An intake manifold of an integrated intercooler with a seal

Abstract

The present invention relates to an intake manifold of an integrated intercooler with a seal, which includes an intercooler, a high-temperature pressure stabilizing chamber, and a low-temperature pressure stabilizing chamber. The high-temperature pressure stabilizing chamber is provided with an air inlet, and a plurality of airway outlets are provided at the lower end of the low-temperature pressure stabilizing chamber; a plurality of hot air flow channels are arranged at the connection between the high-temperature pressure stabilizing chamber and the intercooler at the upper part of the intercooler, a coolant flow channel is arranged between adjacent hot air flow channels, and air fins are arranged in the hot air flow channels; seals are installed in the hot air flow channels at the first and last ends of the intercooler. The seal includes an integrally formed upper cover plate, a vertical connecting plate, and a V-shaped bottom plate. The V-shaped bottom plate is installed in the hot air flow channel and seals the hot air flow channel, which can reduce the hot air flow rate passing through the first and last ends of the intercooler and avoid excessive air from not being fully cooled and passing through the intercooler, improve the uniformity of heat exchange, and thus improve the uniformity of the outlet air temperature of each airway of the intake manifold.

Description

Technical Field

[0001] The present invention relates to the technical field of automotive engines, and particularly to an intake manifold of an integrated intercooler with a seal. Background Art

[0002] Currently, with the continuous tightening of automotive emission regulations, automotive engines are developing towards miniaturization, integration, and lightweighting. At the same time, some technologies that can reduce engine emissions have attracted increasing attention from vehicle manufacturers and the entire engine industry. As a key component of the intake system, in order to meet the requirements of lightweighting and integration and the requirements of the latest emission regulations, 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 the high-temperature and high-pressure gas from the turbocharger through the built-in intercooler, reduce the density of the intake air, increase the intake air volume of the engine, improve the charging efficiency, and introduce the gas into the corresponding engine combustion chambers through the airway design in the manifold, improve the engine performance, and at the same time reduce the emission of nitrogen oxides in the combustion chamber 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, considering the flammability of gasoline, during the compression stroke of the engine, since the inhaled gas is greatly compressed, the temperature in the combustion chamber will rise significantly. Therefore, the temperature of the gas introduced from the manifold airway needs to be strictly controlled to avoid pre-ignition due to the initial temperature in individual combustion chambers, resulting in knocking. The uniformity of the outlet gas temperature of different airways has become a key functional requirement for this type of manifold.

[0004] In the plastic intake manifold of an integrated intercooler, the intercooler is the main component for reducing the high-temperature gas from the turbocharger. Its working principle is to conduct heat exchange between the high-temperature gas and the low-temperature coolant through the internal flow channel structure. In order to improve the heat exchange capacity of the cooler, the hot air flow channels and the coolant flow channels in the intercooler are arranged alternately. However, in the conventional intercooler structure design, coolant flow channels cannot be arranged at the head and tail ends, and the side mounting plates need to be directly connected to the hot air flow channels, resulting in a significant reduction in the heat exchange capacity of the hot air flow at the head and tail ends compared to the hot air flow channels on the middle side, resulting in uneven distribution of the heat exchange capacity of the intercooler, and ultimately resulting in higher temperatures at the manifold outlet ports near the head and tail ends, affecting the uniformity of the outlet temperatures of each airway of the manifold. Summary of the Invention

[0005] The object of the present invention is to solve the problem that the outlet gas temperature deviation of each airway of the existing integrated intercooler intake manifold is large and the uniformity is poor due to the inability to arrange coolant flow channels in the hot air flow channels at the head and tail ends, and to provide an intake manifold of an integrated intercooler with a seal.

[0006] The object of the present invention is achieved by the following technical solutions:

[0007] An intake manifold of an integrated intercooler with a seal, comprising 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 high-temperature pressure stabilizing chamber is provided with an air inlet, and the lower end of the low-temperature pressure stabilizing chamber is provided with a plurality of air passage outlets; 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 arranged between adjacent hot air flow channels, and air fins are arranged in the hot air flow channels; seals are installed in the hot air flow channels at the first and last ends of the intercooler. The seal comprises an integrally formed upper cover plate, a vertical connecting plate, and a V-shaped bottom plate. The V-shaped bottom plate is installed in the hot air flow channel and seals the hot air flow channel.

[0008] It can reduce the hot air flow rate passing through the first and last ends of the intercooler, avoid excessive air from not being fully cooled and passing through the intercooler, improve the uniformity of heat exchange, and thus improve the uniformity of the outlet air temperature of each air passage of the intake manifold.

