ATTORNEY DOCKET NO.: 11381.110028
`IN THE UNITED STATES PATENT AND TRADEMARK OFFICE
`
`Applicant: Daniel R. Cohn etal.
`
`Examiner: Not Yet Assigned
`
`Serial No... Not Yet Assigned
`
`Art Unit: Not Yet Assigned
`
`Filing Date: Filed Herewith
`
`Confirmation No.: Not Yet Assigned
`
`Title:
`
`FUEL MANAGEMENT SYSTEMFOR VARIABLE ETHANOL OCTANE
`ENHANCEMENT OF GASOLINE ENGINES
`
`Via EFS-Web
`Commissioner for Patents
`P.O. Box 1450
`Alexandria, VA 22313-1450
`
`Dear Sir:
`
`INTRODUCTORY COMMENTS
`
`Please preliminarily amend the application as follows:
`
`FORD Ex. 1002, page 1
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`

`Application No. Filed Herewith
`Date: May 27, 201)
`
`Docket No.: 11381.110928
`
`In the Specification
`
`Please amend paragraph [0001] on page 1 as follows:
`
`This application is a continuation of United States Patent Application No. 12/815,842
`
`
`filed June 15, 2010 which is a continuation of United States Patent Application No. 12/329,729
`
`filed on December 8, 2008 which is a continuation of United States Patent Application No.
`
`11/840,719 filed on August 17, 2007, whichis a continuation of United States Patent Application
`
`No. 10/991,774, which is nowissued as United States Patent No. 7,314,033.
`
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`Application No.: Filed Herewith
`Date: May 27, 2011
`
`Docket No.: 11386,1 10928
`
`intheClaims
`
` SEAN
`
`1-56 (cancelled)
`
`Please add the following new claims:
`
`57. (new) A turbocharged or supercharged spark ignition engine which is fueled with gasoline
`
`and ethanol where ethanolis introduced into the engine in such a way that the vaporized cooling
`
`provided by the ethanol enhances the octane number more thanit is enhanced by the intrinsic
`
`octane number of the ethanol.
`
`58. (new) The turbocharged or supercharged spark engine of claim 57 where liquid ethanol is
`
`directly injected into the engine cylinders.
`
`59, (new) The turbocharged or supercharged spark ignition engine of claim 58 where the ethanol
`
`18 injected $0 as to have a greater concentration in the end gas region.
`
`60. (new) The turbocharged or supercharged spark ignition engine of claim 39 where the ethanol
`
`has a higher concentration near the wall of the cylinder.
`
`61. (new) The turbocharged or supercharged spark ignition engine of claim 60 further inchiding
`
`swirl,
`
`62. (new) The turbocharged or supercharged spark ignition engine of claim 59 where the knock
`
`resistance is increased relative to uniform distribution of ethanol in the cylinder.
`
`63. Mew) A turbocharged or supercharged spark ignition engine of claim 57 where the spark
`
`retard is changed to prevent knock from occurring when the ethanol energyfraction is reduced.
`
`64. (new) A turbocharged or supercharged spark ignition engine where ethanol is introduced inta
`
`the engine in such a way that it provides a 35 octane numberincrease over gasoline and the
`
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`ce eeeeeeeTEDNN
`
`Application No.. Filed Herewith
`Date: May 27, 2011
`
`Docket No.: 11381.1 10928
`
`octane numberincrease from vaporization cooling is greater than the octane numberincrease
`
`from the intrinsic octane of ethanol.
`
`65. (new) The turbocharged or supercharged spark ignition engine of claim 64 where liquid
`
`ethanol is directly injected into the engine cylinders.
`
`66. (new) The turbocharged or supercharged spark ignition engine of claim 64 where the ethanol
`
`is injected so to have a greater concentration in the end gas region.
`
`67. (new) The turbocharged or supercharged spark ignition engine of claim 64 where the ethanol
`
`has a higher concentration near the wali of the cylinder.
`
`68. (new) The turbocharged or supercharged spark ignition engine ofclaim 64 further including
`
`swirl.
`
`69. (new) The turbocharged or supercharged spark ignition engine of claim 64 where the knock
`
`resistance is increased relative to uniformdistribution of ethanol in the cylinder.
`
`70. (new) A turbocharged or supercharged spark ignition engine of claim 64 where the spark
`
`retard is changed to prevent knock fromm occurring when the ethanol energy fraction is reduced.
