Note: Descriptions are shown in the official language in which they were submitted.
CA 02383209 2002-03-13
WO 01/20162 PCT/IJS00/16747
-1-
IGNITION SYSTEM FOR STRATIFIED FUEL MIXTURES
Background of the Invention
1. Field of the Invention
The present invention is related to the field of ignition systems for internal
combustion engines and, more particularly, to the field of ignition systems
that operate
on a stratified fuel mixture.
2. Related Art
Internal combustion engines are well known. Typical internal combustion
engines include at least one combustion chamber into which a gaseous mixture
of fuel
and air is delivered. The mixture is ignited by a spark provided by a spark
plug.
Conventional spark plugs typically include a center electrode that is
surrounded by
insulating material except for a few millimeters at the end of the center
electrode.
Conventional spark plugs also typically include a second electrode that is
bent over the
center electrode to create a spark gap between the first and second
electrodes. When a
sufficiently high voltage is created between these two electrodes a breakdown
(spark)
occurs between the electrodes. The spark ignites fuel in the combustion
chamber that is
located proximate the spark. In order for the spark to effectively ignite the
fuel, the spark
gap must be inserted far enough into the combustion chamber so that the spark
contacts
the fuel in the combustion chamber.
Fuel may be introduced into the combustion chamber in a number of manners.
One manner is by direct fuel injection. Direct fuel injection introduces a
localized fuel
plume into the combustion chamber. A fuel injector directs the fuel plume into
a
particular portion of the combustion chamber. This fuel plume creates a
stratification in
the combustion chamber. That is. the combustion chamber includes areas where
fuel is
present (within the fuel plume) and areas where fuel is not present (the rest
of the fuel
chamber). Thus, ignition systems that employ direct fuel injection will be
referred to
herein as stratified mixture systems. Another type of fuel delivery system
that create
may create a stratified mixture includes an electronic fuel injection system
that allows
CA 02383209 2002-03-13
WO 01/20162 PCT/US00/16747
-2-
only air to enter the chamber for a first time period and then allows fuel to
enter the
chamber for a second time period.
As discussed above, a conventional spark plug needs to be inserted far enough
into the combustion chamber of an engine employing a stratified mixture system
so that
the spark is located in a region of the combustion chamber that is known or
thought to
contain the fuel (i.e., in the fuel plume).
Summary of the Invention
The above described stratified mixture systems may be thought of as engines
that
l0 have unevenly distributed fuel portions. Ideally, an internal combustion
engine should
have a minimum amount of fuel near the walls of the combustion chamber because
the
flame produced by igniting the fuel plume may be quenched by the walls of the
combustion chamber. This quenching may result in a reduction in engine
efficiency and
higher hydrocarbon emissions. Thus, great care must be taken in present
stratified
15 mixture systems to ensure that the fuel plume is not directed to a location
near the walls
of the combustion chamber.
In addition, stratified mixture engines experience several other challenges.
One
of these challenges is overcoming localized variations in the fuel/air ratio
in the fuel
plume. Due to the small size and duration of the spark created by a
conventional spark
2o plug, if the plug is not positioned in a region that has a high fuel/air
mixture, the engine
may misfire. That is, the fuel in the combustion chamber may fail to ignite.
Another
related problem is that, even though fuel ignites, the fuel only partially
burns. This may
be caused by the fact that stratified mixture systems may produce fuel
droplets that are
relatively large as compared to a homogenized mixture. As these large droplets
25 evaporate, the heat taken out of the system by the evaporation may take
heat away from
the flame and either extinguish or reduce the flame. In turn this reduces
engine
efficiency and increases hydrocarbon emissions.
Furthermore, due to the fact that the spark plug needs to be directly in the
path of
the injected fuel, the spark may be blown out by the passing fuel. In
addition, because
3o the spark plug is in the path of the fuel, the fuel droplets themselves may
extinguish the
spark.
CA 02383209 2002-03-13
WO 01/20162 PCT/US00/16747
-3-
Stratified mixture systems are also highly susceptible to fouling. A spark
plug
may foul due to a build up of soot on the plug. If the fuel is not completely
burned, the
resulting soot accumulates on the insulating material on the outside of the
plug and may
cause the spark to travel down the outside of the plug instead of between the
electrodes.
This condition leads to engine misfires.
Any non-uniformity in a combustion chamber leads to locations of incomplete
combustion and allows for hydrocarbons to evaporate and escape into the
environment.
Placing the plug in the combustion chamber leads to such non-uniformities and
thereby
increases emissions.
to The present invention provides for an ignition system that effectively
ignites
stratified mixtures without the inherent drawbacks caused due to the
introduction of
conventional spark plugs into a combustion chamber. In one embodiment, the
present
invention overcomes these draw backs by providing a plug and associated
electronics
that project a large plasma kernel into a combustion chamber such that it
contacts the
stratified fuel. The plug advantageously does not extend into the combustion
chamber
near as far as conventional spark plugs and therefore avoids the disadvantages
caused by
such intrusion into the combustion chamber by the plug.
In one embodiment, the present invention is directed to an ignition system for
use
in an internal combustion engine. This embodiments includes a plasma-
generating
device and associated electronics. A specific type of plasma-expelling device
is a
travelling spark igniter (TS1), examples of which are disclosed in U.S. Patent
No.
5,704,321, U.S. Patent Application and U.S. Patent Application Serial No.
09/204,440,
both of which are hereby incorporated by reference. In this embodiment, the
plasma-
generating device is mounted in the combustion chamber such that the
electrodes of the
plasma-generating device extend into combustion chamber such that they do not
contact
the stratified fuel plume but may still expel a volume of plasma into
stratified mixture so
that the stratified mixture is ignited. This may be achieved by mounting the
plasma-
generating device such that the electrodes are flush or nearly flush with the
wall of a
combustion chamber. It should be understood that the present invention may be
utilized
3o in non-stratified mixtures engines (e.g., homogenous mixture engines) as is
discussed in
greater detail below.
In another embodiment of the present invention a method of igniting fuel in a
CA 02383209 2002-03-13
WO 01/20162 PCT/US00/16747
-4-
combustion chamber of an internal combustion engine having at least one
combustion
chamber utilizing a traveling spark ignitor having at least two electrodes is
disclosed.
The method includes arranging the ignitor such that ends of electrodes are
substantially
flush with walls of the at least one combustion chamber, providing a first
voltage
between the electrodes to cause an initial breakdown of a gaseous air/fuel
mixture
present between the electrodes and providing a follow-on current that travels
between the
electrodes after the initial breakdown.
In another embodiment of the present invention, a system for igniting a
stratified
fuel mixture is disclosed. The system of this embodiment includes a traveling
spark
ignitor having at least two electrodes and a circuit for providing first and
second voltages
between the electrodes to that creates an initial plasma kernel and then
causes the plasma
kernel to expand and swept outwardly from the ignitor under a Lorentz force.
The
traveling spark ignitor, when used in an engine having a combustion chamber,
is
arranged such that the ends of the electrodes are substantially flush with a
wall of the
combustion chamber.
Brief Description of the Drawings
Various embodiments of the invention are illustrated and described below with
reference to the accompanying drawings, in which like items are identified by
the same
2o reference designation, wherein:
FIG. 1 is a cross-sectional view of a cylindrical Marshall gun with a
pictorial
illustration of its operation, which is useful in understanding the invention.
FIG. 2 is a cross-sectional view of a cylindrical traveling spark ignitor for
one
embodiment of this invention, taken through the axes of the cylinder,
including two
electrodes and wherein the plasma produced travels by expanding in the axial
direction.
FIG. 3A is a detailed view of the tip of a cylindrical traveling spark ignitor
for the
embodiment shown in FIG. 2.
FIG. 3B is a detailed view of one embodiment if a tip of a cylindrical
traveling
spark ignitor.
3o FIG. 4 is a three dimensional cross-sectional view further defining one
embodiment of the present invention.
CA 02383209 2002-03-13
WO 01/20162 PCT/US00/16747
-5-
FIG. 5 is a cross-sectional view of a traveling spark ignitor for another
embodiment of the invention wherein the plasma produced travels by expanding
in the
radial direction.
FIG. 6 is a cutaway pictorial view of a traveling spark ignitor for one
embodiment of the invention, as installed into a cylinder of an engine.
FIG. 7 is a cutaway pictorial view of a traveling spark ignitor for a second
embodiment of the invention, as installed into a cylinder of an engine.
FIG. 8 shows a cross-sectional view of yet another traveling spark ignitor for
an
embodiment of the invention.
1 o FIG. 9A shows a longitudinal cross-sectional view of another traveling
spark
ignitor for another embodiment of the invention.
FIG. 9B is an end view of the traveling spark ignitor of FIG. 9A showing the
free
ends of opposing electrodes.
FIG. 9C is an enlarged view of a portion of FIG. 9B.
FIG. 10 is an illustration of the ignitor embodiment of FIG. 2 coupled to a
schematic diagram of an exemplary electrical ignition circuit to operate the
ignitor,
according to an embodiment of the invention.
FIG. 11 is a high-level block diagram of an ignition circuit according to one
embodiment of the present invention.
FIG. 12 shows a circuit schematic diagram of another ignition circuit
embodiment according to the invention.
FIG. 13 shows one embodiment of the secondary electronics of FIG. 11.
FIGs. 14A-14C show alternative embodiments of a primary electronics of FIG.
11.
FIGs. 15A-15C show alternative embodiments of the secondary electronics of
FIG. 11.
FIG. 16 shows a high-level block diagram of an electrical ignition circuit of
the
present invention.
FIG. 17 is a more detailed version of the circuit disclosed in FIG. 16.
3o FIG. 18 is a more detailed version of the secondary circuit disclosed in
FIG. 17.
FIG. 19 is a graph representing an example of the voltage between the
electrodes
of a spark plug with respect to time that may be created by the circuit of
FIG. 18.
CA 02383209 2002-03-13
WO 01/20162 PCT/US00/16747
-6-
FIG. 20 is an alternative to the secondary circuit shown in FIG. 18.
FIG. 21 is another alternative to the secondary circuit shown in FIG. 18.
FIG. 22 is a variation of the circuit shown in FIG. 21.
FIG. 23 is series connected version of the circuit disclosed in FIG. 17.
FIG. 24 is a variation of the circuit shown in FIG. 23.
FIG. 25 is another variation of the firing circuitry of the present invention.
