An integrated intercooler-equipped intake manifold with a deflector

Abstract

The application relates to an integrated intercooler air intake manifold with a guide plate, comprising an intercooler, a high-temperature stable pressure cavity installed on the upper portion of the intercooler, and a low-temperature stable pressure cavity installed on the lower portion of the intercooler, the inlet of the high-temperature stable pressure cavity is connected with a gas guide pipe, the lower end of the low-temperature stable pressure cavity is provided with a plurality of air channel outlets, and a guide plate with the function of changing the flow direction of high-temperature gas is arranged at the inlet of the high-temperature stable pressure cavity. The guide plate of the application can change the flow direction of high-temperature gas from the gas guide pipe, so that the gas can pass through the intercooler more uniformly, and the purpose of improving the heat exchange capacity and uniformly reducing the temperature can be achieved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of automobile engine, in particular to an integrated intercooler intake manifold with flow guide plates. BACKGROUND

[0002] At present, with the increasingly stringent automobile emission regulations, automobile engines are developing towards miniaturization, integration and lightweight, and some technologies that can reduce engine emissions are also increasingly valued by vehicle manufacturers and the entire engine industry. As a key component of the intake system, the automobile engine intake manifold needs to meet the requirements of lightweight, integration and the latest emission regulations. Therefore, the integrated intercooler intake manifold has become a development trend at home and abroad. The integrated intercooler intake manifold can significantly reduce the temperature of high-temperature and high-pressure gas from the turbocharger through the built-in intercooler, reduce the density of intake air, increase the intake volume of the engine, improve the charging efficiency, and guide the gas into the corresponding combustion chamber of the engine through the gas passage design in the manifold, thereby improving the engine performance and reducing the emission of nitrogen oxides by reducing the temperature in the combustion chamber.

[0003] However, since gasoline engine combustion requires ignition by a spark plug within a specific time window, and considering the flammability of oil, the temperature in the combustion chamber will rise significantly during the compression stroke due to the substantial compression of the intake gas. Therefore, the temperature of the gas introduced from the manifold gas passage needs to be strictly controlled to avoid pre-ignition and knocking in individual combustion chambers due to the initial temperature. The uniformity of the gas temperature in different gas passages has become a key functional requirement for this type of manifold.

[0004] Due to engine layout requirements, the existing plastic intake manifold intake chamber needs to meet the functional requirements of uniformly introducing high-temperature gas to the windward surface of the intercooler and resisting the pressure and vibration impact of high-temperature and high-pressure gas generated during engine operation. The existing intake manifold uses a welding method of multiple plastic shells to produce the high-temperature end intake chamber. Since the plastic product has a weak point in strength near the welding surface after welding, and the existing welding process cannot weld plastic gas chambers with high strength, and each single piece of the piece-welded gas chamber needs to be produced in advance through a plastic injection molding process, this production process cannot produce plastic gas chambers with internal structures, making it difficult to meet the use requirements. SUMMARY

[0005] The purpose of the present application is to provide an integrated intercooler intake manifold with flow guide plates to solve the above problems.

[0006] The purpose of the present application is achieved by the following technical solutions:

[0007] The application discloses an integrated intercooler intake manifold with a guide plate, which comprises an intercooler, a high-temperature stable cavity installed on the upper part of the intercooler and a low-temperature stable cavity installed on the lower part of the intercooler, the inlet of the high-temperature stable cavity is connected with a gas guide pipe, the lower end of the low-temperature stable cavity is provided with a plurality of air outlet channels, and a guide plate with the function of changing the flow direction of high-temperature gas is arranged at the inlet of the high-temperature stable cavity. The guide plate can change the flow direction of high-temperature gas from the gas guide pipe, so that the gas can pass through the intercooler more uniformly, thereby improving the heat exchange capacity and achieving the purpose of uniform temperature reduction.

[0008] Further, the guide plate is a rectangular plate provided with a plurality of air holes, the arrangement direction of the guide plate is parallel to the air flow direction of high-temperature gas entering the inlet of the high-temperature stable cavity, the uniformity of hot air flow through the intercooler can be optimized by changing the number and size of the air holes, and the temperature uniformity of the air outlet channels can be optimized.

[0009] Further, the guide plate is inserted into the inner wall of the high-temperature stable cavity on both sides.

