Shielded insulation for combustion chamber

Claim 1

In an uncooled engine that comprises a cast iron cylindrical block (10) having a bore (16) therein, a cast iron cylinder head (12) having an inside surface facing the bore (16) whereby the bore (16) and the head surface cooperatively form a combustion chamber (32), the cylinder head (12) having an air intake passage (44) and an exhaust passage (46) communicating with the head surface; poppet valves (48) on the head (12) for opening and closing the respective passages, each poppet valve (48) having an end surface thereof exposed to the combustion chamber (32); and a piston (40) having, at the end nearer to the head surface, a cast iron end wall (43); the improvement wherein the bore (16) includes a largest diameter bore section (20) nearest the cylinder head (12), an intermediate bore section (22) surrounding the combustion chamber (32), a shoulder between the largest diameter bore section (20) and the intermediate bore section (22) and a smallest diameter bore section (26) furthest from the cylinder head (12), the largest diameter bore section (20) and the intermediate bore section (22) only having adhered thereto a first insulative coating; there being a first heat resistant layer for covering said first insulative coating comprised of a cylinder (34) extending through the bore (16) for slideably retaining the piston (40), said cylinder (34) being in direct contact with and closely fit within the smallest diameter bore section (22) and having an annular flange (37) engaging the shoulder (24) of the bore (16); the inside surface of the cylinder heat (12) having adhered thereto a second insulative coating and having a second heat resistant layer covering said second insulative coating, said second heat resistant layer held against said second insulative coating by the cylinder (34), the second insulative coating and the second heat resistant layer defining holes at the openings in the air intake passage (44) and the exhaust passage (46); each end surface of the poppet valve (48) being free of flanges or ridges and having adhered thereto a third insulative coating covered by a third heat resistant layer; the third insulative coatings and the third heat resistant layers being congruent with the end surfaces; the end wall (43) of the piston having adhered thereto a fourth insulative coating covered by fourth heat resistant layer comprising a piston cap (63); each of the insulative coatings having a thermal expansion substantially that of cast iron and being made of zirconium oxide; and each of the heat resistant layers being exposed to combustion chamber (32) and being formed of a material resistant to cracking, erosion and wear when subjected to temperature on the order of 2000 degrees Fahrenheit and being effective to shield the respective insulative coatings from erosion and wear incident to the combustion process within the engine.