Cylinder Head Core Assembly Reducing Intake Port Wall Distance
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Solution Overview
Problem
The existing methods for assembling cylinder heads with a water jacket covering the intake port wall surface face challenges in minimizing the distance between the intake port wall surface and the water jacket, as the conventional core print part is too large to be inserted into the water-jacket core, hindering the insertion of the intake-port core and affecting the cooling efficiency.
Innovation Solution
A novel method involving an intake-port core with a separate core print part, allowing the body part to be inserted from the core-print-part joined end into the water-jacket core, with the core print part joined afterwards, enabling a closer proximity of the water jacket to the intake port wall surface, thus reducing the assembly distance and enhancing cooling efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the core print part is made large to ensure proper assembly to the die, then the assembly stability is improved, but the distance between the intake port wall surface and the water jacket increases
Solution Approach 1:
The core print part is divided into a first core print part and a second core print part. The first core print part is inserted into the water-jacket core, while the second core print part remains outside. This segmentation allows the core print part to maintain sufficient size for assembly stability while enabling the body part to be positioned closer to the water jacket, thereby reducing the distance between the intake port wall surface and the water jacket.
2Ease of manufacture
If the body part is inserted from the side where the core print part is not provided, then the injection molding is simplified, but the distance between the intake port wall surface and the water jacket cannot be minimized
Solution Approach 1:
By dividing the core print part into two segments (first and second core print parts), the invention enables insertion from the side where the core print part is provided. The first core print part fits into the water-jacket core, creating a pathway for insertion that was previously blocked by the solid core print part structure.
Solution Approach 2:
The invention changes the insertion direction by utilizing the space created through segmentation. Instead of inserting from the side opposite the core print part, the body part is inserted from the side where the core print part is provided, specifically through the space created by the segmented structure. This dimensional change in insertion approach allows for minimized distance while maintaining manufacturability.
3Temperature
If the distance between the body part and the inner wall is reduced to minimize assembly distance, then the cooling efficiency is improved, but the injector part becomes hindered
Solution Approach 1:
The segmentation of the core print part into first and second parts creates a structured arrangement where the injector part can be positioned on the outer periphery of the body part. This segmented structure provides the necessary space for the injector part while allowing the body part to be inserted close to the inner wall, thereby maintaining both cooling efficiency and injector part accessibility.
Solution Approach 2:
The invention applies local quality by providing different functional zones: the body part is positioned close to the inner wall for optimal cooling, while the injector part is positioned on the outer periphery for accessibility. The segmented core print part structure locally accommodates these different requirements, allowing the body part to be inserted from the appropriate direction without hindering the injector part.
Data Source
AI summary
An intake-port core includes a body part having the same outer shape as that of the intake port, a port-injector part having the same outer shape as that of a port-injector insertion part, and an extending part. A cooling-water flow-passage core includes a water-jacket core having the same outer shape as that of a water jacket. The intake-port core is inserted from the extending part thereof into the water-jacket core so as to join the cooling-water flow-passage core to the intake-port core. Thereafter, a core print part that is a separate body from the intake-port core is joined to the intake-port core.