WO2021259116A1 - 一种无缝密封活塞 - Google Patents

一种无缝密封活塞 Download PDF

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Publication number
WO2021259116A1
WO2021259116A1 PCT/CN2021/100464 CN2021100464W WO2021259116A1 WO 2021259116 A1 WO2021259116 A1 WO 2021259116A1 CN 2021100464 W CN2021100464 W CN 2021100464W WO 2021259116 A1 WO2021259116 A1 WO 2021259116A1
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WIPO (PCT)
Prior art keywords
piston
ring
sealing
sealing ring
cylinder
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PCT/CN2021/100464
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English (en)
French (fr)
Inventor
刘金宏
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东莞宏大动力科技有限公司
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Publication of WO2021259116A1 publication Critical patent/WO2021259116A1/zh

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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02F—CYLINDERS, PISTONS OR CASINGS, FOR COMBUSTION ENGINES; ARRANGEMENTS OF SEALINGS IN COMBUSTION ENGINES
    • F02F3/00—Pistons 
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02F—CYLINDERS, PISTONS OR CASINGS, FOR COMBUSTION ENGINES; ARRANGEMENTS OF SEALINGS IN COMBUSTION ENGINES
    • F02F3/00—Pistons 
    • F02F3/02—Pistons  having means for accommodating or controlling heat expansion
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16J—PISTONS; CYLINDERS; SEALINGS
    • F16J9/00—Piston-rings, e.g. non-metallic piston-rings, seats therefor; Ring sealings of similar construction
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16J—PISTONS; CYLINDERS; SEALINGS
    • F16J9/00—Piston-rings, e.g. non-metallic piston-rings, seats therefor; Ring sealings of similar construction
    • F16J9/12—Details
    • F16J9/20—Rings with special cross-section; Oil-scraping rings

Definitions

  • the invention relates to a piston, especially an internal combustion engine piston.
  • the piston of the internal combustion engine, the cylinder and the cylinder head jointly form the combustion chamber of the internal combustion engine.
  • the piston transmits the working fluid pressure on the top to the connecting rod through the piston pin, and then to the crankshaft, which converts the internal energy of the working fluid into mechanical work.
  • the piston and the cylinder The walls together form a reciprocating sealing device to ensure good sealing performance of the combustion chamber under the condition of volume changes, so that the working fluid gas in the cylinder will not leak into the crankcase, and the oil on the crankcase and cylinder walls will not leak.
  • the piston is an important component of the internal combustion engine.
  • the components related to the piston are also called the piston group.
  • the piston is mainly composed of a piston head, a piston skirt, a piston pin seat, and a piston ring.
  • the piston body is composed of three other parts except the piston ring.
  • the material of the piston body is generally an aluminum-based alloy with a relatively low density. The material should generally have It has the characteristics of low density, good thermal strength, good heat dissipation, low expansion coefficient, good wear resistance, good friction reduction and good manufacturability.
  • the piston head includes two parts: the top and the ring belt.
  • the ring belt is the part with ring grooves on the outer circumference of the piston head. The distance from the top of the piston to the first ring groove is the height of the top land (fire land) of the piston.
  • the piston ring mainly serves as a seal and also transfers the heat of the piston to the cylinder wall.
  • the piston ring is divided into a gas ring and an oil ring.
  • the gas ring mainly serves as a gas seal to prevent the high-pressure gas in the cylinder from leaking into the crankcase.
  • the oil seal plays a supplementary role; the oil ring mainly seals the oil, prevents the oil on the crankcase and cylinder wall from leaking into the combustion chamber, and scrapes the excess oil on the cylinder wall back to the bottom tank when the piston descends.
  • Gasoline engines generally have one to two gas rings and one oil ring; diesel engines generally have two to four gas rings and one to two oil rings.
  • the sealing principle of the piston ring The seal between the piston and the cylinder is achieved by the piston ring of the piston.
  • the piston ring is an elastic metal ring with an opening.
  • the material of the piston ring should generally have wear resistance, heat resistance, corrosion resistance, easy thermal conductivity, strong toughness, appropriate elasticity, etc.
