Systems, apparatus, and methods described herein can overcome some of the disadvantages associated with existing internal combustion engines. In particular, systems, apparatus, and methods described herein relate to improving the combustion process of internal combustion engines through insert technologies, engine modifications, control technologies, and/or other methodologies.

Systems, apparatus, and methods described herein can overcome some of the disadvantages associated with existing internal combustion engines. In particular, systems, apparatus, and methods described herein relate to improving the combustion process of internal combustion engines through insert technologies, engine modifications, control technologies, and/or other methodologies.

A proposed Adiabatic Diesel Engine (ADE), implements no cooling of the cylinders. The mechanism to achieve adiabatic cylinders is based on the separation of the crankcase mechanism from the cylinder mechanism. In an example implementation, the crankcase has a cross head mechanism driven by a connecting rod. The cross head mechanism drives the piston driveshaft(s) through a sliding bearing. The piston driveshaft moves between the crankcase and the cylinders. The cylinder has both a top where compression and combustion occur and a bottom with the piston driveshaft attached. The bottom has an opening for the piston driveshaft to move through. The bottom of the cylinder would normally be used to pump air for charging the combustion chamber. The crankcase mechanism contains lubricating oil and typically is cooled naturally through its casing.

A proposed Adiabatic Diesel Engine (ADE), implements no cooling of the cylinders. The mechanism to achieve adiabatic cylinders is based on the separation of the crankcase mechanism from the cylinder mechanism. In an example implementation, the crankcase has a cross head mechanism driven by a connecting rod. The cross head mechanism drives the piston driveshaft(s) through a sliding bearing. The piston driveshaft moves between the crankcase and the cylinders. The cylinder has both a top where compression and combustion occur and a bottom with the piston driveshaft attached. The bottom has an opening for the piston driveshaft to move through. The bottom of the cylinder would normally be used to pump air for charging the combustion chamber. The crankcase mechanism contains lubricating oil and typically is cooled naturally through its casing.

A method for manufacturing a piston of an internal combustion engine from a piston upper part and a piston lower part may include producing at least the piston lower part as a forged steel part. A partial cross section of a cooling duct may be provided in the piston lower part. A closed supply inlet funnel may be forged within the piston lower part. The closed supply inlet funnel may be bored into the piston lower part from the cooling duct. A borehole may be introduced into the piston lower part obliquely to a piston axis. The piston lower part and the piston upper part may be welded to one another.

A method for manufacturing a piston of an internal combustion engine from a piston upper part and a piston lower part may include producing at least the piston lower part as a forged steel part. A partial cross section of a cooling duct may be provided in the piston lower part. A closed supply inlet funnel may be forged within the piston lower part. The closed supply inlet funnel may be bored into the piston lower part from the cooling duct. A borehole may be introduced into the piston lower part obliquely to a piston axis. The piston lower part and the piston upper part may be welded to one another.

The present disclosure provides a piston, comprising: a skirt having an upper body portion; and a crown formed on the upper body portion by an additive manufacturing process, the crown including at least one air gap formed and positioned to reduce heat transfer from combustion to at least one cooling gallery formed in the piston.

The present disclosure provides a piston, comprising: a skirt having an upper body portion; and a crown formed on the upper body portion by an additive manufacturing process, the crown including at least one air gap formed and positioned to reduce heat transfer from combustion to at least one cooling gallery formed in the piston.

A galleryless steel piston for an internal combustion engine is provided. The piston has a monolithic piston body including an upper wall forming an upper combustion surface with first and second portions. The first portion extends annularly along an outer periphery of the upper wall and the second portion defines a combustion bowl. The piston further includes undercrown surface located directly opposite the combustion bowl with an exposed 2-dimensional surface area allowing for contact of cooling oil. The exposed 2-dimensional surface area ranges from 25 to 60 percent of a cross-sectional area defined by a maximum outer diameter of the piston body. To further enhance cooling, a portion of the undercrown surface is concave or convex, such that oil is channeled during reciprocation of the piston from one side to the opposite side of the piston.

A galleryless steel piston for an internal combustion engine is provided. The piston has a monolithic piston body including an upper wall forming an upper combustion surface with first and second portions. The first portion extends annularly along an outer periphery of the upper wall and the second portion defines a combustion bowl. The piston further includes undercrown surface located directly opposite the combustion bowl with an exposed 2-dimensional surface area allowing for contact of cooling oil. The exposed 2-dimensional surface area ranges from 25 to 60 percent of a cross-sectional area defined by a maximum outer diameter of the piston body. To further enhance cooling, a portion of the undercrown surface is concave or convex, such that oil is channeled during reciprocation of the piston from one side to the opposite side of the piston.