Method and device for manufacturing metallic-sodium-filled engine valve

Abstract

An umbrella part metallic sodium insertion device for inserting rod-shaped metallic sodium into a hollow part of a hollow valve; a melting device for melting the metallic sodium in the hollow part by inserting a push rod from an opening into the hollow part of the hollow valve, in which the metallic sodium has been inserted by the device, and, while pushing the rod-shaped metallic sodium in the hollow part, heating the umbrella part to a temperature at which the metallic sodium is melted; a stem part cooling device for cooling a stem part of the hollow valve, in which the metallic sodium has been melted by the melting device, to a temperature lower than the temperature at which the metallic sodium is melted; and a stem part metallic sodium insertion device for inserting rod-shaped metallic sodium into the hollow part which has been cooled by the device.

Claims

1. A method for manufacturing a metallic-sodium-filled engine valve in which a hollow valve having a hollow part inside a stem part and a head part as well as an opening at an upper end of the stem part is provided thereinside with metallic sodium from the opening of the stem part, and then the opening is closed, the method comprising: a head part metallic sodium insertion step of inserting rod-shaped metallic sodium into the hollow part of the hollow valve; a melting step of melting the metallic sodium in the hollow part by inserting a push rod from the opening into the hollow part of the hollow valve in which the metallic sodium is inserted at the head part metallic sodium insertion step, and by pressing the rod-shaped metallic sodium in the hollow part while heating the head part to a temperature high enough to melt the metallic sodium, and then stopping heating the head part; a stem part cooling step of cooling the stem part of the hollow valve in a state after the metallic sodium is melted and heating the head part of the hollow valve is stopped at the melting step, to below the temperature high enough to melt the metallic sodium by using a stem part cooling device that is capable of detachably gripping the stem part of the hollow valve to transport the hollow valve and is capable of cooling the stem part by coolant circulating inside; and a stem part metallic sodium insertion step of inserting rod-shaped metallic sodium into the hollow part of the hollow valve cooled at the stem part cooling step.

2. The method for manufacturing a metallic-sodium-filled engine valve according to claim 1, further comprising: a getter material adding step of adding getter material into the hollow part of the hollow valve before the metallic sodium is inserted at the head part metallic sodium insertion step.

3. The method for manufacturing a metallic-sodium-filled engine valve according to claim 1, wherein the head part of the hollow valve is heated by high frequency induction heating at the melting step.

4. A device for manufacturing a metallic-sodium-filled engine valve, for use to perform the method for manufacturing a metallic-sodium-filled engine valve according to claim 1, the device comprising: a head part metallic sodium insertion unit that inserts rod-shaped metallic sodium into the hollow part of the hollow valve; a melting unit that melts the metallic sodium in the hollow part by inserting a push rod from the opening into the hollow part of the hollow valve in which the metallic sodium is inserted with the head part metallic sodium insertion unit, and by pressing the rod-shaped metallic sodium in the hollow part while heating the head part to a temperature high enough to melt the metallic sodium; a stem part cooling unit that cools the stem part of the hollow valve in a state after the metallic sodium is melted and heating the head part of the hollow valve is stopped with the melting unit, to below the temperature high enough to melt the metallic sodium by using a stem part cooling device that is capable of detachably gripping the stem part of the hollow valve to transport the hollow valve and is capable of cooling the stem part by coolant circulating inside; and a stem part metallic sodium insertion unit that inserts rod-shaped metallic sodium into the hollow part of the hollow valve cooled with the stem part cooling unit.

5. The device for manufacturing a metallic-sodium-filled engine valve according to claim 4, wherein the melting unit includes a heater that heats the head part of the hollow valve with the head part placed thereon so as to support the hollow valve, and a metallic sodium press that is arranged above the heater, and that moves the push rod vertically so as to insert and pull the push rod into and out of the hollow part through the opening of the hollow valve.

6. The device for manufacturing a metallic-sodium-filled engine valve according to claim 5, wherein the heater is a high frequency induction heater.

7. The device for manufacturing a metallic-sodium-filled engine valve according to claim 4, further comprising: a getter material adding unit that adds getter material into the hollow part of the hollow valve before the metallic sodium is inserted with the head part metallic sodium insertion unit.

Description

BRIEF DESCRIPTION OF DRAWINGS

(1) FIG. 1 is a block diagram illustrating a schematic configuration of a main part of a main embodiment of a device for manufacturing metallic-sodium-filled engine valves according to the present invention.

(2) FIG. 2 is a schematic structure diagram of a hollow valve.

