Method for producing a piston

Abstract

A method for producing a piston may include producing a piston top part and a piston bottom part each including an inner support element having an inner joining surface and an outer support element having an outer joining surface. At least one of the joining surfaces may include a solder depository. The method may also include pre-machining at least one of the joining surfaces and introducing a high-temperature soldering material in at least one solder depository. The method may further include assembling the piston top part and the piston bottom part to form a piston body via creating at least one of circular contact and linear contact between the joining surfaces such that a gap width is 20 m to 150 m. The method may also include transferring the piston body into a soldering oven, melting the high-temperature soldering material via heating the piston body, and cooling the piston body.

Claims

1. A method for producing a piston, comprising: producing a piston top part and a piston bottom part each including an inner support element having an inner joining surface and an outer support element having an outer joining surface, wherein at least one of the inner joining surface of the piston top part, the inner joining surface of the piston bottom part, the outer joining surface of the piston top part, and the outer joining surface of the piston bottom part includes a solder depository; pre-machining at least one of the inner joining surface of the piston top part, the inner joining surface of the piston bottom part, the outer joining surface of the piston top part, and the outer joining surface of the piston bottom part such that in a joined together state i) the inner joining surface of the piston top part and the inner joining surface of the piston bottom part, and ii) the outer joining surface of the piston top part and the outer joining surface of the piston bottom part do not butt flat against each other, and define a zero gap therebetween, introducing a high-temperature soldering material in at least one solder depository; assembling the piston top part and the piston bottom part to form a piston body via creating at least one of circular contact and linear contact i) between the inner joining surface of the piston top part and the inner joining surface of the piston bottom part, and ii) between the outer joining surfaces of the piston top part and the outer joining surface of the piston bottom part such that a gap width is 20 m to 150 m; transferring the piston body into a soldering oven; melting the high-temperature soldering material via heating the piston body to a soldering temperature of approximately 1300 C or less; and cooling the piston body until the high-temperature soldering material has completely solidified.

2. The method according to claim 1, wherein assembling the piston top part and the piston bottom part to form the piston body includes creating a linear contact i) between the inner joining surface of the piston top part and the inner joining surface of the piston bottom part, and ii) between the outer joining surfaces of the piston top part and the outer joining surface of the piston bottom part such that a gap width is 20 m to 80 m.

3. The method according to claim 1, wherein melting the high-temperature soldering material includes heating the piston body at a pressure of 10.sup.2 mbar or less.

4. A piston comprising: a piston top part including an inner support element having an inner joining surface and an outer support element having an outer joining surface; a piston bottom part including an inner support element having an inner joining surface and an outer support element having an outer joining surface, the piston bottom part arranged such that i) the inner joining surface of the piston bottom part and the inner joining surface of the piston top part contact one another in at least one of a circular manner and linear manner defining an inner gap of 20 m to 150 m therebetween, and ii) the outer joining surface of the piston bottom part and the outer joining surface of the piston top part contact one another in at least one of a circular manner and linear manner defining an outer gap of 20 m to 150 m therebetween; at least one solder depository disposed in one of the inner joining surface of the piston top part, the inner joining surface of the piston bottom part, the outer joining surface of the piston top part, and the outer joining surface of the piston bottom part; and a solder seam composed of a high-temperature soldering material disposed within the at least one solder depository, the inner gap, and the outer gap, the solder seam connecting the piston top part and the piston bottom part to define a piston body.

5. The piston according to claim 4, wherein the at least one solder depository includes two solder depositories disposed in one of the inner joining surface of the piston top part, the inner joining surface of the piston bottom part, the outer joining surface of the piston top part, and the outer joining surface of the piston bottom part.

6. The piston according to claim 4, wherein at least one of: one of the inner joining surface of the piston top part and the inner joining surface of the piston bottom part extends perpendicularly to a piston axis and the other of the inner joining surface of the piston top part and the inner joining surface of the piston bottom part extends obliquely to the piston axis; and one of the outer joining surface of the piston top part and the outer joining surface of the piston bottom part extends perpendicularly to the piston axis and the other of the outer joining surface of the piston top part and the outer joining surface of the piston bottom part extends obliquely to the piston axis.

7. The piston according to claim 4, wherein at least one of; one of the inner joining surface of the piston top part and the inner joining surface of the piston bottom part extends perpendicularly to a piston axis and the other of the inner joining surface of the piston top part and the inner joining surface of the piston bottom part is configured kinked; and one of the outer joining surface of the piston top part and the outer joining surface of the piston bottom part extends perpendicularly to the piston axis and the other of the outer joining surface of the piston top part and the outer joining surface of the piston bottom part is configured kinked.

