Valve-open-close mechanism

BACKGROUND OF THE INVENTION

The present invention relates to a valve-open-close mechanism operated by an electromagnetic actuator and used mainly in an automotive internal combustion engine.

A conventional valve-open-close mechanism for automotive internal combustion engines is disclosed e.g. in Japanese patent publication 11-93629. Referring to

FIG. 1

, which shows one embodiment of the present invention, an electromagnetic actuator

4

includes a pair of electromagnets

6

,

7

each made up of a stator

5

and a coil

18

that are opposed to each other by with a gap S therebetween. An armature

3

is disposed in the gap

10

so as to be reciprocable between two electromagnets

6

,

7

. A first stem

15

for transmitting the movement of the armature

3

from the electromagnet

6

toward the one electromagnet

7

to external is provided on one surface of the armature

3

.

The electromagnetic actuator

4

is housed in a housing

8

fixed in an internal combustion engine

19

. The tip of the first stem

15

of the electromagnetic actuator

4

is brought into abutment with the tip of the valve

9

so that by moving the armature

3

toward the electromagnet

7

, the first stem

15

pushes the valve

9

to open it. Further, in order to impart a biasing force for opening the valve

9

, a retainer

13

is provided on the valve

9

, and a first return spring

2

is mounted between the retainer

13

and the internal combustion engine body

19

; a second stem

14

is provided on a surface opposite to the surface of the armature

3

on which is provided the first stem

15

; and the retainer

13

is provided on the second stem

14

, and a second return spring

1

for imparting a biasing force in the direction in which the second stem

14

pushes the armature

3

is mounted between the retainer

13

and the housing

8

.

In this valve-open-close mechanism, the weights of directly driven parts during actuation have a direct influence on the driving power consumption of the electromagnetic actuator

4

as an inertia weight. Since the driving power is normally supplied from an on-board battery, an increase in the power consumption is not preferable. Also, the weights of other parts that are not directly driven will also has a direct influence on the total weight of the internal combustion engine. Thus, if it is used in an automobile, it will have a direct influence on the fuel consumption.

But heretofore, for these parts, as disclosed in the above publication, no consideration has been given regarding the material and lightening of the weight and iron-family or steel-family materials having a specific weight of 7 to 8 are used.

In attempting to lighten the weight of each of these parts, a reduction in the mechanical strength of each part will result from lightening of the weight. For the retainer

3

, mechanical strength to withstand a load from the coil spring

1

or

2

is required.

An object of this invention is to provide a retainer which can sufficiently withstand a spring load even if its weight is reduced.

SUMMARY OF THE INVENTION

In order to solve this object, according to the present invention, the retainer comprises a boss and a surrounding spring support, and in view of the fact that the corner portion extending from the spring support to the boss is the weakest portion subjected to the spring load, the corner portion of the retainer is formed to be arcuate. Since it is arcuate, stress concentration is relieved, so that chipping at the corner portion is eliminated.

According to this invention, there is provided the valve-open-close mechanism for an internal combustion wherein the electromagnetic actuator comprises a pair of electromagnets each made up of a stator and a coil opposed to each other with a gap therebetween; an armature disposed in the gap so as to be reciprocable between the pair of electromagnets by driving the electromagnets; and a first stem for transmitting to external the movement of the armature from one electromagnet toward the other electromagnet; the electromagnetic actuator being housed in a housing mounted to an internal combustion engine body; the armature being moved from the one electromagnet toward the other electromagnet, so that the first stem opens the valve by pushing the valve; the electromagnetic actuator further comprising a first retainer provided on the valve for imparting a biasing force to the valve for a valve-closing operation, and a first return spring mounted between the first retainer and the internal combustion engine body; a second stem provided at a surface of the armature on the side not coupled to the first stem; and a second retainer provided on the second stem, and a second return spring mounted between the second retainer and the housing for imparting a biasing force.

According to this invention, the radius of curvature R of the arc of the corner portion is derived from the following formula:

K=P×d×

(1−0.4

R

)≦

C×t=Q[N

·mm]

wherein

Q: Allowable stress for the retainer

13

P: Spring load produced when spring

1

,

2

is compressed to the limit

d: Wire diameter (mm) of spring

1

,

2

t: Fatigue strength of material used for retainer

C: Constant

Here, the permissible stress level Q of the retainer is, as will be apparent from the above formula, a value determined by the material, and is obtained from the experiment results as a numerical value which is correlated with the stress state (See the below-described mechanical strength test for the retainer.). P×d is a stress level applied to the retainer and (1−0.4R) is an approximate formula for stress concentration defined in a non-dimension. They were obtained by this kind of experiments. R is a numerical value in millimeter as a unit.

Since arcuation of the corner portion achieves lowering of stress concentration, it is necessary not to form steps at the continuous portion between the end of the arcuate corner portion and the spring abutting surface of the retainer and the end of the boss peripheral surface in view of cut-out effect. In particular, it is preferable that the corner portion has such an arcuate shape that the curvature gradually increases toward the abutting surface and the peripheral surface of the boss.

The retainer is preferably formed of a powder molded article such as an aluminum alloy hardened material by forging. The arcuate shape of the corner portion may be formed simultaneously with the formation of the retainer or formed by machining after molding.

At least one of the first stem, second stem, housing, valve, first return coil spring and second return coil spring may be formed of a metal smaller in specific weight than iron, its alloy, an alloy reinforced with aggregate and having a smaller specific weight than iron, a ceramics, a fiber- or whisker-strengthened ceramics.

