One-Piece Cast Piston Rib Cooling Channel Design
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Solution Overview
Problem
Existing pistons for internal combustion engines face challenges in balancing mechanical strength and thermal management while minimizing weight, with two-part constructions being difficult to manufacture and limiting design freedom.
Innovation Solution
A one-piece, cast piston with a rib formed on the inside opposite to the combustion chamber bowl bottom and a cooling channel extending along the piston axis, allowing for efficient production and enhanced heat dissipation without the need for continuous coolant exchange.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a two-part piston construction is used (one forged, one cast), then mechanical strength can be improved, but manufacturing complexity increases and design freedom is restricted
Solution Approach 1:
The patent merges the forged and cast parts into a single cast piston construction, eliminating the need for separate manufacturing processes and assembly operations. This one-piece design maintains mechanical strength while significantly reducing manufacturing complexity and improving design freedom.
Solution Approach 2:
Within the unified cast structure, the patent introduces functional segmentation through cooling channels and ribs that divide the piston into distinct thermal and structural zones, allowing optimized heat management and mechanical support without requiring multiple physical parts.
2Strength
If a two-part piston construction is used, then mechanical strength can be improved, but production efficiency decreases
Solution Approach 1:
By combining what would have been two separate manufacturing operations (forging and casting) into a single casting process, the patent eliminates the need for intermediate assembly steps, thereby improving production efficiency while maintaining the structural benefits of both forged and cast designs.
3Temperature
If cooling channels are added to the piston, then thermal management is improved, but device complexity increases
Solution Approach 1:
The cooling channels are nested within the solid piston structure, creating a hollow internal pathway system that enables effective heat removal without adding external complexity. The channels are integrated into the piston body during the casting process, maintaining a clean external appearance and simple overall structure.
4Weight of moving object
If the piston is designed to minimize weight, then fuel efficiency is improved, but mechanical strength may be compromised
Solution Approach 1:
The patent applies local quality optimization by strategically placing ribs in high-stress areas to reinforce the piston where needed, while keeping other areas lightweight. This allows the piston to minimize overall weight while maintaining sufficient mechanical strength through localized reinforcement rather than uniform thickening.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The one-piece design improves mechanical strength and thermal management, enabling efficient production and reduced weight with effective heat dissipation, making it suitable for diesel engines.
Implementation Method 1
the at least one rib has an advantageous effect with regard to the dissipation of the heat generated in that the heat-conducting cross section is enlarged, and the temperature can thus be reduced
Implementation Method 2
the at least one rib has an advantageous effect with regard to the dissipation of the heat generated in that the heat-conducting cross section is enlarged
Data Source
Figure 1
AI summary
The invention relates to a one-piece cast piston (10) for an internal combustion engine, comprising a cooling channel (12) and at least one rib (18) on the inner side of the piston with respect to the recess base of a combustion bowl (14).