Piston for internal combustion engine

Abstract

A piston in which a solid lubricant resin layer made of a resin containing a solid lubricant is formed at a skirt portion. A guide groove absent area where no guide groove is formed, which is provided in a predetermined range of the solid lubricant resin layer at a center portion in a width direction. The guide grooves directing from the both ends in the width direction of the guide groove absent area to both ends in the width direction of the skirt portion. The end portions of the guide grooves extended to end edges of the solid lubricant resin layer to form open ends. The solid lubricant resin layer and the guide grooves are formed at least at a thrust side skirt portion. The guide grooves are formed in a shape inclined upward from the guide groove absent area toward the end edges of the solid lubricant resin layer.

Claims

1. A piston for an internal combustion engine having a crown portion and a skirt portion projecting downward from the crown portion, the skirt portion having a thrust-side skirt portion and an anti-thrust-side skirt portion with the thrust-side skirt portion being located along a first direction away from a piston pin and the anti-thrust-side skirt portion being located along a second direction, opposite to the first direction, from the piston pin, a solid lubricant resin layer made of a resin containing a solid lubricant is located on each of the thrust-side skirt portion and the anti-thrust-side skirt portion in a predetermined pattern, guide grooves for guiding lubricating oil are formed at a portion of each of the thrust-side skirt portion and the anti-thrust-side skirt portion where no solid lubricant resin layer is formed, comprising: a center portion in a width direction of each of the thrust-side skirt portion and the anti-thrust-side skirt portion is formed with the solid lubricant resin layer having no guide groove, each guide groove is formed from an end in the width direction of the center portion toward an end in the width direction of the thrust-side-skirt portion or the anti-thrust-side skirt portion, each guide groove has an open end, nearest the end in the width direction of the thrust-side skirt-portion or the anti-thrust-side skirt portion; and all the guide grooves of the thrust-side skirt portion having a shape inclined upward from the center portion toward the end in the width direction of the thrust-side skirt-portion, and being provided so as to move the lubricating oil existing in the vicinity of the end in the width direction of the thrust-side skirt-portion into the center portion when the piston moves upward, all the guide grooves of the anti-thrust-side skirt portion having a shape inclined downward from the center portion toward the end in the width direction of the anti-thrust-side skirt-portion, and being provided so as to move the lubricating oil existing in the vicinity of the end in the width direction of the anti-thrust side skirt-portion into the center portion when the piston moves downward, and the center portion is formed in a range within ±10° to ±40° with respect to a reference line set as 0° around intersection of the axis of the piston pin and the reference line is set as a center, the reference line being a line orthogonal to an axis of the piston pin and extending in a diametrical direction of the piston.

2. The piston for an internal combustion engine according to claim 1, wherein introduction portions are formed at the respective ends in the width direction of the thrust-side skirt portion or the anti-thrust side skirt portion, which has no solid lubricant resin layer, for introducing the lubricating oil and the introduction portions communicate with the open ends of the guide grooves.

Description

BRIEF DESCRIPTION OF DRAWINGS

(1) FIG. 1(A) is a side view of a thrust side and FIG. 1(B) is a side view of an anti-thrust side of the piston for an internal combustion engine according to the present invention.

(2) FIG. 2(A) is a side view of a thrust side and FIG. 2(B) is a side view of an anti-thrust side of the piston for an internal combustion engine according to a modified example of the present invention.

(3) FIG. 3(A) is a side view of a thrust side and FIG. 3(B) is a side view of an anti-thrust side of the piston according to the present invention which is used for the motoring friction test.

(4) FIG. 4 is a graph illustrating the result of the motoring friction test.

(5) FIGS. 5(A) and 5(B) are schematic explanation drawings of the conventional piston, and FIG. 5(A) is a front view, and FIG. 5(B) is a plan view.

(6) FIG. 6 is an explanation drawing explaining the state of lubrication (Stribeck chart).

(7) FIG. 7 is an explanation drawing of the conventional piston (corresponding to FIG. 6 of the Patent Document 2).

