ENGINE SYSTEM WITH A SINGLE-PIECE INTAKE MANIFOLD AND METHOD FOR ITS MANUFACTURING
Patent Information
- Authority / Receiving Office
- DE · DE
- Patent Type
- Patents
- Current Assignee / Owner
- FORD GLOBAL TECH LLC
- Filing Date
- 2019-01-14
- Publication Date
- 2026-07-30
AI Technical Summary
Traditional intake manifolds are complex to manufacture, requiring assembly of multiple parts, which increases time and cost, and limits shape flexibility, affecting airflow efficiency.
A one-piece intake manifold design with integrated throttle body and fuel injector, formed through additive manufacturing, featuring a chamber with partial walls and gooseneck ducts that merge seamlessly with ram tubes, eliminating the need for seals and allowing for optimized airflow distribution.
The one-piece design reduces manufacturing complexity, enhances airflow efficiency, and minimizes pressure losses, while enabling even gas distribution and turbulence promotion, improving engine performance.
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Abstract
Description
TECHNICAL AREA
[0001] Various embodiments relate to a one-piece intake manifold with integrated throttle body housing and fuel injection for an internal combustion engine in a vehicle and a method for its manufacture. BACKGROUND
[0002] An intake manifold is a part of the engine that supplies the fuel-air mixture to the engine's cylinders. Its primary function is to distribute the intake gases evenly to each intake port in the cylinder heads, as a uniform distribution optimizes engine efficiency and power output. The design and geometry of the intake manifold influence gas flow, turbulence, pressure drops, and other airflow phenomena within the manifold. SUMMARY
[0003] According to one embodiment, an engine component is disclosed. The engine component includes an intake manifold made of layered sheets. The intake manifold defines a plurality of tuned tubes, each having a gas outlet leading to a cylinder head. The intake manifold further defines a chamber with partial walls forming channels that share a common gas inlet extending into a gooseneck pipe with an integrated throttle body, such that the gooseneck pipe transitions into the channels and tuned tubes without a seal. The throttle body may include a shaft integrated into the gooseneck pipe and a valve configured to restrict the gas flow in the gooseneck pipe. The shaft may extend from a first side of the gooseneck pipe to a second side of the gooseneck pipe.The throttle body can be positioned adjacent to an opening located on the opposite side of the gooseneck pipe from the gas inlet. The throttle body can be fully integrated into the gooseneck pipe. The partial walls can form an endoskeletal structure configured to support the intake manifold. The partial walls can project inward from opposite sides of the chamber. The partial walls can be thicker than the rest of the chamber.
[0004] In an alternative embodiment, an engine system is disclosed. The engine system can include a cylinder head and a layered material defining an intake manifold. The intake manifold has a plurality of tuned tubes, each with a gas outlet connected to the cylinder head. The fuel injection system can include a tube tapering from a first end to a nozzle section at a second end. The gooseneck pipe can include a section of increased thickness arranged as a support for the fuel injection, the support extending outward from an outer layer of the gooseneck pipe. The fuel injection system can extend from an outside to an inside of the gooseneck pipe.The nozzle section can extend from an outside of the gooseneck pipe to an inside of the gooseneck pipe in close proximity to an opening of the gooseneck pipe. The nozzle section can include a tip with multiple apertures to inject gas into the gooseneck pipe. The engine system can further include a throttle body located within a cavity of the gooseneck pipe. The throttle body and fuel injection can be adjacent to each other, such that the nozzle section is configured to expel fuel toward a flap of the throttle body to prevent gas from entering the gooseneck pipe.
