Patent Publication Number: US-9410525-B2

Title: Valve controlled combustion system

Description:
FIELD 
     The present disclosure relates to valve controlled combustion systems. 
     BACKGROUND 
     This section provides background information related to the present disclosure, which is not necessarily prior art. 
     Internal combustion engines (“ICEs”) typically include a combustion chamber, an intake and exhaust port, a compression device, a fuel delivery system, and an ignition device. ICEs place the ignition device into constant contact with the combustible mixture of air and fuel and control the ignition of that mixture by intermittent activation of the ignition device. For example, intermittent operation of a spark plug, activated by a high voltage pulse to produce a plasma flame kernel. However, in order to achieve higher fuel efficiency, the compression ratios of ICEs are growing higher, and the air-fuel mixtures are becoming leaner. This requires ignition devices such as spark plugs to use higher voltages for consistent combustion. 
     Furthermore, the ignition devices are exposed to the high ranges of pressures, temperatures, and chemical mixtures that exist in the combustion chamber during the entire engine cycle. This exposure can lead to degradation of the ignition device, including buildup of soot, which can result in inconsistent combustion and loss of fuel economy and power. Additionally, ignition devices in ICEs utilizing compressed natural gas (“CNG”) as the fuel tend to build up soot more quickly than ICEs operating on traditional fuels, such as gasoline, for example. This additional buildup can require more frequent maintenance, often making CNG ICEs impractical or too costly for certain applications. 
     The geometry and operation of sparkplugs also makes controlling the propagation of the flame front difficult. This can lead to premature flameout resulting in inconsistent combustion, and loss of fuel economy and power. 
     SUMMARY 
     This section provides a general summary of the disclosure, and is not a comprehensive disclosure of its full scope or all of its features. 
     The present teachings provide for an internal combustion engine combustion system, including an ignition element and an ignition actuation member. The ignition element is configured to ignite an air-fuel mixture compressed within a combustion chamber of an internal combustion engine. The ignition actuation member is movable between a first position in which the ignition actuation member prevents ignition of the air-fuel mixture when present in the combustion chamber, and a second position in which the ignition actuation member permits ignition of the air-fuel mixture by exposing the ignition element to the air-fuel mixture when the air-fuel mixture is present in the combustion chamber. 
     The present teachings also provide for an internal combustion engine combustion system, including an ignition surface, an ignition actuation member, an isolation cavity, an isolation member, and an actuating device. The ignition surface is configured to be heated to a temperature sufficient to create an ignition element to ignite an air-fuel mixture compressed within a combustion chamber of the internal combustion engine. The ignition actuation member is movable between a first position in which the ignition actuation member prevents ignition of the air-fuel mixture when present in the combustion chamber, and a second position in which the actuation member permits ignition of the air-fuel mixture by exposing the ignition element to the air-fuel mixture when the air-fuel mixture is present in the combustion chamber. The isolation member seals the ignition surface within the isolation cavity in the first position. The actuating device is configured to move the ignition actuation member between the first and second positions. 
     The present teachings further provide for a method of operating an internal combustion engine. The method includes moving an ignition actuation member from a first position, in which the ignition actuation member prevents ignition of an air-fuel mixture present in a combustion chamber of an internal combustion engine by preventing exposure of an ignition element to the air-fuel mixture therein, to a second position in which the ignition actuation member permits ignition of the air-fuel mixture by permitting exposure of the ignition element to the air-fuel mixture, and returning the ignition actuation member to the first position after ignition of at least a portion of the air-fuel mixture. 
     Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure. 
    
    
     
       DRAWINGS 
       The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure. 
         FIG. 1  is a representative vehicle including an internal combustion engine in accordance with the present teachings; 
         FIG. 2  is a cut-away view of a combustion chamber and ignition elements associated therewith of the internal combustion engine in a first configuration with an ignition actuation member in a first position; 
         FIG. 3  is a cut-away view of a combustion chamber and ignition elements associated therewith of the internal combustion engine of  FIG. 2 , with the ignition actuation member in a second position; 
         FIG. 4  is a cut-away view of a combustion chamber and ignition elements associated therewith of the internal combustion engine in a second configuration with an ignition actuation member in a second position; 
         FIG. 5  is a cut-away view of a combustion chamber and ignition elements associated therewith of the internal combustion engine in a third configuration with an ignition actuation member in a second position; 
         FIG. 6  is a cut-away view of a combustion chamber and ignition elements associated therewith of the internal combustion engine in a fourth configuration with an ignition actuation member in a first position; 
         FIG. 7  is a cut-away view of a combustion chamber and ignition elements associated therewith of the internal combustion engine of  FIG. 6  with the ignition actuation member in a second position; 
         FIG. 8  is a cut-away view of a combustion chamber and ignition elements associated therewith of the internal combustion engine in a fifth configuration with an ignition actuation member in a first position; 
         FIG. 9  is a cut-away view of a combustion chamber and ignition elements associated therewith of the internal combustion engine of  FIG. 8  with the ignition actuation member in a second position; and 
         FIG. 10  is a cut-away view of a combustion chamber and ignition elements associated therewith of the internal combustion engine in a sixth configuration with an ignition actuation member in a first and second position. 