[0010] Further, the inner wall of the high-temperature stable cavity is provided with a nail-shaped column, the guide plate is provided with a nail-shaped cap matched with the nail-shaped column, and the nail-shaped cap is installed on the nail-shaped column, so that the guide plate is installed on the inner wall of the high-temperature stable cavity. The guide plate is installed on the nail-shaped column through a hot tenon process, the slicing and welding step is omitted, the installation and manufacturing are more convenient, and the direction of the guide plate can be flexibly adjusted according to the direction of high-temperature gas to achieve the purpose of optimizing the outlet air temperature.

[0011] Further, the gas guide pipe comprises a rear-end gas guide pipe and a front-end gas guide pipe, and the front-end gas guide pipe is provided with an air inlet.

[0012] Further, the rear-end gas guide pipe and the front-end gas guide pipe are formed through one-time injection molding by two opposite rotating core pulling actions of an injection mold, so that the slicing and welding process is avoided, and the structural strength is improved.

[0013] Further, a plurality of hot air flow channels are arranged on the upper part of the intercooler at the connection between the high-temperature stable cavity and the intercooler, cooling liquid flow channels are arranged between adjacent hot air flow channels, and air fins are arranged in the hot air flow channels.

[0014] Further, the hot air flow channels are long strip-shaped holes, a plurality of hot air flow channels are arranged in parallel at equal intervals on the upper part of the intercooler, the air fins are uniformly installed in the hot air flow channels in a character type, the hot air passing through is cooled, and cooling liquid is introduced into the cooling liquid flow channels to cool and lower the temperature of the hot air flow channels and the air fins.

[0015] Further, the intercooler is a square shell, and the high-temperature stable cavity gradually narrows from one end of the air inlet.

[0016] Further, the low-temperature stable cavity lower part is provided with three airway outlets.

[0017] The specific working principle of the integrated intake manifold of the intercooler is as follows: during the working process of the engine, high-temperature and high-pressure gas from the turbocharger enters the intake manifold through the intake port, the high-temperature gas enters the high-temperature stable cavity through the gas guide pipe, after the high-temperature gas passes through the intercooler, the gas enters the low-temperature stable cavity after the temperature of the gas is reduced, and then enters the combustion chamber of the engine through the airway outlet.

[0018] The flow guide plate can change the flow direction of the high-temperature gas from the rear-end gas guide pipe, so that the gas passes through the intercooler more uniformly, thereby improving the heat exchange capacity and achieving the purpose of uniform temperature reduction; and the number and size of the air holes can be changed to further optimize the uniformity of the hot air flow through the intercooler, thereby optimizing the temperature uniformity of the air outlet.

[0019] From the aspect of installation and manufacturing, the flow guide plate is fixed in the high-temperature stable cavity by a nail-shaped cap formed by a thermal dowel process; from the aspect of product strength, the front-end gas guide pipe and the rear-end gas guide pipe of the high-temperature end shell can be integrally formed by using a core-pulling structure in the injection mold, thereby omitting the piece welding process, improving the strength, and saving the cost.

[0020] Compared with the prior art, the present application has the following advantages:

[0021] 1. Uniform gas outlet temperature: the independent flow guide plate with built-in air holes and fixed by a nail-shaped cap can optimize the temperature uniformity of the gas outlet, and the number and size of the air holes can be adjusted or cancelled. It is flexible and easy to produce.

[0022] 2. High structural strength: the high-temperature end shell of the present application is designed to be integrally formed by one injection molding through two opposite rotational core-pulling actions in the injection mold, thereby avoiding the piece welding process and improving the structural strength.

[0023] 3. Wide range of applications: the direction of the flow guide plate can be adjusted flexibly according to the direction of the high-temperature gas to optimize the outlet temperature.

[0024] 4. Low manufacturing cost: the flow guide plate is fixed by a thermal dowel process, and the high-temperature end shell is integrally formed by omitting the piece welding process. BRIEF DESCRIPTION OF DRAWINGS

[0025] Figure 1 It is an exploded structural schematic view of the intake manifold of the present application;

[0026] Figure 2 It is a front view structural schematic view of the intake manifold;

[0027] Figure 3 This is a schematic diagram of the installation of the guide plate in the high-temperature pressure stabilization cavity of the intake manifold;

[0028] Figure 4 for Figure 3 Schematic diagram without the deflector plate;

[0029] In the figure: air inlet 1, front air duct 2, rear air duct 3, high-temperature pressure stabilizing chamber 4, guide plate 5, intercooler 6, low-temperature pressure stabilizing chamber 7, air duct outlet 8 (composed of air outlets 81, 82, 83), nail-shaped cap 9, nail-shaped column 10, vent 11. DETAILED DESCRIPTION

[0030] The present invention will be described in detail below with reference to the accompanying drawings and specific embodiments.

