CN1193375A - 纤维增强陶瓷基复合材料内燃机气缸盖和气缸盖衬套 - Google Patents
纤维增强陶瓷基复合材料内燃机气缸盖和气缸盖衬套 Download PDFInfo
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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- Y10T29/49272—Cylinder, cylinder head or engine valve sleeve making with liner, coating, or sleeve
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- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Combustion & Propulsion (AREA)
- Mechanical Engineering (AREA)
- General Engineering & Computer Science (AREA)
- Ceramic Engineering (AREA)
- Cylinder Crankcases Of Internal Combustion Engines (AREA)
Abstract
本发明涉及内燃机部件,具体涉及内燃机全陶瓷气缸盖(10)或纤维增强陶瓷基复合材料气缸盖衬套(11)。本发明解决了由于热冲击、轻微冲击而导致损坏、磨蚀和内燃机重量等而造成失败的问题。全陶瓷气缸盖(10)或纤维增强陶瓷基复合材料气缸盖衬套(11)在它们的上表面上还包括冷却装置(12),从而使触摸温度保持在适当的水平上。陶瓷气缸盖或气缸盖衬套可用在位于汽车发动机罩之下的汽车发动机,而不使汽车中的其它***受到辐射热的损害。
Description
本发明涉及内燃机部件,具体涉及内燃机全陶瓷气缸盖或纤维增强陶瓷基复合材料气缸盖衬套,包括结构纤维增强陶瓷基复合材料气缸盖。
典型的内燃机具有由一个或多个气缸组成的气缸体,随着气缸中燃料的燃烧,活塞在气缸中上下运动。如图1、2所示,气缸由气缸盖10盖住并封闭。在压缩条件下,燃料燃烧产生动能及热能。因此,内燃机部件可能会变得非常热。为防止出现过热导致金属损伤、润滑油分解、部件过度热膨胀造成内燃机卡住的问题,需要将热量导出以便使内燃机的运行温度限定在设计标准内。通常采用两种方法中的一种进行导热。如图1所示,气缸盖10可以在其中配置冷却液套12,其中,冷却液套12经由连接管30、32接通在气缸体和风冷散热装置之间循环的水。如图2所示,气缸盖10可以有一些散热片14,这些散热片具有较大的散热面积,直接向流经散热片的空气辐射热量。由于在运行环境中产生的高热负荷要与容许的发动机罩内温度要求相适应,所以摩托车、割草机等适合于采用散热片14,而轿车、卡车等适合于采用冷却液套12。另外,冷却液套12还为汽车供暧、通风及空调(HVAC)***提供热源。
因此,本发明的目的是提供一种内燃机陶瓷气缸盖或结构纤维增强陶瓷基复合材料气缸盖衬套,用于考虑降低气缸盖外表面温度水平的内燃机。
本发明的另一个目的是为安装在发动机罩内的发动机提供一种陶瓷气缸盖或结构纤维增强陶瓷基复合材料气缸盖衬套,从而使汽车中的其它***不受辐射热的伤害。
本发明的再一个目的是为需向客厢供热***输送热水的发动机提供一种陶瓷气缸盖或结构纤维增强陶瓷基复合材料气缸盖衬套。
通过参照附图阅读下文中的说明,本发明的其它目的和优点将变得更加明确。
借助于本发明内燃机陶瓷气缸盖和陶瓷气缸盖衬套可以实现上述目的,本发明包括由充满处于陶瓷状态的预陶瓷树脂(pre-ceramic resin)的普通纤维体系构成的气缸盖和将气缸盖热量导出的装置。
