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NOTE: The stated aim of the United States Department of

Energy FreedomCAR and Vehicle Technology (FCVT) Program


“is to develop ‘leap frog’ technologies that will provide
Americans with greater freedom of mobility and
energy security, while lowering costs and reducing impacts
on the environment.”

This booklet describes such a “leap-frog” technology


for Plug-In Hybrid Electric Vehicles (PHEVs).

____________
®
DISCLOSURE: ROTAPOWER Engines have been in development by Moller International and
Freedom Motors for several years. They have been demonstrated to run successfully in a variety
of different types of applications – everything from a series hybrid automobile to gen-set, from an
ATV to a powerboat.

SAFE HARBOR STATEMENT: This booklet may contain forward-looking statements. The
words “estimate” and “seeking” and similar expressions identify forward-looking statements,
which speak only as to the date the statement was made. Freedom Motors, Moller International,
and The Pollution Solutionssm Group undertake no obligation to publicly update or revise any
forward-looking statements, whether because of new information, future events, or otherwise.
Forward-looking statements are inherently subject to risks and uncertainties, some of which
cannot be predicted or quantified. Future events and actual results could differ materially from
those set forth in, contemplated by, or underlying the forward-looking statements. The risks and
uncertainties to which forward-looking statements are subject include, but are not limited to, the
effect of government regulation, competition, and other material risks.
® ®
ROTAPOWER and Skycar are trademarks of Moller International in the USA and other
countries. All other trademarks are the property of their respective owners.

____________

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© 2007 The Pollution Solutionssm Group LLC
TODAY’S CHALLENGES

• Dependence on petroleum
• Pollution from emissions
• Piston engines that are heavy and increasingly complex
• Existing and future EPA fuel and emissions standards

THE GOAL

• A new market-ready, general-purpose engine that


meets these challenges in many profitable applications,
including Plug-In Hybrid Electric Vehicles

THE SOLUTION

• Freedom Motors’ ROTAPOWER® Engines –


“The Little Engines That CAN…!”

ROTAPOWER® Engines being developed by Freedom Motors / Moller International are


the ideal new general-purpose internal combustion engines because of their:

• lighter weight and smaller size than piston engines of comparable horsepower

• greatly reduced emissions – up to 99% less than piston engines

• ability to run efficiently on a variety of fuels

• mechanical simplicity, which means lower manufacturing and maintenance costs

• flexibility of size and horsepower that fit many applications

• virtual freedom from vibration


____________

Freedom Motors’ ROTAPOWER® Engines can be used to improve


existing products, and to create new products and new markets
that meet today’s critical challenges and needs.

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© 2007 The Pollution Solutionssm Group LLC
BASIC COMPOUND
ROTAPOWER® ROTAPOWER®
Engines Engines
SUMMARY: 1 or more rotors in parallel 1 or 2 pairs of series rotors
Benefits of
Applications: Lawnmowers,
BASIC Applications: Hybrid Electric
hand-held power tools,
® Vehicles (HEVs andPHEVs),
ROTAPOWER snowmobiles, small outboard
Industrial engines, agricultural
and engines, leaf-blowers, trimmers,
engines, marine engines, generator
chain saws, tuk-tuks, motor-
COMPOUND sets, diesel-fueled engines
scooters, etc.
®
ROTAPOWER
Engines Compared to Compared to Compared to Comments on
2-Stroke 4-Stroke
4-Stroke COMPOUND
piston piston piston ROTAPOWER®
engines engines engines Engines
-Projected-
Up to 60% Up to 70% Power increases
Size & Weight Similar
smaller smaller faster than size
Up to Less fuel needed
40% less than due to recovery
Fuel Usage 30% less Similar
4-stroke piston of exhaust
engines energy

CO and HC = CO and HC = Reduced fuel


Untreated CO, over 95% less, over 95% less, CO and HC = consumption
HC and NOX NOX = NOX =
less than BASIC further reduces
Emissions ROTAPOWER® CO and HC
50% less 90% less emissions
Reduced fuel
40% less than
CO2 Emissions 30% less Similar
4-stroke pistons
consumption
reduces CO2
Even lower than
Less torsional
Vibration Much lower Much lower BASIC
vibration
ROTAPOWER®
All Compound
sizes projected as
Similar to 40-50% less than
Manufacturing 20-30% less than 20% less
2-Stroke piston 4-Stroke piston
Cost 4-Stroke piston expensive than
engines engines
engines 4-stroke piston
engines

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© 2007 The Pollution Solutionssm Group LLC
Table of Contents

U.S. D.O.E.’s Aim is to develop “Leap-Frog Technologies” 2

Challenges – Goal – Solution 3

ROTAPOWER® Engines: SUMMARY of Features & Benefits 4

Table of Contents 5

Abstract 7

1. A TECHNOLOGY WHOSE TIME HAS COME 8


Figure A: End View of a Rotary Engine 8
Institute of Transportation Studies-UCD Chart #1 10

2. FREEDOM MOTORS’ BASIC ROTAPOWER® ENGINES 11


Table 1: Untreated Emissions Comparison 11
Table 2: Untreated Emissions Comparison (graph) 12
®
Figure B: 27cc ROTAPOWER Engine 13
Figure C: 530cc ROTAPOWER® Engine 14
Table 3: Internal Combustion Engines Compared 15
Institute of Transportation Studies-UCD Chart #2 16

3. THE NON-AUTOMOTIVE MARKET FOR BASIC


ROTAPOWER® ENGINES 17
Table 4: Applications and Horsepower ranges of
BASIC ROTAPOWER® Engines 17
Figure D: Various Applications already developed by
Freedom Motors 18
Figure E: Tuk-Tuks in Bangkok, Thailand 19
Table 5: Worldwide Non-Automotive Engine Production, 2004 19
Figure F: Typical 2-Stroke Piston Outboard Engine & Chain Saw 20
Figure G: Dr. Moller with his 10kW “ROTAPAC” powered
by a 150cc BASIC ROTAPOWER® Engine 22

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© 2007 The Pollution Solutionssm Group LLC
4. BASIC ROTAPOWER® ENGINES IN HEVs 23
Figure I: Freedom Motors’ HEV 23

5. WHAT ARE “COMPOUND ROTAPOWER®” ENGINES? 23


Table 6: Maximum engine efficiency as a function
of power fraction (P/Pmax) 25
Figure H: A 27cc COMPOUND ROTAPOWER® Engine
for Tools & Small Applications 26
Table 7: Applications and Horsepower Range of the COMPOUND
ROTAPOWER® Engine 26

6. COMPOUND ROTAPOWER® ENGINES FOR HEVs


and PHEVs 27
Figure J: A 150cc COMPOUND ROTAPOWER® Engine 27
Figure K: Proposed Engines for Parallel Hybrid Vehicles 28
Table 8: Worldwide Automotive Engine Production, 2004 29

7. ARE COMPOUND ROTAPOWER® ENGINES SUITABLE


FOR ALL HEV and PHEV MANUFACTURERS? 29
Figure L: The “ROTAPAC” 25kW 30
Figure M: Comparing 25kW Generators: Gillette vs.
ROTAPAC 30
Figure N: 4-Stroke Engine Complexity Compared 31

8. WHY SHOULD HEV and PHEV MANUFACTURERS


CONSIDER A NEW ENGINE WHEN THEIR BIGGEST
IMMEDIATE PROBLEM IS BATTERIES? 32

FAQs 34
Conclusion 36
APPENDIX A: History of ROTAPOWER® Rotary Engines 37
APPENDIX B: Freedom Motors 38
APPENDIX C: Paul Moller, Ph.D. 39
APPENDIX D: The Pollution Solutionssm Group 40

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© 2007 The Pollution Solutionssm Group LLC
ABSTRACT

BASIC ROTAPOWER® Engines are the ideal low-emissions solution for


many non-automotive applications worldwide, with special attention to
replacing ubiquitous but highly polluting 2-stroke piston engines. With its
simplicity, small size and untreated CO and HC emissions of over 95% less
than all piston engines, BASIC ROTAPOWER® Engines should be considered to
replace 2- and 4-stroke piston engines in countless non-automotive applications,
including everything from lawnmowers to portable electrical generators,
snowmobiles to chain saws, outboard engines to motor scooters.

