Patent Publication Number: US-2019186354-A1

Title: Internal Combustion Engine

Description:
FIELD 
     The present disclosure relates to an internal combustion engine with at least one double cylinder, in which two inner pistons and two outer pistons are arranged such that they can be moved back and forth in the double cylinder by at least one respective inner connecting rod or a respective first outer connecting rod and a respective second outer connecting rod by a crankshaft. 
     The double cylinder has two opposing cylinders which are on the same axis. These cylinders each have opposing pistons. 
     BACKGROUND 
     An internal combustion engine with coaxial cylinders with inner and outer pistons is disclosed in US 2015/0114358 A1. It consists of a first outer piston over a swiveling main connecting rod connected to a crankshaft journal and a second outer piston is arranged coaxially to the first outer piston. The second outer piston is connected to a swiveling auxiliary connecting rod, which is connected to the crankshaft via the main connecting rod. A disadvantage of this method is that the pivoting movement of the main and auxiliary connecting rods introduces transverse forces into the outer piston and the crankshaft. Furthermore, the pivoting movement also creates the need for a space between the outer pistons and the connecting rods. 
     Assemblies with fixed inner connecting rods with two arranged on a crankshaft with one piston each are described by Parson&#39;s Engine for simple double-cylinder piston engines. This version only moves the pistons and the connecting rods translationally along a straight line. For a four-cylinder engine a transfer disc is installed in front of the first crank throw. A second transfer disc is arranged between the two cylinders and a third transfer disc is installed after the second crank throw. Each of the two ends of the crankshaft have an externally toothed gear. Each of these gears engage with a ring gear. Due to the many parts needed and the complicated construction, this arrangement is not ideal. 
     In other purely kinematic solutions, which are hardly used, things such as crank grinding can result high loads and bearing friction. This means the components must be very robust to survive. 
     An internal combustion engine that eliminates these disadvantages and maintains high efficiency is desired. 
     SUMMARY 
     According to the disclosure, this purpose is achieved by arranging the first two outer connecting rods and the two outer pistons coaxially and preferably of one piece, and that the two second outer connecting rods are coaxial and preferably of one piece. The advantage of this is that no pivoting movement is necessary, which avoids the lateral forces introduced into the pistons and piston pins. Consequently, it also prevents excessive stress and wear. Each outer piston can be directly connected to its respective connecting rod without the need for an articulated connection. Furthermore, there is no longer a need for a piston sleeve to better guide the pistons in the cylinder. Since the friction on the piston is largely attributable to the lateral forces, the friction is significantly reduced. 
     As no bending forces are created by lateral acceleration of the outer connecting rods as they are with pivoting connecting rods, the outer connecting rods can be radial to the cylinder and flat, thus saving space and weight. The conserved space can be used for the gas exchange. 
     The outer connecting rods are rigidly connected. It is possible to make them all one piece. The two first outer connecting rods and the two second outer connecting rods are each connected to the crankshaft by a circular bearing. 
     Another advantage of this arrangement is that it reduces inertial forces, especially those of higher order. These forces are less of an issue for the inner connecting rods, since they are shorter. 
     By eliminating the lateral forces, the design also avoids tribological problems with friction and lubrication that occur in the conventional piston design. The disclosed design can use a simple cylindrical outer piston without an oval shape or crowning. 
     Because the outer connecting rods do not need to pivot, the space required for this pivoting can be saved. This space can instead be used for passages for intake and exhaust flows, i.e. gas exchange. 
     The first outer connecting rods are connected to the crankshaft via a first transfer disc that rotates relative to the connecting rods; and the second outer connecting rods are connected to the crankshaft via a second transfer disc that rotates relative to the connecting rods. The first and second transfer discs are attached eccentrically to an outer crankshaft journal of the crankshaft such that they can rotate. Both transfer discs are installed in the circular bearings of the outer connecting rods. 
     An advantage of this design is that due to the geometry, the eccentricity of the crankshaft journal amounts to only a quarter of a stroke, which is only half of that of the conventional crank drive, in which it is half a stroke distance. 
     Reducing the eccentricity by half compared to the conventional crank mechanism greatly improves the overlap between the main bearing of the crankshaft and the following crankshaft journals. The crankshaft itself is therefore much stiffer and sturdier and can be made more compact and at lower manufacturing cost. 
