Inlet manifold with water-carrying tubes

Abstract

An intake manifold (100) comprising:an air plenum (110) comprising an air plenum base (104) and an air plenum top (102) positioned adjacent to the air plenum base (104); andat least one tube (310) supported on and extending from the air plenum base (104) toward the air plenum top (102) for transporting water, the at least one tube (310) comprising first and second spaced-apart tubes, the first tube differing from the second tube in at least one of a cross-sectional area and an extending length.

Description

TECHNICAL FIELD

[0001] The present invention relates, in one or more embodiments, to an intake manifold having one or more water-transporting tubes. BACKGROUND

[0002] In internal combustion engines, intake manifolds may be used at cylinders to supply air or an air-fuel mixture. A throttle body may be connected to the intake manifold to provide pressure and flow control at the intake manifold. The air flow is transported from the throttle body into the plenum chamber and then to the cylinder via a series of flow tubes.

[0003] For example, US patent application publication number US 2009 / 0 260 906 A1 discloses an air intake manifold positioned in close proximity to an air intake and piping to an engine block.

[0004] DE 10 2011 006 117 A1 describes an air intake device for a vehicle, in which an intake manifold has an expansion tank or air collector, in which an outlet into a tube for transporting water is provided in a lower section, which tube extends towards an upper section of the air collector. SUMMARY

[0005] In one or more embodiments, an intake manifold comprises at least the features according to claims 1, 10 or 15. In one embodiment, an intake manifold may comprise an air plenum comprising an air plenum base and an air plenum top positioned adjacent to the air plenum base, and at least one tube supported on the air plenum base and extending therefrom towards the air plenum top for transporting water, wherein the at least one tube may further comprise a first opening for discharging water, wherein the first opening is positioned closer to the air plenum top than the air plenum base, and wherein the at least one tube may further comprise a second opening for admitting water, wherein the second opening is positioned closer to the air plenum base than the air plenum top.

[0006] The cross-section of the at least one tube may include a wall enclosing a void.

[0007] The at least one tube may be spaced from the air collector top.

[0008] The air collector base may comprise a cavity, wherein the at least one tube is positioned on and in contact with the cavity.

[0009] The at least one tube may be formed integrally with the air collector base.

[0010] The at least one tube may comprise a first part and a second part along a longitudinal direction, wherein the second part has a different cross-sectional area than the first part.

[0011] The at least one tube comprises a first and a second tube spaced apart from each other, wherein the first tube differs from the second tube at least in the cross-sectional area and / or the extending length.

[0012] One or more advantageous features as described herein will become clear from the following detailed description of one or more embodiments in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] For a more complete understanding of one or more embodiments of the present invention, reference will now be made to one or more embodiments illustrated in more detail in the accompanying drawings and described below, in which: Fig. 1 illustrates a perspective view of an intake manifold according to one or more embodiments of the present invention; Fig. 2 shows a perspective partial view of the intake manifold according to Fig. 1 represents; Fig. 3 shows a cross-sectional view of the intake manifold according to Fig. 1 positioned relative to an engine block; Fig. 4A shows an enlarged partial view of the intake manifold according to Fig. 3 represents; Fig. 4B illustrates another enlarged partial view of the intake manifold according to Fig. 3 represents; Fig. 4C illustrates another enlarged partial view of the intake manifold according to Fig. 3 represents; Fig. 5 shows an alternative view of the intake manifold according to Fig. 3 represents; Fig. 6 shows an alternative view of the intake manifold according to Fig. 4A; and Fig. 7 shows another alternative view of the intake manifold according to Fig. 4A. DETAILED DESCRIPTION OF ONE OR MORE EMBODIMENTS

[0014] Throughout the figures, like reference numbers may be used to refer to like parameters and components or similar modifications and alternatives thereof. These specific parameters and components are provided by way of example and are not intended to be limiting. The drawings referenced herein are schematic, and related views thereof are not necessarily drawn to scale.

[0015] It is believed that the present invention, in one or more embodiments, advantageously reflects the understanding that undesirable water may accumulate inside an intake manifold, and that removal of such water may be compromised for various reasons, one being the formation of an oil film or layer covering the water, thus resulting in reduced water evaporation. Water accumulation may be particularly pronounced on cold weather days when ice forms in the intake manifold and then turns to water as temperatures rise, such as during a so-called "hot soak."