在优选实施例中,将气缸盖热量导出的装置取决于所设计内燃机的特定应用。典型的汽车内燃机通常采用液体冷却***将过多的热量从气缸盖中导出,同时也可为客厢供热***提供热源;而小型通用内燃机通常采用风冷方式。
在一个实施例中,将热量从气缸盖中导出的装置包括在气缸盖上表面上形成的散热片,从而将热量导入叶片周围的空气中。
在另一个实施例中,将热量从气缸盖上表面导出的装置由安装在气缸盖上表面上的金属散热装置构成,金属散热装置包括将热量导入叶片周围空气中的散热片。
在产生副产品热水的实施例中,将热量从气缸盖中导出的装置包括在气缸盖上表面上形成的金属冷却液套,其中,冷却液套具有进水管和出水管,内燃机冷却液或在客厢供热***中使用的其它液体流经它们。本实施例装置可以在陶瓷气缸盖上直接铸造成形。
第四实施例是水冷气缸盖中使用的可粘结纤维增强陶瓷基复合材料气缸盖衬套。
第五实施例是风冷气缸盖中使用的机械夹紧的纤维增强陶瓷基复合材料气缸盖衬套。
图1是现有技术气缸盖的简化横剖视图,该气缸盖具有冷却液套,是在汽车中典型应用的代表;
图2是现有技术气缸盖的简化横剖视图,该气缸盖采用风冷方式,是在小型通用内燃机中的典型应用;
图3是本发明第一实施例陶瓷气缸盖的简化横剖视图,该气缸盖具有整体式风冷散热片;
图4是本发明第二实施例陶瓷气缸盖的简化横剖视图,该气缸盖具有作为附加部件用螺栓连接在气缸盖上的金属风冷散热片;
图5是本发明第三实施例陶瓷气缸盖的简化横剖视图,该气缸盖安装有铸造金属冷却液套;
图6是本发明第四实施例陶瓷气缸盖的简化横剖视图,该气缸盖安装有铸造金属冷却液套;
图7是本发明第五实施例陶瓷气缸盖的简化横剖视图,该气缸盖安装有铸造金属冷却液套。
在图3所示的本发明的一个实施例中,用结构纤维增强陶瓷基复合(FRCMC)材料制造气缸盖10′。制造气缸盖10′的结构纤维增强陶瓷基复合材料具体包括经过模仿聚合物复合处理工艺的变性处理使其中遍布普通纤维体系(generic fiber system)纤维的聚合物衍生陶瓷树脂或胶结树脂(cementatious resin)。优选的纤维增强陶瓷基复合材料采用几种可商购的预陶瓷(pre-ceramic)树脂中的一种与普通纤维体系结合,可商购的预陶瓷树脂例如有硅羧基树脂(由Allied Signal公司以商品名Blackglas出售)、硅酸铝树脂(由Applied Poleramics公司以产品代号C02出售)或磷酸一铝树脂,上述普通纤维体系包括(但不局限于)氧化铝、Altex、Nextel312、Nextel440、Nextel510、Nextel550、氮化硅、碳化硅、HPZ、石墨、碳、泥炭等。为提高材料的韧性,可以为纤维体系预先涂上一层0.1~5.0微米厚的界面材料,界面材料包括(但不局限于)碳、氮化硅、硅羧基、碳化硅和氮化硼,也可以采用上述一种或几种界面材料分层涂在纤维体系上。界面材料防止树脂直接粘附在纤维体系的纤维上。因此,当树脂转化成陶瓷基体时,在陶瓷和纤维之间存在细微的间隙,从而使最终获得的纤维增强陶瓷基复合材料达到预期的性能。
另外,为防止燃烧产生的腐蚀性材料的磨蚀,最好在纤维增强陶瓷基复合材料气缸盖或气缸盖衬套面向燃烧环境气缸孔的表面涂上抗磨蚀涂层,抗磨蚀涂层可借助于可商购的防侵蚀涂层(例如等离子喷涂的氧化铝粉或汽相沉积的氮化钛)或采用常规等离子喷涂技术和本发明人未批准的“减小结构增强陶瓷基复合材料汽车发动机滑动接触部件间的磨蚀”专利申请中指出的材料,该专利申请的系列号为______________申请时间与本发明相同。在本发明的第一实施例中,为纤维增强陶瓷基复合材料气缸盖或气缸盖衬套在面向燃烧环境的表面上涂上抗磨蚀涂层,采用纤维织物毡或纤维非织物毡。在本实施例中,结构纤维增强陶瓷基复合材料部件的接触表面被涂上抗磨蚀涂层,该涂层紧紧粘接在纤维增强陶瓷基复合材料结构的摩擦表面上。为达到上述目的,抗磨蚀涂层优选地包括富铝红柱石(即硅酸铝Al2Si4)、氧化铝(即Al2O3)或其它等效材料,采用人们所知的普通的等离子喷涂技术。
