Piston for a heat engine, heat engine comprising such a piston, and methods

Abstract

Various implementations include a combustion engine piston, including a skirt in a counter-part and including a first contact area of the piston in the counter-part, a head which extends transverse to a central axis, and a ring carrier which comprises at least two lands and at least two grooves for receiving the rings, including a first land adjoining the head and a second land situated between the first land and the skirt, wherein the lands include at least one contact land having a diameter greater than a minimum diameter of the skirt to form a second contact area of the piston in the counter-part, and wherein at least one contact land comprises a friction-reducing surface coating, formed at least on a radial sector covering an angle of at least 30 degrees, and up to on a single sector covering an angle of 360 degrees.

Claims

1. A combustion engine piston, comprising: a skirt for guiding the piston in translation along a central axis in a counter-part and including a first contact area of the piston in the counter-part, a head which extends transverse to the central axis and is arrangeable to be in contact with the combustion gases, and a ring carrier which comprises at least two lands and at least two grooves for receiving rings, including a first land adjoining the head and a second land situated between the first land and the skirt, wherein the lands include at least one contact land having a diameter greater than a minimum diameter of the skirt to form a second contact area of the piston in the counter-part, wherein the at least one contact land comprises a friction-reducing surface coating formed at least on a radial sector covering an angle of at least 30 degrees, and up to on a single sector covering an angle of 360 degrees, and wherein the diameter of the contact land is considered without the coating, and the diameter of the skirt is considered without bore.

2. The piston according to claim 1, wherein at least one contact land has a diameter greater than an average diameter of the skirt.

3. The piston according to claim 1, wherein the piston is a short piston, having a diameter and a height smaller than the diameter.

4. The piston according to claim 1, wherein the base material of the piston is steel.

5. The piston according to claim 1, wherein the friction-reducing surface coating is made from DLC-type amorphous carbon a-C:H.

6. The piston according to claim 1, wherein the friction-reducing surface coating is made from DLC-type amorphous carbon ta-C.

7. The piston according to claim 1, wherein the at least one contact land includes at least one sublayer formed below the friction-reducing surface coating.

8. The piston according to claim 1, wherein the second land has a diameter larger than the first land.

9. The piston according to claim 1, wherein among the lands of the ring carrier, only the at least one contact land-include a friction-reducing surface coating.

10. The piston according to claim 1, wherein the ring carrier comprises a single contact land.

11. The piston according to claim 10, wherein in that the single contact land is the second land.

12. The piston according to claim 1, wherein the ring carrier comprises two contact lands.

13. The piston according to claim 12, wherein the two contact lands are the second land and a third land.

14. The piston according to claim 12, wherein the two contact lands are the first land and the second land.

15. A heat engine, comprising: a piston according to claim 1; and a counter-part receiving the piston.

16. The heat engine according to claim 15, wherein the counter-part includes a friction-reducing surface coating made from amorphous carbon of the DLC type.

17. A method for coating a piston according to claim 1, wherein the method comprises the following steps: a step for positioning a mask on the piston, and a step for localized deposition of a friction-reducing surface coating through the mask, at least on the at least one contact land.

18. A method for implementing a heat engine according to claim 15, wherein the skirt and the at least one contact land including the friction-reducing surface coating make up the contact areas of the piston in the counter-part.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The invention will be better understood upon reading the following description, given solely as a non-limiting example, and made with reference to the accompanying figures wherein:

(2) FIG. 1 is a side view, in partial cross-section, of a piston according to the invention, of the short piston type, where the second land constitutes a contact land including a surface coating;

(3) FIG. 2 is a perspective view of the piston of FIG. 1;

(4) FIG. 3 is an enlarged partial cross-section of the ring carrier, showing the second land having a diameter larger than the skirt, as well as the first and third land;

(5) FIG. 4 is an enlarged partial cross-section of the second land, shown in a variant in which the second land includes a sublayer formed below the surface coating;

(6) FIG. 5 is a perspective view showing a mask provided to cover the piston during the deposition of the surface coating;

(7) FIG. 6 is a cross-section of the mask in the transverse plane defined by line VI-VI in FIG. 5;

(8) FIGS. 7, 8 and 9 are cross-sections similar to FIG. 6, showing mask variants;

(9) FIG. 10 is a view similar to FIG. 5, showing another mask variant;

(10) FIGS. 11 to 14 are partial cross-sections similar to FIG. 3, showing different piston variants;

(11) FIG. 15 is a perspective view similar to FIG. 2, showing a variant in which the ring carrier includes only two lands; and

(12) FIG. 16 is a view similar to FIG. 2, showing a variant in which the piston is of the long piston type.

