chambers at a cylinder head. Swirl chambers of an engine with swirl chambers are described in Japanese Utility Model Laid-Open No. 21024/1984, for example. In this engine with swirl chambers, swirl chambers are provided to a cylinder head, swirl chamber blocks constituting the swirl chambers are made of a ceramic material as a whole, an air layer is defined in the major proportion of the fitting portions between the ceramic swirl chamber blocks and the cylinder head, the end portions of the fitting portions between the swirl chamber blocks and the cylinder head on the cylinder side are sealed gas-tight by a sealing material, and the fitting portions between the swirl chamber blocks and their insertion members are also sealed gas-tight by the sealing material. Furthermore, a heat-insulating engine with swirl chambers have been developed to improve combustion of heat-insulating engines. For example, Japanese Patent Laid-Open No. 119616/1990 filed by the Applicant of the present invention discloses a heat-insulating engine with swirl chambers. In this heat-insulating engine with swirl chambers, swirl chambers equipped with fuel injection nozzles and having a heat-insulating structure are communicated with main chambers equipped with intake/exhaust valves by communication ports, control valves are disposed to open and close the communication ports, and the control valves open the communication ports near the end of a compression stroke of the engine so as to introduce at a stretch the intake air into the swirl chambers and close the communication ports during an intake stroke so as to inhibit the introduction of the intake air into the swirl chambers. However, the problem with the engine having the swirl chambers is that when the combustion gas moves from the swirl chambers to the main chambers when the communication ports communicating the main chambers with the swirl chambers are throttled, a throttle loss occurs due to the communication ports and engine performance drops. On the other hand, the smaller the passage sectional area of the communication port, the higher the flowing speed of the vortex flow formed by the intake air introduced into the swirl chambers. In engines with swirl chambers in general, forced stream of the combustion gas, that is, the flame, from the swirl chambers to the main chambers is limited to one direction. The out-flowing speed at the initial stage of forced stream of the flame is high in the former half of flame blow-off if the pressure difference is great between the swirl chambers and the main chambers but drops in the latter stage of forced flame stream. Mixing with air existing in the main chambers needs a long time in this case, the combustion time becomes long, a fuel efficiency lowers and the drop of the outflowing speed results in the occurrence of hydrocarbons HC. It is necessary in the heat-insulating engine with swirl chambers to elevate the combustion speed and to complete the combustion at an early stage. For, when a compression end temperature is higher by about 250 °C than a cold engine as in the case of the heat-insulating engine, the viscosity of the compressed air increases and the fuel injected into this air cannot mix ideally with the air. On the other hand, an ignition delay of the fuel is small in a high temperature atmosphere and the fuel can be ignited within a time of about 1/5 of that of the cold engine. Therefore, the fuel and the air must be mixed instantaneously but the initial stage mixing and combustion of the air and the fuel are preferably carried out in the rich fuel-air mixture with a limited equivalent ratio and lean premixed combustion are preferably carried out in a diffusion combustion portion. A further known engine with a swirl chamber is disclosed in EP-A-0276193. Here, the swirl chamber and a main combustion chamber are linked by a main communication port, and a narrower compressed air introducing hole. The main communication port is closed by a valve which is mechanically operated to open at a predetermined part of the cycle through a linkage to the power crankshaft. It is a main object of the present invention to solve the problem described above. According to the present invention there is provided a heat-insulating engine with swirl chambers sequentially operated in a cycle of an intake stroke, a compression stroke, an expansion stroke and an exhaust stroke, comprising a cylinder block defining cylinders therein, a cylinder head fixed to said cylinder block, swirl chamber blocks disposed inside cavities formed in said cylinder head and defining swirl chambers having a heat-insulating structure, pistons mounted for reciprocation inside said cylinders, main chambers defined in piston heads of said pistons, communication ports formed in said swirl chamber blocks providing communication between said main chambers and said swirl chambers, including small communication ports having a small passage area and large