  • the piston ring is installed in the piston ring groove.
  • the outer peripheral surface of the piston ring closely adheres to the cylinder wall with a certain elastic force to form the first sealing surface.
  • the piston ring has air leakage: the piston ring has cuts. Although the cuts are small and are sealed by multiple air rings, the air leakage is inevitable; in general, due to the high-speed operation of the engine, each compression and work The time is very short, so the air leakage has a slight impact; but when the engine is running at low speed and when the engine is working at high pressure, the piston ring leakage will have a great impact on the efficiency of the engine. Piston gaps have a great impact on internal combustion engines. Due to the design of piston rings, many gaps will inevitably be formed; first is the gap between the top bank and the cylinder wall.
  • the top bank is the distance from the first ring groove on the outer circumference of the piston head to the top of the piston. Due to the different expansion coefficients of the piston and the cylinder, generally speaking, the expansion coefficient of the piston is larger than that of the cylinder, so there must be a gap between the top land of the piston and the cylinder wall. Otherwise, when the temperature of the piston is high, The piston head will expand and press against the cylinder wall, which will greatly increase the frictional resistance and easily cause the cylinder pulling phenomenon; the same situation exists in the ring land; there will also be a gap between the piston ring and the piston groove; when the mixed gas When compressed and combusted in the combustion chamber, the mixed gas mixed with fuel will inevitably enter the gap.
  • the piston When inhaling and compressing, the piston The pressure difference between the two sides of the ring is completely opposite, so that the piston ring will swing back and forth on both sides of the ring groove.
  • the carbon particles or other impurity particles in the ring groove will make the piston ring and the piston ring groove not fit completely, which will increase air leakage. In severe cases, the piston ring may be twisted and deformed, jammed, or even broken.
  • the compression ratio is the main factor affecting the thermal efficiency of reciprocating piston internal combustion engines.
  • the most important method is to increase the compression ratio. Increasing the compression ratio will also increase the pressure of the working fluid gas. This will also cause the piston ring leakage to become more serious, and the piston ring will become An important factor affecting thermal efficiency, the design of the leaking piston ring is no longer suitable for the application of high-pressure internal combustion engines.
  • the piston ring seal design of the piston inevitably creates many gaps, which will have a serious impact on the thermal efficiency and exhaust emissions of the engine, and even the stable operation of the engine.
  • Piston gaps will have a serious impact on the thermal efficiency and exhaust emissions of the engine, and even the stable operation of the engine. How to strengthen the sealing performance of the piston is a difficult problem in the design and manufacture of current internal combustion engines.
  • the leakage of the piston ring seal of the internal combustion engine piston will cause incomplete combustion, which will reduce the thermal efficiency of the internal combustion engine and cause excessive emission of polluting exhaust gas. It is even easy to produce carbon particles and cause damage to the piston ring.
  • the present invention provides a seamless sealing solution for the piston, which can completely overcome and solve the above problems.
  • the outer circumference of the piston head is a sealing ring
  • the sealing ring is a tubular or cylindrical component, the upper part of which is flush with the top of the piston, and the lower part of the sealing ring is connected to the middle of the piston and is close to the outside of the connected part.
  • the diameter is slightly smaller.
  • the outer surface of the sealing ring is attached to the cylinder wall with a slight elastic force to form a sealing surface.
  • Figure 1 is a longitudinal cross-sectional structure diagram of the piston.
  • the markings in the figure are: 1. Piston head intermediate body, 2. Seal ring, 3. Separation groove and filling material, 4. Oil Ring groove, 5. Piston pin seat, 6. Piston skirt.
  • the piston head includes: piston head intermediate, sealing ring, separation groove and filling material.
  • the sealing ring replaces the function of gas ring sealing as a gas seal; the oil seal still retains the oil ring and the oil ring groove; the piston pin seat and the piston
  • the skirt is basically the same as the previous piston.
  • Figure 3 is a front view of the top of the piston, marked in the figure: 1. Piston head intermediate body, 2. Seal ring, 3. Separating groove and filling material. The outermost part is the sealing ring, the middle part is the piston head intermediate body, and the separation groove and filling material are between the two parts.