FIG. 26 is yet another embodiment of the firing circuitry of the present
invention.
FIG. 27 shows the secondary electronics as included in an add-on unit to be
used
in combination with a conventional ignition system.
FIG. 28 shows how a conventional spark plug may be placed in a combustion
chamber.
FIG. 29 shows how embodiments of the present invention may be placed in a
combustion chamber.
Detailed Description
IS The following detailed description will describe several embodiments and
components of aspects of the present invention. It should be understood that
various
aspects of the invention may be combined or omitted depending upon the context
and
that the required elements for each embodiment are included only in the
appended
claims.
I. General Theory of Operation
The following discussion will relate to the general operation of a plasma-
generating device in order to more clearly explain aspects of the present
invention.
FIG. 1 shows a simplified embodiment of a prior art Marshall gun (plasma gun)
that, with limitation, presents an effective way of creating a large volume of
plasma. The
schematic presentation in FIG. 1 shows the electric field 2 and magnetic field
4 in an
illustrative Marshall gun, where Be is the poloidal magnetic field directed
along field line
4. The plasma 16 is moved in an outward direction 6 by the action of the
Lorentz force
vector F and thermal expansion, with new plasma being continually created by
the
3o breakdown of fresh gas as the discharge continues. V, is the plasma kernel
speed vector,
also directed in the z-direction represented by arrow 6. Thus, the plasma 16
grows as it
moves along and through the spaces between electrodes 10, 12 (which are
maintained in
CA 02383209 2002-03-13
WO 01/20162 PCT/US00/16747
7_
a spaced relationship by isolator or dielectric 14). Once the plasma 16 leaves
the
electrodes 10, 12, it expands in volume, cooling in the process. It ignites
the
combustibles mixture after it has cooled to the ignition temperature.
Fortunately,
increasing plasma volume is consistent with acknowledged strategies for
reducing
emissions and improving fuel economy. Two such strategies are to increase the
dilution
of the gas mixture inside the cylinder and to reduce the cycle-to-cycle
variations.
Dilution of the gas mixture, which is most commonly achieved by the use of
either excess air (running the engine lean) or exhaust gas recirculation
(EGR), reduces
the formation of oxides of nitrogen by lowering the combustion temperature.
Oxides of
nitrogen play a critical role in the formation of smog, and their reduction is
one of the
continuing challenges for the automotive industry. Dilution of the gas mixture
also
increases the fuel efficiency by lowering temperature and thus reducing the
heat loss
through the combustion chamber walls, improving the ratio of specific heats,
and by
lowering the pumping losses at a partial load.
Zeilinger determined the nitrogen oxide formation per horsepower-hour of work
done, as a function of the air to fuel ratio, for three different spark
timings (Zeilinger, K.,
Ph.D. thesis, Technical University of Munich (1974)). He found that both the
air-to-fuel
ratio and the spark timing affect the combustion temperature, and thus the
nitrogen oxide
formation. As the combustible mixture or air/fuel ratio (A/F) is diluted with
excess air
(i.e., A/F larger than stoichiometric), the temperature drops. At first, this
effect is
diminished by the increase in the amount of oxygen. The NO,~ formation
increases.
When the mixture is further diluted, the NOX formation decreases to values
much below
those at a stoichiometric mixture because the combustion temperature decline
overwhelms the increase in 02.
A more advanced spark timing (i.e., initiating ignition more degrees before
top
dead center) raises the peak temperature and decreases engine efficiency
because a larger
fraction of the combustible mixture burns before the piston reaches top dead
center
(TDC) and the mixture is compressed to a higher temperature, hence leading to
much
higher NO~ levels and heat losses. As the mixture is made lean, the spark
timing which
3o gives the maximum brake torque (MBT timing) increases.
Dilution of the mixture results in a reduction of the energy density and the
flame
propagation speed, which affect ignition and combustion. The lower energy
density
CA 02383209 2002-03-13
WO 01/20162 PCT/US00/16747
_g_
reduces the heat released from the chemical reaction within a given volume,
and thus
shifts the balance between the chemical heat release and the heat lost to the
surrounding
gas. If the heat released is less than that lost, the flame will not
propagate. Thus, a larger
initial flame is needed.
Reducing the flame propagation speed increases the combustion duration.
Ignition delay results from the fact that the flame front is very small in the
beginning,
which causes it to grow very slowly, as the quantity of fuel-air mixture
ignited is
proportional to the surface area. The increase in the ignition delay and the
combustion
duration leads to an increase of the spark advance and larger cycle-to-cycle
variations
l0 which reduces the work output and increases engine roughness. A larger
ignition kernel
will reduce the advance in spark timing required, and thus lessen the adverse
effects
associated with such an advance. (These adverse effects are an increased
difficulty to
ignite the combustible mixture, due to the lower density and temperature at
the time of
the spark, and an increase in the variation of the ignition delay, which
causes driveability
15 to deteriorate).
Cyclic variations are caused by unavoidable variations in the local air-to-
fuel
ratio, temperature, amount of residual gas, and turbulence. The effect of
these variations
on the cylinder pressure is due largely to their impact on the initial
expansion velocity of
the flame. This impact can be significantly reduced by providing a spark
volume which
20 is appreciably larger than the mean sizes of the inhomogeneities.
A decrease in the cyclic variations of the engine combustion process will
reduce
emissions and increase efficiency, by reducing the number of poor burn cycles,
and by
extending the operating air fuel ratio range of the engine.
While increasing spark volume, some embodiments of the present invention may
25 also provide for expelling the spark deeper into the combustible mixture,
with the effect
of reducing the combustion duration.
To achieve these goals, some embodiments of the present invention utilize
ignitors having electrodes of relatively short length with a relatively large
distance
between them; that is, the distance between the electrodes is large relative
to electrode
30 length.
II. Configuration of the Plasma-Generating Devices (ignitors)
CA 02383209 2002-03-13
WO 01/20162 PCT/US00/16747
-9-
The following description will explain various aspects of embodiments of
plasma-generating devices according to the present invention.
FIG. 2 shows one illustrative embodiment of a TSI 17 according to the present
invention. This embodiment has standard mounting means 19 such as threads for
mounting the TSI 17 in a combustion chamber such as a piston chamber of an
internal
combustion engine. These threads may mount the TSI in the combustion chamber
such
that the electrodes extend specific distances into the combustion chamber. The
mounting
of the TSI 17 may affect the operation of an internal combustion engine and is
discussed
in greater detail below.
l0 The TSI 17 also contains a standard male spark plug connector 21, and
insulating
material 23. The tip 22 of the TSI 17 varies greatly from a standard spark
plug. In one
embodiment, the tip 22 includes two electrodes, a first electrode 18 and a
second
electrode 20. The particular embodiment shown in FIG. 2 has the first
electrode 18
coaxially disposed within the second electrode 20; that is, the second
electrode 20
surrounds the first electrode 18. The first electrode 18 is attached to a
distal boot
connector 21. The space between the electrodes is substantially filled with
insulating
material (or dielectric) 23.
Application of a voltage to the TSI 17 between the first and second
electrodes, 18
and 20, causes a discharge originating on the surface of the insulating
material 23. The
2o voltage required for a discharge across the insulating material 23 is lower
than for a
discharge between the electrodes 18 and 20 some distance away from the
insulating
material 23. Therefore, the initial discharge occurs across the insulating
material 23.
The location of the initial discharge shall be referred to herein as the
"initiation region."
This initial discharge constitutes an ionization of the gas (an air/fuel
mixture), thereby
creating a plasma 24. This plasma 24 is a good conductor and supports a
current
between the first electrode 18 and the second electrode 20 at a lower voltage
than was
required to form the plasma. The current through the plasma serves to ionize
even more
gas into a plasma. The current-induced magnetic fields surrounding the
electrode and the
current passing through plasma the interact to produce a Lorentz force on the
plasma.
This force causes the point of origin of current though the plasma to move
and, thus,
creates a larger volume of plasma. This is in contrast to traditional ignition
systems
wherein the spark initiation region remains fixed. The Lorentz force created
also serves
CA 02383209 2002-03-13
WO 01/20162 PCT/US00/16747
- 10-
to expel the plasma from the TSI 17. Inherent thermal expansion of the plasma
aids in
this expulsion. That is, as the plasma heats and expands it is forced to
travel outwardly,
away from the surface of the dielectric material 23.
The first and seconds electrodes, 18 and 20, respectively, may be made from
materials which may include any suitable conductor such as steel, clad metals,
platinum-
plated steel (for erosion resistance or "performance engines"), copper, and
high-
temperature electrode metals such as molybdenum or tungsten, for example. The
electrodes (one or both) may be of a metal having a controlled thermal
expansion like
Kovar (a trademark and product of Carpenter Technology Corp.) and coated with
a
1 o material such as cuprous oxide so as to give good subsequent seals to
glass or ceramics.
Electrode materials may also be selected to reduce power consumption. For
instance,
thoriated tungsten could be used, as its slight radioactivity may help to pre-
ionize the air
or air-fuel mixture between the electrodes, possibly reducing the required
ignition
voltage. Also, the electrodes may be made of high-Curie temperature permanent
magnet
15 materials, polarized to assist the Lorentz force in expelling the plasma.
The electrodes, except for a few millimeters at their ends, are separated by
insulating material 23 which may be an isolator or insulating material which
is a high
temperature dielectric. This material can be porcelain, or a fired ceramic
with a glaze, as
is used in conventional spark plugs, for example. Alternatively, it can be
formed of
2o refractory cement, a machinable glass-ceramic such as Macor (a trademark
and product
of Corning Glass Company), or molded alumina, stabilized zirconia or the like
fired and
sealed to the metal electrodes such as with a solder glass frit, for example.
As above, the
ceramic could also comprise a permanent magnet material such as barium
ferrite.
It should be appreciated that the second electrode 20 need not necessarily be
a
25 complete cylinder that completely surrounds the first electrode 18. That
is, the second
electrode 20 may have portions removed from it so that there are spaces
separating
pieces of the second electrode 20 from other pieces. These pieces, if
connected, would
create a complete circle that surrounds the first electrode 18.
FIG. 3A is a more detailed cross-sectional view of one possible embodiment for
3o the tip 22 shown in FIG. 2. The particular embodiment shown here relates to
TSI 17.
However. it should be noted that the specific properties of this configuration
could be
CA 02383209 2002-03-13
WO 01/20162 PCT/US00/16747
-11-
applied to any of the below-discussed embodiments, for example TSI's 27, 101
and 120,
or to any embodiment later discovered.