communication ports having a large passage area, formed in said swirl chamber blocks, fuel injection nozzles having injection ports thereof opening in to said swirl chambers, and control valves provided for opening and closing said large communication ports; characterised in that said control valves are arranged to open said large communication ports in response to the pressure inside said swirl chambers, when this rises above a predetermined pressure, said large communication ports closing during said compression stroke and opening at the time of the pressure rise in said swirl chambers during said expansion stroke after the injection of the fuel from said fuel injection nozzles. By means of the communication ports the passage area is increased so as to reduce a throttle loss due to the communication ports when a combustion gas is transferred from the swirl chambers to the main chambers through the communication ports, the passage sectional area is reduced so as to increase the flowing speed of a vortex flow when intake air is introduced from the main chamber side into the swirl chambers through the communication ports, both of the communication ports are opened when the passage sectional area of the communication ports is to be increased, and one of the communication ports are closed by control valves when the passage sectional area of the communication ports is to be reduced. Since the control valves of this heat-insulating engine with swirl chambers open the large communication ports in response to a pressure above a predetermined pressure inside the swirl chambers, the structure itself can be made simple. In addition to the opening operation of the large communication ports by the control valves in response to the pressure above the predetermined pressure inside the swirl chambers, the control valves can be operated by an extremely small electromagnetic force if the control valves are constituted as solenoid valves operated by the electromagnetic force. Therefore, the control valves can be made compact and the response in the opening/closing operation can be improved. In the heat-insulating engine with swirl chambers, air flows into the swirl chambers through the small communication ports during the compression stroke of the engine and can form a strong vortex flow inside the swirl chambers. in a preferred embodiment fuel atomization injected from multiple injection ports of the fuel injection nozzles in such a manner as to flow with this strong vortex flow travels while forming a free jet flow, enters an accelerated vortex flow zone, impinges against square wall surfaces of the swirl chambers, that is, the wall surfaces of the swirl chamber blocks while being carried by the vortex flow, is reflected by the wall surfaces, flows along the wall surfaces on the outer peripheral side of the vortex flow, and is uniformly dispersed, so that the fuel and the air are mixed at a stretch, ignited and burnt in match with the state where the ignition delay is short in the high temperature atmosphere. The ignited fuel-air mixture burns quickly, the internal pressure of the swirl chambers rises instantaneously and the combustion is promoted. At the same time, the control valves that have so far closed the large communication ports are opened, the communication area becomes instantaneously great, the combustion gas and the flame inside the swirl chambers flow at a stretch into the main combustion chambers, the combustion speed rises without lowering the flame stream speed and in this manner, ideal secondary combustion is completed. Accordingly, this heat-insulating engine with swirl chambers can reduce the throttle loss due to a communication port passage area that communicate the swirl chambers with the main chambers. An embodiment of the invention will be described, by way of example only, with reference to the following drawing in which: Fig. 1 is a sectional view showing an embodiment of a heat-insulating engine with swirl chambers according to the present invention. Hereinafter, an embodiment of the heat-insulating engine with swirl chambers of the present invention will be explained with reference to the drawing. Fig. 1 is a sectional view showing an embodiment of the heat-insulating engine with swirl chambers according to the present invention. As shown in the drawing, this heat-insulating engine with swirl chambers includes a cylinder block 14, a cylinder head 7 fixed to the cylinder block 14 and equipped with intake/exhaust ports 25 (only one of them being shown), swirl chambers 2 formed in the cylinder head 7 and having a heat-insulating structure, cylinder liners 22 fitted into hole portions defined in the cylinder block 14, a piston 17 reciprocating inside each cylinder 18 formed in the cylinder liner 22, a fuel injection nozzle 6 having multiple injection holes 16 thereof disposed inside each swirl chamber 2 and main chambers 1 each being constituted by a cavity 20 formed in the piston