[0031] like Figure 1 、 2 An intake manifold with an integrated intercooler and a deflector includes an intercooler 6, a high-temperature stabilizing chamber 4 mounted above the intercooler 6, and a low-temperature stabilizing chamber 7 mounted below the intercooler 6. The inlet of the high-temperature stabilizing chamber 4 is connected to an air duct, and the lower end of the low-temperature stabilizing chamber 7 is provided with multiple airway outlets 8. A deflector 5 is provided at the inlet of the high-temperature stabilizing chamber 4 to redirect the high-temperature gas flow. The deflector 5 redirects the high-temperature gas from the air duct, allowing the gas to flow more evenly through the intercooler 6, thereby improving heat exchange capacity and achieving uniform temperature reduction.

[0032] like Figure 3 The guide plate 5 is a rectangular plate with a plurality of vent holes 11. The arrangement direction thereof is parallel to the airflow direction of the high-temperature gas entering through the inlet of the high-temperature pressure stabilizing chamber 4. Both sides of the guide plate 5 are plugged into the inner wall of the high-temperature pressure stabilizing chamber 4. The uniformity of the hot air flow through the intercooler 6 can be optimized by changing the number and size of the vent holes 11, thereby optimizing the uniformity of the air duct outlet temperature.

[0033] like Figure 4 The inner wall of the pressure stabilizing chamber is provided with a spike-shaped column 10. Spike-shaped caps 9 are provided on both sides of the guide plate 5 to match the spike-shaped columns 10. The spike-shaped caps 9 are mounted on the spike-shaped columns 10, so that the guide plate 5 is mounted on the inner wall of the high-temperature pressure stabilizing chamber 4. The guide plate 5 is mounted on the spike-shaped columns 10 by a hot doweling process, which omits the step of separate piece welding, making installation and manufacturing more convenient. The direction of the guide plate 5 can be flexibly adjusted according to the direction of the high-temperature gas to achieve the purpose of optimizing the outlet gas temperature.

[0034] The air duct includes a rear end air duct 3 and a front end air duct 2. The front end air duct 2 is provided with an air inlet 1. The rear end air duct 3 and the front end air duct 2 are made by one-time injection molding through two opposite direction rotating core pulling actions in the injection mold, avoiding the fragmentation welding process and improving the structural strength.

[0035] In addition, the upper portion of the intercooler 6 is arranged with several hot air flow channels at the connection between the high-temperature stable pressure chamber 4 and the intercooler 6, cooling liquid flow channels are arranged between adjacent hot air flow channels, and air fins are arranged in the hot air flow channels. The hot air flow channels are long strip-shaped holes, and a plurality of hot air flow channels are arranged in parallel at equal intervals on the upper portion of the intercooler 6. The air fins are uniformly installed in the hot air flow channels in a character type, cool the passing hot air, and the cooling liquid flow channels pass in cooling liquid to cool and lower the temperature of the hot air flow channels and the air fins. The intercooler 6 is a square shell, and the high-temperature stable pressure chamber 4 gradually narrows from the air inlet end cavity. The lower portion of the low-temperature stable pressure chamber 7 is provided with three air outlet ports 81, 82 and 83.

[0036] The specific working principle of the intake manifold of the integrated intercooler is as follows:

[0037] In the working process of the engine, high-temperature and high-pressure gas from the turbocharger enters the intake manifold through the air inlet 1. The high-temperature gas enters the high-temperature stable pressure chamber 44 through the front air guide pipe 2 and the rear air guide pipe 3. After the high-temperature gas passes through the intercooler 6, the gas is lowered in temperature and enters the low-temperature stable pressure chamber 7. Then, the gas enters the combustion chamber of the engine through the air outlet 8.

[0038] The flow guide plate 5 of the present application can change the flow direction of the high-temperature gas from the rear air guide pipe 3, so that the gas passes through the intercooler 6 more uniformly, thereby improving the heat exchange capacity and achieving the purpose of uniform cooling. In addition, the number and size of the air holes 11 can be changed to further optimize the uniformity of the hot air flow through the intercooler 6, thereby optimizing the temperature uniformity of the air outlet ports 81, 82 and 83.

[0039] From the aspect of installation and manufacturing, the flow guide plate 5 of the present application is fixed in the high-temperature stable pressure chamber 4 by forming a nail-shaped cap 9 from a nail-shaped column 10 through a hot tenon process.