The tip 22, as shown, includes a first electrode 18 and a second electrode 20.
Between the first and second electrodes is an insulating material 23. The
insulating
material 23 fills a substantial portion of the space between the electrodes 18
and 20. The
portion of the space between the electrodes 18 and 20 not filled by the
insulating material
23 is referred to herein as the discharge gap. This discharge gap has a width
Wdo which
is the distance between the electrodes 18 and 20 and is measured at their
nearest point.
The length by which the first electrode 18 extends beyond the insulating
material 23 is
1 o denoted herein as 1i and the length by which the second electrode 20
extends beyond the
insulating material is denoted as 1z. The shorter of 1~ or h shall be referred
to herein as
the length of the discharge gap. The first electrode 18 has a radius r~ and
the second
electrode 20 has a radius r2. The difference between the radii of the second
and first
electrodes, r2-r,, represents the width of the discharge gap Wa. It should be
noted
however that Wb may also be represented by the distance between two spaced
apart non-
concentric electrodes.
The current through the first electrode 18 and the plasma 24 to the second
electrode 20 creates around the first electrode 18 a poloidal (angular)
magnetic field Be
(I, r), which depends on the current and distance (radius r~, see FIG. 1 )
from the axis of
2o the first electrode 18. Hence, a current I flowing through the plasma 24
perpendicular to
the poloidal magnetic field Be generates a Lorentz force F on the charged
particles in
the plasma 24 along the axial direction z of the electrodes 18, 20. The force
is
approximately computed as follows in equation ( 1 ):
F~IxB-~FZ~Ir~Bo (1)
This force accelerates the charged particles which, due to collisions with non-
charged
particles, accelerates all the plasma. Note that the plasma consists of
charged particles
(electrons and ions), and neutral atoms. The temperature is not sufficiently
high in the
discharge gap to fully ionize all atoms.
3o The original Marshall guns as a source of plasma for fusion devices were
operated in a vacuum with a short pulse of gas injection between the
electrodes. The
plasma created between the electrodes by the discharge of a capacitor was
accelerated a
CA 02383209 2002-03-13
WO 01/20162 PCT/US00/16747
-12-
distance of a dozen centimeters to a final velocity of about 10' cm/sec. The
drag force F,,
on the plasma is approximately proportional to the square of the plasma
velocity, as
shown below in equation (2):
F~wP2
The distance over which the plasma accelerates is short (1-3mm). Indeed,
experimentation has shown that increasing the length of the plasma
acceleration distance
beyond 1 to 3 mm does not significantly increase the plasma exit velocity,
although
to electrical energy used to drive such a TSI is increased significantly. At
atmospheric
pressures and for electrical input energy of about 300mJ, the average velocity
is close to
Sx104 cm/sec and will be lower at high pressure in the engine. At a
compression ratio of
8:1, this average velocity will be approximately 3x104 cm/sec.
By contrast, if more energy is put into a single discharge of a conventional
spark,
15 its intensity is increased somewhat, but the volume of the plasma created
does not
increase significantly. In a conventional spark, a much larger fraction of the
energy input
goes into heating the electrodes when the conductivity of the discharge path
is increased.
Given the above dimensioning constraints, the present invention optimizes the
combination of the electro-magnetic (Lorentz) and thermal expansion forces
when the
20 TSI is configured according to the following approximate condition:
(r2 - r~)/ 1X >_ 1/3 (3)
where 1X is the length of the shorter one of 1~ or 1~. It should be noted that
the
25 dimensional boundaries just expressed are approximate; small deviations
above or below
them still yield a functional TSI according to the present invention though
probably with
less than optimal performance. Also, as these dimensions define only the outer
bounds,
one skilled in the art would realize that there are many configurations which
will satisfy
these dimensional characteristics.
3o The quantity (r2 - r~)/ h represents the gap-to-length ratio in this
representation.
A smaller gap-to-length ratio may increase the Lorentz force that drives the
plasma out
of the TSI for the same input energy (when there is a larger current due to
lower plasma
CA 02383209 2002-03-13
WO 01/20162 PCT/US00/16747
-13-
resistance). If this gap-to-length ratio is too small, the additional energy
provided by the
Lorentz force goes primarily into erosion of the electrodes due to an increase
of the
sputtering process on the electrodes. Further, as described above, an
optimally
performing TSI should form a large volume plasma. Increasing the gap-to-length
ratio
for the same electrode length increases the volume in which the plasma may be
formed
and thereby contributes to the increase of the plasma volume produced. Thus,
the TSI of
the present invention preferably has a sufficiently large gap-to-length ratio
such that
there is enough volume within which to form a plasma. This volume constraint
also
serves to set a lower limit for the gap-to-length ratio. A gap-to-length ratio
of
l0 approximately 1/3 or higher has been found to create an optimal balance
between these
two constraints.
Contrary to early attempts where acceleration of plasma led to the input
energy
loss due to drag forces which grow with the square of velocity, the large gap-
to-length
ratio provides for the generation of a large volume of plasma which expelled
at a lower
velocity. The lower velocity reduces the drag force, thereby reducing the
required input
energy. Reduced input energy results in a lesser degree of electrode erosion,
leading, in
turn, to a TSI having a previously unattainable lifetime.
Preferably, the TSI ignition system of the present invention uses no more than
about 400 mJ per firing. By contrast, early plasma and Marshall gun ignitors
have not
achieved practical utility because they employed much larger ignition energies
(e.g., 2-10
Joules per firing), which caused rapid erosion of the ignitor and short life.
Further
efficiency gains in engine performance were surrendered by increased ignition
system
energy consumption.
FIG. 3B shows an alternative embodiment of a tip 22 portion of a TSI. In this
embodiment there exists an air gap 200 in the direct path over the surface of
insulating
material 23 between the first electrode 18 and the second electrode 20. This
air gap 200
has a width Wao and a depth Dab. The width Wa; and the depth Dao may vary
between
individual TSI's but are fixed for each individual TSI. The insulating
material in this
configuration includes a upper surface 204 and a lower surface 205 located at
the base
3o bottom of the air gap 200. An ignitor having an upper surface 204 and lower
surface 205
such as that shown in FIG. 3B shall be referred to herein as a "semi-surface
discharge"
CA 02383209 2002-03-13
WO 01/20162 PCTNS00/16747
-14-
ignitor. It should be appreciated that a semi-surface discharge ignitor need
not have the
dimensional ratios shown in FIG. 3B.
The air gap 200 serves several distinct purposes but its dominant effect is to
increase the lifetime of the TSI. First, the air gap 200 helps to prevent the
electrodes 18
and 20 from being short circuited due to a build up of a complete conduction
path over
the insulating material 23. Such a conduction path may be created by a number
of
mechanisms. For example, every time a TSI is fired, a portion of the metal of
the
electrodes is blasted away. This removal of electrode metal is known as
ablation.
Ablation of the electrodes produces a film of metal deposits over the surface
of the
insulating material 23. This film, over time, may become solid and thick
enough to carry
a current and thereby become a conduction path. Another way in which a
conduction
path between the electrodes could be created is from an excessive build up of
carbon
deposits or the like on the conduction material 204. If the build up of carbon
deposits
becomes large enough to carry a current, a short circuit of the electrodes may
result.
This direct interconnection leads to a greater amount of energy being imparted
to and
consumed by the TSI 17 without an appreciable increase in plasma volume. The
air gap
200 provides a physical barrier which the conduction path must bridge before
such a
short circuit condition may occur. That is, in order for a short circuit to
occur, the air gap
would have to be completely bridged with metal or carbon or a combination
thereof.
2o The air gap 200 also serves to help reduce electrode wear. In the absence
of the
air gap 200, the initial discharge has been found to occur between the same
points on the
electrodes every time the TSI 17 is used to ignite a plasma kernel. Namely,
the initial
discharge would occur at the point where the insulating material contacted the
second
electrode 20 (assuming a discharge from the first electrode 18 to the second
electrode
20). Because the discharge occurs at the same point, the second electrode 20
wears out
quicker at the point of discharge and eventually is destroyed. Introduction of
the air gap
200 causes the initial discharge points to vary. By spreading the discharge
points across
electrode 20, the wear is spread over a greater surface; this significantly
increases
electrode life. The second electrode 20 is preferably a substantially smooth
surface.
3o This allows for the spark to jump to more places on the second electrode 20
and thereby
increases the area over which wear occurs. This is shown schematically and
discussed in
more detail in relation to FIG. 4.
CA 02383209 2002-03-13
WO 01/20162 PCT/US00/16747
-15-
FIG. 4 is an example of a cut-away side view of one side of a section of a
discharge gap of a TSI. This example includes the first electrode 18, the
second
electrode 20, the insulating material 23 and the air gap 200. As previously
discussed, if
the air gap 200 did not exist, the initial breakdown point would occur at
substantially the
same location, i.e., the closest point of contact between the second electrode
20 and the
insulating material 23. This leads to a rapid erosion of the second electrode
20 at that
point and limits ignitor life. The air gap 200 helps to overcome this problem
by varying
the location of the initial discharge such that the second electrode 20 is not
worn away
(ablated) at the same point every discharge. This is shown graphically in Fig.
4 where an
1o area of ablation 400 is of width Wa and a height Ha. The first time the
ignitor is fired, the
initial breakdown will occur at the point when the two electrodes are closest
to one
another. At this time, some ablation of the electrode will occur causing that
point to no
longer be the closest point so, the next breakdown occurs at the "new" closest
point
(assuming a uniform gas mixture). Thus, the air gap 200 considerably expands
the
region over which the discharge occurs. When a thing ring of ablation is
formed over the
entire perimeter of the second electrode 20, the closest point will be
slightly above or
below this ring where a new discharge initiation region will be formed. This
occurs
during the entire life of the ignitor.
Eventually, the area of ablation, 400, is formed; the size of this area is
large
2o enough that the ignitor lasts for a commercially practicable time before
the second
electrode 20 is ablated away. The width of the air gap Wao is limited to being
about one-
half the width of the discharge gap Wdb when, if this width is any larger, the
effects of
breakdown across the insulating material 23 may be lost due to an increase in
resistance
occasioned by the increase in space between the electrodes.
