CROSS-REFERENCE TO RELATED APPLICATION

|OO0! j This U.S, utility patent application claims the benefit of U.S. provisional patent application no. 62/256,986, filed November 18, 2015, and U.S. provisional patent application no. 62/280,971 , filed January 20, 2016, and U.S. utility patent application no. 15/352,418, filed November 15, 2016, the entire contents of which are incorporated herein by reference.

BACKGROU D OF THE INVENTION

1. Field of the Invention

[00021 This invention relates generally to pistons for internal combustion engines, and methods for manufacturing the pistons,

2, Related Art

|00©3] Pistons used In internal combustion engines, such as heavy duty diesel pistons, are exposed to extremely high temperatures during operation, especially along the crown of the piston. Therefore, to moderate the temperature, some pistons are designed with an open cooling gallery beneath the crown, and cooling oil Is sprayed into the cooling gallery as the piston reciprocates along a cylinder bore of the engine. The oil Hows along the inner surface of the crown and dissipates heat away from the crown,. However, to control the piston temperature during operation, a high flow of oil must be maintained constantly- In addition, the oil degrades over time due to the high temperature of the internal combustion engine, and the oil must be changed periodically to maintain engine life, furthermore, when the cooling gallery temperature exceeds 350° C, the oil tends to burn at a higher rate, referred to as oil coking, and adhere to the surface of the gallery. |θ©$4] Another option is to design the piston with a sealed cooling gallery containing cooling oil or another coolant to control the piston temperature, U.S. Paterst No. 9, 127,619 discloses an example of a piston including a sealed cooling gallery' partially filled with a liquid containing metal particles having a high thermal conductivity, The liquid carries the metal particles throughout the cooling gallery as the piston reciprocates in the internal combustion engine, and the metal particles remove heat away from the crown. The metal particles ears re-distribute the heat flow, and thus reduce carbon deposits, coking, and oil degradation along the crown,

[TOSS] It is also desirable to reduce heat loss from the combustion chamber to the piston crown, in order to maintain a high temperature in the combustion chamber and achieve higher engine brake thermal efficiency. Thus, a thermal barrier coating can be applied to the piston crown for additional insulation, However, engine manufacturers continuously strive to develop new and improved methods to better maintain heat in the combustion chamber, reduce the operating temperature of the piston, and thus further improve engine brake thermal efficiency.

SUMMARY OF THE INVENTION

[0006] One aspect of the invention comprises a piston for an internal combustion providing the engine with improved brake thermal efficiency (BTE), The piston includes a body formed of a metal material The body includes a crown presenting a combustion surface. The crown includes an outer side wail depending from the combustion surface, and the outer side wall presents an outer diameter of the body. The crown also includes an outer cooling gallery and an undercrown cooling gallery. The outer cooling gallery extends circumferential!}' along the outer side wall beneath the combustion surface, the outer cooling gallery is sealed and contains a first cooling media. The undercrown cooling gallery is surrounded by the outer cooling gallery beneath a first undercrown surface, and the undercrown cooling gallery contains a second cooling media. The crown includes a lower wall extending along the undercrown coolin gallery, and the lov/er wall includes an inlet hole to the undercrown cooling gallery.

f00 7| Another aspect of the invention provides a method of manufacturing a piston for an Interna! combustion engine. The method includes providing a body formed of a metal material, ihe body including a crown presenting a combustion surface, the crown including an outer side wall depending from the combustion surface, ihe outer side wail presenting an outer diameter of the body, the crown including an outer cooling gallery being sealed and an undercrown cooling gallery, the outer cooling gallery extending clrcumferenfia!ly along the outer side wall beneath the combustion surface _^ the undercrown cooling gallery being surrounded by the outer cooling gallery beneath a first undercrown surface, ihe crown including a lower wall extending along the undercrown cooling gallery, and the lower wall including an Inlet hole to the undercrown cooling gallery. The method further includes providing a first cooling media in the outer cooling gallery and a second cooling media in the undercrown cooling gallery,

BRIEF DESCRIPTION OF THE DRAWINGS

[0008] Other advantages of the present invention will be readily appreciated, as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawing wherein:

[0009] Figure 1 is a side cross-sectional view of a piston according to one example embodiment with a sealed outer cooling gallery extending circumferential!}' around ihe piston and containing a first cooling media;

fOO! ] Figure 2 is a side cross-sectional view of a piston according to another example embodiment which includes a sealed undercrown cooling gallery filled with a second cooling media in addition to the sealed outer cooling gallery; and [0011 J Figure 3 is a side cross-sectional view of a piston according to yet another example embodiment which includes the sealed outer cooling gallery and the undercro n cooling gallery, wherein She undercro n cooling gallery includes an open in!et hole and contains the second cooling media.

