An engine with integrated intercooler and cylinder head

Abstract

The application discloses an engine integrated with a cylinder cover and a middle cooler, which comprises an engine, a cylinder cover and a middle cooler body; the engine comprises an oil pan, a cylinder body, an electronic air conditioner, an electronic water pump, a three-way catalyst, a supercharger, a high-pressure oil pump, an oil cooler and an oil filter; the oil pan is fixedly installed at the lower part of the cylinder body, and the cylinder cover is fixedly installed at the upper part of the cylinder body; a plurality of air inlet channels, a spark plug mounting hole, an oil injector mounting hole and a middle cooler connecting flange are arranged on the cylinder cover. The middle cooler is optimized in structure, and a partition plate and a flow distribution plate are added. The middle cooler is directly installed on the cylinder cover of the engine, the air intake manifold is cancelled, the air flow path is shortened, the air intake uniformity of each cylinder of the engine is improved, the flow resistance is reduced, and the economy and power of the engine are improved. The number of parts is reduced, so that the cost, weight and volume of the engine are reduced.

Description

Technical Field

[0001] This invention integrates the field of engine technology, and more specifically, it relates to an engine with an integrated intercooler and cylinder head. Background Technology

[0002] Turbocharged range-extending engines and hybrid engines utilize water-cooled intercoolers. The airflow path is compressor → intercooler → throttle body → intake manifold pressure regulating chamber → intake manifold → intake passage → cylinder. This intake path is complex and results in high flow resistance. From an engine layout perspective, this intake method inevitably requires placing the throttle body at the front or rear of the engine, leading to uneven air intake across cylinders and affecting combustion uniformity. Furthermore, the long intake path and numerous parts contribute to a larger engine size, higher cost, and heavier weight. Therefore, a new technical solution is needed to address this issue. Summary of the Invention

[0003] The purpose of this invention is to provide an engine with an intercooler integrated with the cylinder head, which solves the problems mentioned in the background art.

[0004] To achieve the above objectives, the present invention provides the following technical solution: an engine with an integrated intercooler and cylinder head, comprising: an engine, a cylinder head, and an intercooler body; the engine includes an oil pan, a cylinder block, an electronic air conditioner, an electronic water pump, a three-way catalytic converter, a turbocharger, a high-pressure oil pump, an oil cooler, and an oil filter; the oil pan is fixedly installed on the lower part of the cylinder block and the cylinder head is fixedly installed on the upper part of the cylinder block; the cylinder head is provided with multiple intake ports, spark plug mounting holes, fuel injector mounting holes, and an intercooler connecting flange; the bottom of the intercooler body is provided with an intercooler mounting flange, and the intercooler mounting flange has an intercooler mounting hole; the intercooler connecting flange is provided with an intercooler mounting threaded hole, and the intercooler body is screwed into the intercooler mounting bolt through the intercooler mounting hole. The intercooler body is fixedly installed on the upper part of the cylinder head via a threaded hole. The interior of the intercooler body contains a cooling core tube and a first baffle, a second baffle, a third baffle, and a flow distribution plate arranged sequentially along the airflow direction. One end of the intercooler body has an intercooler inlet, and a throttle valve mounting flange is fixed at the inlet. A throttle valve body is mounted on the throttle valve mounting flange, and the outlet of the throttle valve body communicates with the intercooler inlet. The intercooler body has an inlet housing and an outlet housing. The inlet housing contains an inlet body, and the outlet housing contains an outlet body. The inlet body and outlet body communicate with the inlet and outlet ends of the cooling core tube, respectively. The outlet of the intercooler body is directly connected to the intake passage on the cylinder head, and the intake passage of the cylinder head communicates with the cylinder combustion chamber.

[0005] In a preferred embodiment of the present invention, the first partition, the second partition and the third partition divide the interior of the intercooler body into multiple cooling channels, and the flow distribution plate is disposed on the airflow outlet side to evenly distribute the cooled air to the intake manifold of each cylinder.

[0006] In a preferred embodiment of the present invention, the cylinder head is further provided with a pressure stabilizing chamber, which is located between the intake manifold and the outlet of the intercooler body.

[0007] In a preferred embodiment of the present invention, the throttle valve mounting flange is provided with a throttle valve mounting threaded hole and the throttle valve body is fixed to the throttle valve mounting flange by throttle valve fixing bolts.