[0005] In a further alternative embodiment, a method for forming material layers defining an intake manifold for internal combustion engines is disclosed by additive manufacturing. The intake manifold has a plurality of resonating tubes, each having a gas outlet leading to a cylinder head, and a chamber with partial walls forming channels that create a common gas inlet extending outward into a gooseneck pipe containing a fuel injection unit, a throttle body, or both. The gooseneck pipe transitions into the channels and resonating tubes so that there is no seal between the gooseneck pipe, chamber, and resonating tubes. The partial walls form an endoskeletal structure configured to support the intake manifold. The method can further include forming a support for the fuel injection unit in an outer layer of the gooseneck pipe.The formation process can involve shaping the fuel injection nozzle as a tube that is partially located on the outside of the gooseneck pipe and extends into the interior of the gooseneck pipe. The formation process can involve shaping the fuel injection nozzle as a tube that is partially located on the outside of the gooseneck pipe and extends into the interior of the gooseneck pipe. The formation process can involve forming a fuel injection nozzle with a variety of apertures. List of characters Fig. Figure 1 illustrates a scheme of a non-restrictive example of an internal combustion engine capable of applying various embodiments of the present disclosure; Fig. Figure 2 illustrates an exploded view of an example intake manifold according to the state of the art; Fig. Figure 3 illustrates an exploded view of an alternative example intake manifold according to the prior art; Fig. Figure 4 illustrates a perspective view of a non-restrictive example of a one-piece intake manifold according to one or more embodiments; Fig. Figure 5 shows a cross-sectional view through the one-piece intake manifold of Fig. 4 along the line 5 - 5 ; Fig. Figure 6 shows an alternative cross-sectional view through the one-piece intake manifold of Fig. 4 along the line 6 - 6 ; Fig. Figure 7 shows an alternative cross-sectional view through the one-piece intake manifold of Fig. 4 along the line 7 - 7 ; Fig. Figure 8 shows an alternative embodiment of the one-piece intake manifold with a non-restrictive example of a gas inlet channel disclosed herein; Fig. Figure 9 illustrates a cross-sectional view through the section of the gas inlet channel of Fig. 8 along the line 9 - 9 ; Fig. Figure 10 shows a detailed view of a section of the in Fig. 9 shown fuel injection; Fig. Figure 11 shows a cross-sectional view of an example PVC device. Fig. 9 along the line 11 - 11 ; Fig. Figure 12 shows an alternative view of the PCV device; and Fig. Figure 13 shows a further alternative view of the gas intake channel with an example EGR device. DETAILED DESCRIPTION
[0006] Embodiments of the present disclosure are described herein. However, it should be understood that the disclosed embodiments are merely examples and that other embodiments may take multiple and alternative forms. The figures are not necessarily to scale; some features may be exaggerated or minimized to show details of certain components. Therefore, the specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching a person skilled in the art that the present invention may be used in a variety of ways. The average person skilled in the art understands that several features illustrated and described with reference to any one of the figures can be combined with features in one or more other figures to produce embodiments that are not explicitly illustrated or described.The combinations of illustrated features provide representative embodiments for typical applications. However, multiple combinations and modifications of the features in accordance with the teachings of this disclosure may be desirable for certain applications or implementations.
[0007] Unless expressly stated otherwise, all numerical quantities in this description that indicate dimensions or material properties are to be understood as modified by the word "approximately" to describe the broadest possible scope of the present disclosure.
[0008] The first definition of an acronym or other abbreviation applies to all subsequent uses of the same abbreviation and accordingly to normal grammatical variations of the originally defined abbreviation. Unless explicitly stated otherwise, the measurement of a property is determined by the same technique to which reference was made before or after for that same property.
[0009] Reference is made to the compositions, embodiments, and methods of the present invention, which are known to the inventors. However, it should be understood that the disclosed embodiments are only exemplary of the present invention, which can be embodied in various and alternative forms. Therefore, the specific details disclosed herein are not to be interpreted as limiting, but merely as representative bases for teaching a person skilled in the art, enabling them to use the present invention in a variety of ways.
[0010] The geometry, orientation, and design of an intake manifold have a direct influence on the efficiency of the internal combustion engine. Fig. Figure 1 illustrates a schematic, non-restrictive example of an internal combustion engine. 20 The engine 20 features a large number of cylinders 22 on, one of which is illustrated. The engine 20can have any number of cylinders 22 They can have three, four, six, eight, or any other number. The cylinders can be positioned in various configurations within the engine, for example, as a V-engine, inline engine, or another arrangement.
[0011] The example engine 20 has a combustion chamber 24 up, which each cylinder 22 is assigned. The cylinder 22 is through cylinder walls 32 and pistons 34 formed. The piston 34 is equipped with a crankshaft 36 connected. The combustion chamber 24 is in fluid contact with an example intake manifold 38 and the exhaust manifold 40 An inlet valve 42 controls the flow from the intake manifold 38 into the combustion chamber 24 An exhaust valve 44 controls the flow from the combustion chamber 24 to the exhaust manifold 40The intake and exhaust valves 42 , 44 They can be operated in various ways, as is known in the technology for controlling engine operation.
