FORM 2
THE PATENT ACT, 1970,
(39 OF 1970)
&
THE PATENTS RULE, 2003
COMPLETE SPECIFICATION
(SEE SECTION 10; RULE 13)
"HPDC ALUMINIUM CYLINDER BLOCK FOR ENGINE"
MAHINDRA & MAHINDRA LIMITED
AN INDIAN COMPANY,
R&D CENTER, AUTOMOTIVE SECTOR,
89, M.I.D.C., SATPUR,
NASHIK-422 007,
MAHARASHTRA, INDIA.
THE FOLLOWING SPECIFICATION PARTICULARLY DESCRIBES AND ASCERTAINS THE NATURE OF THIS INVENTION AND THE MANNER IN WHICH IT IS TO BE PERFORMED

FIELD OF THE INVENTION:-
The present invention is related to the cylinder block of an engine. More particularly, the present invention is related to HPDC aluminium cylinder block of an engine with internal bypass, waviness on water jacket, uneven liner insert thickness and sheet metal deflector.
BACKGROUND OF THE PRESENT INVENTION:-
The existing engines uses External Hose for coolant by pass and it doesn't uses Sheet metal deflector to divert coolant to cylinder head & separating engine inlet & return coolant passages. Further, the existing engines doesn't' uses waviness in front & rear to achieve better cylinder distortion. To address these drawbacks of the existing engines, the present invention of High pressure die casting aluminium engine is proposed.
BRIEF DESCRIPTION OF THE FIGURES:-
Figure 1 shows HPDC aluminium cylinder block as per the present invention.
Figure 2 shows internal coolant bypass in the cylinder block
Figure 3 shows the profile of water jacket in the present invention
Figure 4 shows profile of the liner in the present invention.
Figure 5 shows the deflector used for cross flow in the present invention.
DETAILED DESCRIPTION OF THE PRESENT INVENTION:-
HPDC Cylinder Block of the present invention has Innovative features like internal bypass, waviness on water jacket, uneven liner insert thickness & Sheet metal Deflector. For a 1.2L 3 Cylinder PFI gasoline Engine, a Compact HPDC aluminium cylinder block design with several innovative features as described below which can results in Low weight compact packaging with improved fuel economy.

Thus, the main objective of the present invention is to provide light weight and compact HPDC aluminium cylinder block for the engine that improves the fuel economy.
Light weight and compact HPDC aluminium cylinder block for the engine comprises of interna! bypass galleries, waviness on water jacket, uneven liner insert thickness and a deflector plate.
Internal Bypass: During Engine warm up condition, coolant bypass has been routed to water pump from cylinder block itself. This is achieved by providing a as cast passage from cylinder block water jacket return line to water pump suction side. This helps in reaching early warm up which will in turn benefits in achieving lower fuel consumption along with improved thermal reliability of the Engine.
Waviness on water jacket: In traditional cylinder blocks water jacket bottom surface used to be horizontal. In this Cylinder block water jacket profile was provided with wavy structure which helped in achieving better cylinder bore distortion in front & Rear.
Uneven liner insert thickness: A compact Bore bridge of 9mm has been selected& 3 mm cross was accommodated between cylinders. This is achieved by reducing the thickness of the liner insert where 3mm drill provided. To take care reverse fitment of liner in manufacturing process, liner thickness was maintained symmetrically on both top & bottom side. This helps in maintaining the cylinder liner wall temperature below the oil coking temperature.
Also in traditional cylinder block liner thickness is used to be uniform around the Cylinder liner. In this cylinder block liner thickness was varying from 6 mm to 10 mm around to get the Cylinder bore distortion minimum.
Deflector: A sheet metal coolant deflector is pressed in the cylinder block which helps in diverting entire coolant to Cylinder head on exhaust side where coolant

is needed to take heat from exhaust ports. This Helps in early warm up & helps in achieving better fuel consumption.
Also the coolant deflector is placed in such way that it will have one side Coolant entry into engine & other side it will have coolant by pass outlet. This helped in avoiding additional hoses connections & hence cost effective.
ADVANTAGES OF THE PRESENT INVENTION:-
HPDC Aluminium cylinder block imparts following technical advantages:
- Reduced cylinder bore distortion helps in achieving better fuel consumption
- Early warm up by Internal bypass, diverting all the coolant to cylinder head by Sheet metal deflector helps in early engine warm up.
- Compact cylinder block with Inter bore cooling can achieve better performance & cost effective.
- Elimination of Radiator by pass hose by internal by pass

WE CLAIM:-
1. Light weight and compact HPDC aluminium cylinder block for the engine comprises of internal bypass galleries, waviness on water jacket, uneven liner insert thickness and a deflector platewherein internal bypass for coolant is routed to water pump from cylinder block itself by providing a cast passage from cylinder block water jacket return line to water pump suction side and helps in reaching early warm up which in turn benefits in achieving lower fuel consumption along with improved thermal reliability of the engine.
2. Light weight and compact HPDC aluminium cylinder block for the engine as claimed in claim 1 wherein wavy structure of the water jacket is provided that helps in achieving better cylinder bore distortion in front and rear.
3. Light weight and compact HPDC aluminium cylinder block for the engine as claimed in claim 1 wherein liner thickness ranges from 6 mm to 10 mm to get the minimum cylinder bore distortion.
4. Light weight and compact HPDC aluminium cylinder block for the engine as claimed in claim 1 wherein a sheet metal coolant deflector is pressed in the cylinder block that helps in diverting entire coolant to cylinder head on exhaust side where coolant is needed to take heat from exhaust ports and the said coolant deflector is placed in such way that it will have one side coolant entry into engine and the other side it will have coolant by pass outlet which eliminates the additional hoses connections.