Composite Cylinder Block Heat-Welding for Uniform Joint Quality
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Solution Overview
Problem
Existing cylinder blocks with metallic and synthetic resinous components suffer from increased weight due to the inclusion of metallic inserts and bolts, which undermines the weight reduction benefits of using synthetic resinous materials.
Innovation Solution
A composite cylinder block design where a metallic main block body and a synthetic resinous outer member are heat-welded together, with all welded surfaces orthogonal to the cylinder axis direction, ensuring uniform welding quality and minimizing the use of metallic inserts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a metallic insert is embedded in the synthetic resinous lateral wall member to provide structural support, then the strength and stability of the composite structure is improved, but the weight of the cylinder block is increased
Solution Approach 1:
The invention removes the metallic insert from the synthetic resinous lateral wall member, extracting the heavy component that was causing weight increase. The structure achieves sufficient strength through the synthetic resinous material itself and the water jacket configuration, eliminating the need for embedded metallic inserts.
Solution Approach 2:
The invention uses a composite structure combining synthetic resinous material with metallic components (cylinder liner and block body) in a way that eliminates the need for heavy metallic inserts within the resinous member. The composite design leverages the lightweight properties of synthetic resins while maintaining structural integrity through proper configuration.
2Reliability
If two metallic bolts are arranged over the entire height of the cylinder block to secure the lateral wall member, then the reliability of the assembly is improved, but the total weight of the cylinder block is increased
Solution Approach 1:
The invention removes the heavy metallic bolts from the assembly, extracting the fastening components that were adding weight. The synthetic resinous lateral wall member is designed to be secured without requiring heavy metallic fasteners, possibly using lighter fastening methods or integrating the attachment function into the resinous structure itself.
3Ease of manufacture
If the welded surfaces are positioned at different locations during heat-welding, then the manufacturing flexibility is improved, but the welding quality becomes non-uniform due to temperature variations
Solution Approach 1:
The invention positions the welded surfaces symmetrically relative to the cylinder axis, creating a configuration where the heating source can uniformly heat both surfaces simultaneously. This symmetric arrangement ensures uniform temperature distribution and consistent welding quality across all welded surfaces.
Solution Approach 2:
The invention designs the welded surfaces to be at the same axial position, creating an equipotential surface for heating. This ensures that all welded surfaces experience the same temperature conditions during the heat-welding process, resulting in uniform welding quality throughout the assembly.
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
Achieves significant weight reduction and uniform welding quality, maintaining structural integrity while reducing manufacturing complexity and costs.
Implementation Method 1
the synthetic resinous outer member and the metallic main block body are heat-welded together with a slight melting of the mating surface of the synthetic resinous outer member
Implementation Method 2
a slight melting of the mating surface of the synthetic resinous outer member
Implementation Method 3
the synthetic resinous outer member and the metallic main block body are heat-welded together
Data Source
AI summary
A composite cylinder block for an internal combustion engine includes a main block body made of a metal material and an outer member made of a synthetic resin material. The main block body has a lower deck, a base part and a cylinder wall. The outer member has an upper deck and a water jacket constituting wall surrounding the cylinder wall to define a water jacket. An outer-member-side mating surface is provided with a welding rib on a lower end of the water jacket constituting wall and is heat-welded to a top surface of the base part by heating the main block body from the lower side and pressing the outer-member-side mating surface against the main block body. The welded surfaces of the main block body and the outer member are in one plane orthogonal to a cylinder axis direction.