Monolithic Opposed-Piston Cylinder Block with 3D Printed Core
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Solution Overview
Problem
Current opposed-piston engine cylinder blocks are constructed from multiple parts, which increases manufacturing complexity, costs, and component count, while also compromising thermal management due to the presence of cylinder liners and sleeves.
Innovation Solution
A parent bore cylinder block is created using a 3-D printed casting core, allowing for a single-piece, monolithic construction with integrated coolant paths and cooling features, such as turbulators, to enhance thermal management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If multiple parts are used to construct the cylinder block, then ease of assembly is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent merges multiple separate components (cylinder block portions, cylinder liners, sleeves, fluid seals, and fasteners) into a single monolithic cylinder block structure. This integration eliminates the need for assembly operations and reduces the total number of parts, thereby reducing device complexity while maintaining ease of manufacturing through a single casting process.
2Ease of manufacture
If multiple parts are used to construct the cylinder block, then ease of manufacturing individual components is improved, but total manufacturing cost and time increase
Solution Approach 1:
The invention combines multiple manufacturing operations into a single casting process that produces the complete monolithic cylinder block in one step. This eliminates sequential manufacturing steps, reduces total manufacturing time, and lowers overall production costs despite the increased complexity of the single-piece design.
3Ease of operation
If cylinder liners and sleeves are used, then thermal management is compromised, but ease of assembly is improved
Solution Approach 1:
The patent integrates the cooling jacket and coolant flow paths directly into the monolithic cylinder block structure, eliminating the need for separate cylinder liners and sleeves. This integration improves thermal management by creating direct coolant contact with the cylinder bore and combustion chamber areas, while the single-piece construction maintains ease of manufacturing through casting.
4Adaptability or versatility
If openings are added for fuel injectors and valves, then engine functionality is improved, but strength of the intermediate portion decreases
Solution Approach 1:
The patent applies local quality by strategically positioning and sizing openings for fuel injectors, valves, and sensors in the intermediate portion of the cylinder block. The monolithic structure provides localized reinforcement around these openings, maintaining overall strength while enabling necessary engine functionalities. The casting process allows for optimized placement that minimizes structural compromise.
Data Source
AI summary
A parent bore cylinder block of an internal combustion, opposed-piston engine includes cooling passages that are formed using a 3-D printed casting core. The casting core can include portions that are ceramic. The parent bore cylinder block can include multiple cylinders, each cylinder with cooling passages and turbulence inducing features in those cooling passages, particularly surrounding the central portions of the cylinders.