  • the piston and the cylinder wall are sealed by the high-pressure gas through the piston sealing ring.
  • the function of the sealing ring is to prevent the high-pressure gas in the cylinder from leaking into the crankcase, and it also supplements the sealing of the oil. Its function is similar to the previous piston gas ring. The effect is basically the same.
  • the pipe wall of the sealing ring is thin, and the manufacturing of the sealing ring is equivalent to the material and process used in the gas ring.
  • the material should have the characteristics of wear resistance, heat resistance, corrosion resistance, easy thermal conductivity, strong toughness, and appropriate elasticity.
  • the sealing ring and the piston body head can be separated and filled with soft, high melting point and corrosion-resistant alloys. The so-called softness means that the hardness is not high and is prone to deformation. The material will change shape under relatively low pressure. Change, such as some softer zinc alloys, copper alloys, tin alloys, etc., especially wrought zinc alloys, or other softer and high-melting non-alloy
  • the sealing ring of the piston head is attached to the inner wall of the cylinder with a slight elasticity, that is, the diameter of the sealing ring is slightly larger than the inner diameter of the cylinder, so that the sealing ring and the inner wall of the cylinder are
  • the extremely small elastic deformation produces a slight elastic force, so that the sealing ring and the inner wall of the cylinder closely fit under the slight elastic force. Due to the high temperature generated in the combustion chamber, when the piston is heated and expands, the piston head intermediate will squeeze the filling material due to expansion.
  • the thermal expansion of the piston has little effect on the adhesion between the piston seal ring and the inner wall of the cylinder, and it will not cause the cylinder to pull due to the heating of the piston; the middle of the piston is left between the cylinder wall The gap, the expansion of the middle of the piston will not squeeze into the cylinder wall; although the piston skirt will also expand due to heat, because the piston skirt is relatively far away from the combustion chamber and is less affected by heat, its expansion is generally not large, which is different from the past The piston situation is basically the same.
  • the sealing principle between the piston and the cylinder wall in the scheme of the present invention The sealing ring closely fits with the inner wall of the cylinder under slight elastic force to form a sealing surface.
  • the cylinder pressure will be directly applied from the top of the piston to the separation material between the seal ring and the piston head. Since the separation material is a relatively soft material, the pressure will be transmitted to the seal through the separation material. Between the ring and the piston head, the pressure received by the sealing ring will also be transmitted to the inner wall of the cylinder, so that the pressure between the sealing ring and the cylinder wall will be strengthened accordingly.
  • the sealing ring will automatically adjust the pressure between it and the cylinder wall according to the pressure in the cylinder, and also automatically adjust the sealing strength between the two, and also change the friction resistance between the two accordingly; enhance the sealing when the cylinder pressure increases, It also causes the frictional resistance to increase, weakens and provides sufficient sealing when the cylinder pressure is reduced, and at the same time reduces the frictional resistance.
  • the piston sealing solution of the present invention can also be applied to non-internal combustion engine pistons with the same requirements.
  • the improvement of the solution of the present invention is that multiple sealing ring grooves are arranged on the outer surface of the sealing ring, so that the sealing ring forms multiple sealing layers.
  • the cross-section of the groove can be rectangular, trapezoidal, or fan-shaped, or triangular. Its main function is to trap foreign particles and oil, keep the cylinder wall smooth and lubricated, remove excess particles and oil, and make the seal better. .
  • Figure 2 is the longitudinal cross-sectional structure diagram of the piston with multiple grooves in the seal ring.
  • the marks in the figure are: 1. Piston head intermediate body, 2. Seal ring, 3. Separating groove And filling materials, 4. Oil ring groove, 5. Piston pin seat, 6. Piston skirt, 7. Seal ring groove.
  • the sealing ring has several more grooves.
  • the sealing ring of the present invention has no gaps, so the seal between the piston and the cylinder will inevitably be sealed more tightly, which can meet the needs of high-pressure internal combustion engines and help improve the thermal efficiency of the internal combustion engine; without gaps, the mixed gas in the combustion chamber will not Will enter the gap, and there will be no incomplete combustion of the gas mixture in the gap, so the mixed gas in the combustion chamber will achieve more complete combustion, which can effectively reduce the emission of pollutants, especially the incomplete combustion of carbon. Emissions of particulate matter (PM) and residual hydrocarbons (HC).
