Abstract: A cooling system for an electric vehicle charge port includes a member having a base wall including an opening and a perimetrical wall extending from the base wall. The base wall and the perimetrical wall defining a volume. A heat spreader arranged in the volume. A terminal extends from the heat spreader through the opening in the base wall. An amount of phase change material (PCM) arranged in the volume, the amount of PCM is in contact with the terminal.

Abstract: A method for preparing a metallic surface of a device includes executing iterations of a first cleaning regimen and executing iterations of a second cleaning regimen. The first cleaning regimen includes applying a hydrocarbon solvent, e.g., an iso-octane solution, to the metallic surface of the device, executing a first sonication event on the device, and rinsing the metallic surface of the device. The second cleaning regimen includes applying a solution of chlorinated solvent to the metallic surface of the device, executing a second sonication event on the device, and rinsing the metallic surface of the device.

Abstract: An insulated exhaust port liner of a cylinder head assembly for fluidly connecting to an internal combustion engine of a motor vehicle includes a sealing layer. The sealing layer has a first surface defining a passage for fluidly connecting to the internal combustion engine and receiving exhaust gas. The sealing layer further includes a second surface opposite to the first surface. The liner further includes a thermal barrier layer coated onto the second surface of the sealing layer. The thermal barrier layer is a porous non-woven material for supporting the sealing layer on the cylinder head and reducing a transfer of heat from the sealing layer to the cylinder head.

Abstract: A linerless engine block includes a polymer matrix composite having an internal surface that defines a bore. The polymer matrix composite has a first thermal conductivity at the internal surface of at least 5 W/m·° C. The linerless engine block also includes a first bond coating disposed on the internal surface within the bore, and a second wear-resistant coating disposed on the first bond coating within the bore such that the second wear-resistant coating is adhered to the polymer matrix composite by the first bond coating. A method of forming the linerless engine block is also described.

Abstract: An insulated exhaust port liner of a cylinder head assembly for fluidly connecting to an internal combustion engine of a motor vehicle includes a sealing layer. The sealing layer has a first surface defining a passage for fluidly connecting to the internal combustion engine and receiving exhaust gas. The sealing layer further includes a second surface opposite to the first surface. The liner further includes a thermal barrier layer coated onto the second surface of the sealing layer. The thermal barrier layer is a porous non-woven material for supporting the sealing layer on the cylinder head and reducing a transfer of heat from the sealing layer to the cylinder head.

Abstract: A linerless engine block includes a polymer matrix composite having an internal surface that defines a bore. The polymer matrix composite has a first thermal conductivity at the internal surface of at least 5 W/m·° C. The linerless engine block also includes a first bond coating disposed on the internal surface within the bore, and a second wear-resistant coating disposed on the first bond coating within the bore such that the second wear-resistant coating is adhered to the polymer matrix composite by the first bond coating. A method of forming the linerless engine block is also described.

Abstract: A temperature-following layer may be applied to a surface of components within an internal combustion engine. The temperature-following layer follows the temperature swing of adjacent gases (for example, in a combustion chamber). The temperature-following layer may be applied directly to a substrate, or the temperature-following layer may be an outer layer of a multi-layer thermal barrier coating. The multi-layer thermal barrier coating may include, for example, an insulating layer, a sealing layer bonded to the insulating layer, and a porous temperature-following layer disposed on the sealing layer. The sealing layer is substantially non-permeable and configured to seal against the insulating layer.

Abstract: A method of manufacturing a highly insulating three-dimensional (3D) structure is provided. The method includes depositing a first layer of hollow microspheres onto a base. The hollow microspheres have a metallic coating formed thereon. A laser beam is scanned over the hollow microspheres so as to sinter the metallic coating of the hollow microspheres at predetermined locations. At least one layer of the hollow microspheres is deposited onto the first layer. Scanning by the laser beam is repeated for each successive layer until a predetermined 3D structure is constructed. The 3D structure includes a composite thermal barrier coating (TBC), which may be applied to a surface of components within an internal combustion engine, and the like. The composite TBC is bonded to the components of the engine to provide low thermal conductivity and low heat capacity insulation that is sealed against combustion gasses.

Abstract: A cylinder head assembly for an engine assembly is provided herein. The cylinder head assembly may include a head framework, an exhaust liner include a thermal barrier material, an intake liner, and a polymeric housing disposed around at least a portion of the metal head framework and the exhaust liner. The cylinder head assembly may further include a plurality of channels for heating and/or cooling the cylinder head assembly, which can be defined in one or more of: the metal head framework, the exhaust liner, and the polymeric housing. Methods of making the cylinder head assembly are also provided herein.

Abstract: A connecting rod includes a shank formed of a composite. The connecting rod also includes a first end portion coupled to the shank and a second end portion coupled to the shank. The first end portion has an annular shaped portion, and the second end portion has an annular shaped portion. The shank defines a channel coupled to the first and second end portions. A method of manufacturing a connecting rod includes placing a plurality of fibers in a predetermined arrangement, and adding a resin to the plurality of fibers to connect the fibers together and form a composite of at least a shank. The method also includes disposing a component inside the shank, and the component is utilized to define a channel in the shank. The method further includes coupling a first end portion to the shank, and coupling a second end portion to the shank.

