Patent Document

BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to an apparatus for regulating the intake area of an internal combustion engine. More particularly, the present invention relates to a rotary throttle valve for an engine induction system. 
     2. Description of Related Art 
     Spark ignition internal combustion engines often employ a butterfly valve in a throttle valve assembly to control air intake. While a butterfly valve works adequately, the horsepower can be increased if the valve employed in the throttle assembly is less restrictive, since the butterfly valve shaft and plate remain in the airflow path, obstructing airflow while in open throttle. In the past, slide throttles, pivoting variable intakes and other means have been used to reduce restriction in the intake path. An important consideration in the design of non-butterfly intake valves is airflow control, turbulence and low throttle response. Because of their long use and development, butterfly intake valves have been developed which adequately address those issues, but many non-butterfly systems still present problems in partial throttle situations. One non-butterfly intake control type utilizes barrel valves which rotate between a closed position and an open position. However, known barrel valve systems have numerous limitations and disadvantages compared to butterfly systems at partial throttle openings. The present invention solves these and other problems previously encountered with barrel valve intake systems. 
     SUMMARY OF THE INVENTION 
     The present invention is for a variable area intake valve for an internal combustion engine which employs at least two barrels which are parallel to one another and geared to one another so that they rotate in synchronization with one another. The barrels contain openings perpendicular to their rotational axes which mate at the interface of the barrels so that they create an opening perpendicular to the barrels which is concentric with an intake port in the engine manifold. The openings in each barrel are signed to provide an opening of a desired size at an open throttle position and a predetermined minimum size at a closed throttle position. The closed position can also be a completely closed position to cut off flow entirely. One benefit of the invention is that the openings in the barrel may be sized so that they can match non-circular intake manifold openings, a situation often encountered with engines with more than one intake valve per cylinder. 
     A further benefit of the present invention is that the openings can be sized and the gearing between barrels chosen, so that the intake area at intermediate throttle settings is a non-linear function of throttle control setting applied to the barrel valves. In this way, tuning of the intake system response can be varied to obtain a desired throttle response. 
     In one aspect, the invention is a variable aperture valve comprising a first cylinder having a first aperture and a second cylinder having a second aperture. The first cylinder moves between a first position and a second position. The second cylinder moves in cooperation with the first cylinder such that the first aperture and the second aperture form a variable sized opening when the first cylinder moves from the first position towards the second position. The variable sized opening is in a relatively closed position when in the first position. The valve comprises a block body including a passage for allowing air to pass therethrough. The first cylinder and the second cylinder are coupled to the block body and configured in a predetermined position such that the variable sized opening is in communication with the passage. The valve also includes an axle for driving the first cylinder and the second cylinder. 
     In one presently preferred embodiment of the invention, a variable valve comprises a first cylinder having a first aperture, wherein the first cylinder moves between a first position and a second position. A second cylinder has a second aperture. The second cylinder moves between the first position and the second position such that the first aperture and the second aperture form a variable sized opening when the first cylinder and the second move from the first position toward the second position, the second cylinder moving in cooperation with the first cylinder. The valve further comprises a gear assembly having a first set of gears coupled to the first cylinder and a second set of gears coupled to the second cylinder. The first set of gears and the second set of gears are geared to one another. The variable sized opening is in a closed position when the first cylinder and the second cylinder are in the first position. The valve further comprises a block body which includes a passage for allowing air to pass through the block body. The first cylinder and the second cylinder are coupled to the block body and configured in a predetermined position. The variable sized opening is in communication with the passage. The valve further comprises an axle for driving the first cylinder and the second cylinder. The axle is coupled to the block body. The first cylinder and the second cylinder move in an opposite direction from one another or in a same direction with one another. In a currently preferred embodiment, the first cylinder and second cylinder rotate respective axes which are parallel to one another. 
