Composite Cylinder Head with Bolted Flange for High Pressure
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Solution Overview
Problem
Existing piston engine cylinder heads face challenges in achieving high pressures and temperatures while maintaining lightweight construction, as they require materials that are both mechanically resistant and thermally efficient, but these materials often compromise on weight or assembly complexity.
Innovation Solution
A cylinder head design featuring a sole made of a high-density material with a bolt body of lower density and hardness, assembled using peripheral screws and a central fixing part with a threaded end, which provides increased tightening force to withstand high pressures and temperatures, and incorporates an internal cooling circuit for efficient heat management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the cylinder head is made of heavy materials like steel or cast iron to withstand high pressures and temperatures, then the mechanical strength and temperature resistance are improved, but the weight of the engine increases
Solution Approach 1:
The cylinder head is constructed as a composite structure with a base made of heavy material (steel or cast iron) for strength and a crown made of light material (aluminum alloy or magnesium alloy) for weight reduction. This composite construction allows the engine to achieve both high mechanical strength and reduced weight, resolving the contradiction between these two parameters.
2Weight of moving object
If the cylinder head face opposite the combustion chamber is made of light material to reduce weight, then the engine weight is reduced, but the resistance to high pressures and temperatures deteriorates
Solution Approach 1:
The cylinder head uses a composite structure where the base (facing the combustion chamber) is made of heavy material for pressure and temperature resistance, while the crown is made of light material for weight reduction. This arrangement allows the light material to be used in the weight-critical area while the heavy material provides the necessary thermal and mechanical resistance where needed.
Solution Approach 2:
Different parts of the cylinder head have different material properties optimized for their specific functions: the base near the combustion chamber uses heavy material for high temperature and pressure resistance, while the crown uses light material for weight reduction. This local differentiation of material quality resolves the contradiction between weight reduction and pressure/temperature resistance.
3Strength
If a two-part cylinder head with different materials is assembled using welding to achieve high strength, then the mechanical strength is improved, but the assembly complexity and manufacturing cost increase
Solution Approach 1:
The cylinder head is divided into two separate parts (base and crown) that can be manufactured independently using different materials optimized for their specific requirements. This segmentation allows each part to be produced separately and then assembled, reducing manufacturing complexity while maintaining the strength benefits of different materials.
Solution Approach 2:
A base plate is introduced as an intermediary element between the combustion chamber and the light material crown, providing a stable mounting surface and facilitating the assembly of the two different materials without requiring complex welding operations. This intermediary simplifies the overall assembly process while maintaining structural integrity.
4Ease of operation
If the cylinder head is designed as a single piece to simplify assembly, then the assembly process is simplified, but the ability to replace components and recycle materials is reduced
Solution Approach 1:
The cylinder head is segmented into a base and a crown that can be assembled and disassembled independently. This segmentation maintains assembly simplicity while enabling component replacement and recycling, as each part can be separately manufactured, replaced, or recycled without affecting the other components.
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
This design allows for higher pressures and temperatures (up to 300 bars and 250°C) without increasing weight, simplifies assembly, ensures better geometric conformity, and facilitates easier replacement, while maintaining mechanical strength and thermal efficiency.
Implementation Method 1
incorporates an internal cooling circuit for efficient heat management
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The present invention relates to a cylinder head, an element and a flange of a longitudinally extending piston engine comprising a piston head body (4) and a flange (5) on at least one element (6), the flange (5) being to interpose between a combustion chamber and the piston head body (4), comprising an upper face (7) facing the piston head body (4) and an opposite lower face (8) to be arranged facing the combustion chamber and being attached on the piston head body (4), the piston head body (4) being made from a material with a density and hardness that is less than those of the material constituting the flange (5). The flange (5) and the body (4) are assembled by bolts (12) for fastening the flange (5) on the piston head (4) located towards the edge of the flange (5) and of the body (4) and by at least one part (16) for fastening the piston head (4) on the flange (5) comprising a threaded end (17) for fastening in a corresponding hole (18) of the flange (5), said hole (18) being situated closer to the centre of the baseplate (5) than the fastening bolts (12).