[0008] In a preferred embodiment of the present invention, the intercooler body and the cylinder head are uniformly fixed circumferentially by a plurality of intercooler mounting bolts.

[0009] In a preferred embodiment of the present invention, the coolant of the intercooler body enters the cooling core tube through the inlet body, absorbs the heat of the compressed air, and then flows out through the outlet body.

[0010] In a preferred embodiment of the present invention, the outlet body of the intercooler faces upwards to expel gas from the intercooler.

[0011] In a preferred embodiment of the present invention, a sealing gasket is provided between the intercooler body and the cylinder head.

[0012] Compared with the prior art, the beneficial effects of the present invention are as follows: This invention optimizes the intercooler structure by adding baffles and flow distribution plates. It is directly mounted to the engine cylinder head, eliminating the intake manifold, shortening the airflow path, improving the uniformity of air intake to each cylinder, reducing flow resistance, and improving engine economy and power. The number of parts is reduced, thereby lowering costs, weight, and engine size. By directly mounting the intercooler to the cylinder head and eliminating the traditional independent intake manifold, the boost air path is shortened from "compressor → intercooler → throttle body → intake manifold pressure regulating chamber → intake manifold → intake passage → cylinder" to "compressor → throttle body → intercooler → pressure regulating chamber → intake passage → cylinder." This significantly reduces pipe length and bends, lowers intake flow resistance, and improves engine charging efficiency and dynamic response speed. The intercooler internally features multiple baffles arranged in a staggered pattern. The air is forced to circulate between the cooling core tubes, achieving efficient cooling. A flow distribution plate is set on the outlet side to precisely distribute the airflow according to the position of each cylinder, so that each cylinder receives an equal amount and isothermal intake air, solving the unevenness problem caused by traditional one-end intake. This improves the combustion uniformity of each cylinder, reduces vibration, knock tendency and harmful emissions. A water-cooled intercooler is used and integrated with the low-temperature cooling cycle system independently owned by the intake system, saving space and energy consumption. The water-cooled heat exchange efficiency is high and is not affected by vehicle speed, ensuring stable intake air temperature under various operating conditions and enhancing the engine's anti-knock capability. Attached Figure Description

[0013] Figure 1 This is a schematic diagram of the overall front-view structure of the engine of the present invention; Figure 2 This is a schematic diagram of the overall rear-view structure of the engine of the present invention; Figure 3 This is an exploded structural diagram of the connection between the intercooler and the cylinder head of the present invention; Figure 4 This is a schematic diagram of the overall structure of the intercooler of the present invention; Figure 5 This is a schematic diagram of the exploded structure of the intercooler of the present invention; Figure 6 This is a schematic diagram of the overall structure of the cylinder head of the present invention; Figure 7 This is a cross-sectional view of the cylinder head and a schematic diagram of the intercooler assembly structure of the present invention.

[0014] In the diagram: 1. Cylinder head; 2. Engine; 3. Intercooler body; 4. Throttle body; 5. Sealing gasket; 6. Throttle body fixing bolt; 7. Outlet body; 8. Inlet and outlet housings; 9. Throttle mounting flange; 10. Intercooler inlet; 11. Throttle mounting threaded hole; 12. Inlet housing; 13. Inlet body; 14. Intercooler mounting hole; 15. Intercooler mounting flange; 16. First partition; 17. Second partition; 18. ... 19. Three-part partition; 20. Flow distribution plate; 21. Cooling core tube; 22. Oil pan; 23. Electronic air conditioning; 24. Electronic water pump; 25. Three-way catalytic converter; 26. Turbocharger; 27. High-pressure oil pump; 28. Cylinder block; 29. ​​Oil cooler; 10. Oil filter; 110. Spark plug mounting hole; 111. Injector mounting hole; 112. Intake manifold; 113. Intercooler mounting threaded hole; 114. Intercooler connecting flange; 115. Pressure regulating chamber. Detailed Implementation

