Classifications

• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
  • C08F283/00—Macromolecular compounds obtained by polymerising monomers on to polymers provided for in subclass C08G
  • C08F283/12—Macromolecular compounds obtained by polymerising monomers on to polymers provided for in subclass C08G on to polysiloxanes
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B27/00—Layered products comprising a layer of synthetic resin
  • B32B27/04—Layered products comprising a layer of synthetic resin as impregnant, bonding, or embedding substance
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
  • C08G77/00—Macromolecular compounds obtained by reactions forming a linkage containing silicon with or without sulfur, nitrogen, oxygen or carbon in the main chain of the macromolecule
  • C08G77/04—Polysiloxanes
  • C08G77/045—Polysiloxanes containing less than 25 silicon atoms
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
  • C08G77/00—Macromolecular compounds obtained by reactions forming a linkage containing silicon with or without sulfur, nitrogen, oxygen or carbon in the main chain of the macromolecule
  • C08G77/04—Polysiloxanes
  • C08G77/06—Preparatory processes
  • C08G77/08—Preparatory processes characterised by the catalysts used
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
  • C08G77/00—Macromolecular compounds obtained by reactions forming a linkage containing silicon with or without sulfur, nitrogen, oxygen or carbon in the main chain of the macromolecule
  • C08G77/04—Polysiloxanes
  • C08G77/14—Polysiloxanes containing silicon bound to oxygen-containing groups
  • C08G77/18—Polysiloxanes containing silicon bound to oxygen-containing groups to alkoxy or aryloxy groups
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
  • C08L83/00—Compositions of macromolecular compounds obtained by reactions forming in the main chain of the macromolecule a linkage containing silicon with or without sulfur, nitrogen, oxygen or carbon only; Compositions of derivatives of such polymers
  • C08L83/04—Polysiloxanes
  • C08L83/06—Polysiloxanes containing silicon bound to oxygen-containing groups
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
  • Y10T156/10—Methods of surface bonding and/or assembly therefor
  • Y10T156/1052—Methods of surface bonding and/or assembly therefor with cutting, punching, tearing or severing
  • Y10T156/1062—Prior to assembly
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T428/00—Stock material or miscellaneous articles
  • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
  • Y10T428/24802—Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
  • Y10T428/24926—Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.] including ceramic, glass, porcelain or quartz layer

