Internal combustion engine and manufacturing method therefor

• US 9,863,312 B2
• Filed: 07/30/2014
• Issued: 01/09/2018
• Est. Priority Date: 08/05/2013
• Status: Active Grant

• Current Assignee: Toyota Jidosha Kabushiki Kaisha (Toyota Motor Corporation)
• Original Assignee: Toyota Jidosha Kabushiki Kaisha (Toyota Motor Corporation)
• Inventors: Nishikawa, Naoki, Makino, Hiroshi, Takagishi, Reona, Kawaguchi, Akio, Wakisaka, Yoshifumi, Shimizu, Fumio, Horie, Toshio
• Primary Examiner(s): McMahon, Marguerite
• Application Number:
  US14/910,320
• Publication Number:
  US 20160177818A1
• Time in Patent Office: 1,259 Days
• Field of Search: 123668
• CPC Class Codes: C22C 21/02 with silicon as the next major constituent
• CPC Class Codes: C22C 21/06 with magnesium as the next major constituent
• CPC Class Codes: C25D 11/04 of aluminium or alloys based thereon
• CPC Class Codes: C25D 11/18 After-treatment, e.g. pore-sealing
• CPC Class Codes: C25D 11/246 for sealing layers
• CPC Class Codes: F02B 77/11 Thermal or acoustic insulation
• CPC Class Codes: F02F 1/24 Cylinder heads
• CPC Class Codes: F02F 3/12 on piston heads
• CPC Class Codes: F05C 2203/0869 Aluminium oxide

Abstract

In an internal combustion engine in which an anodic oxide film (10) is formed on part or all of a wall surface facing a combustion chamber, the anodic oxide film (10) has a thickness of 30 μm to 170 μm, the anodic oxide film (10) has first micropores (1a) having a micro-size diameter, nanopores having a nano-size diameter and second micropores (1b) having a micro-size diameter, the first micropores (1a) and the nanopores extending from a surface of the anodic oxide film (10) toward an inside of the anodic oxide film (10) in a thickness direction of the anodic oxide film (10) or substantially the thickness direction, the second micropores (1b) being provided inside the anodic oxide film (10), at least part of the first micropores (1a) and the nanopores are sealed with a seal (2) converted from a sealant (2), and at least part of the second micropores (1b) are not sealed.

Claims

1. An internal combustion engine comprising:

an anodic oxide film forming on part or all of an aluminum-based wall surface facing a combustion chamber, wherein

an aluminum-based material that forms the aluminum-based wall surface contains Si and Cu as an alloy component, a content of Si in the aluminum-based material is higher than or equal to 5% and less than 20% and a content of Cu in the aluminum-based material is higher than or equal to 0.4% and less than 7%,

the anodic oxide film has a thickness of 30 μ

m to 170 μ

m;

the anodic oxide film has first micropores having a micro-size diameter, nanopores having a nano-size diameter and second micropores having a micro-size diameter, the first micropores and second micropores have a sectional diameter or maximum size of a range of 1 to 100 μ

m and the nanopores have a sectional diameter or maximum size of a range of 10 to 100 nm, the first micropores and the nanopores extending from a surface of the anodic oxide film toward an inside of the anodic oxide film in a thickness direction of the anodic oxide film or substantially the thickness direction, the second micropores being provided inside the anodic oxide film;

the first micropores are cracks extending from the surface of the anodic oxide film to the inside of the anodic oxide film;

the second micropores are internal defects not present at the surface of the anodic oxide film but present inside the film;

the nanopores are originated from anodizing and are regularly arranged;

at least part of the first micropores and the nanopores are sealed with a seal that is converted from a sealant,

at least part of the second micropores are not sealed; and

the anodic oxide film sealed with the seal has a porosity of 20 to 70%.

2. The internal combustion engine according to claim 1, wherein the seal is made of a substance that includes silica as a main component.

3. The internal combustion engine according to claim 1, wherein the sealant is made of any one of polysiloxane, polysilazane and sodium silicate.

4. The internal combustion engine according to claim 1, wherein the aluminum-based material that forms the aluminum-based wall surface further contains at least one of Mg, Ni, and Fe as the alloy component.

5. A manufacturing method for an internal combustion engine, comprising:

a first step of forming an anodic oxide film on part or all of an aluminum-based wall surface facing a combustion chamber, the anodic oxide film having first micropores having a micro-size diameter, nanopores having a nano-size diameter and second micropores having a micro-size diameter, the first micropores and second micropores having a sectional diameter or maximum size of a range of 1 to 100 μ

m and the nanopores having a sectional diameter or maximum size of a range of 10 to 100 nm, the first micropores and the nanopores extending from a surface of the anodic oxide film toward an inside of the anodic oxide film in a thickness direction of the anodic oxide film or substantially the thickness direction, the second micropores being provided inside the anodic oxide film, the anodic oxide film having a thickness of 30 μ

m to 170 μ

m; and

a second step of forming the anodic oxide film subjected to sealing in which a sealant is applied to the surface of the anodic oxide film, the sealant penetrates into at least part of the first micropores and the nanopores, the sealant is converted into a seal, at least part of the first micropores and the nanopores are sealed with the seal and at least part of the second micropores are not sealed,

wherein

an aluminum-based material that forms the aluminum-based wall surface contains Si and Cu as an alloy component, a content of Si in the aluminum-based material is higher than or equal to 5% and less than 20% and a content of Cu in the aluminum-based material is higher than or equal to 0.4% and less than 7%; and

the anodic oxide film sealed with the seal has a porosity of 20 to 70%.

6. The manufacturing method according to claim 5, wherein the seal is made of a substance that includes silica as a main component.

7. The manufacturing method according to claim 5, wherein the sealant is made of any one of polysiloxane, polysilazane and sodium silicate.

8. The manufacturing method according to claim 5, wherein the aluminum-based material that forms the aluminum-based wall surface further contains at least one of Mg, Ni, and Fe as the alloy component.