     
    
    
     Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings. 
     DETAILED DESCRIPTION 
     Example embodiments will now be described more fully with reference to the accompanying drawings. 
     The present teachings are directed to a combustion system and method for use in an internal combustion engine (“ICE”). The ICE can be of any type, such as a piston-cylinder engine or a Wankel engine, for example. The ICE may be located within a vehicle, such as an automobile, truck, machinery, aircraft, watercraft, or any other vehicle to provide power for locomotion, for example. However, it is also contemplated that the ICE could be used in other applications with or without a vehicle such as an electrical generator or to operate machinery, for example.  FIG. 1  illustrates an example of a vehicle  10  with an ICE  12 . 
       FIGS. 2-10  illustrate cut-away views of the inside of a portion of the ICE  12  in various configurations. The ICE  12  can include a compression device  14 , a combustion chamber  16 , an intake port  18 , an exhaust port  20 , an ignition device  22 , and an ignition element  22   a.    
     The compression device  14  can include a piston  24  coupled to a piston rod  26  disposed within a cylinder  28 , such as that illustrated in  FIGS. 2-10 . However, the compression device  14  can be any other type of compression device found in any other type of ICE, such as a rotor in a Wankel engine, for example. 
     The combustion chamber  16  is configured to contain an air-fuel mixture under compression by the compression device  14 . The combustion chamber  16  is further configured to contain the combustion of the air-fuel mixture when the air-fuel mixture is ignited by the ignition element  22   a.    
     The ignition device  22  can be a typical spark plug and the ignition element  22   a  can be a spark generated to ignite the air-fuel mixture. The ignition device  22  can also be a geometric shape, such as a ring, toroid, plate, cylinder, sphere, or any other geometry, and the ignition element  22   a  can be the surface of ignition device  22  and be configured to be heated to a temperature sufficient to ignite the air-fuel mixture within the combustion chamber. The ignition element  22   a  can be heated, for example, by electrical resistance, infrared, laser, or induction heating. The ignition device  22  can alternatively be configured to emit the ignition element  22   a  as radiation, such as infrared, or laser radiation for example, the radiation configured to ignite the air-fuel mixture within the combustion chamber. When the ignition device  22  is operated by an electrically powered means, the combustion system can be connected to a power source  66 , such as a battery, an alternator, or a power grid, for example. The shape of the ignition element  22   a  can be configured to control the propagation of a flame front during combustion to ensure more complete combustion within the combustion chamber  16 . 
     During the typical operation of a piston-cylinder type ICE  12 , the compression device  14  compresses the air-fuel mixture within the combustion chamber  16  during a compression stroke of the piston  24 . During the compression stroke, the volume of the combustion chamber  16  is decreased, causing the pressure of the air-fuel mixture to increase. At or near a combustion pressure, the ignition element  22   a  ignites the air-fuel mixture. The ignition of the air-fuel mixture can start with a plasma flame kernel originating at the ignition element  22   a . The combustion of the air-fuel can propagate from the ignition element  22   a  through the air-fuel mixture in the combustion chamber  16  by the flame front. The combustion of the air-fuel mixture forces the piston  24  to begin a power stroke, in which the volume of the combustion chamber  16  increases, and the piston  24  performs work, such as linear motion from the piston  24 , rotation of a crankshaft (not shown), or rotation of a rotor of an electrical generator (not shown), for example. 