The area of ablation, 400, leads to another physical constraint for an ignitor
according to one embodiment of the invention. In the case of concentric
cylindrical
electrodes, the inside of the second electrode 20 should be substantially
smooth to ensure
that the distance between the electrodes is substantially the same throughout
the entire
length of the discharge gap. Particularly, in the vicinity of the top of the
air gap 200, no
portion of the second electrode 20 should be any closer to the first electrode
18 than in
any other area of the gap. A substantially smooth surface of the second
electrode 20
CA 02383209 2002-03-13
WO 01/20162 PCT/US00/16747
-16-
allows for the ablation of the second electrode 20 to occur around the entire
ablation area
400.
Currently, those conventional spark plugs which are concentric in nature and
have a center electrode extending beyond a dielectric material have outer
electrodes that
are not suited to take advantage of the Lorentz force. In these conventional
plugs, the
bulk of the outer electrode is directed (at least to a certain degree)
radially away from the
center electrode. In order to generate Lorentz force on the plasma, the outer
electrode
must provide a return path for the electric current which is substantially
parallel to the
center electrode. Thus, in some embodiments, it may be desired to have the
first and
second electrodes arranged such that the facing sides of the electrodes remain
substantially parallel at least in the initiation region. In other
embodiments, the
electrodes should be substantially parallel to one another throughout the
length of the
discharge gap. That is, the first and second electrodes should be parallel to
one another
from at least a region near the upper surface 204 to the ends of the
electrodes. In other
embodiments, the first and second electrodes may remain parallel to one
another some
distance below the upper surface 204. For instance, the first and second
electrodes may
remain parallel to one another a distance below the upper surface 204 which is
approximately equal to the width of the discharge gap Wd~ or remain parallel
to one
another for a distance which represents any fraction between zero and one of
the width of
the discharge gap Wd~. It should be appreciated that the electrodes of any of
the TSI
embodiments disclosed herein may also be so arranged.
Referring again to the embodiment of FIG. 3B, there may exist another gap, the
expand gap 202, between the insulating material 23 and the first electrode 18.
The
expand gap 202 has an initial width, We, when the TSI 17 is cold. In some
embodiments,
the expand gap 202 exists between the insulating material 23 and the first
electrode 18
for substantially the entire length of the TSI 17. In other embodiments, the
expand gap
202 may only exist in between the first electrode 18 and the dielectric
material 23 for a
few (e.g. .5-5) cm below the upper surface 204
One purpose of the expand gap 202 is to provide a space into which the first
electrode 18 may expand as it heats up during operation. Without the expand
gap 202
any expansion of the first electrode 18 could cause the insulating material 23
to crack. If
the insulating material is cracked, its dielectric properties could be altered
and thereby
CA 02383209 2002-03-13
WO 01/20162 PCT/US00/16747
-17-
reduce the efficiency of the TSI. Further, the expand gap 202 helps to reduce
the
possibility of short circuits in a manner similar to that for the air gap 200.
It should be
understood however, that the embodiment shown in FIG. 3B could be implemented
without the expand gap 202, if a more flexible/less brittle insulating
material is
discovered.
A TSI shown to work well has been made with an air gap width Waa of about
0.53mm, an air gap depth Dab of about S.OOmm and an expand gap width We of
about
0.08mm. These dimensions are implemented in a concentric electrode TSI similar
to TSI
17 of FIG. 2 wherein the length of the first electrode 18 is about 2.7mm, the
length of the
second electrode 20 is about l.2mm and the gap between them (rZ-r,) is about
2.4mm.
It should be understood that either or both the air gap and the expand gap
discussed above may be utilized in any of the embodiments of a TSI discussed
below.
FIG. 5 is an example of another embodiment of a TSI according to the present
invention. TSI 27 includes an internal electrode 25 that is placed coaxially
within an
external electrode 28. The space between the electrodes 25 and 28 is
substantially filled
with an insulating material 23 (e.g., ceramic). A difference between the
embodiment in
FIG. 5 and that in FIG. 2 is that there is a flat, disk-shaped (circular)
electrode surface
26 formed integrally with, or attached to, the free end of the center
electrode 25,
extending transversely to the longitudinal axis of electrode 25 and facing
electrode 28.
2o Note further that the horizontal plane of disk 26 is parallel to the
associated piston head
(not shown) when the plasma ignitor 27 is installed in a piston cylinder. The
end surface
of electrode 28 which faces disk electrode 26 is a substantially flat circular
shape
extending parallel to the facing surface of electrode 26. As a result, an
annular cavity 29
is formed between opposing surfaces of electrodes 26 and 28. More precisely,
there are
two substantially parallel surfaces of electrodes 26 and 28 spaced apart and
oriented to be
parallel to the top of an associated piston head, as opposed to the embodiment
of FIG. 2
wherein the electrodes run perpendicularly to an associated piston head when
in use.
Consider that when the air/fuel mixture is ignited, the associated piston
"rises" and is
close to the spark plug or ignitor 27, so that it is preferably further from
gap 29 of the
3o ignitor 27 to the wall of the associated cylinder than to the piston head.
The essentially
parallel electrodes 26 and 28 are substantially parallel to the longest
dimension of the
volume of the combustible mixture at the moment of ignition, instead of being
oriented
CA 02383209 2002-03-13
WO 01/20162 PCT/US00/16747
-18-
perpendicularly to this dimension and toward the piston head as in the
embodiment of
FIG. 2, and the prior art. It was discovered that when the same electrical
conditions are
used for energizing ignitors 17 and 27, the plasma acceleration lengths 1 and
L,
respectively. are substantially equal for obtaining optimal plasma production.
Also, for
TSI 27, under these conditions the following dimensions work well: the radius
of the
disk electrode 26 is R2 = 6.8 mm, the radius of the isolating ceramic is R~ =
4.3 mm, the
gap between the electrodes g2 = 1.2 mm and the length L = 2.5 mm.
In the illustrative embodiment of FIG. 5, the plasma 32 initiates in discharge
gap
29 at the exposed surface of insulator 25, and grows and expands outwardly in
the radial
to direction of arrows 29A. This may provide advantages over the TSI
embodiment of FIG.
2. First, the surface area of the disk electrode 26 exposed to the plasma 32
is
substantially equal to that of the end portion of the outer electrode 28
exposed to the
plasma 32. This means that the erosion of the inner portion of disk electrode
26 can be
expected to be significantly less than that of the exposed portion of inner
electrode 18 of
TSI 17 of FIG. 2, the latter having a much smaller surface area exposed to the
plasma.
Secondly, the insulator material 23 in TSI 27 provides an additional heat
conducting
path for electrode 26. The added insulator material 23 will keep the inner
metal of
electrodes 25, 26 cooler than electrode 18. In addition, in using TSI 27, the
plasma will
not be impinging on and perhaps eroding the associated piston head.
FIGS. 6 and 7 illustrate pictorially the differences in plasma trajectories
between
TSI 17 of FIG. 2, and TSI 27 of FIG. 5 when installed in an engine. In FIG. 6,
a TSI 17
is mounted in a cylinder head 90, associated with a cylinder 92 and a piston
94 which is
reciprocating - i.e., moving up and down - in the cylinder 92. As in any
conventional
internal combustion engine, as the piston head 96 nears top dead center, the
TSI 17 will
be energized. This will produce the plasma 24, which will travel in the
direction of
arrow 98 only a short distance toward or to the piston head 96. During this
travel, the
plasma 24 will ignite the air/fuel mixture (not shown) in the cylinder 92. The
ignition
begins in the vicinity of the plasma 24. In contrast to such travel of plasma
24, the TSI
27, as shown in FIG. 7, provides for the plasma 32 to travel in the direction
of arrows
3o 100, resulting in the ignition of a greater amount of air/fuel mixture than
provided by TSI
17, as previously explained.
CA 02383209 2002-03-13
WO 01/20162 PCT/US00116747
-19-
A trigger electrode can be added between the inner and outer electrodes of
FIGS.
2 through 5 to lower the voltage required to cause an initial breakdown
between the first
and second electrodes. FIG. 8 shows such a three electrode plasma ignitor 101
schematically. Also shown in FIG. 8 is a simplified version of the electronics
which may
drive a TSI. An internal electrode 104 is placed coaxially within the external
electrode
106, both having diameters on the order of several millimeters. Radially
placed between
the internal electrode 104 and the external electrode 106 is a third electrode
108. This
third electrode 108 is connected to a high voltage (HV) coil 110. The third
electrode 108
initiates a discharge between the two main electrodes 104 and 106 by charging
the
to exposed surface 114 of the insulator 112. The space between all three
electrodes 104,
106, 108 is filled with insulating material 112 (e.g., ceramic) except for the
last 2-3 mm
space between electrodes 104 and 106 at the combustion end of the ignitor 101.
A
discharge between the two main electrodes 104 and 106, after initiation by the
third
electrode 108, starts along the surface 114 of the insulator 112. The gas (air-
fuel
mixture) is ionized by the discharge. This discharge creates a plasma, which
becomes a
good electrical conductor and permits an increase in the magnitude of the
current. The
increased current ionizes more gas (air-fuel mixture) and increases the volume
of the
plasma, as previously explained.
The high voltage between the tip of the third electrode 108 and the external
2o electrode 106 provides a low current discharge, which is sufficient to
create enough
charged particles on the surface 114 of the insulator 112 for an initial
discharge to occur
between electrodes 104 and 106.
As shown in FIGS. 9A, 9B and 9C, another embodiment of the invention
includes a TSI 120 having parallel rod-shaped electrodes 122 and 124. The
parallel
electrodes 122, 124 have a substantial portion of their respective lengths
encapsulated by
dielectric insulator material 126, as shown. A top end of the dielectric 126
retains a
spark plug boot connector 21 that is both mechanically and electrically
secured to the top
end of electrode 122. The dielectric material 126 rigidly retains electrodes
122 and 124
in parallel, and a portion rigidly retains the outer metallic body 128 having
mounting
3o threads 19 about a lower portion, as shown. Electrode 124 is both
mechanically and
electrically secured to an inside wall of metallic body 128 via a rigid mount
130, as
shown, in this example. As shown in FIG. 9A, each of the electrodes 122 and
124
CA 02383209 2002-03-13
WO 01/20162 PCT/US00/16747
-20-
extends a distance l~ and 12, respectively, outwardly from the surface of the
bottom end
of dielectric 126.
With reference to FIGS. 9B and 9C, the electrodes 122 and 124 may be parallel
rods that are spaced apart a distance G, where G is understood to represent
the width of
the discharge gap between the electrodes 122, 124 (see FIG. 9C).