[0012] A fuel injection system 46 supplies fuel from a fuel system directly into the combustion chamber 24 so that the engine is a direct injection engine. A low-pressure or high-pressure fuel injection system can be used with the engine. 20 An ignition system includes a spark plug. 48 , which is controlled in such a way that it provides energy in the form of a spark to ignite a fuel-air mixture in the combustion chamber 24 provides. In other embodiments, other fuel supply systems and ignition systems or techniques, including compression ignition, may be used.
[0013] The engine 20It includes a control unit and various sensors configured to provide signals to the control unit for managing the air and fuel supply to the engine, ignition timing, engine power and torque, and the like. Engine sensors may include an oxygen sensor in the exhaust manifold. 40 , an engine coolant temperature sensor, an accelerator pedal position sensor, an engine distributor pressure sensor (MAP), an engine position sensor for the crankshaft position, an air mass sensor in the intake manifold 38 , including a throttle position sensor and the like, but are not limited to that.
[0014] In some embodiments, the motor 20It can be used as the sole drive motor in a vehicle, such as a conventional vehicle or a stop-start vehicle. In other embodiments, the motor can be used in a hybrid vehicle where an additional drive motor, such as an electric motor, is available to provide additional power for propelling the vehicle.
[0015] Each cylinder 22 It can be operated under a four-stroke cycle, which includes an intake stroke, a compression stroke, a firing stroke, and an exhaust stroke. In other embodiments, the engine can be operated with a two-stroke cycle. During the intake stroke, the intake valve opens. 42 and the exhaust valve 44 closes while the piston 34 from the top of the cylinder 22 to the underside of the cylinder 22 moved to draw air from the intake manifold 38into the combustion chamber 24 to introduce the piston position 34 at the top of the cylinder 22 This is generally referred to as top dead center (TDC). The piston position 34 at the bottom of the cylinder 22 is generally referred to as bottom dead center (BDC).
[0016] During the compression stroke, the intake and exhaust valves 42 , 44 closed. The piston 34 moves from bottom to top towards the cylinder 22 , to the air in the combustion chamber 24 to compress.
[0017] The fuel is then fed into the combustion chamber. 24 introduced and ignited. In the depicted engine 20 The fuel is fed into the chamber 24 injected and then via the spark plug 48 Ignited. In other examples, the fuel can be ignited by compression ignition.
[0018] During the expansion stroke, the ignited fuel-air mixture expands in the combustion chamber. 24 out, causing the piston 34 from the top of the cylinder 22 to the underside of the cylinder 22 moves. The movement of the piston. 34 This causes a corresponding movement of the crankshaft 36 and provides mechanical torque for the engine 20 .
[0019] The inlet valve remains closed during the exhaust stroke. 42 closed and the outlet valve 44 opens. The piston 34 moves from the bottom of the cylinder to the top of the cylinder 22 , to remove the exhaust gases and combustion products from the combustion chamber 24 to remove by increasing the volume of the chamber 24 reduced. The exhaust gases flow from the combustion cylinder. 22 to the exhaust manifold 40 and to a post-treatment system, such as a catalyst.
[0020] The positions and timing of the inlet and outlet valves 42 , 44 Furthermore, the fuel injection timing and the ignition timing can be varied for the different engine strokes.
[0021] The engine 20 includes a cooling system to remove heat from the engine 20 to dissipate, and can be used as a cooling jacket with water or another coolant in the engine. 20 be integrated.
[0022] Between the cylinder block 76 and the cylinder head 79 can a cylinder head gasket 78 be inserted to fit the cylinders 22 to seal.
[0023] The illustrated non-restrictive example of the intake manifold 38 , which leads to the engine 20 leads, includes a chamber housing 50 , which directs the intake gases onto the vibration tubes 56 distributed. The vibration tubes 56 adjust the intake valves 42The intake gases, including ambient air, exhaust gases from exhaust gas recirculation, the like, or a combination thereof, are provided. A throttle valve 90 is provided to allow the flow of intake gases to the chamber housing 50 to control the throttle valve 90 It can be connected to an electronic throttle body for electronic control of the valve position. The intake manifold 38 It may be connected to an exhaust gas recirculation (EGR) system, a canister purge valve (CPV), a fuel system, a positive crankcase ventilation (PCV) system, a brake booster system, or the like, or a combination thereof. Upstream of the throttle valve. 90 An air filter (not shown) can be provided.
