I have about reached the limit for AERO and Temperature Efficiency Improvements like Grill Covers and Wheel Covers for my CMAX. With temps in the 80's*F I can average 50-54mpg at 65-70mph with no A/C on the HWY. Not bad, but I'm still looking to improve more. I remembered someone had said the ICE is very inefficient so I looked it up and to my surprise it is only 25-30% at best. WOW So looking at GOV site and Wikipedia
"Modern gasoline engines have a maximum thermal efficiency of about 25% to 30% when used to power a car. In other words, even when the engine is operating at its point of maximum thermal efficiency, of the total heat energy released by the gasoline consumed, about 70-75% is rejected as heat without being turned into useful work, i.e. turning the crankshaft. Approximately half of this rejected heat is carried away by the exhaust gases, and half passes through the cylinder walls or cylinder head into the engine cooling system, and is passed to the atmosphere via the cooling system radiator. Some of the work generated is also lost as friction, noise, air turbulence, and work used to turn engine equipment and appliances such as water and oil pumps and the electricalgenerator, leaving only about 25-30% of the energy released by the fuel consumed available to move the vehicle.
In the past 3–4 years, GDI (Gasoline Direct Injection) increased the efficiency of the engines equipped with this fueling system up to 35%. Currently, the technology is available in a wide variety of vehicles ranging from less expensive cars produced by Mazda, Ford and Chevrolet to more expensive cars produced by BMW, Mercedes-Benz, and Volkswagen Auto Group."
As you can see about 30% of the energy is absorbed by the cooling system from piston, cylinder walls and cylinder head and another 30% goes out the tale pipe.
This got me to thinking about using a material that has very low Thermal Conductivity and as it turns out I help to develop STAR21G, a
black material with Thermal Conductivity of: 1.25 W/(m K) at 25*C, 160 times lower than Aluminum,34 times lower than Steel.
Aluminum: 205 W/m K) at 25*C
steel: 43 W/m K) at 25*C
Here are the advantages that I can think of.:
1. Potential MPG improvement of two times.
2. Almost instantaneous operating temp, no energy being absorbed by combustion parts and lower pollution.
3. Eliminate the need for a cooling system there by saving the cost for having one, may need oil cooling.
4. Cut pollution in half by using half as much gas for each mile.
5. ICE cars will be cheaper to own and operate then All-electric Cars and create similar amount of air pollution assuming they use coal fired power to charge battery.
6. Hybrids could improve MPG's more if we can use exhaust gases to run a steam engine generator to charge HVB from using exhaust gases.
7. Would increase HP and Torque by a factor of two for the same ICE design.
8. There maybe more advantages and I will add when I or someone else comes up with them.
I'm thinking 100 mpg/ 1400mi. on a tank with a CMAX Hybrid on the HWY for 2018. (Maybe 2K miles with Hypermiling)
This isn't a cost effective solution for current CMAX/ICE vehicles, but for Future Hybrid/ICE vehicles this could be a huge improvement in MPG/HP/ Torque and cheaper to make. IMO anyway. I might try to add this to my ICE now that I'm out of warranty if I get the opportunity. (133K mi)
It would be interesting if I could get someone at FORD interested in my idea otherwise I'm going to put this information out to the Public Outlets and see what happens. I have applied for a patent too.
Let me know what you think.
I thought I might clarify how a ICE (internal combustion engine) would work using STAR21G, black material. This is the way our 4 cycle engine works :
Induction Cycle pulls in cool air from intake through cylinder head into combustion chamber cooling cylinder head, cylinder walls, piston and valves.
Compression Cycle the air in the combustion chamber compresses further cooling it until the piston gets close to the top where it gets hot and fuel is injected into combustion chamber.
Power Cycle fuel is burned and is slightly absorbed into combustion chamber.
Exhaust Cycle hot gases are pushed out of combustion chamber with a little more heat absorbed into surfaces of combustion chamber.
As you can see about half of the time the combustion chamber is being heated up and the other half it is cooling down. Because the ICE absorbs very little heat it shouldn't be that hot on the outside of the ICE. This is also why you will double your MPG's, because 30% of the total energy lost to cooling system won't be lost now. Or 60% of the energy will be moving the car and 30 % will be going out of the exhaust pipe.
Edited by ptjones, 12 June 2016 - 02:57 PM.