(3) FIG. 3 is a schematic configuration diagram illustrating a main part of a getter material adding device of the manufacturing device in FIG. 1.

(4) FIG. 4 is a schematic configuration diagram illustrating a main part of a head part metallic sodium forming device of the manufacturing device in FIG. 1.

(5) FIG. 5 is a schematic configuration diagram illustrating a main part of a head part metallic sodium insertion device of the manufacturing device in FIG. 1.

(6) FIG. 6 is a schematic configuration diagram illustrating a main part of a melting device of the manufacturing device in FIG. 1.

(7) FIG. 7 is a schematic configuration diagram illustrating a main part of a stem part cooling device of the manufacturing device in FIG. 1.

(8) FIG. 8 is a schematic configuration diagram illustrating a main part of a stem part metallic sodium forming device of the manufacturing device in FIG. 1.

(9) FIG. 9 is a schematic configuration diagram illustrating a main part of a stem part metallic sodium insertion device of the manufacturing device in FIG. 1.

(10) FIG. 10 is a schematic explanatory diagram illustrating a main part of a getter material adding step of a main embodiment of a method for manufacturing metallic-sodium-filled engine valves according to the present invention.

(11) FIG. 11 is a schematic explanatory diagram illustrating a main part of a head part metallic sodium forming step of the main embodiment of the method for manufacturing metallic-sodium-filled engine valves according to the present invention.

(12) FIG. 12 is a schematic explanatory diagram illustrating a main part of a head part metallic sodium insertion step of the main embodiment of the method for manufacturing metallic-sodium-filled engine valves according to the present invention.

(13) FIG. 13 is a schematic explanatory diagram illustrating a main part of a melting step of the main embodiment of the method for manufacturing metallic-sodium-filled engine valves according to the present invention.

(14) FIG. 14 is a schematic explanatory diagram illustrating a main part of a stem part cooling step of the main embodiment of the method for manufacturing metallic-sodium-filled engine valves according to the present invention.

(15) FIG. 15 is a schematic explanatory diagram illustrating a main part of a stem part metallic sodium forming step of the main embodiment of the method for manufacturing metallic-sodium-filled engine valves according to the present invention.

(16) FIG. 16 is a schematic explanatory diagram illustrating a main part of a stem part metallic sodium insertion step of the main embodiment of the method for manufacturing metallic-sodium-filled engine valves according to the present invention.

(17) FIG. 17 is a schematic structure diagram illustrating a hollow valve in which metallic sodium is inserted.

DESCRIPTION OF EMBODIMENTS

(18) Although description will be provided for an embodiment of a method and a device for manufacturing metallic-sodium-filled engine valves according to the present invention based on the drawings, the present invention is not limited only to the embodiment described based on the drawings.

Main Embodiment

(19) Description will be provided for a main embodiment of a method and a device for manufacturing metallic-sodium-filled engine valves according to the present invention based on FIGS. 1 to 17.

(20) First, as illustrated in FIG. 2, a hollow valve to be filled with metallic sodium has a hollow part H inside a stem part S and a head part A as well as an opening O at the upper end of the stem part S. Metallic-sodium-filled engine valves which are filled with metallic sodium Na in its inside can be manufactured by putting metallic sodium Na from the opening O of the stem part S of this hollow valve V into the hollow part H, and then closing the opening O.

(21) As illustrated in FIG. 1, a manufacturing device according to this embodiment for manufacturing such metallic-sodium-filled engine valves includes: a head part metallic sodium insertion device 130 which is a head part metallic sodium insertion unit that inserts rod-shaped metallic sodium Na into the hollow part H of the hollow valve V; a melting device 140 which is a melting unit that melts the metallic sodium Na in the hollow part H by inserting a push rod from the opening O into the hollow part H of the hollow valve V in which the metallic sodium Na is inserted with the head part metallic sodium insertion device 130, and pressing the rod-shaped metallic sodium Na in the hollow part H while heating the head part A to a temperature high enough to melt the metallic sodium Na; a stem part cooling device 150 which is a stem part cooling unit that cools the stem part S of the hollow valve V in a state after the metallic sodium Na is melted with the melting device 140, to below the temperature high enough to melt the metallic sodium Na; and a stem part metallic sodium insertion device 170 which is a stem part metallic sodium insertion unit that inserts the rod-shaped metallic sodium Na into the hollow part H of the hollow valve V cooled with the stem part cooling device 150, and further includes a getter material adding device 110 which is a getter material adding unit that adds getter material G into the hollow part H of the hollow valve V before the metallic sodium Na is inserted with the head part metallic sodium insertion device 130.