[0015] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0016] Please see Figure 1-7This invention provides a technical solution: an engine with an integrated intercooler and cylinder head, comprising: an engine 2, a cylinder head 1, and an intercooler body 3; the engine 2 includes an oil pan 21, a cylinder block 27, an electronic air conditioner 22, an electronic water pump 23, a three-way catalytic converter 24, a turbocharger 25, a high-pressure oil pump 26, an oil cooler 28, and an oil filter 29; the oil pan 21 is fixedly installed on the lower part of the cylinder block 27, and the cylinder head 1 is fixedly installed on the upper part of the cylinder block 27. The intercooler body 3 is provided with multiple intake ports 112, spark plug mounting holes 110, fuel injector mounting holes 111, and an intercooler connecting flange 114; the bottom of the intercooler body 3 is provided with an intercooler mounting flange 15, and the intercooler mounting flange 15 has intercooler mounting holes 14; the intercooler connecting flange 114 has intercooler mounting threaded holes 113, and the intercooler body 3 is fixedly installed by intercooler mounting bolts passing through the intercooler mounting holes 14 and screwing them into the intercooler mounting threaded holes 113. The upper part of the cylinder head 1; the interior of the intercooler body 3 is provided with a cooling core tube 20 and a first baffle 16, a second baffle 17, a third baffle 18 and a flow distribution plate 19 arranged sequentially along the airflow direction; one end of the intercooler body 3 is provided with an intercooler inlet 10 and a throttle valve mounting flange 9 is fixed at the intercooler inlet 10, a throttle valve body 4 is mounted on the throttle valve mounting flange 9, and the outlet of the throttle valve body 4 is connected to the intercooler inlet 10; the intercooler body 3 The intercooler is equipped with an inlet housing 12 and an outlet housing 8. The inlet housing 12 contains an inlet body 13, and the outlet housing 8 contains an outlet body 7. The inlet body 13 and outlet body 7 are respectively connected to the inlet and outlet ends of the cooling core tube 20. The outlet of the intercooler body 3 is directly connected to the intake passage 112 on the cylinder head 1, and the intake passage 112 of the cylinder head 1 is connected to the cylinder combustion chamber. The intercooler structure is optimized by adding baffles and a flow distribution plate 19. It is directly installed on the cylinder head 1 of the engine 2, eliminating the intake manifold, shortening the airflow path, improving the uniformity of air intake in each cylinder of the engine 2, reducing flow resistance, and improving the economy and power of the engine 2.The number of parts was reduced, thereby lowering costs, weight, and engine size. The intercooler was directly mounted on the cylinder head 1, and the traditional independent intake manifold was eliminated. This shortened the boost air path from "compressor → intercooler → throttle body 4 → intake manifold pressure regulating chamber 115 → intake manifold → intake passage 112 → cylinder" to "compressor → throttle body → intercooler → pressure regulating chamber 115 → intake passage 112 → cylinder". This significantly reduced pipe length and bends, lowered intake flow resistance, and improved the charging efficiency and dynamic response speed of engine 2. The intercooler internally features a staggered arrangement of... Multiple baffles force air to circulate within the cooling core tubes 20, achieving efficient cooling. A flow distribution plate 19 is installed on the outlet side to precisely distribute airflow according to the position of each cylinder, ensuring that each cylinder receives an equal amount and temperature of intake air. This solves the unevenness problem caused by traditional one-end intake, thereby improving the combustion uniformity of each cylinder, reducing vibration, knocking tendency, and harmful emissions. A water-cooled intercooler is used, integrated with the intake system's independently owned low-temperature cooling cycle system, saving space and energy. The water-cooled heat exchange efficiency is high and unaffected by vehicle speed, ensuring stable intake air temperature under various operating conditions and enhancing the engine's anti-knock capability.

[0017] Further improvements, such as Figure 5 As shown: the first baffle 16, the second baffle 17, and the third baffle 18 divide the interior of the intercooler body 3 into multiple cooling channels. The flow distribution plate 19 is set on the airflow outlet side to evenly distribute the cooled air to the intake passages 112 of each cylinder. The first, second, and third baffles 18 divide the interior of the intercooler into multiple series or meandering cooling channels, forcing the high-temperature compressed air to flow along an extended path between the cooling core tubes 20 and to fully contact the cooling core tubes 20, which significantly improves the heat exchange efficiency. The flow distribution plate 19 is set with distribution holes of different diameters and densities on the airflow outlet side according to the position of each cylinder, so that the cooled air is accurately and evenly distributed to the intake passages 112 of each cylinder, which effectively solves the problem of uneven air intake in each cylinder caused by traditional one-end air intake, improves combustion uniformity, and reduces vibration and emissions.

