Piston for a cylinder for an internal combustion engine
10801439 · 2020-10-13
Assignee
Inventors
Cpc classification
F02B23/0672
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02B2023/0612
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02B23/0669
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
C23C4/02
CHEMISTRY; METALLURGY
F02F3/14
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02B23/0651
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02B23/0603
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
C23C4/01
CHEMISTRY; METALLURGY
F02F3/12
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16J1/00
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Y02T10/12
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
International classification
F02F3/14
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16J1/00
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02F3/12
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
C23C4/01
CHEMISTRY; METALLURGY
F02B23/06
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
C23C4/02
CHEMISTRY; METALLURGY
Abstract
A piston for a cylinder for an internal combustion engine has a piston bowl surface adapted for facing a combustion chamber of the cylinder, the piston bowl surface being provided with a thermal barrier coating layer, wherein the thermal barrier coating layer is provided on a plurality of circumferentially spaced surface parts of the piston bowl surface. A method for producing a piston for a cylinder for an internal combustion engine includes the steps of providing a piston for a cylinder for an internal combustion engine, the piston having a piston bowl surface adapted for facing a combustion chamber of the cylinder, and providing the piston bowl surface with a thermal barrier coating layer, wherein the step of providing the thermal barrier coating layer is made on a plurality of circumferentially spaced surface parts of the piston bowl surface.
Claims
1. A piston for a cylinder for an internal combustion engine, the piston having a piston bowl surface adapted for facing a combustion chamber of the cylinder, the piston bowl surface being provided with a thermal barrier coating layer, wherein the thermal barrier coating layer is provided on a plurality of circumferentially spaced surface parts of the piston bowl surface.
2. A piston according to claim 1, wherein a surface extension of each thermal barrier coating layer surface part is adapted to lower a temperature of the piston at the surface part below a threshold temperature, the threshold temperature being a critical temperature for piston material corrosion.
3. A piston according to claim 1, wherein the thermal barrier coating layer is made of a heat insulating ceramic material.
4. A piston according to claim 3, wherein the heat insulating ceramic material comprises zirconium oxide.
5. A piston according to claim 1, wherein the piston bowl surface comprises at least one fuel spray impingement portion and wherein a position of at least one of the thermal barrier coating layer surface parts at least partly covers the fuel spray impingement portion.
6. A piston according to claim 5, wherein at least one of the thermal barrier coating layer surface parts is centered with regard to its associated fuel spray impingement portion.
7. A piston according to claim 1, wherein the piston bowl surface comprises a circumferential rim portion and a floor portion connected to and surrounded by the circumferential rim portion, wherein at least one of the thermal barrier coating layer surface parts is located at and has an extension along the circumferential rim portion.
8. A piston according to claim 7, wherein each thermal barrier coating layer surface part along the rim portion is distended from one another by a piston bowl surface without any thermal barrier coating layer.
9. A piston according to claim 8, wherein each thermal barrier coating layer surface part is surrounded by a piston bowl surface without any thermal barrier coating layer.
10. A piston according to claim 7, wherein each thermal barrier coating layer surface part has an extension into a piston bowl.
11. A piston according to claim 7, wherein each thermal barrier coating layer surface part has an extension on both sides of the circumferential rim portion.
12. A piston according to claim 1, wherein a thickness of the surface coating at each thermal barrier coating layer surface part is thicker in a center portion than at an outer boundary.
13. A piston according to claim 1, wherein a thickness of the thermal barrier coating layer at each thermal barrier coating layer surface part is greatest at a circumferential rim portion.
14. A piston according to claim 13, wherein the thickness is smallest at the outer boundary of each thermal barrier coating layer surface part.
15. A piston according to claim 12, wherein the thickness is varying continuously.
16. A piston according to claim 1, wherein a thickness of the thermal barrier coating layer is 5 to 4000.mu.m.
17. A piston according to claim 1, wherein the circumferential rim portion is covered by the thermal barrier coating layer surface parts to between 30 and 70%.
18. A piston according to claim 1, wherein each thermal barrier coating layer surface part has a generally rounded surface extension, preferably a generally oval surface extension.
19. A piston according to claim 1, wherein the thermal barrier coating layer is bonded to the piston through a bond layer.
20. A piston according to claim 18, wherein the bond layer is nickel based.
21. A piston according to claim 19, wherein the bond layer has a thickness of 20 to 250.mu.m, preferably 75 to 150.mu.m, and more preferably approximately 100 .mu.m.