DETAILED DESCRIPTION OF SOME EMBODIMENTS

(13) FIGS. 1 to 3 show a piston 1 according to the invention.

(14) The piston 1 is provided to equip a heat engine, more specifically an engine with alternating movement and internal combustion. The piston 1 is arranged in a sleeve C of a cylinder block B, partially shown only in FIG. 1 for simplification purposes. Preferably, the sleeve C includes a friction-reducing surface coating R made from amorphous carbon of the DLC type.

(15) The piston 1 is made from metal, preferably steel, aluminum alloy, or formed by an assembly of parts made from different metallic materials.

(16) The piston 1 has a longitudinal central axis X1, a height H1 defined parallel to the axis X1 and a diameter D1 defined radially to the axis X1. The piston 1 is a short piston, having a height H1 smaller than its diameter D1.

(17) The piston 1 comprises a skirt 2, a head 3 and a ring carrier 4. The piston 1 is provided to receive rings, not shown for simplification reasons.

(18) Within the engine, the piston 1 is driven in an alternating translational movement along the axis X1 in the counter-part formed by the sleeve C.

(19) More specifically, the piston 1 moves in the sleeve C according to a main translational movement along the axis X1, and secondary movements that can be summarized by a lateral movement perpendicular to the axis X1 and a rotational movement around an axis perpendicular to the axis X1 (tilting movement).

(20) This results in guiding of the piston 1 in the sleeve C owing to a contact between its skirt 2 and the sleeve C, contact that can be more pronounced between the sleeve C and the lower end of the skirt 2. The tilting movement and the deformations of the skirt 3 also cause contact between the sleeve C and the head 3 and/or the ring carrier 4 of the piston 1 on the tilting side.

(21) The skirt 2 is made up of an overall tubular wall centered on the axis X1, having an outer diameter D2. The skirt 2 is provided to guide the piston 1 in the sleeve C, and makes up a first contact area Z2 of the piston 1 in the sleeve C. The skirt 2 preferably includes a friction-reducing surface coating.

(22) Preferably, the coating of the skirt 2 is made from amorphous carbon of the DLC type.

(23) Alternatively, the coating of the skirt 2 can be made from graphite or any other material suitable for the targeted application.

(24) The head 3 is made up by a wall that extends transversely to the axis X1. The head 3 is provided to be arranged in contact with the combustion gases, and to receive the forces due to said combustion.

(25) In the example of the figures, the head 3 is made up of a planar wall. Alternatively, the head 3 can be made up of a hollow wall, including a blind cavity open on the outer side.

(26) The ring carrier 4 is located between the skirt 2 and the head 3. The ring carrier 4 comprises three lands 11, 12 and 13, as well as three grooves 14, 15 and 16 provided to receive rings. Each land 11, 12 and 13 is made up of a cylindrical surface. Each groove 14, 15 and 16 is made up of a cylindrical surface withdrawn relative to the adjacent lands, as well as two annular planar surfaces connected to the adjacent lands.

(27) The first land 11 is located in the immediate vicinity of the head 3, in contact with the gases and the fire.

(28) The second land 12 is located in the intermediate part of the ring carrier 4 between the skirt 2 and the head 3, while being slightly closer to the head 3.

(29) The third land 13 is located close to the skirt 2.

(30) The groove 14 is located between the lands 11 and 12. The groove 14 is provided to receive the fire ring, in contact with the gases and the fire.