`
`FORD Ex. 1002, page 4
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`Application No.: Filed Herewith
`Date: May 27, 2011
`
`Docket No.: 1£1381.£10928
`
`Remarks
`
`Claims 1-56 have been cancelled. New claims 57-70 are being added. No new matteris
`
`being introduced.
`
`Iyespectfally Submitted,
`ff
`ig
`
`r
`
`*
`
`
`
`Sam (Bo) Pasternack
`Registration Number: 29576
`Massachusetts Institute of Technology
`One Cambridge Center
`Room NE18-501
`Cambridge, MA 02142
`617.258.7171
`
`FORD Ex. 1002, page 5
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`

`
`
`DECLARATION
`
`I believe I am an original, first and joint inventor ofthe subject matter which is claimed and
`for which a patent is sought on the invention entitled:
`
`FUEL MANAGEMENTSYSTEM FOR VARIABLE ETHANGL OCTANE
`ENHANCEMENT OF GASOLINE ENGINES
`
`the specification ofwhich (1 authorize Choate, Hall & Stewart to check one ofthe following
`three choices, and fill in the blanks, if applicable):
`
`
`
`is attached hereto
`
`
`X___. was filed on November 18, 2004 as Application Serial No. 10/991.774 sad
`
`
`
`was filed as PCT international application No.
`and was amended under PCT Article 19
`(if applicabic).
`
`on
`on
`
`I hereby state that I have reviewed and understood the contents of the above-identified
`specification, including the claims, ss amended by any amendment referred to above.
`
`I acknowledged the duty to disclose information which is material to the examination of
`this application in accordance with Title 37, Code ofFederal Regulations, §1.56.
`
`i hereby claim forcign priority benefits under Title 35, United States Code, §119 of any
`foreign application(s) for patent or inventor's certificate listed below and have siso identified
`below any foreign application for patent or inventor's certificate having a filing date before that
`of the application on which priority is claimed:
`
`Prior Foreign Application(s):
`
`Priority Claimed
`
`(Namber)
`
`(Country
`
`(Day/Month/Year/Filed)
`
`Yes No
`
`(Number)
`
`(Country)
`
`(Day/Month/Year/Filed)
`
`Yes No
`
`Page 1 of 3
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`I hereby claim the benefit under Title 35, United States Code, §120 of any United States
`application(s) or PCT international application(s) designating the United States of America listed
`belowand, insofar as the subject matter ofeach of the claims ofthis application is not disclosed
`in the prior United States application in the manner provided by the first paragraph ofTitle 35,
`United States Code, §112, I acknowledge the duty to disclose material information as defined in
`Title 37, Code of Federal Regulations, §1.56 which became available between the fling date of
`the prior application and the national or PCT international filing date of this application:
`
`(Application Serial No.)
`
`(filing date)
`
`(siatus-patented, pending, abandoned)
`
`
`
`(Application Serial No.}—_(filing date) (status-patented, pending, abandoned)
`
`PCT Applications designating the United States:
`
`(PCT Appl. No.)
`
`(US8.N)}
`
`(status-patented, pending, abandoned)
`
`[hereby claim the benefit under Title 35, United States Code, §119(¢) of any United States
`provisional application(s) listed below and, insofar as the sublect matter of each of the claims of
`this application is not disclosed in the prior United States application in the manner provided by
`the first paragraph ofTitle 35, United States Code, §112, Lacknowledge the duty to disclose
`information which is material to patentability as defined in Title 37, Code ofFederal
`Regulations, §1.56 which became available between the filing date of the prior application and
`the national filing date of this application.
`
`rovisional Application(s):
`
`
`
`{Application Serial No.}=(filing dats} (status)
`
`{Application SerialNo.)
`
`(filingdate}
`
` -
`
`{status}
`
`Thereby declare that all statements made herein of my own knowledge are true and that
`all staternents made on information and belief are believed to be true: and further that these
`siatements were made with the mowledge that willful filse statements and the Hike so made are
`punishable by fine or imprisonment, or both, under Section 1001 ofTitle 18 ofthe United State
`Code and that such willful false statements may jeopardize the validity of the application or any
`patents issued thercon.
