Note: Descriptions are shown in the official language in which they were submitted.
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PLASMA HEADER GASKET AND SYSTEM
DESCRIPTION
BACKGROUND OF THE INVENTION
[Para 1] The present invention generally relates to a gasket for use
between
an engine block and engine header. The gasket includes electrodes disposed in
the openings corresponding to piston cylinders. The electrodes spark in time
with the other ignition parameters, i.e., spark plug or compression, to
increase
the efficiency of the combustion.
[Para 2] The basic operation of standard internal combustion (IC) engines
varies somewhat based on the type of fuel or combustion process, the quantity
of cylinders and the desired use/functionality. Certain types of fuel, such as
gasoline, require a spark as from a spark plug to initiate combustion. Other
types of fuel, such as diesel, require merely compression to raise the
temperature of the air, which results in spontaneous combustion of the diesel
when introduced. Diesel engines include glow-plugs to add heat and initiate
combustion in a cold diesel engine. Engines may also be designed to use
alternative fuels, such as biodiesel, liquid natural gas, liquefied petroleum
gas,
compressed natural gas and ethanol, to name a few. Combustion of all of these
types of fuel usually leaves some residual, uncombusted fuel and other
components after combustion.
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[Para 3] In a traditional two-stroke engine, oil is pre-mixed with fuel and
air before entry into the crankcase. The oil/fuel/air mixture is drawn into
the
crankcase by a vacuum created by the piston during intake. The oil/fuel
mixture provides lubrication for the cylinder walls, crankshaft and connecting
rod bearings in the crankcase. The fuel is then compressed and ignited by a
spark plug that causes the fuel to burn. The piston is then pushed downwardly
and the exhaust fumes are allowed to exit the cylinder when the piston exposes
the exhaust port. The movement of the piston pressurizes the remaining
oil/fuel in the crankcase and allows additional fresh oil/fuel/air to rush
into the
cylinder, thereby simultaneously pushing the remaining exhaust out the
exhaust port. Momentum drives the piston back into the compression stroke
as the process repeats itself. In a four-stroke engine, oil lubrication of the
crankshaft and connecting rod bearings is separate from the fuel/air mixture.
Here, the crankcase is filled mainly with air and oil. It is the intake
manifold
that receives and mixes fuel and air from separate sources. The fuel/air
mixture in the intake manifold is drawn into the combustion chamber where it
is ignited by the spark plugs and burned. Both types of engines employ a spark
to combust the fuel and both leave residual, uncombusted fuel and other
components in the combustion chamber.
[Para 4] Thus, there exists a significant need for an improved ignition
system to increase the efficiency of combustion in most types of engines
burning most types of fuels. Such an ignition system would ideally work in
tandem with existing prior art ignition systems for retrofit designs, as well
as,
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be available for original equipment manufacturers as a stand-alone system.
The improved ignition system should include a plasma header gasket
disposable between the engine and header blocks of an internal combustion
engine, and having igniters presenting electrodes disposed in the piston
cylinder apertures of the gasket. A microprocessor control unit and plasma
amplifier augment the ignition typically generated by a prior art ignition
system
to produce a plasma ionization field - the plasma ionization field producing
over 200 Amps per discharge. The present invention fulfills these needs and
provides further related advantages.
SUMMARY OF THE INVENTION
[Para 5] The present invention is directed to a plasma header gasket
configured for placement between an engine block and a header block of an
internal combustion engine, similar to a prior art header gasket. The plasma
header gasket comprises a laminated substrate having an aperture
corresponding to a piston cylinder in an engine block of an internal
combustion
engine, similar to a prior art header gasket. A pair of Thorium-alloy
conductors
are associated with the substrate and are electrically connected to a switched
plasma-igniter. The switched plasma-igniter comprises a plasma-amplifier
electrode disposed in the aperture, the plasma-amplifier electrode comprising
a
half-sphere conductor surrounded by an electrically isolated toroidal plasma-
emitter ring defining a plasma gap therebetween. Different types of conductive
coatings may be applied to the half-sphere conductor and the toroidal plasma-
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emitter ting, such as platinum, stainless steel, other noble metals, and
alloys
thereof.