head 4 of the piston 17. The heat-insulating structure of the swirl chambers comprises, for example, swirl chamber blocks 3 disposed in a cavity 19 formed in the cylinder head 7 and made of a high heat-resistant and high heat-insulating ceramic material. The sectional shape of each swirl chamber 3 in the cylinder axial direction is shaped into the substantially square wall surfaces and this block 3 is fixed to the cylinder head 7 by fixing metals 27. A heat-insulating air layer can be formed, at time, between the outer side surface of the swirl chamber block 3 and the cavity 19 of the cylinder head 7 to improve the heat-insulating property of the swirl chamber 2. Each main chamber 1 is constituted in a heat-insulating structure by forming the cavity 22 of the piston head 4 by a heat-insulating wall body made of a ceramic, that is, by a main chamber block 10. An intake/exhaust valve 26 is disposed in each intake/exhaust port 25. In this heat-insulating engine with swirl chambers, in particular, the thin wall member 15 of the lower surface of the swirl chamber block 3 constitutes part of the cylinder head lower surface 13. Large communication ports 9 are formed on the center side of the cylinder 18 of the swirl chamber block 3 and small communication ports 8 are formed around the peripheral side of the cylinder 18 of the swirl chamber block 3. Each communication port 9 is a passage having a large sectional area of the passage, and a switch valve, that is, a control valve 11, is disposed for opening and closing this passage. Each small communication port 8 is a passage having a small sectional area, and communicates always the swirl chamber 2 and the main chamber 1. In this heat-insulating engine with swirl chambers, further, the small communication ports 8 always communicate the main chambers 1 and the swirl chambers 2, and the control valve 11 is disposed in each large communication port 9. For example, the passage sectional area of the small communication port 8 is so formed as to be up to 0.9% of the cylinder sectional area and the passage sectional area of the large communication port 9 is so formed as to be up to 3%. A valve face and a valve stem 23 constituting the control valve 11 are made of a high heat-resistant ceramic. Preferably, a valve guide 32 of the control valve 11 is formed integrally with the swirl chamber block 3 by a high heat-resistant ceramic. If the valve guide 32 and the valve stem 23 are made of a high heat-resistant ceramic, clearance between them hardly changes even when any temperature difference occurs between the valve guide 32 and the stem 23, so that the control valve 11 can slide smoothly and the gas does not leak from the swirl chambers 2 to the outside. Although not in accordance with the invention the control valve 11 as shown in the drawing is constituted by a solenoid driving valve driven by the electro-magnetic force. An attraction plate 21 made of a magnetic material is fitted to one of the ends of the valve stem 23 of the control valve 11, a coil case 33 serving as a magnetic path is disposed around the outer periphery of the upper part of the valve stem 23 and a solenoid coil 12 is disposed inside the coil case 33. A return spring 31 for biasing the control valve 11 in the closing direction is sandwiched between the coil case 33 and the attraction plate 21. The opening/closing operation of the control valve 11 for supplying a current to the solenoid coil 12 is controlled by the instruction from a controller 30. Signals representing the engine operating state such as the engine revolution, crank position, engine load, etc, are inputted to the controller 30 and the opening/closing operation of the control valve 11 is controlled in response to the operating state. The engine load can be detected by a load sensor 24 for detecting the fuel flow rate supplied to the fuel injection nozzles or the step-on quantity of an acceleration pedal. The crank position can be detected by a position sensor 28. Engine RPMs can be detected by a rotation sensor 29. Receiving the angle signals of the engine operating state described above, the controller 30 decides and controls the opening timing and valve lift quantity of the control valve 11 in response to the angle signals. Alternatively, in accordance with the invention the control valve 11 may be constituted in such a manner as to open the large communication ports 9 in response to a pressure above a predetermined set pressure inside the swirl chamber 2, instead of being controlled by the controller 30. For example, the control valve 11 is closed by the force of a spring and when the internal pressure of the swirl chamber 2 exceeds a set pressure, the control valve 11 is allowed to descend against this spring force so as to open the large communication ports 9. The fuel injection nozzle 6 disposed in each swirl chamber 2 in this heat-insulating engine with swirl chambers is equipped with multiple injection ports 