Pre-Chamber Tip Thermal Management via Composite Body

Solution Overview

Problem

Existing pre-chamber designs for internal combustion engines face high thermal loads and wear at the tip portion, leading to complex and costly manufacturing processes and increased mechanical stress due to thermal expansion.

Innovation Solution

A pre-chamber design where the body consists of a material with higher thermal conductivity than the tip portion, joined using a welding or brazing process, allowing for efficient heat dissipation and reduced mechanical stress, with a simplified manufacturing method that includes machining of contours before or after joining the parts.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If the pre-chamber tip portion is made from a material with high thermal conductivity to reduce temperatures, then the temperature at the tip is reduced, but the manufacturing complexity and cost increase due to complex multi-cavity shell production and core material introduction

Engineering Contradiction:

Improvetemperature at pre-chamber tipVSAvoidmanufacturing process complexity

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The pre-chamber is designed with spatially varying thermal conductivity: the body portion uses high thermal conductivity material (e.g., copper or copper alloy) to conduct heat away from the tip, while the tip portion uses lower thermal conductivity material (e.g., steel or steel alloy) to withstand thermal loading and wear. This local differentiation allows each region to have optimized thermal properties for its specific function, reducing tip temperature without requiring complex multi-cavity structures.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The pre-chamber employs a composite construction with two distinct materials joined together: a high thermal conductivity material for the body and a lower thermal conductivity, wear-resistant material for the tip portion. This composite approach enables the system to simultaneously achieve heat dissipation in the body and thermal resistance plus wear resistance at the tip, avoiding the manufacturing complexity of alternative solutions.

Inventive Principle:

Principle #40Composite materials

2Temperature

If the pre-chamber tip portion is made from a material with high thermal conductivity to reduce temperatures, then the temperature at the tip is reduced, but the manufacturing cost increases due to complex manufacturing processes

Engineering Contradiction:

Improvetemperature at pre-chamber tipVSAvoidmanufacturing cost

Core Design Contradiction:

TemperatureVSEase of manufacture

Solution Approach 1:

The pre-chamber is designed with spatially varying thermal conductivity: the body portion uses high thermal conductivity material (e.g., copper or copper alloy) to conduct heat away from the tip, while the tip portion uses lower thermal conductivity material (e.g., steel or steel alloy) to withstand thermal loading and wear. This local differentiation allows each region to have optimized thermal properties for its specific function, reducing tip temperature without requiring complex multi-cavity structures.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The pre-chamber employs a composite construction with two distinct materials joined together: a high thermal conductivity material for the body and a lower thermal conductivity, wear-resistant material for the tip portion. This composite approach enables the system to simultaneously achieve heat dissipation in the body and thermal resistance plus wear resistance at the tip, avoiding the manufacturing complexity of alternative solutions.

Inventive Principle:

Principle #40Composite materials

3Ease of manufacture

If the pre-chamber is made as a single piece to simplify manufacturing, then the manufacturing process is simplified, but the wear at the tip intersection region increases due to high temperatures

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidwear resistance at tip

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The pre-chamber is divided into two separate components: a body portion and a tip portion, which are manufactured separately and then joined together. This segmentation allows the tip portion to be made from wear-resistant material specifically optimized for the high-stress intersection region, while the body can be made from heat-conductive material. The separate manufacturing of components simplifies production compared to complex monolithic designs while enabling superior wear resistance at the critical tip area.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The pre-chamber employs a composite construction with two distinct materials joined together: a high thermal conductivity material for the body and a lower thermal conductivity, wear-resistant material for the tip portion. This composite approach enables the system to simultaneously achieve heat dissipation in the body and thermal resistance plus wear resistance at the tip, avoiding the manufacturing complexity of alternative solutions.

Inventive Principle:

Principle #40Composite materials

4Temperature

If the pre-chamber body uses high thermal conductivity material to conduct heat away, then the temperature at the tip is reduced, but the mechanical stress due to thermal expansion increases

Engineering Contradiction:

Improvetemperature at pre-chamber tipVSAvoidmechanical stress from thermal expansion

Core Design Contradiction:

TemperatureVSStress or pressure

Solution Approach 1:

The pre-chamber is designed with spatially varying thermal conductivity: the body portion uses high thermal conductivity material (e.g., copper or copper alloy) to conduct heat away from the tip, while the tip portion uses lower thermal conductivity material (e.g., steel or steel alloy) to withstand thermal loading and wear. This local differentiation allows each region to have optimized thermal properties for its specific function, reducing tip temperature without requiring complex multi-cavity structures.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The pre-chamber employs a composite construction with two distinct materials joined together: a high thermal conductivity material for the body and a lower thermal conductivity, wear-resistant material for the tip portion. This composite approach enables the system to simultaneously achieve heat dissipation in the body and thermal resistance plus wear resistance at the tip, avoiding the manufacturing complexity of alternative solutions.

Inventive Principle:

Principle #40Composite 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 solution results in lower temperatures and mechanical stress at the pre-chamber tip, reducing wear and manufacturing costs while maintaining effective ignition performance, with the added flexibility of a more straightforward production process.

Implementation Method 1

the pre-chamber body consists of a material with higher thermal conductivity than the pre-chamber tip portion

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

the pre-chamber tip portion is affixed to the pre-chamber body by a welding process or a brazing process

Methodology Applied

Scientific EffectWelding: Welding

Implementation Method 3

the pre-chamber tip portion is affixed to the pre-chamber body by a welding process or a brazing process

Methodology Applied

Scientific EffectBrazing: Brazing

Data Source

PatentUS12025050B2Pre-chamber and method for producing a pre-chamber

Publication Date: 2024.07.02 GE JENBACHER GMBH & CO OG

AI summary

Pre-chamber for an internal combustion engine, preferably gas engine, comprising:a pre-chamber body;a pre-chamber volume which is surrounded by the pre-chamber body; anda pre-chamber tip portion comprising at least two, preferably more than two, spray nozzles, wherein the at least two spray nozzles are in fluid communication with the pre-chamber volume, and the pre-chamber tip portion is affixed to the pre-chamber body by a welding process or a brazing process;wherein the pre-chamber body consists of a material with higher thermal conductivity than the pre-chamber tip portion.