按下述方法喷涂抗磨蚀涂层。首先,在喷涂之前,对用于火花塞、气门、活塞销等的所有孔进行机器加工。为达到上述目的,建议采用商品级金刚石切削工具。也可以采用下述的任何一种其它的机器进行上述加工。在机加工完成后,如果部件表面有少量的尖棱,则使用砂纸(diamond paper)将其打平。
在完成对部件的机器加工后,将其放入加热室中一段时间,加热室的温度能够保证“烧掉”任何在机器加工过程中使用的切削液。(典型的加热室温度为700°F、加热时间为2小时,但是加热时间与加热温度视切削液而定)
本发明的关键是使抗磨蚀涂层粘结在纤维增强陶瓷基复合材料结构上。如果不对纤维增强陶瓷基复合材料结构表面进行适当的预处理,抗磨蚀涂层易于剥落,不能提供长期的保护。在优选的方法中,对纤维增强陶瓷基复合材料结构表面进行轻微的喷砂处理以便在纤维增强陶瓷基复合材料结构的陶瓷基中形成小麻点。同样可以相信,轻微的喷砂处理使暴露的普通纤维体系纤维露出纤维丝或须,抗磨蚀涂层将其夹住并粘于其上。典型的被证明是成功的喷砂处理法是在20磅/英寸2压力下喷砂粒度为100(100grit@20PSI)。
在第二种可能的方法中,可以为纤维增强陶瓷基复合材料结构的表面配置一系列窄、浅、规则间隔的沟纹,上述沟纹与螺母或螺栓的细牙螺纹相似,抗磨蚀涂层可以机械锁定在上述沟纹中。其本质是,在纤维增强陶瓷基复合材料结构表面上刻痕,使该表面成为粗糙的表面而不是平滑的表面。上述沟纹的深度、宽度及间隔不是非常严格的,对每个部件而言不经严格的试验就可以确定上述深度、宽度和间隔。通常上述沟纹的间隔应当紧密配置以便将任何大块平滑表面区域减到最小。在大块平滑表面区域,抗磨蚀涂层可能会失去粘性并剥落。因此,为在最终研磨后能够获得平滑的磨蚀表面,开沟纹过多需要使用较多的耐磨材料,除了这一点以外,在上述表面上多开沟纹要优于开沟纹不足。上述沟纹的深度应较浅,以便能为抗磨蚀涂层提供机械锁定区域,同时又不明显地降低抗磨蚀涂层下面纤维增强陶瓷基复合材料结构的结构强度。
在部件表面处理完成后,使用洁净的干燥压缩空气清洗部件,然后将部件安装在恰当的支承卡具上进行等离子喷涂处理。采用定向空气压缩机在进行抗磨蚀涂层喷涂的过程中冷却部件的另一面。
然后进行抗磨蚀涂层等离子喷涂,设定淀积速率(depositionrate)为5克/分钟或更高。设定支承夹具速度、喷枪沿部件表面的移动速度及喷涂宽度以实现50%重叠的理发店招牌喷涂模式。喷枪距离喷涂表面0.1~3英寸。喷涂所用颗粒的大小为170~400目。用足够的抗磨蚀材料来进行上述等离子喷涂以便将来精加工。
在抗磨蚀涂层喷涂完成后,用砂纸或恰当的成形工具(建议采用商品级金刚石切削工具)将喷涂表面弄平,从而获得最终的表面轮廓。
在另一个实施例中,在部件未成形之前,将粉末状的抗磨蚀材料分散在基体材料即树脂中以提高抗磨蚀性能。或者采用等离子喷涂,然后将粘结有抗磨蚀涂层的部件再浸渗(reinfiltrate)预陶瓷聚合物树脂,然后再转化为陶瓷状态。其结果是,通过从本质上将涂层结合进混合的或复合的陶瓷基复合材料中对涂层进行又一次韧化处理,陶瓷基复合材料由纤维增强陶瓷基复合材料和陶瓷基增强整体抗磨蚀涂层通过普通陶瓷基整体结合而合成。
另外,为防止燃烧产生的腐蚀性材料的磨蚀,可以为纤维增强陶瓷基复合材料气缸盖或气缸盖衬套面向燃烧环境的表面涂上抗磨蚀涂层,抗磨蚀涂层可借助于可商购的防侵蚀涂料,例如等离子喷涂的氧化铝粉或物理蒸气沉积的氮化钛,或者采用常规等离子喷涂技术及本发明人的一起待批准的“制造陶瓷基复合材料衬汽车部件和纤维增强陶瓷基复合材料汽车部件的方法与装置”专利申请中指出的材料,该专利申请的系列号为_________________,申请时间与本申请相同。第一个方面是制造具有抗破裂陶瓷衬套的金属部件的方法,其步骤是:制造具有一个容纳衬套的配合面的金属部件;制造含孔陶瓷材料衬套;向上述孔中填充预陶瓷聚合物树脂;在一定温度下焙烧预陶瓷聚合物树脂浸透的衬套一段时间(由树脂的制造者指出温度的高低和时间的长短),从而使孔中的树脂转化为陶瓷;然后,将陶瓷衬套粘接到金属部件的配合面上。
