Complex Swirl Static Mixer for Engines

The air/fuel mixture of an internal combustion engine may be formed by a carburator or by a fuel injection device. Particles of fuel when entering the combustion chamber of an engine are not small enough to insure complete combustion. There are many devices and methods which cause better mixing of the mixture before combustion. One group of these devices involves the use of a static mixer for scattering the particles of fuel. However, these devices of static mixing type are not good enough to give good performance at all running conditions. Some give bad acceleration but good reduction in CO exhaust at idle rotation like the known one-direction-swirl generating mixer when fixed under the carburator. Others give low power output like the using of a metallic net fixed at the passage of the inlet manifold.

The present invention relates to a new method which improves the vaporization of an air-fuel mixture by generating the mixture partitively in different directions forming complex swirls. The formation of complex swirls does not give a big centrifugal force to the fuel particles like the single-direction-swirl mixer does. It rotates the mixture partitively in different directions so that the mixture is being whirled towards the center of an inlet manifold thereby giving good mixing of fuel with air.

It is the present object of the invention to improve the combustion efficiency of engines by rotating the mixture in different directions to form complex swirls through the use of a multi-swirl-generating device.

It is another object of the present invention to reduce the polluted exhausts of engines by the use of complex swirl-producing devices mounted in the inlet manifold of a combustion engine.

It is also another object of the present invention to develop several clean internal combustion engines with high power output by using the present method of fuel and air and through the use of devices based on the present method.

It is also another object of the present invention to provide high power and smooth driving conditions for modern lean burning internal combustion engines.

FIG. 1 is an elevational view in partial section illustrating a first embodiment of the present invention;

FIG. 2 is a perspective of one embodiment of the present complex swirl mixer;

FIG. 3 is a perspective view of a second embodiment of the present complex swirl mixer;

FIGS. 4a, 4b, 4c and 4d are detailed schematic views of the several types of wings used to form a complex swirl mixer according to the invention;

FIG. 5 is a detailed plan view in partially schematic form illustrating a further embodiment of the invention;

FIG. 6 is a detailed plan view in partially schematic form illustrating yet another embodiment of the present swirl mixer;

FIG. 7 is a detailed plan view in partially schematic form illustrating another embodiment of the present complex swirl mixer;

FIG. 8 is a detailed schematic view illustrating a mode of operation of the present invention;

FIG. 9 is a detailed schematic view illustrating the projected area of the wings of an embodiment of the present swirl mixer on the cross-sectional plane of a manifold of an internal combustion engine;

FIG. 10 is a detailed schematic view of a cylinder head of an engine fitted with a complex swirl generating mixer of the invention;

FIG. 11 is an idealized perspective view illustrating the disposition of two swirl generating devices in the cylinder head of an engine;

FIG. 12 is a schematic view illustrating the flow of gas in a cylinder head fitted with two of the present devices;

FIG. 13 is a schematic view of the flow of gas caused by a further arrangement of two of the present swirl generating devices in a cylinder head;

FIG. 14 is a schematic view of an embodiment of the invention wherein a flow of gas is directed from valves toward a plug by two of the present swirl generating devices; and

FIG. 15 is a schematic view of still another embodiment of the present invention wherein two of the present swirl generating devices are disposed within a cylinder head to cause the flow of gas to be directed towards two plugs.

The present method of improving the combustion efficiency of internal combustion engines is by generating complex swirls using a static mixer which can be a circular ring usually being cut and bent inwardly about portions of the circumference of the ring to form wings. Sometimes, the mixer is formed by attaching wings on the inner circumference of a part of a manifold or the spacer under a carburator. These wings usually are arranged into several sets. In order to rotate the mixture, wings of the same set are arranged facing the same circular direction of the circumference, while wings of neighbouring sets are faced in the opposite circular direction of the circumference. A pair of neighbouring wings of different sets facing each other are called a pair of concentrating wings, while a pair of wings facing against each other are called a pair of separating wings. A wing which changes the direction of flow is called a directing wing while a centering wing directs the flow towards the center of the mixer.

Many types of complex swirls can be generated by suitable designs by using several combinations of the four types of wings. When the mixture passes through such a mixer fixed in the manifold, the wings of the mixer change the direction of flow so that the flow is caused to be rotated partitively in different directions towards the center of the manifold, thereby forming complex swirls.

In order to create a good result of mixing, it is found that the number of sets should not be more than six and is usually partitively arranged in even symmetric sets, since this is the best arrangement for these symmetric complex swirls to be rotated effectively towards the center.

When the mixer is being fixed under the carburator, in order to get a good performance at all slotter opennings, a pair of separating wings of neighbouring sets or a concentrating wing should be arranged at a position which is located on the line perpendicular to the slotter valve of the carburator. This setting ensures good vaporization of gas even at small slotter openings, since the flow of gas after passing the slotter valve is being changed effectively by the pair of separating wings or a centering wing to insure better vaporization.

For an internal combustion engine having a multi-swirl mixer, the best percentage of the total projecting area of wings on the crossection of the manifold depends on the structure, length, angle and number of the wings. However, it is found that this percentage should be between 5 to 50% of the total area of crossection.

When the mixer is fixed in the manifold at a position near the inlet valve, complex turbulences are being formed also inside the combustion chamber. The flow could be used to clean the poles of the plugs while inleting the mixture, and gives a fast transfer of flame after ignition; consequently giving better fuel consumption, high power and low polluted exhausts.

