Porous Polymer Resin Layer for Combustion Heat Insulation

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Solution Overview

Problem

Internal combustion engines suffer from low thermal efficiency due to significant heat energy dissipation, and existing heat insulation materials lack sufficient heat resistance and adherence when used in high-temperature, high-pressure combustion environments.

Innovation Solution

A porous polymer resin layer with low density, thermal conductivity, and volume heat capacity is developed, comprising a binder resin with pores and dispersed aerogels, which is applied to internal combustion engine components to reduce heat energy discharge and improve engine efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If aerogels are added to binder resin to decrease heat capacity, then thermal efficiency is improved, but adherence of heat insulation film is reduced

Engineering Contradiction:

Improvethermal efficiencyVSAvoidadherence of heat insulation film

Core Design Contradiction:

Use of energy by moving objectVSReliability

Solution Approach 1:

The invention uses porous polymer resin beads with controlled pore structures (mean maximum diameter 0.5-1.6mm) as the heat insulation material. These porous beads are dispersed in the binder resin to create a composite coating that maintains low thermal conductivity and heat capacity while ensuring proper adherence to the piston surface.

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The invention creates a composite heat insulation coating by combining porous polymer resin beads with binder resin. The binder resin content is controlled at 10-50 wt% of the total coating weight, creating an optimal balance between adherence (provided by the binder) and thermal insulation performance (provided by the porous beads).

Inventive Principle:

Principle #40Composite materials

2Temperature

If high heat resistant binder resin is used, then heat resistance is improved, but volume heat capacity is not reduced sufficiently

Engineering Contradiction:

Improveheat resistanceVSAvoidvolume heat capacity

Core Design Contradiction:

TemperatureVSUse of energy by moving object

Solution Approach 1:

The invention employs porous polymer resin beads with high porosity to reduce the volume heat capacity of the coating. The pores contain air or vacuum which has very low heat capacity, allowing the coating to achieve low volume heat capacity while the binder resin provides the necessary heat resistance for combustion chamber conditions.

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The invention changes the physical structure of the polymer resin from solid to porous form, fundamentally altering its thermal properties. The porous structure reduces density and volume heat capacity while the binder resin composition is selected to maintain heat resistance, achieving both requirements simultaneously.

Inventive Principle:

Principle #35Parameter changes

3Loss of energy

If aerogel content is increased to decrease thermal conductivity, then heat insulation property is improved, but adherence is reduced

Engineering Contradiction:

Improveheat insulation propertyVSAvoidadherence

Core Design Contradiction:

Loss of energyVSReliability

Solution Approach 1:

The invention uses porous polymer resin beads as the primary heat insulation component instead of aerogels. These beads provide effective thermal insulation through their porous structure while maintaining a composition that ensures proper adherence to the piston surface in the combustion chamber environment.

Inventive Principle:

Principle #31Porous materials

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 polymer resin layer effectively reduces thermal conductivity and heat capacity, enhancing heat resistance and engine efficiency while maintaining mechanical properties, thereby improving fuel efficiency and reducing heat energy loss in internal combustion engines.

Implementation Method 1

the porous polymer can be applied to an internal combustion engine and thus can reduce heat energy discharged outside thereby improving efficiency of an internal combustion engine

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Implementation Method 2

a binder resin comprising pores and an aerogel dispersed in the binder resin

Methodology Applied

Scientific EffectPorosity: Porosity

Implementation Method 3

an aerogel dispersed in the binder resin... the porous polymer resin layer may have reduced density, thermal conductivity, and volume heat capacity

Methodology Applied

Scientific EffectHeat absorption: Absorption (EM radiation)

Data Source

PatentUS9970383B2Porous polymer resin layer and method for manufacturing the same

Publication Date: 2018.05.15 HYUNDAI MOTOR CO LTD

AI summary

The present invention provides a porous polymer resin layer that comprises a binder resin with pores having a mean maximum diameter of about 0.5 mm to 1.6 mm; and aerogels dispersed in the binder resin. In particular, the porous polymer resin layer has a density of about 0.5 g/ml to 1.6 g/ml.