[0024] Typically, as in Fig. 2 shown, an intake manifold 138 They are manufactured in individual parts that are then assembled. This shows Fig. 2 for example an exploded view of an intake manifold system 138 according to one embodiment for use with the engine in Fig. 1. The intake manifold 138 is a modular system that allows various separate components of the intake manifold to be positioned variably and connected to the manifold 138 to assemble. The assembly requires the production of individual parts, so the intake manifold 138 It can be assembled in several configurations based on the engine position and vehicle packaging considerations. The individual components include the chamber body. 150 , the end plate 152 to accommodate the internal volume of the chamber body 150 , the openings 154 of the chamber body 150 for mounting vibration tubes 156 and a throttle body connection 158 .
[0025] Other intake manifolds with only one installation position within the engine, such as an intake manifold 138' , as in Fig. 3 shown, are typically manufactured in individual pieces or parts and then assembled and secured with fasteners, adhesives, welds or a combination thereof. Fig. 3 represents an intake manifold 138' with several discrete parts, including a chamber 150 and a unique piece that incorporates a multitude of vibration tubes 156 and a flange 160 forms, which at an upper end 162 the chamber 150 with fasteners 162 can be attached. To the chamber 150 To further reinforce the ribs, they are typically 164 on the outer part of the chamber 150 appropriate.
[0026] However, assembling the various components into a typical intake manifold is quite complex and time-consuming. For improved fuel efficiency, some of the parts may be made from lightweight materials such as composites and plastics. This can result in a number of connecting parts made from different materials, which typically presents a challenge, especially if the connection needs to be leak-proof. Assembly is time-consuming and increases cycle time. Furthermore, whenever a connection of at least two components is required, necessary quality control checks are essential to ensure the connection is made correctly. Such checks are expensive and increase cycle time.
[0027] Furthermore, traditional manufacturing methods and the need to assemble individual parts impose limitations on the shape of the individual parts that can be produced. Therefore, the overall efficiency of the intake manifold may be limited, as the shape may not be practical from an aerodynamic perspective due to cost, assembly, and time constraints.
[0028] Therefore, it would be desirable to equip an intake manifold with reduced manufacturing complexity, improved efficiency, and reduced time and cost expenditure for intake manifold production.
[0029] In one or more embodiments, a one-piece intake manifold is used. 238 disclosed, which overcomes one or more disadvantages of the aforementioned prior art. The one-piece intake manifold 238 , as for example in Fig. 4 shown includes a chamber or chamber housing 250with a gas inlet 264 , which gradually splits into a multitude of channels 256 extends. The chamber 250 It is hollow and provides an internal volume for the intake gases that enter through the channels. 256 to be distributed to the engine. The chamber 250 It can be dimensioned and shaped to maintain a partial vacuum during engine operation. The intake gas(es) can contain fuel, ambient air, EGR gas, or a combination thereof.
[0030] In a non-restrictive example, the chamber may 250 Additional features include, for example, a sensor holder for a sensor such as an inlet gas temperature sensor, a pressure sensor, a similar sensor, or a combination thereof. The chamber 250 can be a fastening function 252 include those used to connect or support the intake manifold 238is used with the engine, the vehicle, or both. The fastening function 252 may include a flange, an aperture or the like, so that the one-piece intake manifold 238 It can be attached to the engine, the vehicle, or both.
[0031] While, according to the prior art, the chamber is typically a “logarithmic” chamber body with a width of the inner cavity and a distance between the longest sides that is quite regular, the disclosed chamber exhibits 250 a varying form, which is formed by a multitude of channels 256 is defined. The chamber 250 includes partial walls 272 , which the channels 256 form, which are formed by the common gas inlet 264 exit. The partial walls 272 form an endoskeletal structure that is configured to support the intake manifold 250 to support the partial walls. 272 separate the channels 256from each other. The partial walls 272 can from opposite sides of the chamber 250 They protrude into the cavity of the chamber, extend from one side of the chamber to the other, but do not connect the opposite sides of the chamber. 250 Alternatively, the partial walls can be 272 even on only one side of the chamber 250 be formed. The chamber 250 Therefore, it has no ribs on the outside, since the endoskeleton, which is formed by the partial walls 272 is formed, the chamber 250 reinforced.