`
`Page 2 of 3
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`

` Residence LA ___¥ dal chroot
`Citizenship
`
`
`lnventor’s signa
`
`Residence
`
`
`
`
`
`
`Fuil name of third invente Inventor's signature_ alee ay : -
`ResidenceGUEMelkellHeeck MechaWi0S—Citizenship UUSAR
`
`
`
`
`
`
`Page 3 of 3
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`

`
`
`Electronic Patent Application Fee Transmittal
`
`Filing Date:
`
`Title of Invention:
`
`FUEL MANAGEMENTSYSTEM FOR VARIABLE ETHANOL OCTANE
`ENHANCEMENT OF GASOLINE ENGINES
`
`
`
`
`
`First Named Inventor/Applicant Name: Daniel R. Cohn
`
`Filer:
`
`Sam Pasternack/Ellen Byal
`
`Attorney Docket Number:
`
`11381.110928
`
`Filed as Large Entity
`
`Utility under 35 USC 111(a) Filing Fees
`
`Description
`
`Fee Code
`
`Quantity
`
`Amount
`
`Sub-Total in
`USD(S)
`
`Basic Filing:
`
`Utility Search Fee
`
`1111
`
`1
`
`540
`
`540
`
`Claims:
`
`
`Miscellaneous-Filing:
`
`Petition:
`
`
`Patent-Appeals-and-Interference:
`
`Post-Allowance-and-Post-Issuance:
`
`
`FORD Ex. 1002, page 9
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`

`

`
`
`
`
`
`
`
`
`Sub-Total in
`Fee Code Quantity AmountDescription USD(S)
`
`Total in USD ($)
`
`Extension-of-Time:
`
`
`Miscellaneous:
`
`
`FORD Ex. 1002, page 10
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`

`Electronic AcknowledgementReceipt
`
`10184071
`
`International Application Number:
`
`Confirmation Number:
`
`Title of Invention:
`
`FUEL MANAGEMENTSYSTEM FOR VARIABLE ETHANOL OCTANE
`ENHANCEMENT OF GASOLINE ENGINES
`
`
`
`First Named Inventor/Applicant Name:
`
`Daniel R. Cohn
`
`Customer Number:
`
`91197
`
`
`
`
`
`Filer Authorized By: Sam Pasternack
`
`Attorney Docket Number:
`
`11381.110928
`
`Filing Date:
`
`Time Stamp:
`
`13:24:12
`
`Application Type:
`
`Utility under 35 USC 111)
`
`Paymentinformation:
`
`
`Submitted with Payment
`
`Payment Type
`
`Credit Card
`
`
`
`192553
`Deposit Account
`
`Authorized User
`O'BRIEN,DANIEL
`
`The Director of the USPTO is hereby authorized to charge indicated fees and credit any overpaymentas follows:
`Charge any Additional Fees required under 37 C.F.R. Section 1.17 (Patent application and reexamination processing fees)
`Charge any Additional Fees required under 37 C.F.R. Section 1.19 (Document supply fees)
`
`FORD Ex.1002, page 11
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`Charge any Additional Fees required under 37 C.F.R. Section 1.21 (Miscellaneous fees and charges)
`
`File Listing:
`Document
`File Size(Bytes)/
`
`File Name Message Digest|Part/.zip| (if appl.)
`DocumentDescription
`Number
`263130
`
`
`
`Application Data Sheet
`
`11381110928ads.pdf
`
`4e1 cb91b3a7e18370d8da79302cObf97802]
`b7b67
`
`Information:
`
`This is not an USPTO supplied ADS fillable form
`
`Specification
`
`11381110928spec.pdf
`
`Drawings-only black and whiteline
`drawings
`
`11381110928figs.pdf
`
`Preliminary Amendment
`
`11381110928PA. pdf
`
`Information:
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`597230
`
`cAfce7647780346073268384.60A41 Adal
`7308
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`Oath or Declaration filed
`11381110928dec.pdf
`6c110812eb79712141047a1c29e00768«.
`16N6by
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`Fee Warksheet (PTO-875)
`
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`{05728373ea3b | 3b7F11536eb1 d6fd{38701
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`1272923
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`FORD Ex. 1002, page 12
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`
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`This Acknowledgement Receipt evidences receipt on the noted date by the USPTO of the indicated documents,
`characterized by the applicant, and including page counts, where applicable. It serves as evidence of receipt similar toa
`Post Card, as described in MPEP 503.
