CYLINDER HEAD HOUSING, METHOD FOR PRODUCING A CYLINDER HEAD HOUSING, AND CASTING CORE

Abstract

A cylinder head housing for a combustion unit, which forms at least two cylinders arranged in-line, having receiving openings for one outlet valve each, which are assigned to the individual cylinders of the combustion unit, comprising exhaust gas channels, which extend from these outlet valve receiving openings and are merged into an exhaust gas outlet channel, and cooling channels having a roof distribution channel which is connected to an injector cooling channel provided for an arrangement above a cylinder and/or having a manifold distribution channel, which extends along the row of outlet valve receiving openings, the manifold distribution channel being connected to a plurality of manifold network channels running along the exhaust gas channels, which are directly or indirectly connected to a manifold collection channel, which extends along the row of outlet valve receiving openings.

Claims

1. A cylinder head housing for a combustion unit, which forms at least two cylinders arranged in-line, comprising: receiving openings for one outlet valve each, which are assigned to the individual cylinders of the combustion unit; exhaust gas channels that extend from the outlet valve receiving openings and are merged into an exhaust gas outlet channel; and cooling channels that comprise: a roof distribution channel, which is connected to an injector cooling channel provided for an arrangement above a cylinder, the injector cooling channels being connected to a plurality of roof network channels, which extend in different radial directions with respect to a longitudinal axis of the particular injector cooling channel and which are directly or indirectly connected to at least two roof collection channels, which are arranged on different sides with respect to the row defined by the injector cooling channels; and/or a manifold distribution channel, which extends along the row of outlet valve receiving openings, the manifold distribution channel being directly or indirectly connected to a plurality of manifold network channels running along the exhaust gas channels, which are directly or indirectly connected to a manifold collection channel, which extends along the row of outlet valve receiving openings.

2. The cylinder head housing according to claim 1, further comprising receiving openings for one fuel injector or one spark plug each, which are assigned to the individual cylinders of the combustion unit, the injector cooling channels surrounding these injector receiving openings in an annular manner.

3. The cylinder head housing according to claim 1, wherein the average flow cross section of the roof network channels is smaller than the average flow cross section of the roof distribution channel, the injector cooling channels and the roof collection channels, and/or the smallest flow cross section of the roof network channels is smaller than the smallest flow cross section of the roof distribution channel, the injector cooling channels and the roof collection channels; and/or wherein the average flow cross section of the manifold network channels is smaller than the average flow cross section of both the manifold distribution channel and the manifold collection channel, and/or the smallest flow cross section of the manifold network channels is smaller than the smallest flow cross section of both the manifold distribution channel and the manifold collection channel.

4. The cylinder head housing according to claim 1, wherein the roof network channels extending out of the individual injector cooling channels transition into one or multiple roof ring channels, which at least partially encircle the longitudinal axis of the particular injector cooling channel and which open into the roof collection channels.

5. The cylinder head housing according to claim 1, wherein the manifold network channels are at least partially connected to one or multiple manifold ring channels, which at least partially encircle one or multiple of the exhaust gas channels and which are connected to the manifold distribution channel.

6. The cylinder head housing according to claim 1, wherein the manifold distribution channel and the manifold collection channel are disposed on different sides with respect to a row formed by the exhaust gas channels.

7. The cylinder head housing according to claim 1, wherein a longitudinally axial end of the roof distribution channel transitions into a roof inflow or outflow channel, and/or a longitudinally axial end of the roof collection channels each transition into a roof outflow or inflow channel.

8. The cylinder head housing according to claim 1, wherein a manifold inflow channel transitions into the manifold distribution channel in a section of the manifold distribution channel abutting the exhaust gas outlet channel, and/or a manifold outflow channel extends out of the manifold collection channel.

9. The cylinder head housing according to claim 1, further comprising an exhaust gas outlet cooling channel, which connects the manifold distribution channel and the manifold collection channel and which encircles the exhaust gas outlet channel.

10. The cylinder head housing according to claim 1, wherein the roof distribution channel and/or the roof collection channels and/or the manifold distribution channel and/or the manifold collection channel is/are guided along the entire row of exhaust gas channels.

11. A method for manufacturing a cylinder head housing according to claim 1, characterized by the formation via a generative manufacturing method or by casting, using an expendable casting core which forms at least the cooling channels.

