Patent Publication Number: US-6663718-B1

Title: Internal combustion engine cleaning apparatus and method

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention, in general, relates to engine cleaning equipment and methods and, more particularly, to devices that utilize ultrasound to clean internal combustion (hereinafter “IC”) engines, including the various sub-systems associated with IC engines. 
     The thorough cleaning of IC engines and the sub-systems they have can prolong their life expectancy and improve their reliability. Wherever there is a fluid associated with an IC engine, it can be regarded as part of a particular sub-system that is either necessary or useful to the functioning of the engine. Certainly, one of the most common sub-systems involves the lubrication of the IC engine and it is so important to the engine&#39;s operation and longevity that the lubrication of an IC engine is generally regarded as an essential type of a sub-system for an IC engine. 
     With all IC sub-systems that involve the use of a fluid, eventually it becomes necessary to change that fluid. For example, in an IC engine, both the engine oil (i.e., lubricating oil) and the oil filter are periodically changed. 
     However, merely changing the oil and filter does not adequately clean sludge and other deposits from the interior portions of these engines. Various contaminants such as sludge, varnish, gum, metal and other deposits remain in the engine after the oil and filter have been changed where they may continue to contribute to rapid and excessive engine wear. It is desirable to remove these from the engine so as to limit their deleterious effects. 
     Accordingly, equipment has been designed and is therefore known to aid in cleaning the interior of an IC engine. Typically, these types of devices (i.e., cleaning machines) connect to the engine through various types of adapters that attach where desired to the engine. 
     Common areas of connection are at the oil filter port and also simultaneously at the oil drain pan (i.e., the oil drain plug hole) thereby creating a “circuit”. A cleaning solution is pumped in under pressure through one of the adapter locations. This is done either after the oil has first been drained (i.e., removed from the engine) or, alternatively, it could conceivable occur during the oil change process itself. 
     The cleaning solution may be required to remain in the engine for a time and then it is flushed out. A rinse solution may be pumped in after the cleaning solution has been used to aid in removing both the cleaning solution and any sludge or other contaminants that have been loosened from the engine. After the cleaning and rinse solutions have been drained from the engine, the adapters are removed, the new oil filter and drain plug are installed, and new engine oil is added to complete the cleaning process. 
     There is potential for cleaning any part inside of an IC engine that any of the fluids of any of the sub-systems may contact. This includes, considering for example the fuel sub-system, any area that the fuel (or resultant combustion gases which are also considered to be part of the “fluid” path) may contact such as the heads, cylinders, pistons, fuel injectors, throttle bodies, etc. The advantage of cleaning in this manner is that disassembly of the engine is not generally required (other than where the various adapters are installed). 
     Similarly to aid in cleaning the various other types of sub-systems and their respective fluids equipment, cleaning solutions, or processes have, in general, been used. Some of these remaining IC engine sub-systems include the cooling (i.e., coolant), transmission, power steering, differential, and braking systems. Sometimes IC engines are used specifically to power simple to elaborate hydraulic based sub-systems such as are found, for example, on tractors and other agricultural or construction types of equipment and vehicles. The hydraulic sub-system likely would also benefit from a periodic “deep” cleaning. 
     For example, it is generally well known to “reverse-flush” the coolant system of an IC engine to aid in cleaning it by running a fluid in an opposite direction as compared to the direction that it is normally circulated throughout the engine. 
     However, all of these processes have heretobefore incurred various disadvantages. The first and most significant is that they are not optimally effective. Sludge and other contaminants are often difficult to dislodge from the surfaces that they are attached to and may therefore be especially difficult to flush out and remove from the engine. 
     Therefore, the cleaning solutions may be required to sit for a period of time in contact with the sludge and other contaminants to improve their efficacy. This, in turn, slows down the cleaning process which drives up the cost of cleaning. 
     There are effective devices and methods known for cleaning parts that rely upon the use of ultrasonic devices that impart ultrasound (i.e., high frequency longitudinal vibrational energy) to a fluid. The fluid may also include a cleaning solution. An object (i.e., a part) that is to be cleaned is placed in the cleaning solution. The ultrasound energy alternately impacts and cavitates upon the surface of the object so as to effectively and quickly clean it. 
     But for these ultrasonic cleaning devices to function, the object that is to be cleaned must first be disassembled into its component parts. It is then necessary to place these smaller component parts in the cleaning solution of the ultrasonic cleaning device. 