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`New Applications Under 35 U.S.C. 111
`If a new application is being filed and the application includes the necessary componentsfor a filing date (see 37 CFR
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`If a new international application is being filed and the international application includes the necessary componentsfor
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`PTO/SBM4 (14-08)
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`
`|“Attomey Docket Number
`|
`| 14384.110928
`|
`
`| Application Data Sheet 37 CFR 1.76 | Fr oo |
`
`[L
`_ Application Number
`i
`i
`iFUEL MANAGEMENTSYSTEM FOR VARIABLE ETHANOL OCTANE ENHANCEMENT OF GASOLINE
`ENGINES
`
`Title of Invention
`
`| The application data sheet is part of the provisional or nonprovisional application forwhich itis being submitted. The following form contains the
`bibliographic data arrangedin a formai specified by the United Staies Patent and Trademark Office as outlined in 37 CFR 1.76.
`This document may be completed electronically and submitted to the Office in electronic format using ihe Electronic Filing System (EFS) or the
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`Portionsorall of the application associated with this Application Data2 Sheetmay fall under a Secracy Order pursuant to,
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`Applicant 1
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`
`Applicant information:
`| Applicant Authority @lnventor|OQ1LegaiRepresentiative under 35 U.S.C. 117 |OParty of Interest under 35 U.S.C. 118
`
`Prefix Given Name
`| Middle Name
`| Family Name
`Suffix;
`
`_ Danie’
`R
`| Cohn
`-
`7 [
`,
`Residence information (Select One)T@ US Residency
`QO NonUS Residency
`(Oo Active US Military Service
`
`City| Cambridge
`isState/Province[hsMA | Countryof
`ReResidencd | US
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`us
`
`
`Mailing Address of Applicant:
`Address 4
`"400 Memorial Drive Apt. 11-22 B
`
`
`Address20 EEEEEEEEEEEEEO /
`‘Gity|Cambigge_ |StateProvinceMA
`
`| PostalCode “02142,
`2~C*~“‘*‘“*;*‘;*YSCintr
`|S OS
`-
`
`Pomroronrotcnncenncaernrrramancceenercnren
`~
`~
`“|
`
`_Applicant2_
`
`
`|
`
`(OParty of Interest under 35 U.S.C. 118
`| Applicant Authority |@Inventor | (Legal Representative under 25 U.S.C. 117
`Family Name
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`Middie Name
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`
`| Lesfie i ——— |Bromberg _
`_ of |
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`©) Non US Residency C) Active US Miltary Service
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`ity|Sharonoe__|State/Province||!MA |Country of Residencd US
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`|_Sitizenship under37 CFR 1Ae) | US
` Address 2
`r
`| 02087
`| Clty
`| Sharon
`| Postal Code
` Applicant3__tS—
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`| Applicant Authority @) Inventor| OLegal Representative under 35 U.Ss.C. 147 |Party of interest under£35 U.S.C.118
`[ Prefix’ Given Name
`
`
`| Family Name[MiddleName Suffixaoe+
`
`
`| dohn
`i 8.
`Heywood
`|
`|Residence information (Select One) ® US Residency
`C) Non US Residency
`(©) Active US Military Service
`{
`rnA8
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`7
`yt
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`|_ City | Newtonvilie
`i
`
`EFS Web 2.2.2
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`| Attorney Docket Number
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`i
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`Application Data Sheet 37 CFR 1.76 |
`|
`ee
`| Application Number
`Y EUEL MANAGEMENT SYSTEM FOR VARIABLE ETHANOL OCTANE ENHANCEMENT OF GASOLINE
`Title of Invention
`ENGINES
`
`
`
`
`/
`-
`| US
`| Citizenship under 37 CFR 4.41(b)
`
`| Mailing Address of Applicant:
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`nD ne a
`4
`
`
`|
`|
`
`4
`
`Address 14
`[238 Mili St.
`_Address2
`|: pe a
`|_Sity | Newtonviile
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`| MA
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`| 91197
`|Email Address
`
`
`
`
`
`Application information:
`aneteA—
`FUEL MANAGEMENT SYSTEMFOR VARIABLE ETHANOL GCTANE ENHANCEMENT OF
`'
`¥ th
`i
`
`| Title of the Invention
`|_ GASOLINE ENGINES
`
`; Attorney Docket Number,
`11381.110928
`| Application Type
`Nonprovisional
`
`| Subject Matter
`Utility
`| Suggested Class GFany)
`[anne
`ab.