(22) The manufacturing device 100 described above further includes: a head part metallic sodium forming device 120 which is a head part metallic sodium forming unit for forming rod-shaped metallic sodium Na to be inserted into the hollow valve V with the head part metallic sodium insertion device 130; and a stem part metallic sodium forming device 160 which is a stem part metallic sodium forming unit for forming rod-shaped metallic sodium Na to be inserted into the hollow valve V with the stem part metallic sodium insertion device 170.

(23) As illustrated in FIG. 3, the getter material adding device 110 includes a storage pipe 111 for storing getter material G which is titanium powder or the like, a measuring pipe 112 the upper portion of which is connected to the lower portion of the storage pipe 111 and which measures the getter material G, a first shutter 113 which is openable and closable and provided so as to partition the storage pipe 111 and the measuring pipe 112, and a second shutter 114 which is openable and closable and provided at the lower portion of the measuring pipe 112.

(24) As illustrated in FIG. 4, the head part metallic sodium forming device 120 includes: an injection cylinder 121, into which block-shaped metallic sodium Na can be put from the proximal end side; a pressing piston 122 which can be moved to-and-fro inside the injection cylinder 121; an injection nozzle 123 which is connected to the distal end of the injection cylinder 121 and injects the block-shaped metallic sodium Na into a rod shape; a measuring pipe 124 which is arranged at the distal end side of the injection nozzle 123 to be movable and measures the rod-shaped metallic sodium Na; a cutter 125 arranged to be capable of moving forward and backward between the distal end of the injection nozzle 123 and the proximal end of the measuring pipe 124; and a shutter 126 which is openable and closable and provided at the distal end of the measuring pipe 124.

(25) As illustrated in FIG. 5, the head part metallic sodium insertion device 130 includes: a measuring pipe moving device 131 which detachably holds the measuring pipe 124 of the head part metallic sodium forming device 120 and moves the measuring pipe 124 and the shutter 126; and an extrusion device 132 which moves an extrusion rod 132a to-and-fro such that the extrusion rod 132a is inserted into and pulled out of the measuring pipe 124.

(26) As illustrated in FIG. 6, the melting device 140 includes: a high frequency induction heater 141 which is a heater for heating the head part A of the hollow valve V by high frequency induction heating with the head part A placed thereon so as to support the hollow valve V; and a metallic sodium pressing device 142 which is a metallic sodium press which is arranged above the high frequency induction heater 141 and moves a push rod 142a vertically such that the push rod 142a is inserted into and pulled out of the hollow part H through the opening O of the hollow valve V.

(27) As illustrated in FIG. 7, the stem part cooling device 150 is capable of detachably gripping the stem part S of the hollow valve V to transport the hollow valve V and cooling the stem part S by coolant circulating the inside.

(28) As illustrated in FIG. 8, the stem part metallic sodium forming device 160 includes: an injection cylinder 161, into which block-shaped metallic sodium Na can be put from the proximal end side; a pressing piston 162 which can be moved to-and-fro inside the injection cylinder 161; an injection nozzle 163 which is connected to the distal end of the injection cylinder 161 and injects the block-shaped metallic sodium Na into a rod shape; a measuring pipe 164 which is arranged at the distal end side of the injection nozzle 163 to be movable and measures the rod-shaped metallic sodium Na; a cutter 165 arranged to be capable of moving forward and backward between the distal end of the injection nozzle 163 and the proximal end of the measuring pipe 164; and a shutter 166 which is openable and closable and provided at the distal end of the measuring pipe 164.

(29) As illustrated in FIG. 9, the head part metallic sodium insertion device 170 includes: a measuring pipe moving device 171 which detachably holds the measuring pipe 164 of the stem part metallic sodium forming device 160 and moves the measuring pipe 164 and the shutter 166; and an extrusion device 172 which moves an extrusion rod 172a to-and-fro such that the extrusion rod 172a is inserted into and pulled out of the measuring pipe 164.

(30) Next, descriptions will be provided for a method for manufacturing metallic-sodium-filled engine valves using the above manufacturing device 100 according to this embodiment.

(31) As illustrated in FIG. 10A, the hollow valve V is placed at a specified position in the getter material adding device 110 of the manufacturing device 100. When the second shutter 114 is closed and the first shutter 113 is opened, the getter material Gin the storage pipe 111 is supplied to the measuring pipe 112 to fill the inside of the measuring pipe 112.

