Integral Cylinder Head with Exhaust Gas Recirculator

Abstract

The present disclosure provides "an integrated cylinder head with an exhaust gas recirculator". A powertrain system includes: an exhaust manifold having an exhaust gas flow and a control valve for releasing the exhaust gas; and a layered material defining an integrated engine cylinder head and an exhaust gas recirculator, the exhaust gas recirculator being connected to the exhaust gas flow and the valve, including a tubular inlet defining a plurality of branches around the cylinder head and having a plurality of nozzles extending into a cavity of an intake passage of the cylinder head. Each of the branches surrounds an outer surface of one of the intake passages in the intake passage, such that there is no seal between the recirculator and the cylinder head.

Description

Technical Field

[0001] Various embodiments relate to an integrated cylinder head for an internal combustion engine in a vehicle, the cylinder head being characterized by having an exhaust gas recirculator, and a method of manufacturing the cylinder head. Background Art

[0002] The cylinder head is part of the powertrain and serves as a housing for various engine components such as the intake manifold, exhaust valves, springs, tappets, and combustion chambers. The cylinder head is configured to distribute various fluids. Multiple channels or ports formed in the cylinder head allow gases such as ambient air and fuel to flow inside the cylinder. At the same time, the cylinder head allows the exhaust gas to flow out therefrom. The cylinder head also directs the coolant fluid into the engine block to cool down the engine components. Summary of the Invention

[0003] In at least one embodiment, a powertrain is disclosed. The system includes an exhaust manifold having an exhaust flow and a control valve for releasing the exhaust. The system further includes a layered material that defines an integrated engine cylinder head and an exhaust gas recirculator, the exhaust gas recirculator being connected to the exhaust flow and the valve, including a tubular inlet that defines a plurality of branches around the cylinder head and having a plurality of nozzles extending into the cavity of the intake passage of the cylinder head, each of the branches surrounding the outer surface of one of the intake passages in the intake passage such that there is no seal between the recirculator and the cylinder head. The branches may only partially surround the outer surface of one of the intake passages. The branches may be symmetric. Each of the plurality of nozzles may include a longitudinal body that narrows towards the cavity of one of the intake passages. The body may be cylindrical. Each of the plurality of nozzles may include a diverter that divides the exhaust flow when the exhaust flow enters the intake passage. The diverter may be tapered.

[0004] In an alternative embodiment, an exhaust gas recirculator is disclosed. The recirculator includes a curved layered tubular member that defines at least two nozzles on one side of the tubular member, each of the at least two nozzles having a longitudinal body and a tip having at least one hole, the tip extending into the cavity of the intake passage of the integrated cylinder head such that there is no seal between the tubular member and the cylinder head. The longitudinal body may narrow towards the cavity of the intake passage. The at least one nozzle may include a diverter. The diverter may be tapered on at least one side. There may be at least two types of diverters in the tubular member. The tubular member may include a plurality of nozzles regularly spaced apart from each other.

[0005] In yet another alternative embodiment, an engine component is disclosed. The engine component includes a stratified duct that forms an exhaust gas recirculator configured to reduce NOx of the engine and having two bent ends. The tubular member houses at least two nozzles that are capable of releasing NOx into a cavity of an intake passage of an integrated cylinder head via a tip having a plurality of holes such that there is no seal between the tubular member and the cylinder head. Each intake passage may include the stratified tubular member. The at least one nozzle may include a plurality of nozzles having different tips. The tip may include a diverter. The diverter may taper on at least one side. The layered tubular member may be connected to at least one other tubular member that forms the exhaust gas recirculator. The connection may be via a pipe fitting incorporated into the integrated cylinder head. BRIEF DESCRIPTION OF THE DRAWINGS

[0006] Figure 1 A schematic diagram showing a non - limiting example of an internal combustion engine capable of adopting various embodiments of the present disclosure;

[0007] Figure 2 A schematic perspective view showing an exemplary cylinder head employing the ports disclosed herein;

[0008] Figure 3 Showing Figure 2 A detailed view of a portion of the cylinder head depicted having an exemplary integral fluid delivery port;

[0009] Figures 4A to 4C Showing Figure 2 and Figure 3 various embodiments of a fluid distribution port integral with the cylinder head of;

[0010] Figure 5 Showing Figure 3 an alternative view of the intake passage and the integral fluid distribution port of the cylinder head of;

[0011] Figure 6 Showing Figure 5 a cross - sectional view of the fluid distribution port of;

[0012] Figure 7 Showing an alternative exemplary embodiment of a fluid distribution port within a cylinder head;

[0013] Figure 8 Showing Figure 7 different views of the fluid distribution port of;

[0014] Figure 9 Showing a non - limiting example of a nozzle having a tip for fluid distribution that projects into the interior of a cylinder head intake passage;

[0015] Figures 10A to 10C Shows an alternative exemplary embodiment of the nozzle of the fluid distribution port disclosed herein; and

[0016] Figure 11 Schematically shows the connection between the fluid supply device and the fluid distribution port. Detailed Description

[0017] Embodiments of the present disclosure are described herein. However, it should be understood that the disclosed embodiments are merely examples, and other embodiments may take various forms and alternative forms. The drawings are not necessarily to scale; some features may be exaggerated or minimized to show details of particular components. Thus, the specific structural and functional details disclosed herein should not be construed as limiting, but merely as a representative basis for teaching one skilled in the art to employ the invention in different ways. As will be understood by one of ordinary skill in the art, the various features shown and described with reference to any one of the drawings may be combined with features shown in one or more other drawings to produce embodiments not explicitly shown or described. Combinations of the features shown provide representative embodiments for typical applications. However, various combinations and modifications of the features consistent with the teachings of the present disclosure may be desired for a particular application or implementation.

