Exhaust manifold and method of coating the same

• US 10,450,935 B2
• Filed: 08/22/2017
• Issued: 10/22/2019
• Est. Priority Date: 11/09/2016
• Status: Active Grant

• Current Assignee: Hyundai Motor Company (Hyundai Motor Group), Kia Motors Corporation (Kia Corp.)
• Original Assignee: Hyundai Motor Company (Hyundai Motor Group)
• Inventors: Ohn, Hyung Seuk, Hong, Woong Pyo, Baek, Hong Kil, Kim, Bo Kyung, Park, Se Hoon, Lee, Seung Woo, Kang, Tae Jun
• Primary Examiner(s): Dounis, Laert
• Assistant Examiner(s): Largi, Matthew T
• Application Number:
  US15/683,482
• Publication Number:
  US 20180128151A1
• Time in Patent Office: 791 Days
• CPC Class Codes: F01N 13/102 having thermal insulation
• CPC Class Codes: F01N 13/16 Selection of particular materials
• CPC Class Codes: F01N 2310/00 Selection of sound absorbing or insulating material
• CPC Class Codes: F01N 2510/02 for thermal insulation

Abstract

An exhaust manifold may include a main body provided with a plurality of branching passages communicating with a vehicle engine and provided with a single passage communicating with an exhaust canister, the branching passages merging with the single passage; and a coating layer coated on an internal surface of the main body forming the branching passages and the single passage, the coating layer including an aerogel.

Claims

1. An exhaust manifold comprising:

a main body provided with a plurality of branching passages communicating with a vehicle engine, and provided with a single passage communicating with an exhaust canister, the plurality of branching passages merging with the single passage; and

a coating layer coated on an internal surface of the main body forming the plurality of branching passages and the single passage, the coating layer including an aerogel;

wherein the coating layer further includes an additive to improve adhesion, wherein particles form an aerogel cluster on the internal surface of the main body; and

wherein the additive includes 60 to 80 wt % of zirconia and 20 to 40 wt % of silicon.

2. The exhaust manifold of claim 1, wherein the main body includes:

an upper portion provided with a first curved surface on a bottom surface thereof by being curved upwardly at a location corresponding to a location where the plurality of branching passages and the single passage are provided, and provided with a first bonding surface between the plurality of the branching passages; and

a lower portion provided with a second curved surface on a top surface thereof by being curved downwardly, forming the plurality of branching passages and the single passage by being coupled with the upper portion, and provided with a second bonding surface between the plurality of the branching passages to contact with the first bonding surface,

wherein the coating layer is coated along the first curved surface and the second curved surface to have a predetermined thickness.

3. The exhaust manifold of claim 1, wherein

the coating layer is in a multilayer structure formed by repeatedly layering a plurality of layers including the particles and the additive, and

air pores exist between the particles.

4. The exhaust manifold of claim 1, wherein the additive further includes at least one of zirconium, aluminum, and calcium.