[Para 6] The substrate comprises dielectric layers with the pair of Thorium-
alloy conductors being electrically conductive Thorium-alloy circuit traces
disposed between the dielectric layers. The Thorium-alloy conductors more
freely contribute free electrons to the connecting circuit than typical
conductors. A switching block is preferably disposed on the substrate and
electrically connected to the pair of Thorium-alloy conductors. The Thorium-
alloy circuit traces electrically connect the switched plasma-igniter to the
switching block. The plasma header gasket also includes a plasma field sensor
associated with the aperture and electrically connected to the switching block
by a secondary conductor associated with the substrate.
[Para 7] The plasma header gasket may comprise a plurality of pairs of
Thorium-alloy conductors associated with the substrate and electrically
connected to the switching block. The plasma header gasket may also
comprise a plurality of switched plasma-igniters, each electrically connected
to
one of the plurality of pairs of Thorium-alloy conductors. Each of the
plurality
of switched plasma-igniters comprises a plasma-amplifier electrode disposed
in the aperture, the plasma-amplifier electrode comprising a half-sphere
conductor surrounded by an electrically isolated toroidal plasma-emitter ring
defining a plasma gap therebetween.
[Para 8] The laminated substrate may have a plurality of apertures with
each
aperture corresponding to one of a plurality of piston cylinders in the engine
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block. With a plurality of apertures and a plurality of switched-plasma
igniters,
each of the plurality of switched plasma-igniters comprises a plasma-amplifier
electrode disposed in one of the plurality of apertures, the plasma-amplifier
electrode comprising a half-sphere conductor surrounded by an electrically
isolated toroidal plasma-emitter ring defining a plasma gap therebetween. In
such case, each of the plurality of switched plasma-igniters is conjointly
electrically connected to a respective one of the plurality of pairs of
Thorium-
alloy conductors.
[Para 9] A plasma header gasket system of the present invention may
comprise a plasma header gasket as described above and further include a fully
programmable microprocessor control unit electrically connected to the
switching block. The microprocessor control unit is fully programmable to
ignite the switched plasma-igniter in time with a piston in the piston
cylinder.
The switched plasma-igniter comprises a plasma-amplifier electrode, which
electrode is controllable by the microprocessor control unit. The plasma-
amplifier electrode produces a plasma ionization field through the switched
plasma-igniter when the microprocessor control unit ignites the switched
plasma-igniter. The microprocessor control unit may be programmed to ignite
the plurality of switched plasma-igniters sequentially around a particular
aperture so as to create a combustion vortex in the corresponding piston
cylinder.
[Para 1 0] Other features and advantages of the present invention will
become
apparent from the following more detailed description, taken in conjunction
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with the accompanying drawings, which illustrate, by way of example, the
principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[Para 11] The accompanying drawings illustrate the invention. In such
drawings:
[Para 1 2] FIGURE 1 is an environmental, exploded perspective view of an
internal combustion engine incorporating the inventive plasma header gasket;
[Para 1 3] FIGURE 2 is an exploded perspective view of the plasma header
gasket of the present invention;
[Para 14] FIGURE 3 is a close-up view of FIG. 2 designated by the circle 3;
[Para 1 5] FIGURE 4 is a perspective view of one of the laminates with
circuit
traces of the plasma header gasket of the present invention;
[Para 1 6] FIGURE 5 is a close-up view of FIG. 4 in the area designated by
circle 4;
[Para 1 7] FIGURE 6 is a schematic illustration of the inventive plasma
header
gasket system of the present invention; and
[Para 1 8] FIGURE 7 is a schematic illustration of the inventive plasma
header
gasket system of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[Para 1 9] As shown in the drawings for purposes of illustration, the
present
invention for a plasma header gasket is referred to generally by the reference
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number 10. In FIG. 1, the plasma header gasket 10 is illustrated as being
disposed between an engine block 12 and engine header 14. The plasma
header gasket 10 may include four apertures 16 that correspond to four piston
cylinders 18 in the engine block 12. Although not depicted, there are
corresponding header cylinders in the engine header 14, as is understood by
those skilled in the art. The plasma header gasket 10 also includes a
plurality
of bolt openings 20 to accommodate connectors (not shown) that secure the
engine header 14 to the engine block 12.
