Reciprocating Engine Composite Cylinder Head
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Solution Overview
Problem
Current methods for cleaning engine blocks after casting are expensive and complicated due to integrated cast internal functions like water jackets and passages, and fail to meet the increased cleanliness and performance requirements of high-performance engines.
Innovation Solution
A reciprocating internal combustion engine design featuring a composite with a plate-shaped cylinder head support surface, where the composite is formed in one piece and inserted into the crankcase, allowing for a coolant space between cylinders and enabling a thin, filigree water jacket geometry without the need for draft angles or loose parts, simplifying cleaning and production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If integrated cast internal functions (water jackets, passages, channels) are incorporated into the crankcase, then functional integration is improved, but cleaning complexity and cost increase significantly
Solution Approach 1:
The crankcase is divided into two separate components: the crankcase proper and the composite (cylinder assembly with integrated coolant channels). The composite is produced separately with its own coolant passages, then assembled into the crankcase. This segmentation allows the crankcase to be cleaned independently without the complexity of integrated internal channels, while the composite can be designed with optimized coolant flow paths.
2Manufacturing precision
If manual pressure blasting devices are used to clean inner contours, then cleaning effectiveness is improved, but production cost and time increase
Solution Approach 1:
The composite is designed and produced with open, accessible coolant channels and passages that are easily cleanable before final assembly. The plate-shaped cylinder head support surface is designed without penetrations except for cylinder recesses, creating smooth internal surfaces that can be cleaned efficiently using automated blasting techniques without requiring manual intervention in complex geometries.
3Use of energy by moving object
If the plate-shaped cylinder head support surface has penetrations for coolant conduction, then coolant flow is improved, but structural integrity and cleanliness are compromised
Solution Approach 1:
The coolant conduction function is extracted from the plate-shaped cylinder head support surface. Instead of creating penetrations through the plate, coolant channels are formed in the composite structure around and between the cylinders, utilizing the intermediate areas of adjacent cylinders. The plate remains intact without penetrations, maintaining its structural integrity and providing a clean, smooth surface that resists sand and sizing residue accumulation.
4Temperature
If thick water jacket geometry is used to ensure adequate cooling, then cooling performance is improved, but coolant volume and pumping power requirements increase
Solution Approach 1:
The coolant channels are positioned in the intermediate areas between adjacent cylinders, utilizing the three-dimensional space efficiently. This allows for optimized coolant flow paths that provide adequate cooling performance with reduced coolant volume requirements, as the channels are strategically located where heat transfer is most effective without requiring excessive wall thickness.
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 reduces coolant requirements, lowers pumping power, and allows for a more efficient and cost-effective engine production with improved accessibility and mechanical properties, meeting the demands of high-performance engines.
Implementation Method 1
The outer wall areas of the cylinders of the composite and the wall portions of the recess for receiving the composite of the crankcase form a coolant space
Implementation Method 2
at least one coolant duct is arranged between the cylinders of the composite, whereby the coolant conduction of the composite is realized by drilling through the intermediate area of two adjacent cylinders and/or by a cooling channel core
Data Source
Figure 1~2
Figure 3a~3c
Figure 3d
AI summary
The invention relates to a composite, a crankcase, a reciprocating internal combustion engine, and a method for producing a reciprocating internal combustion engine. A problem faced in the production of engine blocks is that requirements concerning component cleanliness and residual soiling standards have recently been greatly increased. Therefore, the problem addressed by this invention is that of simplifying engine block cleaning after casting, and allowing current and future residual soiling standards to be adhered to, while providing a solution to the challenges of current and future high-powered engines specifically for the load regions, namely the head plate and the cylinder pipe, and providing potential for locally improving properties in the crankcase in the additional load regions, namely the head and crankshaft bearing screw connection. This problem is solved inter alia by virtue of a composite that consists of at least two cylinders and one planar cylinder head support surface that connects these, wherein said composite consisting of at least two cylinders and the planar cylinder head support surface that connects these is made as a single piece, said planar cylinder head support surface having a recess for each cylinder, and the composite being able to be inserted into or placed onto a crankcase of a reciprocating internal combustion engine; and is solved in that at least one coolant guide is arranged between said cylinders.