Polymeric and metal cylinder head and method of making the same
AssigneeGM Global Technology Operations LLC
InventorsAnthony M. COPPOLA, Peter P. ANDRUSKIEWICZ, IV, Hamid G. KIA, Paul M. NAJT
Life of this patent
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Abstract
A cylinder head assembly for an engine assembly is provided herein. The cylinder head assembly may include a head framework, an exhaust liner include a thermal barrier material, an intake liner, and a polymeric housing disposed around at least a portion of the metal head framework and the exhaust liner. The cylinder head assembly may further include a plurality of channels for heating and/or cooling the cylinder head assembly, which can be defined in one or more of: the metal head framework, the exhaust liner, and the polymeric housing. Methods of making the cylinder head assembly are also provided herein.
Claims20
A cylinder head assembly for an engine comprising:
- a metal head framework defining a portion of:
- a combustion chamber, an intake valve guide, and an exhaust valve guide;
- an exhaust liner defining an exhaust port, wherein the exhaust liner comprises a thermal barrier material comprising an insulating layer, and wherein at least a portion of the exhaust liner is disposed adjacent to at least a portion of the metal head framework;
- an intake liner defining an intake port, wherein the intake liner comprises a material selected from the group consisting of a metal material, a polymeric material, the thermal barrier material, and combinations thereof;
- a polymeric housing disposed around at least a portion of the metal head framework and the exhaust liner;
- and
- a plurality of channels defined in one or more of:
- (i) the metal head framework;
- (ii) the exhaust liner;
- and
- (iii) the polymeric housing.
A method of manufacturing a cylinder head assembly for an engine comprising:
- (a) a thermal barrier formation step comprising one or more of the following:
- (i) applying an insulating layer precursor to a second exterior surface of an exhaust port form and solidifying the insulating layer precursor applied to the second exterior surface of the exhaust port form to form an exhaust liner comprising a thermal barrier material;
- (ii) applying the insulating layer precursor to a third exterior surface of an intake port form and solidifying the insulating layer precursor applied to the third exterior surface of the intake port form to form an intake liner comprising the thermal barrier material;
- and
- (iii) performing a casting, molding, or three-dimensional (3D) printing process to form the exhaust liner defining an exhaust port and/or the intake liner defining an intake port and providing a packing material to the exhaust port and/or the intake port;
- (b) a casting step comprising one or more of the following:
- (i) arranging the exhaust liner in a first mold and casting a metal head framework defining a portion of a combustion chamber;
- and
- (ii) arranging the intake liner in the first mold and casting the metal head framework;
- (c) a channel formation step for forming an intermediate assembly comprising applying a channel precursor material comprising a sacrificial material to the exhaust liner, the metal head framework, or a combination thereof;
- and
- (d) a polymeric formation step comprising:
- placing the intermediate assembly in a second mold;
- introducing a polymer precursor into the second mold;
- solidifying the polymer precursor to form a solid polymeric assembly comprising a polymeric housing disposed around one or more of:
- at least a portion of the metal head framework, at least a portion of the exhaust liner;
- and
- at least a portion of the intake liner;
- and
- if present, removing the sacrificial material to form a plurality of channels defined in one or more of:
- (i) the metal head framework
- (ii) the polymeric housing;
- and
- (iii) the exhaust liner.
Dependencies are inferred from the claim text.