If a metal smaller in specific weight than an iron-family member which has a specific weight of 7-8, its alloy, an alloy reinforced with aggregate, a ceramics, or a fiber- or whisker-strengthened ceramic material, which has heretofore been used, is used for the parts, this leads to reduction in the inertia weight and total weight.

According to the present invention, the first return coil spring or second return coil spring is made of an alloy steel containing 0.55-0.70 wt % of C, 1.0-2.2 wt % of Si, 1 wt % or under of Cr, 1 wt % or under of Mn, 0.2 wt % or under of V, having a tensile strength of 1960 N/mm

2

or over, containing inclusions of a size of 25 μm or under, and having a tempered martensitic structure.

Further, besides the desired spring properties, for achieving a reduction in weight, the first return spring or second return spring is made of a titanium alloy comprising a total of 13 wt % or over of Al and V, having a tensile strength of 1500 N/mm

2

or over and having a surface coating having a good wear resistance.

Furthermore, in order to achieve a similar object, the first return spring or second return spring is made of an aluminum alloy containing a total of 5 wt % or more of Cu, Mg and Zn, having long crystal particles having an aspect ratio of the crystal particle diameter of 3 or over, and a tensile strength of 600 N/mm

2

or over.

Also, while the valve comprises a marginal portion and a stem portion, in order to maintain heat resistance of the marginal portion and reduce the weight, the marginal portion may be made from a heat-resistant steel alloy and the stem portion may be made from an aluminum alloy sintered member formed by powder molding.

Also, in order to achieve a similar object, the valve may be made from a ceramic material whose major component is silicon nitride or SIALON.

Other features and objects of the present invention will become apparent from the following description made with reference to the accompanying drawings, in which:

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1

is a sectional view of a valve-open-close mechanism embodying the present invention;

FIG. 2

is an enlarged sectional view of a portion of another embodiment;

FIG. 3

is a front view showing a valve;

FIG. 4A

is a plan view of a stator embodying this invention;

FIG. 4B

is a front sectional view of the stator of

FIG. 4A

;

FIG. 5

is a perspective view showing one example of a retainer and a spring;

FIG. 6

is a view showing how the retainer and the spring operate;

FIG. 7A

is a plan view showing an example of a conventional stator; and

FIG. 7B

is a front sectional view of the same.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The electromagnetic actuator

4

for an internal combustion engine according to this invention has, as shown in

FIG. 1

, a pair of electromagnets

6

,

7

, an armature

3

, and a first stem

15

.

The armature

3

is mainly made from a magnetic material. The electromagnets

6

,

7

are each made up of a stator

5

and a coil

18

. By passing a current through the coils

18

, a magnetic field is produced. The pair of electromagnets

6

,

7

are provided opposite to each other with a gap

10

therebetween. The armature

3

is disposed in the gap

10

. Thus, the armature

3

is reciprocable between the two electromagnets

6

,

7

by the magnetic field produced by the electromagnets. If the armature is joined or mechanically fastened to the first stem

15

or the second stem

14

, by the first stem

15

or the second stem

14

or if an inter-electromagnet housing

8

c

is provided very close to the outer peripheral surface of the armature

3

, using the inter-electromagnet housing

8

c

as a guide, the armature

3

can be smoothly reciprocated between two electromagnets

6

,

7

.

In order to transmit the movement of the armature

3

from one electromagnet

6

toward the other electromagnet

7

, the first stem

15

is provided at one side of the armature to which it moves. By the first stem

15

, the movement of the armature

3

from the side of the electromagnet

6

toward the side of the electromagnet

7

acts on the valve

9

, which is in abutment with the tip of first stem

15

, thereby opening the valve of the internal combustion engine. The first stem

15

may be integral with the valve

9

.

The stators

5

may be manufactured by machining an iron-family material, but may be manufactured by molding an iron-family powder by powder molding. Specifically, it can be manufactured by molding iron-family powder by cold mold press molding, warm mold press molding or an injection molding.

In contrast, with a conventional electromagnet, as shown in

FIG. 7

, since a coil is wound around a stator

34

formed with a recess

32

to house an electromagnetic copper plate

31

or a guide hole

33

is formed by machining, it is large in volume as an electromagnet, and machining such as cutting is necessary.

Thus, by employing by powder molding, as shown in

FIG. 4

, the recess

21

and the guide hole

22

can be formed with good accuracy, so that machining after molding can be omitted. The stator can be designed more compact than a conventional one. Also, since it is possible to mount a pre-made coil in the recess

21

, the number of manufacturing steps is fewer and mass-productivity is high.

In order to increase the density of the molded member obtained, obtain the same flux density as conventional electromagnets, and mold more compact stators

5

, warm pressing or injection molding is advantageous.

The iron-family powder used for powder molding may be an ordinary iron-family powder, but an iron-family powder having an iron oxide film or a resin coated film is preferable. If powder molding is carried out using such an iron-family powder, as a constituent component of stators obtained, part or whole of the iron oxide film or coated resin film remains. Thus, formation of eddy current, which tends to be produced in a solid metal, is suppressed, so that stators

5

with low iron loss are obtained. The stator can be disigned more compact than a conventional one. The iron oxide film is a film formed by oxidising the surface of an iron-family powder. The resin coated film is a film formed on the surface of an iron-family powder by applying, immersing or depositing a thermoplastic or thermosetting resin.

Thus, with the electromagnets

6

,

7

using such stators, due to the effect of reduction in volume, reduction in volume of the constituent parts including the below-described housing

8

is achieved, so that it is possible to reduce their weights.