COMPOUND ROTAPOWER® Engines simultaneously meet our two most


urgent needs – (1) to decrease greenhouse emissions, and (2) to substantially
diminish the world’s dependence on petroleum fuel.

With up to 40% less fuel consumption, over 95% fewer untreated emissions,
and with far less size and weight of piston engines, COMPOUND
ROTAPOWER® Engines have the potential to revolutionize the automotive
industry in the early 21st Century. They are the ideal engine for PHEVs (Plug-In
Hybrid Electric Vehicles) of both the Parallel and Series concept, as well as a
wide array of industrial, agricultural, and marine applications that demand low
emissions and high fuel efficiency.

COMPOUND ROTAPOWER® Engines are also simpler, less expensive to


manufacture and maintain, and are flex-fuel ready: gasoline, E85, pure ethanol,
biofuels, LPG, natural gas, diesel, methane, and hydrogen when that becomes
economically viable.1

1
Qualifies as a Flex-Fuel Vehicle (FFV), or “mixed-fuel vehicle” as defined in the Energy Policy Act of
2005 by the U.S. Congress.

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© 2007 The Pollution Solutionssm Group LLC
1. A TECHNOLOGY WHOSE TIME HAS COME
Dr. Felix Wankel first developed his working models of “rotary” engines in the 1950s.

Automobile manufacturers immediately recognized their tremendous promise – here was


a powerful internal-combustion engine, smaller and lighter than prevailing piston
engines, that was also efficient and “vibration-free” because, unlike piston engines, its
combustion force operated in the same rotational vector as its drive shaft!

FIGURE A: End View of a Rotary Engine.


The triangular rotor, revolving in a “figure-eight” pattern inside the oval
housing, turns the drive shaft and functions as both piston and valves!

Here, too, was a powerful new engine with all the emissions benefits of the 4-stroke
combustion process but with only a small fraction of the moving parts of a 4-stroke
piston engine. Thus this new engine could greatly reduce their costs of manufacturing and
maintenance.

So, in the 1960s and 1970s, virtually every major automobile manufacturer embarked on
the race to try to adapt rotary engines to its own automobiles. Of these, only Mazda
prevailed, creating an engine that is legendary in automobile racing circles even today.2

2
In fact Mazda’s rotary engine has a mystique of its own in the world of automobile racing – and was so
successful in racing that it was banned from competing against piston engines! John Z. DeLorean’s original
plans for the iconic DMC-12 included a Citroen Wankel rotary engine, dubbed Comotar (developed by
NSU and Citroën) Of course, that never happened and the DeLorean ended up with an underpowered 130
bhp V6 engine jointly developed by Renault, Peugeot and Volvo. However, some lads decided to hook on
DeLorean’s original vision and replace the ill-fated French V6 with a 300Hp strong, 2.0-liter 3-rotor rotary
engine from the 1990 Mazda Eunos Cosmo. <http://carscoop.blogspot.com/2007/05/delorean-with-300hp-
mazda-rotary-engine.html>

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© 2007 The Pollution Solutionssm Group LLC
But despite all this excitement and experimentation, rotary engines were not widely
adopted by the automobile industry as a whole.

Why is this?

First, Wankel’s rotary engines were somewhat less fuel-efficient than the best piston
engines of the time. The Oil Crisis of 1973 made it clear for the first time that fuel
efficiency would be a concern for manufacturers and consumers henceforth.

Second, early Mazda rotary engines had problems with their composite oil seals that were
designed to prevent oil from migrating from the oil-cooled rotor into the combustion
chamber, and this perception has been hard to erase even though Mazda redesigned
its seals years ago.

Third, GM’s Wankel engines did not comply with then-current emissions levels, and, in
the 1970s, low emissions were just beginning to be recognized as a goal.
GM cancelled further development of its rotary engines in 1974.

As a result, manufacturers and inventors returned to the task of trying to overcome the
inherent inefficiencies of the piston engine’s fundamental design. The resulting
accretion of more and more add-ons has band-aided the fuel efficiency and emissions
problems of piston engines, but have also rendered today’s gasoline piston engines
overly complex and overly expensive to manufacture and maintain.

For the past three decades, the tremendous potential of rotary engines has remained
untapped.

Now, finally, with the advances and innovations being made by


Freedom Motors, the rotary concept is poised for success in many
industrial, commercial, recreational, power tool, military, and
transportation applications.
_______________________

Some of the benefits of ROTAPOWER® Engines that make them attractive for Hybrid
Electric Vehicles (HEVs) are excerpted here from a 2006 presentation by Dr. Andrew
Burke, recognized expert in series hybrid technology from the independent Institute of
Transportation Studies at the University of California, Davis3 –

3
Andrew F. Burke, Ph.D., “Hybrid Vehicles with Batteries and Ultracapacitors in China,” Powerpoint
Presentation, 2006.

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© 2007 The Pollution Solutionssm Group LLC
ROTARY ENGINES IN HYBRID VEHICLES
• “Small size of the rotary engine makes packaging much less difficult
than with a reciprocating engine”
• “The cost of the rotary engine in volume production should be less
than other engine types”
• “Two-cycle engine size and cost, with 4-cycle engine efficiency and
low emissions”
• “Rotary engines are smooth and quiet compared to other engine
types”

ITS-UCD
Institute of Transportation Studies, University of California, Davis

Freedom Motors is now taking this technology to its next level by compounding its
BASIC ROTAPOWER® Engine to create the COMPOUND ROTAPOWER® Engine.
In fact, Freedom Motors’ COMPOUND ROTAPOWER® Engine is the ideal engine
component in the emergent transportation technology known as Plug-In Hybrid Electric
Vehicles – PHEVs.

PHEVs have been targeted by the United State Department of Energy (D.O.E.) as the
important next goal in the development of fuel-efficient passenger automobiles and light
trucks, because PHEVs will:
“provide Americans with greater freedom of mobility and
energy security, while lowering costs and reducing
impacts on the environment.”4

Battery chemistry is advancing rapidly and will soon make PHEVs practical in mass
production. These advanced batteries coupled with Freedom Motors’ COMPOUND
ROTAPOWER® Engines answer today’s most urgent energy needs – lower emissions
and higher fuel economy.

With the innovations of Freedom Motors’


BASIC ROTAPOWER® and COMPOUND ROTAPOWER® technology,
the rotary engine is finally a technology whose time has come.
__________________________

4
“Mission, Vision, & Goals” of the U.S. Department of Energy “FreedomCAR & Vehicle Technologies
Program. <http://www1.eere.energy.gov/vehiclesandfuels/about/fcvt_mission.html>

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© 2007 The Pollution Solutionssm Group LLC
2. FREEDOM MOTORS’ ROTAPOWER® ENGINES –
“The Little Engines That CAN…!”
Freedom Motors’ BASIC ROTAPOWER® and COMPOUND ROTAPOWER® Engines
have overcome the limitations associated with earlier rotary engines, and these
advancements now make both types of ROTAPOWER® Engines ideal for everything
from lawnmowers to outboard motors, motor scooters to portable generators, as well as
PHEVs.

