CN109072811A - 具有先进的催化能量释放的活塞 - Google Patents

具有先进的催化能量释放的活塞 Download PDF

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Publication number
CN109072811A
CN109072811A CN201780028069.7A CN201780028069A CN109072811A CN 109072811 A CN109072811 A CN 109072811A CN 201780028069 A CN201780028069 A CN 201780028069A CN 109072811 A CN109072811 A CN 109072811A
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layer
piston
thermal insulation
coating
insulation layer
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M·阿泽维多
W·B·莱恩托恩
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Federer - Moguer LLC
Federal Mogul LLC
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Federer - Moguer LLC
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    • F02B23/00—Other engines characterised by special shape or construction of combustion chambers to improve operation
    • F02B23/02—Other engines characterised by special shape or construction of combustion chambers to improve operation with compression ignition
    • F02B23/06—Other engines characterised by special shape or construction of combustion chambers to improve operation with compression ignition the combustion space being arranged in working piston
    • F02B23/0603—Other engines characterised by special shape or construction of combustion chambers to improve operation with compression ignition the combustion space being arranged in working piston at least part of the interior volume or the wall of the combustion space being made of material different from the surrounding piston part, e.g. combustion space formed within a ceramic part fixed to a metal piston head
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    • B01J21/066—Zirconium or hafnium; Oxides or hydroxides thereof