DESCRIPTION OF THE EXAMPLE EMBODIMENTS

| 012J A piston 20 for an interna! combustion engine according to example embodiments is generally shown in Figures 1 -3, The piston 28 includes a sealed outer cooling gallery 26 containing a first cooling media 28 and/or n undererown cooling gallery 2S'contai ng a second cooling media 28' to reduce heat loss from the combustion chamber ihrough the piston 20, and thus improve brake thermal efficiency (8TE) when the piston 2& is used in an internal combustion engine. Brake thermal efficiency is known to those of ordinary skill in the art as brake power of the engine divided by thermal power of the engine. The brake thermal efficiency is typically used io determine how well {he engine converts heai from fuel to mechanical energy.

|0013| As shown in the Figures, the piston 2S comprises a body 22 formed of a metal material such as steel, extending csreumferenisaily around a center axis A and longitudinally along the center axis A from an upper end 3Θ to a lower end 32. The body 22 includes a crown 24 presenting a combustion surface 34 which is exposed to a combustion chamber during use in the internal combustion engine. The crown 24 also presents a first undererown surface 36 facing opposite the combustion surface 54.

|GGI4) The crown 24 includes the outer cooling gallery 26 extending along at least a portion of the crown 24. The crown 24 includes an upper wall 3§, a lower wall 4(1, an outer side wall 42, and an Inner side wall 44 which together define the outer coo!ing gallery 26. This outer cooling gallery 26 is disposed along an outer portion of the first undererown surface 36 and extends eircumferentiaSSy around the center axis A. The outer cooling gallery 26 Is disposed along only a portion of the upper wail 38 of the crown 24 and is spaced radially from the center axis A. The outer side wail 42 and inner side wall 44 are formed by ibs which are joined together to define the outer cooling gallery 26, In this embodiment the outer ribs are connected by welds 51 to form the outer side wall 42, and the inner ribs are connected by welds 50 to form the inner side wall 44, The ribs could alternatively be attached to one another using another joining method, such as bonding weld or a mechanics! attachment. At least one of she walls 3§, 40, 42, 44, and typically the lower wall 40, includes an opening 52 for allowing the first cooling media 28 to enter the outer cooling gallery 26, The opening 52 to the outer cooling gallery 26 is then sealed, for example by a plug, as shown in the Figures. Alternatively, the opening 52 could be sealed by disposing an adhesive in the opening 52, welding a material to the opening 52, or brazing the opening 52, Alternatively, the piston 20 cowld be cast as a single piece including the sealed outer cooling gallery 26.

f HS] According to another example embodiment, as shown in Figures 2 and

3, the piston 20 includes the undercrown cooling gallery 26* along the first undercrown surface 36 at the center axis A of the piston 20, This undercrown cooling gallery 26' is only- disposed along a portion of the upper wall 38 of the crown 24 and is surrounded by the circumferential outer cooling gallery 26. The upper wall 38, lower wail 40, and inner side wall 44 together define the undercrown cooling gallery 26\ in this embodiment, the lower wall 40 includes a second undercrown surface 36* facing opposite the combustion surface 34. The undercrown cooling gallery 26' is preferably used in combination with the circumferential outer cooling gallery 26, but can be used independent of the circumferential outer cooling gallery 26, The undercrown cooling gallery 26* is also at least partially filled with a second cooling media 28 ^? to further reduce heat (low through the piston 28 andtor to reduce oil degradation. The second cooling media 28' used in the undercrown cooling gallery 26' can be the same or different from the first cooling media 28 used in the outer cooling gallery 26,

(00161 In the embodiment of Figure 2 _S the ursdererown cooling gallery 26' is sealed to contain the second cooling media 28' and so thai no other substance can enter or exit the cooling gallery 26', According to another embodiment, as shown in Figure 3, the ursdererown cooling gallery 26' is not sealed. A small open inlet hole 46 is located in the lower wall 0 along the center axis A of the pisiora 2% to allow air to enter the ursdercrowrs cooling gallery 26Λ The inlet hole 46 may also allow a small amount of oil from the erankcase in the form of a splash or mist to enter the undererown cooling gallery 26*. In the embodiment of Figure 2, however, the inlet hole 46 to the undererown cooling gallery 26' is sealed with a plug 52. The diameter of the inlet hole 46 is 1 % to 25% of the outer diameter of the piston 26\ Typically, the diameter of the inlet hole 46 is less than 4% of the outer diameter of the piston 20, or from 2% to 4% of Ae outer diameter of the piston 2§. The ouier diameter of the piston 20 is defined as the largest outer diameter along the skirt sections 62 in the thrust direction. Typically, the outer diameter of the piston 20 is measured where the piston 20 to liner clearance is defined. For example, the diameter of the inlet hole 46 could be approximately 5 mm or less. Optionally, the inlet hole 46 can be tapered, such that the diameter of the inlet hole 46 increases moving from the inside of the undererown cooling gallery 46 to the outside, and away from the combustion surface 34. The tapered hole 46 may facilitate the process of oil entering into the undererown cooling gallery 26' and/or keep the second cooling media 28 ^¾ inside the undererown cooling gallery 26 ¹ . A revered tapered hole 46, wherein the diameter of the inlet hole 46 decreases moving from the inside of the undererown cooling gallery 46 to the outside, and away from the combustion surface 34, can also he used to facilitate the manufacturing process of drilling from the side of the undercrown cooling gallery 26' 0017) in the piston 20 of the example embodiment, the combustion surface