Specifically ––

1. Tremendous reductions of emissions are provided by all ROTAPOWER® Engines


when compared with 4-cycle and 2-cycle piston engines. In laboratory testing and
analysis, BASIC ROTAPOWER® Engines remarkably produce less than 1% of
the untreated CO emissions, and less than 1% of the untreated HC emissions, of
a standard 4-stroke gasoline piston engine!5

In fact, ROTAPOWER® Engines are the only internal combustion engines with
untreated emissions lower than California's ULEV (Ultra-Low Emissions
Vehicle) standards for all three - CO, HC, and NOx!

TABLE 1: Comparing the Untreated Emissions of BASIC


ROTAPOWER® Engines with other internal combustion engines.
UNTREATED
EMISSIONS CO* HC* NOx*
Calif. ULEV Standards 6.8 0.16 0.8
2-Stroke Gasoline 231.0 116.0 1.2
4-Stroke Gasoline 339.0 15.0 7.5
4-Stroke LPG 28.0 1.68 12
4-Stroke Diesel 5.0 1.8 6.9
BASIC ROTAPOWER® on gasoline 1.2 0.06 0.65

*gm/hp-hr

References: Data for Gasoline, LPG and CNG from EPA Report No. NR-010b; Diesel Data from EPA
Report No. NR-009. ROTAPOWER® ULEV data in conjunction with Dr. Andrew Burke, the independent
Institute of Transportation Studies, University of California, Davis.

5
Four-stroke gasoline piston data provided by EPA report #NR-010b. BASIC ROTAPOWER® data
confirmed by the Institute of Transportation Studies, University of California, Davis.

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© 2007 The Pollution Solutionssm Group LLC
TABLE 2: Untreated Emissions for BASIC ROTAPOWER® Engines compared (logarithmically)
with other Internal Combustion Engines. (COMPOUND ROTAPOWER® Engines are projected to reduce
fuel consumption and CO2 emissions by up to an additional 40%!)

The Little Engines That CAN


10/1/07
© 2007 The Pollution Solutionssm Group LLC
8:34 AM Page 12 of 40.
References:
Data for Gasoline, LPG and CNG from EPA Report No. NR-010b; Diesel data from EPA Report No. NR-009
Freedom ULEV data in conjunction with Dr. Andrew Burke, ITS, University of California, Davis
Freedom SULEV data from Moller International dyno and emission tests
2. BASIC ROTAPOWER® Engines have just two critical moving parts!
COMPOUND ROTAPOWER® Engines have just three critical moving parts!
This makes them less expensive to manufacture and to service.6

3. BASIC ROTAPOWER® Engines are “charge-cooled” by the incoming fuel/air


mix passing through the rotor, thus BASIC ROTAPOWER® Engines avoid
completely the leakage and energy loss that result in oil-cooled rotors such as the
Mazda engine.7

4. Because of their compactness and light weight – up to 70% lighter than piston
engines of comparable power – all ROTAPOWER® Engines use far less fuel to
propel the weight of the engine itself, a significant savings of fuel and a resulting
reduction of CO2.

FIGURE B: This 27cc Single Rotor BASIC ROTAPOWER® Engine


weighs only 4 pounds (1.8kg), yet generates over 2 horsepower
(1.5kW)!

5. All ROTAPOWER® Engines are effectively “vibration-free,” because there are no


reciprocating parts as in piston engines.

6
According to Outboard Marine Corporation (OMC), which began mass producing an air-cooled
snowmobile rotary engine in the early 1970's, the cost of producing rotary engines in quantity is about 40%
less than 4-cylinder piston engines. Between 1983 and 1989, Moller International, parent company of
Freedom Motors, acquired the entire rotary engine assets of OMC.
7
Paul Moller, “The Operation and Performance of the Charge Cooled ROTAPOWER® Rotary Engine vs.
Oil Cooled Rotor Rotary Engines”, Freedom Motors paper #9912, 1999.

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© 2007 The Pollution Solutionssm Group LLC
6. All ROTAPOWER® Engines can operate successfully using a wide variety of
Flex Fuels –– gasoline, E85, pure ethanol, many biofuels, LPG, natural gas, and
even hydrogen (when that becomes economically available). COMPOUND
ROTAPOWER® Engines can also operate on diesel and biodiesel.

7. All ROTAPOWER® Engines are widely scalable, ranging from a


displacement as small as 27cc that fits in the palm of your hand, to as large
as 2700cc that generates 270 horsepower. (See Table 4)

8. BASIC ROTAPOWER® Engines have the fuel efficiency roughly equivalent to a


4-stroke piston engine, with the simplicity and cost of a 2-stroke piston engine.

9. Remarkably, the next generation ROTAPOWER® Engines, COMPOUND


ROTAPOWER® Engines, explained in detail in Section 5 of this booklet, are
expected to reduce fuel consumption by as much as 40% compared to a gasoline
piston engine of similar horsepower. 8 In other words, compared to a piston
engine of the same power, as much as 4 gallons of fuel out every 10 gallons could
be saved! Not only could this remarkably reduce our dependence on petroleum
but, for EACH 4 gallons of fuel saved, up to 80 lbs less CO2 would be released
into the atmosphere! (see the paragraph regarding the calculation of CO2 from
burned gasoline on page 23).

FIGURE C: This
530cc BASIC
ROTAPOWER® Engine,
weighs only 60 pounds
and generates
50 horsepower (37kW).

8
Edward Willis & John McFadden, “NASA’s Rotary Engine Technology Enablement Program-1983
through 1991”, 1992. This NASA study evaluated the potential of the rotary engine to achieve lower
specific fuel consumption. They successfully demonstrated that, with turbo-charging, the rotary engine was
able to achieve a specific fuel consumption of .375 LB/HP HR or a thermal efficiency of 37%. This is equal
or better than the best turbo-charged piston engine using gasoline. Because the energy in an engine’s
exhaust exceeds that necessary to drive a turbo-charger, considerable energy is normally lost. NASA goes
on to show that extracting a larger portion of this energy would lead to a thermal efficiency between 43.5%
and 46.5 % compared to the standard gasoline engine at 32%, or similar to the turbo-charged diesel engine
(the gold standard as the most energy efficient internal combustion engine).

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© 2007 The Pollution Solutionssm Group LLC
TABLE 3: ROTAPOWER® Engines combine the best
characteristics of 2-stroke and 4-stroke gasoline piston engines
and diesel engines.

INTERNAL COMBUSTION ENGINES COMPARED

2-Stroke 4-Stroke Diesel BASIC COMPOUND


Piston* Piston* Piston ROTAPOWER®* ROTAPOWER®*

EMISSIONS
(no catalyst)
CO High Moderate LOW LOW LOW
HC High Moderate Moderate LOW LOW
NOx Moderate Moderate High LOW LOW
FREE OF PARTICULATES YES YES No YES YES
LIGHTER WEIGHT YES No No YES YES
SIMPLE DESIGN YES No No YES YES
EASIER MAINTENANCE YES No No YES YES
FREE OF VIBRATION No No No YES YES
COST LOW Moderate High LOW LOW
POWER/WEIGHT HIGH Moderate Low HIGH HIGH
FUEL EFFICIENCY Poor Moderate GOOD Moderate GOOD
EASE OF STARTING GOOD GOOD Moderate GOOD GOOD
FLEX-FUEL ABLE Low MODERATE Low** MODERATE HIGH***
RPM CAPABILITY HIGH Moderate Low HIGH HIGH
CRITICAL MOVING PARTS 3 14 15 2 3

* gasoline
** diesel or biodiesel only
*** COMPOUND ROTAPOWER® Engines can also run on diesel and biodiesel

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© 2007 The Pollution Solutionssm Group LLC
Here are more excerpts from Dr. Andrew Burke of the independent Institute of
Transportation Studies9 regarding BASIC ROTAPOWER® Engines from Freedom
Motors / Moller International –