Heretofore, when the stems were passed through the guide holes

33

of the stators

34

, it was necessary to mount slide bearings. In contrast, if the above stators

5

are used, since surface smoothness and dimensional accuracy of the molded members are assured, no slide bearings are necessary, so that it is possible to insert the first stem

15

and the second stem

14

into the guide holes

22

,

22

′. This leads to reduction of the number of parts, which in turn results in reduction in weight and improved mass-productivity.

The coils

18

may be formed from a copper-family material. But it is preferable to form them from aluminum or a material containing aluminum as its major component. With this arrangement, a reduction of weight of the coils

18

is achieved. As the coils

18

, a 1000-family or 6000-family aluminum alloy specified in JIS H 4000 may be used. As a coating material of the coils 18, heat resistance of 180° C. or over is required. It may be an esterimide, a polyimide or a polyamide-imide.

Next, the valve-open-close mechanism for an internal combustion engine according to this invention comprises an electromagnetic actuator

4

, a housing

8

, a valve

9

and a second stem

14

.

The electromagnetic actuator

4

is housed in a housing

8

, which is fixed to an internal combustion engine body

19

by fixing members

20

.

The housing

8

comprises, as shown in

FIG. 1

, a housing

8

a

covering the outer peripheral surfaces of the electromagnets

6

and

7

, a housing

8

b

covering the top ends of the electromagnets

6

,

7

, and an inter-electromagnet housing

8

c

for keeping the gap

10

between the two electromagnets

6

,

7

. But as the housing

8

, it is not limited to a structure formed of these three members but may be formed of any desired members according to the assembling conditions of the valve-open-close mechanism for an internal combustion engine according to this invention.

The material forming the housing

8

may be an iron-family material, but an impregnated composite material in which a metallic material has been impregnated into an aggregate comprising a metallic porous member is preferable. By using such a material, a housing high in strength is obtained. Also, reduction in the wall thickness of the housing and making it compact are possible. Thus, it is possible to lighten the weight.

The metallic porous member may be manufactured by subjecting a foamed resin to a conductive treatment with graphite or the like, electroplating it, and subjecting it to heat treatment to remove the foamed resin, or by impregnating a foamed resin with metal/resin slurry, drying and subjecting it to heat treatment to remove the foamed resin.

As the metallic porous member, a high-strength alloy material containing Fe, Cr, Ni, etc. is preferable. Its volume rate is, though it depends on the required strength and weight, preferably within the range of 3 to 20%.

As the metallic material to be impregnated into the aggregate comprising the metallic porous member, one or two or more selected from a material containing aluminum as its major component such as an aluminum metal, an aluminum alloy or the like, a material whose major component is a magnesium such as a magnesium metal or a magnesium alloy or the like, and foamed aluminum may be used.

As a method of impregnating an aggregate comprising a metallic porous member with a metallic material, a die-cast method, a high-pressure forging method such as molten metal forging, or an impregnation-forging method at a low pressure of several MPa or under can be used. This is because the cell hole diameter of the metallic porous member is of a relatively large size of 0.1 mm to 1 mm and it has an open-cell structure in which all cells communicate with one another.

The foamed aluminum is a foamed-state aluminum or aluminum alloy obtained by melting aluminum or an aluminum alloy such as an aluminum-calcium alloy, and adding a foaming agent such as titanium hydride or zirconium hydride to it to cause foaming by decomposition of the foaming agent.

With the thus obtained impregnated composite material, if an aluminum-family material or a magnesium-family material is used as the metallic material, it is possible to reduce the weight as a whole and thus the weight of the housing

8

itself.

As the fixing members

20

, bolts are usually used as shown in FIG.

1

. As the material for the fixing members

20

, an iron-family material can be used. But it is preferable to use a material whose major component is an aluminum such as aluminum metal or an aluminum alloy.

By using a material whose major component is aluminum as the fixing members

20

, reduction in the weight is achieved. Also this is preferable because the internal combustion engine body

19

for mounting the housing

8

, such as an engine head, is made from an aluminum-family material, so that it is possible to suppress stress due to a difference in the thermal expansion coefficient when a change in temperature occurs during assembling or operation. As specific examples of the material forming the fixing members

20

, materials specified under JIS H 4000 are preferable. In view of tensile strength, 4000-, 5000-, 6000- and 7000-family materials (under JIS H 4000) are preferable.

For the internal combustion engine

19

, a valve

9

for communicating an intake port

25

and an exhaust port

26

with a combustion chamber

27

and shutting them off is provided.

The valve

9

is provided such that by moving the armature

3

from the electromagnet

6

toward the electromagnet

7

, the tip of the first stem

15

of the electromagnetic actuator

4

abuts the tip of the stem portion

16

of the valve

9

so that the valve opens.

In order to impart a biasing force for valve-closing operation to the valve

9

, a retainer

13

is provided on the stem portion

16

of the valve

9

and a first return spring

2

is mounted between the retainer

13

and the internal combustion engine body

19

. Further, a valve guide

11

for guiding the valve-opening and closing motion is provided on the internal combustion engine body

19

.

Specifically, the marginal portion

17

of the valve

9

is provided at the boundary between the intake port

25

or exhaust port

26

and the combustion chamber

27

, and at the boundary, a valve seat

12

is mounted. The valve

9

is closed by the first return spring

2

and the intake port

25

and exhaust port

26

are shut off from the combustion chamber

27

. When the first stem

15

pushes the stem portion

16

of the valve

9

by the movement of the armature

3

, the marginal portion

17

is pushed into the combustion chamber

27

, so that the intake port

25

or exhaust port

26

and the combustion chamber

27

communicate with each other. Thereafter, by the biasing force imparted by the first return spring

2

, the marginal portion

17

is again pressed against the valve seat

12

, so that this line is shut off. Here, the valve seat

12

is a member for seating the marginal portion

17

. This prevents the marginal portion

17

from directly colliding against the internal combustion engine body

19

.