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    • B01J23/76—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of the iron group metals or copper combined with metals, oxides or hydroxides provided for in groups B01J23/02 - B01J23/36
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    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
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Abstract

提供一种能够减少不良“爆震”、减少碳氢化合物排放以及提供更完全燃烧的活塞。该活塞包括设置在上部燃烧表面的、具有500微米或更小厚度的多层涂层。该涂层包括包含设置在上部燃烧表面的镍的打底涂层。包括陶瓷成分的隔热层设置在打底涂层上。由金属形成的密封剂层设置在隔热层上。包括铂、钌、铑、钯、锇和铱中的至少一种的催化剂层设置在密封剂层上。该催化剂层可以设置在选择区域或整个上部燃烧表面，以通过催化反应促进燃烧。

Description

具有先进的催化能量释放的活塞
相关申请的交叉引用
本申请要求2016年3月16日提交的美国临时专利申请号为62/309,055和2017年3月14日提交的美国发明专利申请号为15/458,495的优先权，并且将其全部内容通过引用并入此申请中。
技术领域
本发明总体涉及用于内燃机的活塞，以及制造该活塞的方法。
背景技术
各种设计的钢活塞在柴油燃烧系统中使用，其在点火延迟期(ID)结束时，从燃料-空气的预混合物中迅速释放出能量。随后出现一种令人类听觉反感的脉冲噪声信号，并表现为特有的柴油“爆震”。在该初始能量释放的步骤中，发生高缸内温度(例如2000-3000℃)的时段，通常为几毫秒。高缸内温度产生高NOx水平，而发动机制造商更希望避免这种情况。
发明内容
本发明的一方面提供包括具有上部燃烧表面的上冠壁的活塞。在上部燃烧表面设置涂层。该涂层包括隔热层、密封剂层和催化剂层。该隔热层设置在上部燃烧表面并包括陶瓷成分。该密封剂层设置在隔热层上并包括金属。设置的催化剂层设置在密封剂层上，并且该催化剂层包括铂、钌、铑、钯、锇和铱中的至少一种。
本发明的另一个方面提供制造活塞的方法。该方法包括在上冠壁的上部燃烧表面上设置涂层。该涂层包括隔热层、密封剂层和催化剂层。该隔热层设置在上部燃烧表面并包括陶瓷成分。该密封剂层设置在隔热层上并包括金属。设置的催化剂层设置在催化剂层，并且该催化剂层包括铂、钌、铑、钯、锇和铱中的至少一种。
附图说明
结合附图，本发明的这些和其他方面、特征和优势将更容易，其中：
图1是示例性实施例的可以包括多层涂层的无通道活塞的仰视图；
图2是根据另一个示例性实施例的可以包括多层涂层的通道冷却活塞的侧剖面视图；
图3是另一个示例性实施例的活塞的侧视图，其可以是施加有多层涂层的无通道或通道冷却活塞；以及
图3A是示例性实施例的多层涂层的分解图。
具体实施方式
图1～3例示了根据本发明的实例实施例构造的钢活塞10的视图，该活塞用于在内燃机(例如现代、紧凑、高性能汽车发动机)的缸膛或腔室(未示出)内做往复运动。为了促进早期燃烧，并从而减少不需要的柴油“爆震”，多层涂层38施加到活塞10上，下面将进一步讨论。多层涂层38施加到其上的活塞10可以包括各种不同的设计。例如，活塞10可以是如图1所示的无通道活塞，或可以包括如图2所示的密封冷却通道。可选地，活塞10可以包括开放式冷却通道，允许来自油喷射器的冷却油进入通道。