[0016] Accordingly, and as described in detail elsewhere herein, relatively greater effective water evaporation and thus water removal can be achieved by employing one or more tubes implemented within the intake manifold. Such tubes can be positioned to advantageously facilitate water evaporation and removal despite the presence of the oil film or layer.

[0017] As clearly shown in Fig. 1 to Fig. 4A, the present invention, in one or more embodiments, provides an intake manifold, generally shown at 100. The intake manifold 100 includes an air plenum or plenum chamber 110, which in turn includes an air plenum base 104 and an air plenum top 102 positioned adjacent the air plenum base 104, and at least one tube 310 supported on the air plenum base 104 and extending therefrom toward the air plenum top 102 for transporting and removing water. In certain embodiments, the intake manifold 100 may include one or more of the tubes 180.

[0018] With further reference to Fig. 3 and Fig. 4A, the at least one tube 310 may be configured to extend above or beyond an oil film or layer 420 that would otherwise inevitably result in a reduction in water evaporation from a water pool 320 below the oil layer 420. In this configuration, water from the water pool 320 may move across the at least one tube 310 while bypassing the obstructive oil layer 420 and exiting from and above the oil layer 420 for evaporation and removal.

[0019] In certain embodiments and as illustrated in Fig. 4A, the at least one tube 310 comprises a main channel 410 extending along a longitudinal direction L from the air collector lower part 104 toward the air collector upper part 102. A cross-section taken along the line 4B-4B is clearly shown in Fig. 4B and defines a side wall 350 that encloses a void corresponding to the main channel 410. A cross-sectional width W3 of the main channel 410 may have any suitable value in relation to a cross-sectional thickness T of the side wall 350. In certain embodiments, the ratio of W3 to T is not less than 1. The main channel 410 serves as a main conduit for transporting water from the water accumulation 320 for removal from and above the oil layer 420. However, in certain embodiments and as clearly shown in Fig. 4C, the main channel 410 may be configured to include a number of channels, such as channels 410a, 410b, 410c, 410d, 410e, and 410f, spaced apart from one another and strategically distributed across a cross-section of the at least one tube 310. In this configuration, each of the channels 410a-410f may be configured to have relatively small cross-sectional area-to-length ratios, which are believed to provide desired capillary effects in directing water through the channels.

[0020] The size and dimension of the at least one tube 310 may each be independently varied depending on the distribution, position, and / or depth of the water accumulation 320; and accordingly, in one or more embodiments, the present invention further provides versatility in the design of the intake manifold 100 to accommodate operating conditions in which the presence of water may vary.

[0021] For example, and as clearly shown in Fig. 2, the plenum base 104 of the intake manifold 100 may be configured to include one or more cavities 210 designed to collect water as it forms and accumulates. The cavities 210 are strategically positioned with respect to the adjacent raised structures to collect water, and the presence of at least one tube 310 at or near the cavities 210 is believed to be particularly beneficial in removing water that is excessive and undesirable. This configuration, as noted elsewhere herein, is believed to promote water removal and thus reduce water ingress into a nearby engine block 370 via tubes 180, and accordingly reduce engine malfunction, including engine misfire, due to undesirable water ingress.

[0022] Referring again to Fig. 1 and Fig. In Figure 3, the plenum 110 of the intake manifold 100 is illustrated with the plenum top 102 and the plenum bottom 104 as two separable parts. However, in certain embodiments, the plenum top 102 and the plenum bottom 104 may be integrally formed as one piece or as a single component. Furthermore, the plenum top 102 and the plenum bottom 104 may have any suitable shape, configuration, and dimensions, and may be made of any suitable material.

[0023] The water transporting tubes described herein according to one or more embodiments, such as the tubes 310, which are illustrated in Fig. 3, can be easily used to remove water in situations where there is no interference due to the presence of an oil layer or film. In these scenarios, certain design parameters, such as the position of water outlet openings relative to the corresponding water inlet openings, may be less stringent.

[0024] Referring again to Fig. 2, the at least one tube 310 may be positioned at or near each of the cavities 210. Due to their proximity to various inlet openings 280 of the tubes 180, the presence of the at least one tube 310 relative to the cavities 210 is believed to provide effective and localized water removal and protect against water ingress through the inlet openings 280.