     The intake port  18  can include an intake valve  30 . The intake valve  30  can be configured to move between an open position and a closed position to selectively allow air to pass through the intake port  18  and enter the combustion chamber  16  when the intake valve  30  is in the open position. The air-fuel mixture for combustion can be created by mixing fuel with air before the air enters the combustion chamber  16 . Alternatively, fuel can be injected separately into the combustion chamber  16  and allowed to mix with the air in the combustion chamber  16  to create the air-fuel mixture therein. The fuel can enter the combustion chamber separately through a fuel injector (not shown). The fuel can be any type of fuel used in ICEs, such as gasoline, diesel, bio-diesel, natural gas, ethanol, or any other type of fuel, or blend of fuels. 
     When the intake valve  30  is in the closed position, the intake valve  30  prevents the air-fuel mixture from passing through the intake port  18 . During the typical operation of a piston-cylinder type ICE  12 , the intake valve  30  will generally be in the open position during an intake stroke of the piston  24 . The intake valve  30  would generally be in the closed position during compression, power, and exhaust strokes of the piston  24 . However, it is known that variations on the timing of opening or closing the intake valve  30  may be used. 
     The exhaust port  20  can include an exhaust valve  32 . The exhaust valve  32  can be configured to move between an open position and a closed position to selectively allow combustion gases, along with any uncombusted air and fuel, to pass through the exhaust port  20  and exit the combustion chamber  16  when the exhaust valve  32  is in the open position. During the typical operation of a piston-cylinder type ICE  12 , the exhaust valve  32  will generally be in the open position during an exhaust stroke of the piston  24 . The exhaust valve  32  would generally be in the closed position during intake, compression, and power strokes of the piston  24 . However, it is known that variations in the timing of opening or closing the exhaust valve  32  may be used. 
     An ignition actuation member  34  can selectively isolate the ignition element  22   a  from communication with the combustion chamber  16  in a first position, and selectively allow communication between the ignition element  22   a  and the combustion chamber  16  in a second position. The ignition actuation member  34  can be actuated between the first and second positions by an actuation device  68 . The actuation device  68  can be any electrical, mechanical, or electro-mechanical means, such as a solenoid, or cam and follower, for example. The ignition actuation member  34  can be moved from the first position to the second position when the air-fuel mixture is compressed at or near a combustion pressure. The actuation of the ignition actuation member  34  from the first position to the second position exposes the ignition element  22   a  to the air-fuel mixture and ignites the air-fuel mixture, causing combustion within the combustion chamber  16 . The actuation of the ignition actuation member  34  can be controlled to expose the ignition element  22   a  at a desired time before, during or after full compression of the air-fuel mixture, in the case of a piston-cylinder engine, top-dead center. The ignition actuation member  34  can be returned to the first position after the air-fuel mixture begins combustion. When in the first position, the ignition element  22   a  is protected from the combustion products. The ignition actuation member  34  can be returned to the first position before the combusted air-fuel mixture is expelled from the combustion chamber  16  during the exhaust stroke. The ignition actuation member  34  can further be returned to the first position before the combustion event, or power stroke is complete.  FIGS. 2-7  illustrate the ignition actuation member  34  linearly moving between the first and second positions, though the ignition actuation member  34  could move in other fashions to expose the ignition element  22   a.    
     With reference to  FIGS. 2-5 , the ICE  12  can define an isolation cavity  36 , adjacent to the combustion chamber  16  and connected to the combustion chamber  16  by a combustion aperture  38 . The ignition actuation member  34  can include an actuated portion  34   a , a sealing portion  34   b  and a sealing surface  34   c  on the sealing portion  34   b . The actuated portion can be actuated by the actuating device  68 . The sealing surface  34   c  can seal the combustion aperture  38 , thus isolating the isolation cavity  36  from the combustion chamber  16 . The ignition element  22   a  can be located within the isolation cavity  36 . The isolation cavity  36  can be sized according to the application, but generally should be sized to minimize the volume around the ignition element  22   a . The ignition element  22   a  can be fixed to the isolation cavity  36  to remain within the isolation cavity  36  while the ignition actuation member  34  is in both the first and second positions. In such a configuration, the ignition element  22   a  may be fixed to a wall  36   a  of the isolation cavity  36  by any fastening means such as bolts, screws, adhesives, press or interference fit, or pins, for example. In other configurations, the ignition element  22   a  can be fixed to the ignition actuation member  34  to move with the ignition actuation member  34  between the first and second positions. In such a configuration, the ignition element  22   a  may be fixed to the actuated portion  34   a  of the ignition actuation member  34 , or may be fixed to the sealing portion  34   b  of the ignition actuation member  34 . The ignition element  22   a  may be fixed to the ignition actuation member  34  by any fastening means such as bolts, screws, adhesives, press or interference fit, or pins, for example. The ignition actuation member  34  can seal the combustion aperture  38  and isolate the ignition element  22   a  from the combustion chamber  16  in the first position (see  FIG. 2 ). The ICE  12  can optionally include a pressure equalization channel  40 . The pressure equalization channel  40  can be in communication with the combustion chamber  16  and the isolation cavity  36  to allow the pressure within the combustion chamber  16  to be hydrostatically substantially equal to the pressure within the isolation cavity  36 . The pressure equalization channel  40  can be sized to the application, but generally is sufficiently small as to prevent ignition of the air-fuel mixture during pressure equalization. 