34 of the body 22 presents an apex at the center axis A, a bowl-shape surrounding the apex, arsd a bowl rim surrounding the bowl-shape. The outer side wall 42 also includes a plurality of ring grooves 56 facing away f om the center axis A and extending circumferential!}' around the center axis A. The ring grooves 56 are spaced from one another by lands 48. and the lands 48 present the outer diameter of the body 22. The piston 20 of the example embodiment further includes at least one pin boss 58, but typically a pair of pin bosses 58, each depending from the crown 24 and extending circumferentialiy about the center axis A. The at least one pin boss 58 presents a pin bore 6© extending perpendicular to the center axis A for receiving a wrist pin (not shown). The body 22 also includes at least one skirt section 62, but typically a pair of skirt sections 62, depending from the crown 24 and extending circumferential ly about the center axis A. The at least one skirt section 62 is joined to the at least one pin boss 58, Typically, the skirt sections 62 are spaced from one another drcumferentially about the center axis A by the pin bosses 58. it s noted that the body 22 of the piston 2@ could comprise various other designs other than the design disclosed in Figures 1 and 2, while still including the outer cooling gallery 26 and/or the undercrown cooling gallery 26* for containing the cooling media 28 and/or 28\

fOOlSj The first cooling media 2S located in the outer cooling gallery 2€ and/or the second cooling media 28' located in the undercrown cooling gallery 26' can be in the form of a gas, liquid, solid, and/or a mixture. Typically, when the cooling media 28 or 28' is in the form of a gas, the gas fills 100 volume percent (vol, %} of the cooling gallery 26, 26*. Various different types of gas could be used for the cooling media 28 or 28', for example air, helium, argon, helium, xenon, carbon dioxide, another gas, or even a partial vacuum. The gas cooling media 28 or 2ΙΓ has a thermal conductivity which is lower than solid materials, multiphase Siquid/gas mixtures, and liquids, such as conventional cooling oils. For example, at 25° C, air has a thermal conductivity of about 0,024 (m- ), helium has a ihermal conductivity of about 0, 142 W/{nvK) _t and argon has a thermal conductivity of about 0.016 W (nr .). According to one example embodiment, the second cooling media 28' which fills the undercfown cooling gallery 26' is argon, a partial vacuum, or another gas that is more effective at reducing heat flow than air, Either argon, air, or another type of first cooling media 28 then fills the outer cooling gallery 26.

|ΘΘ19| According to anoiher example embodiment, the first cooling media 28 which fills or partially fills the outer cooling gallery 26 and/or the second cooling media 28* which f ls or partially fills the undercrown cooling gallery 26 ^? is a liquid, solid, or a mixture of solids and liquids. Examples of compositions which ears be used as the cooling media 28 or 28' are disclosed in U.S. Patent Nos, 912761 , 8955486, 8662026; and US Provisional Patent Application No. 62/262,704. According to one example embodiment, a coolant having the trade name EnviroKooi™ is used as the second cooling media 28* which partially Sills the undercrown cooling gallery 26', In this case, air or another type of first cooling media 28 fills or partially Oils the outer cooling gallery 26. According to anoiher example embodiment, the firsl cooling media 2S consists of air and 1113s S 00¾ of a volume of the outer cooling gallery 26; and the second cooling media 2§* consists of air and fills 100% of a volume of the undercrown cooling gallery' 26'.

|iM>20] According to yet another embodiment, standard engine oil is the first cooling media 2g which partially fills the outer cooling gallery 26 and/or the second cooling media 28' which partially fills the undercrown cooling gallery 26'. If only one of the cooling galleries 26, 26' includes the engine oil then air or another type of cooling media 28, 28' fills or partially fills the other cooling gallery 26, 26*. In the case engine oil is used to partially fill the outer cooling gallery 26 and/or the undercrown cooling gallery 26', the engine oil may create a coked oil layer along the inner surface of the cooling gallery 26, 26'

