THERMALLY ENHANCED EXHAUST PORT LINER

• US 20200132014A1
• Filed: 10/29/2019
• Published: 04/30/2020
• Est. Priority Date: 10/29/2018
• Status: Active Grant

• Current Assignee: Cartridge Ltd.
• Original Assignee: Cartridge Ltd.
• Inventors: Kloss, Joachim, Steinbronn, Andreas
• Granted Patent: US 10,989,137 B2
• Time in Patent Office: Days
• CPC Class Codes: B22F 10/25 Direct deposition of metal particles, e.g. direct metal deposition [DMD] or laser engineered net shaping [LENS]
• CPC Class Codes: B22F 10/28 Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
• CPC Class Codes: B22F 10/68 Cleaning or washing
• CPC Class Codes: B22F 2301/15 Nickel or cobalt
• CPC Class Codes: B22F 3/115 by spraying molten metal, i.e. spray sintering, spray casting
• CPC Class Codes: B22F 5/008 of engine cylinder parts or of piston parts other than piston rings of piston rings B22F5/02
• CPC Class Codes: B33Y 10/00 Processes of additive manufacturing
• CPC Class Codes: B33Y 70/00 Materials specially adapted for additive manufacturing
• CPC Class Codes: B33Y 80/00 Products made by additive manufacturing
• CPC Class Codes: C22C 1/0433 Nickel- or cobalt-based alloys
• CPC Class Codes: F02F 1/30 Finned cylinder heads
• CPC Class Codes: F02F 1/4271 with an exhaust liner
• CPC Class Codes: F02F 11/002 involving cylinder heads
• CPC Class Codes: F02F 2200/06 Casting
• CPC Class Codes: Y02P 10/25 Process efficiency

Abstract

An exhaust port liner, which may include a superalloy and may be manufactured by an additive manufacturing process, includes a monolithic structure including an outlet disposed an angle relative to an inlet, and a sidewall defining a cavity to provide enhanced thermal performance in reciprocating internal combustion engines. A cylinder head of an internal combustion engine may include a cylinder head frame, and the exhaust port liner may be disposed proximate the frame inner mounting surface, with an outer surface of the exhaust port liner conforming to an inner mounting surface of the cylinder head frame.

Claims

1. An exhaust port liner for a cylinder head of an internal combustion engine, the exhaust port liner comprising:

a monolithic structure comprising;

an inlet;

an outlet disposed at an angle relative to the inlet; and

a sidewall comprising a metal disposed between the inlet and the outlet defining an exhaust gas flow passage through the monolithic structure, the sidewall comprising an inner wall and an outer wall defining a cavity therebetween.

2. The exhaust port liner of claim 1, wherein the metal comprises a superalloy.

4. The exhaust port liner of claim 1, wherein the cavity comprises at least one of air, an inert gas, or a partial vacuum.

5. The exhaust port liner of claim 1, wherein the cavity is sealed.

7. The exhaust port liner of claim 1, wherein the metal comprises a laser-sintered material.

8. The exhaust port liner of claim 1, wherein the sidewall defines at least one aperture extending therethrough.

11. The exhaust port liner of claim 1, wherein the monolithic structure comprises at least one filled opening forming a boundary of the cavity.

13. The exhaust port liner of claim 1, wherein the angle is in a range of 30°

to 135°

.

14. The exhaust port liner of claim 1, further comprising one or more pillars disposed in the cavity and spanning from the inner wall to the outer wall.

16. The exhaust port liner of claim 1, further comprising:

a second inlet adjacent to the inlet, wherein the inlet and the second inlet are in flow communication with the outlet

3. (canceled)

6. (canceled)

9-10. -10. (canceled)

12. (canceled)

15. (canceled)

17. (canceled)

18. A method for fabricating an exhaust port liner, the method comprising the steps of:

receiving by an additive manufacturing system control instructions for fabricating the exhaust port liner comprising;

a monolithic structure comprising;

an inlet;

an outlet disposed at an angle relative to the inlet; and

a sidewall comprising a metal disposed between the inlet and the outlet defining an exhaust gas flow passage through the monolithic structure, the sidewall comprising an inner wall and an outer wall defining a cavity therebetween; and

executing the control instructions by the additive manufacturing system to fabricate the exhaust port liner.