[0018] Unless explicitly stated, all numerical quantities representing dimensions or material properties in this specification should be understood to be modified by the word "about" when describing the broadest scope of the present disclosure.

[0019] The first definition of an acronym or other abbreviation applies to all subsequent uses of the same abbreviation in this document and, with necessary changes, to normal grammatical variants of the initially defined abbreviation. Unless explicitly stated to the contrary, measurements of properties are determined by the same technique as that referenced for the same property before or after.

[0020] Reference is made in detail to the compositions, embodiments, and methods of the invention known to the inventors. However, it should be understood that the disclosed embodiments are merely examples of the invention, which may be embodied in various forms and alternative forms. Thus, the specific details disclosed herein should not be construed as limiting, but merely as a representative basis for teaching one skilled in the art to employ the invention in various ways.

[0021] An internal combustion engine includes an engine having one or more cylinders. Each of the cylinders is covered by a cylinder head that is placed above each cylinder and located on top of the cylinder block. The cylinder head closes at the top of the cylinder and thus forms a combustion chamber. Additionally, the cylinder head provides space for passages to feed fuel, ambient air, exhaust gas recirculation (EGR) gas, etc. as a mixture into the cylinder and to allow the exhaust gas to escape. The cylinder head may also be a suitable location for mounting a spark plug, valves, and fuel injectors.

[0022] The cylinder head is characterized by having a plurality of ports, passages, and / or conduits for directing various fluids to the cylinders and other components of the engine. The geometry, orientation, and design of the cylinder head have a direct impact on the efficiency of the internal combustion engine. Figure 1 A schematic non-limiting example of an internal combustion engine 20 is shown. The engine 20 has a plurality of cylinders 22, one of which is shown. The engine 20 can have any number of cylinders 22, including three, four, six, eight, or other numbers. The cylinders can be positioned in the engine in various configurations, such as a V-engine, an in-line engine, or other arrangements.

[0023] The exemplary engine 20 has a combustion chamber 24 associated with each cylinder 22. The cylinder 22 is formed by a cylinder wall 32 and a piston 34. The piston 34 is connected to a crankshaft 36. The combustion chamber 24 is in fluid communication with an exemplary intake manifold 38 and an exhaust manifold 40. An intake valve 42 controls the flow into the combustion chamber 24 from the intake manifold 38. An exhaust valve 44 controls the flow from the combustion chamber 24 to the exhaust manifold 40. The intake valve 42 and the exhaust valve 44 can be operated in various ways known in the art to control engine operation.

[0024] A fuel injector 46 delivers fuel directly from a fuel system into the combustion chamber 24 such that the engine is a direct injection engine. A low-pressure or high-pressure fuel injection system can be used with the engine 20, or an intake port injection system can be used in other examples. The ignition system includes a spark plug 48 that is controlled to provide energy in the form of a spark for igniting the fuel-air mixture in the combustion chamber 24. In other embodiments, other fuel delivery systems and ignition systems or techniques can be used, including compression ignition.

[0025] The engine 20 includes a controller and various sensors configured to provide signals to the controller for controlling air and fuel delivery to the engine, ignition timing, power and torque output from the engine, and the like. Engine sensors can include, but are not limited to, an oxygen sensor in the exhaust manifold 40, an engine coolant temperature sensor, an accelerator pedal position sensor, an engine manifold pressure (MAP) sensor, an engine position sensor for crankshaft position, an air mass sensor in the air intake manifold 38, a throttle position sensor, and the like.

[0026] In some embodiments, the engine 20 can be used as the sole prime mover in a vehicle, such as a conventional vehicle or a stop-start vehicle. In other embodiments, the engine can be used in a hybrid vehicle in which an additional prime mover, such as an electric motor, can be used to provide additional power to propel the vehicle.

[0027] Each cylinder 22 can operate in a four-stroke cycle, which includes an intake stroke, a compression stroke, a power stroke, and an exhaust stroke. In other embodiments, the engine can operate in a two-stroke cycle. During the intake stroke, the intake valve 42 is open and the exhaust valve 44 is closed while the piston 34 moves from the top of the cylinder 22 to the bottom of the cylinder 22 to introduce air from the intake manifold 38 into the combustion chamber 24. The position of the piston 34 at the top of the cylinder 22 is commonly referred to as top dead center (TDC). The position of the piston 34 at the bottom of the cylinder 22 is commonly referred to as bottom dead center (BDC).