Also, the first return spring

2

is housed in a recess formed in the internal combustion engine body

19

, and the valve guide

11

is provided so as to guide the stem portion

16

of the valve

9

, which extends through the portion between the recess and the intake port

25

or exhaust port

26

.

As for the material forming the retainers

13

,

13

′, it may be an iron-family material. But for the purpose of reducing the inertia weight for improving the quick open-close properties of the valve

9

and reducing the total weight of the internal combustion engine, it is preferable to use aluminum alloy sintered material formed by sintering aluminum alloy powder molded using the below-described powder molding (hereinafter referred to as “aluminum alloy hardened material”).

Since the aluminum alloy hardened material has heat resistance in a sliding condition, it is preferable that it has an alloy structure in which in fine aluminum-based crystal particles, a similarly fine intermetallic compound deposits to strengthen the heat resistance and also it is a dense material. As such an example, Al-17 wt %, Si-1.5 wt %, Zr-1.5%, Ni-2%, Fe-5%, Mm can be cited. Here, “Mm” is misch metal, namely, a composite metal formed mainly of rare earth elements such as lanthanum, cerium. By blowing high-pressure gas against alloy molten metal having such a composition, quenched solidified powder is formed. This is compressed, heated at about 500° C., and hot-forged to impart shapes for densification and at the same time to make it into a part. The thus obtained aluminum alloy hardened material having a predetermined shape is formed of fine aluminum-based crystal particles of about 100-1000 nm and strengthened by fine deposition of hard composite intermetallic compound of aluminum and other element metals on the base. The degree of densification is preferably 95% or over.

As the material for the retainers

13

, the abovementioned aluminum alloy hardened material is preferable. This is because high fatigue characteristics are required because they are subjected to repeated stresses from the compression springs

1

,

2

. Thus it is necessary to adopt an alloy design in which fine crystal particles on a submicron order are formed and a quick-cool-solidifying process. By using this, it is possible to lessen the weights of the retainers

13

themselves.

Also, for the retainers

13

, because sliding occurs against the first return spring

2

and second return spring

1

during high-speed valve operation, the aluminum alloy hardened material is sometimes insufficient. In such a case, by using the aluminum alloy hardened material formed from the above aluminum alloy powder containing 10 wt % hard particles having an average diameter of about 1-5 μm, and a maximum diameter of about 15 μm, it is possible to suppress wear. As the hard particles, nitride ceramic, oxide ceramic, carbide ceramic are preferable. As examples, silicone nitride, alumina, and silicon carbide can be cited.

The second stem

14

is provided at a surface opposite the surface of the armature

3

provided with the first stem

15

. On the second stem

14

, a retainer

13

is provided. Between the retainer

13

′ and the housing

8

, the second return spring

1

for imparting a biasing force in the direction in which the second stem

14

pushes the armature

3

is provided.

The second return spring

1

opposes the biasing force of the first return spring

2

, which acts on the armature

3

to prevent the armature from being pressed toward the other electromagnet

6

by the biasing force of the first return spring

2

.

As shown in

FIGS. 5 and 6

, the retainers

13

comprise a boss

13

a

and a spring support

13

b

. A corner portion

13

d

extending from a spring-abutting horizontal surface

13

c

of the spring support

13

b

to the boss

13

a

is made arcuate. The radius of curvature R of the arc is derived from the following formula:

K=P×d×

(1−0.4

R

)≦

C×t=Q[N

·mm]

wherein

Q: Allowable stress for the retainer

13

P: Spring load produced when spring

1

,

2

is compressed to the limit

d: Wire diameter (mm) of spring

1

,

2

t: Fatigue strength of material used for retainer

13

C: Constant

The inner-diameter corner e of the end of the spring

1

,

2

has a cut shape so as not to ride on the corner portion

13

d

of the retainer

13

. Also, on the abutting surfaces

13

c

of the retainer

13

, it is preferable to provide a coating such as DLC (diamond-like carbon) to achieve a reduction in sliding resistance.

The material forming the first stem

15

or second stem

14

may be an iron-family material. But in order to achieve reduction in weight, a ceramic material whose major component is silicon nitride or SIARON, aluminum alloy hardened material, titanium alloy, etc may be used. As the silicon nitride, to ensure reliability against breakage, use of a sintered member containing 80 wt % or more of silicon nitride or SIALON and having a relative density of 95 wt % or over is preferable.

The usable ceramics include fiber-reinforced ceramics and whisker-reinforced ceramics.

As the aluminum alloy hardened material, it is required that it is a high-temperature slide member having a heat resistance in a sliding condition, the abovesaid aluminum alloy hardened material may be used.

The first stem

15

and second stem

14

may be made of the same material or different materials.

On the surface of the first stem

15

and the second stem

14

, a ceramic coating film or a carbon-family coating film may be provided. This reduces the dynamic friction coefficient and possibility of seizure on the sliding surface when the first stem

15

or second stem

14

is driven in the guide hole

22

of the stator

5

and thus reduces the energy loss due to sliding.

As the material forming the coating film, a ceramic coating film of a nitride, carbide, carbonitride, oxy-nitride, oxy-carbide or carbo-oxy-nitride of a metal in the IVa, Va, VIa groups of the periodic table or aluminum (Al), boron (B) or silicon (Si), a DLC (diamond-like carbon) film, a diamond film or a carbon nitride film can be cited.