     Another advantage is that the piston movement is naturally harmonic; i.e. it is sinusoidal. The total mass can be easily balanced with counterweights on the crankshaft and transfer disc. 
     The transfer discs in the outer rods can be installed, for example, in a sliding bearing or in a roller bearing. This is because of the manageable loads on the bearings in this area, as well as the possible sliding and rolling speeds. No sliding or linear bearings are necessary. 
     In some embodiments, external teeth on the transfer disc engage with internal teeth of a ring gear, which is fixed to the external housing. The external teeth and the internal teeth have a gear ratio of 1:2. 
     A particularly simple arrangement is created when the first longitudinal axis of the first outer connecting rods, the second longitudinal axis of the second outer connecting rods, and the stroke axis of the outer piston and the inner piston all lie in a single plane. 
     No articulated connection is needed between the outer connecting rods and the outer piston. The arrangement is particularly simple and robust with the two outer pistons fully fixed to the first and second outer connecting rods. 
     This is particularly simple because the first and second outer connecting rods are connected both to each other and to the outer piston via a T-shaped component. The two first and the two second outer connecting rods and the two T-shaped connecting components form a unit with the two outer pistons. These individual parts move as a unit, with no need for movement relative to each other. 
     An accurate guide for the outer piston is created by the T-shaped connecting element with its two ends in the guide recesses of each cylinder of the double cylinder, wherein the two ends are installed parallel to the level sliding surfaces. 
     To avoid pivoting movement of the inner connecting rods, in some embodiments, both inner connecting rods to be of one piece and attached to the crankshaft by a third transfer disc, wherein the third transfer disc is arranged eccentrically to an inner crankshaft journal, and is attached to both the crankshaft and the inner connecting rods in a rotating fashion. 
     A simpler method of assembly can be developed by creating the crank arm portion of the crankshaft out of at least two individual parts, with two conical surfaces, connected with bolts or stud bolts. 
     The assembly can be further simplified by using stud bolts that have two sections of thread. Each section would have a different pitch, and the pitch of the second section is larger than that of the first section. The first section of thread is inserted into the crank arm, and the second section of thread is screwed into its respective crankshaft journal. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The disclosure is explained more thoroughly by the following non-limiting figures. 
         FIGS. 1, 2, 4, 5, and 6  are views of an internal combustion engine from a first isometric view, a second isometric view, a top view, a front view, and a side view, respectively; 
         FIG. 3  Is a cross section of the internal combustion engine of  FIGS. 1, 2, 4, 5, and 6 ; 
         FIG. 7  is a side view of a first outer connecting rod with a first transfer disc and a ring gear; 
         FIG. 8  is an isometric view of the crankshaft, connecting rods, and ring gears of the internal combustion engine of  FIGS. 1, 2   4 - 6 ; 
         FIG. 9  a top view of the internal combustion engine without the cylinders or housing; 
         FIG. 10  shows a second embodiment of an internal combustion engine according to embodiments of the disclosure in cross section. 
         FIG. 11  is a schematic sketch of the crankshaft in a side view; 
         FIG. 12 a    is a schematic sketch of the crankshaft in side view; 
         FIG. 12 b    shows a cardanic circle pair of  FIG. 12   a;    
         FIG. 12 c    shows the crankshaft and an outer crankshaft journal of  FIG. 12   a;    
         FIG. 12   d  shows the first transfer disk of  FIG. 12   a;    
         FIGS. 13 a   - 3  are schematic sketches of the crankshaft in the side view in first, second, third, fourth, and fifth positions; 
         FIG. 14  a schematic sketch of a side view of the first transfer disc; 
         FIG. 15  a schematic representation of the forces on the internal combustion engine; 
         FIG. 16  a third example of the internal combustion engine; and 
         FIG. 17  the crankshaft of a fourth example of the internal combustion engine. 
     
    
    
     DETAILED DESCRIPTION 
       FIG. 1  shows a first example of an internal combustion engine  1  disclosed herein. Engine  1  has a double cylinder  2 . Each cylinder  3  of double cylinder  2  is situated along a central stroke axis, A, on either side of a crankshaft  4 . Crankshaft  4  is mounted so that is able to rotate in a housing  5 . Cylinders  3  are attached to housing  5 . 