[0028] During the compression stroke, the intake valve 42 and the exhaust valve 44 are closed. The piston 34 moves from the bottom of the cylinder 22 towards the top to compress the air within the combustion chamber 24.

[0029] Fuel is then introduced into the combustion chamber 24 and ignited. In the illustrated engine 20, fuel is injected into the chamber 24 and then ignited using the spark plug 48. In other examples, compression ignition can be used to ignite the fuel.

[0030] During the power stroke, the ignited fuel-air mixture within the combustion chamber 24 expands, causing the piston 34 to move from the top of the cylinder 22 to the bottom of the cylinder 22. The movement of the piston 34 causes a corresponding movement of the crankshaft 36 and provides a mechanical torque output from the engine 20.

[0031] During the exhaust stroke, the intake valve 42 remains closed and the exhaust valve 44 is open. The piston 34 moves from the bottom of the cylinder to the top of the cylinder 22 to remove exhaust gases and combustion products from the combustion chamber 24 by reducing the volume of the chamber 24. The exhaust flows from the combustion cylinder 22 to the exhaust manifold 40 and to a post-treatment system (such as a catalytic converter).

[0032] The position and timing of the intake valve 42 and the exhaust valve 44, as well as the fuel injection timing and ignition timing, can vary for the various engine strokes.

[0033] The engine 20 includes a cooling system for removing heat from the engine 20 and can be integrated into the engine 20 as a cooling jacket containing water or another coolant.

[0034] A cylinder head gasket 78 can be interposed between the cylinder block 76 and the cylinder head 79 to seal the cylinder 22.

[0035] Typically, a cylinder head is made of metal and / or ceramic. However, traditional manufacturing methods include multiple steps and / or multiple parts, such that the cylinder head is manufactured as separate parts that are subsequently assembled together. Even if the cylinder head is cast as a single piece, traditional metal forming and / or composite forming techniques (such as casting or molding) have manufacturing limitations regarding the geometry of the cylinder head. Thus, complex detail parts may be added only as separate pieces, thereby requiring many connecting parts. If the connecting parts are made of a different material than the cylinder head itself, then the connection is often a challenge, especially when the bonding is leak-proof. Therefore, the assembly can be time-consuming and increase the cycle time. Additionally, whenever at least two components need to be bonded, the necessary control checks are crucial to ensure that the bonding is properly provided. Such checks are expensive and increase the cycle time.

[0036] In one or more embodiments, a cylinder head 100 is disclosed herein that overcomes one or more of the above problems. Figure 2 A non-limiting example of the cylinder head 100 is shown, which can be used in Figure 1 an internal combustion engine 20 or in different internal combustion engine systems. The cylinder head 100 can be made of a metal such as iron, stainless steel, aluminum. Alternatively, the cylinder head 100 can be made of at least two types of materials including composites. Thus, the cylinder head 100 is characterized in that it can have parts made of polymeric materials, ceramics, composites, metals, or combinations thereof. The cylinder head 100 has such a geometry and materials that enable it to withstand combustion pressure and thermal loads, while allowing the cylinder head 100 to be lightweight and thus contribute to better fuel efficiency. Compared to cast iron or aluminum cylinder heads, the cylinder head 100 can have other advantages such as good corrosion resistance, thermal benefits (such as optimized heat transfer), maintained rigidity, and / or reduced number of machine operations during the production of the cylinder head.

[0037] The cylinder head 100 is characterized in that it can have the following components: one or more valve stem guides, an exhaust surface, one or more intake valve spring seats, one or more exhaust valve spring seats, a fire deck, one or more domes of one or more combustion chambers, one or more head bolt studs, or combinations thereof. The fire deck or cylinder head deck can include one or more intake passages and / or exhaust passages, which are passages leading from a manifold to the respective valves. Specifically, the cylinder head includes an exhaust passage leading to an exhaust manifold (not depicted).

[0038] Additionally, the cylinder head 100 includes one or more intake passages 102 that lead to or are connected to an intake manifold (not depicted), specifically from one or more flow passages of the intake manifold to the outlet of the intake manifold. Figure 3A more detailed view showing two intake passages 102 is presented. Each intake passage 102 includes an outer lower side 106 and an upper side 108.

[0039] The component, as well as many other components and / or parts, may be an integral part of the cylinder head 100 such that a portion of the cylinder head 100 gradually transitions into another portion of the cylinder head 100.

[0040] The depicted cylinder head 100 is characterized by having fluid ports 200 that can direct fluid into the cylinder head 100. The fluid can be used for various functions and for various destinations. The fluid can be an additive fluid, a service fluid, such as a fluid capable of cleaning a part of the engine or a fluid capable of improving engine performance. Exemplary fluids can include nitrous oxide, fuel injector cleaner, engine degreaser, crankcase conditioner, general cleaner, carburetor cleaner, etc., or combinations thereof. Other fluids such as exhaust or condensate are conceivable.

