Abstract

A method is provided for designing and producing fiber-reinforced polymer (FRP) pistons. Pistons made with FRP have a lower mass than prior art metal pistons conferring advantageous engine efficiency and stability. FRP pistons also increase the thermal efficiency of engines by having a lower thermal conductivity, with tighter piston-to-bore clearance, and/increased air-fuel ratio than pistons of metal. The technical parameters of the piston are identified, and a piston body blank is produced. The blank is then machined, a bearing surface for the pin bore is created, the piston blank is optionally coated, is optionally subjected to Heavy Metal Ion Implantation (HMII) treatment and is subjected to sodium silicate impregnation to produce the final pistons.

IPC Classes  ?

• B23P 15/10 - Making specific metal objects by operations not covered by a single other subclass or a group in this subclass pistons
• F02F 3/00 - Pistons

Abstract

Methods of designing and producing a connecting rod using carbon fiber reinforced epoxy molding compound composite material are provided, such that the method allows connecting rod designer to machine several different connecting rod designs, lengths, and beams. The material is molded into a near-net shape. After molding, the blank is machined into the final shape of a connecting rod and the material is sealed.

IPC Classes  ?

• B29C 70/34 - Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or coreShaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression
• B29C 33/38 - Moulds or coresDetails thereof or accessories therefor characterised by the material or the manufacturing process
• B23B 35/00 - Methods for boring or drilling, or for working essentially requiring the use of boring or drilling machinesUse of auxiliary equipment in connection with such methods
• B29C 70/54 - Component parts, details or accessoriesAuxiliary operations
• B29L 31/06 - Rods, e.g. connecting rods
• B29K 307/04 - Carbon
• B29K 63/00 - Use of epoxy resins as moulding material

Abstract

Fiber-reinforced polymer (FRP) tappets or lifters and methods of designing and producing tappets are described. The methods described herein provide FRP tappet having reduced mass compared to conventional metal tappets thereby increasing engine efficiency and stability. The technical parameters of the tappet are identified, and a tappet body blank is produced. The tappet body blank is machined, and a bearing surface for the cup register is generated to obtain tappet blank. The tappet blank is optionally subjected to secondary treatments including coating, Heavy Metal Ion Implantation treatment, or sodium silicate impregnation to produce the tappet. A plastic or a FRP tie bar including methods of designing and producing tie bars is described. The tie bar is applicable in both FRP and conventional metal tappets. The plastic or FRP tie bar reduces the mass of tie bars compared to conventional metal tie bars.

IPC Classes  ?

• F01L 1/14 - TappetsPush-rods
• B24C 1/10 - Methods for use of abrasive blasting for producing particular effectsUse of auxiliary equipment in connection with such methods for compacting surfaces, e.g. shot-peening
• B23P 15/00 - Making specific metal objects by operations not covered by a single other subclass or a group in this subclass

Abstract

A method is provided of designing and producing a carbon fiber composite wrist pin using a combination of a carbon fiber composite pultruded rod that is overwrapped with a carbon fiber prepreg fabric. The use of the carbon fiber pultruded rod and the carbon fiber prepreg fabric results in a rod with optimal flexural strength properties to endure the flexural stress placed on a wrist pin during the cycling of an internal combustion engine. In addition, the overwrapping of the pultruded rod with a carbon fiber prepreg fabric allows for one pultruded rod blank to produce multiple wrist pin sizes by allowing one to change the outer diameter of the wrist pin by changing the thickness of the carbon fiber prepreg fabric overwrapping. After overwrapping, the rod blank is cut to a chosen specific length, optionally inserted into a metal sleeve, and coated with a thermal barrier coating. The wrist pin is then ground to a chosen specific tolerance and coated with an anti-friction coating.

IPC Classes  ?

• B29C 70/34 - Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or coreShaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression
• B29C 33/38 - Moulds or coresDetails thereof or accessories therefor characterised by the material or the manufacturing process
• B29C 70/54 - Component parts, details or accessoriesAuxiliary operations
• B29L 31/06 - Rods, e.g. connecting rods

Abstract

A method is provided of designing and producing a carbon fiber composite wrist pin using a combination of a carbon fiber composite pultruded rod that is overwrapped with a carbon fiber prepreg fabric. The use of the carbon fiber pultruded rod and the carbon fiber prepreg fabric results in a rod with optimal flexural strength properties to endure the flexural stress placed on a wrist pin during the cycling of an internal combustion engine. In addition, the overwrapping of the pultruded rod with a carbon fiber prepreg fabric allows for one pultruded rod blank to produce multiple wrist pin sizes by allowing one to change the outer diameter of the wrist pin by changing the thickness of the carbon fiber prepreg fabric overwrapping. After overwrapping, the rod blank is cut to a chosen specific length, optionally inserted into a metal sleeve, and coated with a thermal barrier coating. The wrist pin is then ground to a chosen specific tolerance and coated with an anti-friction coating.

IPC Classes  ?

• B29C 70/34 - Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or coreShaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression
• B29C 33/38 - Moulds or coresDetails thereof or accessories therefor characterised by the material or the manufacturing process
• B29C 70/54 - Component parts, details or accessoriesAuxiliary operations
• B29L 31/06 - Rods, e.g. connecting rods