[0018] Further improvements, such as Figure 6 , 7 As shown: The cylinder head 1 is also provided with a pressure stabilizing chamber 115. The pressure stabilizing chamber 115 is located between the intake port 112 and the outlet of the intercooler body 3. The pressure stabilizing chamber 115 plays a buffering and flow stabilizing role for the air after it has been cooled and distributed by the intercooler, eliminating airflow fluctuations caused by changes in throttle opening or pulsation of the turbocharger 25, making the air pressure entering the intake port 112 of each cylinder more stable, further improving the intake consistency of each cylinder, and reducing intake noise at the same time.

[0019] Further improvements, such as Figure 4As shown: The throttle body mounting flange 9 is provided with a throttle body mounting threaded hole 11, and the throttle body 4 is fixed to the throttle body mounting flange 9 by throttle body fixing bolts 6. The throttle body 4 is directly fixed to the throttle body mounting flange 9 integrated into the intercooler body 3 by bolts, without the need for a separate bracket and connecting pipeline, and the structure is compact and reliable; the threaded connection method facilitates the disassembly, maintenance and replacement of the throttle body 4, while ensuring the sealing and stability of the connection.

[0020] Further improvements, such as Figure 3 As shown: The intercooler body 3 and the cylinder head 1 are evenly fixed together circumferentially by multiple intercooler mounting bolts. The multiple bolts are evenly distributed circumferentially to make the clamping force between the intercooler body 3 and the cylinder head 1 uniform, ensuring that the sealing gasket 5 is subjected to consistent force in all parts, and preventing air leakage due to insufficient local pressure; the uniform fixing can also resist the influence of engine 2 vibration on the connection and improve long-term reliability.

[0021] Further improvements, such as Figure 5 As shown: The coolant of the intercooler body 3 enters the cooling core tube 20 through the inlet body 13, absorbs the heat of the compressed air, and flows out through the outlet body 7. The compressed air is cooled by the low-temperature coolant circulation system independently owned by the intake system, which saves space and energy consumption. The water-cooled heat exchange efficiency is significantly higher than that of air-cooled and is not affected by vehicle speed and external airflow, ensuring the stability of intake air temperature under various operating conditions, thereby improving the anti-knock ability and charging efficiency of the engine 2.

[0022] Further improvements, such as Figure 4 As shown: The outlet body 7 of the intercooler has an upward opening, which discharges the air in the cooling core tube 20 and cooling channel when adding coolant, to avoid the accumulation of air and the formation of air blockage, and to ensure that the coolant can completely fill the cooling core tube 20 and give full play to the cooling capacity.

[0023] Further improvements, such as Figure 3 As shown: A sealing gasket 5 is provided between the intercooler body 3 and the cylinder head 1. The sealing gasket 5 fills the micro gap between the intercooler body 3 and the cylinder head 1 mating surface. Under the action of bolt tightening force, a reliable airtight and liquid-tight seal is formed to prevent high temperature and high pressure pressurized air from leaking from the mating surface, and at the same time prevent external dust from entering.

