Ford Global Technolgoies, LLC

Mathew Hintzen

Antony Schepak

Theodore Beyer

Jody Michael Slike

Clifford E Maki

Justin Craft

Phil Cierpial

Paul Shoemaker

Mark W Thibault

John Riegger

Daryl Self

Mohammed Yusuf Ali

Ian Cattermole

Baran Celikten

Christopher Donald Wicks

James Maurice Boileau

Mohammad Ali Moetakef

James Matthew Kindree

Darren Sipila

Charles Krysztof

Charles Joseph Patanis

William Michael Sanderson

Marc Thomas Wilkins

Venkat Nara

David Krenk

Charles Raymond Kvasnicka

Systems are provided for cooling a cylinder block via bore bridge cooling passages. In one example, a cylinder block with a bore bridge positioned between a first cylinder and a second cylinder, the cylinder block also including a coolant jacket at least partially surrounding the first cylinder and the second cylinder, has at least one cooling passage positioned within the bore bridge. An inlet of the at least one cooling passage has a larger area than an outlet of the at least one cooling passage and at least a portion of the at least one cooling passage has a non-cylindrical geometry formed by a lost core.

Bore bridge cooling channels

Methods and systems are provided for a water jacket diverter. In one example, the water jacket diverter has a continuous upper rail with a profile including curved and linear portions where the profile of the upper rail is optimized to moderate coolant flow through the water jacket. The water jacket diverter further includes at least one protrusion extending outwards from an outer face of the diverter, the at least one protrusion positioned in front of a coolant inlet.

Water jacket diverter with low flow restriction

Systems are provided for cooling a cylinder block via bore bridge cooling passages. In one example, a system may include a cylinder block with a first cylinder and a second cylinder adjacent to the first cylinder and a bore bridge positioned between the first cylinder and the second cylinder, the cylinder block further including a coolant jacket at least partially surrounding the first cylinder and the second cylinder. The system may further include a cooling passage positioned within the bore bridge, the cooling passage including an inlet fluidly coupled to the coolant jacket and an outlet positioned at a deck face of the cylinder block, the cooling passage curving from the inlet to the outlet with a curvature greater than zero.

Engine blocks and methods of forming engine blocks are disclosed. The engine block may include a cast aluminum body and a plurality of cast-in liners. Each cast-in liner may include (a) an outer layer of 2xxx-series aluminum molecularly bonded to the cast aluminum body and (b) an inner layer directly contacting the outer layer and forming at least a portion of an engine bore. The inner layer may be a wear-resistant coating, such as a steel coating. The method may include extruding an elongated 2xxx-series aluminum extrusion having an inner cavity bounded by an inner surface and applying a wear-resistant coating to the inner surface. The extrusion may be sectioned into a plurality of cylinder liners and the cylinder liners may be into an aluminum engine block such that each cast-in liner forms at least a portion of an inner surface of an engine bore in the engine block.

Coated bore aluminum cylinder liner for aluminum cast blocks

According to one embodiment, a vehicle powertrain includes an engine having a first locking feature defining first mating surfaces, and a differential coupled to a transfer case via a driveshaft. The differential includes a second locking feature defining second mating surfaces. The first and second locking features are engaged such that the first and second mating surfaces are disposed against each other connecting the engine and the differential. A fastener is disposed within the engine and the differential.

Differential mounting system

A cylinder head includes an inner structural member having a plate forming a deck face of the cylinder head and forming at least one dished cylinder roof, and a plurality of cylinder head bolt columns extending from the plate. An outer member is supported by the inner structural member and forms a cooling jacket, intake ports, and exhaust ports. Passages of the cooling jacket are lined with metal walls in contact with the composite structure of the outer member. A method of forming a cylinder head includes positioning a structural insert and a lost core insert in a tool, and injecting material into the tool to form a body surrounding the structural insert and the lost core insert thereby forming a head preform. The lost core insert is shaped to form a cooling jacket and has a lost core material generally encapsulated in a metal shell.