[0041] As Figures 4A to 4C Depicted, the fluid delivery port or ports 200 may include at least one pipe, conduit, fitting, or tube 201 having an inlet 202. The inlet can be tubular with a cross-section having the following shapes: symmetric, asymmetric, regular, irregular, circular, oval, square, rectangular, triangular, oblong, etc. The inlet 202 can be located on the outside of the cylinder head 100. For example, the inlet 202 can be positioned adjacent to the outer wall of the cylinder head 100, extend along the outer wall of the cylinder head 100, and / or extend perpendicular to the outer wall of the cylinder head 100. The tube 201 having the inlet 202 can also be an integral part of the cylinder head 100 body such that a portion of the tube 201 is an integral part of the cylinder head body, adjacent to the body, or forms part of the cylinder head body.

[0042] The port 200 may include one or more branches or arms 204 that extend into the interior of the cylinder head 100 such that there is no seal between the fluid delivery port 200 and the cylinder head 100. In other words, the port 200 and the cylinder head 100 are formed as an integral part, a layered one-piece, such that the port 200 seamlessly transitions into the cylinder head 100. The fluid delivery port 200 can include 2, 3, 4, 5, 6, 8, 10, or more branches 204. In at least one embodiment, a portion of the branch 204 can be located on the outside of the cylinder head 100 while another portion of the branch 204 can be located on the inside of the cylinder head 100.

[0043] Figure 4A A fitting 201 divided into two branches 204 is shown. In Figure 4BIn at least one alternative embodiment depicted, a single inlet 202 may supply fluid to four separate but interconnected branches 204. In Figure 4C In yet another alternative embodiment, the inlet 202 may transition into a single branch 204 that is independent of the additional pipe fittings 201, inlet 202, and branch 204.

[0044] As Figure 3 shown in detail, the individual branches 204 may approach the cylinder head 100 and attach to the outer surface of the cylinder head 100 at, adjacent to, or between one or more intake ports 102. As Figure 3 shown, the branch may approach the cylinder head 100 through a connection between two intake ports 110, specifically at the port underside 106.

[0045] The number and location of the branches 204 depend on the specific design of the cylinder head 100. For example, a single branch 204 may be dedicated to an intake port 102. In Figure 2 and Figure 3 In the alternative embodiments depicted, a single branch 204 supplies fluid to two wings 206, each wing 206 surrounding an intake port 102. In a non-limiting example, a single branch 204 may be connected to each wing 206 via a connector 210, as depicted, for example, in Figure 3 The connection may be a gradual transition from the branch 204 into the wing 206. The connection may be located at the end portion 212, central portion 214 of the wing 206, or within the curved portion of the wing 206.

[0046] In at least one embodiment, an example of which is shown in Figure 3 each branch 204 may further extend into a set of wings or sub-branches 206. The extension of the branch 204 into the set of wings 206 may form a bifurcated tube. The set of wings may include two adjacent wings 206. The division of the branch 204 into the set of wings 206 may be symmetric such that the division may include curved connectors 210 entering each wing 206 from the branch 204, one connector 210 bending at an angle to the right and a second connector 210 bending at an angle to the left. The angle may be 20 degrees, 30 degrees, 40 degrees, 45 degrees, 50 degrees, 60 degrees, 70 degrees, 75 degrees, 80 degrees, 90 degrees, or more degrees relative to the direction of the branch 204. The diameter of the connection may increase or decrease as the connection transitions into the wing 206.

[0047] The connector 210 gradually transitions from the branch 204 into the wing or sub-branch 206. The transition can be located at the end portion 212, the central portion 214 of the wing 206, or within the curved portion of the wing 206. It may be beneficial to place the connector 210 further away from the end portion 212 of the wing 206 to provide a uniform flow of fluid within the wing 206.

[0048] Each wing 206 can be symmetric or asymmetric. For example, each wing 206 can form a uniform or non-uniform curvature at each end 212. The wing 206 can be tubular or hollow, or form a tubular member or hollow member or duct to allow fluid to flow internally. The tubular curvature can enable the fluid to flow uniformly from the branch 204 through the wing 206 to a destination such as the nozzle 208, from which the fluid enters the internal cavity of the cylinder head 100.

[0049] Each wing 206 can form a semi-ring, semi-ellipse, quarter-ring, quarter-ellipse, 3 / 4-ring, 3 / 4-ellipse, entire ring or entire ellipse, circular ring, rounded rectangle, rounded square. Other lengths of the wing 206 are conceivable. In at least one embodiment, the wing 206 is characterized in that it can have a non-bent or non-oval shape such that the shape of the wing 206 can be a square or rectangular corner with sharp corners. However, with this design, it may be more difficult to achieve an optimal uniform flow of fluid.