在一个实施例中,制造含孔陶瓷材料衬套的步骤包括:向衬套成形模具中浇注廉价的可浇铸胶结稀浆;在一定温度下焙烧模制稀浆材料一段时间,将稀浆材料转化为能拿得起的预陶瓷结构;从模具中移去预陶瓷结构;在一定温度下焙烧预陶瓷结构一段时间,将预陶瓷结构转化为含孔陶瓷结构,上述孔由释气而形成。并且,用聚合物衍生陶瓷树脂充填上述孔的步骤包括:将衬套放入装有液态预陶瓷聚合物树脂的池中,直到上述孔中充满树脂。上述树脂优选地是硅羧基树脂(由Allied Signal公司以商品名Blackglas出售)。
在第二个实施例中,制造含孔陶瓷材料衬套的步骤包括:将纤维预型件放入衬套成形模具中,使其占有30%~60%模具空间;通过预型件将液态预陶瓷树脂注入模具,使液态预陶瓷树脂占据模具其余的空间;在一定温度下焙烧模具一段时间,将液态预陶瓷树脂转化为能拿得起的预陶瓷结构;从模具中移去预陶瓷结构;在一定温度下焙烧预陶瓷结构一段时间,将液态预陶瓷聚合物树脂转化为含孔陶瓷基复合材料结构,上述孔由释气而形成。上述液态预陶瓷聚合树脂优选地是硅羧基树脂,例如Blackglas。
本发明的第二个方面是制造具有抗破裂陶瓷衬套的金属部件的方法,其步骤是:制造含孔陶瓷材料衬套;向上述孔中填充预陶瓷聚合物树脂;在一定温度下焙烧预陶瓷聚合物树脂饱和的衬套一段时间(由树脂的制造者指出温度的高低与时间的长短),从而将孔中的树脂转化为陶瓷;将衬套定位在用于铸造金属部件的模具中,衬套的配合表面朝向铸造部件的金属将要占据的模具部分;然后,将熔化的金属注入模具以铸造部件。
如同第一个方面,制造含孔陶瓷材料衬套的步骤可以包括上述两种方法中的任何一种。并且,用聚合物衍生陶瓷树脂充填上述孔的步骤还包括:将衬套放入装有液态预陶瓷聚合物树脂的池中,直到树脂充满上述孔;在一定温度下焙烧预陶瓷聚合物树脂饱和的衬套一段时间,将上述孔中的树脂转化为陶瓷。
在充填由释气而形成的孔的各种情形中,最好多次重复进行充填和再加热过程,从而实际上彻底地消除最终产品中的孔。
在本发明的另一个方面中,披露了一种制造纤维增强陶瓷基复合材料汽车部件的方法,其步骤包括:用可在纤维增强陶瓷基复合材料中使用的普通纤维体系的纤维制造部件形状的预型件;将上述预型件放入模具的具有部件形状的腔中;加压使液态聚合物衍生陶瓷树脂通过上述腔,以充满上述腔并浸透上述预型件;按照聚合物衍生陶瓷树脂的要求,在一定温度下加热模具一段时间,将液态聚合物衍生陶瓷树脂饱和的预型件转化为聚合物复合材料部件;从模具中移去聚合物复合材料部件;按照聚合物衍生陶瓷树脂的要求,在惰性气体环境中在一定温度下焙烧聚合物复合材料部件一段时间,将聚合物衍生陶瓷树脂转化为陶瓷,由此聚合物复合材料部件转化为纤维增强陶瓷基复合材料部件。
优选地是,上述方法还包括以下步骤:将含孔纤维增强陶瓷基复合材料部件放入装有液态聚合物衍生陶瓷树脂的池中,使液态聚合物衍生陶瓷树脂充满上述孔,上述孔是在焙烧过程中释气而形成的;按照聚合物衍生陶瓷树脂的要求,在惰性气体环境中在一定温度下焙烧纤维增强陶瓷基复合材料部件一段时间,将孔中的聚合物衍生陶瓷树脂转化为陶瓷;并且重复进行上述过程,直到最终纤维增强陶瓷基复合材料部件中孔隙率低于预先设定的百分比,在这一百分比下可以保证部件的最大强度。
