Coolant Jacket Core for Narrow Web Cylinder Crankcase
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Solution Overview
Problem
Existing methods for producing coolant jacket cores for cylinder crankcases with narrow web widths face challenges in ensuring sufficient cooling and stability, as conventional cores tend to break or have limited heat dissipation due to small web areas, and previous solutions like using glass or ceramic inserts are either ineffective or costly and difficult to produce.
Innovation Solution
A coolant jacket core design featuring individually manufactured web cores that are axially arranged and fixed to a base core, forming a large flow cross-section for coolant, which are easy to produce and assemble, ensuring stable heat dissipation without additional fastening steps, and can be made from materials like sand, salt, glass, or ceramics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional sand or salt cores are used to form water jackets with small web widths, then the core can be manufactured, but the cores crack due to stresses in the core box, during storage, or during casting
Solution Approach 1:
The core is divided into a base core and multiple separate web cores that are inserted into the base core. The web cores are manufactured separately with larger dimensions to ensure stability, then positioned into the base core to form the final narrow web structure. This segmentation allows each component to be manufactured independently with appropriate tolerances while achieving the overall narrow web width requirement.
2Manufacturing precision
If glass or ceramic inserts are used to form cooling channels in the web area, then a coolant channel can be formed, but the heat dissipation remains very limited due to the small outer circumference of the glass tube
Solution Approach 1:
Instead of using a single small-diameter glass tube, the solution uses multiple web cores arranged axially to create multiple coolant channels. This transforms the cooling approach from a single small channel to multiple channels distributed across the web area, significantly increasing the total heat dissipation surface area while maintaining the narrow web width.
3Reliability
If ceramic plates are arranged in the web area to improve core stability, then the core stability increases, but the plate remains in the cylinder crankcase and does not form a cooling channel, and production and removal are challenging
Solution Approach 1:
The web cores are designed to be removable from the finished cylinder crankcase. After casting, the web cores can be extracted from the base core, leaving only the desired narrow web structure and coolant channels in the crankcase. This eliminates the problem of leaving unwanted material in the final product while maintaining core stability during casting.
4Weight of moving object
If cylinders are placed at increasingly smaller distances to reduce weight and installation space, then weight and space are reduced, but forming a water jacket encompassing the cylinders becomes very difficult
Solution Approach 1:
The water jacket is formed by inserting multiple web cores into the base core, creating segmented coolant channels between closely spaced cylinders. This modular approach allows the cooling system to adapt to reduced cylinder spacing while maintaining effective coolant flow paths, as the web cores can be positioned precisely to maintain appropriate coolant channel dimensions despite smaller overall web widths.
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 ensures complete coolant flow around cylinders with very short distances, providing effective heat dissipation and increased stability while being cost-effective and easy to manufacture, eliminating the risk of core breakage and reducing production complexity.
Implementation Method 1
a water channel is formed between the cylinders, i.e., in the web area, thus guaranteeing flow around at least an axial section of the cylinder
Implementation Method 2
adequate cooling of each cylinder must be ensured to prevent thermal overload of the crankcase
Data Source
Figure 1~2
Figure 3~4
AI summary
Coolant jacket core (16) for producing a cylinder crank housing (10) with a narrow ridge width, comprises at least an integral base core (20), which comprises at least two adjacently arranged core body in hollow cylindrical section form, and a bar core (18), which interconnects the opposite radial ends of each core body in the cutting plane. Each of the two adjacently arranged core body exhibits a common axially extending cutting plane, which forms a connection surface between radial ends of the adjacent core body. The bar core comprises many axially superimposed removable single bar cores. Coolant jacket core (16) for producing a cylinder crank housing (10) with a narrow ridge width, comprises at least an integral base core (20), which comprises at least two adjacently arranged core body in hollow cylindrical section form, and a bar core (18), which interconnects the opposite radial ends of each core body in the cutting plane. Each of the two adjacently arranged core body exhibits a common axially extending cutting plane, which forms a connection surface between radial ends of the adjacent core body. The bar core comprises many axially superimposed removable single bar cores. The single bar cores are attached to the base core at the opposite radial ends of the core body arranged in the cutting plane. An independent claim is also included for producing the coolant jacket core for cylinder crank housing, comprising firing the base core, producing many single bar cores separately, and attaching single bar cores in the base core in an axially superimposed manner in the cutting plane between the two adjacent hollow cylindrical section shaped core body of the base core at the opposite radial ends of the core body.