Composite hybrid cam carrier

Patent metadata

Field	Value
Publication number	US-9822671-B2
Application number	US-201615058843-A
Country	US
Kind code	B2
Filing date	Mar 2, 2016
Priority date	Mar 2, 2016
Publication date	Nov 21, 2017
Grant date	Nov 21, 2017

Abstract

A cam carrier assembly includes a body made of a material lighter than aluminum. The body has a first side operably coupled with a cylinder head and a second side having bearing surfaces with bearing inserts. The bearing inserts support the camshaft. A series of apertures extend between the first and second sides of the body. Lobes of the camshaft operably couple with the valves of the cylinder head through the series of apertures extending between the first and second sides of the body.

First claim

What is claimed is:

1. A cam carrier assembly, comprising:
a cylinder head having valves;
a camshaft having lobes;
a cam carrier constructed from a carbon fiber composite and having a first lower side operably coupled with the cylinder head, and a second upper side having semi-circular lower bearing surfaces with semi-circular bearing inserts operably coupled therewith, the semi-circular bearing inserts supporting the camshaft;
a series of apertures extending between the first lower side and the second upper side;
one or more bucket tappets disposed within the series of apertures and operably coupled between the lobes of the camshaft and the valves of the cylinder head; and
one or more tappet bore inserts operably coupled between the cam carrier and the bucket tappets within the series of apertures.

2. The cam carrier assembly of claim 1 , further comprising:
one or more cam caps coupled with the second upper side of the cam carrier, each having a semi-circular upper bearing surface for directly engaging the camshaft, the cam caps made of the same material as the bearing inserts.

3. The cam carrier assembly of claim 1 , further comprising:
a gasket operably coupled to a peripheral edge of the first lower side of the cam carrier and configured to sealably engage the cam carrier to the cylinder head.

4. The cam carrier assembly of claim 1 , wherein the carbon fiber composite includes a resin and a fiber configured for injection molding the cam carrier, and wherein the cylinder head includes an aluminum alloy.

5. The cam carrier assembly of claim 1 , further comprising:
one or more threaded fasteners that extend through the cam carrier and into threaded engagement with corresponding fastening holes in the cylinder head.

6. The cam carrier assembly of claim 5 , wherein the one or more threaded fasteners is at least equal to the number of cylinders present in the cylinder head.

7. The cam carrier assembly of claim 1 , wherein the tappet bore inserts are made of a copper alloy.

8. The cam carrier assembly of claim 7 , wherein the copper alloy is AMPCO® 18.

9. A cam carrier, comprising:
a body formed from a single piece of carbon fiber composite;
a first side engaging a cylinder head;
a second side with semi-circular lower bearing surfaces for supporting a camshaft; and
a series of apertures extending between the first side and second side in linear alignment with the semi-circular lower bearing surfaces such that the camshaft operably couples with valves on the cylinder head.

10. The cam carrier of claim 9 , wherein the carbon fiber composite includes thermal expansion properties that differ from the thermal expansion properties of the cylinder head by at least 25%.

11. The cam carrier of claim 9 , wherein the carbon fiber composite includes a thermosetting resin and a chopped carbon fiber combined to support forces acting on the camshaft.

12. The cam carrier of claim 9 , further comprising:
one or more cam caps fastened to the second side of the cam carrier with fasteners operably coupled to the cam carrier on opposing sides of the camshaft, each cam cap having a semi-circular upper bearing surface for directly engaging the camshaft.

13. The cam carrier of claim 9 , wherein the first side of the cam carrier includes a locating member protruding downward for engaging a corresponding locating aperture on the cylinder head.

14. The cam carrier of claim 9 , wherein the single piece of carbon fiber composite includes oil feed channels formed integrally therein and extending to a circumference of the semi-circular lower bearing surfaces for providing lubrication to the camshaft.

15. The cam carrier of claim 9 , further comprising:
a fuel pump pedestal formed separately from the cam carrier and fastened to the second side of the cam carrier with threaded fasteners.

16. A cam carrier assembly, comprising:
a body made of a material lighter than aluminum and having:
a first lower side operably coupled with a cylinder head, and a second upper side having semi-circular lower bearing surfaces with semi-circular bearing inserts operably coupled therewith, the semi-circular bearing inserts supporting a camshaft;
a series of apertures extending between the first lower side and second upper side; and
lobes of the camshaft operably coupling with valves of the cylinder head through the series of apertures extending between the first lower side and second upper side.

17. The cam carrier assembly of claim 16 , wherein the material lighter than aluminum is a thermosetting resin.

18. The cam carrier assembly of claim 16 , further comprising:
one or more cam caps operably coupled with the second upper side of the cam carrier, each having a semi-circular upper bearing surface for directly engaging the camshaft.

19. The cam carrier assembly of claim 16 , further comprising:
a gasket attached around a peripheral edge of the first side of the cam carrier and configured to sealably engage the cam carrier to the cylinder head.

20. The cam carrier assembly of claim 16 , further comprising:
a fuel pump pedestal operably coupled with the second side of the cam carrier for supporting a fuel pump.

Assignees

• Ford Global Tech Llc

Inventors

• Madin Mark Michael
• Wicks Christopher Donald

Classifications

• F01L1/143

  for use with overhead camshafts · CPC title

• F01L2301/00

  Using particular materials · CPC title

• F01L2001/0471

  Assembled camshafts · CPC title

• F01L1/047

  Camshafts · CPC title

• F01M11/02

  Arrangements of lubricant conduits · CPC title