[Para 20] FIG. 1 also illustrates a firewall 22 as exists between an engine
compartment and a passenger compartment on a vehicle. A microprocessor
control unit 24 is preferably mounted on the firewall 22 and electrically
connected to the plasma header gasket 10. An ignition coil 26 is also included
in the engine compartment and is electrically connected to the microprocessor
control unit 24. The interconnection of these components will be described in
more detail below.
[Para 21] The engine depicted in FIG. 1 is intended to depict a typical
diesel
engine. However, the plasma header gasket 10 of the present invention may be
compatible with other types of internal combustion engines, whether two-
stroke or four-stroke engines, or burning alternate fuels, i.e., gasoline,
diesel,
biodiesel, liquid natural gas, liquefied petroleum gas, compressed natural
gas,
or ethanol, to name a few. The ionization associated with a plasma ignition is
preferable to the spark associated with a spark ignition because of the
magnitude of increase in power associated therewith.
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[Para 22] FIGS. 2 and 3 illustrate the plasma header gasket 10 of the
present
invention. The plasma header gasket 10 is a laminated structure comprising at
least an upper laminate 28 and a lower laminate 30. Pairs of conductors 32 are
disposed on either the upper laminate 28 or the lower laminate 30. These pairs
of conductors 32 are configured to provide positive and negative electrical
communication paths as are found in typical electrical connections. The pairs
of conductors 32 comprise Thorium-alloy circuit traces disposed on the
laminate 28, 30. The Thorium-alloy may comprise any known alloy of Thorium,
but is preferably a Thorium-Tungsten alloy - or a Tungsten conductor coated in
Thorium. The Thorium-alloy conductors 32 more freely contribute free
electrons to the connecting circuit than typical conductors.
[Para 23] Thorium is useful as an alloy in devices that propagate finely
controlled electronic systems because the 232 isotope of Thorium continuously
emits free electrons (6.02 x 1017 per square cm/sec) without also exhibiting
the release of any of the other emission products associated with nuclear
decay.
In the inventive plasma header gasket, the free electrons supplied by the
Thorium-alloy significantly increase the amount of actual electron output by
the device. This amplifying feature renders the current invention functionally
superior to any known devices of similar construction or application. The
Thorium-alloyed conductors allow for super-fast switching with exceptionally
low resistance. The material allows for free electron field saturation with
virtually zero residual charge persistence.
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[Para 24] One end 32a of the pairs of Thorium-alloy conductors 32 is
connected to a switched plasma-igniter 34 disposed in an aperture 16. As
shown in the close-up of FIG. 3, the switched plasma-igniter 34 comprises a
plasma-amplifier electrode 36 disposed in the aperture 16 - extending from
the perimeter. The plasma-amplifier electrode 36 comprises a half-sphere
conductor 36a surrounded by an electrically isolated toroidal plasma-emitter
ring 36b defining a plasma gap 38 therebetween. The other end 32b of the
pair of Thorium-alloy conductors 32 extend to an edge portion 30a of the
laminate 30 where they are coupled to a switching block 40. The switching
block 40 facilitates connection of the plasma header gasket 10 to other
components of the plasma header gasket system described more fully below.
The structure of the switched plasma igniter 34 is similar to that described
in
U.S. Patent No. 9,236,714, the entire disclosure of which is herein
incorporated
by this reference.