As the structure of the coating film, a coating film formed of one kind of material among the above materials, a mixed film formed of two kinds or more of them, and a laminated film formed of the above said coating film and the abovesaid mixed film. By providing such a coating film, it becomes unnecessary to forcibly supply lubricating oil to the sliding surface when the first stem

15

or the second stem

14

is driven in the guide hole

22

of the stator

5

. This suppresses a failure of the actuator

4

.

The armature

3

may be, if necessary, joined to or mechanically fastened to one or both of the first stem

15

and second stem

14

. With this arrangement, it is possible to guide the reciprocating movement of the armature

3

between the electromagnets

6

and

7

.

As the first stem

15

or second stem

14

to be joined to or mechanically fastened to the armature

3

, if a stem using a material smaller in specific weight than the armature

3

is selected, it is possible to reduce the weight than when an integral driving member is formed using a material as the same kind as the armature

3

.

As a method of coupling the armature

3

and first stem

15

by joining or mechanical coupling, slidably coupling them together, bonding them together, or mechanically coupling them together can be cited. To ensure reliability of detaching and attaching, a joint means using a retainer in which a recessed groove is formed in the circumferential direction of the stem and the armature

3

is sandwiched there. Here, as a lighter material than the armature

3

, ceramic material whose major component is silicon nitride or SIALON, an aluminum sintered material by powder molding, and a titanium alloy can be cited.

The material forming the first return spring

2

or the second return spring

1

may be an iron-family material. But by using the following material, namely, an alloy steel containing C: 0.55-0.70 wt %, Si: 1.0-2.2 wt %, Cr: 1 wt % or under, Mn: 1 wt % or under, V: 0.2 wt % or under, and if necessary, Mo and Nb, having a tensile strength of 1960 N/mm

2

, inclusion such as SiO

2

and Al

2

O

3

being 25 μm or under, and having a tempered martensitic structure, it is possible to obtain desired spring characteristics and lessen the spring weight. In the case of such a high-strength steel, after melt casting and hot pressing, it is worked to an intended wire diameter by combining shaving, wire drawing and patenting, and then hardening and tempering to obtain a steel wire. Thereafter, coiling, strain-removing annealing, shot peening, and if necessary, nitriding, shot peening and strain-removing annealing are usually carried out.

Further, as the material of the first return spring

2

or second return spring

1

, if a titanium alloy comprising a total of 13 wt % of Al and V, having a tensile strength of 1500 N/mm

2

and having a surface coating that is good in wear resistance is used, it is possible to obtain desired spring characteristics and lessen the spring weight. The high-strength titanium alloy is melted in a vacuum, melt-forged repeatedly until component segregation decreases sufficiently, hot-pressed, then solution treatment and wire drawing repeatedly. After it has been worked to an intended wire diameter, it is subjected to ageing treatment. The steps after coiling are basically the same as mentioned above.

Furthermore, as the material of the first return spring

2

or second return spring

1

, if an aluminum alloy containing a total of 5 wt % or more of Cu, Mg and Zn, having long crystal particles having an aspect ratio of the crystal particle diameter of 3 or over, and a tensile strength of 600 N/mm

2

or over, it is possible to obtain desired spring characteristics and lessen the spring weight. The high-strength aluminum alloy is formed into a powder of an intended composition, the powder is solidified into an ingot, and subjected to either or both of forging and pressing, wire drawing and solution treatment repeatedly to an intended wire diameter, and finally, ageing treatment. The steps after coiling are basically the same as with high-strength steel but no nitriding is done.

Also, in order to use the abovementioned titanium alloy and aluminum alloy for the first return spring

2

or second return spring

1

, a coating film may be provided to improve the wear resistance of the surface, if necessary.

The valve

9

is formed from a marginal portion

17

forming a valve and a stem portion

16

forming a shaft. The material forming the valve

9

may be an iron-family material but may be such a material that the marginal portion

17

has heat resistance. For example, an aluminum alloy hardened material may be used as the stem portion

16

and a heat-resistant steel alloy as the marginal portion

17

. A ceramic material whose major component is silicon nitride or SIALON may be used for both the stem portion

16

and marginal portion

17

. By using these materials, it is possible to maintain heat resistance of the marginal portion

17

forming the valve and contribute to the reduction in weight.

As the heat-resistant steel alloy, JIS SUH3 (Fe-11 wt % Cr-2 wt % Si-1 wt % Mo-0.6 wt % Mn-0.4 wt % C) or the like can be cited as an example.

As the silicon nitride, to ensure reliability against breakage, use of a sintered member containing 80 wt % or more of silicon nitride or SIALON and having a relative density of 95 wt % or over is preferable.

The ceramics include fiber-reinforced ceramics and whisker-reinforced ceramics.

If such an aluminum alloy hardened material is used as the stem portion

16

and a heat-resistant steel alloy is used as the marginal portion

17

, they can be joined together by hot pressing.

By making the stem portion

16

and the marginal portion

17

from different materials and joining them together, it is possible to form most part of the valve

9

from an aluminum alloy and thus reduce the weight, and to selectively strengthen the portion that will be exposed to burning and heated to high temperature.

Also, for the aluminum alloy hardened material and titanium alloy material, in order to improve wear resistance of the sliding surface on the surface of the stem portion

16

, the below-described ceramic coating film or carbon-family coating film, or an oxide film may be provided.

In this invention, if the stator

5

is formed by molding an iron-family powder by powder molding, during operation of the valve-open-close mechanism, if the armature

3

and the stator

5

contact directly each other, it is liable to wear or chipping. Thus, it is preferable to reciprocate the armature

3

so as not to directly contact the stator

5

. For this purpose, the reciprocating motion of the armature

3

may be controlled by an electric circuit, or stoppers

23

may be provided between the stator

5

and the armature

3

as shown in FIG.