BASIC ROTAPOWER® ENGINES

• “Paul Moller and Moller [International] have been leaders


in the development of the modern rotary engine since
1985”

• “The Moller [Rotapower®] engines are superior to the


Mazda engines in several respects: rotor cooling,
lubrication, [reduced] engine friction, and rotor surface
coating”

• “The efficiency of the Moller [Rotapower®] engines is the


same as conventional engines at most torque and
RPM conditions”

• “Emission tests of Moller [Rotapower®] engines have


shown the capability to meet California ULEV
standards in vehicles without exhaust after-treatment”

ITS-UCD
Institute of Transportation Studies, University of California, Davis

9
Burke, op. cit.

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© 2007 The Pollution Solutionssm Group LLC
3. THE NON-AUTOMOTIVE MARKET FOR BASIC ROTAPOWER®
ENGINES
One of the most valuable and remarkable features of all ROTAPOWER® Engines are
their scalability. ROTAPOWER® Engines have already been developed as small as 27cc
that weigh only 4lbs (1.8kg) and produce 2 hp (about 1.5kW), to as large as 2700cc that
can produce up to 270 hp (about 201kW). The following table shows specifically how
various sizes of BASIC ROTAPOWER® Engines can be matched to a wide array of
applications.

TABLE 4
Applications and Horsepower
®
Range of the
BASIC ROTAPOWER Engine
Maximum Commercial
Horsepower Displacement Configuration Applications
2.5 hp 27cc* single Lawnmowers, leaf
blowers, hand-held
4 hp 40cc single power tools, trimmers
7.5 hp 75cc single Tuk-tuks, portable
generators. Recreational
15 hp 150cc* single uses like motor scooters,
powered surf boards, etc.
20 hp 200cc single
30 hp 300cc 2-rotors Motorcycles, all terrain
vehicles, recreational
45 hp 450cc* single aircraft, jet skis, and
90 hp 900cc* 2-rotors small jet boats. Any high
performance use where
135 hp 1350cc* 3-rotors light weight and small
size is important.
180 hp 1800cc* 4-rotors
270 hp 2700cc* 6-rotors
65 hp 650cc* single
130 hp 1300cc* 2-rotors
*Sizes already being developed by Freedom Motors
Color represents models generated from same basic configuration to minimize tooling
changes.

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© 2007 The Pollution Solutionssm Group LLC
FIGURE D: Various Applications using BASIC ROTAPOWER® Engines
already developed by Freedom Motors

Commercial Engine
(27cc)
Aircraft Engine (1060cc)
Industrial Engine (650cc)

Mini Jet Boat (1060cc)

Jet ski (1300cc)

Unmanned Aerial Vehicle (530cc)


All Terrain Vehicle - ATV (530cc)

Series Hybrid Electric


Vehicle (530cc)

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© 2007 The Pollution Solutionssm Group LLC
According to a recent study,10 the worldwide market for non-automotive engines like the
BASIC ROTAPOWER® is almost 90 million engines per year – with total sales equal to
$25 billion U.S. (see TABLE 5, below). This includes over 25 million motor scooters,
small motorcycles, and utility vehicles produced each year in India, China, and the
ASEAN (Association of Southeast Asian Nations) countries. The snapshot of massed
Tuk-tuks below is but a miniscule tip of a vast 2-cycle-engine iceberg.

FIGURE E: Tuk-tuks in Bangkok, Thailand.


Photo by Heinrich Damm, June 2005. Used by permission from Wikipedia Commons.

TABLE 5:
2004 Worldwide Non-Automotive Engine Production11
1-20 HP 20-300 HP TOTAL

Africa 13,156 5,228 18,384


Australasia 433,819 135 433,954
Central Asia 31,004,689 1,367,719 32,372,408
Central/South America 596,582 46,614 643,196
Eastern Europe 366,531 272,955 639,486
Far East 12,525,987 3,863,429 16,389,416
Middle East 34,987 611 35,598
North America 21,242,620 1,495,553 22,738,173
Southeast Asia 3,734,527 145,934 3,880,461
Western Europe 11,136,778 1,435,128 12,571,906
TOTAL 81,089,676 8,633,306 89,722,982

10
Power Systems Research, op.cit.
11
Market analysis by Power Systems Research, Brussels, Belgium, August 2005.

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© 2007 The Pollution Solutionssm Group LLC
Tragically, 2-stroke piston engines are noted for their very high emissions of unburned
hydrocarbon and carbon monoxide, and thus are sources of devastating air pollution in
countless areas around the globe. Many governments are now demanding cleaner
engines.

EPA Report No. NR-010b. states that 2-stroke piston engines produce 34 times higher
emissions of CO, and an astounding 725 times higher emissions of hydrocarbons,
than California’s ULEV standards.

Consequently, various U.S. and international entities have been legislating the
replacement of the ubiquitous 2-stroke piston engines with 4-stroke piston engines to
reduce emissions. However, 4-stroke pistons engines have over 10 times the moving
parts of 2-strokes and are therefore more expensive to build, to own, and to maintain than
2-stroke engines or BASIC ROTAPOWER® Engines. A 4-stroke piston engine is also
heavier and larger, and would likely require the re-design of many existing applications.

Within the United States, highly polluting 2-stroke piston engines are still in wide use in
lawnmowers, chainsaws, trimmers, as well as in some outboard motors, snowmobiles, jet
skis, scooters, karts, mopeds, and some motor scooters and small motorcycles, spewing
pollution wherever they operate.

FIGURE F: A Typical 2-Stroke Piston Outboard Motor


and 2-Stroke Piston Chain Saw

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© 2007 The Pollution Solutionssm Group LLC
According to the United States Environmental Protection Agency, “some forms of water
recreational activities contribute to nonpoint source pollution or “pollution runoff”…. the
old 2-cycle (2-stroke piston) motors have been said to cause more pollution in two
hours than a car running for an entire year.”12

Because fuel leaks through the exhaust port each time a new charge of air/fuel is loaded
into the combustion chamber of a 2-stroke piston engine, fuel and oil pollution is a
problem at many National Parks and outdoor recreation areas that allow four-wheelers,
snowmobiles, dirt bikes, and small watercraft.13 According to the Sierra Club, “The
small, inefficient two-stroke engines of some of these machines spew out as much as 30
percent of their fuel unburned – polluting the soils, air, and water of our National Forests,
National Parks, and other public lands. For example, one jet-ski driven for one 8 hour
period emits the same amount of pollution as a car driven for 100,000 miles.”14

These shameless sources of pollution can be effectively mitigated by wide adoption of


ROTAPOWER® Engines.

The solution to the worldwide emissions problem in


non-automotive applications are simple, small, inexpensive
4-stroke BASIC ROTAPOWER® Engines, which have been
shown in both independent and observed tests to reduce
emissions by up to 99% without the use of a catalytic
converter! Imagine the reduction of pollution worldwide if
we could replace ALL 2-stroke piston engines with
BASIC ROTAPOWER® Engines!

Furthermore, BASIC ROTAPOWER® Engines’ multi-fuel burning capability is essential


in many locations and applications in the world market – BASIC ROTAPOWER®
Engines run well on gasoline, E85, ethanol, natural gas, propane, LPG, and other fuels.
In some applications, BASIC ROTAPOWER® Engines’ ability to use methane gas from
processed cow manure will be an additional factor in their favor.

There is also a continuous worldwide need for low-cost and low emission engines for
numerous other applications, such as pumps and generators. The Figures on the
following page compare the size, weight, and volume of a 10kW “ROTAPAC” with a
13.5kW commercial generator.