(31) The groove 15 is located between the lands 12 and 13. The groove 15 is provided to receive the sealing ring, providing total sealing of the gases, while blocking those that would have passed the fire ring.

(32) The groove 16 is located between the land 13 and the skirt 2. The groove 16 is provided to receive the scraping ring, providing the scraping of the lubricant on the surface of the sleeve C.

(33) In the new moving parts concepts, the ring carrier 4 is able to become a second contact area Z4 of the piston 1 in the sleeve C, in other words a second contact and friction area of the piston 1 with the sleeve C.

(34) In the embodiment of the invention illustrated in FIGS. 1 to 3, the land 12 has a diameter D12 greater than a minimum diameter D2 of the skirt 2. Thus, the land 12 is a contact land making up the second contact area Z4 of the piston 1 in the sleeve C, in addition to the first contact area Z2 formed by the skirt 2. Preferably, the diameter D12 is greater than the average diameter D2 of the skirt 2, which can deform during operation. For example, the diameter D12 can be 10 to 50 μm larger than the diameter D2.

(35) Furthermore, the land 12 includes a friction-reducing surface coating 20, formed on a sector covering an angle of 360 degrees around the axis X1. In other words, the coating 20 is deposited on the entire circumference of the land 12. The coating 20 makes it possible to reduce the friction coefficient between the land 12 and the sleeve C, in contact and in motion relative to one another. Furthermore, the coating 20 makes it possible to greatly reduce the wear and/or the risk of seizing.

(36) As shown in FIG. 3, the diameter D12 of the land 12 is considered without the coating 20. In turn, the diameter D2 of the skirt 2 is considered without the bores and recesses.

(37) More generally, in the context of the invention, the piston 1 comprises at least one contact land having a diameter larger than the minimum outer diameter of the skirt and including a friction-reducing coating formed at least over a radial sector covering an angle of at least 30 degrees, and up to over a single sector covering an angle of 360 degrees. In other words, the coating extends around the axis X1 at least over a radial sector of 30 degrees, at most over a sector of 360 degrees, and can extend over several radial sectors each covering an angle of at least 30 degrees.

(38) In the embodiment of FIGS. 1 to 3, the coating 20 is formed only on the surface of the land 12, without overflowing in the adjacent grooves 14 and 15. Indeed, for some applications and/or for some materials, the coating 20 present in the grooves could be subject to a pulling-out phenomenon, generating pollution in contact between the ring carriers 4 and the sleeve C.

(39) Alternatively, the coating 20 can be formed on the surface of the land 12 and in the adjacent grooves 14 and 15. In this case, the deposition of the coating 20 is simplified.

(40) Furthermore, the coating 20 is formed over the entire height of the land 12, defined parallel to the axis X1.

(41) Alternatively, the coating 20 can be formed only over a portion of the height of the land 12, in particular in its center. This makes it possible to avoid any overflow of the coating 20 in the grooves 14 and 15 during its deposition on the land 12.

(42) The coating 20 has a maximum roughness Rz less than or equal to 2 μm, preferably less than or equal to 0.5 μm, for example obtained by polishing or sanding.

(43) The coating 20 has a thickness, defined radially to the axis X1, preferably equal to 2 μm. Alternatively, said thickness can be between 1 and 5 μm, preferably between 2 and 3 μm. The thickness of the coating 20 can in particular vary as a function of the diameter D1. For example, in the case where the piston 1 equips a heavy vehicle engine, it is conceivable for this thickness to reach up to 10 μm. Preferably, the coating 20 has a constant thickness, defined radially to the axis X1.

(44) In practice, in the contact area Z4, the land 12 can rub against the sleeve C over a single radial sector, and not over its entire circumference. Thus, it is sufficient to deposit the coating 20 on a single radial sector covering an angle of at least 30 degrees.

(45) Alternatively, in the contact area Z4, the land 12 can rub against the sleeve C in two diametrically opposite portions. In this case, it is sufficient to deposit the coating 20 on two diametrically opposite radial sectors of the land 12, each covering an angle of at least 30 degrees.