     In each cylinder  3  of double cylinder  2 , there is an inner piston  6  and an outer piston  7 , as shown in  FIG. 2 . The two inner pistons  6  and the two outer pistons  7  reciprocate in their associated cylinder  3 , opposite each other along the central stroke axis, A. 
     Inner pistons  6  are attached via two inner connecting rods  8  to the rotating crankshaft  4 . The inner connecting rods  8  are each connected via a piston pins  9  in such a manner that they can pivot. 
     Outer pistons  7  are each connected to a first outer connecting rod  11   a  and a second outer connecting rod  11   b  via a T-shaped connecting component  10 . To further counteract any tilting movement of the outer piston  7 , two ends  10   a  of T-shaped connecting element  10  connected to outer connecting rods  11   a ,  11   b . T-shaped connecting element has a middle body  10   b  and sliding surfaces  12 . Each T-shaped element  10  is guided by recessed slots  13  ( FIG. 1 ) in each cylinder  3  to keep them parallel to the central stroke axis, A. 
     One pair of outer connecting rods pairs  11   a  are arranged coaxially along a first axis, B, which is parallel to stroke axis, A, of inner piston  6  and outer piston  7 . The other pair of outer connecting rods  11   b  are arranged on a second axis, C, which is also parallel to the central stroke axis, A. 
     Outer connecting rods  11   a  are attached to crankshaft  4  via a first transfer disc  14   a  in such a way that the disc may rotate. Outer connecting rods  11   b  are attached analogously to a second transfer disc  14   b . Transfer discs  14   a ,  14   b  may be mounted so that they slide or roll. Transfer discs  14   a ,  14   b  have external teeth  15 . These external teeth  15  are arranged to engage inner teeth  16  of a ring gear  17 . 
     Referring now to  FIG. 3 , transfer discs  14   a ,  14   b  each rotate on an outer crankshaft journal  18  of crankshaft  4 . They are eccentric. The rotational axis, D, of transfer discs  14   a ,  14   b  are offset from a rotational axis, E, of outer crankshaft journal  18 . The term rotational axis D, E refers to the axis of of rotational symmetry, not to rotation of the body in question (crankshaft journal  18  or transfer discs  14   a ,  14   b ). 
     Each outer crankshaft journal  18  has a respective transfer disc  14   a ,  14   b  designed as an outer crankshaft bearing surface  19 . Crankshaft  4  is bolted together in the area of the crank arms  20 . The individual parts can also be coupled by an equivalent bonding agent, or it can be of one piece. This allows outer crankshaft journals  18  to be press-fit into transfer discs  14   a ,  14   b  and allowing outer connecting rods  11   a ,  11   b  to be one piece. 
     Between the two crank arms  20 , there is an inner crankshaft journal  21 . In the example shown, it is connected to the crank arms  20  via bolts  22 . 
     Outer connecting rods  11   a ,  11   b  are each connected to transfer discs  14   a ,  14   b  via a roller bearing  23  in the example shown in  FIG. 3 . 
     Stroke axis, A, of inner piston  6  and outer piston  7 , the first longitudinal axis, B, and the second longitudinal axis, C, lie in a plane, E, which represents the section plane of  FIG. 3 . 
     Crankshaft  4  is mounted in housing  5  such that it can rotate about an axis, F. Ring gear  17  is fixed in housing  5 . The axis, F, is also the axis of rotational symmetry of ring gear  17 . 
       FIGS. 10 and 11  show a second example of the internal combustion engine  1 . In this example, first transfer disc  14   a  and second transfer disc  14   b  have no external teeth. Outer crankshaft journal  18  is attached such that it can slide in an eccentric recess  14   c  of transfer discs  14   a ,  14   b.    
     Kinematically, the internal combustion engine of this disclosure is based on the cardanic circle pair: if one places an inner, smaller circle along an outer, larger circle with double the radius of the inner, as the small circle moves, each point of it is straight on the diameter of the larger circle. 
