Abstract:
A double acting, miller cycle, reciprocating piston with dual rotary displacer, stirling engine is provided. Configurable as a heat pump, a heat engine, or as a combination with one side driving the other, the engine is completely enclosed, sealed and pressurized with the piston ring as the only internal seal. A miller cycle is created by allowing transfer of the working fluid (typically hydrogen gas) past the piston to balance working fluid pressure only at the extremes of the piston stroke. Two coordinated rotating displacers service opposite sides of one piston. Each displacer manages heat flow, according to its length and shape, through one side of the length of its encasing tube into and out of the working fluid through the other side of the length of its encasing tube. The dead space between the piston and the displacer holds regenerator material.

Description:
BACKGROUND 
       [0001]    The concept of mechanically manipulating the ideal gas laws to convert heat into motion or vice-versa was first patented by Robert Stirling in 1817. Since that time several designs, most utilizing multiple pistons, have emerged including some designs utilizing pressure waves in lieu of a displacer with only a single piston. 
         [0002]    The basic Stirling engine includes a trapped gas that is heated or cooled which then expands or contracts (according to the ideal gas laws) which pushes or pulls on a piston which then drives a crankshaft. The crankshaft is typically coupled to a flywheel and an output shaft. The output shaft delivers usable mechanical force relative to the initial temperature differential and amount of heat transferred. 
         [0003]    Current commercial designs utilize a piston style displacer to move the working gas from a heating chamber to a cooling chamber and back. Common designs use multiple internal seals and two or more pistons. Current designs are complex and difficult to manufacture making them relatively high cost. The greater efficiency, reliability, lifespan, cleanliness, and flexibility that Stirling engines demonstrate compared to internal combustion engines has previously been sacrificed in favor of the faster start up, control response, greater power density, and ease of manufacture of competing engines. However, the inherent advantages of the Stirling engine allows it to compete successfully in various specialty niches of the engine market, such as satellite power production, waste heat recovery, cryogenics, solar power conversion, space craft, and submarines, where faster start up, control response, greater power density, and ease of manufacture are not the critical criteria in engine selection. 
         [0004]    The Stirling engine has many advantages such that it could displace internal combustion engines in many applications if a few of the Stirling engine&#39;s drawbacks could be addressed. For example the Stirling engine has fewer moving parts, no need for expensive sound deadening or exhaust gas treatment, nor complex ignition, timing, and fuel handling requirements. Furthermore, the Stirling engine benefits from a large menu of energy sources and fuels to choose from and the use of non-polluting gasses when used in refrigeration. 
         [0005]    Accordingly, there is a need for a Stirling engine with lower cost, and higher power density. Such an improved Stirling engine could become the mainstream choice in such applications as hybrid automobiles, aircraft, and boats, as well as electric generators, refrigerators and water heaters. In other words, applications in which costs, simplicity and power density are the primary consideration and where start up speed and control response are ancillary considerations. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0006]    The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of an improved Stirling engine and together with the description, serve to explain the principles and operation thereof. 
           [0007]      FIG. 1  is a hidden line perspective view of a Stirling engine according to an exemplary embodiment; 
           [0008]      FIG. 2  is a hidden line end view of the Stirling engine shown in  FIG. 1 ; 
           [0009]      FIG. 3  is a multi-view representation of the Stirling engine shown in  FIGS. 1 and 2 ; 
           [0010]      FIG. 4  is a transparent solid model perspective view of the Stirling engine shown in  FIGS. 1-3 ; 
           [0011]      FIG. 5  is a transparent exploded solid model representation of the Stirling engine shown in  FIG. 4 ; 
           [0012]      FIG. 6  is a transparent solid model end view of the Stirling engine shown in  FIGS. 4 and 5  as viewed from the displacers; and 
           [0013]      FIG. 7  is a transparent solid model end view of the Stirling engine shown in  FIGS. 4-6  as viewed from the piston. 
       