(46) According to other alternatives, the coating 20 can be deposited on one or two radial sectors of the land 12, each covering an angle limited to 45, 60, 90 or 120 degrees, around the axis X1.

(47) The coating 20 has a friction coefficient lower than the constituent material of the ring carrier 4. Thus, the friction between the sleeve C and the land 12 provided with the coating 20 is reduced, compared with the land 12 lacking coating 20.

(48) Preferably, the coating 20 is made from amorphous carbon of the DLC type. In other words, the coating 20 is a layer of hybridized carbon in sp.sup.2 or sp.sup.a, with or without hydrogen. For example, the coating 20 can be made from ta-C, a-C:H or ta-C:H. Also preferably, the coating 20 is made from a-C:H.

(49) Alternatively, the coating 20 can be made from graphite or any other material suitable for the targeted application. Preferably, the coating 20 is homogeneous.

(50) In FIG. 4, the second land 12 includes a sublayer 22 formed below the surface coating 20. For example, said sublayer 22 includes a Cr and/or W and/or Ni base.

(51) FIGS. 5 and 6 show an example coating method of a piston 1 according to the invention, aiming to deposit the coating 20 on the land 12.

(52) The method comprises at least one step for positioning a mask 40 on the piston 1, then a step for depositing the coating 20 on the land 12 through the mask 40. The method may include other steps within the scope of the invention.

(53) The mask 40 is positioned on the piston 1 according to a translational movement T40 oriented along the axis X1, as illustrated by an arrow in FIG. 5. The mask 40 then covers at least part of the piston 1, during the deposition of the coating 20.

(54) The mask 40 comprises a tubular part 42 and a planar part 43. When the mask 40 is positioned on the piston 1, the part 42 covers the ring carrier 4, while the part 43 covers the head 3.

(55) In the planar part 42, an intermediate portion 44 comprises two diametrically opposite slits 45 and 46, as well as two diametrically opposite junction zones 47 and 48. The slits 45 and 46 formed through the mask 40 allow the deposition of the coating 20 on the land 12. The areas 47 and 48 make it possible to connect the parts 42 and 43.

(56) As shown in FIG. 6, when the mask 40 is positioned on the piston 1, the slit 45 defines a sector with angle α1 corresponding to the radial sector 21 of the coating 20, the slit 46 defines a sector with angle α2 corresponding to the radial sector 22 of the coating 20, the area 47 defines a sector with angle θ1 and the area 48 defines a sector with angle β2, around the axis X1.

(57) The geometry of the portion 44 of the mask 40 determines the geometry of the coating 20. In particular, the geometry of the slits 45 and 46 determines the coverage of the sectors 21 and 22 of the coating 20 formed on the land 12.

(58) In the example of FIG. 6, the angles α1 and α2 each measure 156 degrees. Alternatively, the angles α1 and α2 can have different values, as a function of the desired coverage for the sectors 21 and 22.

(59) Still in the example of FIG. 6, the angles α1 and α2 are identical, like the angles β1 and β2 are identical; nevertheless, it is possible to consider providing different angles to define different sectors 21 and 22.

(60) Thus, the mask 40 makes it possible to isolate the parts of the piston 1 that it is not provided to coat, and to limit the deposition of coating 20 to the desired portions of the land 12 and the skirt 3.

(61) The material of the mask 40 can be chosen according to the deposition technique of the coating 20. For example, the mask 40 can be made from steel or aluminum.

(62) As a non-limiting example, the step for depositing the coating 20 can be carried out according to the teachings of document WO2012/156647.

(63) Depending on the shape of the piston 1, the nature of the materials of the piston 1 and the sleeve C, and the nature of the contact, the piston 1/sleeve C friction represents 20 to 30% of the losses by engine friction.

(64) Thus, the deposition of a coating on the skirt 2 and the land 12 can be leveraged in terms of decreasing friction, and therefore fuel consumption and CO2 emissions.

(65) On first approach, the new geometry of the pistons should lead to attributing between 5 and 10% of the losses by engine friction to the contact between the land 12 and the sleeve C. Under these conditions, the coating 20 applied on the land 12 should make it possible to decrease the losses by engine friction by about 2 to 5%.

