Disclosure of Invention
Against this background, it is an object of the present invention to overcome the disadvantages of the prior art and to improve a device and a method of the type mentioned at the outset.
This object is solved with a cylinder head for an internal combustion engine. The cylinder head is provided with a plurality of discharge passages and an exhaust manifold integrated in the cylinder head, the discharge passages being formed by exactly one sheet metal shell, wherein the cylinder head is cast around the sheet metal casing, characterized in that all discharge channels are at least partly sectioned and the exhaust manifold is formed by the one sheet metal casing located in the cylinder head in a cast manner, wherein the exhaust manifold serves as a collecting main and combines the individual exhaust passages of the combustion chambers of the internal combustion engine into a common exhaust pipe, wherein the sheet metal housing is assembled from a plurality of housing parts, wherein one housing part is an upper half shell of the sheet metal housing and the other housing part is a lower half shell of the sheet metal housing, and wherein each half-shell is associated with the other half of the cross-section of the exhaust channel or exhaust manifold.
According to the invention, a cylinder head of an internal combustion engine is therefore provided for which all the outlet channels are formed at least in sections and the exhaust manifold by a sheet metal casing, around which the cylinder head is cast. Hereby it is achieved that the exhaust gas channel formed by the discharge channel and the exhaust manifold is created with a material having a smaller heat transfer capacity and a high stability with respect to aggressive exhaust gases.
In one embodiment of the invention, the sheet metal housing is designed in such a way that all the outlet channels are completely lined with the sheet metal housing, in particular from the valve seat up to the exhaust manifold. In an alternative, production-technically simpler and therefore preferred embodiment, the sheet metal housing extends from the exhaust manifold over only a partial length section of the discharge channel. For example, the sheet metal jacket extends from the exhaust manifold only up to the beginning of a sharp bend in the central section of the exhaust gas duct, so that the sheet metal jacket has an approximately flat geometry over its entire extent.
It has proven advantageous to embody the sheet metal housing as a single piece. This allows, on the one hand, a rapid and precise loading of the casting mould and, on the other hand, the geometry of the exhaust duct can be precisely predefined by the sheet metal jacket and can be individualized independently of the casting mould. Furthermore, the one-piece sheet metal housing has only a small number of joining areas and connecting interfaces, which reduces the outlay for producing a guide channel for the exhaust gas seal.
It has proven practical for the sheet metal cover shell to be filled with sand cores, which are removed only after casting. It is hereby simpler and more reliable to handle thin-walled and therefore sensitive sheet metal enclosures.
However, it may also be advantageous if the sheet metal housing is assembled from a plurality of housing parts, preferably from two housing parts. This makes it easier to handle the sheet metal housing, in particular during its production, during transport, storage and during further processing (for example insertion into a casting mold). The sheet metal housing can be easily deformed due to its small wall thickness and thus become unusable.
A casting mold typically comprises two mold halves. Since the two mold halves are also provided for casting independently of one another, it is advantageous if one housing part is an upper half shell of the sheet metal housing and the other housing part is a lower half shell of the sheet metal housing. Each half shell is associated here with the other half of the cross section of the exhaust channel or exhaust manifold. The half-shells are inserted into the respective mould halves before the casting mould is closed.
It is particularly desirable for the sheet metal housing to be oriented partially perpendicular to the envelope curve of the exhaust duct and/or the exhaust manifold in the region of the joint between two adjacent housing parts. In this way, it is possible to achieve a high level of tightness against the exhaust gas if the sheet metal housing is multi-part. The edge sections of the two housing parts oriented perpendicularly to the envelope curve bear against one another and are connected in a force-fitting and/or material-fitting manner during the casting process. This makes it impossible for exhaust gas to flow behind the sheet metal casing, in particular to be squeezed between the sheet metal casing and the cylinder head. This serves to protect the cylinder head and also the insulating layer which may be provided between the sheet metal cover shell and the cylinder head.
It has proven to be highly possible for the sheet metal housing to have a coating at least in sections at the outer face facing the cylinder head and/or at the inner face facing the exhaust gas duct. The coating is formed from a ceramic material and/or from an enamel material and/or from a pre-cerammed polymer, wherein the coating is applied to the sheet metal casing prior to casting of the cylinder head. The application of the coating is preferably carried out by means of thermal application, spraying and/or dipping. Here, a plurality of layers of different materials is possible. Zirconia and alumina have proven to be particularly useful as ceramic materials.
The exhaust passage is a passage structure that includes an exhaust passage and an exhaust manifold between the combustion chamber and an exhaust pipe coupled to the cylinder head and that guides exhaust gas.
The heat transfer between the sheet metal jacket and the cylinder head made of aluminum is greater than in the case of a cladding inserted in the middle and/or a sheet metal jacket with a certain structure (strukturring). The coating or a certain structure applied on the outer face of the sheet metal housing is protected from the exhaust gas. The coating has a thickness of 0.1 to 10 mm, preferably 0.5 mm. The sheet metal housing has a thickness of 0.1 to 10 mm, preferably 0.5 mm. According to a particular embodiment, the sheet metal housing and the coating have the same thickness.
The heat insulation of the sheet metal cover with respect to the cylinder head is also achieved according to the invention in that the sheet metal cover has a structure at least in sections at the outer face facing the cylinder head. The certain structure can be formed by an application and/or a recess on the outer face. The gap for isolation is provided between the sheet metal housing and the cylinder head by the certain structure.
Furthermore, by thermally isolating the exhaust gas from the cylinder head, the thermal load on the cylinder head and thus the cooling requirement can be reduced.
This object is also solved with a method for manufacturing the cylinder head. In the method for producing the cylinder head, the individual shell parts of the sheet metal shell are first coated at least in sections by means of a thermal coating method, then inserted into a casting mold and finally the cylinder head is formed from a casting material by casting around the individual shell parts of the sheet metal shell.
According to the invention, a method is therefore provided for producing a cylinder head of an internal combustion engine, in which method the individual shell parts of the one-piece sheet metal shell or the multi-piece sheet metal shell are first provided at least in sections with a coating and/or a structure. The individual housing parts of the one-piece sheet metal housing or of the multi-piece sheet metal housing are then inserted into the casting mold and the casting mold is closed. Finally, the cylinder head is formed from a casting material by casting around a sheet metal casing. The coating of the sheet metal housing is effected by means of a thermal coating process, for example flame spraying, and/or by means of spraying and/or by means of dipping. The metal sheet housing is structured by means of sand blasting and/or by means of chemical reaction and/or by means of a laser beam.
In the case of a preceraming polymer as a coating, the preceraming polymer transforms into a ceramic material above a certain temperature. This conversion is effected during casting or during the operation of the internal combustion engine.