Abstract
The present invention is related to a method for manufacturing a water cooling system (20) inside a casted cylinder head (10), the water cooling system (20) comprising an upper water jacket (21) and a lower water jacket (22) and wherein a transition channel (23) is located between the upper water jacket (21) and the lower water jacket (22). Further, the invention is related to a water cooling system (20) inside a casted cylinder head (10), comprising an upper water jacket (21) and a lower water jacket (22) wherein the upper water jacket (21) and the lower water jacket (22) are fluidly connected by at least one transition channel (23).
Claims
1.-10. (canceled)
11. A method for manufacturing a water cooling system inside a casted cylinder head, the water cooling system comprising an upper water jacket and a lower water jacket and wherein a transition channel is located between the upper water jacket and the lower water jacket, characterized in following steps: a) Arranging an upper water jacket core for the upper water jacket and a lower water jacket core for the lower water jacket, wherein the upper water jacket core and the lower water jacket core are adjoining to each other at least in or at the region of the transition channel to be manufactured and wherein at least one of the water jacket cores comprises a recess at the region of the transition channel to be manufactured, b) Casting of the cylinder head, wherein due to the recess a protrusion is formed and due to the arrangement of the water jacket cores a core flash is formed on the protrusion and wherein the transition channel to be manufactured is at least partly blocked by the protrusion and the core flash, c) Removing of the upper water jacket core and the lower water jacket core, and d) Adjusting the width of the transition channel to be manufactured by removing the core flash and at least a part of the protrusion.
12. The method according to claim 11, wherein in step d) the removing includes drilling.
13. The method according to claim 12, wherein the drilling is performed in a direction perpendicular to an intended flow direction of the cooling water in the transition channel.
14. The method according to claim 11, wherein a hole in the cylinder head, is closed with a plug.
15. The method according to claim 11, wherein both water jacket cores comprise a recess at the region of the transition channel to be manufactured and that in step b) due to the recesses a common protrusion is formed.
16. The method according to claim 11, wherein in step b) the transition channel to be manufactured is completely blocked by the protrusion and the core flash.
17. The method according to claim 11, wherein in step a) the upper water jacket core and the lower water jacket core are arranged in the vicinity of an exhaust core.
18. The method according to claim 17, wherein the upper water jacket core and the lower water jacket core are arranged such that the exhaust core is at least in sections surrounded by the upper water jacket core and the lower water jacket core.
19. A water cooling system inside a casted cylinder head, comprising an upper water jacket and a lower water jacket, wherein the upper water jacket and the lower water jacket are fluidly connected by at least one transition channel, wherein after the casting of the cylinder head the transition channel is at least partly blocked by a protrusion and a core flash arranged at the protrusion and that the width of the transition channel is adjusted by removing the core flash and at least a part of the protrusion.
20. The water cooling system inside a casted cylinder head, wherein the water cooling system is manufactured using a method according to claim 11.
21. A method according to claim 14, wherein a hole in the cylinder head caused by the removing in step d) is closed with a plug.
Description
[0023] The present invention is described with respect to the accompanied figures. The figures show schematically:
[0024] FIG. 1a, b, c a method for manufacturing a water cooling system according to the invention and
[0025] FIG. 2 a water cooling system according to the invention.
[0026] Elements having the same functions and mode of action are provided in FIGS. 1a, b, c and 2 with the same reference signs.