12
“Nonpoint Source Pollution (Polluted Runoff)”, U.S. Environmental Protection Agency website
< http://www.epa.gov/region02/water/npspage.htm>.
13
<http://science.howstuffworks.com/two-stroke6.htm>
14
“Shattered Solitude: Off-Road Vehicles on our Public Lands,” Sierra Club website
< http://www.sierraclub.org/wildlands/orv/factsheet.asp>

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© 2007 The Pollution Solutionssm Group LLC
FIGURE G: Engine/Generator comparison

Dr. Moller holds


Freedom Motors’
“ROTAPAC”
engine/generator that
produces 10kW and
weighs 40lbs (18.1kg.)

In front of him: a
Gillette “portable”
generator
that produces 13.5kW
and weighs 350lbs
(158.8kg).

The “ROTAPAC” – a 150cc


BASIC ROTAPOWER® Engine
with generator, carburetor and
magneto weighs just 40lbs and
produces 10kW. Adding the fuel
tank, cooling system and exhaust
system brings the total package
to just 60lbs (27.2kg).
The “ROTAPAC” can be scaled
to many other sizes.
Scale at bottom of frame
measures 1ft (30.5cm).

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© 2007 The Pollution Solutionssm Group LLC
4. BASIC ROTAPOWER® ENGINES IN HEVs (HYBRID ELECTRIC
VEHICLES)
Freedom Motors in cooperation with Moller International has built and tested a Hybrid
Electric Vehicle (HEV) using only a single-rotor 530cc BASIC ROTAPOWER®
Engine that delivers 50hp (about 37kW) to run its 25kW generator. This generator
supplies power to the vehicle’s batteries and to its 200hp (150kW) electric motor that
powers the car’s wheels. Acceleration from 0 to 60mph is less than 6 seconds.

FIGURE I: Freedom Motors’


HEV, propelled by a 200hp
(150kW) electric motor that is
powered by batteries recharged
by a BASIC ROTAPOWER®
Engine.

Dr. Andrew Burke, of the Institute of Transportation Studies at the University of


California at Davis states:
The fuel economies of hybrid-electric vehicles with standard gasoline
engines in city traffic are about 45%-50% better than those of comparable
conventional engine-powered vehicles. Larger fuel economy improvements
are projected using the rotary and lean-burn ultra-clean hybrid-electric
vehicles of various types….(my emphasis)15

5. WHAT ARE “COMPOUND” ROTAPOWER® ENGINES?


Most of our discussion so far has concentrated on Freedom Motors’ BASIC
ROTAPOWER® Engines which have, as we have demonstrated, vast applicability and
potential in commercial applications worldwide. But despite their brilliantly simple
design and amazingly low emissions, BASIC ROTAPOWER® Engines do not provide
better fuel efficiencies than 4-stroke piston engines.

In BASIC ROTAPOWER® Engines, two or more rotors on the same axis can be used to
produce more power, smoother instantaneous torque (vibration), and reduce exhaust
noise. When BASIC ROTAPOWER® Engines employ more than one rotor they are
referred to as “parallel-rotor” engines because the rotors are working in parallel – that is,
each rotor is producing its own complete 4-cycle combustion process.

Now, in a major technological leap forward –

15
Andrew F. Burke, Ph.D., “Performance and fuel economy characteristics of hybrid-electric vehicles
appropriate for China”, Davis, California, 2007.

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© 2007 The Pollution Solutionssm Group LLC
Freedom Motors is also developing high performance
rotary engines for Hybrid Electric Vehicles,
for Plug-In Hybrid Electric Vehicles, and
for many important industrial applications
where low emissions and high fuel economy are major objectives.
These are called COMPOUND ROTAPOWER® Engines.

COMPOUND ROTAPOWER® Engines will generate the same power and low torsional
vibration of two rotors on the same shaft, but with each rotor performing complementary
consecutive functions – that is, the two rotors work in series rather than in parallel.

Freedom Motors’ method of “compounding” sets it apart from any other. Specifically, in
Freedom Motors’ COMPOUND ROTAPOWER® Engines the first rotor supercharges
the air and fuel before sending it to the second/combustion rotor. In the second rotor, the
charge is further compressed prior to combustion. The combusted gases, expanding in
the second rotor, provide output power before exiting under significant pressure into the
first rotor, where additional expansion extracts additional energy. The exhaust then exits
the first rotor with little pressure or noise.16

Remarkably, Freedom Motors’ COMPOUND ROTAPOWER® Engines, with two rotors


running in series, are expected to produce the same power as two single rotors running in
parallel with an estimated increase in thermal efficiency of up to 45% and therefore an
additional reduction of CO2 emissions by up to 40%! 17

This increase in thermal efficiency means that less fuel is needed for the same power; and
reduced fuel translates directly to less carbon dioxide (CO2) being released into the
atmosphere. During the natural combustion process of fossil fuels, each carbon atom
combines with two oxygen atoms in the air to create one CO2 molecule. Because carbon
has an atomic weight of 12 and each oxygen atom has an atomic weight of 16, the
combined weight of the CO2 molecule is 44 (12+16+16). Thus the weight of the CO2
molecule is 44/12 times the weight of the carbon atom alone. Since gasoline is about
87% carbon, burning one gallon of gasoline (that weighs about 6.3 lbs) produces over
20 lbs of CO2!! (6.3 lbs x 87% x 44/12 = 20.1 lbs).

First-and-second generation versions of COMPOUND ROTAPOWER® Engines have


run successfully in dynamometer tests.

16
Rolls Royce had experimented with a compound rotary engine in 1972 that weighed about 950 pounds
in which the compressor rotor sat atop the combustion rotor, and the two were linked by gears.
COMPOUND ROTAPOWER® Engines use a similar principal but greatly reduce the complexity of the RR design
by finding a patent-pending way to link the drive shafts of both rotors together on the same axis.
17
Willis & McFadden, op.cit.

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As compared with BASIC ROTAPOWER® Engines, the very promising preliminary
results for the COMPOUND ROTAPOWER® Engine are as follows:
• Exhaust noise reduced by 93% (20dbA)
• Exhaust temperature reduced by 50% (800º F)
(lower exhaust temps produce less NOx)
• Specific fuel consumption reduced (not yet optimized)
• Emissions expected to meet ULEV and SULEV standards.

Improvements have been identified for 3rd generation COMPOUND ROTAPOWER®


Engines and are addressed in Freedom Motors’ pending patent.

It is important to compare the power output characteristics of COMPOUND


ROTAPOWER® Engines with turbo-charged diesels. COMPOUND ROTAPOWER®
Engines are expected to achieve essentially the same thermal efficiency as the turbo-
charged diesel at twice the P/Pmax ratio! This means that ROTAPOWER® Engines could
have one half the displacement or size for the same power at the same specific fuel
consumption, as shown in the following table.

TABLE 6: Maximum engine efficiency as a function


of power fraction(P/Pmax)
ENGINE EFFICIENCY (%)
Lean-
burn Turbo-
Standard Gasoline charged COMPOUND
Power BASIC Gasoline Engine Diesel ROTAPOWER®
fraction ROTAPOWER® Engine (Honda Engine Engine
P/Pmax Engine (Saturn) Insight) (Audi) (Projected)*
20% 23.0 28.6 37.7 38.5 31.4
30% 29.0 32.1 37.7 39.7 39.4
40% 31.9 32.7 37.2 39.7 43.4
50% 31.9 32.7 36.3 38.5 43.4
60% 30.7 30.0 35.3 37.0 41.8
70% 29.2 26.7 33.1 35.4 39.7
80% 29.0 26.0 28.5 31.2 39.4
100% 25.7 25.3 27.0 27.8 35.0
Source: Andrew Burke Ph.D., “Performance and fuel economy characteristics of hybrid-electric vehicles
appropriate for China”, Institute for Transportation Studies, UC Davis. *Freedom COMPOUND
ROTAPOWER® projected figures based on NASA study, Willis & McFadden, op.cit.