8. The piston according to claim 4, wherein at least one of: one of the inner joining surface of the piston top part and the inner joining surface of the piston bottom part extends perpendicularly to a piston axis and the other of the inner joining surface of the piston top part and the inner joining surface of the piston bottom part is configured one of concave and convex; and one of the outer joining surface of the piston top part and the outer joining surface of the piston bottom part extends perpendicularly to the piston axis and the other of the outer joining surface of the piston top part and the outer joining surface of the piston bottom part is configured one of concave and convex.

9. The piston according to claim 4, wherein at least one of the inner joining surface of the piston top part, the inner joining surface of the piston bottom part, the outer joining surface of the piston top part, and the outer joining surface of the piston bottom part extends parallel to a piston axis and has a defined local projection.

10. An internal combustion engine comprising at least one cylinder and a piston arranged therein, the piston including: a piston top part including an inner support element having an inner joining surface and an outer support element having an outer joining surface; a piston bottom part including an inner support element having an inner joining surface and an outer support element having an outer joining surface, the piston bottom part arranged such that i) the inner joining surface of the piston bottom part and the inner joining surface of the piston top part contact one another in at least one of a circular manner and linear manner defining an inner gap of 20 m to 150 m therebetween, and ii) the outer joining surface of the piston bottom part and the outer joining surface of the piston top part contact one another in at least one of a circular manner and linear manner defining an outer gap of 20 m to 150 m therebetween; at least one solder depository disposed in one of the inner joining surface of the piston top part, the inner joining surface of the piston bottom part, the outer joining surface of the piston top part, and the outer joining surface of the piston bottom part; and a solder seam composed of a high-temperature soldering material disposed within the at least one solder depository, the inner gap, and the outer gap, the solder seam connecting the piston top part and the piston bottom part to define a piston body.

11. The internal combustion engine according to claim 10, wherein at least one of: one of the inner joining surface of the piston top part and the inner joining surface of the piston bottom part extends perpendicularly to a piston axis and the other of the inner joining surface of the piston top part and the inner joining surface of the piston bottom part extends obliquely to the piston axis; and one of the outer joining surface of the piston top part and the outer joining surface of the piston bottom part extends perpendicularly to the piston axis and the other of the outer joining surface of the piston top part and the outer joining surface of the piston bottom part extends obliquely to the piston axis.

12. The internal combustion engine according to claim 10, wherein at least one of: one of the inner joining surface of the piston top part and the inner joining surface of the piston bottom part extends perpendicularly to a piston axis and the other of the inner joining surface of the piston top part and the inner joining surface of the piston bottom part is configured kinked; and one of the outer joining surface of the piston top part and the outer joining surface of the piston bottom part extends perpendicularly to the piston axis and the other of the outer joining surface of the piston top part and the outer joining surface of the piston bottom part is configured kinked.

13. The internal combustion engine according to claim 10, wherein at least one of: one of the inner joining surface of the piston top part and the inner joining surface of the piston bottom part extends perpendicularly to a piston axis and the other of the inner joining surface of the piston top part and the inner joining surface of the piston bottom part is configured one of concave and convex; and one of the outer joining surface of the piston top part and the outer joining surface of the piston bottom part extends perpendicularly to the piston axis and the other of the outer joining surface of the piston top part and the outer joining surface of the piston bottom part is configured one of concave and convex.

14. The method according to claim 1, wherein melting the high-temperature soldering material includes evacuating at least a portion of a soldering oven gas from within the soldering oven.

15. The method according to claim 1, wherein producing the piston top part and the piston bottom part includes arranging the solder depository in at least one of the inner joining surface of the piston top part, the inner joining surface of the piston bottom part, the outer joining surface of the piston top part, and the outer joining surface of the piston bottom part such that a flow of the high-temperature soldering material is directed in a flow direction via a capillary effect when melting the high-temperature soldering material.

16. The method according to claim 1, wherein assembling the piston top part and the piston bottom part to form the piston body includes creating at least one of circular contact and linear contact such that the gap width is larger in a region of the piston body subjected to a lower load force during operation than another region of the piston body.

17. The piston according to claim 4, wherein: a first solder depository of the at least one solder depository is disposed in one of the inner joining surface of the piston top part and the inner joining surface of the piston bottom part; and a second solder depository of the at least one solder depository is disposed in one of the outer joining surface of the piston top part and the outer joining surface of the piston bottom part.