上述优选的方法还适用于成形中空的部件,例如内燃机集流腔,所采取的步骤是:用可在纤维增强陶瓷基复合材料中使用的普通纤维体系中的纤维制造具有集流腔下半部分形状的第一预型件;将第一预型件放入具有集流腔下半部分形状的第一模具的腔中;将液态聚合物衍生陶瓷树脂注入上述腔中,充填上述腔并浸透第一预型件;按照聚合物衍生陶瓷树脂的要求,在一定温度下加热第一模具一段时间,将液态聚合物衍生陶瓷树脂饱和的第一预型件转化为第一聚合物复合材料部件;从模具中移去第一聚合物复合材料部件;用普通纤维体系中的纤维制造具有集流腔上半部分形状的第二预型件;将第二预型件放入具有集流腔上半部分形状的第二模具的腔中;将液态聚合物衍生陶瓷树脂注入上述腔中,充填上述腔并浸透第二预型件;按照聚合物衍生陶瓷树脂的要求,在一定温度下加热第二模具一段时间,将液态聚合物衍生陶瓷树脂饱和的第二预型件转化为第二聚合物复合材料部件;从模具中移去第二聚合物复合材料部件;沿配合边将第一聚合物复合材料部件和第二聚合物复合材料部件安装到一起以形成集流腔,成为中空管道形状的部件;然后,按照聚合物衍生陶瓷树脂的要求,在惰性气体环境中在一定温度下焙烧聚合物复合材料集流腔一段时间,将聚合物衍生陶瓷树脂转化为陶瓷,由此聚合物复合材料集流腔转化为纤维增强陶瓷基复合材料集流腔,并且其上半部分和下半部分沿配合边熔接在一起。
优选地是,在上述方法中由释气生成的孔闭合,从而使所得到的集流腔具有最大的强度,并且避免了沿配合边可能出现的渗漏。
在集流腔为内部充填有泡沫陶瓷催化剂衬底结构的排气集流腔的情形中,加工过程和所需的工具可以极大地简化,在将第二预型件放入具有集流腔上半部分形状的第二模具的腔中之前,其步骤还包括:将第一预型件作为第二模具的腔形成壁的一部分;并且将泡沫陶瓷催化剂衬底结构放入第一预型件中,由此第一预型件和泡沫陶瓷催化剂衬底结构结合构成第二壁的腔部分。
继续参照图3,气缸盖10′的散热片14与气缸盖10′整体成形,因此提供了单一的纤维增强陶瓷基复合材料单元。另外,采用等离子喷涂工艺,将抗磨蚀涂层28喷涂在气缸盖面向燃烧环境的一面,从而提高抗磨蚀性能。散热片14不具有金属散热片的抗裂性能。因此,本实施例在大多数应用中不是优选的。
在图4所示的气缸盖10′中,同样采用散热片14;但是,在这种情形中,散热片14是金属散热装置16的一部分,使用螺栓18将散热装置16固定在气缸盖的顶部,螺栓18用来将气缸盖10′固定在内燃机气缸体上。散热装置16及其散热片14可以是最适合特定用途的焊接钢、铸铝或铸铁等。另外,采用等离子喷涂工艺,将抗磨蚀涂层28喷涂在气缸盖面向燃烧环境的一面,从而提高抗磨蚀性能。本实施例优选地适合于小型内燃机,例如草坪和花园机械。
本发明有三个优选实施例适合于大型动力装置,例如汽车动力装置及固定动力源。
图5示出其中第一优选实施例。气缸盖10′由金属材料制造,其上铸有金属冷却液套12以及整体镶塑有衬套11。冷却液套12具有常规进水管30和排水管32。由于气缸盖衬套11材料是陶瓷,所以它能够承受水套浇铸成形过程中熔化金属的高温而不损坏。因此,在一个优选的制造方法中,应当首先制造陶瓷衬套11。然后,将衬套11放入铸造冷却液套12的模具中作为模具腔的壁的一部分。通过向模具中浇注熔化的金属,将冷却液套12直接浇铸在气缸盖衬套11上,与气缸盖衬套11的接触面紧密结合,最大程度保证结构上的整体性。另外,采用等离子喷涂工艺,将抗磨蚀涂层28喷涂在气缸盖/气缸盖衬套面向燃烧环境的一面,从而提高抗磨蚀性能。
图6示出其中第二优选实施例。如上所述制造气缸盖衬套11′。除了气缸盖燃烧室区域较大、内侧形状与纤维增强陶瓷基复合材料气缸盖衬套11′非面向燃烧室一面的轮廓相匹配以外,制造单独的、常规的具有冷却液套12的金属气缸盖10″采用的是现行工艺。然后,使用可商购的高温胶粘剂即硅橡胶34将纤维增强陶瓷基复合材料衬套粘合在恰当的位置上,上述硅橡胶34包括(但不限于)PERMATEX ULTRACOPPER衬垫材料。另外,采用等离子喷涂工艺,将抗磨蚀涂层28喷涂在纤维增强陶瓷基复合材料气缸盖衬套面向燃烧环境的一面,从而提高抗磨蚀性能。
图7示出其中第三优选实施例。如上所述制造气缸盖衬套11′。除了气缸盖燃烧室区域较大、内侧形状与纤维增强陶瓷基复合材料气缸盖衬套11′非面向燃烧室一面的轮廓相匹配以外,制造单独的、常规的具有冷却液套的金属气缸盖10采用的是现行工艺。然后,纤维增强陶瓷基复合材料气缸盖衬套被用如上所述的气缸盖螺栓18机械夹在气缸体(未示出)和常规金属气缸盖10之间。另外,采用等离子喷涂工艺,将抗磨蚀涂层28喷涂在纤维增强陶瓷基复合材料气缸盖/气缸盖衬套面向燃烧环境的一面,从而提高抗磨蚀性能。
