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

Abstract: An engine cylinder head comprising an internal metal structure formed from a metal material and an external polymer composite structure formed from a polymer composite material, wherein the external polymer composite structure at least partially surrounds the internal metal structure.

Abstract: Methods and systems are provided for a variable compression ratio engine. In one example, an engine system may comprise: varying a compression ratio of a cylinder by selectively releasing combustion charge from the cylinder through a bleed valve on a cylinder head; and transforming the released combustion charge into usable electrical power at a turbine generator coupled downstream of the bleed valve. In this way, the compression ratio may be varied based on engine operating conditions to promote better engine performance and efficiency while producing electrical power from the charge gas bled from one or more cylinders in the engine.

Abstract: Methods and systems are provided for a variable compression ratio engine. In one example, an engine system may comprise: varying a compression ratio of a cylinder by selectively releasing combustion charge from the cylinder through a bleed valve on a cylinder head; and transforming the released combustion charge into usable electrical power at a turbine generator coupled downstream of the bleed valve. In this way, the compression ratio may be varied based on engine operating conditions to promote better engine performance and efficiency while producing electrical power from the charge gas bled from one or more cylinders in the engine.

Abstract: A method for operating an engine system is provided, the method may include varying a compression ratio of a cylinder by selectively releasing combustion charge from the cylinder through a cylinder bleed valve of a cylinder head, the cylinder bleed valve coupled to a bleed manifold with a turbine-generator, and varying combustion charge flow through a turbine-generator bypass conduit bypassing the turbine-generator based on engine operating conditions. In this way, the compression ratio may be varied by selectively bleeding combustion charge from the cylinder based on engine operating conditions to promote better engine performance. Additionally, the combustion charge bleed from the cylinder can routed around a turbine-generator to increase combustion efficiency during certain operating conditions, such as during start-up, to further improve engine performance.

Abstract: A system and methods for routing condensate collected in a heat exchanger reservoir to either an air intake system or a position in the engine exhaust based on the type of contaminate in the condensate and operating parameters of the engine or the catalyst are described. In one particular example, condensate is routed to a first position along the engine air intake system in a first mode of operation, and a second position upstream of the catalyst along the engine exhaust in a second mode of operation, and a third position downstream of the catalyst along the engine exhaust in a third mode of operation. When substantially no contaminates are detected, the condensate may be routed into the engine exhaust upstream of the catalyst in order to cool the catalyst.

Abstract: An engine cylinder head includes an internal metal structure formed from a metal material, at least a portion of which includes a thermal coating and an external polymer composite structure formed from a polymer composite material, wherein the external polymer composite structure at least partially surrounds the internal metal structure.

Abstract: Methods and systems are provided for injecting air from a compressed air source into an intake port of a Miller Cycle engine. In one example, a method may comprise positioning an intake valve, coupled to a cylinder of a four-cycle internal combustion engine, in an open position during a portion of an intake stroke through a portion of a compression stroke of a piston reciprocating within said cylinder. The method may additionally comprise supplying air to said intake valve from a first source, and injecting air against said intake valve from a second source while said intake valve is open during said compression stroke.

Abstract: Methods and systems are provided for introducing a charge motion to a cylinder via a protrusion system coupled to an intake port of an engine. In one example, a system may include positioning a tongue from inside a spring-loaded casing to extend into air intake runner, generating desired tumble and swirl along an intake port proximate to an engine cylinder.

Abstract: An engine has a cylinder block with first and second cylinders separated by a bore bridge, and a block cooling jacket having a slot in the bore bridge and intersecting a block deck face. The engine has one of a cylinder head and a head gasket with a surface configured to mate with the block deck face, the surface having a tab sized to be received by the slot to form a cooling passage therebetween. An engine has a cylinder block with a block deck face defining a first cylinder and a second cylinder separated by an interbore region. The block is independent of a cylinder liner. The block forms a cooling jacket with a fluid passage surrounding the first and second cylinders and an open channel extending across the interbore region and intersecting the block deck face.

Abstract: An engine cylinder head includes an internal metal structure formed from a metal material, at least a portion of which includes a thermal coating and an external polymer composite structure formed from a polymer composite material, wherein the external polymer composite structure at least partially surrounds the internal metal structure.

Abstract: A combustion engine is provided that includes an engine block with a fiber material in a resin. The engine block defines a piston bore and a bore liner positioned within the piston bore and includes a substrate and a coating positioned on an interior surface of the substrate. An exterior surface of the substrate defines a retention feature.

Abstract: Methods and systems are provided for introducing a charge motion to a cylinder via a bladder in an intake manifold runner. In one example, a system may include positioning a bladder in an intake port proximate to a cylinder.

Abstract: Methods and systems are provided for introducing a charge motion to a cylinder via a protrusion system coupled to an intake port of an engine. In one example, a system may include positioning a tongue from inside a spring-loaded casing to extend into air intake runner, generating desired tumble and swirl along an intake port proximate to an engine cylinder.

Abstract: Methods and systems are provided for introducing a charge motion to a cylinder via a bladder in an intake manifold runner. In one example, a system may include positioning a bladder in an intake port proximate to a cylinder.

Abstract: A cam carrier assembly includes a body made of a material lighter than aluminum. The body has a first side operably coupled with a cylinder head and a second side having bearing surfaces with bearing inserts. The bearing inserts support the camshaft. A series of apertures extend between the first and second sides of the body. Lobes of the camshaft operably couple with the valves of the cylinder head through the series of apertures extending between the first and second sides of the body.

Abstract: A valve cover module includes a unitary cover and carrier made of a carbon fiber composite. The unitary cover and carrier has a lower side with a peripheral edge for attaching to a cylinder head. The lower side of the unitary cover and carrier also has a series of cavities interconnected with aligned apertures defining bearing surfaces. A plurality of cam lobes is disposed in the series of cavities. Also, the valve cover module includes a camshaft rotatable on the bearing surfaces and extending through the aligned apertures to couple with the cam lobes.

Abstract: Methods and systems are provided for regulating airflow through a charge air cooler integrated in an intake assembly. In one example, an engine intake assembly comprises a plenum having an integrated charge air cooler (CAC), a first header seal positioned around a circumference of a first CAC header, and a first rotatably movable seal positioned in a bypass passage of the plenum. The first movable seal interfaces via sliding contact with the first header seal and adjusting a position of the first movable seal may vary the amount of airflow through the bypass passage.

Abstract: An engine has a cylinder block with first and second cylinders separated by a bore bridge. The block has a cooling jacket with a cooling channel intersecting a block deck face and circumferentially surrounding the first and second cylinders such that the engine block has an open deck configuration. The engine has a cylinder head with a surface configured to mate with the deck face of the block. The surface of the head has a sleeve protruding therefrom. The sleeve is sized to be received by the channel to circumferentially surround the first and second cylinders to structurally support the cylinders.

Abstract: Methods and systems are provided for introducing a charge motion to a cylinder via a bladder in an intake manifold runner. In one example, a system may include positioning a bladder in an intake port proximate to a cylinder.