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© 2007 The Pollution Solutionssm Group LLC
Freedom Motors / Moller International has a family of COMPOUND ROTAPOWER®
Engines on the drawing boards that, paired with appropriate generators, can produce from
2kW to 200kW for a wide array of applications including power tools and highly portable
electrical generator packs (as small as backpack-size
electrical generators!) See Figure H –

FIGURE H: A 27cc COMPOUND ROTAPOWER®


Engine for small applications and tools. This engine is
capable of producing 7 hp (5kW).

TABLE 7
Applications and Horsepower Range of the
COMPOUND ROTAPOWER® Engine
Maximum
Potential Applications
Horsepower Displacement Configuration
7 hp 27cc* 2-rotors Unmanned Aerial Vehicles
(UAV) (long range),
10 hp 40cc 2-rotors portable gen-sets for
military field applications,
20 hp 75cc 2-rotors Series Hybrid automobiles
(PHEV) and other fuel
40 hp 150cc* 2-rotors efficient transportation
55 hp 200cc 2-rotors options.

80 hp 300cc 4-rotors Parallel Hybrid automobiles,


Industrial pumps,
120 hp 450cc* 2-rotors compressors, generators,
Aircraft. Diesel engines for
240 hp 900cc 2-rotors industrial, agricultural and
marine use.
175 hp 650cc* 2-rotors
345 hp 1300cc 4-rotors
*Sizes already being developed by Freedom Motors
Color represents models generated from same basic configuration to minimize tooling
changes.

In the transportation sector, the many sizes of COMPOUND ROTAPOWER® Engines


are applicable for motorcycles, very small personal vehicles such as Smart Cars, as well
as PHEV-powered automobiles, delivery vans and passenger vans:

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© 2007 The Pollution Solutionssm Group LLC
6. COMPOUND ROTAPOWER® ENGINES FOR HEVs AND PHEVs
Hybrid Electric Vehicles (HEVs) as becoming increasingly widespread. The next
development in hybrid-electric vehicles is to add the capability of recharging their
batteries from grid electricity (or solar electricity) rather than only from an auto’s engine.
These are known as Plug-In Hybrid Electric Vehicles (PHEVS) and are the principal
focus of such groups as CalCars, EVWorld, the Electric Power Research Institute, and
the US Department of Energy’s FreedomCAR program.
This new HEV and PHEV technology requires an engine with precisely the attributes of
Freedom Motors’ COMPOUND ROTAPOWER® Engine, that can:
1. occupy up to 70% less space than a piston engine, allowing more room for
batteries – essential in PHEV design,
2. weigh much less than piston engines of comparable horsepower, requiring less
fuel to propel the vehicle,
3. be easier and cost less to manufacture, aiding in price-competitiveness,
4. be able to meet California’s ULEV emission standards, and
5. compete with a turbo-charged diesel engine in fuel efficiency.

COMPOUND ROTAPOWER® Engines are expected to be competitive in every


dimension of measured performance – emissions, smoothness, power, compactness, and
weight. HEVs and PHEVs are certain to play an increasing role in the automobile
industry in the near future as well as the longer run, and COMPOUND ROTAPOWER®
Engines are clearly the most advantageous choice for all HEVs and PHEVs. According
to J.D.Powers and Associates the market for hybrid cars is projected to total 350,000
units annually by 2008, with sales accelerating exponentially in the future. For example,
Toyota’s North American Sales Chief Jim Lentz says that Toyota expects to sell 1 million
hybrid vehicles per year by early next decade.18

Figure J: A 150cc COMPOUND


ROTAPOWER® Engine, designed for
a Series PHEV, will weigh less than
40lbs (18kg), and will produce over
40 horsepower (30kW). Note its
extraordinarily compact size for an
internal combustion engine of this
power.

18
Reuters, New York, Sept. 10, 2007

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Below, compare the displacement, weight, and volume of a proposed VW turbo-charged
®.
diesel Hybrid Engine with the proposed COMPOUND ROTAPOWER Engine.
Both have approximately the same horsepower and are designed for Parallel Hybrids like
the Toyota Prius, but the COMPOUND ROTAPOWER®. Engine has 25% of the volume,
47% of the weight, 60% of the estimated cost of the VW engine, and is projected to
consume 9% less fuel than VW’s turbo-charged diesel!

FIGURE K:
Proposed Engines for Parallel Drive Hybrid Vehicles

VW Hybrid Engine
-Displacement = 1 Liter
-Turbo-charged
-Weight ~ 260 lbs.
-Volume ~ 8 ft3
-Power ~ 112 hp / 83 kW

ROTAPOWER® Engine
-Displacement = 0.9 Liter
(equivalent)
-Compounded
-Weight ~ 122 lbs.
-Volume ~ 2 ft3
-Power ~ 125 hp / 93 kW

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Table 8 is reprinted from a recent study that indicates that worldwide demand for
automobile engines exceeded 61 million units in 2004. Note that the U.S. market is
concentrated in the higher horsepower ranges, This no doubt expresses the U.S. auto
owner’s demand for responsive acceleration, and their reluctance to sacrifice that in return for
increased fuel mileage. The U.S. auto market can now have both – acceleration and fuel
economy – in a PHEV full-hybrid 19 car with a COMPOUND ROTAPOWER® Engine!

TABLE 8: WORLDWIDE AUTOMOTIVE ENGINE PRODUCTION, 2004 20


20-50 HP 50-100 HP 100-200 HP 200-300 HP TOTAL
Africa 0 139,220 3,578 0 142,798
Australasia 0 20,585 293,704 180,211 494,500
Central Asia 1,154,900 3,050,036 1,457,568 130,223 5,792,727
Central/So. America 286,148 1,894,527 642,886 79,374 2,902,935
Eastern Europe 163,315 2,102,794 2,181,706 152,209 4,600,024
Far East 1,133,267 5,810,236 8,607,264 1,760,343 17,305,110
Middle East 0 68,426 25,253 0 93,679
North America 0 19,831 6,883,304 6,317,358 13,220,493
Southeast Asia 0 495,383 455,720 253 951,356
Western Europe 440,020 8,820,255 5,594,662 1,295,916 16,150,853

TOTAL 3,177,650 22,241,293 26,139,645 9,915,887 61,654,475

As worldwide demand for automobiles continues to increase, so does the urgency to fill
as much of this demand as possible with low-emissions vehicles of all kinds. Imagine the
astounding worldwide reduction in polluting emissions even if only 10% of these 61
million new automobiles each year were PHEVs powered by electricity from the grid,
supplemented by ultra-low-emissions COMPOUND ROTAPOWER® engines!

7. ARE COMPOUND ROTAPOWER® ENGINES SUITABLE FOR


ALL HEV AND PHEV MANUFACTURERS?
Yes. COMPOUND ROTAPOWER® Engines are the optimal choice and can be easily
adopted as the power-source-of-choice in all makes, models and sizes of HEVs and

19
As compared to a “A mild hybrid design uses the electric motor to contribute to propulsion, as well as
running the electronic systems, supporting stop-start, and other fuel-saving measures, but not as a sole
source of motive power.” Green Car Congress “A Short Field Guide to Hybrids”, August 5, 2004.
< http://www.greencarcongress.com/2004/08/a_short_field_g.html>
20
Market analysis by Power Systems Research, Brussels, Belgium, August 2005.

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© 2007 The Pollution Solutionssm Group LLC
PHEVs – whether currently being tested or still on the drawing boards, whether series or
parallel.

Virtually all automobile manufacturers have committed themselves to developing HEVs


and PHEVs. General Motors is working on the Volt; Saturn is proposing the PHEV Vue
for 2009; Toyota is working on the Prius II as a PHEV; Ford has announced a program to
convert and demonstrate some of its 2008 Escape SUVs to be fully “PHEV capable”;
Honda is working on its PHEV Insight; DaimlerChrysler is testing its Sprinter PHEV (a
commercial van) in Germany; Dodge has delivered its PHEV Sprinter delivery van for
use by the New York Times, etc.