[0050] The wing 206 can at least partially surround a part of the cylinder head 100, as Figure 3 depicted. For example, the wing 206 can partially or completely surround the intake passage 102. When the wing 206 partially or completely surrounds the intake passage 102, a part of the wing 206 can project through at least a part of the cylinder head 100 located between two adjacent intake passages 102 at the connection between the intake passages 110. Thus, the entire circumference or length of the intake passage 102, 3 / 4, 1 / 2, 1 / 4 or another part of the circumference of the intake passage 102 can be surrounded by the wing 206. In this case, the nozzle 208 present in the wing 206 can be provided only in a part of the wing 206 or in the entire length of the wing 206.

[0051] Each port 200 can include Figures 5 to 10COne or more nozzles 208 depicted therein. The number of nozzles can be different, depending on the needs of the specific application. The nozzles 208 can extend from the branches 204 or from the wings 206. For example, each branch 204 can include more than one nozzle 208. Alternatively, each wing 206 can include more than one nozzle 208. In a non-limiting example, the wing can include 1, 2, 3, 4, 5, 6, 7, 8, 9, 10 or more nozzles. The nozzles 208 can be the same or different in each wing 206, branch 204, port 200.

[0052] The branch 204 or the wing 206 can include nozzles 208 along its entire length or only along a portion of its length, as for example Figure 5 shown. The nozzles 208 can be spaced evenly or unevenly along the length of the branch 204 or the wing 206. For example, in a non-limiting exemplary embodiment where the wing 206 partially surrounds the intake passage 102, the nozzles 208 can be positioned along the entire length of the wing 206.

[0053] The nozzles 208 can have a body 216 and a tip 218, as Figure 5 and Figure 7 depicted. The body 216 can be elongate. The dimensions of the body 216 can be uniform or non-uniform. For example, the body 216 can narrow or widen in the direction from the port 200, branch 204, wing 206 towards the interior of the cylinder head 100. The width of the diameter of the nozzle 208 is sufficient for fluid to flow from the port 200 to the interior of the cylinder head 100. The diameter of the nozzle 208 can be smaller than the diameter of the branch 204, wing 206 or both. The diameter of the nozzle 208 can be one-eighth, one-quarter, one-half of the diameter of the branch 204, wing 206 or both. Alternatively, the diameter of the nozzle 208 can be one time, two times, three times, four times, five times, eight times or ten times smaller than the diameter of the branch 204, wing 206 or both.

[0054] Each nozzle 208 can have the same or different dimensions from the body 216. For example, nozzles 208 having a first diameter can be alternated with nozzles 208 having a second diameter, the second diameter being different from the first diameter. The first diameter can be smaller or larger than the second diameter. Third, fourth, fifth diameters can be envisioned, each of which is different from each other and from the first and second diameters. Alternatively, nozzles 208 having a first diameter can be the outermost nozzles 208, while nozzles 208 having a second diameter can be located between the outermost nozzles 208.

[0055] As Figure 5 and Figure 6 shown, the tip 218 can include a hole 220 and / or be flush with the inner surface 114 of the intake passage 102. Alternatively, asFigure 7 and Figure 8 As shown in Figure 8 , the tip 218 of the nozzle 208 can extend into the cavity of the cylinder head 100. Therefore, the tip 218 can form a notch. The extension can include only the tip 218 and / or another part of the nozzle 208. The tip 218 protruding into the internal space of the cylinder head 100 is further depicted in Figure 9 in further detail.

[0056] The position, purpose, angle, and other properties of the port 200 determine the shape of the nozzle 208, the tip 218, or both. For example, the tip 218 can have a conical, truncated conical, hemispherical, or domed shape with a rounded or pointed head. Other shapes can be envisioned. The tip 218 is characterized by having at least one hole or opening 220. There can be multiple openings 220, which are arranged, for example, in a part of the tip 218, around the entire circumference of the tip 218, in rows, regularly, or irregularly spaced from each other. As can be seen in the non-limiting example of Figure 9 , three rows of openings 220 can be included on each tip 218, and the openings 220 are present on half of the cavity of the tip 218 pointing to the intake passage 102. The rows are characterized by having the same or different openings 220. For example, the first row is characterized by having openings 220 with a diameter smaller than or larger than the openings 220 in the second row and / or the third row. The number of openings 220 in each row can be the same or different.

[0057] In Figure 5 and Figure 6 shown in the alternative embodiment, the nozzle 208 can have a circular opening 220 flush with the inner surface of the intake passage 102, and the nozzle 208 is characterized by having a plurality of splitters 222. The splitters 222 can be tapered or curved. The splitters 222 can be placed in various positions. The function of the splitters 222 is to assist in guiding the fluid in a specified direction to help disperse the fluid onto a desired surface or to avoid spraying the fluid onto a surface that may be vulnerable to high heat or other conditions due to the fluid being distributed into the cylinder head 100.

[0058] For example, depending on the type of fluid dispensed from the nozzle 208, it may be desirable to avoid spraying the separator 116, the central part of the intake passage 102 to avoid overheating of the surface of the separator 116. Additionally, it is generally desirable to avoid spraying the fluid onto the separator 116 because the fluid should advance into the internal passage of the cylinder head 100 rather than adhere to the wall of the intake passage 102. However, if a cleaning fluid for cleaning the internal space of the cylinder head 100 is supplied via the port 200, then it may be desirable to spray the cleaning fluid directly onto the wall. In this case, the splitters 222 can be precisely shaped to direct the fluid onto the separator 116 and / or other inner surfaces 114 of the intake passage 102.