18. The piston according to claim 4, wherein at least one gap of the inner gap and outer gap is configured larger in a region of the piston body subjected to a lower load force during operation than another region of the piston body.

19. The piston according to claim 4, wherein the at least one solder depository is arranged such that a flow of the high-temperature soldering material is directed in a flow direction when the high-temperature soldering material is melted to form the solder seam.

20. The piston according to claim 9, wherein the local projection extends perpendicular to the piston axis and abuts at least one of the inner joining surface of the piston top part, the inner joining surface of the piston bottom part, the outer joining surface of the piston top part, and the outer joining surface of the piston bottom part such that the local projection at least partially defines at least one of the inner gap and outer gap.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) In the drawing, schematically in each case,

(2) FIG. 1 shows a sectional view through a piston according to the invention,

(3) FIG. 2 shows a detailed view from FIG. 1 in the region of two opposite disposed joining surfaces with one joining surface extending perpendicularly to a piston axis and one joining surface extending obliquely to a piston axis,

(4) FIG. 3 shows a view as in FIG. 2, but with two solder depositories in the oblique joining surface,

(5) FIG. 4 shows one joining surface extending perpendicularly to the piston axis and one concave oppositely disposed joining surface,

(6) FIG. 5 shows a view as in FIG. 4, but with one convex joining surface,

(7) FIG. 6 shows a detailed view from FIG. 1 with one joining surface extending perpendicularly to the piston axis and one oppositely disposed groove-like joining surface with a solder depository,

(8) FIG. 7 shows a view as in FIG. 6, but with two groove-like joining surfaces,

(9) FIG. 8 shows a modification from FIG. 6,

(10) FIG. 9 shows joining surfaces extending parallel to a piston axis, with a defined local projection,

(11) FIG. 10 shows a view rotated by 90 in relation to FIG. 9, with radially extending joining surfaces with a local projection.

DETAILED DESCRIPTION

(12) Shown in accordance with FIG. 1 is a piston 1 according to the invention which has a piston top part 2 and a piston bottom part 3. The piston top part 2 has in this case an inner support element 4 and an outer support element 5, in the same way as the piston bottom part 3. The piston top part 2 is supported in this case via its inner support element 4 in relation to the inner support element 4 of the piston bottom part 3 and by its outer support element 5 is supported in relation to the outer support element 5 of the piston bottom part 3. A cooling channel 6 is included in this case between the inner support elements 4 and the outer support elements 5. According to the invention, the piston top part 2 is now supported by its inner support element 4, via an inner joining surface 7, on an associated inner joining surface 7 of the inner support element 4 of the piston bottom part 3. In the same way, the piston top part 2 is supported by its outer support element 5, via an outer support surface 8, in relation to an outer support surface 8 of the outer support element 5 of the piston bottom part 3. A soldering gap 9 (cf. FIGS. 2 to 10) is formed in this case between the respectively oppositely disposed joining surfaces 7, 7 and 8, 8.

(13) The respective joining surfaces 7, 7, 8, 8 of the piston top part 2 and/or of the piston bottom part 3 are produced, especially angled, in this case in such a way that in the joined together state these do not butt flat against each other, forming a zero gap. The soldering gap 9 is therefore wedge shaped, for example.

(14) The described piston top part 2 and piston bottom part 3 can naturally be referred to a first and a second piston part so that the first piston part represents for example a piston basic body and the second piston part represents for example a ring belt.

(15) The piston 1 according to the invention is now produced by means of a production method according to the invention which is divided into the following method steps: first of all the piston top part 2 and the piston bottom part 3, each having an inner support element 4 with inner joining surfaces 7, 7 and each having an outer support element 5 with outer joining surfaces 8, 8 are produced, wherein at least one solder depository 10 (cf. FIGS. 2 to 10) is introduced in at least one inner joining surface 7, 7 and/or in at least one outer joining surface 8, 8. Purely theoretically, the solder depository 10 according to FIGS. 2 to 10 is always arranged in this case in the region of the respective joining surface 7, 7, 8, 8, wherein it is naturally also conceivable that one of the joining surfaces 7, 7, 8, 8 extends in the radial direction, that is to say extends orthogonally to a piston axis 11 and the solder depository 10 is arranged there. In this case, the radially extended joining surface 7, 7, 8, 8 would then be removed after soldering by means of for example a metal cutting process.