  • the solution of the present invention does not have an air ring, so the air ring swings, leaks, and the air ring is damaged or broken.
  • the beneficial effects of the present invention are that the seal between the piston and the cylinder has no gaps, which makes the seal tighter, enhances the sealing performance, and helps to improve the thermal efficiency of the internal combustion engine; the fuel burns more fully, which effectively reduces the emission of pollutants; and the internal combustion engine is not easy to appear Failure to ensure more stable operation of the internal combustion engine.
  • Figure 1 is a longitudinal cross-sectional structure diagram of the piston.
  • Figure 2 is a longitudinal cross-sectional structural view of a piston with multiple grooves in the sealing ring.
  • Figure 3 is a front view of the top of the piston.
  • the implementation example of the present invention uses a gasoline engine piston as a prototype for an improved design, as shown in Figure 2 for the construction scheme.
  • the same structural part as the prototype of the gasoline engine piston, the piston pin seat (5) and piston skirt (6) have the same structure, and the oil ring and oil ring groove (4) as the oil seal are also basically unchanged.
  • the oil ring groove can be slightly towards the middle of the piston. It can be moved to leave enough space for the separation groove.
  • the peripheral part of the piston head is replaced with a sealing ring (2), a separation groove and a filling material (3).
  • the thickness of the sealing ring is about 1-2mm.
  • the manufacturing material of the sealing ring is basically the same as that of the gas ring, and it must be treated with wear resistance and corrosion resistance.
  • the height of the sealing ring is about 20-25mm, and the part that is attached to the cylinder is 15- About 20mm, the outer diameter of the lower part of the seal ring that does not fit with the cylinder wall is slightly smaller, and the height is about 5mm.
  • the lower part of the seal ring is connected to the piston body above the oil ring groove, and can be screwed together; the seal ring and the cylinder fit part Two grooves are opened on the outer surface to divide the bonding part into three sections to form a three-layer seamless sealing surface.
  • the width of each groove is about 1mm and the depth is 1/5 to 1/3 of the thickness of the sealing ring.
  • the height of the separation groove is approximately the same as the height of the sealing ring, and the width is about 5-10mm.
  • the longitudinal section of the separation groove can be rectangular or trapezoidal;
  • the filling material of the separation groove mainly uses deformed zinc alloy, such as copper-aluminum-zinc alloy with zinc as the main component, which is deformed Zinc alloy is prone to creep deformation or plastic deformation, can well eliminate thermal expansion stress, and can transmit the working fluid gas pressure well, so that the sealing performance of the sealing ring is better;
  • the surface of the separation groove should be as rough as possible to make the filling The material adheres tightly to the seal ring and the piston body, so as not to cause gaps.
  • the filling material of the separation groove When the piston body is heated and expands, the filling material of the separation groove will be deformed under pressure, which can effectively reduce the stress pressure of the piston seal ring on the cylinder wall; when the piston body cools down, because the filling material adheres tightly to the seal ring and the piston body, The filling material can be deformed again.
  • the separation groove filling material can transmit part of the pressure to the sealing ring to increase the pressure between the sealing ring and the cylinder wall to increase the seal between the piston and the cylinder; when the gas pressure in the cylinder combustion chamber decreases When it is small, the corresponding stress and pressure will also decrease. While ensuring sufficient sealing, the friction between the piston and the cylinder is correspondingly reduced, and friction loss is reduced.
  • the solution of the present invention uses different structural solutions and materials from the existing pistons, and the material requirements do not exceed the existing standards.
  • the design and process are relatively simple, and the manufacturing cost is relatively low; it can effectively strengthen the sealing performance between the piston and the cylinder. , Is beneficial to improve the thermal efficiency of internal combustion engines; fuel combustion is more sufficient, effectively reducing polluting and harmful emissions; internal combustion engines are not prone to failures, ensuring more stable operation of internal combustion engines; suitable for large-scale manufacturing and application, and strong practicability.