       FIG. 3  illustrates the ICE  12  of  FIG. 2  with the ignition actuation member  34  in the second position. In the second position, the ignition actuation member  34  unseals the combustion aperture  38  and allows fluid communication between the ignition element  22   a  and the combustion chamber  16 . The air-fuel mixture is then allowed to enter the isolation cavity  36  and ignite upon exposure to the ignition element  22   a . In this first configuration, the ignition element  22   a  is fixed to the wall  36   a  of the isolation cavity  36  and remains within the isolation cavity  36  when the ignition actuation member  34  is in the second position. The ignition element  22   a  may be fixed to the wall  36   a  by any fastening means such as bolts, screws, adhesives, press or interference fit, or pins, for example. 
       FIG. 4  illustrates the ICE  12  in a second configuration, with the ignition actuation member  34  in the second position. In the second configuration, the ignition element  22   a  is coupled to the ignition actuation member  34 . The ignition element  22   a  may be fixed to the actuated portion  34   a  of the ignition actuation member  34  or to the sealing portion  34   b . The ignition element  22   a  can move between the isolation cavity  36  and the combustion chamber  16 , through the combustion aperture  38 , when the ignition actuation member  34  moves between the first and second positions. The ignition element  22   a  may alternatively be fixed to the actuated portion  34   a  such that it remains within the isolation cavity  36  in the second position, but moves within the isolation cavity  36  with the actuated portion  34   a . The ignition element  22   a  may be fixed to the ignition actuation member  34  by any fastening means such as bolts, screws, adhesives, press or interference fit, or pins, for example. In the second position the ignition element  22   a  is in fluid communication with the air-fuel mixture within the combustion chamber  16  and the air-fuel mixture may be ignited. 
       FIG. 5  illustrates the ICE  12  in a third configuration, with the ignition actuation member  34  in the second position. In the third configuration, the ignition actuation member  34  is actuated between the first and second positions by a solenoid  42 . The ignition actuation member  34  includes a first sealing surface  44  that seals the combustion aperture  38 , isolating the ignition element  22   a  from the combustion chamber  16  when the ignition actuation member  34  is in the first position. In the second position, the first sealing surface  44  allows fluid communication between the ignition element  22   a  and the combustion chamber  16 . The ignition actuation member  34  also includes a second sealing surface  46 . The second sealing surface  46  fluidly isolates the solenoid  42  from the combustion chamber  16  when the ignition actuation member  34  is in the second position. While  FIG. 5  shows the ignition element  22   a  fixed in the isolation cavity  36 , in this configuration, the ignition element  22   a  can alternatively be fixed to the ignition actuation member  34 . The ignition element  22   a  may be fixed to the isolation cavity  36  or the ignition actuation member  34  by any fastening means such as bolts, screws, adhesives, press or interference fit, or pins, for example. 
       FIG. 6  illustrates a fourth configuration of the ICE  12 , with the ignition actuation member  34  in the first position. The ignition actuation member  34  includes an actuated member  48  coupled to a cap  50 . The cap  50  defines the isolation cavity  36  within the combustion chamber  16 . The isolation cavity  36  is fluidly isolated from the combustion chamber  16  in the first position. The ignition element  22   a  can be fixed to a wall  16   a  of the combustion chamber  16 . In this configuration, the ignition element  22   a  can alternatively be fixed to either the actuated member  48  or the cap  50 . The ignition element  22   a  may be fixed to the wall  16   a  or the ignition actuation member  34  by any fastening means such as bolts, screws, adhesives, press or interference fit, or pins, for example. 