It has been discovered that. while operating a TSI as described above, a great
deal
of RF noise may be generated. During the initial high voltage breakdown,
current flows
in one direction through a first electrode and in another through a second
electrode.
These opposite flowing currents generate the RF noise. In conventional spark
plugs this
1 o is not an issue because a resistive element may be placed within the plug
in the incoming
current path. However, due to the large currents experienced during the high
current
stage of operation of the present invention, such a solution is not feasible
because such a
resistor would not allow enough current to flow to generate a large plasma
kernel.
Such RF noise may interfere with various electronic devices and may violate
regulations if not properly shielded. As such, and referring again to FIG. 9A,
the TSI
120 may also include a co-axial connector 140 for attaching a co-axial cable
(not shown)
to the TSI 120. The co-axial connector 140 may be threads, a snap connection,
or any
other suitable connectors for attaching a co-axial cable to an ignitor. It
should be
understood that while not illustrated in the above embodiment, such a co-axial
connector
140 could be included in any of the above embodiments. Furthermore, the co-
axial
connector 140 may be included in any semi-surface ignitor currently available
or later
produced. Cables of this sort will typically provide electricity to the boot
connector 21,
surround the dielectric 126 and mate with the body 128 to provide a ground.
The cable
should be able to withstand high voltages (during the primary discharge),
carry a high
current (during the secondary discharge) and survive the hostile operating
environment
in an engine compartment. One suitable co-axial cable is a RG-225 Teflon co-
axial
cable with a double braided shield. Other suitable cables include those
disclosed in PCT
Published Application WO 98/10431, entitled High Power Spark Plug Wire, filed
September 7, 1997, which is hereby incorporated by reference.
3o
III. The Firing Circuitry
CA 02383209 2002-03-13
WO 01/20162 PCT/US00/16747
-21 -
The following description will focus on various embodiments of the firing
circuitry which may lead to effective utilization of the plasma-generating
devices
disclosed above. It should be appreciated that the application of the firing
circuitry
electronics disclosed below are applicable to other types of spark plugs as
well.
FIG. 10 shows a TSI 17 with a schematic of the basic elements of an electrical
or
electronic ignition circuit connected thereto, which supplies the voltage and
current for
the discharge (plasma). (The same circuitry and circuit elements may be used
for driving
any embodiment of a TSI disclosed herein or later discovered.) A discharge
between the
two electrodes 18 and 20 starts along the surface 56 of the dielectric
material 23. The
1 o gas air/fuel mixture is ionized by the discharge, creating a plasma 24
which becomes a
good conductor of current and permits current between the electrodes at a
lower voltage
than that which initiated the plasma. This current ionizes more gas (air/fuel
mixture) and
increases the volume of the plasma 24.
As shown, the discharge travels from first electrode 18 to the second
electrode
20. One of ordinary skill would realize that the polarity of the electrodes
could be
reversed. However, there are advantages to having the discharge travel from
the first
electrode 18 to the second electrode 20. Physical constraints, namely the fact
that the
second electrode 20 surrounds the first electrode 18 in this embodiment, allow
for the
second electrode 20 to have a greater total surface area. The greater the
surface area of
2o an electrode the more resistant to ablation the electrode is. Having the
second electrode
be the target of the positive ion bombardment, because of its greater
resistance to
ablation, allows for the production of a TSI 17 having a longer useful life.
The electrical circuit shown in FIG. 10 includes a conventional ignition
system
42 (e.g., capacitive discharge ignition (CDI) or transistorized coil ignition
(TCI)), a low
voltage (VS) supply 44, capacitors 46 and 48 diodes 50 and 52, and a resistor
54. The
conventional ignition system 42 provides the high voltage necessary to break
down, or
ionize, the air/fuel mixture in the discharge gap along the surface 56 of the
dielectric
material 23 17. Once the conducting path has been established, the capacitor
46 quickly
discharges through diode 50, providing a high power input, or current, into
the plasma
24. The diodes 50 and 52 electrically isolate the ignition coil (not shown) of
the
conventional ignition system 42 from the relatively large capacitor 46
(between 1 and 4
qF). If the diodes 50, 52 were not present. the coil would not be able to
produce a high
CA 02383209 2002-03-13
WO 01/20162 PCT/US00/16747
-22-
voltage, due to the low impedance provided by capacitor 46. The coil would
instead
charge the capacitor 46. The function of the resistor 54, the capacitor 48,
and the voltage
source 44 is to recharge the capacitor 46 after a discharge cycle. The use of
resistor 54 is
one way to prevent a low resistance current path between the voltage source 44
and the
spark gap of TSI 17.
FIG. 11 is a high level block diagram of one illustrative embodiment of a
firing
circuit 200 according to the present invention. The circuit of this embodiment
includes a
primary circuit 202, an ignition coil 300, and a secondary circuit 208.
In one embodiment, the primary circuit 202 includes a power supply 210. The
to power supply 210 may be, for example, a DC to DC converter with an input of
12 volts
and an output of 400-500 volts. In other embodiments, the power supply 210
could be
an oscillating voltage source. The primary circuit 202 may also include a
charging
circuit 212 and a coil driver circuit 214. The charging circuit charges a
device, such as a
capacitor (not shown), in order to supply the coil driver circuit 214 with a
charge to drive
the ignition coil 300. In one embodiment, the power supply 210, the charging
circuit
212, and the coil driver 214 may be a CDI circuit. However, it should be
understood that
these three elements could be combined to form any type of conventional
ignition circuit
capable of causing a discharge between two electrodes of a spark plug, for
example, a
TCI system. The coil driver circuit 214 is connected to a low voltage winding
of the
ignition coil 300. The high voltage winding of the ignition coil 300 is
electrically
coupled to the secondary circuit 208.
In the embodiment of FIG. 11, the secondary circuit 208 includes a spark plug
and associated circuitry 220, a secondary charging circuit 222, and a power
supply 224.
The spark plug and associated circuitry 220 may include a capacitor (not
shown) which
is used to store energy in the secondary circuit 208. The two power supplies.
210 and
224, for the primary and secondary circuits, 202 and 208, respectively. may be
derived
from a single power source. It should be appreciated that the term "spark
plug" as used
in relation to the following firing circuitry may refer to any plug capable of
producing a
plasma, such as the plasma-generating and plasma expelling devices described
above.
3o FIG. 12 is a more detailed version of the circuit described above in
relation to
FIG. 10. In a commercial application, the circuit of FIG. 12 is preferred for
recharging
capacitor 46 (FIG. 10) in a more energy-efficient manner, using a resonant
circuit.
CA 02383209 2002-03-13
WO 01/20162 PCT/US00/16747
-23-
Furthermore, the conventional ignition system 42 (FIG. 10), whose sole purpose
is to
create the initial breakdown, is modified so as to use less energy and to
discharge more
quickly than has been conventional. Almost all of the ignition energy is
supplied by
capacitor 46 (FIG. 10). The modification is primarily to reduce high voltage
coil
inductance by the use of fewer secondary turns. This is possible because the
initiating
discharge can be of a much lower voltage when the discharge occurs over an
insulator
surface. The voltage required can be about one-third that required to cause a
gaseous
breakdown in air for the same distance.
Matching the electronic circuit to the parameters of the TSI (length of
electrodes,
1 o diameters of coaxial cylinders, duration of the discharge) maximizes the
volume of the
plasma when it leaves the TSI for a given store of electrical energy. By
choosing the
parameters of the electronic circuit properly, it is possible to obtain
current and voltage
time profiles that transfer substantially maximum electrical energy to the
plasma.
The ignition electronics can be divided into four parts, as shown: the primary
and
secondary circuits, 202 and 208, respectively, and their associated charging
circuits, 212
and 222, respectively. The primary circuit 202 also includes a coil driver
circuit 214.
The secondary circuit 208 may include spark plug and associated electronics
circuitry
220 which may be broken down into a high voltage section 283, and a low
voltage
section 285.
The primary and secondary circuits, 202 and 208, respectively, correspond to
primary 258 and secondary 260 windings of an ignition coil 300. When the SCR
264 is
turned on via application of a trigger signal to its gate 265, the capacitor
266 discharges
through the SCR 264, which causes a current in the coil primary winding 258.
This in
turn imparts a high voltage across the associated secondary winding 260, which
causes
the gas in a region near the spark plug 206 to break down and form a
conductive path,
i.e. a plasma. Once the plasma has been created, diodes 286 turn on and the
secondary
capacitor 270 discharges.
After the primary and secondary capacitors 266 and 270, respectively, have
discharged, they are recharged by their respective charging circuits 212 and
222. Both
3o charging circuits 212 and 222 incorporate an inductor 272, 274
(respectively) and a
diode 276, 278 (respectively), together with a power supply 210, 224
(respectively). The
function of the inductors 272 and 274 is to prevent the power supplies from
being short-
CA 02383209 2002-03-13
WO 01/20162 PCT/US00/16747
-24-
circuited through the spark plug 206. The function of the diodes 276 and 278
is to avoid
oscillations. The capacitor 284 prevents the power supply 224 voltage VZ from
the going
through large fluctuations.
The power supplies 210 and 224 both supply on the order of 500 volts or less
for
voltages V ~ and V2, respectively. They could be combined into one power
supply.
Power supplies 210 and 224 may be DC-to-DC converters from a CDI (capacitive
discharge ignition) system, which can be powered by a 12-volt automobile
electrical
system, for example.
The high current diodes 286 connected in series have a high total reverse
I o breakdown voltage, larger than the maximum spark plug breakdown voltage of
any of
the above disclosed plasma-generating devices, for all engine operating
conditions. The
function of the diode 286 is to isolate the secondary capacitor 270 from the
ignition coil
300, by blocking current from secondary winding 260 to capacitor 270. If this
isolation
were not present, the secondary voltage of ignition coil 300 would charge the
secondary
capacitor 270; and, given a large capacitance, the ignition coil 300 would
never be able
to develop a sufficiently high voltage to break down the air/fuel mixture in a
region near
the spark plug 206.
Diode 288 prevents capacitor 270 from discharging through the secondary
winding 260. Finally, the optional resistor 290 may be used to reduce current
through
2o secondary winding 260, thereby reducing electromagnetic radiation (radio
noise) emitted
by the circuit.
FIGS. 13-1 S detail general various alternative secondary circuits 208 which
may
be used according to the present invention.