Based on current technology, Freedom Motors calculates that the ideal configuration for
a “standard-sized” Series PHEV automobile is a 150cc COMPOUND ROTAPOWER®
Engine running a generator that produces over 25kW of power. This same combination
can also be used as a stand-alone generator known as a “ROTAPAC.”

FIGURE L: Freedom Motors’ “ROTAPAC”


consists of a 150cc COMPOUND ROTAPOWER®
Engine & 25kW Generator, and can function as a
drop-in component for a Series PHEV or stand-
alone electric generator. This “ROTAPAC”
includes cooling, fuel, oil, and muffler.

FIGURE M: Compare
the Dimensions, Volume,
and Weight of the
“ROTAPAC” with
another generator
design of equal power
output.
(Which would you rather
have to move?)

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© 2007 The Pollution Solutionssm Group LLC
The following Figures demonstrate the tremendous economic advantage that
COMPOUND ROTAPOWER® Engines provide over piston engines regarding
manufacturing costs and maintenance costs. COMPOUND ROTAPOWER® Engines
contain just 3 critical moving parts, compared to the 32 critical moving parts of any
4-cylinder gasoline piston engine.

FIGURE N: 4-Stroke Engine Complexity Compared


FREEDOM MOTORS’ COMPOUND ROTAPOWER® ENGINE
3 Critical Moving Parts - Total Parts 163

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© 2007 The Pollution Solutionssm Group LLC
STANDARD 4-CYLINDER PISTON ENGINE
32 Critical Moving Parts - Total Parts 282

8. WHY SHOULD HEV AND PHEV MANUFACTURERS CONSIDER


A NEW ENGINE WHEN THEIR BIGGEST IMMEDIATE PROBLEM
IS BATTERIES?
This is certainly a pertinent and timely question. So far, all researchers and
manufacturers interested in HEVs and PHEVs appear to be focusing their tremendous
creative energies on (1) improving reciprocating internal combustion engines (ICEs,) and
(2) developing new battery technologies, because they have found that currently existing
battery technology is inadequate for future HEVs and PHEVs.21 Other researchers are

21
“Toyota Motor Corp., which used the green image of its gasoline-electric Toyota Prius to propel a U.S.
sales surge, has decided to delay by one to two years the launches on new high-mileage hybrids with
lithium-ion battery technology because of potential safety problems.” Norihiko Shirouze, “Toyota Delays
Next Hybrids on Safety Concerns,” The Wall Street Journal Online, August 9, 2007.

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© 2007 The Pollution Solutionssm Group LLC
looking forward to the day when fuel cells and hydrogen become practicable, but most
expect that economically viable hydrogen is at least a decade in the future.22

The United States D.O.E. emphasizes that PHEVs are a near-term top priority for
transportation in the U.S. Obviously, research aimed at developing new energy storage
systems must be given immediate attention in order to make PHEVs (and electric cars)
practicable.

Ironically, manufacturers and researchers currently committed to developing 21st century


PHEVs are giving most of their attention to a “vintage” 19th and 20th century engine
technology – piston engines – as the internal combustion power source in these vehicles.
Designers, manufacturers, and researchers are trying to address the inherent shortcomings
of piston engines by simply making compromises – making them smaller; reducing the
number of cylinders to three,23 increasing their complexity, looking for ways to control
Homogenous Charge Compression Ignition, etc.

Manufacturers seeking to fully optimize their PHEVs must certainly be drawn to


COMPOUND ROTAPOWER® Engines for the many reasons already enumerated.

Demand for HEVs is increasing rapidly. New battery technology is also


advancing rapidly and will soon enable production of the next wave in
automobile design: Plug-In Hybrid Electric Vehicles.
The “economic advantage” as well as the “emissions and fuel-efficiency
advantage” for HEVs and PHEVs will be awarded to those companies that
adopt emerging technology engine technology, as well!
And that emerging technology is
COMPOUND ROTAPOWER® Engines!

VALENCE
+ = $uccess!
TECHNOLOGY

22
John Heywood & Anup Bandivadekar, Chart: ”Time Scales for Significant U.S. Fleet Impact” in
Powerpower Presentation “Assessment of Future ICE and Fuel-Cell powered Vehicles and Their Potential
Impacts. DEER Conference, San Diego, CA, 2004. Available on the D.O.E. Website:
<http://www1.eere.energy.gov/vehiclesandfuels/pdfs/deer_2004/plenary/2004_deer_heywood.pdf>
23
which will generate high radial and torsional vibration levels – not a good thing!

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© 2007 The Pollution Solutionssm Group LLC
FAQs

1. Will adoption of ROTAPOWER® Engines require extensive retooling


by auto mechanics and automotive repair shops?

No. Rotary engines are still internal combustion engines and operate on the same
basic principal as piston engines. Yet rotary engines are far simpler to produce
and to maintain. Most maintenance on rotary engines can be accomplished with
standard mechanic’s tools, and the few special tools needed are already available
for Mazda maintenance.

2. What limitations of the Mazda rotary engine have been overcome in


Freedom Motors’ COMPOUND ROTAPOWER® Engines?

Patented COMPOUND ROTAPOWER® Engines can:

• Very significantly reduce specific fuel consumption;

• Extend seal life from 2,000 hours to over 10,000 hours; and

• Eliminate the complex mechanical arrangement of cooling the rotor with


oil. This results in much lower emissions, higher thermal efficiency
and the elimination of the very complex rotor side seal;

• Make possible portable applications that would otherwise be infeasible.

And according to Andrew F. Burke, of the Research Faculty at the independent Institute
of Transportation Studies at the University of California at Davis:

The Moller rotary engines are superior to the Mazda engines in


several respects: rotor cooling, lubrication, (reduced) engine friction,
and rotor surface coating.24

24
Andrew F. Burke, Ph.D., Powerpoint Presentation,”Hybrid Vehicles with Batteries and Ultracapacitors
in China.”

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© 2007 The Pollution Solutionssm Group LLC
3. Will fuel cells compete with and/or replace COMPOUND
ROTAPOWER® Engines?

Fuel cells are a very promising technology that is essentially in the “early
research” stage. Most sources believe that cost-effective fuel cell technology is at
least 10 years in the future. PHEVs will be needed and likely fully developed
much sooner. Since ROTAPOWER® Engines can run on hydrogen, they will be
able to make the transition to hydrogen fuel at any time.

4. What research in developing ROTAPOWER® Engines has already


been accomplished? At what point are BASICROTAPOWER® and
COMPOUND ROTAPOWER® Engines in research and
development?

Moller International and Freedom Motors have successfully completed research


contracts with NASA, General Electric, Infinite Machines Corp, and the United
States, Army and Air Force to create, test, and demonstrate low-cost, high-
powered rotary engines that produce very little emissions and operate on many
different fuels in numerous applications.

Each of these research contracts has confirmed that ROTAPOWER® Engines


hold tremendous promise as a general-purpose power source, with remarkably
reduced emissions compared to other internal combustion engines of comparable
power.

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© 2007 The Pollution Solutionssm Group LLC
CONCLUSION

Freedom Motors’ ROTAPOWER® Engines have the potential for broad


applicability worldwide because of their ultra low emissions, low production
cost, simple maintenance, and high power output for their weight.

Freedom Motors’ COMPOUND ROTAPOWER® Engines –

(1) are a “leap frog” technology that will “provide Americans


with greater freedom of mobility and energy security,
while lowering costs and reducing impacts on the
environment.”

(2) are ideal for all manufacturers engaged in the exciting


competition to create practical and marketable Hybrid
and Plug-In Hybrid Electric Vehicles.