`| as
`rn ere7
`“SuggestedTeTechnologyyCenter(ifarany}
`3
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`PTOMSB/14 (11-08)
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` +
`| Application Number
`|an.
`Application Data Sheet 37 CFR 1.76 |
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`| FUEL MANAGEMENT SYSTen FOR VARIABLE ETHANOL OCTANEENHANCEMENT OF GASOLINE
`:
`.
`Title of invention |
`a
`| ENGINES
`CustomerNumber | 91197
`
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`| This section allows ffor the.applicant to either claim, benefit under 35U.$c. +49(e), 420, 12%, or 365(c) or indicate Nationa! Stage
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`Prior Appiication Status | Pending
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`PriorApplication:Number|
`Continuity Type
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`| 2010-06-15
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`Aitorney Docket Number | 11381. 110928 ' -
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`| Title of Invention | FUEL MANAGEMENT SYSTEMFOR VARIABLE ETHANOL OCTANE ENHANCEMENT OF GASOLINE
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`Fuel Management System for Variable Ethanol Octane Enhancement
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`of Gasoline Eagines
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`[0001]
`
`This application is a continuation of United States Patent Application No. 11/840,719
`
`filed on August 17, 2007, which is a continuation of United States Patent Application Neo.
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`10/991,774, which is nowissued as United States Patent No. 7,314,033.
`
`BACKGROUND
`
`10002)
`
`This invention relates to spark ignition gasoline engines utilizing an antiknack agent
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`which is a liquid fucl with a higher octane number than gasoline such as ethanol to improve
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`engine efficiency.
`
`[@803;
`
`itis known that the efficiency of spark ignition (SI) gasoline engines can be increased
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`by high compression ratio operation and particularly by engine downsizing. The engine
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`downsizing is made possible bythe use of substantial pressure boosting from either
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`turbocharging or supercharging. Such pressure boasting makes it possible to obtain the same
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`performancein a significantly smatler engine. See, J. Stokes, ef a/., “A Gasoline Engine
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`Concept For fmproved Fuel Economy The Lean-Boost System,” SAE Paper 2001-01-2902.
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`The use of these techniques to increase engine efficiency, however, 1s limited by the onset of
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`engine knock. Knock is the undesired detonation of fuel and can severely damage an engine. If
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`knock can be prevented, then high compression ratio operation and high pressure boosting can be
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`used to increase engine efficicney by up to twonty-five percent.
`
`[@004)
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` Gctane numberrepresents the resistance of 4 fuel to knocking but the use of higher
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`octane gasoline only modestlyalleviaies the tendency to knock. For example, the difference
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`between regular and premium gasoline is typically six octane numbers. That is significantly less
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`than is needed to realize fully the efficiency benefits of high compression ratio or turbocharged
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`operation. There is thus anced for a practical means for achieving a much higherlevel of octane
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`enhancementso that engines can be operated much more efficiently.
`
`tatts
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`[68051
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`itis known to replace a portion of gasoline with small amounts of ethanol added at the
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`refinery. Ethanol has a blending octane number (ON) of 110 (versus 95 for premium gasoline)
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`(see J.B. Heywood, “Internal Combustion Engine Fundamentals,” McGraw Hill, 1988, p. 477}
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`and is also aitractive becauseit is a renewable energy, biomass-derived fuel, but the small
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`amounts of ethanol that have heretofore becn added to gasoline have had a relatively smal!
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`impact on enginc performance. Ethanol is much more expensive than gasoline and the amount
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`ofethanolthat is readily available is much smaller than that of gasoline because ofthe relatively
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`limited amount of biomass that is available for its production. An object of the present invention
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`is to minimize the amount of ethanol or other antiknock agent that is used to achieve a given
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`level of engine efficiency increase, By restricting the use of ethanolto the relatively small
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`fraction of time in an operating cycle when it is needed to prevent knock m a higher load regime
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`and by minimizing its use at these times, the amount of ethanol that is required can be limited to
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`a relatively small fraction of the fuci used by the spark ignition gasoline engine.