(32) Subsequently, as illustrated in FIG. 10B, when the first shutter 113 is closed and the second shutter 114 is opened, the getter material G in the measuring pipe 112 is added into the hollow part H through the opening O of the hollow valve V (up to this point, a getter material adding step). With this, a specified amount of the getter material G is supplied into the hollow valve V, and the concentration of oxygen in the atmosphere (air) inside the hollow part H is reduced.

(33) As illustrated in FIG. 11A, when the block-shaped metallic sodium Na in the injection cylinder 121 of the head part metallic sodium forming device 120 is pressed by the pressing piston 122, the metallic sodium Na is extruded in a rod shape from the injection nozzle 123 and supplied into the measuring pipe 124.

(34) Subsequently, as illustrated in FIG. 11B, by moving in the cutter 125 between the distal end of the injection nozzle 123 and the proximal end of the measuring pipe 124, the metallic sodium Na therebetween is cut, and a specified amount of the metallic sodium Na is formed inside the measuring pipe 124 in a rod shape (up to this point, a head part metallic sodium forming step).

(35) Then, as illustrated in FIG. 12A, the hollow valve V to which the getter material G has been added with the getter material adding device 110 is moved to the head part metallic sodium insertion device 130, while the measuring pipe 124 of the head part metallic sodium forming device 120 is held with the measuring pipe moving device 131 and moved to a specified position in the above head part metallic sodium insertion device 130.

(36) Subsequently, as illustrated in FIG. 12B, after the shutter 126 is opened, by operating the extrusion device 132 to extrude the metallic sodium Na in the measuring pipe 124 with the extrusion rod 132a, a specified amount of the rod-shaped metallic sodium Na is inserted into the hollow part H of the hollow valve V (up to this point, a head part metallic sodium insertion step).

(37) Next, after the hollow valve V into which the specified amount of the rod-shaped metallic sodium Na is inserted with the head part metallic sodium insertion device 130 is moved onto the high frequency induction heater 141 of the melting device 140 as illustrated in FIG. 13A, the metallic sodium pressing device 142 is operated such that the distal end of the push rod 142a comes in contact with the upper end of the rod-shaped metallic sodium Na in the hollow part H of the hollow valve V through the opening O, as illustrated in FIG. 13B.

(38) Subsequently, as illustrated in FIGS. 13C to 13E, the metallic sodium pressing device 142 and the high frequency induction heater 141 are operated such that the rod-shaped metallic sodium Na is pressed with the distal end of the push rod 142a while the head part A of the hollow valve V is heated to a temperature (about 98 C. or more) at which metallic sodium is melted, so that the metallic sodium Na in the hollow part H of the hollow valve V is melted and put into the head part A.

(39) Then, when the push rod 142a of the metallic sodium pressing device 142 is inserted into the hollow part H of the hollow valve V by a specified length, the metallic sodium pressing device 142 is operated to finish pressing the metallic sodium Na with the push rod 142a and pull the push rod 142a out of the hollow part H of the hollow valve V, while the operation of the high frequency induction heater 141 is stopped to stop heating the head part A of the hollow valve V (up to this point, a melting step).

(40) Next, as illustrated in FIG. 14, by the stem part cooling device 150 holding the stem part S of the hollow valve V in a state after the metallic sodium Na is and put into the head part A with the melting device 140, the stem part S of the hollow valve V is cooled to below the temperature (about 98 C.) at which metallic sodium N is melted while the hollow valve V is moved to a specified position in the stem part metallic sodium insertion device 170 (up to this point, a stem part cooling step).

(41) Meanwhile, as illustrated in FIG. 15A, when the block-shaped metallic sodium Na in the injection cylinder 161 of the stem part metallic sodium forming device 160 is pressed with the pressing piston 162, the metallic sodium Na is extruded into a rod shape from the injection nozzle 163 and supplied into the measuring pipe 164.

(42) Subsequently, as illustrated in FIG. 15B, by moving in the cutter 165 between the distal end of the injection nozzle 163 and the proximal end of the measuring pipe 164, the metallic sodium Na therebetween is cut, and a specified amount of the metallic sodium Na is formed inside the measuring pipe 164 in a rod shape (up to this point, a stem part metallic sodium forming step).

(43) Then, as illustrated in FIG. 16A, the measuring pipe 164 of the stem part metallic sodium forming device 160 is held with the measuring pipe moving device 171 of the stem part metallic sodium insertion device 170 and moved to a specified position in the stem part metallic sodium insertion device 170.