Abstract: A composite thermal barrier coating (TBC) may be applied to a surface of components within an internal combustion engine. The composite TBC provides low thermal conductivity and low heat capacity insulation that is sealed against combustion gasses. The composite TBC includes three layers, bonded to one another, i.e., a first (bonding) layer, a second (insulating) layer, and a third (sealing) layer. The insulating layer is disposed between the bonding layer and the sealing layer. The bonding layer is bonded to the component and to the insulating layer. The insulating layer includes hollow microspheres that are sintered together to form insulation that provides a low effective thermal conductivity and low effective heat capacity. The sealing layer is a thin film that is configured to resist the high temperatures, present within the engine. The sealing layer is impermeable to gasses and presents a smooth surface.

Abstract: A cylinder liner assembly includes an inner wear cylinder, a shell disposed radially outside of an outer surface of the inner wear cylinder, and a central layer disposed between the inner wear cylinder and the shell. The inner wear cylinder is a metal or ceramic, the central layer is a porous material, and the shell is a fiber reinforced polymer. The cylinder liner assembly may include a coolant passage disposed adjacent to the outer surface of the inner wear cylinder, between the inner wear cylinder and the shell. The coolant passage is operable to circulate a coolant therethrough for cooling the inner wear cylinder.

Abstract: An engine block assembly includes a head structure assembly, and a cylinder structure assembly. A plurality of fasteners interconnect the head structure assembly and the cylinder structure assembly. An outer shell encapsulates and supports both the head structure assembly and the cylinder structure assembly. The outer shell is a unitary polymer structure that is simultaneously over-molded onto the head structure assembly and the cylinder structure assembly. The head structure assembly and the cylinder structure assembly are constructed of components that are designed to carry the operational loads of the engine with minimal weight. The outer shell provides additional structural integrity, and provides fluid passages for lubrication and cooling, as well as support for other engine components.

Abstract: A temperature-following layer may be applied to a surface of components within an internal combustion engine. The temperature-following layer follows the temperature swing of adjacent gases (for example, in a combustion chamber). The temperature-following layer may be applied directly to a substrate, or the temperature-following layer may be an outer layer of a multi-layer thermal barrier coating. The multi-layer thermal barrier coating may include, for example, an insulating layer, a sealing layer bonded to the insulating layer, and a porous temperature-following layer disposed on the sealing layer. The sealing layer is substantially non-permeable and configured to seal against the insulating layer.

Abstract: A multi-layer thermal barrier coating is provided that includes an insulating layer having an outer surface defining a plurality of crevices therein and a sealing layer bonded to the outer surface of the insulating layer. The sealing layer is substantially non-permeable and is configured to seal against the insulating layer. The sealing layer fills in at least a portion of the crevices. A method of forming a thermal barrier coating is also provided, which includes a step of providing a plurality of hollow round microstructures bonded together, each having a diameter in the range of 10 to 100 microns to create an insulating layer. The method further includes depositing a plurality of metal particles onto the insulating layer and heating the plurality of metal particles to form a substantially non-permeable sealing layer over the insulating layer.

Abstract: A cylinder liner assembly includes an inner wear cylinder, a shell disposed radially outside of an outer surface of the inner wear cylinder, and a central layer disposed between the inner wear cylinder and the shell. The inner wear cylinder is a metal or ceramic, the central layer is a porous material, and the shell is a fiber reinforced polymer. The cylinder liner assembly may include a coolant passage disposed adjacent to the outer surface of the inner wear cylinder, between the inner wear cylinder and the shell. The coolant passage is operable to circulate a coolant therethrough for cooling the inner wear cylinder.

Abstract: An engine block assembly includes a head structure assembly, and a cylinder structure assembly. A plurality of fasteners interconnect the head structure assembly and the cylinder structure assembly. An outer shell encapsulates and supports both the head structure assembly and the cylinder structure assembly. The outer shell is a unitary polymer structure that is simultaneously over-molded onto the head structure assembly and the cylinder structure assembly. The head structure assembly and the cylinder structure assembly are constructed of components that are designed to carry the operational loads of the engine with minimal weight. The outer shell provides additional structural integrity, and provides fluid passages for lubrication and cooling, as well as support for other engine components.

Abstract: A multi-layer thermal barrier may be applied to a surface of components within an internal combustion engine. The multi-layer thermal barrier provides low thermal conductivity and low heat capacity insulation that is sealed against combustion gasses. The multi-layer thermal barrier includes two, three, or more layers, bonded to one another, e.g., a first (bonding) layer, a second (insulating) layer, and a third (sealing) layer. The insulating layer is disposed between the bonding layer and the sealing layer. The bonding layer is bonded to the component. The insulating layer includes hollow microstructures that may be sintered together to form insulation that provides a low effective thermal conductivity and low effective heat capacity. The sealing layer may be formed of a ceramic material, and the insulating layer may include deformed microstructures having a greater width than height.

Abstract: An internal combustion engine includes a component configured to be subjected to combustion gasses, the component includes a substrate presenting a surface and a coating applied to the surface of the substrate. The coating includes an insulating layer applied to the surface having a plurality of microspheres and a sealing layer bonded to the insulating layer and seals against the insulating layer.

Abstract: A thermal barrier coating for a component includes an insulating layer applied to a surface of a substrate. The insulating layer comprises a plurality of ceramic microspheres. A sealing layer is bonded to the insulating layer. The sealing layer is non-permeable such that the sealing layer seals against the insulating layer. A method for applying a thermal barrier coating to a surface of a substrate of a component includes providing a plurality of ceramic microspheres and applying the plurality of ceramic microspheres to the surface of the substrate. At least one heat treatment is applied to the plurality of ceramic microspheres on the surface of the component to create an insulating layer on the surface of the substrate.