     Philippe de La Hire first proved in 1706 that the hypotrochoids of cardanic circles are all ellipses. When the ratio of the larger cardanic circle, a, to the smaller cardanic circle, b, is 2:1, and the smaller circle, b, is rolling inside the larger circle, a, each point that is rotated through by the smaller circle, b, describes an ellipse. If the point of rotation lies within the circle, b, the ellipse also lies completely inside the larger circle, a. If the point of rotation lies outside of the smaller circle, b, the ellipse is partly outside of the larger circle, a. In the special case where the point of rotation is exactly on the circumference of the smaller circle, b, it moves on a straight line, namely on a diameter of the larger circle, a. 
     This straight line can be understood as a degenerated ellipse, and this particular geometric case is of importance for the disclosed engine. This special case makes it possible to translate the oscillating movement of the outer connecting rods into a rotational movement. 
     This geometric principle is applied in this disclosure, as shown in  FIG. 12 a - d    and  FIG. 13 a - e   . Each show an outer crankshaft journal  18  thusly arranged in the circular, eccentric recess  14   c  of transfer discs  14   a ,  14   b , so that upon clockwise rotation of transfer discs  14   a ,  14   b  with simultaneous counterclockwise rotation of crankshaft  4 , the crankshaft journal  18 , the center G of the transfer disc  14   a ,  14   b  is displaced along a straight line. Ergo, the whole system of the transfer disc  14   a ,  14   b  with pressed-in crankshaft journal  18  moves along a line, the longitudinal axis B, C of the outer connecting rods  11   a ,  11   b , which is parallel to the stroke axis A, when transfer disc  14   a ,  14   b  and crankshaft  4  are rotated in opposite directions. 
     Conversely, this also means that a movement of transfer disc  14   a ,  14   b  along longitudinal axes, B and C, forces transfer disc  14   a ,  14   b  and outer crankshaft journal  18  to turn against each other, thereby creating a rotational movement of crankshaft  4 . This movement is translated to outer connecting rods  11   a ,  11   b , where transfer discs  14   a ,  14   b  are set into an opening  11   c  in connecting rod  11   b , which connects outer connecting rods  11   a ,  11   b  to outer crankshaft journal  18  in such a way that they can move. 
     Analogously to the kinematic principle of the cardanic circles, a and b, the linear part of the disclosure can be represented by lever arms  25   a ,  25   b  as shown in  FIG. 14 : a first eccentricity e between axis, F, of crankshaft  4 , and the center of a main bearing  24  and the rotation axis, E, of the outer crankshaft journal  18  represents a first lever arm  25   a  whose length is one quarter of stroke length, H. A second eccentricity, f, between the center, G, of transfer discs  14   a ,  14   b  and axis of rotation, E, of outer crankshaft journal  18  creates a second lever arm  15   b , which also has one quarter of stroke length, H. 
     Crankshaft  4  has the same rotational speed as transfer discs  14   a ,  14   b , but rotates in the opposite direction. In these conditions, center, G, of transfer discs  14   a ,  14   b  moves along a straight line. 
     One can better understand the representation of lever arms  25   a ,  25   b  with a depiction of the cardanic circles a, b, such that axis, F, of crankshaft  4  and the center of main bearing  24  lie in the central point, I, of the larger cardanic circle, a. The axis of rotation, E, of outer crankshaft journal  18  is in the center of the smaller cardanic circle, b. The center, G, of the transfer disc  14   a ,  14   b  is a reference point, J, for both cardanic circles, a, and b, in their exact centers. Over the course of the stroke, H, they move horizontally along the diameter of the larger cardanic circle, a. 
     Outer connecting rods  11   a ,  11   b  and outer piston  7  oscillate with harmonic movement. This means that the deflection of the outer connecting rods  11   a ,  11   b  and the outer piston  7  is sinusoidal. 
     A force, K, which is introduced by outer piston  7 , exerts a torque, L, on crankshaft  4 , and the force is absorbed by main bearing  24  and outer crankshaft bearing  19 . 
     An analysis showed that the forces on the linear sliding bearing for one after the principle moving piston are smaller than in a crank mechanism with the rod length to eccentricity ratio of 10. (For car engines, a ratio of 3 to 3.5 is common.) 