[0032] The partial walls 272 can have a greater thickness / height than the thickness of the other sections of the chamber 250 The partial walls 272 They can have varying heights, so that at least one partial wall extends further into the cavity of the chamber. 250 extends beyond at least one other partial wall 272 The height of the partial walls 272This will be explained below. Alternatively, all partial walls can be used. 272 the same height in the cavity of the chamber 250 exhibit.
[0033] The canals 256 , divided by the partial walls 272 , can be shaped in various ways. For example, the channels can 256 For example, they can be straight, curved, or both. The channels 256 Depending on the engine design, the channels can have different lengths. 256 They can be configured to take advantage of the Helmholtz resonance effect. Each channel 256 It can be shaped differently, have a different geometry, to maximize airflow into the engine. For example, at least one channel can 256 have different dimensions than the other channels 256 The dimensions can include length, angle of curvature, and width. The dimensions can be within the length of a channel. 256vary. For example, the channel may 256 towards the air intake 264 to an opening 254 expand.
[0034] As the Fig. 5 and Fig. 6 shows the gas inlet 264 a first end of the canals 256 The channels 256 indicate a second end 266 on, which through an opening or aperture 254 is formed. The channels 256 can via the opening 254 stepwise into vibrating tubes 268 over. The channels 256 They transition into the vibration tubes, so that there is no seal between the chamber 250 and the vibration tubes 268 is available.
[0035] The aperture 254 is at the opposite end of each channel 256 when the gas intake 264 positioned. The aperture 254 can be perpendicular to the flow of intake gases via the gas inlet 264be arranged. The opening 254 It could be a bell mouth opening. The bell mouth opening 254 is a tapered opening where the cone may resemble a bell shape. The bell mouth opening 254 It can be an expanding or contracting opening. The angle of the opening 254 It can be tapered at approximately 30-60° or at approximately 45°. The opening 254 extends gradually or leads into a multitude of vibrating tubes 268 The transition from the canals 256 into the openings 254 and into the vibration tubes 268 It can proceed smoothly without interrupting the airflow, a gradual transition of the curves of the same material. The transition of the channels. 256 A flange can be used for the opening. 282 and a notch 255 include for which in Fig. Seven examples are shown.
[0036] The vibration tubes or channels 268, whose cross-section in Fig. As shown in Figure 7, they form a convergent intake air path that directs the intake gas into the engine's intake or into an intake port in the cylinder head. The oscillating tubes 268 They can have the same or different dimensions, shape, or both. The vibration tube 268 It can have a circular, oval, or rectangular cross-section. The vibrating tube 268 can have the same cross-section as the opening 254 exhibit the vibration tube 268 can become smaller if the gas passes through an outlet 270 flows into the engine. The vibration tube 268 It can have a uniform geometry, width, or both along its entire length. The integration of the bell mouth opening. 254 , which belong to the vibration tubes 268 This can lead to an increase in the efficiency of the airflow through the intake manifold. 238 to increase the engine height.
[0037] The cross-sectional area of the bell mouth opening 254 can be larger than that of the vibration tube 268 The cross-sectional area of the bell mouth opening 254 can be larger than the area of the vibration tube 268 The cross-sectional area of the bell mouth opening 254 It can be dimensioned so that the air velocity entering the bell mouth opening is low in order to reduce noise, turbulence, pressure loss and the like, and gradually increases to the desired design velocity of the vibrating tube. 268 increases.
[0038] The cross-section of the opening 254 It can be rectangular, square, round, oval, or the like. The opening 254 can a flange 282 exhibit at least part of its circumference. The opening 254 can have the same, smaller, or larger diameter than the diameter of the gas inlet. 264 .
[0039] As in Fig. 6 in relation to the channels 256 As can be seen further, the individual channels 256 separated from each other. The division can be achieved by one or more areas, the partial walls. 272 form the partial walls 272 can form raised sections that extend towards the interior of the chamber 250 extend, but not opposite surfaces of the chamber 250 connect the partial walls 272 can side sections of each channel 256 form. The height of the partial walls 272 can vary. The partial walls 272 peaks 278 exhibiting the highest sections of the separation surfaces 272 form.
[0040] The canals 256 They therefore contain the flattest section 274 with the height h1 , where the partial walls have a central section 276 with the height h2 and a tip 278 with the height h3exhibit. h1 > h2 > h3 Additional raised sections of the partial walls 272 with additional heights that are h1 , h2 , h3 Any deviations will be taken into consideration.
