Thermally insulating pistons for internal combustion engines and method for the manufacture thereof

Claim 2

In a thermally insulating piston for the combustion space of internal combustion engines; the improvement comprising: the piston crown or the dished combustion space-facing portion of the piston having a single thermally insulating liner imposed thereon, said liner being constituted of a composite material having one side thereof facing the combustion space consisting entirely of a ceramic material, and the other side of the liner facing the piston crown or its dished combustion space-facing portion consisting of a metallic or metal-ceramic material which is hot-isostatically pressed with said ceramic material so as to be intimately bonded thereto to provide said composite material, and which liner has the metallic or metal-ceramic side thereof directly fused to the piston material.

Claim 3

Piston as claimed in claim 1, wherein the ceramic liner material has a thermal conductivity λ of less than 2 to 3 W/m°K.

Claim 4

Piston as claimed in claim 2, wherein the ceramic material is PSZ, Mullit, ZrSiO 4 , aluminum titanate or silicon nitride.

Claim 5

Piston as claimed in claim 1, wherein the metallic component of the metal-ceramic material of the liner comprises iron.

Claim 6

Piston as claimed in claim 1, wherein the piston material is an alloyed or unalloyed cast Al-alloy or gray cast iron.

Claim 7

Piston as claimed in claim 5, wherein the cast Al alloy is selected from the group consisting of Silumin, Al Si 12 Cu Mg Ni, Al Si 18 Cu Mg Ni, Al Si 25 Cu Mg Ni or Al Cu 4 Ni Mg.

Claim 8

In a method for the manufacturing of a thermally insulating piston for internal combustion engines; the improvement comprising: (a) providing a member of sheet-like configuration as a thermally insulating liner for predetermined surface portions of said piston; (i) conforming the external configuration of the member to the shape of the piston crown or its dished combustion space-facing portion; (ii) providing on one side of the member adapted to face the combustion space of the internal combustion engine with at least one layer of a completely ceramic material; and (iii) providing the opposite side of the member adapted to contact the piston crown or its dished combustion space-facing portion with at least one layer of metallic or metal-ceramic material; hot-isostatically pressing said composite member so as to intimately bond said ceramic material and said metallic or metal-ceramic material so as to constitute a composite material member; and (b) subsequently pouring the molten piston metal onto the resultant compacted member to directly fuse the metallic or metal-ceramic side of said composite material member to said piston metal.

Claim 9

In a method for the manufacturing of a thermally insulating piston for internal combustion engines; the improvement comprising: (a) providing a member of sheet-like configuration as a thermally insulating liner for predetermined surface portions of said piston; (i) conforming the external configuration of the member to the shape of the piston crown or its dished combustion space-facing portion; (ii) providing on one side of the member adapted to face the combustion space of the internal combustion engine with at least one layer of a completely ceramic material; and (iii) providing the opposite side of the member adapted to contact the piston crown or its dished combustion space-facing portion with at least one layer of metallic or metal-ceramic material; hot-isostatically pressing said composite member so as to intimately bond said ceramic material and said metallic or metal-ceramic material so as to constitute a composite material member; and (b) subsequently pouring the molten piston metal onto the resultant compacted member to directly fuse the metallic or metal-ceramic side of said composite material member to said piston metal.

Claim 10

Method as claimed in claim 7, wherein the hot-isostatic pressing process is effected at a pressure of about 1000 to 1500 bar, and at a temperature of about 1000° to 1450° C.

Claim 11

Method as claimed in claim 8, wherein the pressure is about 1200 to 1300 bar, and the temperature about 1200° to 1350° C.