     A third example is shown in  FIG. 16 , in which internal combustion engine  1  has a third transfer disc  26  to inner piston  6 , which is coupled to two inner connecting rods  8 . Inner connecting rods  8  are then arranged along the stroke axis, A; and are of one piece. Third transfer disc  26  rotates about inner crankshaft journal  18 . The function is analogous to first transfer disc  14  and to the second transfer disc  14   b.    
     As a result, this design can achieve the same advantages as outer pistons  7  and outer connecting rods  11   a ,  11   b . Third transfer disc  26  has no outer teeth facing housing  5 . 
     In a fourth example, shown in  FIG. 17 , the crankshaft is made up of multiple parts. In this example, outer crankshaft journals  18  and outer parts  4   a  of crankshaft  4  form a unit. Outer crankshaft journals  18  have a conical outer surface  18   a  that faces an external connecting surface  27 . External connecting surface  27  is connected to outer surface  18   a  via a conical inner surface  18   b . Inner crankshaft journal  21  has two inner connecting surfaces  28 , with which it contacts crank arms  20 . External connecting surfaces  27  are also located on recesses of crank arms  20 , which are essentially of a corresponding shape to outer crankshaft journals  18 . 
     Inner crankshaft journal  21  has an outer truncated conical surface  21   a  and an inner truncated conical surface  21   b  for each crank arm  20 . 
     Crank arms  20  are connected to inner crankshaft journal  21  via stud bolts  22   a . Stud bolts  22   a  each have a first section of thread  22   b  and a second section of thread  22   c . The first section of thread  22   b  has thread pitch, p 1 , and the second section of thread  22   c  has thread pitch, p 2 , which in the example shown is twice as large as the first pitch, p 1 . 
     To connect crank arm  20  with inner crankshaft journal  21  and crank arm  20  with outer crankshaft journal  18 , stud bolt  22   a  is installed with first thread  22   c  screwed into crank arm  20  up to a certain depth (in the example shown, about half of the engagement of second thread  22   c  at double first thread pitch p 1 ). Then the respective crankshaft journal  18 ,  21  is in contact with the stud bolt  22   a  and second thread section  22   c  is screwed into crankshaft journals  18 ,  21 . Crank arm  20  and crankshaft journal  18 ,  21  are brought closer to each other. Between the truncated conical surface  21   a  and crank arm  20  and between conical outer surface  18   a  and crank arm  20  there is an interference fit. 
     Conical outer surface  18   a  and outer truncated conical surface  21   a , in the example shown, each have a pitch of less than 1°. 
     To ensure exact positioning of crankshaft journals  18 ,  21  to crank arms  20 , there is an adjusting spring  29  provided for each connection between crankshaft journals  18 ,  21  and crank arm  20 . This ensures that the tolerances for the angle of crankshaft  4  can be maintained exactly. Adjusting spring  29  is installed in each case between outer truncated conical surface  21   a  and crank arm  20  and between each conical outer surface  18   a  and crank arm  20 . 
     Due to their first and second thread pitches, p 1  and p 2 , being different, disassembly of crankshaft  4  is quite simple. Stud bolts  22   a  of crank arm  20  are removed. Crankshaft journals  18 ,  21  move away from crank arm  20  because of the larger second thread pitch, p 2 . 
     There is no contact between conical inner surface  18   b  and crank arm  20 . Similarly, there is no contact between inner truncated conical surface  21   b  and crank arm  20 . In the example shown, rounded surfaces between conical inner surface  18   b  and conical outer surface  18   a  do not touch crank arms  20 . Analogously, the rounded surfaces between outer truncated conical surface  21   a  and inner truncated conical surface  21   b  do not touch crank arms  20 . 
     Briefly summarized, the disclosure relates to an internal combustion engine  1  with at least one double cylinder  2 , in which two inner pistons  6  and two outer pistons  7  are each connected by at least one inner connecting rod  8 , a first outer connecting rod  11   a , and a second outer connecting rod  11   b , arranged in double cylinder  2  thus that they are moved back and forth by a crankshaft  4 . A feature of the disclosed internal combustion engine  1  is that outer connecting rods  11   a ,  11   b  do not pivot. According to the disclosure, the lack of pivot of outer connecting rods  11   a ,  11   b  is fulfilled by the fact that outer connecting rods  11   a ,  11   b  are coupled to two outer pistons  7  are respectively coaxial and of one piece.