举例:纤维增强陶瓷基复合材料气缸盖衬套的制造
1.按照所要求的尺寸制造或购买气缸盖衬套预型件(有许多美国厂商编织用于复合材料的复合材料预型件),上述预型件由纤维制成,包括(但不局限于)氧化铝、Altex、Nextel312、Nextel440、Nextel510、Nextel550、氮化硅、碳化硅、HPZ、石墨、碳、泥炭等。制造预型件使得当其放在模制工具中时,预型件占据30%~70%封闭工具的中空空间。
2.然后,按照每个工厂的最佳方法为预型件喷涂纤维界面涂层。本发明申请的受让人,Northrop公司,目前有许多有关界面涂层涂敷的专利,其中包括:专利号为5,034,181的美国专利“用于制造预型件方法的装置”,专利号为5,110,771的美国专利“产生预裂纤维涂层以提高陶瓷纤维基复合材料韧性的方法”,专利号为5,275,984的美国专利“提高陶瓷纤维基复合材料韧性的未粘合多层纤维涂层”,专利号为5,162,271的美国专利“产生韧性纤维涂层以提高非氧化物陶瓷基复合材料的韧性的方法”,以及专利号为5,221,578的美国专利“提高陶瓷纤维基复合材料韧性的具有未充填孔的弱易脆性纤维涂层”,上述专利中的教导可在本文中作为参考。另外,Allied Signal或Sinterials也是提供界面涂层销售服务的商业公司。
3.随后将气缸盖形状的预型件放入衬套形状的模具腔中,然后模具闭合并密闭预型件。
4.模具下部的注料孔通过带阀的软管连接在装有Blackglas树脂的容器上。上排气孔通过带阀通畅软管连接在真空源上。开始时,开启两个阀使树脂被吸入并充满模具。
5.装有Blackglas树脂的容器压力高于15磅/英寸2,即高于大气压力,从而形成正压将树脂注入模具。当树脂流过模具而且在真空源一侧(出口)的管中没有气泡时,关闭两个阀。
6.然后按照下述循环过程加热预型件及树脂混合物封闭在其中的模具:
A)由环境温度以2.7°/分钟的速度迅速升温至150°F;
B)在150°F下保温30分钟;
C)以1.7°/分钟的速度迅速升温至300°F;
D)在300°F下保温60分钟;
E)以1.2°/分钟的速度冷却,直到温度低于140°F,以便部件脱模。
应当注意可以定义多种生成可使用成品的加热循环过程,并且上述过程只是作为一个例子而不应被认为是唯一的。
7.当模具冷却时,将模具拆开,将聚合物复合材料部件从模具上卸下来进行热解。
注意:前面七步定义了一种制造聚合物复合材料部件的树脂转化模制(RTM)方法。制造同样部件的其它可采用的方法是手工铺贴法(Hand-Lay-up)或短纤维注射法(Short Fiber Injection)。上述有效的聚合物复合材料制造工艺包含在本发明及其附加权利要求的范围内并符合其精神。在本文中,上述各种工艺没有作为本发明人的发明而进行申报。
8.然后对聚合物复合材料部件进行热解。对于这一点,为使热解过程能够在标准炉子内进行,需要制造能承受1900°F高温的密封容器,例如不锈钢盒子。在可选择的方法中,如果可能的话可以使用惰性气体炉子。上述容器应当具有两个管接头,一个位于底部一个位于顶部,从而使容器能够充满惰性气体。在这个例子中,将衬套放在容器内,容器放在标准炉子中,不锈钢管连接在容器较低的管接头上并连接在高纯度氩气气源上。当然可以使用任何等效的惰性气体。使氩气流入容器中,并且在整个加热过程中氩气以5~10标准立方英尺/小时的流速从上排气孔排出,因此保证了衬套始终处在惰性气体环境中。关闭炉子并按下述步骤加热炉子:
A)以223°/小时的速度升温至300°F;
B)以43°/小时的速度升温至900°F;
C)以20°/小时的速度升温至1400°F;
D)以50°/小时的速度升温至1600°F;
E)在1600°F下保温4小时;