[Para 25] The configuration of the plasma gap 38 defined by the half-sphere
conductor 36a and the plasma emitter ring 36b optimizes the relationship
between both the geometric and surface area components. The plasma gap 38
is preferably on the order of approximately 0.030 inches. The distal end of
the
half-sphere conductor 36a preferably protrudes beyond the end of the plasma
emitter ring 36b by approximately 0.020 inches. The insulator 14 between the
half-sphere conductor 36a and the plasma emitter ring 36b is situated within
0.030 inches of the exposed surface of the ring 36b. This combination of
materials, along with curved geometric sections and a closely-fixed insulator
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floor provides a conductive surface area which is at least twenty-five times
greater than prior art high performance racing-type spark ignitors as might be
found in NASCAR engines. In addition, this configuration of the plasma
amplifier electrode 36 forces the plasma ionization field into the piston
chamber towards the head of the piston. The combination of increased surface
area of such plasma devices has been shown to improve combustion
effectiveness and efficiency by more than 68% when compared to prior art high
performance spark plugs in identical test applications under typical 4-cycle
gasoline burning internal combustion engine systems.
[Para 26] In combination, the switching block 40 and the microprocessor
control unit 22 are configured to provide high-speed, digitally controlled
switching of the electricity to the plasma-amplifier electrode 36. The
electricity
may be provided by a transformer (not shown) or other similar source as is
known. The switching block 40 outputs an electrical pulse that is initially
high
amperage and then switched to high voltage ("pulse switching"). Preferably,
the
switching block 40 is controllable by the microprocessor control unit 22. The
pulse switching converts the output from a distributor module (not shown)
first
into a high amperage pulse, i.e., about 13.5 volts DC at 30 amps, and then
into
a high voltage pulse, i.e., about 50,000-75,000 volts DC at 0.0036 amps, with
a total pulse duration of about 200 n-sec. The purpose of the pulse switching
is to take full advantage of the plasma-amplifier electrode 36.
[Para 27] When the plasma-amplifier electrode 36 is pulsed with a very fast
(about 50 n-sec) high-rise burst of high amperage (a square wave of about 200
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n-sec duration), the air fuel mixture is molecularly dissociated into
individual
radicals and ions in the generated plasma ionization field. The plasma
ionization field is persistent even when the source of charge has been
terminated. The rate at which the source charge is fully terminated is
critical to
the effectiveness of the molecular dissociation, so the switching block 40
must
convert the plasma ionization field into an ignition field very quickly (in
about
50-100 n-sec). While the constituent radicals and individual ions are still in
a
dissociated plasma state, the introduction of the high voltage ignition source
serves to excite the oxidation reaction with extremely high efficiency. This
operates without a flame front because the entire field now operates as a
single
ignition point in the plasma. Thus, the operation of the switched plasma
igniter
34 first creates a plasma ionization field and then an ignition field within
the
span of about 200 n-sec.
[Para 28] FIGS. 4 and 5 illustrate an alternate embodiment of the lower
laminate 30 of the plasma header gasket 10. In this embodiment, the plasma
header gasket contains six apertures 16. In the earlier embodiment, the
plasma header gasket 10 included four apertures 16. A person skilled in the
art will appreciate that the plasma header gasket 10 may be configured with
any number of apertures 16 as there may exist piston cylinders 18 in an engine
block 12. Thus, a plasma header gasket 10 may be created that has one, two,
three, four, six, eight or any number of apertures 16.