(8) FIG. 8 is an explanation drawing of a forming range of the guide groove absent area.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

(9) Next, an embodiment according to the present invention will be described with reference to the accompanying drawings. The members and portions which are the same as the above mentioned conventional arts are denoted with the same names and reference numerals.

(10) Object to be Treated (Piston for Internal Combustion Engine)

(11) The piston 10 for an internal combustion engine which is an object to be treated in the present invention is not particularly limited as long as it is the piston for internal combustion engines. The present invention is applicable to any piston for a gasoline engine or a diesel engine.

(12) An aluminum-silicon based alloy or the like is generally used as the material of the piston for the internal combustion engine. However, the material of the piston for an internal combustion engine to which the present invention is applied is not particularly limited. Thus the present invention is applicable to the piston made of various materials known as the material of the piston for the internal combustion engine.

(13) Solid Lubricant Resin

(14) The solid lubricant resin layer 15 is formed in a predetermined pattern on the skirt portion 12 of the piston 10 for the internal combustion engine described above, and the guide groove 20 for guiding lubricating oil is formed at a portion where no solid lubricant resin layer 15 is formed.

(15) The solid lubricant resin layer 15 and the guide groove 20 are formed at least on the thrust side skirt portion 12a among the skirt portion 12 (12a, 12b) of the piston 10, preferably the solid lubricant resin layer 15 and the guide groove 20 are formed not only on the thrust side skirt portion 12a but also on the anti-thrust side skirt portion 12b.

(16) This solid lubricant resin is prepared by dispersing one or more types of solid lubricant(s) such as molybdenum disulfide, graphite, fluororesin (tetrafluoroethylene (PTFE) etc.), tungsten disulfide, metal oxide and the like, in a binder made of one or more types of resin(s) such as epoxy resin, phenolic resin, polyamide resin, polyamide-imide resin, or the like. Such solid lubricant resin is applied to the skirt portion 12 of the piston 10 by a known method in a predetermined pattern, then the solid lubricant resin is dried and cured to form the solid lubricant resin layer 15.

(17) The constitution of the solid lubricant resin used in the present invention is not particularly limited and various solid lubricant commercially available may be used as long as it has heat resistance which is sufficient to be used for a piston of an internal combustion engine. As an example, a solid lubricant resin used in the embodiment of the present invention is the solid lubricant resin containing 50% to 70% by mass of molybdenum disulfide in which molybdenum disulfide having an average particle size of 0.1 μm to 10.0 μm is dispersed as a solid lubricant in a binder of a polyamide-imide resin.

(18) The solid lubricant resin layer 15 is formed by coating the solid lubricant resin described above to the surface of the skirt portion 12 of the piston 10 to which necessary pretreatment such as degreasing, chemical conversion treatment, sandblasting, drying is applied. The coating the solid lubricant resin to form the solid lubricant resin layer 15 is performed so that the guide groove 20 described later is formed in a predetermined pattern by using various conventional coating technique such as immersion or spraying or the like, then fixing the coated solid lubricant resin by baking dry or the like.

(19) The film thickness of the solid lubricant resin layer 15 to be formed can be appropriately adjusted according to various conditions, however the film thickness is about 3 μm to 25 μm as an example.

(20) Guide Groove

(21) As already mentioned, in order to reduce the frictional resistance of the piston, it is effective to reduce the frictional resistance of the skirt portion on the side pressed against the inner wall of the cylinder. As one example, since the thrust side skirt portion 12a is in sliding contact with the cylinder inner wall while being pressed against the cylinder inner wall when the piston is moved downward in the combustion step, it is effective to reduce the frictional resistance of the thrust side skirt portion 12a.

(22) Such reduction in the frictional resistance is achieved by thickening the oil film formed between the center portion in the width direction of the thrust side skirt portion 12a and the cylinder inner wall to obtain a state of fluid lubrication, or a state close to the fluid lubrication.