[0025] As clearly shown in Fig. 3, the at least one tube 310 may comprise first and second spaced-apart tubes 310a, 310b, which may be positioned within a single cavity 210 or two differently positioned cavities 210. In certain embodiments, the at least one tube 310 may be configured to comprise a number of individual tubes distributed throughout the air collector base 104 to facilitate water removal for a relatively larger area coverage.

[0026] The at least one tube 310 may further vary in size, dimension, and structural material. In certain embodiments, and as illustrated in Fig. 5, the at least one tube 310 may comprise first and second tubes 510, 520 that differ from each other in at least the cross-sectional area and / or the longitudinal length along the longitudinal direction L. This configuration may be particularly useful and advantageous to accommodate water removal in regions where the depth of water accumulation may vary depending on the position and a covering oil film may also vary in film thickness.

[0027] Referring again to Fig. 4A, the at least one tube 310 may be formed with a height and length L3 relative to a base surface 490 of the plenum base 104, where L3 may have any suitable ratio relative to W1 or W3, non-limiting examples of which include a ratio in the range of 1.5 to 100, 2 to 50, 2.5 to 25. In certain cases, the cross-sectional width W1 or W3 may be kept at a relatively small value, such as a ratio less than 1 / 10 relative to L3, to facilitate water transport via capillary effects.

[0028] As mentioned elsewhere herein, the at least one tube 310 extends from the plenum base 104 toward the plenum top 102, and the extension may take a general direction along the longitudinal direction L. However, the at least one tube 310 itself need not necessarily be straight and may include curves and turns that are intentional or accidental.

[0029] The at least one tube 310 may be formed from a material that is particularly suitable for the operating conditions typical of an automotive intake manifold, while also being a good medium for facilitating water transport and resistant to oil ingress. For example, the at least one tube 310 may be formed from a metal, such as any suitable grade of steel. In certain embodiments, the at least one tube 310 may be integrally formed with the plenum base 104 by any suitable method, such as molding. In certain other embodiments, the at least one tube 310 may be preformed and subsequently attached to the plenum base 104 using other suitable methods, such as welding, fasteners, or adhesives.

[0030] Referring again to Fig. 3 and Fig. 4A, the at least one tube 310 includes an uppermost portion 312 to be positioned above the oil layer 420 and a lowermost portion 314 to be positioned at or below the oil layer 420. The design is intended to allow water vapor to escape from the oil layer 420 from the water collection 320. As mentioned elsewhere herein, one or more openings of any suitable shape and configuration may be positioned on the uppermost portion 312 to facilitate the removal of water.

[0031] In certain embodiments and as illustrated in Fig. 4A, the lowermost portion 314 may be provided with a cross-sectional dimension "W2" that is greater than a cross-sectional dimension "W1" of the uppermost portion 312. Without wishing to be limited to any particular theory, this configuration is believed to advantageously provide structural stability to the at least one tube 310 relative to the plenum base 104 and provide additional design flexibility in water removal. For example, one or more openings 440 may be formed on the lowermost portion 314 of the at least one tube 310 where a water-contacting surface 404 of the plenum base 104 defines a boundary or is part of a boundary defining the one or more of the openings 440.

[0032] With further reference to Fig. 4A, the at least one tube 310 includes one or more openings 435 positioned at the uppermost portion 312 to allow water to exit at a position outside or above the oil layer 420. In the case that the main channel 410 opens toward the plenum top 102, the first opening 435 may be positioned on a sidewall 350 of the at least one tube 310 and open and connected to the main channel 410 to additionally discharge water out through the sidewall 350 for removal from the main channel 410. In the case that the main channel 410 does not open toward the plenum top 102, for example, when the uppermost portion 312 is connected to the plenum top 102, the one or more first openings 435 are the main water outlet.

[0033] Referring again to Fig. 4A, one or more second openings 440 may be positioned at the lowermost portion 314 of the at least one tube 310 to facilitate water inlet from the water collection 320. The one or more second openings 440 are open to the main channel 410 such that water, upon entering through the one or more second openings 440, can move through the main channel 410 along direction L.