     In another aspect of the invention, a variable throttle valve apparatus comprises a body; a first rotatable cylinder and second rotatable cylinder coupled to the body. The first rotatable cylinder is coupled to the body and has a first aperture cut therethrough. The second rotatable cylinder has a second aperture cut therethrough. The second rotatable cylinder is configured to rotate in an opposite direction from the first rotatable cylinder, whereby the first aperture and the second aperture form a variable sized opening. The first aperture and the second aperture do not form the opening when the first rotatable cylinder is in a closed position. The body further comprises a passage for allowing air to pass through the body. The first rotatable cylinder and the second rotatable cylinder are coupled to the body and configured in a predetermined position such that the opening is in communication with the passage. The valve apparatus further comprises an axle for driving the first rotatable cylinder and the second rotatable cylinder, wherein the axle is coupled to the body. The valve apparatus further includes a gear assembly having a first set of gears coupled to the first rotatable cylinder and a second set of gears coupled to the second rotatable cylinder. The first set of gears and the second set of gears are geared to one another. In a currently preferred embodiment, the first rotatable cylinder and the second rotatable cylinder rotate in an opposite direction from one another. Alternatively, the first rotatable cylinder and the second rotatable cylinder may rotate in the same direction as one another. 
     In another aspect of the invention, a variable throttle valve apparatus comprises a body having a passage. A first cylinder is coupled to the body. The first cylinder has a first aperture and is configured to be moved between a first position and a second position. A second cylinder is coupled to the body. The second cylinder has a second aperture and is configured to be moved between the first position and the second position, such that the first aperture and the second aperture form a variable sized opening when the first cylinder and the second cylinder move between the first position and the second position. The variable sized opening is preferably in a closed position when the first cylinder and the second cylinder are in the first position. The body is configured to allow a predetermined amount of air to pass through the passage as the cylinders rotate from a first position to a second position. The body is configured to mate with the variable opening so as to allow a desired amount of air to pass through the passage when in the first position. The valve apparatus further comprises an axle for driving the first cylinder and the second cylinder, wherein the axle rotates in the body. The valve apparatus further comprises a gear assembly having a first set of gears that are coupled to the first cylinder. A second set of gears is coupled to the second cylinder, wherein the first set of gears and the second set of gears are geared to one another. The first cylinder and the second cylinder are configured to rotate in cooperation with one another, whereby the first aperture and the second aperture form a variable sized opening between the first position and the second position. 
     In yet another aspect of the invention, a method of assembling a variable throttle valve apparatus comprises providing a body having a conduit, wherein the conduit is configured to have an open position and a closed position. The method comprises rotatably inserting a first cylinder into the body. The first cylinder has a first aperture and is configured to be moveable such that the first aperture is in complete communication with the conduit in the open position. The method further comprises rotatably inserting a second cylinder into the body. The second cylinder has a second aperture and is configured to be moveable such that the second aperture is in complete communication with the conduit in the open position. The first aperture and the second aperture are not in communication with the conduit when the first aperture and the second aperture are in the closed position. The body includes means for driving the first cylinder and the second cylinder, wherein the means for driving is attached to the body. The body further comprises a gear assembly which has a first set of gears coupled to the first cylinder and a second set of gears coupled to the second cylinder, wherein the first set of gears and the second set of gears are geared to one another. The first cylinder and the second cylinder preferably move in an opposite direction from one another. The first and second cylinders are preferably rotatably moveable about axes which are parallel to one another. 
     In yet another aspect, a throttle valve comprises a body, a first means for channeling air through the body, and a second means for channeling air through the body. The first means and the second means are configured to rotatably move in an opposite direction from one another, thereby forming a variably sized aperture. 
     From the above, it may be seen that the present invention provides a means of configuring intake systems for intake combustion engines which have important advantages over butterfly valves. For example, the intake valve system may be configured for a non-circular opening at wide open throttle, thereby being more easily mated to multi valve cylinder heads, which often do not have circular intake ports. Also, since the apertures in the cylinders may be easily varied in cross-section, it is possible to have different cross-section to rotation angles to tune the intake system as a function of throttle opening. 
     While the invention has been described in the context of an internal combustion intake throttle, those skilled in the art will also recognize that the principles of the engine may be applied to a variety of valve systems for engines and commercial processes and applications. 
    
    
     Other features and advantages of the present invention will become apparent after reviewing the detailed description of the preferred embodiments set forth below. 
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a perspective view of an intake valve system according to the invention mounted on an engine cylinder head. 