[Para 29] One will also observe that each aperture 16 in the plasma header
gasket 10 is illustrated with four switched plasma-igniters 34 in each
aperture
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16. A person skilled in the art will appreciate that the number of switched
plasma-igniters 34 associated with any single aperture 16 may include one or
more switched plasma-igniters 34 as the size and/or configuration of the
engine may allow. When a single aperture 16 includes multiple switched
plasma-igniters 34, each of the switched plasma-igniters 34 associated with a
particular aperture 16 are preferably conjointly connected, either by a single
pair of Thorium-alloy conductors 32 or by multiple pairs of Thorium-alloy
conductors 32 to a single terminal in the switching block 40. Alternatively,
separate pairs of Thorium-alloy conductors 32 running from a plurality of
switched plasma-igniters 34 associated with a single aperture 16 may each be
connected to separate terminals in the switching block 40 but are preferably
controlled in a coordinated manner by the fully programmable microprocessor
control unit 24 so as to form the ionization plasma almost simultaneously in
time with the engine piston. In addition, a plurality of switched plasma-
igniters
34 associated with a single aperture 16 may be programmed to form the
ionization plasma in any predetermined order. For example, the plurality of
switched plasma-igniters 34 in a single aperture 16 may be programmed to
form the ionization plasma sequentially around the perimeter of the aperture
16 so as to create a plasma vortex in the corresponding piston cylinder 18.
[Para 30]
FIGS. 4 and 5 further illustrate a plasma field sensor 42 disposed
proximate to the plasma gap 38 of each switched plasma-igniter 34. FIG. 5
shows the switched plasma igniter 34, the half-sphere conductor 36a, the
electrically isolated toroidal plasma-emitter ring 36b, plasma gap 38, and
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plasma field sensor 42 in close-up. The plasma field sensor 42 is connected by
a secondary conductor 44 to the switching block 40. The plasma field sensor
42 detects and reports the presence of a plasma ionization field in the piston
cylinder 18. The sensor 42 can detect the electron density and other
properties
of the plasma field. Upon receiving this information, the microprocessor
control unit 24 can be programmed to modulate the combustion properties by
under or over compensating for the plasma ionization field generated by each
plasma amplifier electrode 36 as described further below. There is preferably
at least one plasma field sensor 42 per aperture 16. Other sensors may also be
included such as a temperature sensor and/or a pressure sensor to measure
the temperature or pressure in a particular piston cylinder 18. The
microprocessor control unit 24 is configured to pick up data from all of these
environmental sensors. The microprocessor control unit 24 may also have a
connection to the tachometer sensor so that it knows the RPMs of the engine.
[Para 31] FIG. 6 schematically illustrates a system 46 incorporating the
inventive plasma header gasket 10 having four cylinder apertures. As
illustrated, the system 46 may be designed for an engine having varying
numbers of piston cylinders. FIG. 7 alternately illustrates the system 46 with
an
engine block 12 having either six cylinders and corresponding engine headers
14. The plasma header gasket 10 will have a corresponding number of
apertures 16 depending on the number of cylinders 18 in the engine block 12.
These alternate plasma header gasket 10 embodiments have similar
connections to the remainder of the system 46.
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[Para 32] The system 46 includes the microprocessor control unit 24
mounted on or near the firewall 22 of the engine compartment. The
microprocessor control unit preferably includes a dynamic engine control unit
(ECU) module 48, a dynamic ignition (IGN) module 50 and an alternate fuel
processor 52. The system 46 may be installed as the ignition system in a new
engine, in a retrofit to work in parallel with an existing ignition system, or
in a
retrofit as a complete replacement of an existing ignition system.
[Para 33] In the case of a retrofit into an existing engine, the
microprocessor
control unit 24 is wired into the existing ignition system including the OEM
ECU
54, the ignition coil 26, the battery 56, and appropriate electrical grounds
58.
In such a retrofit system, the dynamic ECU module 48 and dynamic IGN module
50 are programmed to work with the existing OEM ECU 54 and ignition coil 26
so as to ignite the switched plasma-igniters 34 on the plasma header gasket 10
in time with the existing ignition source, e.g., spark plugs or compression.
The
intention of this configuration is to improve upon the efficiency of the
combustion occurring in the piston cylinders 18.
