Thermal-Barrier Carbon Scraper for Piston Deposit Removal

Resolve Bottlenecks,
Find Innovative Solutions
Generate Solutions

Solution Overview

Problem

Internal combustion engines face challenges in effectively removing carbon deposits from pistons, which can lead to engine damage and inefficiencies, and existing solutions do not adequately address heat transfer and thermal efficiency.

Innovation Solution

An annular scraper with a metallic shell and an inlaid thermal barrier coating, typically ceramic, is positioned within the cylinder bore to scrape carbon deposits while reducing heat transfer to the cylinder liner, enhancing thermal efficiency and fuel efficiency by minimizing unburnt hydrocarbon emissions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-generated harmful factors

If a metallic scraper ring is used to scrape carbon deposits, then carbon removal effectiveness is improved, but heat transfer loss increases

Engineering Contradiction:
Improvecarbon deposit accumulationVSAvoidheat transfer loss
Core Design Contradiction:
Object-generated harmful factorsVSLoss of energy

Solution Approach 1:

The scraper ring is constructed as a composite structure with a metallic shell providing mechanical strength and scraping functionality, while an insulating material (such as ceramic or polymer) is applied to the outer surface to reduce heat transfer. This composite design allows the ring to effectively scrape carbon deposits while minimizing heat loss to the cylinder liner, thereby resolving the contradiction between carbon removal effectiveness and heat transfer loss.

Inventive Principle:
Principle #40Composite materials

2Temperature

If heat is transferred to the cylinder liner for cooling, then thermal management is improved, but fuel efficiency deteriorates due to increased heat loss

Engineering Contradiction:
Improvecylinder liner temperature controlVSAvoidfuel efficiency
Core Design Contradiction:
TemperatureVSUse of energy by moving object

Solution Approach 1:

The insulating coating is applied locally to specific regions of the scraper ring that contact the piston top land, creating a localized thermal barrier. This allows heat to be retained in the combustion chamber where it is needed for combustion efficiency, while still permitting controlled heat transfer to the cylinder liner in areas where cooling is required. The local application of insulation resolves the contradiction between thermal management and fuel efficiency by optimizing heat flow paths.

Inventive Principle:
Principle #3Local quality

3Object-generated harmful factors

If the scraper ring contacts the piston to remove carbon, then carbon deposit removal is improved, but heat transfer to the piston increases

Engineering Contradiction:
Improvecarbon deposit on pistonVSAvoidheat transfer to piston
Core Design Contradiction:
Object-generated harmful factorsVSLoss of energy

Solution Approach 1:

The scraper ring uses a composite structure with an insulating outer layer that reduces heat transfer to the piston while maintaining the mechanical scraping action against carbon deposits. The metallic core provides the necessary structural integrity for scraping, while the insulating coating minimizes thermal energy transfer, thereby resolving the contradiction between effective carbon removal and heat transfer reduction.

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 effectively removes carbon deposits, reduces heat transfer, and improves engine performance by maintaining a warmer top land crevice volume for complete combustion, thereby enhancing fuel efficiency and reducing emissions.

Implementation Method 1

The inlaid thermal barrier coating portion is positioned between a first edge and a second edge of the annular scraper, where the first edge and the second edge including the annular metallic shell portion... The inlaid thermal barrier coating portion includes a material having a lower thermal conductivity than the outer annular metallic shell portion

Methodology Applied
Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentEP3114338B1Carbon scraper
Publication Date: 2021.04.28 CUMMINS INC
  • EP3114338B1 patent drawingFigure 1~2

AI summary

A carbon scraper, a method of manufacturing a system with a carbon scraper, and method of scraping carbon from a piston of an internal combustion engine are provided. The carbon escaper includes an outer annular metallic shell portion having an annular recess therein. The annular scraper also includes an inlaid thermal barrier coating portion positioned within the annular recess of the outer annular metallic shell portion such that the inlaid thermal barrier coating portion is concentric with an outer annular metallic shell portion.