[0024] Working principle: The mounting flange at the bottom of the intercooler body 3 is evenly fixed to the connecting flange on the upper part of the cylinder head 1 along the circumference using multiple intercooler mounting bolts. A sealing gasket 5 is placed between the two to ensure airtightness. The outlet of the intercooler body 3 is directly connected to the pressure stabilizing chamber 115 and the intake manifold 112 on the cylinder head 1, without any intermediate pipelines. The throttle body 4 is directly installed on the throttle mounting flange 9 at one end of the intercooler body 3 using throttle body fixing bolts 6. The outlet of the throttle body 4 is connected to the intercooler inlet 10. The water inlet and outlet of the intercooler body 3 are respectively connected to the cooling circulation system of the engine 2. The exhaust pipe at the top is opened to exhaust when coolant is added. The high-temperature and high-pressure air discharged from the compressor of the turbocharger 25 enters the intercooler inlet 10 and first flows through multiple meandering cooling channels separated by the first baffle 16, the second baffle 17, and the third baffle 18. Within the channel, the air is forced to change direction multiple times, making full contact with the outer wall of the cooling core tube 20. Coolant enters the cooling core tube 20 from the inlet body 13, absorbs heat from the compressed air, and then flows out from the outlet body 7, returning to the independently owned low-temperature cooling system of the intake system for circulation. After thorough cooling, the air temperature is significantly reduced, and its density increases. The cooled air continues forward to the flow distribution plate 19, which has distribution holes of different sizes and densities according to the position of different cylinders and intake requirements, precisely and evenly distributing the air to the corresponding pressure regulating chamber 115 area of ​​each cylinder. The throttle body 4 adjusts its opening according to the instructions of the engine 2 control unit, controlling the total amount of air entering the engine 2. After passing through the throttle, the air enters the intercooler, where it is cooled before entering the pressure regulating chamber 115 integrated on the cylinder head 1. The pressure regulating chamber 115 acts as a buffer and stabilizer, eliminating airflow pulsation and allowing air to smoothly enter the intake manifold 112 of each cylinder. Finally, air enters the cylinder combustion chamber through the intake manifold 112 and intake valve, mixing and burning with the fuel injected by the injector. During engine operation, the coolant circulates under the drive of the electric water pump 23, flowing through the cylinder block 27 and cylinder head 1 to cool the combustion chamber inside the cylinder head. The coolant outlet body 7 faces upwards to expel air during the initial addition or replenishment of coolant, ensuring no air resistance in the cooling system.

[0025] I. Workflow of this Plan This solution primarily utilizes the direct integration of the intercooler and cylinder head, combined with the internal airflow distribution structure of the intercooler and the integrated pressure-stabilizing structure of the cylinder head, to achieve efficient cooling, precise distribution, and stable intake of the boosted air. The specific operating process is as follows: Assembly and connection stage: The intercooler mounting flange 15 at the bottom of the intercooler body 3 is evenly fixed to the intercooler connecting flange 114 on the upper part of the cylinder head 1 along the circumference using multiple intercooler mounting bolts. A sealing gasket 5 is placed between the mating surfaces of the two to achieve an airtight seal. The outlet of the intercooler body 3 is directly connected to the pressure stabilizing chamber 115 and the intake manifold 112 on the cylinder head 1 without any intermediate connecting pipes. The throttle body 4 is fixed to the throttle mounting flange 9 at one end of the intercooler body 3 using throttle body fixing bolts 6, so that the outlet of the throttle body 4 is connected to the intercooler inlet 10. The water inlet body 13 and the water outlet body 7 of the intercooler body 3 are respectively connected to the independent low-temperature cooling circulation system of the intake system. The opening of the water outlet body 7 faces upward, and when adding coolant, the air in the cooling core tube 20 and the cooling passage is discharged.

[0026] The compressed air cooling stage: The high-temperature and high-pressure air discharged from the compressor of the turbocharger 25 enters the throttle body 4, and then enters the intercooler inlet 10. Subsequently, it flows through multiple meandering cooling channels formed by the first baffle 16, the second baffle 17 and the third baffle 18. The air is forced to change its flow direction multiple times, making full contact with the outer wall of the cooling core tube 20. At the same time, the coolant of the low-temperature cooling circulation system enters the interior of the cooling core tube 20 from the inlet body 13, absorbs the heat of the compressed air and flows out from the outlet body 13, returning to the engine 2 cooling system for circulation, thus completing the cooling of the compressed air.

[0027] Airflow distribution and intake stage: After cooling, the air continues to flow to the flow distribution plate 19 on the outlet side of the intercooler body 3. The flow distribution plate 19 distributes the air precisely and evenly to the corresponding pressure stabilizing chamber 115 area of ​​each cylinder according to the position of each cylinder and the intake demand through distribution holes of different diameters and densities. The air flows through the throttle body 4. The throttle body 4 adjusts the opening according to the command of the engine 2 control unit to control the total amount of air entering the engine 2. After passing through the throttle body, the air enters the intercooler. After being cooled in the intercooler, it enters the pressure stabilizing chamber 115 integrated on the cylinder head 1. The pressure stabilizing chamber 115 buffers and eliminates airflow pulsation, so that the air flows smoothly into the intake manifold 112 of each cylinder. Finally, the air enters the cylinder combustion chamber through the intake manifold 112 and the intake valve, and mixes and burns with the fuel injected by the injector.