[0009] Further, the hot air flow channels are strip-shaped holes, and a plurality of hot air flow channels are arranged in parallel at equal intervals on the upper part of the intercooler.

[0010] Further, the air fins are uniformly installed in the hot air flow channels in a straight line to cool the passing hot air.

[0011] Further, coolant is introduced into the coolant flow channel to cool down the hot air flow channels and the air fins.

[0012] Further, the upper cover plate of the seal is a rectangular plate, the vertical connecting plate is vertically arranged in the middle of the lower part of the upper cover plate, and the V-shaped bottom plate is arranged at the lower end of the vertical connecting plate.

[0013] Further, the height of the seal is greater than the distance between the inner surface of the high-temperature pressure stabilizing chamber and the hot air flow channel. After the seal is installed, the upper part is pressed by the high-temperature pressure stabilizing chamber, so that the lower V-shaped bottom plate is tightly sealed on the inner wall of the hot air flow channel, ensuring that the seal will not fall off from the intercooler and drop into the high-temperature pressure stabilizing chamber during use, and ensuring the use and stability of the seal in the whole system.

[0014] Further, the V-shaped bottom plate has elasticity, and is preferably made of rubber material. The V-shaped bottom plate is installed in an interference fit with the inner wall of the hot air flow channel. The V-shaped bottom plate forms a sealing support angle. After the V-shaped bottom plate is installed in the hot air duct, the intercooler with the installed seal and the high-temperature pressure stabilizing chamber are installed together.

[0015] Further, the included angle between the V-shaped bottom plate and the vertical connecting plate is 30-60°.

[0016] Furthermore, the intercooler is in the shape of a square shell, and the high-temperature pressure stabilizing cavity gradually narrows from the cavity at the air inlet end.

[0017] Furthermore, three air passage outlets are provided at the lower part of the low-temperature pressure stabilizing cavity.

[0018] The specific working principle of the intake manifold of the present invention is as follows:

[0019] During the working process of the engine, the high-temperature and high-pressure gas from the turbocharger enters the intake manifold through the air inlet. The high-temperature gas enters the hot air flow channel after passing through the front high-temperature pressure stabilizing cavity. If there is no coolant flow channel arranged beside the hot air flow channel, the hot air entering the hot air flow channel cannot be sufficiently heat-exchanged with the coolant in the coolant flow channel to reduce its own temperature, which will lead to a large deviation in the outlet air temperature and poor uniformity at each air passage outlet of the manifold.

[0020] After the V-shaped seal is installed in the hot air flow channel of the present invention, the V-shaped seal and the hot air flow channel are in interference fit through the sealing support angle and the inner surface of the hot air flow channel. The V-shaped bottom plate of the V-shaped seal 3 is extruded by the inner surface of the hot air flow channel to generate a reaction force, thereby producing a sealing effect. The hot air cannot pass through the hot air flow channels at the head and tail ends of the intercooler, but turns to pass through the hot air flow channels on the middle side, so as to achieve the effect of being fully cooled and avoid the situation of uneven outlet air temperature at the head and tail ends of the intercooler. Then, the cooled air will flow out from different air passage outlets through the low-temperature pressure stabilizing cavity. Since the hot air passing through each hot air flow channel has fully participated in the heat exchange and cooling, the uniformity of the outlet air temperature of the manifold can be ensured.

[0021] In terms of installation and manufacturing, in the present invention, an interference fit is generated between the sealing angle arranged on the V-shaped seal and the inner surface of the hot air flow channel, and the height of the V-shaped seal is greater than the distance between the inner surface of the high-temperature pressure stabilizing cavity and the hot air flow channel, so as to ensure that the seal will not fall off from the intercooler and fall into the high-temperature pressure stabilizing cavity during use, and ensure the use and stability of the seal in the whole system. The seal can be made of rubber material. After the sealing support angle is first installed in the hot air duct, the intercooler with the installed seal and the high-temperature pressure stabilizing cavity are installed together.

[0022] Compared with the prior art, the present invention has the following advantages:

[0023] 1. Uniform outlet air temperature: The seal arranged in the hot air flow channel in the present invention will greatly reduce the air passing through the corresponding hot air flow channel, so as to avoid that excessive hot air cannot be sufficiently cooled, and improve the heat exchange and the uniformity of the outlet air temperature.

[0024] 2. Easy production: The V-shaped seal of the present invention is fixed together through the interference fit between the sealing angle and the inner surface of the hot air flow channel.

[0025] 3. Wide range of use: The conceptual design of the present invention can also reduce the outlet temperature of a single intercooler.