Definitions

• MSI Multiple Spark Ignition
• German Patent, WO 94/09271 is the earliest recorded patent filed relating to providing multiple spark ignition using head gaskets with embedded electrodes.
• the Clarke MSI composite device is not a head gasket.
• the patent was filed in Germany as DE 3530997 September 4, 1986.
• the patent is specific to teach the use of parallel circuits with diode devices which are necessary for keeping the multiple spark ignition electrodes sparking in balance.
• the Clarke composite device is assembled into the top of the head combustion chamber as a vacuum formed in place MSI composite structure with embedded electrodes connected by an "in series" electrical circuit.
• the Clarke composite device is not directly attached to the ignition source, but uses an arc from the central spark plug electrode to initiate the multiple spark ignition series which is grounded after the last electrode position.
• the Clarke patent, US 6,161,520 is specific to teach the use of a head gasket to provide the multiple spark ignition (MSI).
• the Clarke MSI composite device is not a head gasket.
• the Clarke composite device retains the central spark plug, using its electrode to make an arc attachment with the in series circuit eliminating the costly high voltage 520' patent attachment requirement.
• the Clarke 520' patent is specific to teach that the gasket materials derived from Clarke's copending US patent applications Ser. Nos. 08/962,782; 08/962,783 and 09/185,282, all teach the required use of boron nitride as the catalyst for condensation polymerization of the resin blend needed to produce the gaskets.
• Clarke has verified that boron nitride is not a catalyst as incorrectly claimed. Clarke verified the certainty that boron nitride is not a catalyst by attempting to repeat the 873 patent's Figure 1 "gel" curve at 177 0 C using the preferred CERAC, Inc. item #B-1084- 99.5% pure boron nitride.
• the Clarke SAE 2002-01-0332 paper refers to the use of a head gasket to provide the multiple spark ignition (MSI).
• the Clarke MSI composite device is not a head gasket.
• the Clarke composite device retains the central spark plug, using its electrode to make an arc attachment with the in series circuit eliminating the costly high voltage 520' patent attachment requirement.
• the methods of producing "flexible-ceramic" laminates capable of high-temperature elastic recovery ( Figure 2) are not addressed.
• the flexible-ceramic "self extinguishing" property when heat is removed is an essential requirement to prevent combustion pre-ignition in the MSI fuel saving flexible ceramic composite ignition devices.
• the grounding gap portion of the spark is removed so as to not interfere with the assembly.
• MSI composite device It is the further objective of the MSI composite device to provide sufficient combustion efficiency to realize up to 33% fuel savings for IC engines and to enable retrofitting of standard engines to allow the fuel savings to be also realized in the after market vehicles.
• the invention comprises a "flexible ceramic” multiple spark ignition (MSI) device that fits inside an IC engine combustion chamber increasing its fuel combustion efficiency by up to 33% and methods of fabrication thereof.
• MSI multiple spark ignition
• Composite combustion devices using electric circuits embedded in fabric reinforced polysiloxane (Reference 3) have achieved 33% superior fuel savings using three spark ignition gap electrodes greater than conventional single spark plug ignition.
• the cured laminates and laser cutting innovations produces affordable superior three sparks IC engine ignition devices installed inside the combustion chamber of the IC engine head assembly.
• the key elements of the devices are:
• the device comprises a flexible ceramic composite embedded with an surround multiple ignition circuit located inside the top surface area of the IC engine head closed piston combustion chamber (Figure Ib).
• Figure Ib The discovered high-temperature Figure 2 compression recovery property of flexible-ceramic material enables the outer ring structure of Figure Ia to extend into the piston bore compression ring zone of the head gasket assembly.
• the device also comprises four spark ignition gaps (or combination of such gaps) connected in series from the spark plug gap to the ground. Each gap is connected to the next by an insulated nickel/copper wire (or optionally copper wire) embedded in the flexible ceramic composite device.
• the shape of the embedded circuit (Figure Ib) is a ring of optional spark ignition gaps starting with the spark plug's centrally located "circular gap” extending out into the ring circuit ending at the ground circular gap and "compression spacer". The edge ends at the cylinder bore combustion compression ring
• the device comprises a wire (optional foil) circuit wrapped in up to 25% boron nitride filled polyimide sealed with extruded Teflon® coating and embedded between the laminate plies closer to the metal surface and optionally from 0.10 up to 0.25 inches thickness.
• the composite laminate is processed to a cure ply thickness of 0.0105 (or other Table Ia or b thicknesses), with preferably Table Ia S-glass prepreg and laminate composition.
• the ignition device comprises an assembly method of vacuum molding the device inside the combustion chamber against the metallic (e.g., aluminum) metal surfaces allowing for attachments at the spark plug threads and head gasket joint locations where the ground wire is clamped during the head assembly.
• the device also comprises a simple less costly modified spark plug where the spark plug's stainless steel grounding gap for the spark is eliminated (for prototype work these are simply cut off at the end of the spark electrode gap).
• This enables the central electrode to be threaded into the first circular gap of the in-series multiple gap circuit.
• This unobvious design assures the firing of the circuit through an unobvious circular gap opening discovery.
• the circular opening provides a 360° gap opening for initiating the ignition and to make arc contact without the need for direct attachment. This allows plugs to be replaced, inspected and serviced as needed. Also, the combustion chamber fuel injector optimal location is not affected at the first spark plug gap location which is always a concern of combustion engineers.
• the device fabrication methods comprises laser cutting the majority of openings and edges of the composite device forming ceramic sealed edges.
• the fired surfaces of the composite device are self extinguishing and the preferred nickel gaps are alloyed to sufficient copper to prevent pre-ignition (Reference 1).
• Interior combustion surfaces of the ignition device are optionally YAG (yttrium, alumina, garnet) laser milled forming optional ceramic edge morphology.
• the method of circuit fabrication is shown in Figures 3 to 6.
• the circuit starts with an insulation wrapped wire of nickel-copper alloy which is stipped at the ends and between the ends for allowing for the MSI electrodes. All stripped wire sections are stamped into circular flat sections which are die cut with holes. The electrode circular sections are cut with elliptical holes, then folded over to form the sparking electrodes. The end circular sections are die cut with holes, one of which is the spark plug arcing port and the other is the grounding port.
• the use of a single wire to form the electrodes and port holes as well as accommodate the wire wrapped insulation is a significant economical method eliminating welding the electrodes to copper wire, and forming the port attachments and grounding without welding.
• the methods of fabricating the device also comprises an optional silk screening of vapor grown carbon fiber circuits applied within the composite laminate layers instead of wire or foil circuits or in addition to these circuits.
• Figure IA is a top surface view drawing of the multiple spark ignition (MSI) flexible ceramic device installed in the upper combustion chamber of the IC engine head showing 4 in series electrodes surrounding the central spark plug electrode port in a circuit that ends with the ground.
• MSI multiple spark ignition
• Figure IB is a cut away central view drawing of each of the head combustion chambers containing MSI composite devices revealing embedded four ignition electrodes in series per cylinder with central spark plug circular arc-gap electrode for GM 3500 V6 Engine Cylinder Head Combustion Chamber.
• Figure 3 is a fragmentary, cut away, perspective view of a wrapped wire constructed according to the principles of the present invention
• Figure 4 is a selectively stripped circuit wrapped wire exposing the metallic elements
• Figure 5 is the metallic elements stamped and with die cut holes for electrode, spark ignition electrodes and ground compression port.
• Figure 6 is the circuit with die cut electrodes before assembly within the laminate as a circular structure as shown in Figure IB.
• the MSI composite device 10 of the present invention is illustrated in Figure IA from the inside head cavity view revealing four thermally insulated electrodes fabricated with high temperature boron nitride loaded composite insulation laser cut with ceramic sealed cut edges including electrode cut spark ignition gaps 12.
• the internal electrical circuit starts with a central spark plug electrode port 8 which eliminates the need for a high voltage connector for initiating the multiple spark ignition by providing an open port 8 in which the spark plug electrode is inserted enabling the spark plug electrode to arc to the MSI circuit which consists of sparking electrode gaps 12 and a ground 14 which is compressed against the metal head and cylinder block during assembly.
• the invention also compresses a unique spark plug with the ground removed so as to assure the arc connection advantage.
• Invention provides for spark plug replacement and servicing during engine maintenance and tune up operations.
• the MSI composite device is selectively laser cut to provide valve 16 and 18 clearance holes sealed with a ceramic edge and central spark plug port supporting composite structure with lightener holes allowing for exhaust gas flow during combustion cycles.
• Figure Ib illustrates a cut away view of three individual MSI devices assembled in a GM 3500 V6 engine cylinder head 28 combustion chambers.
• the exposed circuit 20 starts with the spark plug arcing port 8 and continues in series forming a circular set of four sparking electrodes 12 which ends at the grounding port 14.
• Each sparking electrode 24 in the circuit series is positioned to overlap into the head cavity combustion chamber 22 which prevents the initial flame front initiating from the sparking gap from being inhibited by head cavity restrictions.
• the composite device methods of fabrication comprises the laser cutting of the device to assure no restriction of the combustion cavities 22 illustrated in Figure IB.
• the device comprises composite laminate non-conductive fabric and ceramic additive reinforced elastic composite laminate material such as described in the above referenced copending patent applications. Such patent applications should be consulted for a detailed understanding of the formulations, compositions and processing steps proposed for the manufacturing of the MSI composite devices.
• the method of fabricating the wire circuit 20 of the MSI composite device starts with insulation wrapping the wire of Figure 3 between the insulating layers of 25% boron nitride filled polyimide tape wrapped insulation and Teflon ® layers. These insulation layers are selectively stripped (as shown in Figure 4) to allow for the metal forming of the ports and electrodes as shown in Figure 5 for the stamping and die cutting of holes method of metal forming.
• Figure 6 illustrates the completed circuit when the electrode elliptical die cut holes are folded over to form the sparking electrodes.
• the completed MSI composite device provides a surround combustion spark-ignition system 20 is depicted in Figure 1 comprising the ignition elements of spark electrodes, ground connectors and spark plug electrode insertion port 8.
• the invention of the wire circuit metal formed from a nickel-copper alloy composite layered wire metal formed by brinnelling and die cutting with holes used to form the electrodes as depicted in Figures 5 and 6.
• the insulated wire ( Figure 3) is embedded and bonded between the fabric reinforced elastic composite laminate layers forming the composite device 10.