     FIG. 1A illustrates an exploded view of the variable throttle valve according to a preferred embodiment of the present invention. 
     FIG. 1B illustrates a perspective view of one of the cylinders used in the variable throttle valve according to the preferred embodiment of the present invention. 
     FIG. 2A illustrates a perspective view of the variable throttle valve in an open position according to the alternative embodiment of the present invention. 
     FIG. 2B illustrates a perspective view of the variable throttle valve in an intermediate position according to the alternative embodiment of the present invention. 
     FIG. 2C illustrates a perspective view of the variable throttle valve in a closed position according to the alternative embodiment of the present invention. 
     FIG. 3A illustrates a perspective view of the variable throttle valve in an open position according to the preferred embodiment of the present invention. 
     FIG. 3B illustrates a perspective view of the variable throttle valve in an intermediate position according to the preferred embodiment of the present invention. 
     FIG. 3C illustrates a perspective view of the variable throttle valve in a closed position according to the preferred embodiment of the present invention. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     The present invention provides many benefits over prior art intake valve systems and may also be applied to other non-engine applications in which it is desirable to have a robust variable opening valve. While the invention will be described in a presently preferred embodiment in which the opening in the valve in a fully open position has a circular cross-section, the valve may be configured to have a non-circular cross section at a wide open position for various applications. Similarly, while the embodiments which are described illustrate a fully closed position and direct one to one gearing, both the gearing and cylinder cross section may be changed to provide different minimum throttle openings and slopes of area vs throttle inputs as desired. 
     Reference will now be made to preferred and alternative embodiments of the invention, examples of which are illustrated in the accompanying drawings. While the invention will be described in conjunction with the preferred embodiments, it will be understood that they are not intended to limit the invention to these embodiments. On the contrary, the invention is intended to cover alternatives, modifications and equivalents, which may be included within the spirit and scope of the invention as defined by the appended claims. Furthermore, in the following detailed description of the present invention, numerous specific details are set forth in order to provide an understanding of the present invention. However, it should be noted that the present invention may be practiced without these specific details. In other instances, well known methods, procedures and components have not been described in detail as not to unnecessarily obscure aspects of the present invention. 
     FIG. 1 is a perspective view of a valve body  100  according to the invention mounted on a cylinder head of an internal combustion engine. 
     FIG. 1 A illustrates an exploded view of the variable throttle valve  100  according to the preferred embodiment of the present invention. The variable throttle valve  100  includes a block or body  102 , a first cylinder or barrel  104  coupled to the body  102  and a second cylinder or barrel  106  coupled to the body  102 . In addition, the valve  100  includes a first gear  108 , a second gear  110 , a side piece  112  and an axle  114 . The first gear  108  is coupled to the first cylinder  104  and also coupled to a bearing set (not shown) configured in the inner side of the side piece  112 . Similarly, the second gear  110  is coupled to the second cylinder  106  and also coupled to a bearing set (not shown) configured in the inner side of the side piece  112 . The axle  114  is preferably coupled to the first cylinder  104 , whereby the axle  1   14  extends through the side piece and the first gear  108  to the first barrel  104 . Alternatively, the axle  114  is coupled to the second barrel  106 . 
     As shown in FIG. 1A, the block  102  includes several apertures. On the front face of the block  102  is a first opening or passage  116  and a second opening or passage  118 . The first passage  116  extends from the front face  124  to the back face  126 . Similarly, the second passage  118  extends from the front face  124  to the back face  126  of the block  102 . Although the preferred embodiment includes two passages  116  and  118 , alternatively, the block  102  may have any number of passages to support different types of induction intake system. The block  102  includes two side inserts  120  and  122 , wherein the first barrel  104  couples to the first insert  120  and the second barrel  106  couples to the second insert  122 . 
     As shown in FIG. 1A, the first gear  108  couples to the first barrel  104  and the second gear  110  couples to the second barrel  106 . Preferably, the first gear  108  and the second gear  110  are of the same size and dimension. Alternatively, the first gear  108  and the second gear  110  are of a different size and dimension. When the barrels  104  and  106  are positioned within the block  102 , the first gear  108  and the second gear  110  are geared together such that the rotation of one of the barrels will cause the other barrel to rotate in cooperation with the barrel. Although only two gears  108 ,  110 , are shown in this example, more than two gears may be used in the event that a gear train of a different ratio is used. Alternatively, the barrels may be driven by other means, such as levers, electro-mechanical stepper motors or the like to accomplish the appropriate synchronized opening. 