19. The method of claim 18, wherein the additive manufacturing system employs at least in part a process selected from the group consisting of vat polymerization, powder bed fusion, material extrusion, and direct energy deposition.

20. The method of claim 18, wherein the metal comprises a superalloy.

21. The method of claim 18, wherein the superalloy is selected from the group consisting of nickel-based superalloys and cobalt-based superalloys.

22. The method of claim 18, further comprising sealing the cavity.

23-25. -25. (canceled)

26. A cylinder head of an internal combustion engine comprising:

a cylinder head frame defining an inner mounting surface; and

an exhaust port liner disposed proximate the frame inner mounting surface, the exhaust port liner comprising;

a monolithic structure comprising;

an inlet;

an outlet disposed at an angle relative to the inlet; and

a sidewall comprising a metal disposed between the inlet and the outlet defining an exhaust gas flow passage through the monolithic structure, the sidewall comprising an inner wall and an outer wall defining a sealed cavity therebetween,

wherein an outer surface of the exhaust port liner conforms to the inner mounting surface.

27. The cylinder head of claim 26, wherein the metal comprises a superalloy.

29. The cylinder head of claim 26, wherein the sealed cavity comprises at least one of air, an inert gas, or a partial vacuum.

31. The cylinder head of claim 26, wherein the metal comprises a laser-sintered material.

32. The cylinder head of claim 26, wherein the sidewall defines at least one aperture extending therethrough.

36. The cylinder head of claim 26, wherein the monolithic structure comprises at least one filled opening forming a boundary of the cavity.

39. The cylinder head of claim 26, further comprising one or more pillars disposed in the sealed cavity and spanning from the inner wall to the outer wall.

41. The cylinder head of claim 26, wherein the cylinder head frame comprises a second metal.

43. The cylinder head of claim 26, wherein the exhaust port liner is fabricated by additive manufacturing and the cylinder head frame is fabricated by casting a second metal around the exhaust port liner.

44. The cylinder head of claim 26, wherein the exhaust port liner and the cylinder head frame are each fabricated by additive manufacturing.

45. The cylinder head of claim 26, wherein the cylinder head frame defines a plurality of inner mounting surfaces.

48. The cylinder head of claim 26, wherein the cylinder head frame further comprises external cooling fins adapted for air cooling the cylinder head.

49. The cylinder head of claim 26, further comprising an absence of internal water coolant passages.

28. (canceled)

30. (canceled)

33-35. -35. (canceled)

37. (canceled)

38. (canceled)

40. (canceled)

42. (canceled)

46-47. -47. (canceled)

50. A method for fabricating a cylinder head of an internal combustion engine, the method comprising the steps of:

fabricating an exhaust port liner by;

receiving by an additive manufacturing system control instructions for fabricating the exhaust port liner comprising;

a monolithic structure comprising;

an inlet;

an outlet disposed at an angle relative to the inlet; and

a sidewall comprising a metal disposed between the inlet and the outlet defining an exhaust gas flow passage through the monolithic structure, the sidewall comprising an inner wall and an outer wall defining a cavity therebetween; and

executing the control instructions by the additive manufacturing system to fabricate the exhaust port liner; and

fabricating a cylinder head frame around the exhaust port liner to fabricate the cylinder head.

51. The method of claim 50, wherein the additive manufacturing system employs at least in part a process selected from the group consisting of vat polymerization, powder bed fusion, material extrusion, and direct energy deposition.

52. The method of claim 50, wherein the metal comprises a superalloy.

54. The method of claim 50, wherein fabricating the cylinder head frame comprises casting molten metal.

56. The method of claim 50, wherein fabricating the cylinder head frame comprises a second additive manufacturing system receiving and executing control instructions to fabricate the cylinder head frame.

59. The method of claim 50, further comprising sealing the cavity prior to fabricating the cylinder head frame.

53. (canceled)

55. (canceled)

57-58. -58. (canceled)

60-62. -62. (canceled)