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  • Engineering & Computer Science (AREA)
  • General Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Pistons, Piston Rings, And Cylinders (AREA)

Abstract

一种无缝密封活塞，在活塞头部中间体（1）的外周设置无缝密封圈（2），在密封圈（2）与活塞头部中间体（1）之间设置分隔槽及填充材料（3）。

Description

一种无缝密封活塞 技术领域
本发明涉及一种活塞，尤其是内燃机活塞。
 背景技术
内燃机活塞与气缸、气缸盖共同形成内燃机的燃烧室，活塞将顶部所受的工质压力通过活塞销传递给连杆，然后再传递到曲轴，将工质内能转化为机械做功，活塞与气缸壁一起构成往复运动的密封装置，保障燃烧室在容积变化情况下的良好密封性，使气缸内的工质燃气不会泄漏到曲轴箱中，而曲轴箱和气缸壁上的机油也不会泄漏到燃烧室气缸中，活塞是内燃机的重要组成部件，一般地，也将与活塞相关的组件称为活塞组。
活塞主要由活塞头部、活塞裙、活塞销座、活塞环组成，除活塞环外的其他三部分组成活塞体，活塞体的制造材料一般是相对密度较小的铝基合金，材料一般应具有密度较小、热强度好、散热性好、膨胀系数小、耐磨性好、良好的减摩性和工艺性好等的特性。活塞头部包括顶部和环带两部分，环带是活塞头部外周开有环槽的部分，活塞顶部到第一道环槽的距离为活塞的顶岸(火力岸)高度。活塞环主要起密封作用，也把活塞的热量传递到气缸壁；活塞环分为气环和油环，气环主要起气体密封作用，主要防止气缸内的高压气体泄漏到曲轴箱中，也对机油的密封起补充作用；油环主要密封机油，防止曲轴箱和气缸壁上的机油泄漏到燃烧室中，并在活塞下行时将气缸壁上多余的机油刮回到机底箱。汽油机一般有一至二道气环，一道油环；柴油机一般有二至四道气环，一至二道油环。
活塞环的密封原理。活塞与气缸之间的密封是通过活塞的活塞环来实现的。活塞环是带开口的弹性金属环，活塞环的材料一般应有耐磨性、耐热性、耐腐蚀性、易导热性、强韧性、适当的弹性等，活塞环安装在活塞环槽中，活塞环的外周面以一定的弹力与气缸壁紧密贴合，形成第一密封面，当气缸内的高压气体沿气缸壁进入环槽，将环向环槽的侧面压紧，形成第二密封面，并且进入环槽的高压气体作用在环背的压力会使得活塞环对气缸壁的压力增大，又加强了第一密封面，气缸中气体的压力越大，则气环各密封面的压力也越大，气环密封得就越紧密。由于有切口间隙，一般只用一道气环密封是不足够的，往往需要设置多道气环进行密封，形成迷宫式通道，确保气体泄漏减至最小，实现良好的密封作用。
活塞环密封的缺点和问题。活塞环存在漏气的情况：活塞环有切口，虽然切口很小，并且经过有多道气环进行密封，但漏气的情况不可避免；一般情况下，由于发动机高速运转，每次压缩和做功的时间很短，所以漏气情况影响轻微；但在发动机低速运行时，以及发动机工质燃气高压工作时，活塞环漏气情况会对发动机的效率带来极大的影响。