[0026] 4. Low manufacturing cost: The manufacturing process of the seal can use the existing manufacturing process of rubber parts. Brief Description of the Drawings

[0027] Figure 1 It is an exploded structural schematic diagram of the intake manifold of the present integrated intercooler;

[0028] Figure 2 It is a front view structural schematic diagram of the intake manifold of the present integrated intercooler;

[0029] Figure 3 is Figure 1 An enlarged structural schematic diagram of part B in;

[0030] Figure 4 is Figure 2 An enlarged structural schematic diagram of part A in. Detailed Embodiment

[0031] The present invention will be described in detail below with reference to the drawings and specific embodiments.

[0032] Such as Figure 1 , 2 , an intake manifold of an integrated intercooler with a seal, including an intercooler 6, a high-temperature pressure stabilizing chamber 2 installed on the upper part of the intercooler 6, and a low-temperature pressure stabilizing chamber 7 installed on the lower part of the intercooler 6. The intercooler 6 is in a square shell shape. The high-temperature pressure stabilizing chamber 2 is provided with an air inlet 1, and the cavity of the high-temperature pressure stabilizing chamber 2 gradually shrinks from one end of the air inlet 1. The lower part of the low-temperature pressure stabilizing chamber 7 is provided with an air passage outlet 8 (which is jointly composed of air passage outlets 81, 82, and 83).

[0033] On the upper part of the intercooler 6, several hot air flow channels 4 are arranged at the connection between the high-temperature pressure stabilizing chamber 2 and the intercooler 6. A coolant flow channel is provided between adjacent hot air flow channels 4. Wind fins 5 are arranged in the hot air flow channels 4. The hot air flow channels 4 are long strip-shaped channels, and multiple hot air flow channels 4 are arranged in parallel at equal intervals on the upper part of the intercooler 6. The wind fins 5 are evenly installed in the hot air flow channels 4 in a straight line to cool the passing hot air. Coolant is passed through the coolant flow channel to cool the hot air flow channels 4 and the wind fins 5.

[0034] Such as Figure 3, seals 3 are installed in the hot air flow channels 4 at the head and tail ends of the intercooler 6. The seal 3 includes an integrally formed upper cover plate, a vertical connecting plate, and a V-shaped bottom plate (sealing support angle 31). The V-shaped bottom plate is installed in the hot air flow channel 4 and seals the hot air flow channel 4. The upper cover plate of the seal 3 is a rectangular plate. The vertical connecting plate is vertically provided in the middle of the lower part of the upper cover plate. The V-shaped bottom plate is provided at the lower end of the vertical connecting plate.

[0035] As Figure 4 , the height H2 of the seal 3 is greater than the distance H1 between the inner surface of the high-temperature steady-pressure cavity 2 and the hot air flow channel 4. The width of the V-shaped bottom plate is greater than the width of the hot air flow channel 4. The included angle between the V-shaped bottom plate and the vertical connecting plate is 60°. After the seal 3 is installed, the upper part is pressed by the high-temperature steady-pressure cavity 2, so that the lower V-shaped bottom plate is tightly sealed on the inner wall of the hot air flow channel 4, ensuring that the seal 3 will not fall off from the intercooler 6 and fall into the high-temperature steady-pressure cavity 2 during use, and ensuring the use and stability of the seal 3 in the whole system. The V-shaped bottom plate has elasticity and is made of rubber material. The V-shaped bottom plate is installed in an interference fit with the inner wall of the hot air flow channel 4. The V-shaped bottom plate forms a sealing support angle. After the V-shaped bottom plate is installed in the hot air duct, the intercooler 6 with the seal 3 installed and the high-temperature steady-pressure cavity 2 are installed together.

[0036] The present invention adds a V-shaped seal 3 to reduce the hot air flow rate passing through the head and tail ends of the intercooler, so as to avoid excessive air not being fully cooled and passing through the intercooler, improve the uniformity of heat exchange, and thus improve the uniformity of the outlet temperatures of each air passage in the intake manifold; the V-shaped seal 3 and the hot air flow channel 4 are in interference fit through the sealing support angle 31 and the inner surface of the hot air flow channel 4. The sealing angle 31 on the V-shaped seal 3 is squeezed by the inner surface of the hot air flow channel 4 to generate a reaction force to achieve the sealing purpose. Due to the ingenuity of the V-shaped seal structure, the high-pressure and high-temperature gas in the high-temperature steady-pressure cavity 2 generates a certain opening force on the sealing support angle 31 of the seal 3, thereby increasing the acting force between the sealing support angle 31 and the inner surface of the hot air flow channel 4 and improving the sealing ability and reliability.