[0059] In addition to the diverter 222, the nozzle 208 and / or the tip 218 may include one or more filters (not depicted) for purifying the fluid to be released into the cylinder head 100. Alternatively, one or more filters may be placed at any other location within the port 200, such as in the inlet 202, the branch 204, the wing 206, or a combination thereof.

[0060] In additional alternative embodiments, Figures 10A to 10C Depicted respectively are a nozzle 208 having a tip 218 with longitudinal holes 220, a nozzle 208 having a rounded tip 218 with a single hole 218, and a nozzle having holes 220 arranged around the entire circumference of the tip 218.

[0061] As mentioned above, the fluid can be nitrous oxide such that the port 200 is configured to connect to a supply device or reservoir of nitrous oxide and is a nitrous oxide delivery device or port suitable for increasing the power output of an internal combustion engine. A typical nitrous oxide delivery device is a single point entry system bolted to the intake manifold. Thus, a typical nitrous oxide delivery system requires many mechanical fittings and has a horn-shaped arrangement, which can be very complex and does not allow for the implementation of fine or even multiple orifices. The port 200 designed as a nitrous oxide port in the cylinder head 100 rather than a port in the intake manifold enables a finer and more uniform distribution of nitrous oxide without causing the disruption to the gas path typically caused by a single point entry system and delivering nitrous oxide closer to the combustion chamber.

[0062] The port 200 may have additional different functions, such as serving as an EGR device. An EGR device serves as a nitrogen oxide reduction device capable of recirculating a portion of the engine exhaust back to the engine cylinders. EGR gas that typically flows through the intake manifold is rich in gases inert to combustion, thereby acting as an absorber of combustion heat, which reduces the peak temperature in the cylinders.

[0063] A typical EGR inlet port is located upstream of the cylinder head, within the gooseneck of the intake manifold, downstream of the throttle body, or near the throttle body adapter area. The port is typically machined, leaving a port with sharp edges. Thus, when the EGR system is active, the exhaust is introduced into the air stream through a single location, which can cause disruption to the air stream. Additionally, due to the single entry point, the mixing of the exhaust with the gas is minimal.

[0064] To improve overall performance and engine efficiency, EGR gas can be directed via port 200, which is arranged to be configured to reduce NOx in the engine and capable of directly distributing NOx into the interior of the cylinder head 100 to an EGR device or exhaust gas recirculator. Thus, the travel of EGR gas via the intake manifold can be eliminated, and the EGR gas can be supplied closer to the cylinder via port 200. The exhaust gas recirculator designed as port 200 can be connected to an exhaust manifold that has an exhaust flow, pipes or pipe fittings, and a valve capable of releasing exhaust gas.

[0065] Additional advantages of port 200 configured as an exhaust gas recirculator can include: better mixing of the gas within the cylinder head 100, exhaust delivery closer to the combustion system, uniform exhaust dispersion that can contribute to and maintain a more stable combustion process, contributing to better thermal control of the system, and protecting the throttle body in the gooseneck tube that is vulnerable to high heat from being exposed to the high temperatures associated with reintroducing exhaust gas into the intake manifold. Thus, port 200 configured as an EGR device becomes part of the cooling device of the engine system.

[0066] Still alternatively, port 200 can be configured as a condensate port, which is configured to supply condensate from a heat exchanger (such as a charge air cooler) capable of collecting condensate to the engine. The connection between the heat exchanger and port 200 can be via pipe fittings, tubes, conduits, etc. or a combination thereof. A control valve can also be provided. A filter can be included in or before port 200 to remove any undesirable contaminants from the condensate.

[0067] Figure 11 The connection of the cylinder head 100 via port 200 to a supply device for fluid 500 is schematically shown. The supply device 500 can be a fluid reservoir, pond, collector, container, storage device, tank, part of the engine, part of the powertrain, exhaust manifold, heat exchanger, or other source. The supply can be continuous or discontinuous. The supply can be a one-time supply, such as a one-time fluid addition that allows fluid to be directly added to the inlet 202 from a container that is not part of the automotive system. For example, fluid can be provided from a container that can be discarded after the addition. The connection can be via pipe fittings, flows, tubes, pipes, pipelines, hoses, channels, passages, conduits, etc. The connection can include or not include a valve 502, which can be a control valve that allows fluid to flow from the supply device 500 to port 200 in a first set of cases and prevents fluid from flowing from the supply device 500 to port 200 in a second set of cases.

[0068] The cylinder head 100 may include more than one port 200, more than one inlet 201, or both. Each port 200 may be configured to supply the same or different fluids. Each port 200 may be connected to the same or different fluid supply devices 500. A single port 200 and / or inlet 201 may also be connected to more than one type of fluid such that the pipe fitting 203 may have a valve that may enable the first fluid, the second fluid, and / or the third fluid to be dispersed into the cylinder head 100 as needed, depending on which liquid is required.