Cylinder head for an internal combustion engine

Extruded cylinder liners and methods of forming the same are disclosed. The extruded engine cylinder liner may include a cylindrical body having a longitudinal axis and defining an inner surface and an outer surface. A plurality of spaced apart features may protrude from the outer surface and may extend in a direction oblique to the longitudinal axis. The method may include extruding a metal material through a die to form a cylindrical body defining an inner surface and an outer surface and a plurality of spaced apart features protruding from the outer surface. The die may be rotated about a longitudinal axis during at least a portion of the extruding step such that the features extend in a direction oblique to the longitudinal axis. The oblique features may allow parent casting material to enter channels therebetween and prevent the liner from moving in the vertical and horizontal directions.

Extruded cylinder liner

An engine has a cylinder block formed by a block material and defining at least one cylinder. The block defines a lubrication circuit with fluid passages including an inlet passage, a main oil gallery, a crankshaft bearing lubrication passage, and a piston ring lubrication passage. The fluid passages are formed by continuous metal walls in contact with and surrounded by the block material. At least one of the fluid passages is curved. A method of forming a component with an internal pressurized lubrication circuit includes positioning a lost core insert in a tool, with the insert shaped to form a lubrication circuit. The lost core insert has a lost core material generally encapsulated in a continuous metal shell, and at least one curved section. Material is provided into the tool to form a body surrounding the lost core insert thereby forming a component preform.

Lubrication circuit and method of forming

An engine includes a cylinder block with first and second saw cuts intersecting a block face on opposed sides of a block bore bridge. A cylinder head has third and fourth saw cuts intersecting a head face on opposed sides of a head bore bridge. A gasket is placed between the block and the head. The gasket defines a cooling passage adapted to fluidly connect the first, second, third and fourth saw cuts and cool the interbore region of the engine. The cooling passage has an inlet and a pair of outlets.

Bore bridge and cylinder cooling

A tool and a method of using the tool are provided for forming an engine component. The engine has a block defining a first cylinder and a second cylinder spaced apart by a bore bridge. The bore bridge defines a first cooling passage spaced apart from a deck face and extending transversely, and a second cooling passage positioned between the first passage and the deck face and extending transversely. The first and second passages are formed by a casting skin. In forming the engine component, a die is provided that defines a locator recess and at least one core. An insert is positioned into the recess on the die. The insert has a cast shell surrounding a lost core. The component is die cast with the die and the insert to form a cooling jacket. The insert is adapted to form the cooling passages for the bore bridge.

Bore bridge cooling passage

Embodiments may provide an engine knock monitoring system that may include an engine block including an engine block body and a cylinder wall defining at least a portion of a combustion chamber. A space may be defined between a top of the cylinder wall and a top of the engine block body. An engine knock sensor may be mounted to the engine block. A pressure pulse transmissive element may be disposed in the space and may be disposed in contact with an outside surface of the cylinder wall and an opposite inside surface of the engine block body.

Engine knock signal transmissive element

An engine has a cylinder head with a deck face defining first and second chambers adjacent to one another and separated by a bore bridge. The body defines a first cooling jacket and a second cooling jacket configured to operate at a lower pressure than the first cooling jacket. The first cooling jacket is positioned substantially between the deck face and the second cooling jacket. The first cooling jacket has a series of passages intersecting the deck face and configured to receive coolant from a cylinder block cooling jacket. The second cooling jacket has an inlet passage intersecting the deck face adjacent to the bore bridge and configured to receive coolant from the cylinder block cooling jacket to cool the bore bridge.

An engine is provided with an open deck cylinder block having an open water jacket that surrounds a plurality of cylinders that are joined together in a Siamese design by a cylinder bore bridge. The engine also includes a cylinder head gasket, and a cylinder head. For the purpose of removing excess heat from the cylinder bore bridge, cooling channels are provided that allow coolant to flow from the engine block water jacket, across the cylinder bore bridge, and into a cylinder head coolant passageway. In addition, coolant is prevented from flowing from the water jacket on one side of the cylinders, across the bore bridge, and into the water jacket on the other side of the cylinders.

Growing community of inventors

Stockbridge, MI, United States of America

Mathew Hintzen