F)以-1′5°/小时的迅速降温至77°F。
同样,除上述程序以外还有多种加热程序,上述程序只是作为一个例子,它将生产出可使用的成品。
9.冷却后,从炉子和容器中移出衬套,并将衬套浸没在装有Blackglas树脂的池中足够长的时间(典型地为5分钟或更长),使空气从衬套中完全除去。在本步骤中同样可以采用真空浸润法。
10.如果需要可以重复进行步骤8和步骤9,直到由释气而在树脂内产生的孔的百分比减到最少,而部件的强度达到最大(典型地为5次)。
11.现在可以对衬套进行喷涂耐磨涂层之前的机加工。这时,在喷涂抗磨蚀涂层之前,机加工出对所有的孔(火花塞、阀等)(建议采用商品级金刚石切削工具)。机加工过程完成后,用砂纸将衬套表面上所有尖锐的棱打平。
12.将衬套放在加热室中一段时间,加热室温度应能保证“烧掉”任何在机加工过程中使用的切削液(典型的情况是在700°F下加热2小时,但是加热温度及加热时间依切削液而定)。
13.对衬套的燃烧室一侧进行喷砂处理,所选用的压力能够除去任何松散的基体材料并将纤维增强陶瓷基复合材料中的纤维露出(典型的是在20磅/英寸2压力下粒度为100)。
14.采用洁净的干燥压缩空气清理衬套。
15.然后为进行等离子喷涂处理将衬套安装在支承夹具上。
16.采用定向空气压缩机冷却衬套的非燃烧室一侧。
17.然后进行抗磨蚀涂层等离子喷涂,设定淀积速率为5克/秒或更高。设定支承夹具转动速度、喷枪沿表面的移动速度及喷涂宽度以实现50%重叠的理发店招牌喷涂模式。喷枪距离喷涂表面0.1~3英寸。喷涂所用颗粒的大小为170~400目。使用足够的抗磨蚀材料来进行上述等离子喷涂。
18.在抗磨蚀涂层喷涂完成后,用砂纸或恰当的成形工具(建议采用商品级金刚石切削工具)将衬套在燃烧室范围内的区域磨平,从而获得最终的内部轮廓。
19.然后可以将衬套粘到其金属配合件上或铸进其金属配合件中,从而恰当地完成特定的实施例。在衬套安装在其配合件上以后,将衬套的缸体配合面加工平整。在图7所示的实施例中,由于衬套没有被永久地连接在金属气缸盖及冷却液套上,所以可以单独将衬套加工平整。
Claims (17)
1.一种内燃机陶瓷气缸盖,包括:
a)气缸盖,该气缸盖由处于陶瓷状态的其中遍布有普通纤维体系的预陶瓷聚合物树脂构成,上述预陶瓷聚合物树脂由聚合物衍生陶瓷树脂构成;以及
b)用于将热量从上述气缸盖的上表面导出的装置,该装置使上述气缸盖温度低于极限温度。
2.如权利要求1所述的陶瓷气缸盖,其特征在于,上述用于将热量从上述气缸盖的上表面导出的装置包括:
在上述气缸盖的上述上表面上形成的一些散热片,这些散热片用于将热量导入上述散热片周围的空气中。
3.如权利要求1所述的陶瓷气缸盖,其特征在于,上述用于将热量从上述气缸盖的上表面导出的装置包括:
安装在上述上表面上的金属散热装置,上述金属散热装置包括散热片,用于将热量导入上述散热片周围的空气中。
4.如权利要求1所述的陶瓷气缸盖,其特征在于,上述用于将热量从上述气缸盖的上表面导出的装置包括:
在上述上表面上形成的金属冷却液套,该冷却液套具有进水管和排水管,内燃机冷却液流经它们。
5.如权利要求1所述的陶瓷气缸盖,其特征在于,上述用于将热量从上述气缸盖的上表面导出的装置包括:
粘结或机械安装在上述上表面上的金属冷却液套,该冷却液套具有进水管和排水管,内燃机冷却液流经它们。
6.如权利要求1所述的陶瓷气缸盖,其特征在于:
上述用于将热量从上述气缸盖的上表面导出的装置包括用于加热客厢供暧***所使用的液体的装置。
7.如权利要求1所述的陶瓷气缸盖,其特征在于,它还包括:
在上述气缸盖面向燃烧室的表面上配置的抗磨蚀涂层,由此提高了上述气缸盖的抗磨蚀性能。
8.一种内燃机陶瓷气缸盖,包括:
a)气缸盖,该气缸盖由处于陶瓷状态的其中遍布有普通纤维体系的预陶瓷聚合物树脂构成,上述预陶瓷聚合物树脂由聚合物衍生陶瓷树脂构成;以及
b)在上述气缸盖的上表面上形成的金属冷却液套,上述冷却液套具有进水管和排水管,内燃机冷却液流经它们,从而使上述气缸盖温度低于极限温度。