[0040] From the aspect of product strength, the high-temperature end shell (composed of the front air guide pipe 2, the rear air guide pipe 3, the high-temperature stable pressure chamber 4 and the nail-shaped column 10) in the present application is designed as shown in Figure 4 The front air guide pipe 2 and the rear air guide pipe 3 can be integrally formed in the injection mold using the core pulling structure with the rotation direction as shown by the two arrows, which omits the piece welding process, improves the strength and saves the cost.

[0041] The present application innovatively adds an independent flow guide plate 5 to improve the uniformity of the outlet gas temperature at the air outlet port 8; as Figure 4As shown, the front end and rear end gas guide pipes of the high-temperature gas chamber design can be manufactured at one time through two rotary cores on the injection mold, avoiding the process of multiple welding; in the structure, the temperature uniformity at the air outlet 8 can be optimized through the air holes on the flow guide plate 5; the flow guide plate 5 in the structure is fixed inside the high-temperature stable pressure chamber 4 through the nail cap 9 formed by the hot tenon process.

[0042] The above description of the embodiments is for the purpose of enabling a person of ordinary skill in the art to understand and use the application. Those skilled in the art can easily make various modifications to these embodiments and apply the general principles described herein to other embodiments without having to go through creative labor. Therefore, the present application is not limited to the above embodiments, and improvements and modifications made by those skilled in the art without departing from the scope of the present application should be within the scope of protection of the present application.

Claims

1. An intake manifold with an integrated intercooler and a guide plate, characterized in that: It includes an intercooler, a high-temperature pressure-stabilizing chamber installed on the upper part of the intercooler, and a low-temperature pressure-stabilizing chamber installed on the lower part of the intercooler. The inlet of the high-temperature stabilizing chamber is connected to the air guide pipe, the lower end of the low-temperature stabilizing chamber is provided with multiple airway outlets, and the inlet of the high-temperature stabilizing chamber is provided with a guide plate having the function of changing the flow direction of the high-temperature gas; Both sides of the guide plate are plugged into the inner wall of the high-temperature pressure stabilizing chamber; A nail-shaped column is provided on the inner wall of the high-temperature pressure-stabilizing chamber, and nail-shaped caps matching the nail-shaped columns are provided on both sides of the guide plate. The nail-shaped caps are mounted on the nail-shaped columns, so that the guide plate is mounted on the inner wall of the high-temperature pressure-stabilizing chamber. The guide plate is mounted on the nail-shaped caps on the nail-shaped columns by a hot tenoning process, omitting the piece-by-piece welding step, making installation and manufacturing more convenient, and the direction of the guide plate can be flexibly adjusted according to the direction of the high-temperature gas to achieve the purpose of optimizing the outlet gas temperature; The airway tube includes a rear airway tube and a front airway tube; The rear end air guide tube and the front end air guide tube are manufactured by one-time injection molding through two rotating core-pulling actions in opposite directions in an injection mold, thereby avoiding a piece-by-piece welding process and improving structural strength.

2. The intake manifold with an integrated intercooler and a guide plate according to claim 1, characterized in that: The guide plate is a rectangular plate provided with a plurality of vent holes, and its arrangement direction is parallel to the airflow direction of the high-temperature gas entering through the inlet of the high-temperature pressure stabilizing chamber.

3. The intake manifold with an integrated intercooler and a guide plate according to claim 1, characterized in that: The front end air guide pipe is provided with an air inlet.

4. The intake manifold with an integrated intercooler and a guide plate according to claim 1, characterized in that: A plurality of hot air flow channels are arranged at the connection between the high-temperature pressure stabilizing chamber and the intercooler on the upper part of the intercooler, a coolant flow channel is provided between adjacent hot air flow channels, and wind fins are provided in the hot air flow channels.

5. The intake manifold with an integrated intercooler and a guide plate according to claim 4, characterized in that: The hot air flow channel is a long strip-shaped channel, and multiple hot air flow channels are arranged in parallel at equal intervals on the upper part of the intercooler. The wind fins are evenly installed in the hot air flow channel in a straight line to cool the hot air passing through. Coolant is introduced into the coolant flow channel to cool the hot air flow channel and the wind fins.

6. The intake manifold with an integrated intercooler and a guide plate according to claim 1, characterized in that: The intercooler is in a square shell shape, and the high-temperature pressure stabilizing cavity gradually shrinks from one end of the air inlet.

7. The intake manifold with an integrated intercooler and a guide plate according to claim 1, characterized in that: The lower part of the low-temperature pressure stabilization chamber is provided with three airway outlets.

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