Piston Anti-Carbon Coating for Cooling Gallery Protection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Internal combustion engine pistons face issues with carbon deposits forming on cooling surfaces due to degraded engine oil, leading to reduced cooling effectiveness, surface oxidation, and mechanical property degradation, which can result in crack formation and reduced durability.
Innovation Solution
A piston design featuring a non-stick material bonded to the undercrown surface and cooling gallery, selected from materials like pure cobalt, WC-17Co, or Co-18Cr-30Mo, to inhibit carbon deposit buildup, ensuring effective cooling and maintaining material strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If cooling galleries are used to reduce piston head temperature, then piston operating temperature is reduced, but carbon deposits form on the cooling surfaces
Solution Approach 1:
The patent applies preliminary anti-action by coating the cooling gallery surfaces and undercrown surfaces with a carbon-resistant material before carbon deposits can form. This preventive coating resists carbonization and oxidation of the cooling oil, stopping the harmful carbon deposit formation process before it begins, while maintaining the cooling function.
2Temperature
If cooling oil is circulated through cooling galleries, then cooling effectiveness is improved, but oil degradation and oxidation occur over time
Solution Approach 1:
The patent introduces an intermediary carbon-resistant coating material that acts as a barrier between the cooling oil and the metal cooling gallery surfaces. This intermediary layer prevents direct contact between the oil and hot metal surfaces, reducing oxidation and degradation of the cooling oil while maintaining effective heat transfer.
3Object-generated harmful factors
If carbon build-up forms on cooling surfaces, then insulation layer is created, but cooling effects are diminished
Solution Approach 1:
The patent converts the harmful effect of carbon buildup into a beneficial outcome by using a carbon-resistant coating material that deliberately allows or accommodates carbon deposition without suffering from its insulating effects. The coating material transforms the potential harm of carbon buildup into a benign or even beneficial phenomenon, maintaining cooling effectiveness.
4Temperature
If cooling surfaces are exposed to high temperature combustion gases, then combustion heat is transferred, but surface oxidation and erosion occur
Solution Approach 1:
The patent employs composite material construction by combining a base piston material with a surface coating layer that has superior resistance to oxidation and erosion. This composite structure allows the piston to benefit from both the heat transfer capabilities of the base material and the protective properties of the coating, enabling effective cooling while resisting harmful surface degradation.
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
The non-stick coating prevents insulation layer formation, maintains the piston's mechanical properties, and extends its operational life by ensuring proper cooling and preventing unintended tempering, thus enhancing running efficiencies and durability.
Implementation Method 1
a non-stick material bonded to at least one of the undercrown surface and at least a portion of the cooling gallery, wherein the non-stick material inhibits the build-up of carbon deposits thereon
Implementation Method 2
it is known to incorporate outer and inner cooling galleries, both open and closed, within the piston head through which engine oil is circulated to reduce the operating temperature of the piston head
Implementation Method 3
both the ring belt region and the combustion surface benefit from cooling action of the circulated oil
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
A piston and method of construction are provided. The piston includes a piston body having an upper combustion surface configured for direct exposure to combustion gases within a cylinder bore with an undercrown surface located beneath the upper combustion surface. The piston body also includes a ring belt region configured for receipt of at least one piston ring adjacent the upper combustion surface with a cooling gallery configured radially inwardly and in substantial radial alignment with the ring belt region. The piston further includes a non-stick material contained in or bonded to at least one of the undercrown surface and at least a portion of the cooling gallery, wherein the non-stick material inhibits the buildup of carbon deposits thereon.