`
`SUMMARY
`
`{9666}
`
`In one aspect, the invention is a fuel management systemfor efficient operation of a
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`spark ignition gasoline engine including a source of an antiknock agent such as cthanol. An
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`injector directly injects the ethanol into a cylinder of the engine and a fuel management system
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`controls injection of the antiknock agent inte the cylinder to control knock with minimum use of
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`the antiknock agent. A preferred antiknock agent is cthanol. Ethanol has a high heat of
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`vaporization so that there is substantial cooling of the air-fuel charge to the cylinder whenit is
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`injected directly into the engine. This cooling effect reduces the octane requirementof the
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`engine by a considerable amount in addition to the improvement in kneck resistance from the
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`relatively high octane number of ethanol. Methanol, tertiary butyl alcohol, MTBE, ETBE,and
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`TAME may also be used. Wherever cthanol is used herein it is to be understood that other
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`antiknock agents are conternplated.
`
`{0607|
`
`The fuel management system uses a fuel management control system that may use a
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`microprocessor that operates in an open loop fashion on a predetermined correlation between
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`octane number enhancement and fraction of fuel provided by the antiknock agent. To conserve
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`the ethanol, if is preferred that it be added only during portions of a drive cycle requiring knock
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`resistance and that its use be minimized during these times. Altematively, the gasoline engine
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`2a ts
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`mayinclude a knock sensorthat provides a feedback signal to a fuel management
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`microprocessor system to minimize the amount of the ethanol added to prevent knock in a closed
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`loop fashion.
`
`{6008]
`
`In one embodiment the injectors stratify the ethanol to provide non-uniform deposition
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`within a cylinder. For example, the ethanol may be injected proximate to the cylinder walls and
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`swirl can create a ring of ethanol near the walls.
`
`j@999]
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`In another embodimentcf this aspect of the invention, the system includes a measure
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`of the amountof the antiknock agent such as ethanol in the source containing the antiknock agent
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`to control turbocharging, supercharging or spark retard when the amount ofethanol is low,
`
`10610{
`
`The direct injection of ethanol provides substantially a 13°C drop in temperature for
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`every ten percent of fuel energy provided by ethanol. An instantaneous octane enhancement of
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`at least 4 octane numbers may be obtained for cvery 20 percent of the engine's energy coming
`from the ethanol.
`
`BRIEF DESCRIPTION GF THE DRAWINGS
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`fG0i1]
`
`FIG. Lis a block diagram of onc embodiment ofthe invention disclosed herein.
`
`{6012]
`
`FIG. 2 is a graph of the drop in temperature within a cylinder as a finction of the
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`fraction of energy provided by ethanol.
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`10013] FG. 3 is a schematic illustration of the stratification of cooler ethanol charge using
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`direct injection and swirl motion for achieving thermal stratification.
`
`{OG14]
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`FIG, 4 is a schematic illustration showing cthanol stratified in an inlet manifold.
`
`{60151
`
`FIG. 5 is a block diagramof an embodiment of the invention in which the fuel
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`management microprocessor is used to control a turbocharger and spark retard based upon the
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`amount of ethanol in a fuel tank.
`
`DETAILED DESCRIPTION
`
`{0016] With reference first io FIG. I, a spark ignition gasolime engine 18 includes a knock
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`scnsor 12 and a fuci management microprocessor system 14. The fuel management
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`microprocessor system 14 controls the direct injection of an antiknock agent such as ethanol
`
`from an ethanol tank 16. The fuel management microprocessor system 14 also controls the
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`delivery of gasoline from a gasoline tank 18 inte cngine manifold 20. A turbocharger 22 is
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`3 of 15
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`provided to improve the torque and power density of the engine 10. The amount ofethanol
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`injection is dictated either by a predetermined correlation between octane number enhancement
`
`and fraction of fuel that is provided by ethanol in an open loop system or by a closed loop
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`control system that uses a signal from the knock sensor 12 as an input to the fuel management
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`microprocessor 14, In both situations, the fuel management! processor 14 will minimize the
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`amount of ethanol added to a cylinder while still preventing knock.
`
`It is also contemplated that
`
`the fuel management microprocessor system 14 could provide a combination of open and closed
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`loop control.
`
`{0617}
`
`As show in FIG.f it is preferred that ethanol be directly injected into the engine 10.
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`Direct injection substantially increases the benefits of ethanol addition and decreases the required
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`amount of ethanol. Recent advances im fuel injector and electronic control technologyallows
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`fucl injection directly into a spark ignition engine rather than into the manifold 20. Because
`
`ethanol has a high heat of vaporization there will be substan