Composite engine architecture, and method of manufacturing the same

Patent metadata

Field	Value
Publication number	US-10487778-B2
Application number	US-201715829449-A
Country	US
Kind code	B2
Filing date	Dec 1, 2017
Priority date	Dec 1, 2017
Publication date	Nov 26, 2019
Grant date	Nov 26, 2019

Abstract

An engine block assembly includes a head structure assembly, and a cylinder structure assembly. A plurality of fasteners interconnect the head structure assembly and the cylinder structure assembly. An outer shell encapsulates and supports both the head structure assembly and the cylinder structure assembly. The outer shell is a unitary polymer structure that is simultaneously over-molded onto the head structure assembly and the cylinder structure assembly. The head structure assembly and the cylinder structure assembly are constructed of components that are designed to carry the operational loads of the engine with minimal weight. The outer shell provides additional structural integrity, and provides fluid passages for lubrication and cooling, as well as support for other engine components.

First claim

What is claimed is:

1. An engine block assembly comprising:
a head structure assembly;
a cylinder structure assembly;
a plurality of fasteners interconnecting the head structure assembly and the cylinder structure assembly; and
an outer shell over-molded onto both the head structure assembly and the cylinder structure assembly as a unitary polymer structure integral with both the head structure assembly and the cylinder structure assembly, such that the outer shell is not removable from the head structure assembly and the cylinder structure assembly, and permanently encapsulates and supports both the head structure assembly and the cylinder structure assembly.

2. The engine block assembly set forth in claim 1 , wherein the head structure assembly includes a head framework including an intake port, an exhaust port, and an upper combustion chamber portion.

3. The engine block assembly set forth in claim 2 , wherein the head structure assembly includes an intake valve guide and an exhaust valve guide.

4. The engine block assembly set forth in claim 2 , wherein the outer shell defines a fluid passage operable to circulate a fluid therethrough.

5. The engine block assembly set forth in claim 2 , wherein the head structure assembly includes an upper support plate engaging the plurality of fasteners.

6. The engine block assembly set forth in claim 5 , wherein the upper support plate and the head framework are integrally formed together as a single manufacture.

7. The engine block assembly set forth in claim 1 , wherein the cylinder structure assembly includes a sleeve forming a cylinder bore.

8. The engine block assembly set forth in claim 7 , wherein the outer shell defines a cylinder coolant passage adjacent the sleeve, wherein the cylinder coolant passage is operable to circulate a coolant for cooling the sleeve.

9. The engine block assembly set forth in claim 7 , wherein the cylinder structure assembly includes a lower framework supporting the sleeve.

10. The engine block assembly set forth in claim 9 , wherein the sleeve includes an upper end disposed adjacent to the head structure assembly, and a lower end disposed adjacent to the lower framework.

11. The engine block assembly set forth in claim 10 , wherein the cylinder structure assembly includes at least one crank cap.

12. The engine block assembly set forth in claim 11 , wherein the cylinder structure assembly includes at least one crank block.

13. The engine block assembly set forth in claim 12 , wherein the cylinder structure assembly includes a crankshaft rotatably supported between the at least one crank block and the at least one crank cap, for rotation about a crank axis.

14. The engine block assembly set forth in claim 12 , wherein the at least one crank block extends between the lower framework and the at least one crank cap, and wherein the sleeve is operable to transmit compressive forces from the plurality of fasteners between the head structure assembly and the lower framework, and with the at least one crank block operable to transmit compressive forces from the plurality of fasteners between the lower framework and the at least one crank cap.

15. The engine block assembly set forth in claim 12 , wherein the at least one crank block extends between the head structure assembly and the at least one crank cap, and wherein the at least one crank block is operable to transmit compressive forces from the plurality of fasteners between the head structure assembly and the at least one crank cap.

16. The engine block assembly set forth in claim 1 , further comprising an accessory embedded in the outer shell.

17. A method of manufacturing an engine block assembly, the method comprising:
forming a head framework that defines an intake port, an exhaust port, and an upper combustion chamber portion;
forming a cylinder structure assembly, which includes at least a sleeve forming a cylinder bore, a lower framework, and a crank block;
attaching the head framework to the cylinder structure assembly with a plurality of fasteners; and
over-molding a polymer onto the head framework and the cylinder structure assembly to form an outer shell, wherein the outer shell is not removable from the head framework and the cylinder structure assembly, and is a unitary structure permanently encapsulating and supporting the head framework and the cylinder structure assembly.

18. The method set forth in claim 17 , wherein forming the head framework is further defined as forming the head framework using one of a three-dimensional printing process or an additive manufacturing process.

19. The method set forth in claim 17 , further comprising forming at least one head coolant passage in the outer shell, at least one cylinder coolant passage in the outer shell, or at least one lubrication passage in the outer shell.

20. The method set forth in claim 17 , wherein over-molding the polymer onto the head framework and the cylinder structure assembly to form the outer shell includes embedding an accessory into the polymer forming the outer shell while over-molding the outer shell.

Assignees

• Gm Global Tech Operations Llc

Inventors

• Coppola Anthony M
• Kia Hamid G
• Najt Paul M
• Durrett Russell P
• Potter Michael A
• Andruskiewicz Peter P
• Brooks David J

Classifications

• F02F1/14

  Cylinders with means for directing, guiding or distributing liquid stream · CPC title

• F02F1/4285

  of both intake and exhaust channel · CPC title

• F02F7/0095

  Constructing engine casings (welded casings F02F7/0034) · CPC title

• F02F1/242

  Arrangement of spark plugs or injectors · CPC title

• B29C70/68

  by incorporating or moulding on preformed parts, e.g. inserts or layers {, e.g. foam blocks (mould constructions therefor B29C33/12; joining preformed parts by moulding B29C65/70)} · CPC title