(66) Advantageously, the coating method of the piston 1 can include the following steps, considered alone or in combination.

(67) Before the step for positioning of the mask 40, the method can include a step for preparing the surface of the second land 12, for example by machining or polishing.

(68) Before the step for depositing the coating 20, generally before the step for positioning the mask 40, the method can include a step for washing the piston 1, and in particular washing the land 12 intended to receive the coating 20.

(69) After the step for depositing the coating 20, the method can include a step for finishing the outer surface of the coating 20, for example by polishing.

(70) Variants of masks 40 for manufacturing a piston 1 according to the invention are shown in FIGS. 7 to 10. For simplification reasons, the component elements of these masks 40 comparable to the mask 40 of FIGS. 5 and 6 bear the same numerical references, and only the differences are outlined hereinafter.

(71) In FIG. 7, the junction areas 47 and 48 are radially offset relative to the rest of the mask 40. Thus, the mask 40 includes a single slit making it possible to form the coating 20 on a sector with 360 degrees around the axis X1, like for the piston 1 of FIGS. 1 to 3.

(72) In FIG. 8, the mask 40 includes a single slit 45 having an angle α1 of 30 degrees. Thus, the mask 40 makes it possible to deposit the coating on a single radial sector 21 limited to 30 degrees.

(73) In FIG. 9, the angle α1 measures 90 degrees, while the angle α2 measures 110 degrees. The slits 45 and 46 have different geometries.

(74) In FIG. 10, the tubular part 42 is more elongated so as to cover the skirt 2. Thus, the skirt 2 can receive a different coating from the land 12, or lack any coating.

(75) Alternatively, the tubular part 42 can be more or less elongated, and therefore cover a greater or lesser height of the skirt 2.

(76) Other embodiments of a piston 1 according to the invention are shown in FIGS. 11 to 16. For simplification reasons, the constituent elements of the piston 1 comparable to those of the first embodiment described above bear the same numerical references, and only the differences are outlined hereinafter.

(77) In FIG. 11, the first land 11 is the contact land having a diameter D1l greater than the minimum diameter D2 of the skirt 2 and provided with a friction-reducing coating 10.

(78) In FIG. 12, the third land 11 is the contact land having a diameter D13 greater than the minimum diameter D2 of the skirt 2 and provided with a friction-reducing coating 30.

(79) In FIG. 13, the first land 11 and the second land 12 are the contact lands having diameters D11 and D12 greater than the minimum diameter D2 of the skirt 2 and provided with friction-reducing coatings 10 and 20.

(80) In this case, the mask 40 used during the deposition of the coatings 10 and 20 can include two superimposed portions 44, provided with slits 45 and 46. Alternatively, the coatings 10 and 20 can be deposited successively by using two different masks 40.

(81) Preferably, the coating 10 is made from the same material as the coating 20.

(82) Optionally, the land 11 can include at least one sublayer formed below the coating 10, like for the coating 20.

(83) In FIG. 14, the second land 12 and the third land 13 are the contact lands having diameters D12 and D13 greater than the minimum diameter D2 of the skirt 2 and provided with friction-reducing coatings 20 and 30.

(84) In FIG. 15, the ring carrier 4 includes only two lands 11 and 12, and no land 13. Only the second land 12 is provided with a friction-reducing coating 20. The ring carrier 4 receives a fire and sealing ring in the groove 14 and a scraping ring in the groove 15.

(85) In FIG. 16, the piston 1 is a long piston, having a height H1 larger than its diameter D1.

(86) Alternatively, the piston 1 can have a height H1 equal to the diameter D1 without going beyond the scope of the invention.

(87) Furthermore, the piston 1 and the mask 40 can be configured differently from FIGS. 1 to 16 without going beyond the scope of the invention. Moreover, the technical characteristics of the various embodiments and variants mentioned above can be, in whole or for some of them, combined with each other. Thus, the piston 1 can be adapted in terms of cost, functionalities and performance.