Internal-combustion engines – Charge forming device – Supercharger
Reexamination Certificate
2000-03-23
2001-12-11
Nguyen, Hoang (Department: 3748)
Internal-combustion engines
Charge forming device
Supercharger
C123S559100
Reexamination Certificate
active
06328024
ABSTRACT:
FIELD OF THE INVENTION
This invention relates to an apparatus for increasing the power output of internal combustion engines.
BACKGROUND OF THE INVENTION
Superchargers are devices for increasing the power output of internal combustion engines. They achieve this by increasing the mass of air, which is input to the cylinders, thereby increasing the combustible mass of the air fuel mixture in each cylinder above that which would be pumped by the pistons at atmospheric pressure.
Superchargers of several types are known in the industry. One type is belt driven by the engine itself and is functional whenever the engine is operating. Such superchargers are large and relatively expensive, complex and add significant weight as some use precision gearing to multiply the speed of the engine rpms to achieve speed necessary to move the amount and pressure of air. Their size limits their ability to be used in the cramped engine compartments of modern automobiles. Their complexity usually requires professional installation as well as modifications to the engine management system. A second type is a turbo supercharger. This type uses the waste exhaust gas from the engine to drive a centrifugal impeller, which compresses the air input to the engine which is on a common shaft with the compressor. A third type of supercharger is electrically driven, does not use the engine itself as its power source directly, but instead uses a separate electric motor which is powered by a battery or other DC power source.
However, electric superchargers still suffer the disadvantages of size, complexity, weight and cost. They also operate whenever the engine is running, even when such operation would not be needed and may actually be undesirable. This could result in unnecessary wear and power loss of the entire system consisting of the engine, supercharger and power source for the supercharger. One other disadvantage of known electric superchargers which use centrifugal impellers is that the impeller must be operated at very high speed, of the order of 50-80,000 revolutions per minute, and therefore requires high current input, even when the engine is operating at low power.
A requirement therefore exists for a supercharger which is relatively small, simple, inexpensive, easy to install and operates only when maximum power is required from the engine. Such occasions could be during passing another car, during emergency maneuvers, or for limited periods during automobile race events. A supercharger which meets these characteristics would have significant use because of its cost and simplicity even if it provided only a modest increase in power, since even a modest increase would be important at critical times, especially in an automotive application.
SUMMARY OF THE INVENTION
According to a first aspect of the invention, an axial flow electric supercharger includes an axial flow fan/compressor, powered by a direct drive electric DC motor (brush or brushless style of commutation). The word fan will be used throughout. However, it should be understood that this apparatus may alternatively be described as a compressor.
An axial flow fan is used for several reasons:
A. It spools to a speed of about 20,000 to 21,000 rpm in less than 0.1 seconds to provide exceptionally quick response due to its light weight construction resulting in low inertia.
B. It does not need to operate continuously, and when not in operation, does not provide any significant restriction on the operators ability to achieve any power setting less than full output.
C. Such fans are relatively small simple and lightweight.
D. They are efficient for the desired mode of operation (i.e. providing large volumes of air at relatively low pressure increases).
E. Because they operate to provide relatively low pressure increases, they can be added without complex plumbing to most existing engines with no change to pre installed air fuel management systems.
F. They can be added to engines which already have traditional turbo or supercharger systems as a way to increase power output without increasing the pressure differential generated by those systems. (Total pressure available to an internal combustion engine equals the ambient pressure plus the pressure generated by mechanical forced air induction systems. The axial flow supercharger increases the ambient pressure of the air flowing into the turbo or supercharger, thus adding to the total air pressure available to the engine)
G. Installation is simple. All that is required to connect an axial flow supercharger are wires, switches, and adapter mounting tubes.
According to a second aspect of the invention, an electric supercharger includes a control system which can be set to operate only when additional engine output is needed or required. It is neither necessary nor desirable to operate a supercharger when less than full output of the engine is desired. When operating at partial output and more power is desired, it can be obtained by increasing throttle setting without actuating the supercharger. This minimizes wear of the electric supercharger and load on the battery or other source of electric power which drives the supercharger's motor. Therefore, a control system has been devised which operates only when maximum power is desired. In one embodiment, it consists of a micro-switch that is mounted to the accelerator pedal in a car, or to the throttle control directly in other embodiments, such that it activates and allows current flow to the motor of the supercharger only when the pedal or throttle are in their maximum positions.
In a preferred embodiment, the assembly is coupled directly to the engine's air input box, without removal of the existing input air filter.
In an other embodiment discussed hereinafter, the electric supercharger assembly is connected to the engine's air input box with the air box filter removed or alternatively replacing the air box and using a separate air filter on the electric supercharger.
In another embodiment, the supercharger is connected at any other location between the engine's air intake system and the atmosphere.
REFERENCES:
patent: 4485310 (1984-11-01), Valroger
patent: 5638796 (1997-06-01), Adams, III et al.
patent: 6135098 (2000-10-01), Allen et al.
Cole Stanley Z
Nguyen Hoang
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