Sodium-Filled Piston Cooling with a Pre-Sealed Coolant Container
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Solution Overview
Problem
The existing methods for filling coolant into pistons, particularly those with multiple skewed bores, are complex and prone to coolant leakage, making the production process difficult and error-prone.
Innovation Solution
A coolant container is pre-filled and sealed separately, then inserted into the piston, allowing for simpler piston manufacturing as it eliminates direct handling of coolant and provides options for closure and positioning to enhance heat transfer and dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the coolant is introduced directly into the space provided in the piston during manufacturing, then the cooling function is achieved, but the production process becomes complex and error-prone due to the need for careful handling and sealing of multiple skewed bores
Solution Approach 1:
The cooling system is divided into two independent parts: the piston structure and the coolant container. The coolant container is manufactured separately, filled with coolant, and sealed independently, then inserted into the piston as a complete unit. This segmentation eliminates the complexity of filling multiple skewed bores during piston manufacturing while ensuring reliable cooling functionality.
Solution Approach 2:
The coolant container is pre-filled and sealed with the coolant before insertion into the piston. This preliminary action of filling and sealing the coolant in a separate, controlled environment eliminates the risk of leakage during piston assembly and simplifies the manufacturing process, as no special precautions are needed during piston production.
2Reliability
If multiple skewed bores are provided in the piston for coolant introduction, then the cooling coverage is improved, but the difficulty of detecting and measuring proper filling increases
Solution Approach 1:
The coolant container serves as an intermediary that encapsulates the coolant and delivers it to the piston in a controlled manner. Instead of directly filling multiple skewed bores, the pre-filled container is inserted as a complete unit, eliminating the difficulty of detecting and measuring proper filling in multiple orientations. The container itself becomes the measurement reference point.
3Reliability
If the coolant is handled directly during piston assembly, then the cooling system is integrated, but the risk of coolant leakage into the environment increases
Solution Approach 1:
The coolant is extracted from the piston assembly process and contained in a separate, pre-sealed container. This extraction eliminates the risk of coolant leakage during piston manufacturing and assembly, as the coolant never leaves the controlled environment of the sealed container until the container itself is inserted into the piston.
Solution Approach 2:
The coolant container is designed as a separate, replaceable component that can be manufactured, filled, and sealed independently. If leakage occurs, only the container needs to be replaced rather than the entire piston, minimizing waste and cost while maintaining system integrity.
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
This approach simplifies the production process, ensures effective heat transfer and dissipation, and maintains the coolant's gas-tight integrity, enabling efficient heat management in internal combustion engines.
Implementation Method 1
the coolant is to be introduced into the space provided in the piston... areas of the piston that are subjected to high temperatures by means of the alkali metal... heat can be better transferred to the coolant and can be dissipated in areas with significantly lower temperatures
Data Source
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AI summary
The invention relates to a piston (1) of an internal combustion engine, comprising an upper part (2) having a ring zone (6) and piston skirt (3) adjoining the upper part (2), wherein at least one space (12) is formed in the piston (1), into which at least one space a coolant is introduced, wherein the coolant is introduced into a coolant container (13) and the coolant container (13) is inserted into the at least one space (12) in the piston (1).