根据图1的实例实施例的活塞10是无通道的，并从而具有减轻的重量，并且在较低的温度下运行，这有助于改善发动机的热效率、油耗和性能。根据这个实施例，活塞10具有由单片金属材料(例如钢)形成的整体式主体。该整体式主体可以通过机加工、锻造或铸造而成，如果需要，随后进行可能的精加工以完成结构。图1的活塞10没有连接在一起的多个部件，例如彼此连接的上部和下部部件，这对于具有由冷却通道底板界定或部分界定的封闭或部分封闭的冷却通道的活塞是常见的。相反地，该活塞10是无通道的，因为它没有界定或部分界定冷却通道的冷却通道底板或其他特征。图1示出了无通道活塞10的仰视图。
由钢或其他金属制成的主体部分坚固耐用，以满足现代高性能内燃机的高性能需求，即升高的温度和压缩负载。根据特定发动机应用中对活塞10的要求，用于构造主体的钢材可以是诸如SAE4140等级或不同的合金。由于活塞10是无通道的，活塞10的重量和压缩高度最小化，因此允许在其中配置活塞10的发动机实现减轻的重量并且使其更紧凑。进一步地，即使活塞10是无通道的，该活塞10可以在使用中足够冷却以承受最严苛的运行温度。
活塞10的主体部分具有提供上冠壁12的上头部或顶部部分。图3示出了上冠壁12的实例。上冠壁12包括上部燃烧表面14，该表面14直接暴露在内燃机缸膛内的燃烧气体。在图1的示例性实施例中，上部燃烧表面14围绕中心轴A形成燃烧碗、或非平面的凹面、或波动面。上冠壁12还包括与上部燃烧表面14相对朝向的顶部底表面32。环带16从上冠壁12悬垂，并且沿活塞10的外径周向延伸。环带16包括由环形槽彼此分离的多个台肩。
活塞10通常包括一对活塞销凸台24，其通常从顶部底表面32悬垂在环带16内。活塞销凸台24限定横向间隔开的一对销孔26，其与顶部底表面32垂直间隔开。活塞10还包括一对裙板28，其从环带16悬垂并位于彼此径向相对处。裙板28通过支柱30耦合到活塞销凸台24上。
图1的活塞10的顶部底表面32形成在上壁12的下侧，与上部燃烧表面14直接相对并且在环带16的径向内侧。顶底表面32优选位于距燃烧碗最小的距离处，并且是基本与燃烧碗直接相对侧的表面。当从底部直接观察活塞10时，顶部底表面32在此限定为可见的表面，不包括任何销孔26。顶部底表面32通常形成为配合到上部燃烧表面14的燃烧碗上。在图1的示例性实施例中，如从活塞10的下侧看到的，顶部底表面32是开放暴露的，并且它没有通过封闭的或部分封闭的冷却通道或倾向于靠近顶部底表面32的保持油或冷却液的任何其他特征来界定。
图1的活塞10的顶底表面32比具有封闭或部分封闭的冷却通道的对照活塞具有更大的总体表面积(沿表面轮廓的3维面积)和更大的投影面积(如在平面视图中看到的平的2维面积)。沿活塞10的下侧的这个敞开区域提供油飞溅的直接进入或从曲轴箱内直接喷洒到顶部底表面32上，从而允许整个顶部底表面32直接由来自曲轴箱内的油飞溅，同时还允许油围绕活塞销(未示出)自由地飞溅，并且进一步显著减轻活塞10的重量。因此，虽然没有典型的封闭或部分封闭冷却通道，无通道活塞10的总体敞开的结构允许顶部底表面32的最优冷却并且润滑了销孔26中的活塞销接头，与此同时，减少了靠近燃烧碗的表面的油停留时间，也就是在这个时间里，大量油保留在表面。
示例性无通道活塞10的顶部底表面32由活塞10的若干区域提供，这些区域包括图1所示的内顶部底面区域34和外部凹穴36。通过内顶部底面区域34提供位于中心轴A的顶部底表面32的第一部分。该内顶部底面区域34由活塞销凸台24、裙板28和支柱30包围。通过内顶部底面区域34提供的顶部底表面32的2维和3维表面面积通常是最大的，从而可以加强由油飞溅或从曲轴箱向上喷洒到暴露表面的冷却，从而加快活塞10的特殊冷却。通过位于活塞销凸台24的外侧的外部凹穴36提供顶部底表面32的第二区域。每个外部凹穴36由活塞销凸台24中的一个、支柱30的一部分和环带16的一部分所包围。
根据图2的示例性实施例的活塞10是通道冷却活塞，并因此具有在顶部底表面32下面并沿环带16周向延伸的密封外冷却通道48。可选择地，冷却通道48可以是开放的，并且因此包括允许来自喷嘴的冷却油喷洒顶部底表面32的开口(未示出)。