[0069] A method of forming an integral cylinder head 100 and fluid delivery ports 200 is also disclosed herein. An enabler for producing the disclosed cylinder head 100 having the unique structural features depicted and described above may be additive manufacturing. Additive manufacturing processes involve techniques for building three-dimensional objects by adding layers on top of material layers. The material may be plastic, metal, concrete, etc. Additive manufacturing includes a variety of techniques such as three-dimensional printing, rapid prototyping, direct manufacturing, layered manufacturing, additive manufacturing, photopolymerization including stereolithography (SLA) and digital light processing (DLP), material jetting, binder jetting, material extrusion, powder bed fusion, sheet lamination, directed energy deposition, etc.

[0070] Early additive manufacturing focused on pre-production visualization models, manufacturing prototypes, etc. The quality of the manufactured articles determines their use, and vice versa. Early articles formed by additive manufacturing were generally not designed to withstand long-term use. Additive manufacturing equipment was also expensive, and speed was a barrier to the widespread use of additive manufacturing in high-volume applications. However, recently, additive manufacturing processes have become faster and less expensive. Additive manufacturing techniques have also improved in terms of the quality of the manufactured articles.

[0071] Any additive manufacturing technique can be used to produce the disclosed monolithic cylinder head 100 and ports 200, as additive manufacturing techniques operate on similar principles. The method can include; a computer, three-dimensional modeling software (computer-aided design or CAD), a machine capable of applying material to create the layered cylinder head 100, and a layered material. An exemplary method can also include; using a three-dimensional modeling program or a three-dimensional scanner to create a virtual design of the cylinder head 100 in a CAD file, the three-dimensional scanner for example making a three-dimensional digital copy of the cylinder head 100 from an already created cylinder head 100. The method can include: slicing the digital file, where each slice contains data such that the cylinder head 100 can be formed layer by layer. The method can include: reading each slice by a machine that applies the layered material. The method can include: adding successive layers of the layered material in liquid, powder, or sheet form and forming the cylinder head while joining each layer to the next layer such that there are few, if any, visually discernible marks of careful layer application. The layers form the above-described three-dimensional solid cylinder head having at least one intake passage and fluid delivery ports 200 such that the additive manufacturing process forms a one-piece monolith. The method can include: forming ports 200 configured to supply fluid to the cylinder head 100, such as an exhaust gas recirculator, nitrous oxide port, additive fluid port, working fluid port, or condensate port. The method can also include: forming additional features as an integral part of the cylinder head 100.

[0072] The additively manufactured cylinder head 100 with ports 200 may need to undergo one or more post-processing steps to produce the final three-dimensional object, such as a stabilization process. The stabilization process involves adjusting, modifying, enhancing, changing, protecting, maintaining, preserving, balancing, or altering one or more properties of the cylinder head 100 formed by additive manufacturing such that the formed cylinder head 100 meets predefined post-manufacture criteria.

[0073] The stabilized cylinder head 100 remains compliant with various criteria for hours, days, weeks, months, years, and / or decades after manufacture. The properties to be changed can relate to physical, chemical, optical, and / or mechanical properties. These properties can include dimensional stability, functionality, durability, abrasion resistance, fade resistance, chemical resistance, water resistance, ultraviolet (UV) resistance, heat resistance, memory retention, desired gloss, color, mechanical properties (such as toughness, strength, flexibility, extensibility), etc., or combinations thereof.

[0074] Additive manufacturing enables the formation of complex shapes, undulating shapes, smooth contours, and gradual transitions between adjacent segments or portions of the one-piece cylinder head 100, resulting in more uniform fluid distribution to the engine. For example, additive manufacturing enables the formation of complex shapes such as branches 204, wings 206, connectors 210, nozzles 208, tips 218, holes 220, splitters 222, etc. The cylinder head 100 and one or more ports 200 formed by the above method may not have any fasteners, adhesives, or other types of bonding typical for traditional cylinder head manufacturing.

[0075] While the above describes exemplary embodiments, it does not mean that these embodiments describe all possible forms of the present disclosure. On the contrary, the words used in this specification are descriptive rather than restrictive, and it should be understood that various changes can be made without departing from the spirit and scope of the present invention. Additionally, the features of the embodiments of various implementations can be combined to form additional embodiments of the present disclosure.

[0076] According to the present invention, there is provided a powertrain having: an exhaust manifold having an exhaust flow and a control valve for releasing the exhaust; and a layered material defining an integrated engine cylinder head and an exhaust gas recirculator, the exhaust gas recirculator being connected to the exhaust flow and the valve, including a tubular inlet defining a plurality of branches around the cylinder head and having a plurality of nozzles extending into a cavity of an intake passage of the cylinder head, each of the branches surrounding an outer surface of one of the intake passages in the intake passage such that there is no seal between the recirculator and the cylinder head.

