Piston including a composite layer applied to metal substrate

Patent metadata

Field	Value
Publication number	US-11850773-B2
Application number	US-202217994687-A
Country	US
Kind code	B2
Filing date	Nov 28, 2022
Priority date	Dec 28, 2015
Publication date	Dec 26, 2023
Grant date	Dec 26, 2023

Abstract

A piston for a heavy duty diesel engine including a composite layer forming at least a portion of a combustion surface is provided. The composite layer has a thickness greater than 500 microns and includes a mixture of components typically used to form brake pads, such as a thermoset resin, an insulating component, strengthening fibers, and an impact toughening additive. According to one example, the thermoset resin is a phenolic resin, the insulating component is a ceramic, the strengthening fibers are graphite, and the impact toughening additive is an aramid pulp of fibrillated chopped synthetic fibers. The composite layer also has a thermal conductivity of 0.8 to 5 W/m·K. The body portion of the piston can include an undercut scroll thread to improve mechanical locking of the composite layer. The piston can also include a ceramic insert between the body portion and the composite layer.

First claim

The invention claimed is:

1. A piston, comprising: a body portion formed of metal; a composite layer applied to said body portion and forming at least a portion of a combustion surface; said composite layer including a thermoset resin, an insulating component, strengthening fibers, and an impact toughening additive; said thermoset resin being present in an amount of 25 wt. % to 35 wt. %, based on the total weight of said composite layer; said insulating component being present in an amount of 50 wt % to 70 wt. %, based on the total weight of said composite layer; said strengthening fibers being present in an amount of 1 wt. % to 10 wt. %, based on the total weight of said composite layer; and said impact toughening additive being present in an amount of 1 wt. % to 10 wt. %, based on the total weight of said composite layer.

2. The piston of claim 1 , wherein said composite layer has a thermal conductivity of 0.8 to 5 W/m·K.

3. The piston of claim 1 including an insert formed of ceramic disposed between said body portion and said composite layer.

4. The piston of claim 3 , wherein said insert includes alumina.

5. The piston of claim 1 , wherein an uppermost surface of said body portion includes an undercut scroll thread, and said composite layer is applied to said undercut scroll thread of said uppermost surface.

6. The piston of claim 1 , wherein said thermoset resin is a phenolic resin, said insulating component is ceramic, said strengthening fibers are graphite, and said impact toughening additive is an aramid pulp of fibrillated chopped synthetic fibers.

7. A piston, comprising: a body portion formed of metal; a composite layer applied to said body portion and forming at least a portion of a combustion surface; said composite layer including a thermoset resin, an insulating component, strengthening fibers, and an impact toughening additive; wherein said thermoset resin is a phenolic resin, said insulating component is ceramic, said strengthening fibers are graphite, and said impact toughening additive is an aramid pulp of fibrillated chopped synthetic fibers.

8. A piston, comprising: a body portion formed of metal; a composite layer applied to said body portion and forming at least a portion of a combustion surface; said composite layer including a thermoset resin, an insulating component, strengthening fibers, and an impact toughening additive; wherein said metal of said body portion is aluminum or steel; said body portion includes a crown extending circumferentially about a center axis from an upper end toward a lower end; said crown presents an uppermost surface at said upper end; said uppermost surface includes a combustion bowl extending inwardly and downwardly from a planar outer rim; said uppermost surface includes an undercut scroll thread, said composite layer is disposed on said undercut scroll thread of said uppermost surface; said composite layer has a thermal conductivity of 0.8 to 5 W/m·K; said thermoset resin is a phenolic resin, said insulating component is a ceramic, said strengthening fibers are graphite, and said impact toughening additive is an aramid pulp of fibrillated chopped synthetic fibers; said thermoset resin is present in an amount of 25 wt. % to 35 wt. %, based on the total weight of said composite layer; said insulating component is present in an amount of 50 wt. % to 70 wt. %, based on the total weight of said composite layer; said strengthening fibers are present in an amount of 1 wt. % to 10 wt. %, based on the total weight of said composite layer; and said impact toughening additive is present in an amount of 1 wt. % to 10 wt. %, based on the total weight of said composite layer.

9. The piston of claim 8 including an insert formed of ceramic disposed between said composite layer and said uppermost surface of said body portion, and said ceramic insert including alumina.

Assignees

• Tenneco Inc

Inventors

• Lineton Warran Boyd
• Evers Ross Allen
• Salenbien Greg

Classifications

• B29C43/18 Primary

  incorporating preformed parts or layers, e.g. compression moulding around inserts or for coating articles {(B29C43/206 takes precedence)} · CPC title

• B29C43/52

  Heating or cooling · CPC title

• B32B3/06 Primary

  for securing layers together; for attaching the product to another member, e.g. to a support {, or to another product, e.g. groove/tongue, interlocking} · CPC title

• B32B5/00

  Layered products characterised by the non- homogeneity or physical structure {, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts} · CPC title

• B32B5/02

  characterised by structural features of a {fibrous or filamentary} layer {(layer formed of metallic wires B32B15/02; layer formed of natural mineral fibres B32B19/02; layer formed of wood fibres B32B21/02)} · CPC title