       FIG. 7  illustrates the ICE  12  of  FIG. 6 , with the ignition actuation member  34  in the second position. In the second position, the ignition actuation member  34  allows fluid communication between the ignition element  22   a  and the combustion chamber  16 . While the ignition element  22   a  is shown fixed to the wall  16   a  of the combustion chamber  16 , the ignition element  22   a  can alternatively be fixed to the ignition actuation member  34  by coupling the ignition element  22   a  to either the actuated member  48  or the cap  50 . 
       FIGS. 8 and 9  illustrate the ICE  12  in a fifth configuration, with the ignition actuation member  34  in the first and second positions, respectively. In the fifth configuration, a main body  52  can be coupled to the combustion chamber  16 . The main body  52  can include a housing portion  54 , a connecting portion  56 , and a protective tip  58 . 
     The housing portion  54  can house an actuating device  60 . The actuating device  60  can selectively move the ignition actuation member  34  between the first and second positions. The actuation device  60  can be any type of mechanical, electrical, or electro-mechanical device capable of selectively moving the ignition actuation member  34 , such as a solenoid, for example. While in the first position, the ignition element  22   a  is within the isolation cavity  36 . The ignition element  22   a  is coupled to the ignition actuation member  34 , and when the ignition actuation member  34  is in the second position, the ignition element  22   a  is moved into the combustion chamber  16  by the ignition actuation member  34 . The ignition element  22   a  may be fixed to the ignition actuation member  34  by any fastening means such as bolts, screws, adhesives, press or interference fit, or pins, for example. 
     The connecting portion  56  can couple the main body  52  to the ICE  12 , and can include a series of threads  62  configured to mesh with a series of mating threads  64  located on the ICE  12 , for example. The series of threads  62  and series of mating threads  64  can allow the main body  52  to be removably coupled to the ICE  12 . 
     The protective tip  58  can isolate the ignition element  22   a  from the combustion chamber  16  when the ignition actuation member  34  is in the first position. The protective tip  58  protects the ignition element from exposure to conditions within the combustion chamber  16  while preventing the ignition element  22  from igniting the air-fuel mixture prematurely. 
       FIG. 10  illustrates a sixth configuration, with the ignition actuation member  34  in the first and second positions, the second position illustrated by dashed lines. In the sixth configuration, the ignition device  22  is sealed within the isolation cavity  36  by an isolation member  70 . The ignition device  22  is configured to emit the ignition element  22   a  as radiation, such as infrared, or laser radiation for example. The isolation member  70  is of a material configured to allow the radiation to pass through the isolation member  70  and into the combustion chamber  16 . The isolation member  70  can also be configured to focus, or concentrate the radiation within a specific area within the combustion chamber  16 . The isolation member  70  can have any suitable focusing shape, such as concave or convex for example, such that the focal point of the radiation is within the combustion chamber  16 . Due to the focusing of the radiation, the focal point of the radiation can be a higher temperature than the temperature of the radiation at the ignition device  22 . While the isolation member  70  is described as having the suitable focusing shape, it is also contemplated that any other suitable device within the isolation cavity  36 , separate or in conjunction with the isolation member  70 , can have the focusing shape to focus the radiation and raise the temperature of the radiation at a focal point within the combustion chamber  16 . 
     The ignition device  22  is attached to the ignition actuation member  34 . When the ignition actuation member  34  is in the first position, the ignition device  22  is away from the combustion chamber  16 , minimizing exposure of the ignition element  22   a  to the air-fuel mixture within the combustion chamber  16 . When the ignition actuation member  34  is in the second position, the ignition device  22  is closer to the combustion chamber  16 , increasing exposure of the ignition element  22   a  to the air-fuel mixture within the combustion chamber  16 . When in the first position, the ignition element  22   a  penetrating the isolation member  70  is insufficient to ignite the air-fuel mixture within the combustion chamber  16 . When in the second position, the ignition element  22   a  penetrating the isolation member  70  is sufficient to ignite the air-fuel mixture within the combustion chamber  16 . 
     The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure. 
     Example embodiments are provided so that this disclosure will be thorough, and will fully convey the scope to those who are skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail. 
     The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used herein, the singular forms “a,” “an,” and “the” may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms “comprises,” “comprising,” “including,” and “having,” are inclusive and therefore specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps may be employed. 
     When an element or layer is referred to as being “on,” “engaged to,” “connected to,” or “coupled to” another element or layer, it may be directly on, engaged, connected or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being “directly on,” “directly engaged to,” “directly connected to,” or “directly coupled to” another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.). As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items. 
     Although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as “first,” “second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example embodiments.