Intake valve structure and method of manufacture

Abstract

A method of manufacturing an intake vallve for an internal combustion engine is disclosed. The method comprises providing a valve base comprising an elongated stem and an enlarged portion. A floating peripheral ring is provided and is positioned on the valve base. The floating peripheral ring is locked into place with an annular locking component. The locking component defines a range of motion of the floating peripheral ring with respect to the valve base.

1 . A method of manufacturing an intake valve for an internal combustion engine comprising:
 providing a valve base comprising an elongated valve stem and an enlarged portion, the valve base having an inner seating surface;   providing a floating peripheral ring with an outer valve seat for seating with a cylinder head seat, an inner seat for seating with the inner seating surface of the valve base, and having an inwardly directed locking flange;   providing an annular locking component having an outwardly directed flange for locking the floating peripheral ring to the valve base;   positioning the floating peripheral ring onto the valve base so that the floating peripheral ring is movable with respect to the valve base;   positioning the annular locking component over the valve base and floating peripheral ring;   affixing the annular locking component to the valve base to define a range of motion for the floating peripheral ring with respect to the valve base; and   e) thereby slidably locking said peripheral ring to said valve base by the outwardly directed flange of the locking component.   
   
   
       2 . The method of  claim 1 , wherein the annular locking component comprises an annular locking ring and wherein the outwardly directed flange of the annular locking ring is continuous. 
   
   
       3 . The method of  claim 2  and further comprising providing the floating peripheral ring prior to positioning the annular locking element over the valve base and floating peripheral ring. 
   
   
       4 . The method of  claim 2  wherein the annular locking ring is locked by means of welding. 
   
   
       5 . The method of  claim 1 , wherein the annular locking component is attached to the valve base by means of threading. 
   
   
       6 . The method of  claim 1  wherein the locking component is combined with the enlarged portion to form a single unitary structure. 
   
   
       7 . The method of  claim 1  wherein the enlarged portion includes at least one machined surface for receiving the annular locking component, and wherein the annular locking component is affixed to the enlarged portion to form a single unitary structure. 
   
   
       8 . The method of  claim 1 , wherein the annular locking component is formed of a plurality of elements that are each permanently or removably affixed to a portion of at least one of the valve stem, the enlarged portion and a connecting radius there between. 
   
   
       9 . The method of  claim 2  wherein a diameter of the annular locking component is smaller than a diameter of the enlarged portion. 
   
   
       10 . The method of  claim 1  wherein the valve is formed from metal, composite, alloy, ceramic or plastic. 
   
   
       11 . The method of  claim 1  wherein a coating is applied to at least a portion of the valve and the coating comprises a low friction coating composition, insulating composition or corrosion-resistant composition. 
   
   
       12 . The method of  claim 1  wherein the annular locking component is permanently or removably affixed to the valve base. 
   
   
       13 . The method of  claim 1  wherein the composition of the valve base comprises a first metal or first metal alloy and the composition of the floating peripheral ring comprises a second metal or second alloy different from the first metal or metal alloy. 
   
   
       14 . An internal combustion engine comprising an intake valve manufactured according to the method of  claim 1 . 
   
   
       15 . A method of manufacturing an intake valve for an internal combustion engine comprising:
 a) providing a valve base with a valve stem and an enlarged portion and having an internal seat area thereon;   b) positioning both a floating peripheral ring and an annular locking component on a region of the enlarged portion, the locking component including an outwardly directed flange that engages an inwardly directed flange of the floating peripheral ring;   c) after step b), securing the locking component to the valve base in a manner that provides a sliding relationship between the floating peripheral ring and the valve base thereby limiting a length of movement of the peripheral ring with respect to the valve base.   
   
   
       16 . The method of  claim 15  wherein before step c), the valve base has a recess formed therein sized to receive the locking component. 
   
   
       17 . The method of  claim 16  wherein the recess is formed by machining. 
   
   
       18 . A method of manufacturing an intake valve for an internal combustion engine, comprising:
 a) providing a valve base with an elongated valve stem, the valve stem having a central longitudinal axis, and having an enlarged portion, the enlarged portion having an inner seat for receiving a floating peripheral ring,   b) providing a floating peripheral ring, the ring having a central ring axis, an exterior seat for mating to a cylinder head seat and an internal seat for mating to the inner seat of the enlarged portion;   b) positioning the floating peripheral ring onto the enlarged portion of the valve base so that the floating peripheral ring is movable along the central longitudinal axis, wherein the central ring-axis is coaxial with the central stem axis;   c) positioning a locking ring for locking the floating peripheral ring to the valve base, wherein the locking ring includes an outwardly directed locking element;   d) locking the locking ring to the valve base to allow the peripheral ring to move in a direction defined by the central ring axis defining a range of motion for the floating peripheral ring; and   e) thereby slidably locking said peripheral ring to said valve base by the outwardly directed locking ring.   
   
   
       19 . The method of  claim 11  wherein the lock element comprises a third metal or composite different from the first metal and the second metal.