(23) On the other hand, when the piston is being moved downward in the combustion step, the thrust side skirt portion 12a is pressed against the inner wall of the cylinder with a large force by the combustion pressure in the combustion chamber thus the surface pressure is increased, therefore, it is difficult to introduce the lubricating oil between the thrust side skirt portion 12a and the cylinder inner wall when the piston 10 is being moved downward, as described above.

(24) Therefore, the inventors of the present invention considered that the frictional resistance can be reduced by introducing lubricating oil between the center portion of the thrust side skirt portion 12a and the cylinder inner wall in the compression step, i.e. the step before entering the combustion step, to create a state in which the lubricating oil is abundantly present, thereby starting the downward movement of the piston 10 in such state.

(25) Moreover, when the piston is moved upward in the compression step, the anti-thrust side skirt portion 12b is pressed against the cylinder inner wall, and the lubricating oil can be introduced between the center portion of the thrust side skirt portion 12a and the cylinder inner wall relatively easily, therefore, it is considered that a relatively thick oil film can be formed in this portion.

(26) Under the above assumption, in the piston 10 of the present invention, the guide groove absent area 15a with no guide groove 20 is formed in the center portion in the width direction of the thrust side skirt portion 12a, that is, in the solid lubricant resin layer 15 which is in sliding contact with the cylinder inner wall.

(27) FIG. 8 is an explanation drawing of the forming range of the guide groove absent area 15a together with one example of formation pattern of the guide groove 20 according to the present invention.

(28) As shown in FIG. 8, a reference line Lb orthogonal to the axis 13c of the piston pin and extending in the diametrical direction of the piston 10 in a plan view of the piston 10 is assumed, the reference line Lb is set to 0°, the intersection X of the axis 13c of the piston pin and the reference line Lb is set as the center, then, this guide groove absent area 15a is formed into a flat surface at the +θ side and the −θ side of the reference line Lb respectively in a range within 5° to 45° (10 to 90 in total), preferably in the range of 10° to 40° (20° to 80° in total), and in the present embodiment, 20° (40° in total). Then a guide grooves 20 inclined upward from both ends in the width direction of the guide groove absent area 15a toward both ends in the width direction of the thrust side skirt portion 12a are formed, and the guide groove 20 are extended to a peripheral edge of the solid lubricant resin layer 15 to form ends of the guide grooves 20 as open ends 20e.

(29) In this way, the guide groove 20 inclined upward is formed from the both ends in the width direction of the guide groove absent area 15a toward the both ends in the width direction of the thrust side skirt portion 12a, and the end of the guide groove 20 is formed as an open end 20e, thereby, when the piston 10 is moved upward in the compression step, the lubricating oil existed on the both end sides in the width direction of the thrust side skirt portion 12a flows into the guide groove 20 via the open end 20e then moved in the guide groove 20 toward the side of the guide groove absent area 15a, then introduced between the guide groove absent area 15a and the cylinder inner wall to increase a thickness of the oil film at this portion, accordingly, the downward movement of the piston in the combustion step subsequent to this compression step can be started in a state in which the lubricating oil is abundantly existed between the guide groove absent area 15a and the cylinder inner wall.

(30) In addition, by forming the guide groove absent area 15a in which the guide groove 20 is not formed at the center portion in the width direction of the thrust side skirt portion 12a to form the portion in sliding contact with the cylinder inner wall as a flat surface, in the guide groove absent area 15a, there is no guide groove 20 that can release the lubricating oil, and by introducing the lubricating oil simultaneously from the both sides in the width direction of the thrust side skirt portion 12a, the lubricating oil introduced into this region is difficult to escape, and, no dents such as grooves are present, accordingly, lubricating oil that does not contribute to the increase of the oil film by being accumulated in the dents does not generate, thereby, the introduced lubricating oil is used for increasing an interval between the guide groove absent area 15a and the cylinder inner wall, thus it is considered that the thickness of the oil film can be simply increased.