S at high surface temperature areas. Thus, the coked oil layer could create additional thermal insulation and further reduce loss through the piston 20.

|SMI21 | The low thermal conductivity of She cooling media 28, 28' maintains heat in the combustion chamber and reduces the amount of heat lost through the piston 20, In other words, the low thermal conductivity reduces heat loss from the combustion chamber through the piston 20 arsd increases the temperature of the combustion chamber. Thus, the cooling media 28, 28' can be referred to as ars insulating media or piston thermal management. Additional energy in the combustion chamber can he reclaimed with this waste heat recovery (WH ) system. In addition, oil coking deposits along surfaces of the cooling gallery 26 and the second undererown surface 36' can be minimized or eliminated. Degradation of cooling oil and lubricating oil which contacts the piston 20 can be reduced. The cooling media 28, 28* can also minimize the temperature of the lower part of the piston 20.

j0022] To provide additional insulation, a thermal barrier coating 54 can be applied to the combustion surface 34 of the upper wall 38 of the crown 24, as shown in Figures I , 2, and 3. The thermal barrier coating 54 can also be applied to the first undererown surface 36 of the piston of Figure 1 which does not include the undererown cooling chamber 26*. Alternatively, the thermal barrier coating 54 can be applied to the second undererown surface 36' of the piston 2© of Figures 2 and 3 which includes the undererown cooling gallery 26'. For example, the piston 20 of Figures 2 and 3 can include the thermal barrier coating 54 on both the first undererown surface 36 and the second undererown surface 36\ or just one of those surfaces, The thermal barrier coating 54 has a thermal conductivity which is lower than the thermal conductivity of the metal used to form the piston body 22. The thermal barrier coating 54 is formed of ars insulating material, such as a ceramic based material, for example yttria stabilized zireonia, eersa stabilized zireonia, or another type of partially stabilized zircoma. The t ermal barrier coating 54 further reduces heal loss through the piston 20 and Increases the combustion chamber temperature.

|θδ23] Another aspect of the Invention provides a method of manufacturing the piston 2 nclu ng the first cooling media 28 in the outer cooling gallery 26 and/or the second cooling media 8' in the ndercrown cooiirsg gallery 26', The method generally includes the steps of providing the body 22 formed of the steel material; and at [east partially Filling at least a portion of the outer cooling gallery 26 ηά/or the isndererown cooiirsg gallery 26* with the cooling media 28, 2§', The method also typically includes sealing the outer cooling gallery 26 and/or the undercrown cooling gallery 26\

[0024j When forming the example piston 20 shown in Figures 1 -3, the step of providing the body 22 includes joining the upper rib to the lower rib to form the inner side wail 44 and the outer side wail 42 defining the outer cooling gallery 26 therebetween. The joining step can include welding, bonding welding, mechanically attaching, or using mother technique to join the ribs,

|002S| The step of filling the outer cooling gallery 26 with the first cooling media 28 typically includes forming the opening 52 in one of the wails 3$, 40, 42, 44 of the crown 24, typically the lower wall 4Θ, and then pumping the first cooling media 28 through the opening 52. In this embodiment, the opening 52 can be formed before or after the joining step, and the step of tilling the cooling gallery 26 occurs after the joining step, finally, this method includes sealing the opening 52 to the outer cooling gallery 26 with a plug and fixing the plug, for example by welding, brazing, a screw, or an adhesive. U.S. Provisional Patent Application No, 62/1 10, 191 , which is incorporated herein by reference, discloses an example method used to seal the cooling gallery 26, Alternatively, the outer cooling gallery 26 can include the opening 52 which can be left unsealed, provided that it will not be aligned with an oil cooling jet, The same steps discussed with regard to the opening 52 can be conducted to fill and seal ihe inlet hole 46 to the undercrown cooling gallery 26*. Alternatively, ihe tmdererown cooling gallery 26' can include the small hole 46 and can be left unsealed,

|0S26| According to another embodiment, ihe piston 20 could be east as a single piece including ihe sealed cooling gallery 28, such that air is ihe first cooling media 28 which fills the sealed outer cooling gallery 28, in other embodiments, a partial vacuum, argon, helium, xenon, carbon dioxide, or another gas having a low thermal conductivity, for example a gas effective in reducing heat flow than air, is disposed in the outer cooling gallery 26 and/or the nndercrown cooling gallery 26' before sealing the cooling gallery 26. The process used to manufacture the piston 20 is much simpler, resulting in lower cost, compared to prior methods.

0 27 Obviously, many modifications and variations of the present invention are possible in light of (he above teachings and may be practiced otherwise ihm as specifically described while within the scope of the following claims.