Porous Thermal Insulation Coating for Internal Combustion Engine
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Solution Overview
Problem
Internal combustion engines face inefficiencies due to high thermal energy discharge, which existing thermal insulation materials and structures fail to adequately address, especially under repeated high temperature and pressure conditions.
Innovation Solution
A porous thermal insulation coating layer with reduced thermal conductivity and volumetric heat capacity is developed, manufactured by reacting metal alkoxides with alcohol and water, followed by thermal treatment, and incorporating a silane-based compound, to enhance durability and bonding with metal substrates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If existing thermal insulation materials are applied to the internal combustion engine, then thermal energy discharge is reduced, but durability under repeated high temperature and pressure conditions deteriorates
Solution Approach 1:
The patent applies a porous coating layer with controlled pore structure (porosity 30-70%, average pore size 0.1-10 μm) to the internal combustion engine. The porous structure provides thermal insulation by reducing thermal conductivity while the specific pore distribution and surface area (50-500 m²/g) ensure durability under high temperature and pressure conditions. The porous morphology directly addresses both thermal insulation performance and structural stability.
Solution Approach 2:
The patent uses composite materials comprising metal oxides (alumina, silica, titania, zirconia) combined with binding agents and porous formers. This composite structure achieves optimal balance between thermal insulation properties and mechanical durability. The composite nature allows the coating to maintain both low thermal conductivity and high resistance to thermal-mechanical stress under repeated high temperature and pressure cycling.
2Loss of energy
If thermal insulation coating is applied to reduce heat discharge, then engine efficiency improves, but bonding strength with metal substrate under high temperature conditions deteriorates
Solution Approach 1:
The patent employs parameter changes in the coating formulation and processing conditions to optimize bonding strength. The coating contains specific metal oxide ratios (alumina 30-70%, silica 20-50%, titania 5-20%, zirconia 5-20%) and binding agents in controlled amounts. The coating is applied and cured under specific temperature and time parameters to achieve strong bonding to the metal substrate while maintaining thermal insulation properties under high temperature operation.
Solution Approach 2:
The patent uses binding agents as intermediary substances that chemically bond to both the metal substrate and the metal oxide particles. These binding agents create a strong interfacial connection between the coating and substrate, preventing delamination under thermal-mechanical stress. The intermediary binding agents ensure durable attachment while the overall coating structure maintains thermal insulation.
3Loss of energy
If porous structure is introduced to reduce thermal conductivity, then thermal insulation performance improves, but mechanical strength and structural stability deteriorate
Solution Approach 1:
The patent optimizes the porous structure parameters to balance thermal insulation and mechanical strength. The coating layer has controlled porosity (30-70%) and average pore size (0.1-10 μm) that provides effective thermal insulation while maintaining structural integrity. The pore size distribution and connectivity are controlled to ensure both thermal performance and resistance to mechanical stress under high temperature and pressure conditions.
Solution Approach 2:
The patent uses composite materials with metal oxides and binding agents to reinforce the porous structure. The metal oxide particles (alumina, silica, titania, zirconia) provide structural framework while the binding agents create a cohesive matrix that maintains mechanical strength. This composite porous structure achieves both low thermal conductivity and high structural stability under operational conditions.
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 porous thermal insulation coating layer effectively reduces thermal energy discharge, improving engine efficiency and fuel efficiency by maintaining excellent durability and thermal insulation properties under high temperature and pressure conditions.
Implementation Method 1
coating a reaction product obtainable, obtained or produced from a reaction of metal alkoxide containing at least one metal selected from the group consisting of aluminum, zirconia, titanium and silicon with alcohol, and water
Implementation Method 2
performing a thermal treatment at a second temperature that is greater than the first temperature and less than about 300° C.
Implementation Method 3
The porous thermal insulation coating layer of the present invention may have reduced thermal conductivity and volumetric heat capacity
Data Source
AI summary
Disclosed are a manufacturing method for a porous thermal insulation coating layer, a porous thermal insulation coating layer with substantially reduced thermal conductivity and volumetric heat capacity and an internal combustion engine including the porous thermal insulation coating layer thereby having excellent durability.