Composite internal combustion engine housing
AssigneeFord Motor Company
InventorsDavid A. Onofrio, William C. Hallandal
Life of this patent
Estimating the term…
Abstract
A cylinder block for an internal combustion engine, comprising: (a) a siamesed cylinder sleeve unit (steel or metal matrix composite) having an annular tongue flange spaced above but adjacent the bottom of the unit; and (b) a plastic jacket (phenolic, vinyl ester, or epoxy) spaced from but surrounding the sleeve unit and having the tongue flange molded integrally with the jacket, the sleeve unit and jacket being adapted for closure by a head having a wall to mate with the planar top of the sleeve and jacket; and (c) sealant deposited at interfacing surfaces of the sleeve unit and jacket which are integraly molded, the sleeve being constituted of a metal-based material having a thermal expansion characteristic differing from the plastic jacket by no greater than 25%.
Claims16
A cylinder block for an internal combustion engine, comprising:
- (a) a siamesed cylinder sleeve unit comprising metal and having a radially outwardly extending annular tongue flange spaced from but adjacent the bottom of said unit;
- and
- (b) a jacket surrounding but spaced from said sleeve unit except at about said unit flange where said jacket and unit are integrally molded together, said jacket being constituted of molded fiber-reinforced plastic substantially matched to the thermal expansion characteristic of said sleeve unit.
A composite block-crankcase assembly for an internal combustion engine, comprising:
- (a) a siamesed cylinder sleeve unit (i) constituted of a matrix composite carrying iron, carbon fiber, or aluminum, and (ii) having a radially outwardly extending annular tongue flange spaced from but adjacent the bottom of said unit;
- (b) a jacket (i) surrounding but spaced from said sleeve unit except at about said unit tongue flange where said jacket and unit are integrally molded together, (ii) having a sealant on the interfacing surfaces of said jacket and unit that are integrally molded, (iii) having a deep depending annular skirt strengthened by a plurality of spaced transverse walls adapted to also serve as an upper crankcase member, (iv) constituted of molded phenolic plastic;
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- (c) a lower oil pan member constituted of molded plastic and adapted for being secured to the skirt of said jacket, said jacket and oil pan member having bushing fittings and molded-in-place oil galleries extending commonly therebetween.
A method of making a cylinder block for an internal combustion engine, comprising:
- (a) fabricating a siamesed cylinder sleeve unit of a material selected from the group consisting of steel and aluminum matrix composite, said unit being defined with a radially outwardly extending annular tongue flange spaced from but adjacent the bottom of the unit;
- (b) implanting said unit in a mold for injection or compression molding of a plastic jacket;
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- (c) molding said plastic jacket to surround but be spaced from said unit except at about said tongue flange where said jacket and unit are integrally molded together.
A cylinder block for an internal combustion engine, comprising:
- (a) a siamesed cylinder sleeve unit having a platform flange and an annular tongue flange spaced above said platform flange;
- (b) a plastic jacket spaced from but surrounding said sleeve unit and having a base molded integrally with said tongue flange and platform flange of said sleeve unit, said sleeve unit and jacket being adapted for closure by a head having a wall to mate with the planar top of said sleeve unit and jacket;
- and
- (c) sealant deposited at surface locations on said sleeve unit and jacket which are integrally molded, said jacket being constituted of phenolic plastic and said sleeve being constituted of a metal-based material having a thermal expansion characteristic differing from said phenolic by no greater than 25%.
Dependencies are inferred from the claim text.