FIG. 13 shows an example of one embodiment of a secondary circuit 208
according to the present invention. This circuit provides for a fast initial
breakdown
across the spark plug 206 followed by a slow follow-on current between the
electrode of
the spark plug 206 due to the inductor Ll. As such, this circuit may be
thought of as a
"fast-slow" circuit.
The secondary (high voltage) winding 260 of the ignition coil 300 receives
3o electrical energy from the primary circuit (not shown), which is attached
to the low side
winding (not shown) of the ignition coil 300, in order to charge capacitor C1
which is
connected in parallel with the ignition coil 300. When the voltage across the
capacitor
CA 02383209 2002-03-13
WO 01/20162 PCT/LTS00/16747
- 25 -
C1 becomes large enough to cause a breakdown over both the spark gap 302 and
between the electrodes of the spark plug 206, the capacitor C 1 is discharged
through the
spark gap 302 and the spark plug 206. The capacitor C1 is prevented from
discharging
into capacitor C2 by inductor L 1 which acts as a large resistance to a
rapidly changing
current.
This initial breakdown caused by the discharge of capacitor C1 is the initial
phase
which begins the formation of a plasma kernel between the electrodes of the
spark plug.
It should be understood that the spark gap 302 could be replaced by a diode or
other device capable of handling the high voltage across the secondary winding
260 and
1 o blocking a large current from discharging into the secondary winding 260.
From time to
time in the following description and in the attached figures, the spark gap
302 will be
described and shown as a diode to illustrate their theoretical
interchangeability for certain
analytical purposes.
Before the initial breakdown occurs, the capacitor C2 is charged by the power
supply 124. The power supply 224 is sized such that it does not create a large
enough
voltage across capacitor C2 in order to cause a breakdown across the spark
plug 206.
After the capacitor C 1 has started to discharge through the spark plug 206,
capacitor C2
then discharges through the spark plug 206. This discharge is a lower voltage,
higher
current discharge than that provided by the discharge of capacitor C 1. The
capacitor C2
2o is prevented from discharging through the secondary coil 260 by the spark
gap 302. As
discussed above, the spark gap 302 could be replaced by a diode capable of
enduring the
high voltage across capacitor C 1 and blocking the high current discharge of
capacitor C2
from traveling to the secondary winding 260 and while still allowing for a
fast discharge
(e.g., a break-over diode or self triggered SCR). The discharge of capacitor
C2 through
the spark plug 206 is the follow-on low-voltage, high-current pulse which
causes the
plasma kernel to expand and be swept out from between the electrodes of the
spark plug
206 as described above.
The discharge of capacitor C2 through the spark plug 206 is slower than the
discharge of capacitor C 1. The reason that the discharge is slower is due to
the inductor
3o L 1, which serves to slow down the rate which capacitor C2 may discharge
through the
spark plug 206. In one embodiment, capacitor C2 is larger than capacitor C 1
and, as is
known in the art, its discharge is thus slower.
CA 02383209 2002-03-13
WO 01/20162 PCT/US00/16747
-26-
Resistor R1 serves as a current limiting resistor so that the power supply
does not
provide a continuous current through the spark plug 206 after capacitor C2 has
discharged and limits the charging current to capacitor C2. It should be
appreciated that
the connection between resistor R1 and the power supply 224 is the Thevenin
equivalent
of a current limited power supply. It should also be appreciated that resistor
R1 could be
replaced with a suitably sized inductor to prevent a continuous current from
the power
supply 224 from persisting through the spark plug 206 and limits the charging
current of
capacitor C2. The combination of resistor R1 and power supply 224 may from
time to
time be referred herein to generally as a secondary charging circuit.
Suitable values for the components described in relation to FIG. 13 include C
1 =
200 pF, Ll = 200 pH, C2 = 2 qf, and R1 = 2K ohms, when power supply 224
provides
SOOV.
FIGS. 14A-14C show various circuit schematics for different variations of the
primary circuit. All of them use a capacitor 620 which is charged by the
primary
charging circuit 212 through the coil primary winding 258. All of the
embodiments
shown in FIGS. 14A-14C also include an SCR 264 which is used to rapidly
discharge the
capacitor 620 through winding 258, which creates the high voltage on the
secondary
winding 260. The three circuits have diode 622 in different places.
FIG. 14A has the SCR 264 in parallel with the primary winding 258. Once the
capacitor 620 is completely discharged and begins to recharge in the opposite
polarity,
the diode 264 becomes conductive, and a current through the primary winding
258
continues through the diode 622 until it is dissipated by the resistances of
the primary
winding and the diode, 258 and 622 respectively, and the energy transfer to
the
secondary winding. Thus the coil current and secondary voltage (high voltage)
do not
change polarity.
FIG. 14B has the diode connected in parallel to the SCR 264. When the SCR
264 fires, the capacitor 620 discharges, and then recharges in the opposite
polarity due to
the inductance of the primary coil 258. Once the capacitor 620 is charged to
the
maximum voltage, the current reverses, passing through the diode 622. This
cycle is
3o then repeated until all of the energy is dissipated. The coil current and
high voltage thus
oscillate.
CA 02383209 2002-03-13
WO 01/20162 PCT/US00/16747
-27-
The circuit of FIG. 14C is designed to give a single pass of current through
the
primary winding 258, recharging the capacitor 620 in the opposite direction.
The second
pass of current in the opposite direction then occurs through the diode 622
and the
inductor 624 (which are connected in series between the cathode of the SCR 264
and
ground), at a slower rate, so that the capacitor is recharged after the spark
in the spark
plug (not shown) has been extinguished. The diode 622 and inductor 624
function as an
energy recovery circuit.
FIGS. 1 SA-1 SC show further embodiments of the secondary circuit 208. The
embodiments shown in FIGS. 15A-15C include the spark plug and associated
circuitry
220 (FIG. 11 ).
The embodiment of FIG. 15A includes a single diode 626. It should be
appreciated that diode 626 could be replaced by a plurality of series
connected diodes.
The diode 626 provides a low impedance path for the capacitor 626 to
discharge. In this
embodiment it is preferably that the two windings, 258 and 260, be completely
separated.
FIG. 15B is an example of a thru-circuit. This embodiment includes the
capacitor
C2 which discharges through the secondary winding 260. Ordinarily this would
result in
a very slow discharge due to the large inductance of the secondary winding
260.
However, if the coil core 628 saturates, dramatically reducing the coil
inductance, then
the discharge can occur more rapidly.
FIG. 1 SC shows another embodiment of a secondary circuit. In this embodiment,
the inductor 632 is in a parallel arrangement with the second winding 260. The
spark
gap 630 is in series between the secondary winding 260 and the spark plug 206.
In the above described embodiments, the nature of the discharge may be
described as being of a dual-stage nature. However, in some situations it may
be
desirable to add a third stage to the discharge. It has been discovered that
an initial high-
current burst may be required to allow the current channel to begin moving
away from
the upper surface of the dielectric material between the electrodes of a
plasma-generating
device. However, if this initial high-current burst delivers the energy too
quickly, the
3o plasma may not move for a long enough time to create a large kernel. That
is, if the
current is large enough to create a Lorentz force sufficient to cause the
spark to travel,
such a current may discharge all of the stored energy to quickly to allow the
spark to
CA 02383209 2002-03-13
WO 01/20162 PCT/US00/16747
-28-
travel far enough to generate an enlarged plasma kernel. Furthermore, large
currents
lead to increased electrode ablation. These drawbacks may be alleviated by
lengthening
the discharge or lowering the amount of current for a given discharge.
However, if the
current is reduced to achieve a longer discharge, the resultant Lorentz force
may not be
strong enough to cause the spark to move away from the location when the spark
originated (e.g., the upper surface of the dielectric). The following examples
discuss
various circuits which overcome these problems, and others, by combining the
initial
breakdown with a fast high-current discharge to get the spark moving and
longer lower-
current discharge to grow the plasma kernel while minimizing electrode
ablation.
to FIG. 16 shows an example what shall be referred to herein as a parallel
three
circuit ignition system 700. This system includes a conventional high-voltage
circuit
702, a secondary circuit 704 and a third circuit 706. The high-voltage circuit
702 and the
secondary 704 circuit are connected in parallel with the spark plug 206. The
parallel
connection is similar to those described above. The high-voltage circuit 702
may be any
15 conventional ignition circuit such as a CDI circuit, a TCI circuit or a
magneto ignition
system. The high-voltage circuit 702 provides the initial high voltage to
ionize the
air/fuel mixture in the discharge gap of a plasma-generating device. In the
following
examples, it should be understood that the high voltage circuit includes both
the primary
and secondary windings of the ignition coil. The secondary circuit 704
provides the
2o follow-on current that serves to expand the plasma kernel. The embodiment
of FIG. 16
also includes a third circuit 706 connected to the secondary circuit 704. In
some
embodiment, the third circuit 706 may be a sub-circuit of the secondary
circuit 704. The
third circuit 706 provides an initial pulse of current during the follow-on
current which
enables the initial current channel (and the surrounding plasma) to move away
from the
25 upper surface of the dielectric.
FIG. 17 shows a more detailed example of the circuit shown in FIG. 16. This
circuit includes a high-voltage circuit 702, secondary circuit 704 and the
third circuit
706.
Connected in parallel with the high-voltage circuit 702 is the first capacitor
C 1.
3o The function of the first capacitor C 1 is to enhance the initial spark
between the
electrodes of the spark plug 206 by providing a rapid, high-voltage discharge.
In some
embodiments, the first capacitor C 1 may be omitted. For purposes of this
discussion, the
CA 02383209 2002-03-13
WO 01/20162 PCT/US00/16747
-29-
combination of capacitor C 1 and high-voltage circuit should be called the
primary circuit
708.
The primary circuit 708 may also include a first sub-circuit SCl connected
between the capacitor C 1 and the spark plug 206. The first sub-circuit SC 1
may be any
device capable of preventing the capacitors of the second circuit 704 and the
third circuit
706 from discharging into the first capacitor C 1 after capacitor C 1 has
discharged. An
additional feature of the first sub-circuit SC1 may be to reduce the rise time
of the high
voltage. Suitable elements that may be used for the first sub-circuit SC1
include, but are
not limited to, diodes, bread-over diodes and spark gaps.
1 o The secondary circuit 704 includes a second capacitor C2, and inductor L
1, and
the second sub-circuit SC2. Attached to the second circuit 704 is the
secondary charger
710 which include resistor R1 and voltage supply 224.