[0041] The flattest section 274 each channel 256 may have a different shape and surface area than in the other channels 256 For example, the canal 256 , which led to the opening 254 leads to the area furthest from the air intake 264 removed, the flattest section 274 include, which serves as an expansion area 275 is arranged. The expansion area 275 can be through a partial wall 272 between the adjacent canals 256 and an outside 280 the chamber 250 can be defined. Another expansion area can be defined as a channel. 256 next to the gas inlet 264It includes being divided by a partial wall 272 and an outside of the chamber 280 is defined. The expansion area 275 can have a width that extends towards the air intake 264 to the mouth opening 254 The expansion area is enlarged. 275 can extend over the entire length between the air intake 264 and the opening 254 extend. The width of the expansion area 275 The expansion area can vary along its entire length to accommodate the most optimized airflow patterns. The varying width of the expansion area allows for a uniform distribution of the intake gas. For example, w3 > w1 > w2.
[0042] In contrast to the expansion area 275 of the outermost channel 256 and / or the one connected to the gas inlet 264 The shallowest section of the adjacent canal may be 274 the other channels 256 not from the gas intake264 extend, but must extend into the middle sections. 276 and lace 278 the partial walls 272 be enclosed. Thus, those via the gas inlet will be affected. 264 into the chamber 250 incoming inlet gases predominantly flow onto the open expansion area 275 Especially the expansion area 275 in the canal 256 adjacent to the gas inlet 264 It allows gas to enter the canal 256 to direct the gas flow, which, according to the prior art, is typically difficult to supply with gas. The purpose of this design is therefore to enable a uniform distribution of the intake gases throughout the entire chamber. 250 and the intake manifold 238 , so that the gases from the gas inlet 264 via the channels 256 to open 254 , via the vibration tubes 268 and the outlet 270Flow evenly. An even distribution optimizes the efficiency and performance of the motor.
[0043] As in the Fig. The intake manifold is shown in figures 4-6. 238 It is designed as a single, unified piece. This unified piece includes the chamber. 250 with the channels 256 , which gradually move into the vibrating tubes 268 to move on. The one-piece intake manifold 238 This therefore represents an article with a surface featuring smooth contours throughout the entire article, with smooth transitions from the gas inlet. 264 to the canal outlets 270 This allows for a uniform distribution of intake gases to the engine, an optimal degree of turbulence-enhancing atomization, and the minimization of pressure losses. One-piece means that the entire intake manifold is a single piece. 238is formed as one piece, so that the sections described individually above are integral sections of the intake manifold. 238 and are not designed as individual parts that are later assembled into an intake manifold. The one-piece intake manifold 238 Therefore, no seals are needed. For example, there is no seal between the chamber. 250 and the vibration tubes 268 available.
[0044] The inner surface of the one-piece intake manifold 238 It can be smooth, textured, rough, or a combination thereof. For example, at least one section of the inner surface can be textured to create a desired level of turbulence within the intake manifold. 238 to produce.
[0045] The wall thickness of the intake manifold can be reduced compared to intake manifolds in the prior art. While, for example, the typical intake manifold has a wall thickness of approximately 3.5 to 4.5 mm and stiffening ribs in the outer part of the chamber, the one-piece intake manifold disclosed herein can be reduced. 238 They have a wall thickness of approximately 2 mm. Stiffening ribs are not required because partial walls 272 are present, which serve to support the intake manifold. 238 are configured.
[0046] In another embodiment, which is described in Fig. As shown in section 8, the one-piece intake manifold includes 238 also a gas inlet channel, duct or gooseneck pipe 284 The swan neck pipe 284 extends from the gas inlet 264 outwards. The swan neck pipe 284 gradually enters the canals 256 over, so that there is no seal between the chamber 250and the swan neck pipe 284 is available.
[0047] The swan neck pipe 284 can have the same diameter as the gas inlet 264 exhibit. The swan neck pipe 284 can withdraw from the chamber 250 out in the same or a similar general direction as the vibration tubes 268 Extend, bend, or both. The swan neck pipe 284 The gooseneck pipe can have uniform dimensions, geometry, or both along its entire length. 284 It can take on a variety of forms. For example, the swan neck pipe can be formed as a cylindrical tube (284). The swan neck pipe 284 can form an elbow-shaped section. The swan-neck pipe 284 It can be straight or curved. The gooseneck pipe 284 It can be hollow. The gooseneck pipe 284It can be partially perforated, perforated along its entire length, or free of perforations. The swan neck conduit 284 may have protrusions, ribs, or other internal structures to optimize gas flow from a first end 285 , which defines a connection, an opening or an aperture, for the gas inlet 264 to guide the cable that forms the second end. The swan neck cable 284 It has an inner or internal section and an external section.