活塞缝隙对内燃机的影响很大，由于活塞环的设计，不可避免会形成很多缝隙；首先是顶岸与气缸壁之间的间隙，顶岸是活塞头部外周第一道环槽至活塞顶部之间的部分，由于活塞与气缸的膨胀系数不同，一般来说，活塞的膨胀系数要比气缸要大，所以活塞顶岸与气缸壁之间要留有空隙，否则，当活塞温度较高时，活塞头部就会膨胀并与气缸壁压紧，会极大地增大摩擦阻力，容易造成拉缸现象；环岸也存在同样的情况；活塞环与活塞槽之间也会有间隙；当混合气体被压缩和在燃烧室进行燃烧时，混合了燃料的混合气体不可避免地会进入到缝隙中，由于缝隙相对远离燃烧室，接近活塞中部和气缸壁，相对温度较低，所以很容易造成不完全燃烧，会生成不完全燃烧的碳晶颗粒物（PM）和残留碳氢化合物（HC），不完全燃烧会增加有害物排放和降低内燃机的热效率，无论是汽油机还是柴油机，都会发生不完全燃烧的情况；活塞缝隙是造成内燃机不完全燃烧和废气有害物排放过高的重要原因之一；由于环槽缝隙的存在，机油也会渗入其中，并会发生机油碳化现象，在吸气和压缩时，活塞环两边的压力差完全相反，使得活塞环会在环槽两侧来回摆动，环槽中的碳粒或其他杂质颗粒会使得活塞环与活塞环槽不能完整地贴合，会增加漏气情况，严重时会发生活塞环扭曲变形，发生卡死，甚至会折断。
理论上压缩比是影响往复活塞式内燃机热效率的主要因素，压缩比越大，热效率就越大。要提高发动机的热效率，最主要的手段就是增大压缩比，增大压缩比也会相应增大工质燃气的压力，这也会导致活塞环漏气的情况变得更加严重，活塞环会成为影响热效率的重要因素，漏气的活塞环设计已经不适合高压内燃机的应用。
随着环保和排放标准的要求越来越严格，活塞缝隙所造成的污染排放影响也越来越严重。
活塞的活塞环密封设计不可避免造成很多缝隙，这些缝隙会对发动机的热效率和废气排放、甚至发动机的稳定运行造成严重的影响。
 技术问题
活塞缝隙会对发动机的热效率和废气排放、甚至发动机的稳定运行造成严重的影响，如何加强活塞的密封性能是当前内燃机设计和制造的难题。
 技术解决方案
内燃机活塞的活塞环密封出现漏气情况，会造成不完全燃烧，从而导致降低内燃机热效率和导致污染废气过量排放，甚至容易产生碳粒等而导致活塞环损坏等问题，为了加强活塞的密封性能，本发明提供一种活塞无缝密封方案，可以完全克服和解决以上这些问题。
本发明所采用的技术方案是，活塞头部外周为密封圈，密封圈是管状或圆筒形状的组件，其上部与活塞顶部平齐，密封圈下部与活塞中部连接，并且接近连接的部分外径略小，密封圈外表面以轻微弹力与缸壁贴合形成密封面，密封圈内表面与活塞头部中间体之间有分隔槽及填充材料，并且分隔槽的填充材料为以软质、耐高温、耐腐蚀的材料粘合填充。
本发明方案活塞的具体构造如图1所示，图1是活塞纵向剖面构造图，图中标记：1.活塞头部中间体，2.密封圈，3.分隔槽及填充材料，4.油环槽，5.活塞销座，6.活塞裙。活塞头部包括：活塞头部中间体、密封圈和分隔槽及填充材料，密封圈作为气体密封代替了气环密封的功能；油封仍保留油环和油环槽不变；活塞销座与活塞裙也与以往的活塞基本相同。
活塞顶部的构造如图3所示，图3是活塞顶部正面视图，图中标记：1.活塞头部中间体，2.密封圈，3.分隔槽及填充材料。最外围是密封圈，中部是活塞头部中间体，两者之间是分隔槽及填充材料。
活塞和气缸壁通过活塞的密封圈进行高压气体的密封，密封圈的作用是防止气缸内的高压气体泄漏到曲轴箱中，也对机油的密封起补充作用，其作用与以往的活塞气环所起的作用基本相同。密封圈的管壁较薄，密封圈的制造与气环所用的材料和工艺相当，材料应有耐磨性、耐热性、耐腐蚀性、易导热性、强韧性、适当的弹性等特性。密封圈与活塞体头部的分隔填充材料可以使用软质、熔点高和防腐蚀性的合金，所谓软质就是硬度不高并且容易发生变形，在相对较低的压力下材料就会发生形状的改变，比如一些质地较软的锌合金、铜合金、锡合金等等，特别是变形锌合金，或者也可以使用其他质地较软和高熔点的非合金材料。