The inductor L 1 serves to slow down the discharge of the second capacitor C2.
As discussed below, this allows for the desired three stage voltage to produce
increased
plasma growth. The second sub-circuit SC2 serves to isolate the secondary
circuit 704
from the high voltage created in the primary circuit 708 to both protect the
secondary
circuit 704 as well as to provide a high impedance to force the primary
circuit 708 to
generate a high enough voltage to cause an initial breakdown between the
electrodes of
the spark plug 206. To this end, the second sub-circuit SC2 may be a high
voltage diode
or an inductor.
The third circuit 706 includes a third capacitor C3 connected in parallel with
the
spark plug 206. The third circuit 706 may optionally also include a third sub-
circuit
SC3. The third capacitor C3 provides an initial pulse of current, which allows
the
plasma to move away from the region of the initial breakdown. The optional
third sub-
circuit SC3 may be used to prevent the rapid recharging of the third capacitor
C3. If the
third sub-circuit SC3 is omitted, the third capacitor C3 may form an
oscillatory circuit
with the second capacitor C2 and the inductor L 1. Possible implementation of
the third
sub-circuit SC3 include, but are not limited to, a diode connected in parallel
with either
an inductor or a resistor or just a single diode. Of course, the diode would
be connected
3o such that its anode is connected to the third capacitor C3 and its cathode
is connected to
the inductor L 1.
CA 02383209 2002-03-13
WO 01/20162 PCT/US00/16747
-30-
FIG. 18 shows another embodiment of a secondary circuit 208. This circuit
provides an initial ''snap" high voltage across the spark plug 206 followed by
a first high
current discharge and a slower discharge. FIG. 18 will be used to further
explain the
operation of a three stage circuit. As discussed above, the high-voltage
circuit (not
shown) delivers power to the secondary coil 260 of the ignition coil 300. When
the
voltage across the secondary coil 260 exceeds the breakdown voltage between
the
electrodes of the spark plug 206, an initial discharge of a high voltage
occurs between
the electrodes. In this embodiment, the first and second sub-circuits have
been replaced
by diodes D 1 and D2.
l0 The initial voltage discharged across the spark plug 206 may be in the
range of
SOOV. Thus, the diode D1 should be able to sustain a voltage drop across it of
close to
SOOV. However, SOOV is given by way of example only and as one of ordinary
skill in
the art will readily realize, this voltage could be higher or lower depending
upon the
application.
The initial high voltage serves several functions. First, this high voltage
may
help knock loose any carbon and/or metal deposits present between the
electrodes of the
spark plug 206. In addition, this high voltage may also begin forming the
plasma kernel.
During the time that the primary circuit is charging the coil 300, the power
supply
224 is charging capacitors C3 and C2. The diode D2 keeps the secondary coil
260 from
discharging through either capacitor C3 or capacitor C2.
After the initial discharge of the secondary coil 260 through the spark plug
206,
both capacitors C2 and C3 begin to discharge through the spark plug 206. The
discharge
of capacitor C3 is a fast discharge as compared to the discharge of capacitor
C2 due to
the inductor L 1 placed between the two. Thus, capacitor C3 provides a fast,
high current
discharge through spark plug 206 which serves to cause the plasma kernel
between the
electrodes of the spark plug 206 to expand and travel outwardly between the
electrodes.
Due to the inductor Ll, the discharge of capacitor C2 is slower than that of
capacitor C3
and sustains a current between the electrode even after capacitor C3 has
discharged.
Capacitor C2 is prevented from discharging through, and thereby charging.
capacitor C3
by blocking diode D3.
FIG. 19 is a graph of voltage across the electrodes of the spark plug 206 as a
function of time. From time to to time t~ the voltage across the electrodes of
the spark
CA 02383209 2002-03-13
WO 01/20162 PCT/US00/16747
-31 -
plug 206 rises as the voltage across the secondary coil 260 increases until
time tl. At
time t,, the voltage has increased to a level where a breakdown can occur
between the
electrodes of the spark plug 206. In addition, because there is no inductor
between
capacitor C3 and the spark plug, capacitor C3 also begins to discharge which
adds to the
current through the spark plug and lead to "the snap" across the electrodes.
Both the
secondary coil 260 and capacitor C3 are allowed to discharge freely. Thus, the
voltage
drops quickly between time t~ and t2. At time t2, capacitor C2 (whose
discharge was
delayed by inductor L 1 ) begins to discharge through the spark plug 206. The
combined
discharges of the secondary winding 260 and of capacitors C2 and C3 accounts
for the
1o flatness of the voltage curve between times t2 and t3. By time t3,
capacitor C3 and the
secondary winding 260 have fully discharged and capacitor C2 is allowed to
discharge
on its own and provide a current through the plasma between the electrode for
an
extended time period (i.e., until it fully discharges or a new cycle begins).
Suitable values for the components of the circuit in FIG. 18 have been found
to
be C2 = 2qF, C3 = 0.2qF, L1 = 200 qH, and Rl = 2K ohms with the power supply
224
providing SOOV.
It should be understood that the preceding functional explanation may apply to
any of the three stage circuits described herein.
FIG. 20 shows another embodiment of a secondary circuit 208. This embodiment
2o is substantially the same as the one discussed in relation to FIG. 18 with
the addition of
the third sub-circuit SC3. In this example, the third sub-circuit SC3 includes
a diode D3
connected in parallel with an inductor L3. The cathode of the diode D3 is
connected
between D2 and L 1 and its anode is connected to the capacitor C3. C 1 has
been omitted
for clarity but may be included as one of ordinary skill will readily realize.
FIG. 21 shows a circuit similar to that of FIG. 18 except that diodes D1 and
D2
have been replaced, respectively, by a spark gap 712 and inductor L2. This
embodiment
functions in much the same manner as FIG. 18. The spark gap 712 and inductor
L2
provide the same functionality as the diodes D 1 and D2 which they replace
albeit in a
different manner. The spark gap 712 provides an impedance so that C3 and C2 do
not
3o discharge in to the secondary coil 260 or charge Cl instead of the spark
plug 206 and
inductor L2 provides a similar impedance to keep the voltage from the
secondary coil
260 from charging capacitors C2 and C3 instead of discharging across the
electrodes of
CA 02383209 2002-03-13
WO 01/20162 PCT/US00/16747
-32-
the spark plug 206. The inductor L2 provides this functionality due to
inherent
characteristics of inductors as well as the characteristic frequency of the
break down
across the spark gap 712. The inductor L2 should be sized such that it
provides a high
enough impedance at the characteristic frequency of the air gap breakdown
(about 10
MHz) while still allowing both C3 and C2 to discharge through L2. In some
embodiments, the spark gap 712 may be replace by solid-state elements that
operate in
manners similar to a spark gap such as a break-over diode or a self triggered
SCR. In
other respects the multi-stage discharge is the same as described above.
Of course, and as shown in FIG. 22, the secondary circuit could include the
third
1 o sub-circuit SC3 described above: In the embodiment of FIG. 22, the third
sub-circuit
SC3 includes a diode D3 connected in parallel with an inductor L3 where the
cathode of
diode D3 is connected between D2 and Ll and its anode is connected to the
capacitor
C3. Of course, SC3 could just include diode D3.
FIG. 23 is an alternative embodiment of a circuit which provides a three stage
discharge through the spark plug 206. In this embodiment, a conventional high-
voltage
circuit 702 may be connected directly to the spark plug 206. The blocking
diode 720 is
connected between the output terminals 722 and 724 of the high voltage circuit
702 and
serves to keep the high voltage circuit from charging capacitors C2 and C3.
Capacitor
C3 is connected between the anode of the blocking diode 720 and ground.
Connected in
2o parallel with capacitor C3 is the series connection of inductor L1 and
capacitor C3. After
the initial break down between the electrodes of the spark plug 206 caused by
the high
voltage of the conventional high-voltage circuit 702, as described above, C3
quickly
discharges through the spark plug 206 while the discharge of C2 is slowed by
inductor
L1. The discharge in this embodiment is similar to that disclosed in FIG. 19.
Of course,
and as discussed above, the circuit of FIG. 23 also includes a charging
circuit 726 to
charge capacitors C2 and C3 before each discharge.
FIG. 24 shows an embodiment similar to that shown in FIG. 23 with the addition
of the third sub-circuit SC3. In this embodiment, includes a diode D3
connected in
parallel with an inductor L3 where the cathode of diode D3 connected between
D2 and
3o L1 and its anode is connected to the capacitor C3.
FIG. 25 is an example of another embodiment of a secondary circuit 208
according to the present invention. This embodiment differs from the prior
embodiments
CA 02383209 2002-03-13
WO 01/20162 PCT/LTS00/16747
in at least two respects. First, this embodiment does not utilize a spark gap
or diode in
order to prevent the capacitor C2 of the secondary circuit 208 from being
charged by the
voltage across the secondary winding 260 of the ignition coil 300. Second, the
power
supply 210 of the primary circuit 202 supplies an oscillating voltage. In one
embodiment, power supply 210 may oscillate at an RF frequency.
The ignition coil 300 in this case has a primary winding 402 which has fewer
turns than the secondary winding 260. In a preferred embodiment, the secondary
winding 260 of the ignition coil 300 has a self resonance approximately equal
to the
oscillation frequency fo of the oscillating power supply 210. Because the
primary
1 o winding 402 of the ignition coil 300 has fewer turns than the secondary
winding, its
resonant frequency does not match that of the oscillating power supply 210. As
such, an
appropriately sized capacitor C~ is used to tune the primary winding 402 to
the resonant
frequency of the oscillating power supply 210. Thus, at node 404 there exists
an
oscillating high voltage. The diode Dl, as discussed above, prevents the
discharge of
capacitor C2 into the secondary winding 260. The diode D 1 also serves as a
half wave
rectifier. As one of ordinary skill in the art would readily realize, however,
the diode D1
could be replaced with a capacitor which will pass the full oscillating signal
while still
blocking the DC discharge from capacitor C2.
In contrast to the prior embodiments discussed above, the voltage across
winding
260 is prevented from discharging into capacitor C2 by the parallel connection
of
inductor L 1 and capacitor C4 instead of by a diode. The inductor L 1
preferably has a
high Q factor which allows it to provide, theoretically, infinite impedance at
its resonant
frequency. Capacitor C4 is used to tune inductor L1 so that its resonant
frequency
matches that of the oscillating power supply 210. In this manner, the
oscillating voltage
is prevented from passing through to the capacitor C2.