[0077] According to one embodiment, the branch only partially surrounds the outer surface of one of the intake passages in the intake passage.

[0078] According to one embodiment, the branch is symmetric.

[0079] According to one embodiment, each of the plurality of nozzles includes a longitudinal body that narrows towards a cavity of one of the intake passages in the intake passage.

[0080] According to one embodiment, the body is cylindrical.

[0081] According to one embodiment, each of the plurality of nozzles includes a splitter that divides the exhaust flow when the exhaust flow enters the intake passage.

[0082] According to one embodiment, the splitter is tapered.

[0083] According to the present invention, an exhaust gas recirculator is provided, which has: a curved layered tubular member that defines at least two nozzles located on one side of the tubular member, each of the at least two nozzles having a longitudinal body and a tip with at least one hole, the tip extending into a cavity of an intake passage of an integrated cylinder head such that there is no seal between the tubular member and the cylinder head.

[0084] According to one embodiment, the longitudinal body tapers towards the cavity of the intake passage.

[0085] According to one embodiment, at least one nozzle includes a diverter.

[0086] According to one embodiment, the diverter tapers on at least one side.

[0087] According to one embodiment, there are at least two types of diverters in the tubular member.

[0088] According to one embodiment, the tubular member includes a plurality of nozzles regularly spaced apart from each other.

[0089] According to the present invention, an engine component is provided, which has: a layered duct that forms an exhaust gas recirculator configured to reduce NOx of the engine and has two curved ends, the tubular member accommodating at least two nozzles that can release NOx into a cavity of an intake passage of an integrated cylinder head via a tip with a plurality of holes such that there is no seal between the tubular member and the cylinder head.

[0090] According to one embodiment, each intake passage includes the layered tubular member.

[0091] According to one embodiment, at least one nozzle includes a plurality of nozzles with different tips.

[0092] According to one embodiment, the tip includes a diverter.

[0093] According to one embodiment, the diverter tapers on at least one side.

[0094] According to one embodiment, the layered tubular member is connected to at least one other tubular member that forms the exhaust gas recirculator.

[0095] According to one embodiment, the connection is via a pipe fitting incorporated into the integrated cylinder head.

Claims

1. A power transmission system, comprising: An exhaust manifold having an exhaust flow and a control valve for releasing the exhaust; And A layered material defining an integrated engine cylinder head and an exhaust gas recirculator, the exhaust gas recirculator being connected to the exhaust flow and the control valve, including a tubular inlet defining a plurality of branches around the cylinder head and having a plurality of nozzles in a cavity of an intake passage extending into the cylinder head, each of the branches surrounding an outer surface of one of the intake passages in the intake passage, such that there is no seal between the exhaust gas recirculator and the cylinder head.

2. The power transmission system according to claim 1, wherein the branch only partially surrounds the outer surface of one of the intake passages.

3. The power transmission system according to claim 1 or 2, wherein the branch is symmetric.

4. The power transmission system according to any one of claims 1 or 2, wherein each of the plurality of nozzles includes a diverter that divides the exhaust flow when the exhaust flow enters the intake passage.

5. The power transmission system according to claim 4, wherein the diverter tapers on at least one side.

6. An exhaust gas recirculator, comprising: A curved layered tubular member defining at least two nozzles on one side of the curved layered tubular member, each of the at least two nozzles having a longitudinal body and a tip having at least one hole, the tip extending into a cavity of an intake passage of a cylinder head integrated with the exhaust gas recirculator, such that there is no seal between the curved layered tubular member and the cylinder head.

7. The exhaust gas recirculator according to claim 6, wherein the longitudinal body narrows toward the cavity of the intake passage.

8. The exhaust gas recirculator according to claim 6 or 7, wherein the at least one nozzle includes a diverter.

9. The exhaust gas recirculator according to any one of claims 6 or 7, wherein there are at least two types of diverters in the curved layered tubular member.

10. The exhaust gas recirculator according to any one of claims 6 or 7, wherein the curved layered tubular member includes a plurality of nozzles regularly spaced apart from each other.

11. The exhaust gas recirculator according to claim 8, wherein the diverter tapers on at least one side.

12. An engine component, comprising: A layered tubular member forming an exhaust gas recirculator configured to reduce NOx of the engine and having two curved ends, the layered tubular member accommodating at least two nozzles capable of releasing NOx into a cavity of an intake passage of an integrated cylinder head via a tip having a plurality of holes, wherein the exhaust gas recirculator is integrated with the cylinder head such that there is no seal between the layered tubular member and the cylinder head.

13. The engine component according to claim 12, wherein each intake passage includes the layered tubular member.

14. The engine component according to claim 12 or 13, wherein the tip includes a diverter.

15. The engine component according to any one of claims 12 or 13, wherein the layered tubular member is connected to at least one other layered tubular member forming the exhaust gas recirculator.

16. The engine component according to claim 15, wherein the connection is via a pipe fitting incorporated into the integrated cylinder head.

17. The engine component according to claim 14, wherein the diverter tapers on at least one side.

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