[0048] The swan neck pipe 284 It can also define various connectors, brackets, sensors, devices, or a combination thereof for connection to the engine, vehicle systems, or both. The gooseneck cable 284 may have a larger or smaller number of ports or sensor connections than in Fig. Figure 8 is shown, and they can be arranged in various ways. For example, the gooseneck pipe284 For example, it may include a brake booster connection, an exhaust gas recirculation (EGR) device, a connection or bracket for a positive crankcase ventilation (PCV) device, a connection or bracket for a canister purge valve (CPV) or system, a throttle body, or the like, or a combination thereof. The arrangement of the connections, brackets, sensors, and devices can be based on their size and packaging considerations, and may be located on the inner or outer section of the gooseneck pipe. 284 or both.
[0049] The swan neck pipe 284 can form a throttle body connection piece. The gooseneck pipe 284 can thus form an element that is a throttle body 286 , whose non-restrictive example in Fig. 9 is shown, with the chamber 250 connects. The swan neck pipe284 This can thus create a limiting and / or a flow channel for the intake gases from the throttle body. 286 to the chamber 250 provide.
[0050] The throttle body 286 can be fully inserted into the swan neck pipe 284 be integrated. The throttle body 286 can a wave 288 , a flap 290 , include an electronic throttle or a combination thereof. The shaft 288 can be used with the one-piece intake manifold 238 It should be integrated so that the shaft is a section of the intake manifold. 238 is formed. The wave 288 extends from one side of the swan neck pipe 284 to a second side of the swan neck pipe 284 Alternatively, in the swan neck pipe 284 an opening housing of the shaft 288 to capture the wave 288 and the shovel or the flap 290be formed. The flap 290 It could be an exhaust valve or another type of valve. The shape and dimensions of the valve, such as the diameter, correspond to those of the gooseneck pipe. 284 .
[0051] The flap 290 can be configured to control the gas flow in the gooseneck pipe 284 to obstruct, if this is desirable. The flap 290 is on the wave 288 movable. The flap 290 is about the wave 288 The formed axis is rotatable. The flap 290 can around the wave 288 be movable around so that the flap 290 It can be oriented in different positions.
[0052] In a first position, the flap can 290 in minimal contact with the sides of the gooseneck pipe 284 The first position is occupied by the swan neck pipe. 284opened so that the gas flow passes through the swan neck pipe 284 is released. In the first position, the gas can flow from the first end. 285 until the second end 264 the swan neck pipe 284 Flow freely. The first position defines a fully open gooseneck pipe. 284 In the first position, the gas flow is minimally limited.
[0053] The valve is in a second position 290 in contact with the swan neck pipe 284 around the circumference of the swan neck pipe 284 around. In the second position, the gas flow is completely restricted, so that the gas flow is minimized or non-existent, while the intake manifold 238 is used.
[0054] The third position is any position between the first and second positions. The flap is in the third position. 290 in partial contact with the sides of the swan neck pipe 284, which affects the gas flow via the swan neck pipe 284 partially limited.
[0055] The throttle body 286 can be located at any point within the gooseneck pipe 284 be arranged in this way. The throttling element can thus 286 for example between the first end 285 the swan neck pipe 284 and the gas inlet 264 the chamber 250 are located. The throttle body 286 can be adjacent to the opening 285 be arranged on opposite sides of the swan neck pipe 284 when the gas intake 264 is located.
[0056] The throttle body 286 can before the chamber 250 , an EGR device 316 , a PCV device 300 , a fuel injection system 292 , such as, or a combination thereof. As in Fig. As can be seen in section 9, it is desirable to remove the throttle body. 286 near a fuel injection system 292 to order.
[0057] The fuel injection 292 can be a tapered pipe or a canal 294 with a nozzle section 296 include the pipe 294 can extend from a first end into the nozzle section 296 taper at a second end. The fuel injection 292 extends from one outside of the gooseneck pipe to the inside of the gooseneck pipe. The tapered channel 294 , the nozzle 296 or both can enter the swan neck pipe via an opening 284 ask.