12. The method according to claim 11, wherein a soluble base material forms the casting core.

13. A casting core for the method according to claim 11, comprising casting core sections, which are configured as a negative mold of the cooling channels of a cylinder housing.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0027] The present invention will become more fully understood from the detailed description given hereinbelow and the accompanying drawings which are given by way of illustration only, and thus, are not limitive of the present invention, and wherein:

[0028] FIG. 1 shows a motor vehicle according to the invention;

[0029] FIG. 2 shows a internal combustion engine according to the invention;

[0030] FIG. 3 shows a simplified representation of the combustion unit of the internal combustion engine according to FIG. 2;

[0031] FIG. 4 shows a first view of a cylinder head housing according to the invention, for example for a combustion unit according to FIG. 3;

[0032] FIG. 5 shows a second view of the cylinder head housing according to FIG. 4;

[0033] FIG. 6 shows a casting core provided for forming roof cooling channels of the cylinder head housing according to FIGS. 4 and 5;

[0034] FIG. 7 shows a casting core provided for forming manifold cooling channels of the cylinder head housing according to FIGS. 5 and 6;

DETAILED DESCRIPTION

[0035] FIG. 1 shows a motor vehicle according to the invention, comprising an internal combustion engine 10, which is illustrated in detail in FIGS. 2 and 3.

[0036] Internal combustion engine 10 comprises a combustion unit 12, which is charged with the aid of a compressor and, during operation, may provide the driving power for the driving operation of the motor vehicle. The compressor is part of an exhaust gas turbocharger. In the present exemplary embodiment according to FIG. 3, combustion unit 12 is designed as a four-cylinder (in-line) reciprocating engine and may be operated, for example, according to the gasoline or diesel principle. For this purpose, cylinders 20 are formed in an engine block 18, in which pistons 22 are longitudinally axially movably arranged. A movement of pistons 22 induced by the combustion process is transmitted via connecting rods 24 to a crankshaft 26 rotatably mounted in engine block 18. This rotation of crankshaft 26 may be transmitted to driven wheels of a motor vehicle according to FIG. 1. Combustion unit 12, or internal combustion engine 10 comprising it, may thus be used to generate driving power for the motor vehicle.

[0037] A rotation of crankshaft 26 is also transmitted to a rotatably mounted first camshaft 32 in a cylinder head housing 30 of combustion unit 12 with the aid of a timing assembly 28, for example in the form of a toothed belt or chain drive. A rotational movement of first camshaft 32 is transmitted to a second camshaft, for example with the aid of a toothed wheel drive 36 (with a gear ratio of one). The second camshaft may be an intake camshaft of combustion unit 12, with the aid of which inlet valves (two per cylinder 20 in each case) may be actuated, via which fresh gas may be introduced in a controlled manner into combustion chambers, which are delimited by cylinders 20, pistons 22 and cylinder head housing 30. This fresh gas is combusted with fuel injected directly into the combustion chambers to effectuate the movement of pistons 22 induced by the rotation of crankshaft 26 within cylinders 20. In contrast, first camshaft 32 may be an outlet camshaft, with the aid of which outlet valves (34) (two per cylinder 20 in each case) are actuated, via which exhaust gas, which was generated upon a combustion of fuel/fresh gas mixtures in the combustion chambers, may be discharged in a controlled manner.

[0038] Fuel from a fuel tank of internal combustion engine 10 is supplied to fuel injectors 38 of combustion unit 12 with the aid of a fuel pump. The fuel is introduced into the combustion chambers in a metered manner under relatively high pressure and at predetermined points in time with the aid of fuel injectors 38. In an embodiment of combustion unit 12 as a diesel engine, fuel injectors 38 assigned to the individual combustion chambers may be arranged approximately centrally between the associated gas exchange valves in each case (inlet valves and outlet valves 34). In an embodiment of combustion unit 12 as a gasoline engine, on the other hand, it may be provided that a spark plug is disposed at this location. In this case, and in a direct-injection embodiment of the gasoline engine, an alternative arrangement with respect to the combustion chambers may then be selected for an integration of fuel injectors. Cylinder head housing 30 has receiving openings for accommodating fuel injectors 38 and/or the spark plugs as well as for accommodating the gas exchange valves.

