Abstract: A crank shaft support assembly for increasing stiffness and reducing thermal mismatch distortion in a crank shaft bore of an engine comprising different materials. A cylinder block comprises a first material and at least two crank journal inserts are insert-molded into respective crank journal regions of the cylinder block and comprise a second material having greater stiffness and a lower thermal coefficient of expansion that the first material. At least two bearing caps are bolted to the respective crank journal inserts and define, along with the crank journal inserts, at least two crank shaft support rings defining a crank shaft bore coaxially aligned with a crank shaft axis. The bearing caps comprise a material having higher stiffness and a lower thermal coefficient of expansion than the first material and are supported on the respective crank journal inserts independently of any direct connection to the cylinder block.

Abstract: A multi-cylinder internal combustion engine cylinder block is formed with communication ports allowing communication between cylinders that, when assembled with pistons and a crankshaft, are 180.degree. out of phase. This allows the trapped mass of air beneath a piston to flow beneath a piston in a different cylinder 180.degree. out of phase. As a result, advancing and returning pistons are matched to effectively balance pressures.

Abstract: A method for preparing an engine block casting having integral cylinder bore liners (10). A barrel slab core (14) includes barrel cores (18). Bore liners (10) surround the barrel cores (18) and are fixed in relation to the barrel slab core (14). A cylinder block mold core package (22) is assembled from the barrel slab core (14), and other cores (24, 26, 28). The liners (10) are heated while they are within the cylinder block mold core package (22) by induction heating. Access holes (30) are defined within the barrel slab core (14), each access hole (30) communicating with the interior of one barrel core (18). A heater (32) is inserted through each access hole (30). Thermal energy is thus transferred across the barrel core (18) to the cylinder bore liner (10) to assure optimum integrity of bonding between a solidified cylinder block casting and the cylinder bore liners (10). The heaters (32) are then retracted before adding the molten metal.

Abstract: An engine cylinder block having a shallow water jacket in either a V-type, in-line, or opposed engine configuration. The engine cylinder block further having an isolation chamber below the shallow water jacket forming a cavity between the cylinder bore walls and the outer engine block wall. Additionally, ventilation passages are located between the crankcase and isolation chamber through the upper crankcase plate.

Abstract: The pattern assembly is comprised of: (a) mating first and second clamshell-shaped foam members, the first and second foam members meeting along exteriorly exposed joint margins defined by mateable surfaces extending along opposite sides of each of the members; (b) at least one other foam member nestable totally within the mated assembly of the first and second members and nestable without joint margins exposed to the exterior of the mated assembly; (c) surfaces enclosed within the mated assembly for piloting the first, second and other member into mating relationship; and (d) adhesive material bonding the first and other members together and bonding the second member to the assembly of the first and other member.

Abstract: First and second clamshell-shaped foam members are mated, the first and second foam members meeting along exteriorly exposed joint margins defined by mateable surfaces extending along opposite sides of each of the members. At least one other foam member is nested totally within the mated assembly of the first and second members and nested without joint margins exposed to the exterior of the mated assembly. The surfaces enclosed within the mated assembly pilot the first, second and other members into mating relationship. The first and other members are adhesively bonded together and the second member is adhesively bonded to the assembly of the first and other member.

Abstract: A method is disclosed for increasing productivity when casting Vee configuration engine blocks in a given size, two-part refractory mold having a single parting plane.