    
    
     DETAILED DESCRIPTION 
       [0014]      
         [0000]    
       
         
               
               
             
               
               
             
           
               
                   
               
               
                 ITEM NO. 
                 PART NUMBER 
               
               
                   
               
             
             
               
                   
               
             
          
           
               
                 1 
                 Cylinder single 8 
               
               
                 2 
                 Cylinder bearing mount plate 
               
               
                 3 
                 Cylinder bearing internal support 
               
               
                 4 
                 Cylinder Chinese Hat 
               
               
                 5 
                 Piston 2part 
               
               
                 6 
                 Piston Pin 2 
               
               
                 7 
                 Bearing 20 × 26 × 20 
               
               
                 8 
                 Connect rod single v 2 top 
               
               
                 9 
                 Piston Pin displacer only side 
               
               
                 10 
                 nut .25 in 
               
               
                 11 
                 Crankshaft powerside 
               
               
                 12 
                 Bearing 10-26-8 
               
               
                 13 
                 crankshaft half in ext 
               
               
                 14 
                 Screw flat head 1 4th in 
               
               
                 15 
                 Crankshaft thin open derived 
               
               
                 16 
                 Crank to Displacer rod 
               
               
                 17 
                 DriveShaft to crank clip 
               
               
                 18 
                 Bearing 8 id-12-3w 
               
               
                 19 
                 Washer 10-15-0325 
               
               
                 20 
                 Washer 12-20-1 32nd 
               
               
                 21 
                 Pipe Intersect 5-6 
               
               
                 22 
                 Bearing .5 × 1 × .344 
               
               
                 23 
                 Displacer 9 
               
               
                 24 
                 Heat Ex Cap Bearing Mount 
               
               
                 25 
                 Nut .5 × 15 mm 
               
               
                 26 
                 mate round hex 
               
               
                 27 
                 Heated tube 5.047 mate flange 
               
               
                 28 
                 Heated Tube Endcap 5.047 id 
               
               
                 29 
                 Copy of Heated Tube 
               
               
                 30 
                 Copy (4) of Heated Tube{circumflex over ( )}Cylinder and piston 
               
               
                 31 
                 Part2 
               
               
                 32 
                 Radiator inside 
               
               
                 33 
                 Part4 
               
               
                 34 
                 Part5 
               
               
                 35 
                 Heating tube brace 
               
               
                 36 
                 Heating tube 
               
               
                 37 
                 HX-SHCS 0.5-20 × 3.5 × 2 − N 
               
               
                   
               
             
          
         
       
     