图2的活塞还包括金属材料(例如，钢)形成的主体，其围绕中心轴线A周向延伸并沿中心轴线A纵向延伸。活塞10包括具有在内燃机中使用过程中暴露于燃烧室的上部燃烧表面14的上冠壁12，以及与燃烧表面14相对的顶部底表面32。活塞10还包括环带16、一对活塞销凸台24和一对裙板28。
与图1的活塞不同，图2的活塞10包括限定密封冷却通道48的内壁50和下壁52。活塞的密封冷却通道48通常通过将顶部连接(例如通过焊接)到底部而形成。该顶部包括环带16的顶部部分和内壁50的上部部分，而底部包括环带16的底部部分和内壁50的下部部分以及下壁52。如图2所示，密封冷却通道通过上冠壁12、环带16的一部分、内壁50和下壁52形成。
在图2的示例性实施例中，密封的外冷却通道48包含冷却介质54，以通过活塞10控制来自燃烧室的热损耗，并从而提高发动机制动热效率(BTE)。冷却介质可以由固体粉末或固体粉末的混合物、液体或多于一种液体的混合物、气体或气体混合物或固相、液相和气相的组合组成。作为用冷却剂组合物填充外冷却通道48的一种替代方案，外冷却通道48可以保持未填充。
为了减小到上冠壁12的热流，促进早期燃烧，并从而降低不需要的柴油“爆震”，多层涂层38施加到活塞10的上部燃烧表面14，并赋予上冠壁12热绝缘性。该图层38包括施加到上部燃烧表面14的打底涂层40、设置在打底涂层40上并通过打底涂层40连接到上部燃烧表面14的隔热层42、设置在隔热层42上的密封剂层44以及设置或沉积在密封剂层44的催化剂层46。图3A例示了示例性实施例的多层涂层38的分解图。如上所述，多层涂层38可以施加在具有图1、图2的设计的活塞上，或施加在具有另一设计的钢活塞上。
如图3A所示，多层涂层38包括直接设置在钢上部燃烧表面14并将隔热层42锚固在上冠壁12的上部燃烧表面14上的打底涂层40。该打底涂层40包括金属或由金属组成，并优选为高温合金。例如，打底涂层40可以由镍基组合物形成，例如镍铬铝钇(NiCrAlY)和/或钴镍铬铝钇(CoNiCrAlY)。打底涂层40可以以粉末的形式提供，并通过热喷涂或其他方法施加到上部燃烧表面14上。打底涂层40通常具有50～150微米的厚度。
多层涂层38接下来包括直接设置在打底涂层40上并由打底涂层40锚固在钢上部燃烧表面14上的隔热层42。隔热层42包括陶瓷成分或由陶瓷成分组成。在示例性实施例中，隔热层42包括某些形式的部分稳定的氧化锆，优选二氧化铈稳定的氧化锆(CSZ)。隔热层42通常通过热喷涂施加150～350微米的厚度。
密封剂层44直接设置在隔热层42上并封闭陶瓷配方固有的气孔，并防止燃烧气体和燃料通过多孔陶瓷吸收、去吸附以及渗透。密封剂层44的成分包括金属或由金属组成，并通常与打底涂层40相似或相同。根据示例性实施例，密封剂层44可以由镍基组合物形成，优选为诸如镍铬铝钇(NiCrAlY)和/或钴镍铬铝钇(CoNiCrAlY)的高温合金。密封剂层44可以产生某些催化活性。密封剂层44优选施加在整个上部燃烧表面14和隔热层42面向密封剂层44的整个最上表面，以履行其密封作用。密封剂层44通常通过热喷涂施加50～100微米的厚度。镍基密封剂层44还可以通过无电镀镍沉积工艺沉积而成。密封剂层44通常通过热喷涂施加50～100微米的厚度，或通过无电镀镍沉积工艺施加5～50微米的厚度。
多层涂层38的催化剂层46直接沉积在金属密封剂层44的顶部，并通过催化反应或催化作用促进燃烧。催化剂层46包括至少一种或多种铂族金属或由至少一种或多种铂族金属组成，铂族金属包括铂、钌、铑、钯、锇以及铱。至少一种铂族金属具有基于催化剂层的总重量的至少10重量％的量。催化剂层46通常分别施加为从10～1000nm范围的非常薄的层。催化剂层46可以从溶液中电沉积或通过物理气相沉积(PVD)工艺来施加。催化剂层46可以设置在整个上部燃烧表面14上，或仅设置在选择区域中，例如，与燃料羽流一致、在火焰峰的周边或在燃烧碗边缘周围。