(44) Subsequently, as illustrated in FIG. 16B, after the shutter 166 is opened, by operating the extrusion device 172 to extrude the metallic sodium Na in the measuring pipe 164 with the extrusion rod 172a, a specified amount of the rod-shaped metallic sodium Na is inserted into the hollow part H of the hollow valve V (up to this point, a stem part metallic sodium insertion step).

(45) With this, a specified amount of the metallic sodium Na is put into the head part A and the stem part S inside the hollow part H of the hollow valve V. After that, the opening O of the hollow valve V is closed to complete manufacturing the metallic-sodium-filled engine valve.

(46) In summary, in this embodiment, first, the rod-shaped metallic sodium Na is inserted into the hollow part H of the hollow valve V. The push rod 142a is inserted through the opening O into the hollow part H of the hollow valve V to press the rod-shaped metallic sodium Na in the hollow part H while the head part A is heated to a temperature high enough to melt metallic sodium Na, so that the metallic sodium Na in the hollow part H rapidly is melted and put into the head part A. Then, after the stem part S is cooled to below the temperature high enough to melt metallic sodium Na, the rod-shaped metallic sodium Na is inserted into the hollow part H of the hollow valve V, so that the metallic sodium Na is put into the stem part S.

(47) As a result, in this embodiment, it is natural that there is no need to supply molten metallic sodium Na through the opening O into the hollow part H of the hollow valve V, and it is possible to put rapidly a target amount of metallic sodium Na into the head part A in the hollow part H before the stem part S is heated to a high temperature along with the heating of the head part A of the hollow valve V.

(48) Thus, this embodiment facilitates the temperature control while making it possible to produce metallic-sodium-filled engine valves continuously and efficiently.

Other Embodiments

(49) Note that although the rod-shaped metallic sodium Na is inserted after adding the getter material G into the hollow part H of the hollow valve V in the embodiment described above, the addition of the getter material G into the hollow part H of the hollow valve V can be eliminated as another embodiment depending on the conditions such as the oxygen concentration or humidity of the surrounding atmosphere, for example.

(50) In addition, although descriptions were provided in the embodiment described above for the case where the manufacturing device 100 includes the metallic sodium forming devices 120 and 160 for forming the rod-shaped metallic sodium Na, it is possible as another embodiment that the metallic sodium forming devices 120 and 160 are eliminated, and, for example, that rod-shaped metallic sodium Na formed in advance is stored in a container and it is inserted into the hollow part H of the hollow valve V with a metallic sodium insertion unit.

(51) In addition, although in the above embodiment, the head part A of the hollow valve V is heated with the high frequency induction heater 141, it is possible as another embodiment to heat the head part A of the hollow valve V with an electric heater or the like, for example. However, heating the head part A of the hollow valve with the high frequency induction heater 141 makes it easy to heat the head part A quickly and raise its temperature to a target temperature in a short time, and thereby is very suitable for continuous production.

(52) In addition, in the embodiment described above, the stem part cooling device 150, which is capable of detachably holding the stem part S of the hollow valve V to transport the hollow valve V and in which coolant circulates internally, cools the stem part S of the hollow valve V. However, as another embodiment, for example, it is possible to transport the hollow valve V using a conveyor or the like and let the stem part S of the hollow valve V cool, or it is also possible to blow air for air-cooling, in addition. However, the application of the stem part cooling device 150 as in the embodiment described above makes it possible to cool the stem part S of the hollow valve V rapidly, and thereby is very suitable for continuous production.

INDUSTRIAL APPLICABILITY

(53) The method and the device for manufacturing metallic-sodium-filled engine valves according to the present invention facilitates the temperature control while making it possible to produce metallic-sodium-filled engine valves continuously and efficiently, so that they can be utilized extremely advantageously from the industrial viewpoint.

REFERENCE SIGNS LIST

(54) 100 manufacturing device 110 getter material adding device 111 storage pipe 112 measuring pipe 113 first shutter 114 second shutter 120 head part metallic sodium forming device 121 injection cylinder 122 pressing piston 123 injection nozzle 124 measuring pipe 125 cutter 126 shutter 130 head part metallic sodium insertion device 131 measuring pipe moving device 132 extrusion device 132a extrusion rod 140 melting device 141 high frequency induction heater 142 metallic sodium pressing device 142a push rod 150 stem part cooling device 160 stem part metallic sodium forming device 161 injection cylinder 162 pressing piston 163 injection nozzle 164 measuring pipe 165 cutter 166 shutter 170 stem part metallic sodium insertion device 171 measuring pipe moving device 172 extrusion device 172a extrusion rod V hollow valve A head part S stem part H hollow part O opening G getter material Na metallic sodium