[Para 34] The microprocessor control unit 24 receives sensor data from the
plasma header gasket 10 through its electrical connections 60 therewith. The
electrical connections 60 include a data connection 62 whereby the
microprocessor control unit 24 receives plasma field, temperature, pressure
and/or other parameter data that may be measured by the plasma header
gasket 10 and its various sensors. An RPM connection 64 receives data from an
existing tachometer sensor in the engine to assist the microprocessor control
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unit 24 in timing the formation of the ionization plasma by the switched
plasma-igniters 34 with the engine timing. A plasma connection 66 provides
the electrical conductivity to the switching block 40 which is in turn passed
through the pairs of Thorium-alloy conductors 32 to the switched plasma-
igniters 34.
[Para 35] This plasma connection 66 passes on a high voltage current from
the microprocessor control unit 24. The high voltage current is configured to
produce a plasma ionization field in the plasma gap 38 of the switched plasma-
igniters 34. Prior art ignition systems typically produced sparks on the order
of
fifteen milliamps in the case of a generic ignition system or thirty milliamps
in
the case of a multiple spark discharge ignition system. The plasma header
gasket system 46 of the present invention is configured to produce plasma
ionization fields having a current on the order of two hundred amperes per
discharge - over ten thousand times the current of a typical prior art spark
ignition system. The dynamic IGN module 50 includes a plasma power module
68 which includes plasma circuitry designed to step up the current supplied by
the ignition system 46 and produce the larger plasma ionization field
resulting
in increased combustion efficiency.
[Para 36] As described above, the plasma field sensor 42 detects the
presence of the plasma ignition field in front of the plasma gap 38 in the
piston
cylinder 18. The plasma field sensor 42 transmits the signal via the secondary
conductor 44 and the data connection 62 to the microprocessor control unit
24. The microprocessor control unit 24 can adjust the output of the plasma
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power module 68 to either over or under compensate for the discharge current
in the switched plasma-igniters 34 to either increase or decrease the size of
the
plasma ignition field in the piston cylinder 18.
[Para 37] As previously suggested, the inventive system 46 may be installed
on any type of fuel burning internal combustion engine, i.e., gasoline or
diesel,
or any other engine requiring combustion of fuel. If installed on a gasoline
engine, the system 46 can use the existing distributor and ignition coil 26
for
the established firing order of the pistons. If installed on a diesel engine,
the
system 46 simulates the firing order by preprogramming the same into the
microprocessor control unit 24. Ignition parameters such as dwell timing can
be programmed in to the microprocessor control unit 24. Such programming
allows for a simulated firing order without an existing distributor or rotor
tied
into the system 46.
[Para 38] With the addition of the plasma header gasket system 46, a diesel
engine can be configured to burn other types of fuel requiring an ignition for
combustion versus compression for combustion. The alternate fuel processor
52 can be programmed with the parameters necessary to initiate combustion
with these other types of fuels. The plasma header gasket system 46 may also
produce a plasma ionization field having sufficient temperature to more fully
combust diesel fuel on top of the combustion initiated by compression. The
thickness of the plasma header gasket 10 may be adjusted to modify the
compression ratio in various engines. In the case of an engine with existing
spark plugs, the plasma header gasket 10 may be installed in parallel with the
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existing spark plugs or in replacement of the existing spark plugs. The plasma
header gasket 10 may also be installed on an existing engine without removing
the same from the engine compartment. It may only be necessary to remove
and/or replace the engine header 14 during installation of the plasma header
gasket 10.
[Para 39] The addition of the switched plasma-igniters 34 on the plasma
header gasket 10 introduces additional ignition sources that produce a cleaner
burn in the piston cylinder 18. This cleaner burn dramatically reduces harmful
emissions resulting from combustion. This improvement is particularly
important for two-stroke engines such as lawnmowers, leaf blowers, outboard
motors and motorcycles. The cleaner burn also drastically reduces particulates
from combustion that are passed through the exhaust system.
[Para 40] Although several embodiments have been described in detail for
purposes of illustration, various modifications may be made without departing
from the scope and spirit of the invention. Accordingly, the invention is not
to
be limited, except as by the appended claims.