(16) A high-temperature soldering material 12 is now introduced in at least one solder depository 10. The piston top part 2 is now assembled with the piston bottom part 3, forming a piston body or the piston 1, and in the process at least one circular and linear contact 13 between the respective inner joining surfaces 7, 7 and the respective outer joining surfaces 8, 8 is created, wherein a gap width w lies between 20 m<w<150 m, preferably between 20 m<w<80 m. In this case, at least one inner joining surface 7, 7 and/or at least one outer joining surface 8, 8 of the piston top part 2 and/or of the piston bottom part 3 lies obliquely to the corresponding joining surface 8, 8, 7 7 of the piston bottom part 3 or of the piston top part 2. The soldering gap 9 which remains between two associated joining surfaces 7, 7 and 8, 8 is therefore wedge-shaped at least in sections. The piston 1 is now transferred into a soldering oven and heated there to a soldering temperature of 1300 C. maximum, usually to a soldering temperature of between 1010 C. and 1180 C. and consequently the high-temperature soldering material 12 is melted. As a result of the melting of the soldering material 12, this is distributed inside the soldering gap 9 and on account of capillary effects penetrates even into the smallest of gaps. By means of the only linear or circular contact between two oppositely disposed joining surfaces 7, 7 and 8, 8 zero gaps which previously often occurred are avoided and as a result the connection quality is significantly increased.

(17) During the soldering process in the soldering oven, a pressure of for example 10.sup.2 mbar maximum is furthermore created, wherein by evacuating the soldering oven gases which can negatively influence the soldering process can especially also be removed and as a result can enhance the quality of the soldered connection.

(18) In FIGS. 2 to 10, the joining surfaces are in each case designated 7, 7 or 8, 8, wherein it is obviously clear that these occur alternatively only in association with the respectively associated inner or outer support element 4, 5.

(19) If consideration is now given to the individual soldering gaps 9, then according to FIG. 2 a soldering gap 9 which is formed by two oppositely disposed joining surfaces 7, 7 and 8, 8 can be seen, wherein one joining surface 7, 8 extends perpendicularly to a piston axis 11 or perpendicularly to a piston axis 11 in a radially encompassing manner, whereas the other joining surface 7, 8 extends obliquely to the piston axis 11. One solder depository 10 is arranged in this case in the joining surface 7, 8 which extends obliquely to the piston axis 11. In the case of the soldering gap 9, in this case it can be a soldering gap between the inner support elements 4 or the outer support elements 5. If consideration is given to the soldering gap 9 according to FIG. 3, then this in the main is similarly designed with the soldering gap 9 according to FIG. 2, wherein, however, two solder depositories 10 are arranged on the joining surface 7, 8.

(20) If consideration is given to the soldering gaps 9 according to FIGS. 4 and 5, then it can be seen that the joining surface 7, 8 extends perpendicularly to the piston axis 11 there, whereas the oppositely disposed joining surface 7, 8 in the case of FIG. 4 is of concave design and in the case of FIG. 5 is of convex design. In both cases, however, a linear contact 13 is formed between the two joining surfaces 7, 7 or 8, 8.

(21) Shown according to FIG. 6 is a soldering gap 9 the joining surface 7, 8 of which again extends perpendicularly to the piston axis 11, like in FIG. 7, whereas the other joining surface 7, 8 is of kinked design and in the region of a kink 14, which according to FIG. 6 is shown only by a discontinuously drawn line, has a solder depository 10. The soldering gap 9 according to FIG. 7 is also designed in the same way, wherein in this case two kinked joining surfaces 7, 8 are provided.

(22) If consideration is given to FIG. 8, then in the soldering gap 9 shown there the joining surface 7, 8 is orientated perpendicularly to the piston axis 11, whereas the oppositely disposed joining surface 7, 8 is of kinked design. The solder depository 10 is in this case, however, arranged in the region of the radially orientated joining surface 7, 8 opposite the kink 14.

(23) If consideration is finally given to FIG. 9, then a soldering gap 9 which extends parallel to the piston axis 11 can be seen there, with again a circular contact point, in the same way as in FIG. 10, wherein the soldering gap 9 according to FIG. 10 is again orientated perpendicularly to the piston axis 11, however.

(24) As basic material for the piston parts 2, 3, for example an AFP steel 38MNVS6 according to DIN EN10267, with material number 1.1303, can be selected, whereas for the high-temperature soldering material 12 for example a nickel-based solder L-BN12 according to EN 1044 or DIN 8513 can be selected.

(25) All embodiments of the piston 1 according to the invention and of the production method according to the invention share the common factor in this case that the zero gaps, previously known from the prior art, which ensued as a result of parallel and flat abutting surfaces can be completely avoided and as a result the connection quality is significantly increased.

(26) The piston 1 according to the invention is used for example in a cylinder of an internal combustion engine 15.