22. A method for producing a piston for a cylinder for an internal combustion engine, comprising the steps of providing a piston for a cylinder for an internal combustion engine, the piston having a piston bowl surface adapted for facing a combustion chamber of the cylinder; and providing the piston bowl surface with a thermal barrier coating layer; wherein the step of providing the piston bowl surface with a thermal barrier coating layer is made on a plurality of circumferentially spaced surface parts of the piston bowl surface.
23. A method according to claim 22, wherein the step of providing the piston bowl surface with a thermal barrier coating layer includes the step of: applying the thermal barrier coating layer through thermal spraying.
24. A method according to claim 22, wherein the thermal spraying process is plasma spraying.
25. A method according to claim 22, wherein the thermal barrier coating layer is made of a heat insulating ceramic material.
26. A method according to claim 25, wherein the heat insulating ceramic material comprises zirconium oxide.
27. A method according to claim 22, wherein the piston bowl surface comprises at least one fuel spray impingement portion, and wherein the step of providing the thermal barrier coating layer on a plurality of circumferentially spaced surface parts of the piston bowl surface includes the step of: providing at least one of the thermal barrier coating layer surface parts at a position which at least partially covers the fuel spray impingement portion.
28. A method according to claim 27, wherein the step of providing at least one of the thermal barrier coating layer surface parts at a position which at least partially covers the fuel spray impingement portion includes the step of: centering the at least one thermal barrier coating layer surface parts with regard to its associated fuel spray impingement portion.
29. A method according to claim 27, wherein the step of applying the thermal barrier coating layer is preceded by the step of: applying a bond layer through thermal spraying, preferably through plasma spraying.
30. A method according to claim 29, wherein the bond layer is nickel based.
31. A method according to claim 22, wherein the step of applying the thermal barrier coating layer is preceded by the step of: blasting the piston bowl surface, preferably through sand blasting.
32. A method according to claim 31, wherein the step of applying the thermal barrier coating layer through thermal spraying includes using a first masking device having openings for each thermal barrier coating layer surface part, such that the thermal spraying only reaches the piston bowl surface at the surface parts.
33. A method according to claim 32, wherein the step of applying a bond layer through thermal spraying includes using a second masking device (40) having openings for each thermal barrier coating layer surface part, such that the thermal spraying only reaches the piston bowl surface at the surface parts.
34. A method according to claim 33, wherein the step of blasting the piston bowl surface includes using a third masking device having openings for each thermal barrier coating layer surface part, such that the thermal spraying only reaches the piston bowl surface at the surface parts.
35. A method according to claim 33, wherein the openings of the first masking device is smaller than the openings of the second masking device.
36. A method according to claim 34, wherein the openings of the second masking device is smaller than the openings of the third masking device.
37. A method according to claim 32, wherein the openings of the first masking device each has an extension which is adapted provide a surface extension of each thermal barrier coating layer surface part which is adapted to lower a temperature of the piston at the surface parts below a threshold temperature, the threshold temperature being a critical temperature for piston material corrosion.
38. A method according to claim 32, wherein a position of at least one of the openings of the first masking device is centered at the fuel spray impingement portion.
39. A method according to claim 32, wherein each opening of the first masking device is distended from one another.
40. An internal combustion engine having at least one piston according to claim 1.
41. An internal combustion engine having at least one piston produced according to the method of claim 22.
42. An internal combustion engine according to claim 40, which is a compression ignited internal combustion engine.
43. A vehicle having an internal combustion engine according to claim 40.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) With reference to the appended drawings, below follows a more detailed description of embodiments of the invention cited as examples.
(2) In the drawings:
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DETAILED DESCRIPTION
(14) With reference to
(15) Each cylinder 15 comprises a reciprocating piston 20, which may be of any type which is suitable for compression ignition. The cylinder 15 is only described in general terms since its parts and functionality is well known in the art. The cylinder 15 configuration may be e.g. straight, V-shaped or any other suitable kind. Each cylinder 15 of
(16) Turning to
(17) Underneath the piston crown 29 there are two, from above mutually separated, volumes: an inner and centrally located cooling chamber 32 and an outer and circumferentially located cooling gallery 33. An annular piston skirt marks the outer diameter of the piston 20. The parts protruding downwardly in
(18) The fuel injector 25 has a plurality of (not disclosed) fuel openings which are adapted to inject fuel into the combustion chamber 16. In the present disclosure there are six evenly spread openings, resulting in six separated fuel spray plumes 34 around the fuel injector 25. This may be better seen in
(19) The layouts of the cylinder 15 and of the piston 20 may be otherwise designed than the one disclosed herein. For example the piston 20 may be designed having a non-rotationally symmetrical cylindrical configuration to correspond to a non-cylindrical configuration of the devices at the top of the cylinder 15. The fuel injector 25 may be located towards the side of the top of the cylinder 15 and from such a location direct fuel spray plumes 34 into the cylinder 15 in a slanting manner. The fuel injector 25 may furthermore direct one or several slightly flattened rather than circular fuel spray plume(s) 34 towards the combustion chamber and the piston 20. Another example is the shape, size and location of the piston bowl 28. It may be non-rotationally symmetrical, it may be shallower and having a smaller diameter. It may have a circumferential rim portion 31 which has a smaller radius of curvature and a smaller elevation, if any one at all. And so on.
