EXHAUST MANIFOLD AND METHOD OF COATING THE SAME

• US 20180128151A1
• Filed: 08/22/2017
• Published: 05/10/2018
• 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), Kia Motors Corporation (Kia Corp.)
• Inventors: OHN, Hyung Seuk, HONG, Woong Pyo, BAEK, Hong kil, KIM, Bo Kyung, PARK, Se Hoon, LEE, Seung Woo, KANG, Tae Jun
• Granted Patent: US 10,450,935 B2
• Time in Patent Office: 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 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.

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

4. The exhaust manifold of claim 3, 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.

5. The exhaust manifold of claim 3, wherein

the additive includes at least one of zirconium, zirconia, aluminum, silicon, and calcium.

6. The exhaust manifold of claim 3, wherein

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

7. A method of coating an exhaust manifold, in which the exhaust manifold is provided with a plurality of branching passages communicating with a vehicle engine and is provided with a single passage communicating with an exhaust canister, the branching passages merging with the single passage, the method including:

a first coating step of forming a first coating layer having an aerogel on an internal surface of an upper portion of the exhaust manifold forming the branching passages and the single passage, the upper portion disposed at an upper portion of the exhaust manifold when the exhaust manifold is divided into two in a direction in parallel with a longitudinal direction of the branching passages and the single passage; and

a second coating step of forming a second coating layer having an aerogel on an internal surface of a lower portion of the exhaust manifold forming the branching passages and the single passage, the lower portion disposed at a lower portion of the exhaust manifold when the exhaust manifold is divided into two in the direction in parallel with the longitudinal direction of the branching passages and the passage.

8. The method of claim 7, wherein

in the first coating step, a first curved surface that forms the internal surface of the upper portion and is curved upwardly at a location corresponding to a location where the branching passages and the single passage are provided is coated with the first coating layer to have a predetermined thickness, and

in the second coating step, a second curved surface that forms the internal surface of the lower portion and is curved downwardly to form the branching passages and the single passage by being coupled with the upper portion is coated with the second coating layer to have a predetermined thickness.

9. The method of claim 7, further including:

a preparation step before the first coating step, wherein

particles that form the aerogel, and additive that improves adhesion to allow the particles to cluster are prepared in a powder form, and the particles and the additive in powder form are mixed to prepare a mixed powder, wherein

in the first coating step and the second coating step,

the mixed powder is melted into a plasma state by applying a current, and is then sprayed on the internal surfaces of the upper portion and the lower portion, forming the first coating layer and the second coating layer.

10. The method of claim 9, wherein

in the preparation step,

the mixed powder is controlled to have an average size ranging from 30 to 100 μ

m.

11. The method of claim 9, wherein

in the first coating step and the second coating step,

the applied current is controlled to be within a range of 470 to 500 A.

12. The method of claim 7, wherein

the first coating step includes a first forming step of forming a first layer including the particles and the additive by use of both particles forming the aerogel on the internal surface of the upper portion and additive improving adhesion to allow the particles to cluster, and

the second coating step includes a second forming step of forming a second layer including the particles and the additive by use of both particles forming the aerogel on the internal surface of the lower portion and additive improving adhesion to allow the particles to cluster, wherein

the first forming step and the second forming step are performed repeatedly, wherein the first layer and the second layer are repeatedly formed to be a multilayer structure, having a predetermined thickness.

13. The method of claim 12, wherein

the first forming step or the second forming step is performed to form the first layer or the second layer, and

after the first layer or the second layer is hardened, the first forming step or the second forming step is performed again.