High efficiency low-pollution engine

• US 6,026,568 A
• Filed: 11/01/1997
• Issued: 02/22/2000
• Est. Priority Date: 08/16/1995
• Status: Expired due to Term

• Current Assignee: Northrop Grumman Systems Corporation (Northrop Grumman Corporation)
• Original Assignee: Northrop Grumman Corporation
• Inventors: Shacter, Philip, Hagen, Michael James, Atmur, Steven Donald, Strasser, Thomas Edward
• Primary Examiner(s): DERRINGTON, JAMES H
• Application Number:
  US08/969,429
• Time in Patent Office: 843 Days
• Field of Search: 264/640, 264/641, 264/642, 264/643, 29/888.06, 29/888.01, 29/888.061
• US Class Current: 29/888.06
• CPC Class Codes: F02B 1/04 with fuel-air mixture admission into cylinder
• CPC Class Codes: F02B 2075/025 two
• CPC Class Codes: F02B 2075/125 Direct injection in the combustion chamber for spark ignition engines, i.e. not in pre-combustion chamber
• CPC Class Codes: F02B 41/00 Engines characterised by special means for improving conversion of heat or pressure energy into mechanical power
• CPC Class Codes: F02F 1/24 Cylinder heads
• CPC Class Codes: F02F 1/38 the cylinder heads being of overhead valve type
• CPC Class Codes: F02F 2001/245 the valve stems being orientated at an angle with the cylinder axis
• CPC Class Codes: F02F 7/0087 Ceramic materials
• CPC Class Codes: F05C 2253/16 Fibres
• CPC Class Codes: Y02T 10/12 Improving ICE efficiencies
• CPC Class Codes: Y10T 29/49231 I.C. [internal combustion] engine making
• CPC Class Codes: Y10T 29/4927 Cylinder, cylinder head or engine valve sleeve making
• CPC Class Codes: Y10T 29/49272 with liner, coating, or sleeve

Abstract

An internal combustion engine of either two-cycle or four-cycle construction including a block having at least one cylinder bore therein having sidewalls carrying a liner of a structural fiber reinforced ceramic matrix composite material disposed in sealed fiber reinforced sliding relationship within the cylinder bore, and a cylinder head sealing atop end of the cylinder bore to form a closed combustion chamber in combination with the piston. The cylinder head also has the structural fiber reinforced ceramic matrix composite material disposed on an inner surface thereof facing the combustion chamber. The preferred engine is a two-cycle engine having an externally scavenged intake system and an oil sump lubricating system thereby eliminating the need to separately mix or inject lubricating oil. Higher operating temperatures and closer tolerances allow higher fuel efficiency and less pollutant production. A preferred structural fiber reinforced ceramic matrix composite material and the method of making same is also disclosed.

Claims

1. A method of forming a structural fiber reinforced ceramic matrix composite cylinder head for an internal combustion engine comprising:

a) coating fibers of a fiber system with an interfacing material which prevents adherence of a modified cementatous resin containing organic binders and derived by emulated polymer composite processing techniques;

b) disposing a pre-ceramic polymer resin throughout the fiber system of the cylinder head so that the coated fibers are mixed with the polymer-derived ceramic resin;

c) forming the resin containing the coated fibers into a cylinder head;

d) firing the cylinder head at a temperature and for a time sufficient to convert the resin to a ceramic; and

e) providing a device for transferring heat away from a top surface of the cylinder head to maintain the cylinder head below a threshold temperature during operation of the cylinder head.

2. The method of claim 1 and additionally including the step of:

selecting the modified cementatous resin containing organic binders and derived by emulated polymer composite processing techniques from the group including silicon-carboxyl resin, alumina silicate resin, and monoaluminum phosphate resin.

3. The method of claim 1 and additionally including the step of:

selecting the fiber system from the group comprising alumina, silicon nitride, silicon carbide, graphite, carbon, and peat.

4. The method of claim 1 and additionally including the step of:

selecting the interfacing material from the group comprising carbon, silicon nitride, silicon carbide, and boron nitride.

5. The method of claim 1 and additionally including the steps of:

selecting the modified cementatous resin containing organic binders and derived by emulated polymer composite processing techniques from the group including silicon-carboxyl resin, alumina silicate resin, and monoaluminum phosphate resin;

b) selecting the fiber system from the group comprising alumina, silicon nitride, silicon carbide, graphite, carbon, and peat; and

,

c) selecting the interfacing material from the group comprising carbon, silicon nitride, silicon carbide, silicon carboxide, and boron nitride.

6. The method of claim 1 wherein step (e) comprises:

providing a metal water jacket formed onto the top surface, whereby the water jacket passes coolant therethrough for transferring heat away from a top surface of the cylinder head to maintain the cylinder head below a threshold temperature during operation of the cylinder head.

7. The method of claim 1 further comprising, after step (e), the step of:

providing a device for heating a fluid used in a passenger compartment heating system.