9.如权利要求8所述的陶瓷气缸盖,其特征在于,它还包括:
在上述气缸盖面向燃烧室的表面上配置的抗磨蚀涂层,由此提高了气缸盖的抗磨蚀性能。
10.一种内燃机陶瓷气缸盖,其包括:
a)气缸盖,该气缸盖由处于陶瓷状态的其中遍布有普通纤维体系的预陶瓷聚合物树脂构成,上述预陶瓷聚合物树脂由聚合物衍生陶瓷树脂构成;以及
b)粘结或机械安装在上述气缸盖的上表面上的金属冷却液套,上述冷却液套具有进水管和排水管,内燃机冷却液流经它们,从而使上述气缸盖温度低于一极限温度。
11.如权利要求10所述的陶瓷气缸盖,其特征在于,它还包括:
在上述气缸盖面向燃烧室的表面上配置的抗磨蚀涂层,由此提高了上述气缸盖的抗磨蚀性能。
12.一种内燃机陶瓷衬气缸盖,包括:
a)具有面向燃烧室的表面的气缸盖衬套,该气缸盖衬套由处于陶瓷状态的其中遍布有普通纤维体系的预陶瓷聚合物树脂构成,上述预陶瓷聚合物树脂由聚合物衍生陶瓷树脂构成;以及
b)配置在上述气缸盖衬套的上表面上的金属气缸盖,上述金属气缸盖包括用于将热量从上述气缸盖衬套的上述上表面导出的装置,从而使上述气缸盖温度低于一极限温度。
13.如权利要求12所述的陶瓷衬气缸盖,其特征在于,上述用于将热量从上述气缸盖衬套的上述上表面导出的装置包括:
一些散热片,这些散热片在上述金属气缸盖的上表面上形成,用于将热量导入上述散热片周围的空气中。
14.如权利要求12所述的陶瓷衬气缸盖,其特征在于,上述用于将热量从上述气缸盖衬套的上述上表面导出的装置包括:
安装在上述金属气缸盖的上表面上的金属散热装置,上述金属散热装置包括散热片,用于将热量导入上述散热片周围的空气中。
15.如权利要求12所述的陶瓷衬气缸盖,其特征在于,上述用于将热量从上述气缸盖衬套的上述上表面导出的装置包括:
在上述金属气缸盖中形成的金属冷却液套,上述冷却液套具有进水管和排水管,内燃机冷却液流经它们。
16.如权利要求12所述的陶瓷衬气缸盖,其特征在于:
上述用于将热量从上述气缸盖衬套的上述上表面导出的装置包括用于加热客厢供暧***中所使用的液体的装置。
17.如权利要求12所述的陶瓷衬气缸盖还包括:
在上述气缸盖衬套的上述面向燃烧室的表面上配置的抗磨蚀涂层,由此提高了气缸盖衬套的抗磨蚀性能。
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CN103925102A (zh) * | 2014-05-07 | 2014-07-16 | 广西玉柴机器股份有限公司 | 复合式气缸盖 |
CN103925102B (zh) * | 2014-05-07 | 2015-04-01 | 广西玉柴机器股份有限公司 | 复合式气缸盖 |
CN117780725A (zh) * | 2023-12-26 | 2024-03-29 | 沈阳欧施盾新材料科技有限公司 | 基于纤维复合材料的轻质高强活塞筒和活塞以及制备方法 |
Also Published As
Publication number | Publication date |
---|---|
KR19990036404A (ko) | 1999-05-25 |
AU6677196A (en) | 1997-03-12 |
MX9801254A (es) | 1998-05-31 |
US6026568A (en) | 2000-02-22 |
US5730096A (en) | 1998-03-24 |
IL123085A0 (en) | 1998-09-24 |
WO1997007328A1 (en) | 1997-02-27 |
US5638779A (en) | 1997-06-17 |
EP0845075A1 (en) | 1998-06-03 |
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