2

.

Also, the valve-open-close mechanism can be used either for an exhaust line or an intake line. If a heat-resistant steel alloy is used for the marginal portion

17

of the valve

9

, it is preferable to use it in an intake line. If silicon nitride or a SIALON-family ceramic material is used for the marginal portion

17

of the valve

9

, it is preferable to use it for an exhaust line.

It is not necessary to manufacture all of the first stem

15

, second stem

14

, housing

8

, valve

9

, first return spring

2

, second return spring

1

, retainers

13

and fixing members

20

of the above-described metal or its alloy, which is smaller in specific weight than iron, an alloy or a ceramic or a fiber- or whisker-reinforced ceramic reinforced with an aggregate which is smaller in specific weight than iron. Even if at least one of them is formed of such a material, and the others are formed of an iron-family material, it is possible to achieve lessening the weight of an electromagnetic actuator for an internal combustion engine or a valve-open-close mechanism for an internal combustion engine obtained.

[EXAMPLES 1, 2]

The parts forming the valve-open-close mechanism shown in

FIG. 1

were manufactured from the following materials to form the valve-open-close mechanism.

(Armature)

As the armature

3

, an existing magnetic steel material was used. The below-described first stem

15

was fitted, pressed and joined.

(Stator)

The stator

5

of a shape shown in

FIG. 4

was manufactured from a powder compressed molded body. Iron powder used was pure iron powder. It was manufactured by steps of preparing a powder solidified by quenching by blowing high-pressure water against molten metal, drying, and adjusting powder particle diameter distribution by passing through a mesh of a predetermined size. These steps are the same as in manufacturing an ordinary starting raw material powder for sintered machine parts. Thereafter, in order to assure insulation between pure iron powders, an oxide film forming step was carried out by heat treatment.

Main impurities before the formation of an oxide film were about 0.1 wt % of oxygen, about 0.05 wt % of Si and Mn, and about 0.005 wt % of carbon, phosphorus and sulfur. The powder particle diameter is controlled in the quench-solidifying step and the particle diameter distribution adjustment step for smooth and uniform flow filling into a mold, and so that as high an apparent density as possible is obtained. The particle diameter distribution thus obtained was such that 5-10 wt % were less than 200 μm and 150 μm or over, 40-50 wt % were less than 150 μm and 75 μm or over, and 40-50 wt % were less than 75 μm and 30 μm or over. According to the flow property evaluation under JSPM standard, which is an index of flow filling properties, for the powder having such a particle diameter distribution, the time taken for 50 grams of powder housed in a funnel container having an outlet diameter of 2.5 mm to pass the outlet was 20-30 seconds. Also, the apparent density under the standard was 2.9-3.5 g/cm

3

.

In order to manufacture the stator

5

by molding this powder, the powder was charged into a mold, and in order to prevent seizure between the mold and the iron powder in uniaxially compressing, 0.5-0.7 wt % of organic resin containing a thermosetting resin as its major component was blended.

The powder compressed molded body obtained by cold-compression-molding the powder was 7.1 g/cm

3

in density. For a powder compressed molded material obtained by warm compression molding, the density was 7.4 g/cm

3

. In warm compression molding, the mold and the powder to be compressed were controlled to a temperature of 130° C. to 150° C. . The reason why the density was high in this case was mainly because the yield stress of the iron powder decreased and the deformability increased due to softening, so that the consolidation property increased.

These molded members were calcined at 200° C. in the atmosphere to obtain stators

5

.

Generally, in an alternating magnetic field, the higher the frequency, the more an eddy current is produced and the more loss of magnetic force occurs. But with an aggregate of such a powder, production of eddy current is suppressed in the powder units, so that it is possible to lower the loss. With this stator

5

, due to its structural feature, there is little anisotropy in permeability. Dimensional variations after molding and calcining were small, so that no additional working was necessary. Thus, there was no need to set a bearing for passing the stem

14

,

15

.

Comparative members were manufactured of a laminated silicon steel plate. For the laminated silicon steel plate, in view of the balance of punching workability and higher permeability than iron, a unidirectional silicon steel plate containing 3 wt % silicon was used. Since anisotropism is produced that the permeability is large in the rolling direction and small in a normal direction, as shown in

FIGS. 7A and 7B

, a laminated structure was used. For the purpose of suppressing eddy current, on the surface of the steel plate, an electric insulating resin layer was formed and it was assembled by superposing steel plates. Plates punched into strips were laminated and assembled, and fixed together by welding their ends with a laser. As for the accuracy of this stator, since the accuracy of the steel plate itself and the accuracy at the time of laminating and assembling are multiplied, it is impossible to expect a high dimensional accuracy compared with a stator formed by powder compression. Thus, machining was necessary at the end face on the side where the housing and the armature

3

contact with each other. Also, the dimensional accuracy of the hole for receiving the stem

14

,

15

was also low, so that additional working and setting a bearing were necessary. The assembled laminated steel plate member had a density of 7.8 g/cm

3

.

The maximum flux density for direct current of the stators thus formed by powder compression molding was 1.3 T for cold-molded members and 1.5 T for warm-molded members. In contrast, the maximum flux density for direct current when laminated silicon steel was used was 1.3 T.

From the above results, compared with laminated silicon copper plates, for powder compression molded members, it was confirmed that they showed equivalent or more than equivalent magnetic properties, though they were low in density and small in the number of manufacturing steps.

(Coil)

As the coil

18

, a 6000-family material having a conductivy of 50% IACS specified in JIS H 4000 was used instead of a conventional copper-family material. As a coating material for the coil member, a polyimide resin was used.