     Obviously, it is not practical to disassemble an IC engine or any of the sub-systems it uses into their component parts in order to clean all of the components parts. Nor is it practical to reassemble the engine or sub-system after such a cleaning. Cost, time, and liability (arising from either losing, damaging, or errors in reassembling) pose too serious of a drawback. 
     Neither is it practical to remove an entire engine and place it in a very large ultrasonic type of a cleaning apparatus. Therefore, the use of ultrasound to clean the interior portions of an IC engine has not previously been available in a practical way to utilize its benefits. 
     Wherever there is an IC engine and a fluid (or a combustion gas), it will be either necessary or desirable to clean it. Certain applications can be especially difficult to service. For example, the various fluids used on marine IC engines often cannot be drained under the influence of gravity (i.e., because the fluid cannot be dumped into a boat or in the water) and therefore it must be flushed out under pressure and captured. Other applications that employ IC engines have similar or other problems.associated with cleaning them and their respective sub-systems. 
     Accordingly, there exists today a need for an internal combustion engine cleaning apparatus and method that can be used to quickly and effectively to clean the various interior portions of an IC engine. Such an apparatus and method is desirable for use also in cleaning the various sub-systems of an IC engine. It is preferable to lessen the amount of disassembly that is required to do so. 
     Clearly, such an apparatus and method would be especially useful and desirable. 
     2. Description of Prior Art 
     Cleaning devices and methods are, in general, known. For example, the use of engine oil flush cleaning systems are known. One such system is known as “Renew Engine Power Flush System™” and is offered by Ontario Limited at 1180 Stellar Drive, Unit 10, Newmarket, Ontario, L3Y 7B9. 
     Commercially available cleaning solutions are also available to aid in the cleaning of the lubricating system and other sub-systems of an IC engine. 
     Other devices and methods (known generally as “flush machines” or “oil flush machines” are available for cleaning the various sub-systems. For example, an oil flush machine may require pumping a heated cleaning solution into an engine, circulating and filtering the solution, and after approximately 10 minutes of doing so (with or without the engine running) removing and collecting the solution and adding fresh motor oil. 
     As another example, reverse flush systems are available for cleaning the cooling system. Flush machines are adaptable for use with other systems like the transmission and cooling sub-systems, for example. 
     Alternatively, various chemicals and other solutions may also be added to the engine crankcase and, after a time of engine operation, disposed of with the engine oil to provide other known types of products and methods. 
     Other types of decarbonization and fuel system cleaners (both chemical and machine based) are also known. 
     While the structural arrangements of the above described devices, at first appearance, have similarities with the present invention, they differ in material respects. These differences, which will be described in more detail hereinafter, are essential for the effective use of the invention and which admit of the advantages that are not available with the prior devices. 
     OBJECTS AND SUMMARY OF THE INVENTION 
     It is an object of the present invention to provide an internal combustion engine cleaning apparatus and method that can be used to clean the interior surfaces of an IC engine. 
     It is also an important object of the invention to provide an internal combustion engine cleaning apparatus and method that is adaptable for use with different types, models, and sizes of IC engines. 
     Another object of the invention is to provide an internal combustion engine cleaning apparatus and method that is adaptable for use in cleaning a gasoline fueled IC type of an engine. 
     Still another object of the invention is to provide an internal combustion engine cleaning apparatus and method that is adaptable for use in cleaning a diesel fueled IC type of an engine. 
     Still yet another object of the invention is to provide an internal combustion engine cleaning apparatus and method that is adaptable for use in cleaning an IC engine subsystem that includes a fluid (or a combustion gas) such as the coolant, transmission, fuel, brake, power steering, differential, or hydraulic sub-systems. 
     Yet another important object of the invention is to provide an internal combustion engine cleaning apparatus and method that can lessen the time required to clean an IC engine or any of its sub-systems. 
     Still yet another important object of the invention is to provide an internal combustion engine cleaning apparatus and method that can lessen the cost of cleaning an IC engine or any of its sub-systems. 
     Still yet another important object of the invention is to provide an internal combustion engine cleaning apparatus and method that can better clean the interior portions of an IC engine or any of its sub-systems. 
     Still yet one other object of the invention is to provide an internal combustion engine cleaning apparatus and method that can be adapted for use to clean part of an IC engine or IC engine sub-system when the engine is shut off. 
     Still yet one other important object of the invention is to provide an internal combustion engine cleaning apparatus and method that can be adapted for use to clean part of an IC engine or IC engine sub-system when the engine is running, for example, as when cleaning the coolant sub-system. 
