Unitary Valve Bridge Additive Manufacturing
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Solution Overview
Problem
Valve bridges in internal combustion engines experience increased wear and maintenance frequency due to frequent opening and closing cycles, leading to higher costs and weights when configured with multiple components.
Innovation Solution
The valve bridge is formed as a single, unitary piece via additive manufacturing, such as 3D printing, reducing the number of components and incorporating passages, orifices, and interior walls that are difficult to achieve with conventional methods, thereby reducing weight and maintenance needs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the valve bridge is configured with multiple components, then the likelihood of wear and maintenance frequency increase, but the weight and cost also increase
Solution Approach 1:
The patent combines multiple valve bridge components into a single integrated unitary structure. The valve bridge body, arms, and internal passages are formed as one piece through additive manufacturing, eliminating the need for separate components that would require assembly. This merging reduces the number of interfaces and potential wear points while simplifying the overall device structure.
Solution Approach 2:
The valve bridge incorporates internal segmentation through hollow passages and cavities formed within the unitary structure. These internal passages allow for oil flow and cooling while maintaining the external integrity of the single-piece construction. The segmentation is achieved through the manufacturing process rather than physical assembly of separate parts.
2Manufacturing precision
If conventional manufacturing methods are used, then passages and orifices are difficult to achieve, but the manufacturing process is simpler
Solution Approach 1:
The patent utilizes additive manufacturing technology to fundamentally change the manufacturing parameters and capabilities. This process enables the creation of complex three-dimensional passages, orifices, and internal geometries that would be extremely difficult or impossible to achieve with conventional subtractive or formative manufacturing methods. The layer-by-layer deposition allows for intricate internal structures to be built directly within the solid material.
3Weight of moving object
If the valve bridge is made as a single unitary piece, then weight is reduced, but manufacturing capability is required
Solution Approach 1:
The patent transitions from traditional two-dimensional or simple three-dimensional manufacturing to true three-dimensional additive manufacturing. This dimensional capability allows material to be deposited in complex spatial patterns, creating hollow structures and passages within the valve bridge body. The resulting unitary structure eliminates unnecessary material while maintaining structural integrity, significantly reducing weight compared to conventional solid or multi-component designs.
Data Source
AI summary
Methods and systems are provided for a valve bridge of an internal combustion engine. In one example, a valve bridge comprises a first arm, a longitudinally opposing second arm, and one or more interior walls forming a passage extending laterally through at least a portion of the valve bridge, the passage disposed between the first arm and second arm and forming a first main opening and an opposing, second main opening. A central support structure is disposed within the passage and is formed by the one or more interior walls.