[0039] Internal combustion engine 10 furthermore comprises a cooling system having at least two cooling circuits, the cooling system being used to cool individual components of internal combustion engine 10, among other things combustion unit 12, an engine oil cooler and a charge air cooler 14 and possibly also other components of the motor vehicle integrating internal combustion engine 10, e.g. a transmission oil cooler. A cooling fluid, which absorbs the thermal energy from the components to be cooled, circulates in the cooling system as a result of an operation of the fuel pump. This thermal energy is then cooled again in a main cooler 16 as well as possibly temporarily in a heater heat exchanger by a heat transfer to ambient air, so that it may be recirculated back to the components to be cooled. A heat transfer from the cooling fluid to the ambient air takes place in main cooler 16 exclusively with the goal of cooling the cooling fluid. A heat transfer within the heater heat exchanger, however, would take place primarily with the goal of controlling the temperature of ambient air, which is to be subsequently supplied to an interior of the motor vehicle.

[0040] To cool combustion unit 12, both engine block 18 and cylinder head housing 30 each form a cooling channel system 42, through which the cooling fluid may be conducted. These two cooling channel systems 42 may be connected in series according to FIG. 3, so that the cooling fluid transported by a coolant pump 40 (cf. FIG. 2) of the internal combustion engine first flows through cooling channel system 42 of cylinder head housing 30 before it flows over cooling channel system 42 of engine block 18.

[0041] The specific embodiment of cooling channel system 42 formed in a cylinder head housing 30 (according to the invention) of a combustion unit 12 according to FIGS. 2 and 3 is illustrated in FIGS. 4 and 5. Cylinder head housing 30 itself is illustrated only in a greatly simplified manner in each case, while the cavities relevant for understanding the invention, which are formed by cylinder head housing 30, are illustrated in detail.

[0042] Accordingly, for each of the combustion chambers or cylinders 20 of engine block 18, cylinder head housing 30 forms two fresh gas channels 44, whose openings into the combustion chambers may each be closed or released as needed with the aid of an inlet valve, the two fresh gas channels 44 assigned to one combustion chamber in each case being integrally designed in an initial section, i.e. as a single channel. These integrally formed initial sections directly abut an intake manifold, which represents a section of a fresh gas system of the internal combustion engine.

[0043] Cylinder head housing 30 furthermore forms two exhaust gas channels 46 for each of the combustion chambers, the transitions of exhaust gas channels 46 into the combustion chambers each being able to be closed or released as needed with the aid of an outlet valve 34. Exhaust gas channels 46, which are guided separately in a first section, transition into a collection section 48 running approximately in the longitudinal direction of cylinder head housing 30, from which an exhaust gas outlet channel 50 extends approximately in the middle with respect to the longitudinal direction of cylinder head housing 30.

[0044] Cooling channel system 42 of cylinder head housing 30 comprises a roof distribution channel 52, which is disposed above the combustion chambers and runs in the longitudinal direction of cylinder head housing 30, offset approximately from the center. A (longitudinally axial) end of roof distribution channel 52 transitions into a roof inflow channel 54, via which the cooling fluid may be supplied to roof distribution channel 52. The other (longitudinally axial) end of roof distribution channel 52, on the other hand, is designed to be closed, or it ends as a dead end within cylinder head housing 30.

[0045] Four injector cooling channels 56 extend from roof distribution channel 52, each of which annularly surrounds one of the injector receiving openings, i.e. a receiving opening, in which either a fuel injector 38 or a spark plug is disposed.

[0046] Extending out of each of injector channels 56 is a plurality of roof network channels 58, which extend in different radial directions with respect to the longitudinal axes of the injector receiving openings and also along these longitudinal axes (in the direction of an increasing approach to the combustion chambers) and which are provided with comparatively small dimensions with respect to their flow cross sections, and which transition into a roof ring channel 60, which completely encircles the particular injector receiving opening in an annual manner in each case, i.e. for all of the roof network channels 58 extending from one of injector cooling channels 56.

[0047] The four roof ring channels 60, in turn, transition into three roof collection channels 62, two of which are disposed on one side and the third on the other side with respect to the row defined by the injector receiving openings, and which also extend along the longitudinal direction of cylinder head housing 30 and thus approximately in parallel to roof distribution channel 52. The cooling fluid situated therein may be discharged via one of the (longitudinally axial) ends of roof collection channels 62 in each case, each of which transitions into a roof outflow channel 74. The two roof collection channels 62 disposed on the same side with respect to the row defined by the injector receiving openings transition into a common roof outflow channel 74. The longitudinally axial ends of roof collection channels 62 which do not transition into a roof outflow channel 74, in turn, end in cylinder head housing 30.