[0034] With further reference to Fig. 6, the first and second elongated openings 610, 620 may be formed on a sidewall of the uppermost portion 312 of the at least one tube 310. The first and second elongated openings 610, 620 may be spaced apart from one another while each extending along a longitudinal direction "L" with a length L1 and L2, respectively. The length L1 may differ from the length L2 to account for variations in water depth and operating temperatures at specific locations on the plenum base 104.

[0035] In certain embodiments and as illustrated in Fig.7, the at least one tube 310 may be configured to include a stem 710 and a branch 720 extending from the stem 710. In this configuration, the branch 720 opens for water to exit at a position outside and above the oil layer 420. If desired, more than one branch may be positioned and extend from the stem 710 as additional water storage.

[0036] In one or more embodiments, the invention set forth herein is believed to overcome certain challenges associated with excessive water accumulation in an intake manifold. From this discussion and the accompanying drawings and claims, it will be readily apparent to those skilled in the art that various changes, modifications, and variations may be made without departing from the true spirit and legitimate scope of the invention as set forth in the following claims.

Claims

[1] Intake manifold (100) comprising: an air collector (110) comprising an air collector lower part (104) and an air collector upper part (102) positioned adjacent to the air collector lower part (104); and at least one tube (310) supported on the air collector base (104) and extending therefrom toward the air collector top (102) for transporting water, the at least one tube (310) comprising first and second spaced-apart tubes, the first tube differing from the second tube at least in a cross-sectional area and / or an extending length. [2] The intake manifold of claim 1, wherein a cross-section of the at least one tube (310) includes a wall enclosing a void. [3] The intake manifold of claim 1 or 2, wherein the at least one tube (310) further comprises a first opening (435) for discharging water, the first opening being positioned closer to the plenum top (102) than the plenum bottom (104). [4] The intake manifold of claim 3, wherein the at least one tube further comprises a second opening (440) for admitting water, the second opening (440) being positioned closer to the plenum base (104) than the plenum top (102). [5] Intake manifold according to one of claims 1 to 4, wherein the at least one tube (310) is spaced from the plenum top (102). [6] Intake manifold according to one of claims 1 to 5, wherein the plenum base (104) comprises a cavity, wherein the at least one tube (310) is positioned on and in contact with the cavity. [7] Intake manifold according to one of claims 1 to 6, wherein the at least one tube (310) is formed integrally with the plenum base (104). [8] Intake manifold according to one of claims 1 to 7, wherein the at least one tube (310) comprises a through-opening positioned on the wall. [9] Intake manifold according to one of claims 1 to 8, wherein the at least one tube (310) comprises a stem (710) and a branch (720) extending from the stem (710). [10] Intake manifold (100) comprising: an air collector (110) comprising an air collector lower part (104) and an air collector upper part (102) positioned adjacent to the air collector lower part (104); and at least one tube (310) supported on the air collector base (104) and extending therefrom towards the air collector top (102), the at least one tube (310) comprising a first opening (435) for discharging water and a second opening (440) for admitting water, the second opening (440) being positioned between the first opening (435) and the air collector base (104), the at least one tube (310) comprising first and second spaced-apart tubes, the first tube differing from the second tube at least in a cross-sectional area and / or an extending length. [11] The intake manifold of claim 10, wherein a cross-section of the at least one tube (310) includes a wall enclosing a void. [12] Intake manifold according to claim 10 or 11, wherein the at least one tube (310) is spaced from the plenum top (102). [13] Intake manifold according to one of claims 10 to 12, wherein the plenum base (104) comprises a cavity, wherein the at least one tube (310) is positioned on and in contact with the cavity. [14] Intake manifold according to one of claims 10 to 13, wherein the at least one tube (310) is formed integrally with the plenum base (104). [15] Intake manifold (100) comprising: an air plenum (110) comprising an air plenum lower portion (104) and an air plenum upper portion (102), the air plenum lower portion (104) being positioned adjacent to the air plenum upper portion (102) and comprising a cavity; and at least one tube (310) formed integrally with the cavity of the air collector base (104) and extending therefrom towards the air collector top (102), wherein the at least one tube (310) comprises a first opening (435) for discharging water and a second opening (440) for admitting water, wherein the second opening (440) is positioned between the first opening (435) and the air collector base (104), wherein the at least one tube (310) comprises first and second spaced-apart tubes, wherein the first tube differs from the second tube at least in a cross-sectional area and / or an extending length.

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