[0037] The specific working principle is as follows: during the operation of the engine, the high-temperature and high-pressure gas from the turbocharger enters the intake manifold through the intake port 1. The high-temperature gas enters the hot air flow channel 4 after passing through the front high-temperature pressure stabilizing chamber 2. There is no coolant flow channel arranged beside the hot air flow channel 4, so the hot air entering the hot air flow channel 4 cannot be sufficiently heat-exchanged with the coolant in the coolant flow channel to reduce its own temperature, which finally leads to a large deviation in the outlet air temperature of each airway of the manifold and poor uniformity. After placing the V-shaped seal 3 into the hot air flow channel 4, the V-shaped seal 3 and the hot air flow channel 4 are in interference fit through the sealing support angle 31 and the inner surface of the hot air flow channel 4. The sealing angle 31 on the V-shaped seal 3 is squeezed by the inner surface of the hot air flow channel 4 to generate a reaction force, thus producing a sealing effect. The hot air cannot pass through the hot air flow channel 4 at the head and tail ends of the intercooler 6, but turns to pass through the hot air flow channel on the middle side, so as to achieve the effect of being fully cooled and avoid the situation of uneven outlet air temperature at the head and tail ends of the intercooler. Then the cooled air will flow out from different airway outlets 8 through the low-temperature pressure stabilizing chamber 7. Since the hot air passing through each hot air flow channel has fully participated in the heat exchange and cooling, the uniformity of the temperature at the manifold outlet 81, 82, 83 can be ensured.

[0038] In terms of installation and manufacturing, in the present invention, an interference fit is generated between the sealing angle 31 arranged on the V-shaped seal 3 and the inner surface of the hot air flow channel, and the height H2 of the V-shaped seal is greater than the distance H1 between the inner surface of the high-temperature pressure stabilizing chamber and the hot air flow channel, so as to ensure that the seal will not fall off from the intercooler and fall into the high-temperature pressure stabilizing chamber 2 during use, ensuring the use and stability of the seal 3 in the whole system. The seal 3 is made of rubber material. The sealing support angle 31 can be first installed into the hot air duct 4, and then the intercooler 6 with the installed seal 3 and the high-temperature pressure stabilizing chamber 2 are installed together.

[0039] The above description of the embodiments is for the convenience of those of ordinary skill in the art to understand and use the invention. Obviously, those skilled in the art can easily make various modifications to these embodiments and apply the general principles described herein to other embodiments without creative labor. Therefore, the present invention is not limited to the above embodiments, and the improvements and modifications made by those skilled in the art without departing from the scope of the present invention according to the disclosure of the present invention should be within the protection scope of the present invention.

Claims

1. An intake manifold with an integrated intercooler having a seal, 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, wherein the high-temperature pressure stabilizing chamber is provided with an air inlet, and the lower end of the low-temperature pressure stabilizing chamber is provided with multiple airway outlets; 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; Sealing members are installed in the hot air flow passages at both ends of the intercooler along the arrangement direction of the hot air ducts, the sealing members comprising an integrally formed upper cover plate, a vertical connecting plate, and a V-shaped bottom plate, the V-shaped bottom plate being installed in the hot air flow passages and sealing the hot air flow passages; The hot air flow channel is a long strip channel, and a plurality of hot air flow channels are arranged in parallel at equal intervals on the upper part of the intercooler; The intercooler is in a square shell shape, and the high-temperature pressure stabilizing chamber gradually shrinks from the volume chamber at one end of the air inlet along the direction of gas flow.

2. The intake manifold with an integrated intercooler having a seal according to claim 1, characterized in that: The wind fins are evenly installed in the hot air flow channel in a straight line to cool the hot air passing through.

3. The intake manifold with an integrated intercooler having a seal according to claim 2, characterized in that: Cooling liquid is passed into the cooling liquid flow channel to cool the hot air flow channel and the air fins.

4. The intake manifold with an integrated intercooler having a seal according to claim 1, characterized in that: The sealing upper cover plate is a rectangular plate, the vertical connecting plate is vertically arranged in the middle of the lower part of the upper cover plate, and the V-shaped bottom plate is arranged at the lower end of the vertical connecting plate.

5. The intake manifold with an integrated intercooler having a seal according to claim 4, characterized in that: The height of the sealing member is greater than the distance between the inner surface of the high-temperature pressure stabilization chamber and the hot air flow channel.

6. The intake manifold with an integrated intercooler having a seal according to claim 5, characterized in that: The V-shaped bottom plate is elastic and is installed with an interference fit on the inner wall of the hot air flow channel.

7. The intake manifold with an integrated intercooler having a seal according to claim 6, characterized in that: The angle between the V-shaped bottom plate and the vertical connecting plate is 30-60°.

8. The intake manifold with an integrated intercooler having a seal 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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