[0028] II. Core Innovations of this Plan The core innovation of this solution lies in its integrated intake system design, which directly integrates the intercooler and cylinder head. This solves the technical problems inherent in traditional turbocharged range-extended engines and hybrid engines with independent intercooler designs, such as complex air intake paths, high flow resistance, uneven air intake across cylinders, numerous parts, large engine size, high cost, and heavy weight. Furthermore, it is the first to deeply integrate a multi-stage flow-guiding cooling structure, a precise flow distribution structure, and a cylinder head integrated pressure-stabilizing structure, achieving integrated functions of efficient cooling, uniform distribution, and stable intake of turbocharged air.

[0029] From a complete logical chain perspective: First, addressing the core pain points of traditional intake systems—"long path, high resistance, and uneven intake"—the intercooler body 3 is directly mounted on the upper part of the cylinder head 1 by eliminating the traditional independent intake manifold, thus shortening the intake path at its source. Second, a first baffle 16, a second baffle 17, and a third baffle 18 are sequentially arranged along the airflow direction inside the intercooler body 3 to form a meandering cooling channel. At the same time, a flow distribution plate 19 is set on the outlet side. The structural design verifies the action logic of "extending the heat exchange path to improve cooling efficiency + precise opening to achieve even airflow distribution." Then, the pressure stabilizing chamber 115 is integrated inside the cylinder head 1 to further stabilize the flow and eliminate airflow pulsation, forming a closed loop of "cooling-distribution-stabilizing flow." Finally, this integrated design has good adaptability. By adjusting the number of baffles, the orifice distribution of the flow distribution plate 19, and the volume of the pressure stabilizing chamber 115, it can be adapted to turbocharged range-extending engines and hybrid engines with different displacements and cylinder numbers.

[0030] III. Technical Effects of Implementing this Plan Implementing this solution can comprehensively improve engine performance from multiple dimensions, including intake efficiency, cooling performance, combustion quality, lightweight structure, and cost control. The specific technical effects are as follows: Significantly reduces intake flow resistance, improving charging efficiency and dynamic response. Based on the principles of frictional resistance and local resistance in fluid mechanics, fluid flow resistance is directly proportional to pipe length and positively correlated with the number of pipe bends. This solution eliminates the traditional independent intake manifold, shortening the boosted air flow path from "compressor → intercooler → throttle body → intake manifold pressure regulating chamber → intake manifold → intake passage → cylinder" to "compressor → throttle body → intercooler → pressure regulating chamber 115 → intake passage 112 → cylinder," significantly reducing pipe length and the number of bends, thus reducing intake flow resistance by 20%-30%. This reduction in intake resistance directly improves the charging efficiency of engine 2, allowing the cylinders to draw in more air. Simultaneously, the engine's dynamic response speed is significantly accelerated, enabling faster response to throttle commands and improving vehicle acceleration performance and driving smoothness.

[0031] This significantly improves the heat exchange efficiency of the intercooler, ensuring stable intake air temperature. According to the basic principles of heat exchange, heat exchange efficiency is positively correlated with heat exchange area, heat exchange time, and fluid turbulence. The first baffle 16, second baffle 17, and third baffle 18 inside the intercooler body 3 divide the internal space into multiple meandering cooling channels, forcing the high-temperature compressed air to change its flow direction multiple times. This increases the contact area and contact time between the air and the cooling core tube 20, while simultaneously enhancing air turbulence, thus improving heat exchange efficiency by more than 15%. Furthermore, this solution uses a water-cooled intercooler. Water-cooled heat exchange efficiency is far higher than air-cooled intercoolers and is unaffected by vehicle speed and external airflow. This ensures the stability of the intake air temperature under various operating conditions such as idling, high speed, and high load, enhancing the engine's anti-knock capability and allowing the engine to use a higher compression ratio, further improving power and fuel economy.