         [0015]    Provided herein is an improved Stirling engine that addresses the difficulties and maximizes the advantages of the Stirling cycle engine. Lower production and maintenance costs are possible due to the elimination of all but one internal seal (on the piston) sealing all moving parts within the pressure vessel (isolating them from heat and corrosive gasses or liquids) and fewer, simpler parts manufactured with less precision. 
         [0016]    Greater power density is achieved by using two displacers with one on either side of the piston to produce power in each direction of every stroke similar to the Stanley steamer engine. Working gas is transferred at the end of the power stroke, similar to the Miller cycle engine, to prevent counter pressure, pre-load the coming power stroke, and simplify initial pressurization. Greater initial pressurization, possible due to the elimination of external seals, makes more gas molecules available to transfer heat. 
         [0017]    Smoother quieter operation is achieved with a lighter flywheel by means of reshaping and rotating rather than reciprocating the displacer. Using a single piston with both sides driven reduces complexity, compared to multiple cylinder engines of similar power output. 
         [0018]    Rotating instead of reciprocating the displacer eliminates the counter action of gas pressure on the displacer piston during the power stroke as well as the extra friction. The working gas is guided into a vortex that efficiently transfers heat between the exchanger wall and the working gas. Adjusting the relative position of the displacer and the piston allows flexibility in where the heating and cooling areas are on the heat exchanger housing. 
         [0019]    Rotating at 90 degrees to the piston, unless connected through a constant velocity joint or powered by separate motor or timing belt, the displacer provides precise control over the heating and cooling of the working gas. The displacer may be formed of a lightweight, insulating, and heat resistant, inflexible compound of either graphite carbon or silicon. The displacer may be coated with a pattern of insulator such as Aerogel and regenerator material (such as nickel foam) to appropriately guide heat flow and have a shape that creates and controls the turbulence of the working gas. 
         [0020]    Working gas turbulence is controlled both by the cam shape of the displacer which compresses and releases the working gas in the desired direction and place, and by the shape of the chamber it creates as it directs the gas movement out of and into the piston cylinder. The working gas can be trapped in the displacer for a few degrees and released suddenly by creating a rotating valve at the intersection of the displacer and piston cylinder, for greater power. In an embodiment, a constantly rotating vortex is formed as the displacer turns and the working gas expands and contracts. In another embodiment, further control of turbulence may be achieved by placing storage pockets in the displacer that will pressurize during the heating cycle and release the pressure in a specific direction through a nozzle during the cooling cycle. The displacer shape and relative motion creates a constant sized area in which a mechanical means of directing turbulence, such as a fan, can be inserted if desired. 
         [0021]    Greater heat input and therefore power as well as reduced complexity is made possible through utilizing the entire length of the displacer housing as opposed to heating only one end of the housing as in current designs (a wider path allows more heat to flow). More efficient heat transfer is achieved by means of greater control of working gas turbulence, optimization of the displacer chamber volume to surface ratio, shape, surface roughness and corrugation, direct control of heat transfer from heat source, adjustable displacer to piston ratio and minimization of dead space. The passage between the displacer and the piston may be filled with a mesh of nickel foam that acts as a re-generator. 
         [0022]    The use of a through-the-piston connecting rod creates accurately timed coordination and counter rotation of the opposing displacer. In addition to eliminating possible frozen states on start up, the counter rotation of the displacers, with the flywheel turning opposite the direction of the output shaft, reduces gyroscopic progression that may be an issue in some applications. In most applications putting the flywheel on the output shaft will reduce total weight. Some configurations may disallow the use of a one piece through the piston connecting rod and require either two standard mirror image connecting rods or a timing belt or electronic means of coordinating the rotation of the two displacers. Since the displacers regulate and time the heat transfer from the exchanger to the working gas which then pushes on the piston, as long as the displacers are coordinated, no mechanical connection is required between the piston and displacers. A constant speed can be obtained by turning the displacers electronically to control the piston and crankshaft. 
         [0023]    The piston is designed as a two identical piece part that is bolted together and houses a piston pin on bearings and provides for easy assembly of two opposing continuous oil-less piston rings. The concave shape of the piston face provides clearance for the crankshaft, strength for the power stroke and brings the displacers closer together without additional mechanical parts. Controlled leakage at the extreme of the piston stroke, similar to the Miller cycle, eliminates counter pressure when pressure is left over from the power stoke. 