As discussed above, when the voltage at node 404 exceeds the breakdown
voltage across the electrodes of the spark plug 206, the secondary winding 260
is
discharged through the electrodes of the spark plug 206. Then capacitor C2
provides the
follow-on current which causes the plasma kernel to expand and be expelled
from
3o between the electrodes of the spark plug 206. The parallel combination of
capacitor C4
and inductor L1 does not affect the discharge of capacitor C2 because this
discharge is at
a lower frequency.
CA 02383209 2002-03-13
WO 01/20162 PCT/US00/16747
-34-
FIG. 26 shows another alternative embodiment circuitry that may be used to
provide a mufti-stage discharge to a plasma-expelling device. This embodiment
includes
a first transformer 730 which is typically part of a high-voltage ignition
system.
Connected to and in parallel with the secondary side 732 of the first
transformer 730 is a
peaking capacitor 734. The peaking capacitor 734 is connected in parallel with
the
series connection of a spark gap 736 and the primary side 738 of a second
transformer
740. In one embodiment, the second transformer 740 is a torodial transformer
(e.g.,
metal core) having a greater number of turns on its secondary side 742 than on
the
primary side 738 (e.g., a turns ratio of 4 to 1 may be appropriate).
l0 When a sufficient voltage is stored in the peaking capacitor 734, a rapid
breakdown across the spark gap 736 may occur. The rapid breakdown induces a
high
voltage in the secondary side 742 of the second transformer 740. The high
voltage
induced in the secondary side 742 causes the initial breakdown between
electrodes of the
spark plug 206 which is connected between the a first terminal 744 of the
secondary side
742 and ground.
Connected between the second terminal 746 of the secondary side 748 and ground
is a
the third capacitor C3. The third capacitor C3 is connected in parallel to the
series
combination of inductor L1 and capacitor C2. A charging circuit 748 may be
connected
to a point between inductor L1 and capacitor C2 to charge capacitors C2 and C3
(such a
charging circuit, as discussed above, may include a power source and a
resistor, the
resistor being connected to the point between inductor L1 and capacitor C2).
After the initial breakdown between the electrode of the spark plug 206,
capacitors C3 and C2 begin to discharge (e.g., current begins to flow from)
through
secondary side 742 of the second transformer 742 to the spark plug 206. The
current
through the secondary side 742 causes the core of the second transformer 740
to saturate
and thereby reduces the effective impedance of the secondary side 742. As
before, the
inductor L I slows the discharge of capacitor C2 to create an discharge
through the spark
plug 206 similar to that shown in FIG. 19. In one embodiment, the first and
second
sides, 732 and 742, respectively, should be phased such the at the induced
current in the
3o secondary side 742 due to the initial breakdown flows in the same direction
as the
discharge from capacitors C2 and C3. This avoids having to reverse the
magnetic field
in the core and thereby avoids losses associated with such a reversal.
CA 02383209 2002-03-13
WO 01/20162 PCT/US00/16747
-35-
Examples of values of components described in relation to FIG. 26 are
Cl=200pF, C2=2.2~F, C3=0.67~F and Ll=200~F.
IV. Add-On Units
Any of the above described secondary circuit embodiments may be implemented
as an add-on unit to be used in conjunction with a conventional ignition
system installed
on an internal combustion engine in order to allow such engines to operate a
plasma-
generating device in an effective manner. For example, and referring now to
FIG. 27,
the secondary circuit 208 could be totally encapsulated in a small package
which is
to connected to the output of the primary electronics (circuit) 202 (which
could be any
conventional ignition system and, as shown, includes the ignition coil 300).
In one
embodiment, the add-on unit includes the two diodes D 1 and D2 or
alternatively, spark
gaps discussed above could be provided in their place. Between the cathodes of
diodes
D1 and D2 is the spark plug 206. The follow-on current producer 602 may
contain any
of the above described secondary circuits as viewed from the right of the
blocking
element D2. It should be appreciated that D2 may be replaced by the parallel
LC
combination disclosed above if the primary electronics utilize an alternating
voltage
source. Furthermore, the power supply 224 could be co-located or receive power
from
the power source of the primary electronics.
In one embodiment, the secondary electronics 208 may be turned off to allow
the
primary electronics only to control the spark plug. This may be advantageous
for some
engine operating conditions. For example, when the engine is running at high
RPM's
due to the fuel/air mixing provided by a carburetor at these speeds. Thus, the
switch 604
may open when it is determined that the engine is operating at high enough
RPM's to
have a good mixture and a follow-on voltage is not needed to create a larger
plasma
kernel.
V. Placement of a Plasma-Generating Device in a Combustion Chamber
Optimal placement of an ignitor will be discussed in relation to FIGs. 26-27
3o below. Generally, when operating on systems containing stratified mixtures,
the ignitor
should be mounted in the combustion chamber so that it does not contact the
fuel plume
CA 02383209 2002-03-13
WO 01/20162 PCT/US00/16747
-36-
introduced into the combustion chamber, but rather, expels the plasma into the
fuel
plume from a distance.
FIG. 28 is an example of a conventional ignition setup for an internal
combustion
engine. A fuel injector 802 periodically injects a fuel plume 804 into a
combustion
chamber 806. After the fuel plume 804 has been injected, the combustion
chamber 806
contains a stratified mixture having a fuel rich region (the fuel plume 804)
and a region
without a 808 substantial amount of fuel. A spark plug such as conventional
spark plug
810 ignites the fuel plume 804 by creating an electrical discharge (spark)
between the
first electrode 812 and a second electrode 814. The spark causes the fuel
plume 804 to
to ignite and drive the piston 816 in the downward direction.
As discussed above, there are several problems associated with such a system.
Namely, the location of the fuel plume 804 must be directed such that there is
a
minimum amount of fuel near the walls of the combustion chamber 806 in order
to avoid
quenching of the flame by the walls of the combustion chamber 806. In
addition, the
discharge between the first and second electrodes 812 and 814 must be
positioned so that
it contacts the fuel plume 804 or the fuel plume 804 may fail to ignite.
Placing the
electrodes 812 and 814 directly in the path of the fuel plume 804 may lead to
the spark
being blown out by passing fuel or create a significant amount of fouling of
the plug 810.
FIG. 29 illustrates by example a way to avoid these problems utilizing the
teachings contained herein. As before, the fuel injector 802 injects a
stratified mixture
(i.e., a fuel plume 804) into the combustion chamber 806. Thus, the combustion
chamber 806 includes a stratified mixture of the fuel plume 804 and a region
808 that
does not contain a significant amount of fuel. It should be appreciated that
the fuel
injector may introduce the fuel plume 804 into the combustion chamber 806 by a
variety
of methods, such as direct fuel injection.
A plasma-generating device 820 is displaced in the combustion chamber so that
the ends of its electrodes 822 and 824 are flush or nearly flush with the wall
of the
combustion chamber 106. In one embodiment, the end of the longer electrode 822
or
824 extends less than about 2.54 cm (1 inch) into the combustion chamber 806.
In other
3o embodiments, the electrodes may extend from any distance between about 0
and 2.54 cm
into the combustion chamber 806. The plasma-generating device 820 generates a
volume of plasma 832, as described above, which is expelled from between the
CA 02383209 2002-03-13
WO 01/20162 PCT/US00/16747
_37-
electrodes 822 and 824 into the fuel plume 804 and ignites the fuel plume 804.
Such a
system allows the ignition system designer to integrate a plasma-generating
device that is
flush or nearly flush with an optimized combustion chamber. Instead of
extending the
spark plug reach (and incurring many of the aforementioned problems) into the
fuel
plume 804, one embodiment of the present invention uses a combination of
special dual-
energy electronics 830 (as described above) and an appropriately designed
plasma-
generating device to form a plasma 832 and inject it into the fuel plume 804.
At high speeds, engines are generally run in a homogenous mixture mode of
operation where the fuel injector injects the fuel plume 804 into the
combustion chamber
806 early in the cycle to provide a uniform mixture throughout the combustion
chamber
806, when combustion initiates near top dead center of the engine cycle. The
ignition
system of the present invention proves advantageous in this mode as well.
First, the
plasma-generating device 820 may be flush or nearly flush with the cylinder
wall, which
reduces hydrocarbon emissions and partial burn that result from flame
quenching around
protruding sparkplugs. Secondly, the plasma-generating device 820 is by design
a
"cold" spark plug, eliminating potential pre-ignition problems resulting from
protruding
plug designs used in stratified mixture engines today. Third, the present
invention allows
the combustion chamber to be designed more optimally for performance at higher
speed.
Finally, the present invention, in some embodiments, may be operated in a
2o conventional mode (as opposed to the dual-stage mode discussed above). In
these
embodiment, the system may include a disabling element (either external or
built-in;
possibly inherent to the electronics) for controlling the application of TSI
operation vs.
conventional operation, according to which areas of operation require a higher-
energy
ignition kernel. The disabling element serves to disable the follow-on current
provider
(e.g., secondary electronics) or, alternatively, to prevent the current
generated in the
provider from discharging through the ignitor. In either case, the net effect
is to prevent
the follow-on current from being transmitted to the ignitor.
The system may switch modes based upon engine RPM, throttle position, the
rate at which the RPM's are changing, or any other available engine condition
that may
3o give insight to how well the fuel is mixed. One simple way to implement
such a system
includes, as referring back to FIG. 27 by way of example only, including an
additional
element (such as a thyristor) between the portion of the circuit which
generates the
CA 02383209 2002-03-13
WO 01/20162 PCT/US00/16747
-38-
follow on current (e.g., to the left of D2) which only allows the follow on
portion to be
provide when the element is active. Such an element, in effect, blocks the
current from
the follow-on current provider. Alternatively, and as discussed above, the
switch 604
could serve to disconnect the follow on current producer when such a follow on
current
is not needed. Either the switch 604 or the additional element, as one will
readily realize,
may be controlled by a circuit which determines the best mode of operation
depending
upon the operating conditions discussed above, as well as others.
Having now described a few embodiments, it should be apparent to those skilled
in the art that the foregoing is merely illustrative and not limiting, having
been presented
by way of example only. Numerous modifications and other embodiments are
within the
scope of one of ordinary skill in the art and are contemplated as falling
within the scope
of the invention.