[0032] This design comprehensively improves the uniformity of air intake across all cylinders, optimizing combustion quality. Traditional intake systems draw air from one end of the engine, which can easily lead to differences in air volume and temperature between cylinders, affecting combustion uniformity. This solution incorporates a flow distribution plate 19 on the outlet side of the intercooler body 3. Based on the position of each cylinder and differences in intake resistance, the size and density of the distribution holes are precisely designed to distribute cooled air equally and isothermally to the intake manifold 112 of each cylinder. Simultaneously, the pressure stabilizing chamber 115 integrated on the cylinder head 1 effectively buffers airflow fluctuations caused by changes in throttle opening or alternating opening and closing of the intake valves, resulting in more stable air pressure entering each cylinder. The intake non-uniformity can be controlled within 3%. This improved intake uniformity leads to a more consistent fuel-air mixture ratio in each cylinder, resulting in more complete combustion. This not only reduces engine vibration and noise but also decreases knock tendency and the generation of harmful emissions such as carbon monoxide and hydrocarbons, extending engine lifespan.

[0033] This solution achieves engine lightweighting and miniaturization, reducing manufacturing costs. It eliminates several components such as the traditional intake manifold and its connecting pipes, and mounting brackets, reducing the number of parts and assembly steps, thus lowering engine manufacturing costs and assembly complexity. Simultaneously, the integrated design significantly reduces the overall size and weight of the engine, shortening the axial dimension by 3%-5% and reducing weight by 5%-8%. This facilitates the engine's overall layout within the vehicle, allowing more space for hybrid and range-extended electric vehicles to accommodate core components such as batteries and motors, thereby improving vehicle space utilization.

[0034] IV. Application Examples Regarding the application embodiment 1 of this solution: Another embodiment of the present invention has the same basic structure as the basic embodiment, except that: the number of baffles inside the intercooler body 3 is adjusted to 2, that is, only the first baffle 16 and the third baffle 18 are retained, and the arrangement density and single tube length of the cooling core tube 20 are adjusted accordingly; the orifice diameter and distribution pattern of the flow distribution plate 19 are adapted to the intake requirements of the 3-cylinder engine; the volume of the pressure stabilizing chamber 115 integrated on the cylinder head 1 is reduced by 10%-15%. The above-mentioned modified solutions can adapt to the intake cooling and airflow distribution requirements of small-displacement 3-cylinder turbocharged hybrid engines, and can achieve the core technical effects of the present invention, falling within the protection scope of the present invention.

[0035] Application Example 2 of this solution: Another embodiment of the present invention has the same basic structure as the basic embodiment, except that: the sealing gasket 5 between the intercooler body 3 and the cylinder head 1 is replaced with a metal sealing gasket with raised ribs, which is suitable for the sealing requirements under high load and high temperature conditions of the engine; a high-temperature resistant fluororubber sealing gasket is added between the throttle body 4 and the throttle mounting flange 9 to further improve the airtightness of the connection; and the intercooler mounting bolts are made of high-strength alloy steel bolts to improve the vibration fatigue resistance of the connection. The above-mentioned modified solutions can enhance the connection reliability and sealing performance of the engine under extreme conditions, and all can achieve the core technical effects of the present invention, falling within the protection scope of the present invention.

[0036] Regarding the application embodiment 3 of this solution: Another embodiment of the present invention has the same basic structure as the basic embodiment, except that: the volume of the pressure stabilizing chamber 115 integrated on the cylinder head 1 is increased by 15%-20%, and an arc-shaped guide plate is added inside the pressure stabilizing chamber 115 to further optimize the airflow direction and reduce airflow turbulence; the cooling core tube 20 of the intercooler body 3 adopts a finned cooling core tube instead of a bare tube cooling core tube to increase the heat exchange area; flow regulating valves are added to the inlet body 13 and outlet body 7 of the intercooler body 3 to adjust the coolant flow according to the engine operating conditions. The above-mentioned modified solutions can improve the intake airflow stabilization effect and cooling efficiency of large-displacement 6-cylinder turbocharged and range-extended engines, and can achieve the core technical effects of the present invention, falling within the protection scope of the present invention.

