Abstract: Engine components are thermally insulated with composite layers for improved engine efficiency. A metallic insulation layer is affixed to the metallic substrate of each component, and a layer of heat and corrosion resistant metal overlies and is bonded to the insulation layer. One preferred embodiment incorporates a preformed sheet layer of stainless steel sintered to a layer of metallic insulation attached to the component body substrate. An alternate embodiment incorporates a plasma-sprayed stainless steel layer over the insulation layer. A preferred process for making the engine component includes casting the component body in a mold containing a preformed insulation composite formed of a layer of stainless steel sheet sintered to a layer of metallic insulation.

Abstract: Engine components are thermally insulated with composite layers for improved engine efficiency. A metallic insulation layer is affixed to the metallic substrate of each component, and a layer of heat and corrosion resistant metal overlies and is bonded to the insulation layer. One preferred embodiment incorporates a preformed sheet layer of stainless steel sintered to a layer of metallic insulation attached to the component body substrate. An alternate embodiment incorporates a plasma-sprayed stainless steel layer over the insulation layer. A preferred process for making the engine component includes casting the component body in a mold containing a preformed insulation composite formed of a layer of stainless steel sheet sintered to a layer of metallic insulation.

Abstract: A composite thermal shield includes an external solid layer of heat and corrosion-resistant metal bonded to a permeable layer of metal. The composite is mechanically affixed to the substrate metal of an engine component, by a method wherein the substrate metal becomes entrained within the interstices of the permeable metal layer. In a first preferred form the permeable metal layer is comprised of a fibrous stainless steel woven wire mesh which is sintered or brazed to the external stainless steel heat and corrosion-resistant layer. In a preferred process, an aluminum substrate piston is formed to include the composite shield, whereby the aluminum is pressed into the permeable layer during formation of the piston in a mold. In a second preferred form, the piston includes an insulation layer wherein two layers of stainless steel wire mesh have an intermediate stainless steel layer sandwiched between them.

Abstract: A reciprocating piston four cycle internal combustion engine utilizes a stepped piston the stepped portion of which, working in an enlarged bore in the block, serves as a compressor to provide a supercharged fuel-air mixture to the combustion chamber. The compressor delivers two compression strokes per engine cycle. The compressed fuel-air mixture travels from the compressor via a bypass manifold, which also serves as an accumulator, to the main cylinder via an intake valve. Fuel-air mixture is admitted to the compressor cylinder through the crankcase and valved passages through the stepped portion of the piston.

Abstract: A rotary valve system for an internal combustion engine is disclosed. Through the provision of an axially movable valve rotor, the system is capable of variable valve opening duration and timing. Ports in the rotor or in the rotor housing, or both, have edges inclined with respect to the axis of the rotor, so that relative axial movement of the rotor and housing ports effects a change in the timing of valve opening and closing. Valve opening duration is also varied. An actuator system which controls the axial translation of the rotor during operation of the engine considers factors affecting engine performance such as engine speed, road speed and engine loading in determining the optimum valve timing and duration setting.

Abstract: An apparatus for applying a stratified charge to a reciprocating internal combustion engine is disclosed. The apparatus comprises a cylindrical rotary valve body disposed for rotation within the head of an internal combustion engine. The valve body defines diametrically extending inlet and exhaust passages which, during rotation of the valve body, place a cylinder of the engine in sequential communication with an inlet manifold and an exhaust manifold secured to the head. The inlet manifold comprises a double-passage gallery for transporting a lean fuel/air charge in a first passage and a rich fuel/air charge in a second passage. Rotation of the inlet passage into communication with the cylinder also brings the inlet passage into sequential communication with the first throat and then the second throat for transporting the first lean charge and then the second rich charge to the cylinder.

Abstract: An improved water cooled exhaust valve structure is disclosed for a rotary valve engine. The exhaust gases from an engine combustion chamber enter a side port in a rotary exhaust valve and flow axially through the valve to an exhaust outlet. Cooling water is sprayed axially into the exhaust valve and is directed in the gas flow direction from a location upstream of the side port. A novel deflector prevents the cooling water from entering the side port.

Abstract: An improved piston assembly for high-power internal combustion engines such as supercharged diesel engines. The piston includes separate head and skirt portions. An elongated bearing member having an external journal surface is formed across the bottom of the piston head. A wrist pin, which is attached to or integral with a connecting rod, defines a generally tubular shaped bearing member having an internal bearing surface in which the piston head bearing member is journaled to permit rotational movement between the connecting rod and the piston head. The external journal surface on the piston head is supported by the wrist pin along its entire length to prevent any flexing of the wrist pin when high compressive forces are applied to the piston head. The skirt is connected to the wrist pin by thrust bearings which engage an external journal surface on the wrist pin substantially along its entire length to permit rotational movement between the piston head and the piston skirt.

Abstract: An apparatus for applying a stratified charge to a reciprocating internal combustion engine is disclosed. The apparatus comprises a cylindrical rotary valve body disposed for rotation within the head of an internal combustion engine. The valve body defines first and second inlet ports and an exhaust port. The first inlet port is disposed, upon rotation in the valve body, to establish communication between an intake manifold for transporting a fuel lean charge and a main combustion chamber of the engine. The second inlet port is disposed for establishing simultaneous communication between a second manifold for transporting a fuel-rich charge and a pre-combustion chamber adjacent the main combustion chamber. The exhaust valve is disposed for establishing communication between an exhaust manifold and the main combustion chamber. In a second embodiment of the invention, the inlet passages and the exhaust passages are located in separate valve bodies mounted for rotation within the head.

Abstract: A seal assembly for a rotary valved internal combustion engine is disclosed. The seal assembly comprises longitudinal side seals for axially sealing an interface between a cylindrical valve housing and a complementary valve rotor body therein. Circumferential ring seals are spaced apart along the valve rotor body for isolating inlet or exhaust ports which extend diametrically through the rotor. The ring seals are provided with a novel means for biasing the seals against the rotor. Spacers are provided for locating and retaining the seals in position within the housing, with bearing rings between the spacers for rotationally supporting the rotor. The assembly also includes means for locating the spacers properly in a head of the engine and for properly orienting the end seals.

Abstract: An improved piston assembly for high-power internal combustion engines such as supercharged diesel engines. The piston includes separate head and skirt portions. An elongated tubular-shaped bearing member having an internal bearing surface and an external journal surface is formed across the bottom of the piston head. A connecting rod passes through an opening in the lower center of the bearing member and is attached to a wrist pin which rotates against the internal bearing surface of the tubular-shaped bearing member to permit rotational movement between the connecting rod and the piston head. The wrist pin is supported by the bearing surface along its entire length to prevent any flexing of the wrist pin when high compressive forces are applied to the piston head. The skirt is connected to the piston head by thrust bearings which engage the external journal surface of the bearing member substantially along its entire length to permit rotational movement between the piston head and the piston skirt.

Abstract: An apparatus for applying a stratified charge to a reciprocating internal combustion engine is disclosed. The apparatus comprises a cylindrical rotary valve body disposed for rotation within the head of an internal combustion engine. The valve body defines diametrically extending inlet and exhaust passages which, during rotation of the valve body, place a cylinder of the engine in sequential communication with an inlet manifold and an exhaust manifold secured to the head. The inlet manifold comprises a double-passage gallery for transporting a lean fuel/air charge in a first passage and a rich fuel/air charge in a second passage. Rotation of the inlet passage into communication with the cylinder also brings the inlet passage into sequential communication with the first throat and then the second throat for transporting the first lean charge and then the second rich charge to the cylinder.