     FIG. 1B illustrates a perspective view of one of the cylinders  106  used in the variable throttle valve according to the preferred embodiment of the present invention. The barrel or cylinder  106  preferably includes a first aperture  103  and a second aperture  109 . Alternatively, the number of apertures would depend on the number of passages that are present in the block, if a block is used in the throttle valve apparatus. Alternatively, if a block is not used, the number of apertures would depend on the number of throttle valves that are desired. The aperture  103  serves as an opening through which flow passes through. Preferably, the flow would be an air flow. Alternatively, the flow would be some other medium, such as other gases or even liquids. The aperture  103  is preferably a semi-circular shape to conform to the shape of the passage  116  in the block  102 . Alternatively, the aperture  103  is any other shape or pattern, such as square, rectangular, etc. The cylinder  106  includes an axis  99  that passes through the length of the cylinder  106 , whereby the cylinder  106  is configured to rotate about the axis  99 . 
     FIG. 2A illustrates a perspective view of the variable throttle valve in an open position according to the present invention. It should be noted that the block  102  has been omitted from FIGS. 2A-2C for illustration purposes, although it is not necessary that the block  102  be used to practice the present invention. As shown in FIG. 2A, the barrels  204  and  206  are positioned such that the semi-circular apertures  203  and  205  form a channel or conduit which is a complete circular aperture. The channel is designated as being in the open position, because the maximum amount of flow passes through the channel. The first gear  208  and the second gear  210  are coupled to one another such that the rotation of one of the barrels will cause the other barrel to rotate in cooperation with the barrel. The rotation of the first barrel  204  causes the second barrel  206  to also rotate, thereby allowing the circular aperture to increase or decrease in dimension or diameter as the barrels rotate. 
     For instance, as shown in FIG. 2A, the valve  200  is shown in the open position. Applying a torque force to the axle  214  will cause the axle  214  to rotate. Shown in FIG. 2A, the rotation is preferably provided in a clockwise manner. It should be noted that the axle  214  alternatively rotates in a counter-clockwise manner. Once the axle  214  rotates clockwise, the first barrel  204  also begins to rotate clockwise about axis  99 . Since the first gear  208  is coupled to the first barrel  204  and also geared to the second gear  210 , the second gear  210  will rotate counter-clockwise along axis  98 . As described above, the second gear  210  is coupled to the second barrel  206 , therefore the second barrel  206  rotates counter-clockwise as the first barrel  204  rotates clockwise. The rotation of the first barrel  204  and the second barrel  206  causes the complete circular aperture to change in dimension, as shown in FIG.  2 B. 
     FIG. 2B illustrates a perspective view of the variable throttle valve in an intermediate position according to the present invention. As the first barrel  204  rotates in the clockwise manner and the second barrel  206  rotates in the counter-clockwise manner, the dimension of the channel decreases in size. This decrease in dimension prevents the maximum amount of flow to pass through the channel. Further, as shown in FIG. 2C, the variable throttle valve  200  is in a closed position as the first barrel  204  and the second barrel  206  rotate opposite of one another even further. 
     FIG. 3A illustrates a perspective view of the variable throttle valve  300  in an open position according to the preferred embodiment of the present invention. As described above in relation to FIG. 2A, the maximum amount of flow is able to pass through the channel when the first aperture  205  and the second aperture  203  are preferably configured to form a complete circular opening. Since the passages  316  and  318  of the block body  302  are preferably circular in shape, the first and second apertures  205  and  203  will be configured to be in communication with the passage  316  when the valve  300  is in the open position, as shown in FIG.  3 A. Similarly, the third and fourth apertures  207  and  209  will be configured to be in communication with the passage  318  when the valve  300  is in the open position. Thus, the maximum amount of flow is able to flow through the passages  316  and  318  when the valve  300  is in the open position and the channel has the largest dimension. 