多层涂层38的总厚度优选约为500微米或更小，这允许它承受住发动机中经受的热负荷和机械负荷。多层涂层38赋予活塞10的上冠壁12保温和绝热性，并可以通过催化作用促进早期燃烧，鉴于现代柴油发动机的缸内环境的特征在于高温(例如800-900℃总体气体平均温度)和高压(如220-280巴)。一个或多个铂族金属的存在可以降低即时燃料裂化和燃烧的活化能。从而，点火延迟可以大大降低，并且可以与预混合燃烧阶段一起降低。剩下的是扩散燃烧方式，即当其进入燃烧环境时立即控制燃料的燃烧。这个阶段可以通过发动机上的电子控制模块进行管理。从而可以减少令人厌烦的燃烧噪声，并由于没有停滞混合物的凹穴，可以降低HC排放。此外，可实现减少NOx的较低峰值温度。通过降低冷却系统的热量损失，可以产生其他的优势，从而通过基础动力装置在废气流中可获得余热用于能量回收。此外，考虑到燃烧室内的严苛环境和催化剂层46的化学作用，喷洒的燃料可以通过大部分预混合阶段立即燃烧，有利于扩散型燃烧。如上所述，扩散型燃烧通过现代发动机的电子控制单元(ECU)可控。
本发明的另一方面提供了一种制造具有多层涂层38的活塞10的方法。该方法包括将多层涂层38施加到上部燃烧表面14的至少一部分。多层涂层38的层40、42、44、46可以通过各种不同方法施加。通常，通过热喷涂技术(例如电弧喷涂、等离子喷涂或高速氧燃料(HVOF)喷涂)分别施加多层涂层38的打底涂层40、隔热层42和密封剂层44。但是，密封剂层44和/或打底涂层40可以是在适当的槽中沉积的无电镀镍。催化剂层46通常可以从溶液中电沉积或通过物理气相沉积(PVD)工艺来施加。
活塞10能够将点火延迟周期减少到这样的程度，即保持大部分平稳的扩散燃烧，从而减少不需要的柴油“爆震”。活塞10还能够降低碳氢化合物的排放并提供更完全的燃烧。其他潜在的优势包括使用更少的精炼燃料、用于基础动力循环能量回收的更高可控制排气温度以及更少的燃料消耗。
鉴于上述教导，本发明的许多修改和变体是可行的，并且可以在本权利要求的范围内以不同于具体描述的方式来实施。还可以预期，所有权利要求和所有实施例的所有特征可以彼此组合，只要这种组合不会相互矛盾。

Claims (20)

1.一种活塞，包括：
具有上部燃烧表面的上冠壁，
设置在所述上部燃烧表面的涂层，
所述涂层包括设置在所述上部燃烧表面的隔热层，
所述隔热层包括陶瓷成分，
所述涂层包括设置在所述隔热层的密封剂层，
所述密封剂层包括金属，
所述涂层包括设置在所述密封剂层的催化剂层，并且
所述催化剂包括铂、钌、铑、钯、锇和铱中的至少一种。
2.根据权利要求1所述的活塞，其特征在于，所述催化剂层包括铂。
3.根据权利要求1所述的活塞，其特征在于，所述催化剂层具有10～1000nm的厚度。
4.根据权利要求1所述的活塞，其特征在于，所述催化剂层设置在所述上部燃烧表面的区域，并设置在小于所述上部燃烧表面的整体上。
5.根据权利要求1所述的活塞，其特征在于，所述隔热层的所述陶瓷成分包括部分稳定的氧化锆。
6.根据权利要求1所述的活塞，其特征在于，所述催化剂层包括镍基组合物。
7.根据权利要求1所述的活塞，其特征在于，所述涂层进一步包括设置在所述上部燃烧表面与所述隔热层之间的打底涂层，并且所述打底涂层包括金属。
8.根据权利要求7所述的活塞，其特征在于，所述打底涂层包括镍基组合物。
9.根据权利要求1所述的活塞，其特征在于，所述涂层具有500微米或更小的总厚度。
10.根据权利要求1所述的活塞，其特征在于，所述涂层进一步包括设置在所述上部燃烧表面与所述隔热层之间的打底涂层，所述打底涂层包括金属，所述打底涂层具有50～150微米的厚度，所述隔热层具有150～350微米的厚度，所述密封剂层具有50～100微米的厚度，并且所述催化剂层具有10～1000nm的厚度。
11.根据权利要求1所述的活塞，其特征在于，所述铂、钌、铑、钯、锇和铱中的至少一种具有基于催化剂层的总重量的至少10重量％的量，
所述涂层进一步包括直接设置在所述上部燃烧表面的打底涂层，
所述打底涂层设置在所述上部燃烧表面与所述隔热层之间，
所述打底涂层包括镍铬铝钇(NiCrAlY)和钴镍铬铝钇(CoNiCrAlY)中的至少一种，
所述打底涂层由粉末组成，
所述打底涂层具有50～150微米的厚度，