16 formed in the peripheral direction of the nozzle axis so that the injected fuel atomized radially into the swirl chamber impinges against the wall surfaces 5 of the swirl chamber block 3. The fuel injection nozzle 6 is so disposed as to extend in the horizontal direction from the center wall surface inside each swirl chamber 2 and the multiple injection ports 16 open towards the wall surfaces 5 of the swirl chamber 2. In other words, the inside of the swirl chamber 2 or the wall surface 5 of the swirl chamber block 3 is shaped so that the section in the axial direction of the cylinder 18 is square and has the square wall surfaces 5 with respect to the flowing direction of an air vortex flow S introduced via the small communication port 8. As to the swirl block 3 constituting each swirl chamber 2, the injection direction of the injected fuel F from the multiple injection ports 16 of the fuel injection nozzle 6 is set so that it impinges against the square wall surfaces 5. Furthermore, in this heat-insulating engine with swirl chambers, a cavity 20 is defined in the piston head 4 and the wall member 10 made of a ceramic, etc, is disposed on the wall surface of the cavity 20 so as to constitute each main chamber 1 in the heat-insulating structure. Each communication port 9 communicating the swirl chamber 2 with the main chamber 1 is so formed in the swirl chamber block 3 as to oppose one of the ends of the main chamber 1. The heat-insulating engine with swirl chambers according to the present invention has the following feature because it is equipped with the small communication ports 8 and large communication ports 9 described above. In other words, the energy of the vortex flow S and free injection flow F occurring in each swirl chamber 2 is positively utilized, the injected fuel is allowed to impinge against the high temperature wall surface 5 and is reflected, mixing of the air and the fuel is instantaneously effected by utilizing heat energy and the combustion rate is increased. Therefore, the intake air introduced from the small communication ports 8 forms the vortex flow S in the vertical direction with respect to the inflowing direction and the vortex flow S swirls as the vortex flow belt inside each swirl chamber 2. The fuel atomization F injected from the fuel injection nozzle 6 has energy of a certain extent and flows as the free injection flow F. This free injection flow F is then impinged against and reflected off the square wall surfaces 5 having a high-temperature, in such a manner that the reflected fuel spray F flows along the wall surfaces 5 and on the outer peripheral side of the vortex flow S, and is uniformly dispersed, and the air and fuel are instaneously mixed. This swirl chamber type heat insulating engine constructed as described above is operated as follows. In a compression stroke in a combustion cycle, in which an intake stroke, a combustion stroke, an expansion stroke and an exhaust stroke are carried out in the mentioned order, in this swirl chamber type heat insulating engine, the large communication port 9 is closed during the compression stroke with the control valve 11, and the small communication port 8 alone is left in a communicating state to reduce a total cross-sectional area of communication ports, whereby the air is introduced at a high speed from the main chamber 1 into the swirl chamber 2 to form a strong vortex flow S. The fuel spray F injected from the multiple injection ports 16 of the fuel injection nozzle 6 into the swirl chamber 2 travels as a free injection flow F, and enters an accelerated vortex flow zone. The free injection flow F then impinges upon the wall surfaces 5 as it is carried by the vortex flow S, and is reflected off the square wall surfaces 5 to flow therealong. The fuel spray is dispersed uniformly, and the fuel and air are mixed in an instance to satisfy the condition in which an ignition delay in a high-temperature atmosphere is short, to form an air-fuel mixture, which then ignites. The ignited mixture burns quickly, and the pressure in the swirl chamber 2 rises instantaneously, the combustion of the mixture being promoted. At the same time, the combustion moves into an expansion stroke, to operate the control valve 11 which has so far closed the large communication port 9 to open this port. When the large communication port 9 is opened, the combustion gas and flames flow into the main chamber 1 to attain ideal combustion. Therefore, since the combustion gas and flames are carried from the swirl chamber 2 into the main chamber 1 through the large and small communication ports 9, 8, the cross-sectional area of the flow passages increases, so that a throttle loss can be reduced. The combustion gas and flames are thus discharged from the swirl chamber 2 to the main chamber 1, and mix in the main chamber 1 with the fresh air existing therein, so that combustion is carried out satisfactorily and in a short period of time.