(20) Turning now to a description of a first embodiment of the present disclosure, this will be provided based on
(21) The thickness of the surface coating at each thermal barrier coating layer surface part 36 is thicker in a centre portion than at an outer boundary thereof. The thickness of the thermal barrier coating layer 37 at each thermal barrier coating layer surface part 36 is greatest at the circumferential rim portion 31. The thickness is smallest at the outer boundary of each thermal barrier coating layer surface part 36. The thickness is varying continuously. This may be gleaned from
(22) The thermal barrier coating layer 37 is bonded to the piston 20 through a bond layer 38. The bond layer 38 is nickel based and has a thickness of 20 to 250 m, preferably 75 to 150 m, and more preferably approximately 100 m.
(23) Turning now to
(24) With reference to
(25) As could be seen from
(26) In
(27) In
(28) Turning back to
(29) According to an alternative embodiment of the present disclosure the number of fuel spray plumes 34 may be different from the number which is disclosed earlier herein. The number may be both odd as well as even. The number of fuel spray impingement portions 35 on the piston 20 corresponds to the number of fuel spray plumes 34. It is consequently also preferably to adapt the number of thermal barrier coating layer surface parts 36 both in size and location to the number of fuel spray impingement portions 35 and fuel spray plumes 34. The number may be from one to a number higher than six.
(30) The thermal barrier coating layer surface parts 36 may also be located at other locations on the piston 20 and piston bowl surface 30 than earlier disclosed. They may also be spread in an uneven manner around the piston 20 and piston bowl surface 30. Furthermore the size and shape of the thermal barrier coating layer surface parts 36 may be different between them. Some may be equal, and others unequal. Also the thickness and thickness distribution may be different between them. Also other parts of the piston 20 and of the piston bowl surface 30 than the fuel spray impingement portions 35 may be covered by thermal barrier coating layer surface parts 36. At least one of the thermal barrier coating layer surface parts 36 should at least to some extent cover one of the fuel spray impingement portions 35 if there are several ones present.
(31) The thermal barrier coating layer surface parts 36 may also be produced such that their upper surface, which is facing the combustion chamber 16 of the cylinder 15, may also be produced such that it is levelled with the surrounding uncoated surface parts. This may e.g. be achieved through the creation of pockets in the piston surface 27. Such pockets may in turn be produced through milling. This results in a levelled piston surface 27 which later may be polished or otherwise post processed.
(32) The piston 20 may generally be post processed as a further step after Step 104. In such a post processing step the resulting piston 20 including the thermal barrier coating layer surface parts 36 may be machined in order to even better distribute the heat over the piston surface 27. This may be done regardless of whether the thermal barrier coating layer surface parts 36 are levelled with the basic piston surface 27, or is protruding therefrom, such as in the embodiment disclosed in
(33) An alternative heat insulating ceramic material may comprise aluminium oxide, titanium oxide or zirconium silicate, but also other ceramics may be useful. In the case of a zirconium oxide, it could be stabilised by yttrium oxide, magnesium oxide, cerium oxide, lathanuum oxide or any other relevant stabiliser.
(34) The thermal barrier coating layer 37 may be applied directly onto the piston surface 27 without any use of a bond layer 38. If a bond layer 38 is used it is preferably made of a metallic material. Such materials are usually based on nickel or iron with other alloying materials such as chrome, aluminium or yttrium.
(35) Alternative ways to apply the thermal barrier coating material and possibly the bond layer 38 material are for example flame spraying, wire-arc spraying and HVOF spraying.
(36) An alternative embodiment of the present disclosure is shown in
(37) The alternative embodiments which have been disclosed above may be combined in any way which is found advantageous, unless anything else is explicitly stated, as long as the features of the main claims are fulfilled.
(38) It is to be understood that the present invention is not limited to the embodiments described above and illustrated in the drawings; rather, the skilled person will recognize that many changes and modifications may be made within the scope of the appended claims.