(Stems)

As the first stem

15

and second stem

14

, specimens made in the following manner were used. A powder in which 5 wt % of yttrium oxide and 2 wt % of aluminum oxide were wet-blended in ethanol into a commercial silicon nitride powder (α-crystal phase ratio: 90% or over, average particle diameter: 0.8 μm) was dried. After a predetermined molding organic binder had been added, the mixture was molded. Sintering was carried out at 1800 degrees in a 4-atm nitrogen gas atmosphere for 10 hours, and it was worked into a predetermined shape with a diamond grindstone. For this sintered member and a sintered member manufactured simultaneously, the three-point bending strength was measured under JIS R 1601. The average strength was 1050 MPa.

(Housing)

The housing

8

was manufactured by the following method. A slurry was prepared by mixing 65 parts by weight of Ni powder containing 18% Fe having an average diameter of 2.5 μm and 8% Cr, 2 parts by weight of a dispersant, 11 parts by weight of water and 12 parts by weight of phenolic resin. The slurry was impregnated into a polyurethane foam which had a thickness of 8 mm and in which the cell number per inch was 29, and excess slurry that adhered was removed by use of a metallic roll, and the sheet was dried for 10 minutes at 120° C. By heat-treating this sheet at 1200° C. under vacuum for one hour, a porous metallic member having a density of 0.91 g/cm

3

was prepared. After the metallic porous member has been worked into a cylindrical shape, it was set in a mold. By injecting under pressure of 1.2 MPa molten metal aluminum alloy (Al containing 2 wt % Cu) heated to 760° C. a housing comprising a metallic porous member/aluminum alloy composite material was manufactured. As a comparative member, a housing was also formed from only an aluminum alloy without compositing the metallic porous member. The tensile strength measured for each of them was as follows: composite material: 231 MPa, aluminum alloy: 142 MPa.

(Return coil spring)

The return coil spring was manufactured by the following method. By repeatedly subjecting a steel comprising C=0.65 wt %, Si=1.98 wt %, Mn=0.78 wt %, Cr=0.75 wt %, V=0.11 wt %, the remainder being substantially Fe to melt-forging, rolling, shaving, wire drawing, and heat treatment to obtain a wire 3.0 mm thick. Non-metallic inclusion were 20 μm at maximum. From this wire, a high-strength coil spring was manufactured by combining coiling, strain-removing annealing, shot peening and nitriding.

(Retainers)

For the retainers

13

, because they retain the valve through a retaining part called cotter (retainer lock), and make a high-speed reciprocating motion integral with the valve

9

, heat fatigue strength and shock strength are required. Also, with the rotation of the valve

9

, they slide against the first return spring

2

and the second return spring

1

, so that wear resistance is also required. To assure heat fatigue strength and shock strength, for an aluminum alloy hardened material, an alloy design for forming submicron fine crystal particles and a rapid-cool-solidifying process are required. As such an aluminum alloy hardened material, using Al-17 wt %, Si-1.52 wt %, Zr-1.5 wt %, Ni-2 wt %, Fe-5 wt %, Mn, an aluminum powder having an average particle diameter of 50 μm was manufactured by gas cooling solidifying process and it was used as a starting material. Also, in view of the requirement of wear resistance, because it is difficult to deal only with an aluminum alloy powder, as hard particles, 9 wt % of alumina particles having an average particle diameter of 2 μm and a maximum particle diameter of 12 μm were added.

After uniaxial powder compression molding, it was heated at 500° C. and densification and imparting final-shape were carried out simultaneously by hot forging. Thereafter, in order to remove burrs and layers at the surface-layer portion where powder bonding was weak, barrel treatment was carried out. No machining was carried out. The density was 3.2 g/cm

3

.

Since the retainers

13

are subjected to repeated spring loads from the coil springs

1

,

2

, mechanical strength is required to withstand the spring loads. Thus, as shown in

FIGS. 5 and 6

, the retainers

13

comprise a boss

13

a

and a spring support

13

b

, and a corner portion

13

d

extending from the spring-abutting horizontal surface

13

c

of the spring support

13

b

to the boss

13

a

is made arcuate so that the radius of curvature R of the arc is a value derived from the above formula 1.

For conventional retainers, steels for machine structures such as JIS 17C or if circumstances require, alloy steels such as JIS 17C SCr415 are often used. The retainer as a comparative member was manufactured using the latter. After shape imparting to the latter alloy steel by hot forging, it was roughly machined, carburized and annealed and then finish working was done. The density was 7.8 g/cm

3

. Heretofore, no consideration has been given to the corner portion

13

d

and the comparative member was as such.

(Bolts)

As the bolts used for mounting the housing

8

to the internal combustion engine body

19

, a 4000-family material stipulated under JIS H 4000 was used against a conventional steel material.

(Valve)

As the valve

9

, 5 wt % of yttrium oxide and 2 wt % of aluminum oxide were wet-blended into a commercial silicon nitride powder (α-crystal phase ratio: 90% or over, average particle diameter: 0.8 μm) in ethanol. The powder obtained was dried. After a predetermined organic molding binder had been added, predetermined molding was carried out. Thereafter sintering was carried out at 1800 degrees in a 4-atm-pressure nitrogen gas atmosphere for 10 hours, and it was worked into a specimen of predetermined shape by a diamond grindstone. For this sintered member and a sintered member manufactured simultaneously, when the three-point bending strengths were measured under JIS R 1601, the average strength was 1050 MPa.

(Valve-open-close mechanism)

Using the abovesaid parts, electromagnetic actuators and valve-open-close mechanisms were manufactured.