(31) On the other hand, on the contrary to the thrust-side skirt portion 12a, the anti-thrust-side skirt portion 12b is pressed against the cylinder inner wall when the piston 10 is moved upward in the compression step or the exhaust step. Therefore, if the upward movement of the piston 10 can be started in a state where the lubricating oil is abundantly existed by introducing the lubricating oil between the guide groove absent area 15a of the anti-thrust side skirt portion and the cylinder inner wall surface when the piston is moved downward in the combustion step or the suction step, the frictional resistance at the time of the upward movement of the piston 10 can also be drastically reduced.

(32) Therefore, in the anti-thrust side skirt portion 12b, the guide grooves 20 inclined downward from the both ends in the width direction of the guide groove absent area 15a toward both ends in the width direction of the anti-thrust side skirt portion 12b are formed, and the end portions of the guide grooves 20 are extended to the peripheral edge of the solid lubricant resin layer 15 so as to form open ends 20e.

(33) With the above configuration, when the piston 10 moved downward, the lubricating oil is flown into the guide grooves 20 (see FIG. 1(B)) provided in the anti-thrust side skirt portion 12b via the open ends 20e, then the flown lubricating oil is further flown into the guide groove absent area 15a to increase the thickness of the oil film between the guide groove absent area 15a and the cylinder inner wall, whereby, the upward movement of the piston in the exhaust step or the compression step subsequent to the combustion step or the suction step can be started in a state where the lubricating oil is abundantly existed.

(34) As described above, in the piston 10 of the present invention, the guide grooves 20 formed in the thrust-side skirt portion 12a and the guide grooves 20 formed in the anti-thrust-side skirt portion 12b are formed in the direction in which the inclination direction is vertically (i.e., in the upper and lower direction) reversed, not only the frictional resistance caused when the piston 10 is moved downward but also the frictional resistance caused when the piston 10 is moved upward can be reduced.

(35) In each of the thrust-side skirt portion 12a and the anti-thrust-side skirt portion 12b, in order to facilitate the introduction of the lubricating oil into the open ends 20e of the guide grooves 20, in the piston 10 of the present invention, the guide groove absent area 15a is provided with a predetermined width at both ends in the width direction of each of the skirt portion 12 (12a, 12b) so to form introduction portions 21 which are provided for introducing for the lubricating oil, and communicates with the open ends 20e of the guide grooves 20.

(36) With such a configuration, not only the lubricating oil existing in the vicinity of the open ends 20e of the guide grooves 20 but also the lubricating oil existing around the introducing portions 21 communicating with the open ends 20e is easily introduced into the guide grooves 20, thereby the lubricating oil can be introduced more smoothly into the guide grooves 20.

(37) In the examples illustrated in FIGS. 1(A) and 1(B), four pairs of the guide grooves 20 are respectively provided so that the guide grooves 20 which are formed at the left side of the drawings and the guide grooves 20 which are formed at the right side of the drawings become paired with respect to the center in the width direction of the skirt portion 12. (12a, 12b). However, the number of the guide grooves 20 to be formed may be more or less than the number of the guide grooves 20 in the example illustrated in FIGS. 1(A) and 1(B).

(38) Furthermore, in the examples illustrated in FIGS. 1(A) and 1(B), the guide grooves 20 forming each pair are arranged at the same height so as to be bilaterally symmetrical with respect to the center of the skirt portion 12 (12a, 12b). However, the guide grooves 20 may be paired with the guide grooves 20 arranged at different heights on the left and right sides.

(39) Further, in the embodiment illustrated in FIG. 1, the above-mentioned guide groove absent area 15a is provided as a belt-shaped portion having a constant width in the height direction, however the shape of the guide groove absent area 15a is not limited to the shape illustrated in FIG. 1 and any shape can be employed as long as the above-mentioned guide groove absent area 15a is provided at least at the portion which is contacted with the cylinder inner wall. As one example, as illustrated in FIGS. 3(A) and 3(B), the guide groove absent areas 15a may be formed so as to have different widths between each of an upper side and an lower side, for example, between the upper side and the lower side in view of the axis of the piston pin 13.