     FIG. 3B illustrates a perspective view of the variable throttle valve  300  within the block in an intermediate position according to the preferred embodiment of the present invention. As shown in FIG. 3B., the block  302  includes two passages  316  and  318  and the first barrel  304  as well as the second barrel  306  positioned within the block  302 . The valve apparatus  300  shown in FIG. 3B is in an intermediate position, because the channel is not in complete communication with the passages  316  and  318 . Thus, an intermediate amount of flow between the minimum and maximum is able to pass through the passages  316  and  318 . 
     FIG. 3C illustrates a perspective view of the variable throttle valve  300  in a closed position according to the preferred embodiment of the present invention. As described above in relation to FIG. 2C, the minimum amount of flow is able to pass through the first barrel  204  and the second barrel  206 , because there is no channel through which the flow is able to pass. Therefore, only a predetermined minimum amount of flow is able to pass through the passages  316  and  318 . 
     The operation of the variable throttle valve of the present invention will now be discussed in view of FIGS. 3A-3C. In the preferred embodiment, the valve  300  is placed in an automobile engine, wherein the block  302  is configured such that air enters through the passages  316  and  318  on the front side  324  and exits through the passages on the back side of the block  326 . Once the air exits the block  302 , the air mixes with fuel which is discharged by the fuel injectors. In FIG. 3C, the engine is preferably in an idle state whereby the valve  300  is in a closed position. As described above, only a predetermined minimum amount of air passes between the first barrel  304  and the second barrel  306 , due to a small amount of space between the first barrel  304  and the second barrel  306  in the closed position. As the throttle is increased, the axle  314  rotates in response to the gas pedal being depressed. The rotation of the axle  314  causes the first barrel  304  to rotate in the same direction as the axle  314  and along axis  99 . The first gear, which is coupled to the first barrel  304 , also rotates about axis  99 . Since the first gear and the second gear are geared together, the rotation of the first gear causes the second gear to rotate in cooperation with the first gear. As described above, the first gear and the second gear preferably rotate in the opposite direction from one another. Alternatively, the first gear and the second gear rotate in the same direction with one another by use of a gear train (not shown). 
     As the second gear rotates about axis  98 , the second barrel  306  also rotates about axis  98 . As described above, the first gear and the second gear may be of the same size and dimension. Therefore, both barrels  304  and  306  rotate at the same rate and distance with respect to one another. Alternatively, the barrels  304  and  306  may be configured such that one barrel rotates at a different rate and distance from the other barrel. 
     As the first barrel  304  rotates with the axle  314 , the second barrel  306  preferably rotates the same distance in an opposite direction. Thus, as the axle  314  rotates further, the apertures of the first barrel and second barrel begin to enlarge in the passage due to the rotation of the barrels, thereby forming a channel. At this point, the valve  300  is in an intermediate position, whereby some air then passes through the channels as well as the passages of the block  302 . In an electronically controlled engine, the engine management system in the engine can determine the desired dimension of the channel and the amount of air passing through the block  302  and cause the appropriate amount of fuel to be released and mix with the air before the mixture is sent to the cylinders. 
     As the throttle is further advanced, the axle  314  rotates further, thereby causing the first barrel  304  and the second barrel  306  to rotate further about their respective axes. The further rotation of the first and second barrels  304  and  306  cause the apertures to rotate such that the channel becomes larger. As the channel becomes larger, more air is allowed to pass through the passage, because there is less obstruction of the barrels in the passage. At full throttle, the first barrel  304  and the second barrel  306  are rotates such that the apertures form a circular channel that is in complete communication with the passages. The valve  300  is in an open position at this point, whereby the maximum amount of air passes through the passages and the channels. In this manner, the first barrel  304  and the second barrel  306  are rotated relative to each other to provide the appropriate amount of flow through the variable throttle valve of the present invention. 
     The present invention has been described in terms of specific embodiments incorporating details to facilitate the understanding of the principles of construction and operation of the invention. It will be apparent to those skilled in the art that modifications may be made in the embodiments chosen for illustration without departing from the spirit and scope of the invention. Accordingly, reference herein to specific embodiments and details thereof is not intended to limit the scope of the claims appended hereto.

Technology Category: f