[EXAMPLES 2]

Except that as the retainers and springs, the retainers

13

and coil springs

1

,

2

were used, electromagnetic actuators and valve-open-close mechanisms were manufactured in the same manner as in Example 1.

(Retainer and Coil Spring)

On the surfaces

13

c

,

1

a

,

2

a

of the retainers

13

and coil springs

1

,

2

manufactured in Example 1, a DLC film was formed in the following method which is a known capacitive coupling type plasma CVD method. A stem base member washed with a solvent or a detergent and dried was mounted to an electrode connected to a high-frequency power source (frequency: 13.56 MHz). After exhausting at a degree of vacuum of 1×10

−4

Pa, argon gas was introduced until it was maintained at a pressure of 1×10

−1

Pa. In this state, a high frequency output of 400 W was supplied to the electrode from the high-frequency power source, and maintained for 15 minutes so that the electrode carrying the stem would be covered by plasma. After a natural oxide film on the surface of the base member had been removed by ion cleaning, the supply of argon gas was stopped and methane gas was introduced until it was maintained at a pressure of 1×10

−1

Pa, and a high frequency output of 600 W was supplied to the electrode from the high-frequency power source to form a DLC film. The film thickness was about 1 μm.

[COMPARATIVE EXAMPLE 1]

Using the abovesaid comparative members for the stator

5

, housing

8

and retainer

13

and coil springs

1

,

2

, and parts formed of an iron-family material for the other parts, an electromagnetic actuator and a valve-open-close mechanism were manufactured.

[Results]

The weights for Examples 1-2 and Comparative Example 1 were measured. For Examples 1 and 2, compared with Comparative Example 1, as the total weight, 70 wt % of weight reduction was achieved.

Also, performance tests were conducted for the valve-open-close mechanisms of Example 1 and those of Example 2 using a 12 V direct current constant-voltage power source. Power consumption at that time was measured. As a result, in Example 2, the consumed power reduced by 5% compared with Example 1. Thus, it was found out that by the formation of the DLC film on the surface

13

c

of the retainer

13

and the surfaces

1

a

,

2

a

of the coil springs

1

,

2

, it was possible to further reduce the sliding resistance between the retainer

13

and the coil springs

1

,

2

.

[Mechanical strength test of retainers]

In order to confirm the mechanical strength of the corner portion

13

d

of the retainer

13

extending from the spring support

13

b

to the boss

13

a

, for the springs

1

,

2

and retainers

13

prepared in the above Examples, tests were conducted with spring wire diameters d and radius of curvature R of the corner portion

13

d

as shown in Table 1. In the test, for each test example, the maximum compressive spring load P was repeatedly applied 10

8

times. ◯ indicates no damage on the corner portion and × indicates damaged and the test became impossible halfway due to damage were indicated by ×.

According to the test results, since usable (◯) and unsable (×) are divided with a point near the K value of 2200 as a boundary (see test examples 4 and 14), the permissible stress level Q is 2200. From this result, C=12.22 [m

4

](t: 180 MPa) is derived, so that it is apparent that the permissible R for the corner portion

13

d

is 0.5 or over, preferably 1.0 mm or over. The value of C is considered to be a constant for determining the permissible stress level Q for other materials too.

According to the present invention, since the mechanical strength of the retainer has been increased, even if the weight of the retainer is reduced, it can withstand practical use sufficiently.

TABLE 1

Spring

Max

wire

spring

R potion

Test

diameter

load

Radius

Test

Example

d (mm)

P (N)

R (mm)

K value

result

1

4.0

800.0

0.1

3072

X

2

4.0

800.0

0.2

2944

X

3

4.0

800.0

0.5

2560

X

4

4.0

800.0

0.8

2176

◯

5

4.0

800.0

1.0

1920

◯

6

4.0

800.0

1.5

1280

◯

7

3.2

800.0

0.1

2457.6

X

8

3.2

800.0

0.2

2355.2

X

9

3.2

800.0

0.5

2048

◯

10

3.2

800.0

0.8

1740.8

◯

11

3.2

800.0

1.0

1536

◯

12

3.2

800.0

1.5

1024

◯

13

4.0

600.0

0.1

2304

X

14

4.0

600.0

0.2

2208

X

15

4.0

600.0

0.5

1920

◯

16

4.0

600.0

0.8

1632

◯

17

4.0

600.0

1.0

1440

◯

18

4.0

600.0

1.5

960

◯

19

3.2

600.0

0.1

1843.2

◯

20

3.2

600.0

0.2

1766.4

◯

21

3.2

600.0

0.5

1536

◯

22

3.2

600.0

0.8

1305.6

◯

23

3.2

600.0

1.0

1152

◯

24

3.2

600.0

1.5

768

◯

Number	Date	Country
11-349868	Dec 1999	JP
2000-148499	May 2000	JP
2000-321007	Oct 2000	JP

Number	Name	Date	Kind
4993376	Fukutome et al.	Feb 1991	A
5553369	Shimizu et al.	Sep 1996	A
6298812	Izuo et al.	Oct 2001	B1

Number	Date	Country
19851214	Nov 1999	DE
19958175	Feb 2001	DE
0985806	Mar 2000	EP
02-102307	Apr 1990	JP
05-141211	Jun 1993	JP
06-010627	Jan 1994	JP
11-93629	Apr 1999	JP

Valve-open-close mechanism

Information

Patent Number

Date Filed

Date Issued

Inventors

Original Assignees

Examiners

Agents

CPC

US Classifications

Field of Search

US

International Classifications

Abstract

Description

Claims

Priority Claims (3)

US Referenced Citations (3)

Foreign Referenced Citations (7)