Landscapes

• Chemical & Material Sciences (AREA)
• Health & Medical Sciences (AREA)
• Chemical Kinetics & Catalysis (AREA)
• Medicinal Chemistry (AREA)
• Polymers & Plastics (AREA)
• Organic Chemistry (AREA)
• Reinforced Plastic Materials (AREA)
• Compositions Of Macromolecular Compounds (AREA)
• Ignition Installations For Internal Combustion Engines (AREA)
• Gasket Seals (AREA)
• Sealing Material Composition (AREA)
• Combustion Methods Of Internal-Combustion Engines (AREA)

Priority Applications (1)

Applications Claiming Priority (2)

Publications (2)

Family

ID=40156563

Family Applications (3)

Family Applications After (2)

Country Status (6)

Families Citing this family (26)

Family Cites Families (36)

• 2008
  • 2008-06-19 US US12/665,717 patent/US8347854B2/en active Active
  • 2008-06-19 JP JP2010513247A patent/JP5307804B2/ja active Active
  • 2008-06-19 WO PCT/US2008/007668 patent/WO2008156822A2/en not_active Ceased
  • 2008-06-19 US US12/665,716 patent/US20100320700A1/en not_active Abandoned
  • 2008-06-19 CN CN200880102632.1A patent/CN101903429B/zh active Active
  • 2008-06-19 US US12/665,715 patent/US8293830B2/en active Active
  • 2008-06-19 WO PCT/US2008/007667 patent/WO2008156821A1/en not_active Ceased
  • 2008-06-19 EP EP08768638.2A patent/EP2162478B1/en active Active
  • 2008-06-19 WO PCT/US2008/007719 patent/WO2008156840A1/en not_active Ceased
  • 2008-06-19 ES ES08768638T patent/ES2862460T3/es active Active

Also Published As

Similar Documents

Legal Events