[0048] Cooling channel system 42 of cylinder head housing 30 furthermore comprises a manifold distribution channel 64 formed over a relatively wide area, which extends along the row of outlet valve receiving openings and therefore primarily in the longitudinal direction of cylinder head housing 30, a manifold ring channel 80 extending out of manifold distribution channel 64 for each separate exhaust gas channel 46, manifold ring channels 80 being arranged preferably close to the proximal ends of exhaust gas channels 46 with respect to cylinders 20 and fully encircling particular exhaust gas channels 46 (cf. FIG. 7). Manifold ring channels 80 of the two exhaust gas channels 46 assigned to a cylinder 20 in each case transition into each other in the area of one circumferential section. Extending from each of manifold ring channels 80 is a plurality of manifold network channels 66, which run along separately guided exhaust gas channels 46 and which are also provided with comparatively small dimensions and transition directly into a manifold collection channel 68, which also extends along the row of outlet valve receiving openings and consequently primarily in the longitudinal direction of cylinder head housing 30. Additional manifold network channels 66 are also provided, which, having a bow-shaped profile, directly connect manifold distribution channel 64 to manifold collection channel 68 and partially encircle collection section 48 of exhaust gas channels 46 on the side of collection section 48 facing away from the outlet valve receiving openings.

[0049] A manifold inflow channel 70 opens into manifold distribution channel 64 approximately in the middle and thus in a section abutting exhaust gas outlet channel 50. Cooling fluid may be supplied to manifold distribution channel 64 via manifold inflow channel 70. This cooling fluid is then distributed within manifold distribution channel 64 and subsequently flows into the large number of manifold network channels 66. Cooling fluid which has flowed through manifold network channels 66 collects in manifold collection channel 68 and may be discharged therefrom via a manifold outflow channel 72 extending out of manifold collection channel 68 approximately in the middle and thus in a section abutting exhaust gas outlet channel 50.

[0050] Cooling channel system 42 of cylinder head housing 30 furthermore comprises an annular exhaust gas outlet cooling channel 78, which connects manifold distribution channel 64 and manifold collection channel 68 to each other in the area of manifold inflow channel 70 and manifold outflow channel 72 and encircles exhaust gas outlet channel 50 in an annular manner.

[0051] The embodiment of roof cooling channels (52, 54, 56, 58, 60, 62 and 74), on the one hand, and manifold cooling channels (64, 66, 68, 70, 72, 78 and 80), on the other hand, each having one inflow channel (54; 70) and at least one outflow channel (74; 72), makes it possible to integrate them in parallel into a cooling circuit of a cooling system of an internal combustion engine, for example, according to FIG. 2, so that cooling fluid, which flows through this cooling circuit in a circulation cycle is conducted through either roof cooling channels (52, 54, 56, 58, 60, 62 and 74) or manifold cooling channels (64, 66, 68, 70, 72, 78 and 80). Alternatively, however, it is possible to integrate roof cooling channels (52, 54, 56, 58, 60, 62 and 74) and manifold cooling channels (64, 66, 68, 70, 72, 78 and 80) in series into the cooling circuit, so that the cooling fluid first flows through roof cooling channels (52, 54, 56, 58, 60, 62 and 74) or manifold cooling channels (64, 66, 68, 70, 72, 78 and 80) and is only subsequently conducted through each of the other cooling channels (52 through 74, 78, 80).

[0052] FIGS. 6 and 7 show two casting cores 76, which may be manufactured, for example, from a lightweight metal alloy by means of casting in a method for manufacturing a cylinder head housing 30 according to FIGS. 4 and 5. Two separate casting cores 76 are illustrated, which, however, may also be connected to each other or formed as a single piece.

[0053] In particular, the casting cores may also be connected to or formed as a single piece with other casting cores, which are used to form the remaining opening and cavities (in particular the injector receiving openings, outlet valve receiving openings, etc.). In FIGS. 6 and 7, the casting core sections which result in the formation of the individual cooling channels (52 through 74, 78, 80) during the manufacture of a corresponding cylinder head housing 30 are marked by the same reference numerals which are also used for these cooling channels (52 through 74, 78, 80), however with the addition of the letter a in each case.

[0054] The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are to be included within the scope of the following claims.