     Still yet one other further object of the invention is to provide an internal combustion engine cleaning apparatus and method that can be adapted for use to decarbonize an IC engine. 
     Still yet one other further important object of the invention is to provide an internal combustion engine cleaning apparatus and method that includes an ultrasonic transducer that is inserted through an orifice into contact with a fluid. 
     Still yet one other further especially important object of the invention is to provide an internal combustion engine cleaning apparatus and method that includes an ultrasonic transducer that is inserted through an orifice and into contact with a cleaning solution. 
     Still yet one other further useful object of the invention is to provide an internal combustion engine cleaning apparatus and method that includes ultrasonic cleaning waves in a fluid to effectively clean the interior portions of an IC engine without substantial engine disassembly. 
     Still yet one other further important and useful object of the invention is to provide an internal combustion engine cleaning apparatus and method that includes an electronic amplifier to supply power to an ultrasonic transducer. 
     Still yet one other further important and especially useful object of the invention is to provide an internal combustion engine cleaning apparatus and method that includes control circuitry to regulate the functioning of the cleaning apparatus. 
     Briefly, an internal combustion engine cleaning apparatus and method that is constructed in accordance with the principles of the present invention includes a transducer that emits ultrasonic energy. An adapter that holds the transducer is attached where desired to an IC engine so that the transducer imparts ultrasonic energy directly to a fluid that is contained within the IC engine or is part of any of the engine&#39;s sub-systems. The transducer is placed in direct contact with the fluid. For example, to clean the interior portions of the IC engine that are exposed to the lubricating oil sub-system, the transducer may be attached to an adapter that includes a portion of the transducer that passes through the oil pan drain hole so that it contacts the fluid. In this instance the engine oil is replaced temporarily by a cleaning solution and the transducer imparts ultrasonic energy to the cleaning solution thereby increasing the efficacy of the cleaning solution and cleaning process. The cleaning solution is later removed and the engine oil is replaced. A different transducer and a different adapter are used for different sizes and different types of IC engines, depending upon the specific requirements. Similarly, a different transducer and a different adapter are used to clean the various sub-systems of the IC engine. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is block diagrammatic view of an internal combustion engine cleaning apparatus and method. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring to FIG. 1 is shown, an internal combustion engine cleaning apparatus and method, identified in general by the reference numeral  10  for use in cleaning the interior portions of an internal combustion type of an engine, the engine being identified in general by the reference numeral  11 . 
     The internal combustion engine cleaning apparatus and method  10  includes an ultrasonic engine cleaning machine, identified in general by the reference numeral  12 . 
     The ultrasonic engine cleaning machine  12  includes a cleaning solution tank  14 . Depending upon what part of the engine  11  is to be cleaned, a different type of a cleaning solution  15  is disposed in the cleaning solution tank  14  and is used. 
     The example shown in the FIG. 1 drawing illustrates use of the internal combustion engine cleaning apparatus and method  10  for the cleaning of the lubrication system (i.e., the motor or engine oil) of the engine  11 . For this purpose, it is preferable to heat the cleaning solution  15  optimally to approximately 140 degrees Fahrenheit. 
     The cleaning solution  15  also contains lubricants, as is well known in the engine oil cleaning arts, so as to prevent a “dry start” of the engine  11 . A dry start occurs when the engine&#39;s  11  lubricating system has been cleaned and contains no lubricants whatsoever. 
     Starting the engine  11  under these conditions results in moving metallic parts directly contacting other metallic parts in the engine  11  briefly until the fresh engine oil is circulated. This brief metal to metal contact can result in disproportionate engine wear and is therefore desirable to avoid. The use of lubricant additives to leave a residual lubricating film in the engine  11  after cleaning is complete is known for use with the cleaning solution  15 . 
     Obviously, the cleaning solution  15  will include any other desirable agent or additive that is useful to cleaning whatever area of the engine  11  is being cleaned by the internal combustion engine cleaning apparatus and method  10 . 
     Although the specification describes with specificity the cleaning of the engine oil lubrication system, it will become obvious to those possessing ordinary skill in the art as to how to adapt the internal combustion engine cleaning apparatus and method  10  for use with any of the sub-systems of the engine  11 . It will also become obvious how to adapt the apparatus and method  10  for use regardless of the size or the type of the engine  11 . 
     An oil filter adapter  16  is attached to the engine  11  at the location where the oil filter (not shown) was removed. An oil filter cleaning solution hose  18  is attached to the oil filter adapter  16  and extends to the ultrasonic engine cleaning machine  12  where it is used to supply the cleaning solution  15  to the engine  11  when desired. 