Claims: A heat-insulating engine with swirl chambers sequentially operated in a cycle of an intake stroke, a compression stroke, an expansion stroke and an exhaust stroke, comprising a cylinder block (14) defining cylinders (18) therein, a cylinder head (7) fixed to said cylinder block (14), swirl chamber blocks (3) disposed inside cavities (19) formed in said cylinder head (7) and defining swirl chambers (2) having a heat-insulating structure, pistons (17) mounted for reciprocation inside said cylinders (18), main chambers (1) defined in piston heads (4) of said pistons (17), communication ports formed in said swirl chamber blocks (3) providing communication between said main chambers (1) and said swirl chambers (2), including small communication ports (8) having a small passage area and large communication ports (9) having a large passage area, formed in said swirl chamber blocks (3), fuel injection nozzles (6) having injection ports (16) thereof opening in to said swirl chambers (2), and control valves (11) provided for opening and closing said large communication ports (9); characterised in that said control valves (11) are arranged to open said large communication ports (9) in response to the pressure inside said swirl chambers (2), when this rises above a predetermined pressure, said control valves closing said large communication ports (9) during said compression stroke and opening at the time of the pressure rise in said swirl chambers (2) during said expansion stroke after the injection of the fuel from said fuel injection nozzles (6). A heat-insulating engine with swirl chambers according to claim 1, wherein the passage area of said small communication ports (8) is not greater than 0.9% of the sectional area of said cylinder (18). A heat-insulating engine with swirl chambers according to claim 1 or 2, wherein said passage area of said large communication ports (9) is not greater than 3% of the sectional area of said cylinder (18). A heat-insulating engine with swirl chambers according to any preceding claim, wherein in operation the air introduced from said main chambers (1) into said swirl chambers (2) through said small communication ports (8) having a small passage area during said compression stroke forms a strong vortex flow inside said swirl chambers (2). A heat-insulating engine with swirl chambers according to claim 4, wherein the fuel is injected from said fuel injection nozzle (6) into said vortex flow formed inside said swirl chambers (2), said fuel and the air mix to form a fuel-air mixture, said fuel-air mixture is ignited, said ignited fuel-air mixture burns rapidly and forms a combustion flame, and the pressure inside said swirl chambers (2) rises. A heat-insulating engine with swirl chambers according to claim 5, wherein said control valves (11) are opened during said expansion stroke, so that said combustion flame inside said swirl chambers (2) flows rapidly from said swirl chambers (2) to said main chambers (1) during said expansion stroke, mixes with the air existing inside said main chambers (1), shortens the combustion time and burns satisfactorily. A heat-insulating engine with swirl chambers according to any preceding claim, wherein said swirl chamber blocks (3) are constituted in a heat-insulating structure by a highly heat-resistant ceramic material. A heat-insulating engine with swirl chambers according to any preceding claim, wherein said control valves (11) are made of a highly heat-resistant ceramic material. A heat-insulating engine with swirl chambers according to any preceding claim, wherein said large communication ports (9) are formed on the side of the swirl chambers near the centre of said cylinders (18) and said small communication ports (8) are formed on the side of the swirl chambers near the periphery of said cylinders (18). A heat-insulating engine with swirl chambers according to any preceding claim, wherein said swirl chambers (2) formed in said swirl chamber blocks (3) are formed so that the section thereof in the axial direction of said cylinders (18) are square wall surfaces and are formed in a square form with respect to the flowing direction of the air vortex flow introduced from said small communication ports. A heat-insulating engine with swirl chambers according to claim 10, wherein the fuel injected from said injection ports (16) of said fuel injection nozzles (6) is directed so as to impinge obliquely against said square wall surfaces.

Inventors: KAWAMURA HIDEO, KAWAMURA, HIDEO
Applicants: ISUZU MOTORS LTD, ISUZU MOTORS LIMITED
Application year: 1992
Main classification: F02B19
IPC codes: F02B19, F02F7, F02D15, F02B77