[0027] In the FIGS. 1a, b, c a method for manufacturing a water cooling system 20 inside a casted cylinder head 10 is depicted. FIG. 1a shows especially step a) of the method according to the invention. An upper water jacket core 30 and a lower water jacket core 31 are arranged at each other. Only the parts of the water jacket cores 30, 31, which are located in an area of the transition channel 23 (see FIGS. 1b, c) to be manufactured are shown. Both water jacket cores 30, 31 comprise a recess 32 located at a contact region of the water jacket cores 30, 31. In addition, an exhaust core 33 is shown. All other parts needed for the casting process of the cylinder head 10 (not shown), like a casting mold, are not depicted. In FIG. 1b the result of the casting process is shown after the removal of the cores 30, 31, 33 (not shown). In the casted cylinder head 10 cavities are formed for the water cooling system 20 and the exhaust 13. The water cooling system 20 is split into an upper water jacket 21, a lower water jacket 22 and a transition channel 23 which fluidly connects the two water jackets 21, 22. An opening 51 of the upper water jacket 21 is connected to a first end 53 of the transition channel 23 and an opening 52 of the lower water jacket 22 is connected to a second end 54 of the transition channel 23. Due to the shape of the water jacket cores 30, 31 (not shown), also a hole 11 is formed in the casted cylinder head 10. It is clearly visible that on the side wall of the casted cylinder head 10 between the transition channel 23 of the water cooling system 20 and the exhaust 13 due to the recesses 32 on the water jacket cores 30, 31 a common protrusion 24 is formed. During the casting process molded metal got between the water jacket cores 30, 31 in the contact region between the water jacket cores 30, 31. That is why on the tip of the protrusion 24 a core flash 25 is formed. It is also clearly visible that the transition channel 23 is almost completely blocked by the protrusion 24 and the core flash 25. Therefore, in step d) of the method according to the invention an adjusting of the width 26 (see FIG. 2) is an important part of the method according to the invention. In this embodiment of the method according to the invention, the removal of the core flash 25 and the protrusion 24 is achieved by using a drill 40. The drill 40 is inserted through the hole 11 and used to remove material of the core flash 25 and the protrusion 24. By choosing the size of the drill 40 and/or the depth of the drilling and/or a sideward movement of the drill 40 the width 26 of the transition channel 23 can be exactly calibrated. Due to the fact that the core flash 25 is exclusively arranged at the protrusion 24, damage to a side wall of the casted cylinder head 10 between the transition channel 23 and the exhaust 13 can be easily prohibited. Using a method according to the invention it is therefore possible to reach an exact calibration of the width 26 of the transition channel 23, a complete removal of core flashes 25 and simultaneously prohibiting a damage done to a side wall in the casted cylinder head 10 between the transition channel 23 and the exhaust 13. The drill 40 is inserted in this embodiment of the method according to the invention in a direction perpendicular to an intended flow direction 50 (see FIG. 2) in the transition channel 23 to be manufactured. This has the advantage that less material of the cylinder head 10 has to be drilled through. This is on the one hand a very easy and cost-efficient way and on the other hand allows to remove the core flash 25 and the protrusion 24 with applying an as low as possible weakening to the casted cylinder head 10.
[0028] In FIG. 2 a water cooling system 20 inside a casted cylinder head 10 according to the invention is shown. Especially, the water cooling system 20 shown in FIG. 2 was manufactured using a method according to the invention as shown in FIGS. 1a, b, c. The hole 11 is now filled with a plug 12, wherein the plug 12 is adjusted to ensure the calibrated width 26 of the transition channel 23. The upper water jacket 21 and the lower water jacket 22 are now connected by the transition channel 23 and cooling water can flow in the flow direction 50 between the two water jackets 21, 22 to cool exhaust gases in the exhaust 13. The transition channel 23 connects the upper water jacket 21 and the lower water jacket 22. Therefore in the shown embodiment cooling water leaves the upper water jacket 21 through an opening 51 connected to a first end 53 of the transition channel 23 and enters the transition channel 23 at the first end 53 of the transition channel 23. Afterwards it flows through the transition channel 23, leaves the transition channel 23 on a second end 54 of the transition channel 23 and enters the lower water jacket 22 through an opening 52 in the lower water jacket 22 connected to the second end 54 of transition channel 23. In an alternative embodiment also a flow of cooling water from the lower water jacket 22 through the transition channel 23 into the upper water jacket 21 is possible (not shown). Therefore the intended flow direction 50 is pointing from the opening 51, (52) in the upper (lower) water jacket 21, (22) to the opening 52, (51) in the lower (upper) water jacket 22, (21), especially following the general direction of the transition channel 23 (the reference signs in brackets are related to the alternative, not shown embodiment). A water cooling system 20 according to the invention has especially the advantages that the width 26 of the transition channel 23 can be exactly calibrated. Another advantage of a water cooling system 20 according to the invention arises due to the fact that the side wall of the casted cylinder head 10 between the transition channel 23 and for instance an exhaust 13 can be manufactured as thin as possible due to the fact that security margins for the removal of core flashes 25 after the casting process can be avoided. An improved cooling can therefore be provided.
REFERENCE SIGNS
[0029] 10 Cylinder head
[0030] 11 Hole
[0031] 12 Plug
[0032] 13 Exhaust
[0033] 20 Water cooling system
[0034] 21 Upper water jacket
[0035] 22 Lower water jacket
[0036] 23 Transition channel
[0037] 24 Protrusion
[0038] 25 Core flash
[0039] 26 Width
[0040] 30 Upper water jacket core
[0041] 31 Lower water jacket core
[0042] 32 Recess
[0043] 33 Exhaust core
[0044] 40 Drill
[0045] 50 Flow direction
[0046] 51 Opening in the upper water jacket
[0047] 52 Opening in the lower water jacket
[0048] 53 First end of the transition channel
[0049] 54 Second end of the transition channel