A preferred embodiment of the mixer has two sets of wings fixed near the inlet valve of a manifold in an internal combustion engine. The angle of the center line of the two sets of wings can be designed such that the combination flow of the two seperate swirls at the center of the mixer is facing towards the plug.

Another embodiment of the present invention is the formation of double swirls inside the combustion chamber by two swirl-generating devices fixed at two separate inlet valves of the engine. Each device has wings rotating the mixture in one direction. Swirls generated by the two devices are rotating in opposite directions towards the center of the combustion chamber. If the wings of the devices are designed in a manner such that the flow of gas from the junction of inlet valves is towards the plug, it cleans the plug and creates smooth transfer of flame. In the case of using two ignition plugs, the arrangement of flow could be also directed from each side of the inlet valves towards the plugs respectively.

Another embodiment of the present invention is the design of an engine with two inlet valves fixed with two double-swirl mixers near the inlet valves, each of the mixers composed of two sets of wings which direct the flow of gas from the center of each valve towards the plug or plugs, respectively.

Many applications of the present invention of generating complex swirls and the devices of the invention could be arranged in several other forms of internal combustion engines, including Wankel's rotary engine and two-stroke reciprocating engines. It is expecially important to mention that the present invention could be used for all the modern lean burning internal combustion engines which operate on a lean air-fuel mixture like the sub-chamber stratified charge system, the turbulence generating pot system and some others. The present invention gives a better mixing of air and fuel of any lean burning engine, thereby improving the performance, power output, fuel consumption and polluted exhausts of the engine, by fixing a complex swirl mixer in the passage of the inlet manifold which inlets the lean mixture.

FIG. 1 shows an embodiment of the present invention, wherein a complex swirl mixer 1 is fixed at the entrance of a manifold 6 under a carburator 16. The air-fuel mixture formed by the carburator will be rotated partitively in different directions towards the center of the manifold when passing through it. Other parts are the usual portions of a reciprocating combustion engine, where 4 is the inlet valve; 5, the exhaust valve; 7, the exhaust; 8, the cylinder; 9, the piston; 12, the slotter valve; 13, the axis of the slotter valve; 14, the plug; 15, the combustion chamber; 17, the air-cleaner.

As shown in FIG. 2, a complex swirl mixer 1 is formed by a press process of a metalic sheet such that it has a flange 2 attached to the main body of the mixer and has several types of wings 3a, 3b, 3c cut and bent inwardly at spaced loci of the circumference of the mixer. FIG. 3 is another embodiment of the complex swirl mixer 1.

There are four types of wings according to their functions, namely, separating wings 3a, which separate the flow into two different directions; concentrating wings 3b, which concentrate the flow to a point at the circumference; guiding wing 3c, which guides the flow to a desired direction, and centering wing 3d, which guides the flow to the center of the device. The relations of the flows of gas with these four types of wings are shown in FIGS. 4A, 4B, 4C and 4D, respectively.

Using the combination of above mentioned types of wings, we can have many types of swirl-generating devices. FIG. 5 shows a mixer which is formed by a pair of seperating wings 3a, two guiding wings 3c and a pair of concentrating wings 3b. When a flow passes through the mixer, it generates two independent symmetric swirls which rotate towards the center, one of which is on the right hand side of the device, another on the left hand side of the device. Wings which are on each side can be considered as a set of swirl-generating wings. FIG. 5 is a mixer with two sets of swirl-generating wings. FIG. 6 shows a four-swirl-generating mixer composed of four sets of wings. FIG. 7 shows a six-swirl-generating mixer formed by three pairs of separating wings 3a and three centering wings 3d. It is clear from FIG. 7 that the function of a centering wing is equilvalent to a pair of concentrating wings.

FIG. 8 shows one way of fixing the device under the carburator. A pair of separating wings are located on the line which is perpendicular to the axis 13 of the slotter valve 12. At small slotter valve openings the flow of gas after passing the slotter valve is efficiently changed by the seperating wings to assure good vaporization as shown by D of FIG. 8.

The projection of the wings on the crossection plane of the manifold is shown by the dark portions a of FIG. 9. The sum of the total area of the dark portions a should be between 5 to 50% of the crossection of manifold.

FIG. 10 shows the cylinder head of an embodiment of the present invention, where a two-swirl-generating device is fixed at a position near the inlet valve 11 so that a strong turbulence is being generated inside the combustion chamber to improve the speed of the transfer of flame. R is a turbulence inside the chamber. N is the center line of the two sets of swirls-generating wings and M is the line connecting the center of the ring with the plug 14. The range of angle between 0.degree. and line N and M is between 45.degree.. However, it is better to design them to be 0.degree., in order to get a good cleaning effect of the poles of plug while inleting the mixture.

FIG. 11 is another embodiment of the present invention, where two swirl-generating devices 1 are located respectively near the two inlet valves 4 of an engine.

FIGS. 12 and 13 show the cylinder heads of two embodiments of the present inventions, in which the flow of gas is being directed from the valves 4 towards the plug or plugs 14 by two single-direction-swirl-generating devices. These embodiments give very strong turbulence of two independent swirls so that very low fuel consumption of the engines can be attained at any operation condition.

FIGS. 14 and 15 are the cylinder heads of two embodiments of the present invention in which the flow of gas is also directed from the valves towards the plug or plugs by two double-swirl-generating devices.