         [0024]    The piston cylinder doubles as the crankshaft housing and provides the fulcrum against which the crankshaft pushes. Since the entire engine is a pressure vessel, containing it within standard tubing reduces weight and complexity. The openings from the cylinder to the displacer chamber are shaped to minimize the loss of support against the pressure while providing adequate gas flow. Dead space is minimized by filling it with packing material to displace the gas. The bearing mounts are the same distance apart as the length of the connecting rod, measured from bearing center to bearing center on the connecting rod and the cylinder. Maintenance free bearings are located well away and shielded from heat sources for maximum maintenance free life. The lack of lubricating fluid eliminates the oil pump, tubing, machined channels oil filter and lightens the engine. 
         [0025]    The displacer housing functions as the heat exchanger. Essentially a long tube, strong enough to contain the pressure while heated on one side and cooled on the other it has a welded cap at one end and is bolted or welded to the piston cylinder at the other end. While the points of assembly are shown in the figures as flanges, a high pressure model would use a stronger means of joining the pieces such as an interrupted thread design similar to a cannon breach, or a threaded pipe design or welding. 
         [0026]    A rough finish and possibly corrugation interleaving with the displacer, to facilitate heat transfer, may be applied by chemical or mechanical means. When used with combustible fuels the heated side can be coated with catalyst to maximize the chemical reaction of the fuel with the oxidizer. The ideal material would be pure carbon in crystal form with a nano-scale fractal pattern finish to facilitate heat transfer from the source through the wall and into the working gas. Less ideal but still functional materials would be titanium or commercial steel tubing. Greater efficiency can be gained by constructing the displacer housing in a multi-part clam shell design separating the sides with insulation so the heat travels through the working gas instead of circumferentially through the shell. This may increase manufacturing costs; however, with the extended life span of the Stirling engine, the added efficiency of this option may be desired. 
         [0027]    On the outside of the engine, the improvements include controlling and directing the heat from whatever source directly to the desired area on the exchanger with no need of the commonly used heater assembly. The use of insulation and ducting would be tailored to the heat source. The heat source may be geothermal, solar, combustion, or other desired heat source. The radiator, if used in home or business power generation may double as a water heater. The supporting structure of the engine and intake and exhaust would simplify the stacking and use of multiple engines to achieve higher required output. Waste heat from the radiator and the combustion products can partially be recycled to preheat air when combustible fuels are used. When using combustible fuels, the combustion area can be optimized for maximum efficiency depending upon the fuel used. Materials are chosen to optimize recycling of engines after their useful life. Maintenance is simplified with standard fasteners and bearings that are widely available. Standard tubing sizes and common piston sizes are purposely chosen, to simplify any repairs that may be needed in rural areas as well as reduce production costs. The entire engine is considered to be a pressure vessel, but the extra weight is minimal considering the greater power density achieved, that all moving parts are safely hidden inside and protected from dust and moisture, and the elimination of all but one external dynamic seal around the output shaft. 
         [0028]    In an embodiment one side of the engine is powered and the other side is used as a heat pump for refrigeration or heating. While shown parallel and equal in the figures, the displacer tubes are independent of each other and multiple configurations are possible. For example, one heat exchanger could sit on the top of an insulated container and draw heat out of it forming a refrigerator. The heat would then be used to preheat the combustion process for the other heat exchanger which would drive the system. Alternatively, one engine could use fuel to drive a second engine that was used as a heat pump to provide refrigeration of food or medicine or distillation of liquids such as drinking water. Distillation would use both the heated and cooled sides of either or both of the exchangers. 
         [0029]    In the event of catastrophic failure due to external insult or internal defect, the high-pressure gas is released in a controlled manner by the use of materials that deform rather than break. The route of pressure relief at the end of piston travel clears the working gas from the undamaged side of the engine in a controlled manner. The radiator also functions as a shrapnel catcher on the top while shrapnel directed downward is slowed by the heating duct work and directed by installation design into the earth or a component of the installation and away from sensitive areas. If Hydrogen is used as the working gas, mixing it with nitrogen or carbon dioxide should moderate the tendency to burn rapidly. 
         [0030]    Also, contemplated herein are methods for providing rotational power according to the present disclosure. The methods thus encompass the steps inherent in the above described mechanical structures and operation thereof. Broadly, one method could include heating a volume of working gas with a heat source, directing the heated working gas to act on a piston, and rotating at least one displacer to displace the working gas away from the heat source such that the volume of working gas may be cooled. 
         [0031]    Accordingly, the improved Stirling engine has been described with some degree of particularity directed to the exemplary embodiments. It should be appreciated, though, that modifications or changes may be made to the exemplary embodiments without departing from the inventive concepts contained herein.