     A first pump  20  is controlled by a first solenoid  22  and when activated supply the heated cleaning solution  15  to the engine  11  through the oil filter adapter  16  under pressure, typically around 40-50 pounds per square inch. 
     An oil drain plug adapter  24  is attached to the engine  11  at the location where the oil drain plug (not shown) was removed. An ultrasonic transducer  26  is preferably included as a part of the oil drain plug adapter  24  or it is attached to the oil drain plug adapter  24  after the oil drain plug adapter  24  is installed. 
     The ultrasonic transducer  26  includes a power amplifier (or the power amplifier is contained as part of either a control electronics assembly  27  or a power supply  28  that are contained in the ultrasonic engine cleaning machine  12 ). A power line  30  (i.e., an electrical cable) is connected intermediate the power supply  28  in the ultrasonic engine cleaning machine  12  and the oil drain plug adapter  24  to supply power to the transducer  26 . 
     The ultrasonic transducer  26  may include a flexible waveguide extension  32  that is useful for imparting ultrasonic energy where desired. 
     A filter assembly  32  is included as part of the ultrasonic engine cleaning machine  12  to filter and clean contaminants from the cleaning solution  15  prior to the cleaning solution  15  being delivered back to the cleaning solution tank  14 . 
     An oil drain hose  34  is attached to the oil drain plug adapter  24  and to the filter assembly  32 . 
     A second pump  36  is controlled by a second solenoid  38  and when activated, receives the cleaning solution  15  from the filter assembly  32  and, before that, from the oil drain plug adapter  24 . The oil drain plug adapter  24  contains an opening  40  to permit fluid flow to occur through it. 
     Operation 
     1. The first step is to remove the engine drain plug and to drain and collect the old engine motor oil for disposal. 
     2. The second step is to remove and dispose of the old vehicle oil filter. 
     3. The third step is to install the oil filter adapter  16  and to connect the oil filter cleaning solution hose  18  to the oil filter adapter  16 . 
     4. The fourth step is to install the ultrasonic transducer  26 , possible waveguide extension  32 , and the associated oil drain plug adapter  24  to the oil drain hole and to connect the oil drain hose  34  and the electrical power line  30  to their respective locations on the oil drain plug adapter  24 . 
     5. The fifth step is to begin the cleaning cycle by pumping the cleaning solution  15  (having a preferred formulation) that is optimally preheated to approximately 140 degrees Fahrenheit into the engine  11  through the oil filter adapter  16 . 
     6. The sixth step is to energize (i.e., to supply power to the transducer  26 ) for a period of time sufficient to effectively clean the engine  11 . The transducer imparts ultrasonic energy of any preferred ultrasonic frequency (or variable range of frequencies such as by “sweeping” frequencies) to the cleaning solution  15  so as to rapidly and effectively clean the interior portions of the engine  11 . The effect of the ultrasonic energy is shown generally by a group of four arrows identified in general by the reference numeral  42 . The time range for this cycle is varied to satisfy the requirements and typically may include a range of from approximately one to five minutes duration. The duration for this cycle is determined by the various control panel settings that are manually selected or which are under program control by the control electronics  27 . Once the settings are complete ideally a simple touch of a “start button  44 ” after all manual connections are complete will cause the machine  12  to perform all of the cleaning cycles automatically. 
     7. The seventh step is to end the cleaning cycle by recovering the bulk of the remaining cleaning solution  15  from the oil drain adapter  24 . The cleaning solution  15  may be filtered by the filter assembly  32  and then stored for reuse back in the cleaning solution tank  14  or it may be replaced when desired with fresh cleaning solution (not shown). 
     8. The eight step is to remove the hoses  18 ,  34  and adapters  16 ,  24  and the transducer  26  and to install the vehicle&#39;s engine drain plug and a new oil filter and to add fresh oil. 
     The cleaning solution will contain some lubricants that remain in the engine  11  to provide a residual coating to prevent dry starts. If desired, the cleaning solution  15  cycle may be followed by repeating the process with a second rinse solution cycle that may, or may not, itself include the use of ultrasonic energy. The cleaning solution  15 , rinse solution, filter screens and filter elements of the filter assembly  32  are replaced or are cleaned when and how desired. 
     The invention has been shown, described, and illustrated in substantial detail with reference to the presently preferred embodiment. It will be understood by those skilled in this art that other and further changes and modifications may be made without departing from the spirit and scope of the invention which is defined by the claims appended hereto.