Further tests are now needed to bring BASIC ROTAPOWER® Engines into
the volume production phase, and further development is needed to bring
COMPOUND ROTAPOWER® Engines into the beta test phase.

Manufacturing, distribution, and new product creation utilizing BASIC


ROTAPOWER® and COMPOUND ROTAPOWER® Engines provide
a very promising financial opportunity.

ROTAPOWER® Engines
“The Little Engines
That CAN…!”
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© 2007 The Pollution Solutionssm Group LLC
APPENDIX A

History of ROTAPOWER® Rotary Engines

Historically, approximately 1,500 patents have been issued, and $3 billion U.S. spent, in
the development of the rotary engine originally imagined by Dr. Felix Wankel. Freedom
Motors' ROTAPOWER® Engines are a highly evolved version of that original rotary
engine, and Freedom Motors’ patents protect its own remarkable technological advances.

Dr. Wankel's engine garnered great enthusiasm for its attributes when it was first
demonstrated in the 1950s. In the 1960's, over 30 companies began developing rotary
engines for their products, which included outboard motors, motorcycles, chain saws,
airplanes and most importantly, automobiles. Virtually every automobile company began
a program. During this same period Moller's predecessor company, M Research, began
researching the potential of the rotary engine. Unfortunately, there was major interruption
in fuel supplies in the mid 1970's, concurrent with government-mandated improvements
in emissions. Retooling for a new engine that was at that time not particularly fuel
efficient while addressing emissions became too risky for the auto industry. In addition,
Mazda Motors, which was the first company to volume-produce rotary-engine-powered
automobiles (RX-2), had a side seal problem that allowed the rotor-cooling oil to enter
the combustion chamber. This required Mazda to recall tens of thousands of their
automobiles for what was in effect a major overhaul. Mazda forged ahead and by 2006
their RX-8 model won the Sport Car of the Year Award. However rotary engines were
never the ideal candidate as the prime mover for automobiles because they operate best
over a narrow RPM band.

The only other company to successfully mass produce rotary engines was Outboard
Marine Corporation (OMC), which began manufacturing an air-cooled snowmobile
rotary engine in the early 1970's. At that time, OMC was the world's leading producer of
outboard motors, and anticipated changing their marine line to use rotary engines as well.
This was motivated by their concern that 2-stroke piston engines that powered all their
products would fail proposed emissions standards. According to their division manager,
OMC developed production-ready models for their marine line at a cost of over $200
million in 1970 dollars. This program established that the rotary engine could be built for
a cost virtually identical to their inexpensive 2-stroke piston engines. When the
administration in Washington changed in 1980, emissions ceased to be a high priority and
OMC dropped their production plans. Between 1983 and 1989, Moller acquired the
entire rotary engine assets of OMC.

In 1997, Moller International also acquired the assets of Infinite Engines, a NASDAQ
listed company which with Moller's help had developed a rotary engine for the marine
and snowmobile markets. By this time, Moller and its predecessor companies
(M Research and Moller Corp) had developed a number of patented improvements to
the rotary engine. With the acquisition of the engine technology from OMC and
Infinite Engines, Moller International incorporated these patented improvements into its
own proven engine designs.

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In addition, Moller International purchased the rotary engine production machine tools
developed for General Motors by Gleason Machine Works. These machines allow the
mass production of the critical components of ROTAPOWER® Engines.

Moller International and Freedom Motors have spent nearly $30 million in engine
development costs to date and have successfully completed numerous research contracts.

APPENDIX B

Freedom Motors

Freedom Motors was founded in 1997 as a wholly owned division of Moller International
(OTC: MLER). In 2001 it became a separate corporation. At that time it acquired the
exclusive rights from Moller International (MI) to manufacture, market and sub-lease its
ROTAPOWER® Engines for worldwide use in all applications except aircraft and ducted
fans.

Freedom Motors has demonstrated that its BASIC ROTAPOWER® Engines can meet
California’s requirements for Ultra Low Emission Vehicles (ULEV) while running on
gasoline, and can meet Super Ultra Low Emission Vehicle levels (SULEV) running on
ethanol. Both of these emissions levels were achieved without a catalytic converter.

Moller International, in contract with Freedom Motors, is also developing and patenting a
unique design that ”compounds” the ROTAPOWER® Engines and gives them the
additional potential to achieve extremely low fuel consumption. COMPOUND
ROTAPOWER® Engines recover the energy normally lost in the exhaust (up to 40%).
These new engines will be incorporated into the “ROTAPAC” (engine+generator), a
system particularly suited as the supplemental power source for Plug-in Hybrid Electric
Vehicles (PHEVs) as well as portable generators. Versions are also being developed to
operate on diesel and aviation fuels.

As part of their license agreement with Moller International, Freedom Motors took
ownership of all of MI's hard engine related assets – tooling, machine tools, production
equipment, engine inventory and ROTAPOWERed® vehicles.

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© 2007 The Pollution Solutionssm Group LLC
APPENDIX C

Paul Moller, Ph.D.

Paul Moller, Chairman of the Board, founded Freedom Motors in 1997 and has served as
the company's President since its formation. He holds a Masters and Ph.D. in
Engineering from McGill University. Dr. Moller was a professor of Mechanical and
Aeronautical Engineering at the University of California, Davis, from 1963 to 1975,
where he developed the Aeronautical Engineering program. Moller invented the
“SuperTrapp Muffler” and in 1972, founded SuperTrapp Industries. As Chief Executive
Officer, he made SuperTrapp the most recognized international name in high-
performance engine silencing systems. SuperTrapp Industries was sold in 1988.

In 1983, he founded Moller International to develop powered lift aircraft. Under his
direction Moller International completed contracts with NASA, NOSC, DARPA, NRL,
Harry Diamond Labs, Hughes Aircraft Company, California Department of Trans-
portation, and the U.S. Army, Navy, and Air Force. These contracts included the
development and deployment of numerous unmanned aerial vehicles and Wankel-based
ROTAPOWER® Engines. In 1998 he received a recognition award from NASA for work
performed under a DARPA contract titled "Tests of Thermal Barrier and Wear Coats in
Rotary Engines".

In 2000 he and Dr. Daniel Goldin, head of NASA, jointly testified before the Aviation
Subcommittee of the US Congress on the "Future of Aviation in America".

Dr. Moller has received 43 patents including the first U.S. patent on a fundamentally new
form of powered lift aircraft, popularly known as the Skycar.25 In fact, Dr. Moller’s
impetus for developing ROTAPOWER® Engines was his need for a lightweight, efficient
engine to power his Skycars, a class of personal vertical-takeoff-and-landing aircraft
(VTOLs) that are capable of traveling on the ground and flying horizontally.

Dr, Moller is also the inventor of a remarkable continuously variable gearless


transmission which, according to Dr. Moller, “can go from 0 output RPM to direct drive.
In the 1-to-1 direct drive case we have no losses and no more than a 2% loss at any other
point in its operation. I am not aware of any other transmission that can do this.” His
continuously variable gearless transmission has been successfully demonstrated in a
small 2hp electric vehicle, in a 25hp motorcycle, and in a 125hp AMC Pacer automobile.

A man of many talents and interests, in 1980 Dr. Moller developed the Davis Research
Park, a 38-acre industrial-research complex within the city of Davis, CA, in which Moller
International is based. He also raises organic almonds and sells organic almond butter on
the internet.

25
See more at <http://www.moller.com/skyc.htm> There are several Skycar models, seating 1-4
passengers, that can travel moderate distances on the ground at up to 40 mph, and in the air at cruising
speeds in excess of 300 mph.

The Little Engines That CAN 10/1/07 8:34 AM Page 39 of 40.


© 2007 The Pollution Solutionssm Group LLC

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