当活塞刚放置进气缸中时，活塞头部的密封圈以较轻微的弹性与气缸内壁贴合，也就是密封圈的直径要比气缸的内径稍微要大一点点，使得密封圈与气缸内壁有极微小的弹性形变，产生较轻微的弹力，使得密封圈与气缸内壁在轻微弹力下紧密贴合。由于燃烧室产生高温，当活塞受热膨胀时，活塞头部中间体会因为膨胀而挤压填充材料，由于填充材料质地较软，其会受压向活塞顶方向变形，只有少部分压力传递到活塞密封圈和气缸壁，所以活塞的受热膨胀对活塞密封圈和其与气缸内壁之间的贴合影响不大，不会因为活塞受热而导致拉缸情况发生；活塞中部由于与气缸壁之间保留有间隙，活塞中部的膨胀不会挤压到气缸壁；活塞裙部虽然也会受热膨胀，但由于活塞裙部与燃烧室距离比较远，受热影响较小，其膨胀幅度一般不大，这与以往的活塞情况基本相同。活塞头部的高温热量会通过分隔槽的填充材料传递到密封圈，再传递到气缸壁，从而降低活塞的温度。所以在本发明方案中，高温和高温受热膨胀对活塞和活塞密封的影响不大。
本发明方案中活塞与气缸壁的密封原理。密封圈与气缸内壁在轻微弹力下紧密贴合，形成密封面。当气缸内燃烧室的压力较大时，气缸压力会从活塞顶部直接施加到密封圈与活塞头部的分隔材料上，由于分隔材料是比较软质的材料，压力会通过分隔材料分别传递到密封圈和活塞头部中间，密封圈受到的压力也会传递到气缸内壁上，使得密封圈与气缸壁的压力相应加强，虽然活塞与气缸之间的摩擦力也会变大，但也使得活塞与气缸密封得更加紧密，压力越大则密封性能越强。并且由于密封圈的管壁较薄，在压力下密封圈的管壁会发生变形，会紧密地贴附在气缸壁面上，加强密封面的密封性。当气缸或燃烧室压力较小时，密封圈与气缸之间的压力也较小，所以活塞与气缸之间的摩擦力也较小。密封圈会根据气缸内压力自动相应调整其与气缸壁间的压力，也相应自动调整两者间的密封性强度，也相应改变两者间的摩擦阻力；在气缸压力增大时增强密封性，也引起摩擦阻力增大，在气缸压力减小时减弱和提供足够的密封性，并且同时减小摩擦阻力。本发明活塞密封方案也可以应用于有同样需求的非内燃机活塞。
与以往的多道密封环进行密封类似，由于活塞与气缸壁之间可能存在较少的杂质微粒，而且同样地，密封面也需要多层除去和刮除机油到机底箱。本发明方案的改进是，在密封圈外表面上设置多道密封圈凹槽，使得密封圈形成多道密封层。凹槽的截面可以是长方形，也可以是梯形、或扇形、或三角形，其主要功能是可以截留杂质微粒和机油，使得气缸壁保持光滑和润滑，去除多余的微粒和机油，使得密封性更加好。
多道密封层活塞的具体构造如图2所示，图2是密封圈多道凹槽活塞纵向剖面构造图，图中标记：1.活塞头部中间体，2.密封圈，3.分隔槽及填充材料，4.油环槽，5.活塞销座，6.活塞裙，7.密封圈凹槽。与最初的方案相比，就是密封圈多开了几道凹槽。
本发明方案的密封圈没有缝隙，所以活塞与气缸之间的密封必然会密封得更加紧密，可以满足高压内燃机的需要，有利于提高内燃机的热效率；没有了缝隙，燃烧室中的混合气体就不会进入缝隙中，不会出现缝隙中燃气混合气体不完全燃烧的情况，所以燃烧室中的混合气体燃气会实现更加充分的燃烧，可以有效减少污染有害物排放，特别是减少不完全燃烧的碳晶颗粒物（PM）和残留碳氢化合物（HC）的排放。本发明方案没有了气环，所以也不会出现气环摆动、漏气和气环损坏折断的情况。
 有益效果