(40) In this case, because of oscillation of the piston 10, in the thrust side skirt portion 12a, the range of sliding contact with the cylinder inner wall tends to be that the sliding contact width at the lower side of the skirt portion 12a becomes wide as indicated by the broken line in FIG. 2(A), and in the anti-thrust side skirt portion 12b, the range of sliding contact with the cylinder inner wall tends to be that the sliding contact width at the upper side of the skirt portion 12b becomes wide as indicated by the broken line in FIG. 2(B). Therefore, the guide groove absent area 15a may be formed with a pattern vertically reversed at the thrust side and the anti-thrust side. Furthermore, either one of the thrust side skirt portion 12a or the anti-thrust side skirt portion 12b, the guide groove absent area 15a having a constant width as described above with reference to FIG. 1(A) may be provided and, on the other side, the guide groove absent area 15a having different width between the upper side and the lower side as illustrated in FIG. 2 may be formed.

(41) Therefore, in the configuration in which the formation width of the guide groove absent area 15a is changed between the upper side and the lower side thereof as described above, the guide groove 20 to be formed has different lengths between the upper side and the lower side of the skirt portion.

EMBODIMENT

(42) Next, a motoring friction test results carried out using the piston 10 of the present invention in which the guide grooves 20 were formed in the above-described pattern in the skirt portion 12 (12 a, 12b) are shown below.

(43) Motoring Friction Test

(1) Purpose of the Test

(44) The test is directed to confirm the frictional resistance of the piston having the guide grooves formed with the pattern according to the present invention is reduced.

(2) Test Method

(45) In the motor friction measurement, an engine (an in-line four-cylinder, 2.5 liter, gasoline engine) for an automobile is used for the test; the output torque of the external motor when the engines are respectively operated by the external motors for the above engine equipped with a piston having the guide grooves formed in the skirt part according to the present invention with the patter of the present invention (Embodiment), and the above engine equipped with a piston in which only the solid lubricant resin layer is formed without the guide groove in the skirt portion (comparative example); then the measured difference in torque is evaluated as the difference in frictional resistance.

(3) Embodiment and Comparative Example

(3-1) Embodiment

(46) In FIG. 3, the formation pattern of the guide groove of the piston according to the present invention (Embodiment) used for the motoring friction measurement is illustrated. In FIG. 3, the gray portion is the portion where the solid lubricant resin layer is formed, and the white portion is the formation portion of the groove (the guide groove 20, the introduction portions 21).

(47) FIG. 3(A) illustrates the pattern of the guide groove formed in the thrust side skirt portion. FIG. 3(B) illustrates the pattern of the guide groove formed in the anti-thrust side skirt portion.

(3-2) Comparative Example

(48) The comparative example is the piston in which no guide groove is provided at the thrust side skirt portion and the anti-thrust side skirt portions, and a solid lubricant resin layer is formed on the entire surface of the skirt portion.

(4) Test Results

(49) FIG. 4 shows the results of the motoring friction test conducted using pistons of the embodiment and comparative example described above.

(50) According to the graph of FIG. 4, in the entire range of the measured rotational speed, when the piston of the embodiment of the present invention was mounted, the piston could be moved with a low torque, thus the frictional resistance of the piston was decreased as compared with the comparative example. This difference in torque exceeded by about 4% on average and exceeded by 5% at the maximum.

(51) Considering that the frictional resistance of the piston system occupies most of the frictional resistance of the piston ring, the reduction of the frictional resistance of the above-mentioned numerical values as a whole for the piston by the structure change of the skirt portion which was confirmed in the test is the good result. Therefore, it was confirmed by the test that the effect of reducing the frictional resistance of the skirt portion by the formation of the guide groove with the pattern of the present invention was extremely prominent.

DESCRIPTION OF REFERENCE NUMERALS

(52) 10 Piston 11 Crown portion 12 Skirt portion 12a Thrust side skirt portion 12b Anti-thrust side skirt portion 13 Piston pin 13c Axis (of the piston pin) 15 Solid lubricant resin layer 15a Guide groove absent area 20 Guide groove 20e Open end 21 Introduction groove 50 Cylinder 51 Connecting rod 110 Piston 112 Skirt portion 115 Solid lubricant resin layer 120 Guide groove