Engine Block Cross Member Resists Cylinder Deformation

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Solution Overview

Problem

Internal combustion engines, particularly wet block engines, are susceptible to deformation under high torque and power conditions, leading to issues like head gasket leaks, cylinder sleeve deformation, increased engine wear, and potential engine seizure, due to insufficient structural strength around the cylinder sleeves.

Innovation Solution

The engine block design is enhanced with additional support structures, including a first cylinder cavity cross member and transverse support walls, which provide a rigid connection between side walls and connect spaced-apart coolant chamber side wall portions, thereby increasing the engine's ability to resist deformation and stress.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If the engine operates for extended periods with high torque and power output, then the engine generates more heat and requires better cooling, but the water cavity and engine block become susceptible to deformation

Engineering Contradiction:

Improvetorque and horsepower outputVSAvoidstructural strength of engine block and water cavity

Core Design Contradiction:

PowerVSStrength

Solution Approach 1:

The engine block is divided into separate functional sections with the water cavity formed as a distinct segmented structure from the cylinder sleeves and engine block material, allowing independent optimization of cooling channels and structural support elements

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The water cavity is nested within the engine block structure, with coolant chambers positioned concentrically around the cylinder sleeves, creating a nested arrangement where the cooling system is embedded within the structural framework

Inventive Principle:

Principle #7Nested doll (Nesting)

2Reliability

If cylinder sleeves are used to define combustion cylinder walls, then the engine can withstand combustion pressures, but the cylinder sleeves are susceptible to deformation under high stress conditions

Engineering Contradiction:

Improveability to withstand combustion environmentVSAvoidresistance to deformation under high torque

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The engine employs composite construction with cylinder sleeves made of stress-resistant material (such as iron or steel) inserted into the aluminum engine block, creating a composite structure that combines the thermal and pressure resistance of the sleeve material with the lightweight properties of the block material

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The cylinder sleeves are provided with enhanced local quality through the formation of reinforcing ribs or webbing structures at specific locations within the water cavity, concentrating structural strength where deformation stresses are highest while maintaining overall lightweight construction

Inventive Principle:

Principle #3Local quality

3Duration of action of stationary object

If the water cavity surrounds the cylinder sleeves for cooling, then the engine can operate for extended periods, but deformation of the water cavity results in fluid leakage and loss of compression

Engineering Contradiction:

Improveoperational durationVSAvoidsealing integrity and compression retention

Core Design Contradiction:

Duration of action of stationary objectVSReliability

Solution Approach 1:

The design changes the geometric parameters of the water cavity by adding reinforcing webbing or rib structures that modify the cavity shape from a simple surround to a segmented structure with increased structural rigidity, preventing deformation that would compromise sealing surfaces

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS7513237B1Engine and methods of manufacturing an engine with increased internal support

Publication Date: 2009.04.07 ELECTROMECHANICAL RESEARCH LABORATORIES INC

AI summary

Support members for a reciprocating piston internal combustion engine are disclosed. Embodiments include an engine block with support members extending between portions of the cylinder cavity and/or enhancing coolant flow for cooling the combustion cylinders. Also disclosed are support members for connection to the side walls of the cylinder cavity and support members with ears and/or holes to enhance combustion cylinder cooling. Further disclosed are methods for modifying an internal combustion engine to increase its internal support and/or cooling.