本发明的有益效果是，活塞与气缸之间的密封没有缝隙，使得密封更加紧密，增强了密封性能，有利于提高内燃机的热效率；燃料燃烧更加充分，有效减少污染有害物排放；内燃机不容易出现故障，保障内燃机更稳定的运行。
 附图说明
下面对附图及其标记进行说明：
       图1是活塞纵向剖面构造图。
       图2是密封圈多道凹槽活塞纵向剖面构造图。
       图3是活塞顶部正面视图。
图中标记说明：
1.活塞头部中间体，2.密封圈，3.分隔槽及填充材料，4.油环槽，
5.活塞销座，6.活塞裙，7.密封圈凹槽。
 本发明的最佳实施方式
三层无缝气体密封活塞。
本发明方案实施实例以汽油机活塞作为原型进行改进设计，如图2构造方案。与汽油机活塞原型相同的构造部分，活塞销座（5）与活塞裙（6）构造不变，作为油封的油环和油环槽（4）也基本不变，油环槽可以向活塞中部稍作移动，可以为分隔槽留下足够空间。活塞头部外围部分以密封圈（2）和分隔槽及填充材料（3）代替。密封圈厚度为1—2mm左右，密封圈的制造材料与气环材料基本相同，还必须进行耐磨、耐腐蚀等处理，密封圈高度约20—25mm左右，其中与气缸贴合部分为15—20mm左右，密封圈下部不与气缸壁贴合部分外径略小，高约5mm，密封圈下部在油环槽之上与活塞体连接，可以用螺纹旋接；密封圈与气缸贴合部分的外表面开两道凹槽，将贴合部分分为三段，形成三层无缝密封面，每道凹槽宽度约1mm，深度为密封圈厚度的1/5至1/3。分隔槽高度与密封圈高度大致相同，宽度约5—10mm，分隔槽纵向截面可以是长方形或梯形；分隔槽的填充材料主要使用变形锌合金，比如以锌为主要成份的铜铝锌合金，变形锌合金容易发生蠕变变形或塑性变形，能很好地消除热膨胀应力，还能很好地传递工质燃气压力，使得密封圈的密封性能更好；分隔槽的表面应当尽量粗糙些，使得填充材料与密封圈和活塞体粘合得紧密，不要导致生成缝隙。
当活塞体受热膨胀时，分隔槽填充材料会受压变形，可以有效减少活塞密封圈对气缸壁的应力压力；当活塞体降温后，由于填充材料与密封圈和活塞体粘合得比较紧密，填充材料又可以回复变形。当气缸燃烧室燃气压力增加时，分隔槽填充材料可以将部分压力传递到密封圈，以增加密封圈与气缸壁的压力，以增加活塞与气缸之间的密封性；当气缸燃烧室燃气压力减小时，相应的应力压力也随着减小，在保证足够密封性的同时，相应地减小活塞与气缸之间的摩擦力，并减小摩擦损耗。
 工业实用性
本发明方案使用了与现有活塞不同的构造方案和材料，材料要求也没有超出现有的标准，设计及工艺相对简单，制造成本相对也比较低；可以有效加强活塞与气缸之间的密封性能，有利于提高内燃机的热效率；燃料燃烧更加充分，有效减少污染有害物排放；内燃机不容易出现故障，保障内燃机更稳定的运行；适合大规模制造和应用，实用性强。

Claims (2)

  1. 一种活塞，其特征是：活塞头部外周为密封圈(2)，密封圈(2)是管状或圆筒形状的组件，其上部与活塞顶部平齐，密封圈下部与活塞中部连接，并且接近连接的部分外径略小，密封圈外表面以轻微弹力与缸壁贴合形成密封面，密封圈内表面与活塞头部中间体(1)之间有分隔槽及填充材料(3)，并且分隔槽的填充材料为以软质、耐高温、耐腐蚀的材料粘合填充。
  2. 根据权利要求1所述的活塞，其特征是：在密封圈外表面上设置多道密封圈凹槽(7)，使得密封圈(2)形成多道密封层。
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