Piston Crown Heat Shield Coating Without Spray Overshoot
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Solution Overview
Problem
The existing methods for applying a heat shield material to a piston's crown surface using spray painting result in poor application efficiency due to overspray, which damages the cylinder bore surface and requires masking, thereby reducing productivity.
Innovation Solution
A method utilizing a dispenser to linearly discharge the heat shield material onto the piston's crown surface, moving the application position in a circumferential direction to form a continuous layer without scattering, and combining with spray painting for efficient coverage, including the annular flat and bulged parts, to prevent adhesion on the side surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If spray painting is used to apply heat shield material to the piston crown surface, then the material can be applied to the surface, but the application efficiency deteriorates due to overspray scattering
Solution Approach 1:
The patent replaces the spray painting mechanical system with a dispenser that applies heat shield material in a linear continuous-line or dot-line manner. This substitution eliminates the scattering and overspray problems inherent in spray painting, thereby improving application efficiency and reducing material loss.
Solution Approach 2:
The patent changes the application parameters from spray dispersion to linear continuous-line or dot-line discharge. By moving the applied position in the circumferential direction and controlling the discharge pattern, the material is applied precisely where needed without scattering, improving both material utilization and productivity.
2Manufacturing precision
If spray painting is used to apply heat shield material, then the crown surface can be coated, but the side surface must be masked to prevent damage from overspray
Solution Approach 1:
The patent replaces spray painting with a dispenser system that applies material in a controlled linear or dot-line pattern. This eliminates overspray that would require masking, simplifying the process and reducing the complexity of auxiliary devices while maintaining precise heat shield layer formation.
Solution Approach 2:
The dispenser applies heat shield material locally and precisely to the crown surface in a linear or dot-line manner, moving in the circumferential direction. This localized application eliminates the need for masking the side surface, as material is discharged only where needed without scattering to adjacent areas.
3Speed
If spray painting is used, then material can be applied quickly, but the heat shield material scatters around the crown surface reducing application efficiency
Solution Approach 1:
The patent replaces spray painting with a dispenser that moves in the circumferential direction while discharging material in a linear continuous-line or dot-line manner. This maintains application speed while eliminating material scattering, thus preventing loss of substance without sacrificing productivity.
Solution Approach 2:
The dispenser continuously discharges heat shield material in a linear or dot-line manner while moving in the circumferential direction, ensuring continuous coverage of the crown surface. This continuous action maintains high application speed while preventing material scattering and loss.
4Area of stationary object
If the applied position is moved in the circumferential direction, then the heat shield layer can be formed on the circumferential edge, but the material must not extend outside the crown surface
Solution Approach 1:
The patent uses a dispenser instead of spray painting to apply material in a controlled linear or dot-line manner. By moving the dispenser in the circumferential direction, the material is applied precisely to the crown surface including the circumferential edge, without extending outside the designated area, thus achieving both full coverage and precise placement.
Solution Approach 2:
The patent changes the discharge pattern from spray to linear continuous-line or dot-line, and controls the movement in the circumferential direction. This parameter change enables precise material placement on the circumferential edge while preventing extension outside the crown surface, achieving both complete coverage and high placement accuracy.
Data Source
AI summary
A method of applying heat shield material to form a heat shield layer on a crown surface of a piston of an engine is provided. The method includes the steps of disposing a dispenser that linearly discharges the heat shield material toward the crown surface, and moving an applied position of the heat shield material with respect to the crown surface in a circumferential direction of the crown surface, while discharging the heat shield material from the dispenser toward the crown surface.