[0037] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from its spirit or essential characteristics. Therefore, the embodiments should be considered illustrative and non-limiting in all respects, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of equivalents of the claims are intended to be included within the present invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

[0038] Finally, the following points should be noted: First, in the description of this application, it should be noted that, unless otherwise specified and limited, the terms "installation", "connection", and "linkage" should be interpreted broadly, and can refer to mechanical or electrical connections, or internal connections between two components, or direct connections. "Up", "down", "left", "right", etc., are only used to indicate relative positional relationships. When the absolute position of the described object changes, the relative positional relationship may change.

[0039] Finally, it should be noted that the above descriptions are merely preferred embodiments of the present invention and are not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. An engine with an intercooler integrated with the cylinder head, characterized in that: include: Engine (2), cylinder head (1) and intercooler body (3); the engine (2) includes an oil pan (21), cylinder block (27), electronic air conditioning (22), electronic water pump (23), three-way catalytic converter (24), turbocharger (25), high-pressure oil pump (26), oil cooler (28) and oil filter (29); the oil pan (21) is fixedly installed on the lower part of the cylinder block (27) and the cylinder head (1) is fixedly installed on the upper part of the cylinder block (27), and the cylinder head (1) is provided with multiple intake ports (112). The intercooler body (3) has a spark plug mounting hole (110), an injector mounting hole (111), and an intercooler connecting flange (114). The bottom of the intercooler body (3) is provided with an intercooler mounting flange (15), and an intercooler mounting hole (14) is provided on the intercooler mounting flange (15). The intercooler connecting flange (114) is provided with an intercooler mounting threaded hole (113). The intercooler body (3) is fixedly installed on the cylinder by passing an intercooler mounting bolt (31) through the intercooler mounting hole (14) and screwing it into the intercooler mounting threaded hole (113). The air intake side of the cover (1); the interior of the intercooler body (3) is provided with a cooling core tube (20) and a first baffle (16), a second baffle (17), a third baffle (18) and a flow distribution plate (19) arranged sequentially along the airflow direction; one end of the intercooler body (3) is provided with an intercooler air inlet (10) and a throttle valve mounting flange (9) is fixed at the intercooler air inlet (10), a throttle valve body (4) is installed on the throttle valve mounting flange (9), and the air outlet of the throttle valve body (4) is connected to the intercooler air inlet (10). The intercooler body (3) is provided with an inlet housing (12) and an outlet housing (8). The inlet housing (12) is provided with an inlet body (13) and the outlet housing (8) is provided with an outlet body (7). The inlet body (13) and the outlet body (7) are respectively connected to the inlet end and outlet end of the cooling core tube (20). The outlet of the intercooler body (3) is directly connected to the intake passage (112) on the cylinder head (1) and the intake passage (112) of the cylinder head (1) is connected to the cylinder head combustion chamber.

2. An engine (2) with an intercooler integrated with the cylinder head according to claim 1, characterized in that: The first partition (16), the second partition (17) and the third partition (18) divide the interior of the intercooler body (3) into multiple cooling channels. The flow distribution plate (19) is located on the airflow outlet side to evenly distribute the cooled air to the intake manifold (112) of each cylinder.

3. An engine (2) with an intercooler integrated with the cylinder head according to claim 1, characterized in that: The cylinder head (1) is also provided with a pressure stabilizing chamber (115), which is located between the intake manifold (112) and the outlet of the intercooler body (3).

4. An engine (2) with an intercooler integrated with the cylinder head according to claim 1, characterized in that: The throttle mounting flange (9) is provided with a throttle mounting threaded hole (11), and the throttle body (4) is fixed to the throttle mounting flange (9) by a throttle fixing bolt (6).

5. An engine (2) with an intercooler integrated with the cylinder head according to claim 1, characterized in that: The intercooler body (3) and the cylinder head (1) are evenly fixed together in the circumferential direction by multiple intercooler mounting bolts.

6. An engine (2) with an intercooler integrated with the cylinder head according to claim 1, characterized in that: The coolant of the intercooler body (3) enters the cooling core tube (20) through the inlet body (13), absorbs the heat of the compressed air, and flows out through the outlet body (7).

7. An engine (2) with an intercooler integrated with the cylinder head according to claim 1, characterized in that: The outlet body 7 has an upward opening, which can expel the gas inside the intercooler body (3).

8. An engine (2) with an intercooler integrated with the cylinder head according to claim 1, characterized in that: A sealing gasket (5) is provided between the intercooler body (3) and the cylinder head (1).

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