Multi-part Piston Vacuum Soldering Joining
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for connecting upper and lower piston parts in internal combustion engines are either labor-intensive or lack reliable parameters for achieving optimal material properties, particularly in terms of strength, hardness, and structure morphology.
Innovation Solution
A method involving the application of high-temperature solder material between joining surfaces of upper and lower piston parts, followed by heating in a vacuum oven to a maximum temperature of 1300°C under low pressure, allowing for a reliable and cost-effective soldered connection without the need for further heat treatment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding or screwing methods are used to connect upper and lower piston parts, then the connection strength is improved, but the manufacturing complexity and labor intensity increase
Solution Approach 1:
The patent replaces mechanical connection methods (welding, screwing) with a thermal joining process using high-temperature solder material. The solder material is applied to joining surfaces and activated through heating in a vacuum oven, creating a metallurgical bond without requiring complex welding equipment or assembly operations
Solution Approach 2:
The patent changes the temperature parameter to extremely high values (soldering temperature of at most 1300°C) to activate the high-temperature solder material. This temperature parameter change enables the solder material to flow and create a strong bond between piston parts, replacing the need for mechanical fastening systems
2Reliability
If traditional soldering methods are used, then the connection reliability is improved, but additional heat treatment processes are required
Solution Approach 1:
The patent merges the soldering process with the heat treatment process into a single operational step. The heating phase in the vacuum oven serves dual purposes: activating the high-temperature solder material for reliable joining and simultaneously performing heat treatment to achieve optimal material properties (strength, hardness, structure morphology) of the piston basic material
Solution Approach 2:
The vacuum oven heating process performs multiple functions simultaneously: it acts as the heat source for soldering, provides the thermal energy for metallurgical bonding, and conducts heat treatment of the piston material. This multi-functionality eliminates the need for separate heat treatment operations and reduces total production time
3Strength
If multiple heat treatment processes are performed after soldering, then the material properties are improved, but the production cost and time increase
Solution Approach 1:
The patent performs the heat treatment action preliminarily during the soldering heating phase itself. By carefully controlling the heating parameters (temperature of at most 1300°C, vacuum pressure of at most 10⁻² mbar, holding time), the basic material achieves optimal strength, hardness, and structure morphology values during the soldering process, eliminating the need for subsequent heat treatment operations
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 method ensures a strong, durable connection with optimal material properties, reducing production time and costs while eliminating the need for additional heat treatment processes.
Implementation Method 1
the body is subsequently placed in a vacuum oven and, after evacuation of the vacuum oven, is heated to a soldering temperature of at most 1300° C., at a pressure of at most 10−2 mbar
Implementation Method 2
the body is subsequently placed in a vacuum oven and, after evacuation of the vacuum oven
Implementation Method 3
the soldered piston is cooled at a pressure of at most 10−2 mbar, until the high-temperature solder material has solidified completely
Data Source
AI summary
The present invention relates to a method for producing a multi-part piston (10, 110) for an internal combustion engine, comprising the following method steps: producing an upper piston part (11) and a lower piston part (12), each having an inner support element (22, 26; 122, 126) having joining surfaces (24, 28; 124, 128) and an outer support element (23, 27; 123, 127) having joining surfaces (25, 29; 125, 129), applying a high-temperature solder material in the area of at least one joining surface (24, 28 or 25, 29; 124, 128 or 125, 129), assembling the upper piston part (11) and the lower piston part (12) to form a piston body by establishing a contact between the joining surfaces (24, 28 or 25, 29; 124, 128 or 125, 129), placing the piston body in a vacuum furnace and evacuating the vacuum furnace; heating the piston body at a pressure of at most 10−2 mbar to a soldering temperature of at most 1300° C.; cooling the soldered piston (10, 110) at a pressure of at most 10−2 mbar until the high-temperature solder material is completely solidified. The present invention further relates to a piston (10, 110) that can be produced by means of the method.