所述隔热层直接设置在所述打底涂层上，
所述隔热层的所述陶瓷成分包括二氧化铈稳定的氧化锆(CSZ)，
所述隔热层具有150～350微米的厚度，
所述密封剂层直接设置在所述隔热层上，
所述密封剂层施加在面向所述密封剂层的所述隔热层的整个最上表面上，
所述密封剂层包括镍铬铝钇(NiCrAlY)和钴镍铬铝钇(CoNiCrAlY)中的至少一种，
所述密封剂层具有50～100微米的厚度，
所述催化剂层直接设置在所述密封剂层上，
所述催化剂层具有10～1000nm的厚度，并且
所述涂层具有500微米或更小的总厚度。
12.根据权利要求1所述的活塞，其特征在于，所述活塞包括由单片钢形成的主体，
所述主体包括具有所述上部燃烧表面的所述上冠壁，
所述上部燃烧表面是围绕中心轴的非平面表面，
所述上冠壁包括与所述上部燃烧表面相对朝向的顶部底表面，
所述顶部底表面从所述活塞的底部暴露出来，
所述主体包括从所述上冠壁悬垂并沿所述活塞的外径周向延伸的环带，
所述环带包括由环形槽彼此分离的多个平台，
所述主体包括一对活塞销凸台，所述活塞销凸台从所述顶部底表面悬垂在所述环带内，
所述活塞销凸台限定横向间隔开的一对销孔，所述销孔与所述顶部底表面垂直间隔开，
所述主体包括一对裙板，所述裙板从所述环带悬垂并位于彼此径向相对处，
所述裙板通过支柱连接到所述活塞销凸台上，
所述顶部底表面包括通过所述活塞销凸台和所述裙板以及所述支柱围绕的内顶部底面区域，
所述顶部底表面包括通过位于所述活塞销凸台外的外部凹穴提供的第二区域，
所述外部凹穴的每一个由所述活塞销凸台的其中一个、所述环带的一部分、以及将所述一个活塞销凸台连接到所述裙板的所述支柱所围绕。
13.根据权利要求1所述的活塞，其特征在于，所述活塞包括由钢形成的主体，
所述主体围绕中心轴周向延伸并沿所述中心轴纵向延伸，
所述主体包括具有所述上部燃烧表面的所述上壁，
所述上部燃烧表面是围绕中心轴的非平面表面，
所述上冠壁包括与所述上部燃烧表面相对朝向的顶部底表面，
所述顶部底表面从所述活塞的底部暴露出来，
所述主体包括从所述上冠壁悬垂并沿所述活塞的外径周向延伸的环带，
所述环带包括由环形槽彼此分离的多个平台，
所述主体包括一对活塞销凸台，所述活塞销凸台从所述顶部底表面悬垂在所述环带内，
所述活塞销凸台限定横向间隔开的一对销孔，所述销孔与所述顶部底表面垂直间隔开，
所述主体包括一对裙板，所述裙板从所述环带悬垂并位于彼此径向相对处，
所述裙板通过支柱连接到所述活塞销凸台上，
所述主体包括顶部，所述顶部连接到其间具有冷却通道的底部，
所述顶部包括所述环带的顶部部分和内壁的上部部分，
所述底部包括所述环带的底部部分和所述内壁的下部部分以及下壁，
所述上冠壁、所述环带的所述部分、所述内壁以及所述下壁具有所述冷却通道。
14.根据权利要求1所述的活塞，其特征在于，所述冷却通道包含冷却介质，并且所述冷却介质包括至少一种固体粉末和/或至少一种液体。
15.一种制造活塞的方法，包括以下步骤：
在上冠壁的上部燃烧表面上设置涂层，
所述涂层包括设置在上部燃烧表面的隔热层，
所述隔热层包括陶瓷成分，
所述涂层包括设置在隔热层的密封剂层，
所述密封剂层包括金属，
所述涂层包括设置在所述密封剂层的催化剂层，并且
所述催化剂层包括铂、钌、铑、钯、锇和铱中的至少一种。
16.根据权利要求15所述的方法，其特征在于，在上部燃烧表面上设置涂层的所述步骤包括通过电沉积或物理气相沉积(PVD)施加催化剂层。
17.根据权利要求15所述的方法，其特征在于，在上部燃烧表面上设置涂层的所述步骤包括通过热喷涂施加隔热层和密封剂层中的至少一种。
18.根据权利要求17所述的方法，其特征在于，所述热喷涂包括电弧喷涂、等离子喷涂以及高速氧燃料(HVOF)喷涂中的至少一种。
19.根据权利要求15所述的方法，其特征在于，在上部燃烧表面上设置涂层的所述步骤包括在上部燃烧表面与隔热层之间施加打底涂层。
20.根据权利要求19所述的方法，其特征在于，施加打底涂层的所述步骤包括热喷涂。
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