[0058] The tapered canal 294 , the nozzle 296 or both can enter the swan neck pipe via an opening 284 protrude. The fuel injection 292 can be on a support section 298be arranged, extending from the pipe section of the swan neck pipe 284 or from an outer layer of the swan neck pipe 284 extends outwards. The support section 298 , the fuel injection 292 or both can be an integral part of the gooseneck pipe 284 form the support section 298 It can have any shape or configuration. For example, the support section can... 298 For example, generally triangular. The support 298 can be a shape with the same or similar contours as the fuel injection channel 294 exhibit the bracket 298 can the entire or partial length of the fuel injection section(s) 292 , who is on the outside of the swan neck pipe 284 located, extend.
[0059] The nozzle 296 can be configured to deliver fuel into the gooseneck pipe 284to expel. The nozzle 296 can be arranged so that they fit the flap 290 of the throttling body 286 The fuel discharge can occur via a tip with a variety of apertures to introduce gas into the gooseneck pipe. 284 to inject. As in Fig. As can be seen 10 further on, the nozzle section 296 its tip has a series of openings 298 have openings from which the fuel is injected. 298 They can have the same or different dimensions. Each opening 298 It can be arranged symmetrically or asymmetrically.
[0060] The nozzle 286 It can be connected to one or more sensors that support fuel injection control. For example, one or more sensors can coordinate the fuel injection. 292 and the throttle body 290 support so that the flap290 is positioned in such a way that it obstructs the gas flow when fuel injection occurs. 292 Fuel into the swan neck pipe 284 releases, whereby the flap opens 290 can be in the second position.
[0061] As in the Fig. 8 and Fig. As can be seen further on in section 9, the swan neck pipe 284 a PCV device 300A typical PCV system includes an intake port located downstream of the throttle body. The intake port is typically a single hole machined through a metal or composite material of the intake manifold. The intake port therefore typically has sharp edges, with the machining extending into the air path. When the system actively draws a vacuum to vent the crankcase, all of the airflow is drawn from this single port. However, drawing air from this single, relatively small, concentrated air source can disrupt the airflow in that particular area. To correct this disruption, the PCV 300 revealed.
[0062] The PCV device 300 can occur on the outer section of the swan neck pipe 284 are located. The PCV device 300 can be separated from an outer layer of the swan neck pipe 284up to the outer edge of the swan neck pipe 284 extend. The PCV device 300 can a case 302 , a canal 304 with an opening 306 and a diversion device 308 include the case 302 can occur in the outer layer of the swan neck pipe 284 be formed. The case 302 It can be rectangular or square in shape. The casing 302 can be elongated. The casing 302 It can be hollow, including an inner section that is hollow. The casing 302 can be one or more openings, ports, apertures or holes 310 include the holes 310 protrude from inside the case 302 into the inner section of the swan neck pipe 284 The holes 310 can be angled, configured to supply gas to / from the crankcase while simultaneously minimizing disturbances in the gas flow in the gooseneck pipe 284to minimize.
[0063] The holes 310 They can be symmetrical, asymmetrical, regularly or irregularly shaped and spaced. The holes 310 They can have the same or different shapes. For example, the holes can... 310 For example, they can be circular, oval, oblong, square, rectangular, and polygonal. Like the Fig. 11 and Fig. 12 show, the case 302 a number of first holes 310' with a circular cross-section and a further number of second holes 310" They include holes shaped like elongated slots. Together, these holes support optimal airflow.
[0064] To further support optimal airflow to / from the crankcase and simultaneously prevent disruption of airflow in the gooseneck pipe 284 To prevent this, the PCV device includes 300 a canal 304 with an opening 306and a diversion device 308 within the canal 304 The canal 304 can be from a central section of the housing 302 protrude and extend to provide air intake for the crankcase. The channel 304 can have a constant diameter. Alternatively, the channel can 304 It must be tapered. The channel contains 304 an opening or an outlet aperture. 306 .
[0065] The PCV device includes a diverter device. 308 The diversion device 308 is located inside the canal 304 and extends to the holes 310 of the case 302 to. Alternatively, the diversion device 308 inside the case 302 arranged, which extends into the canal 304 to open 306 extends there. The diversion device 308 can take any form. The diversion device 308It could be a plate. The diverting device 312 It can generally be flat. The plate can be shaped like a tongue or a shovel, with a first end. 312 , which is tapered, and a second end that has a forked end section 314 forms. The forked end section 314 may have dimensions that are equal to, smaller than, or larger than the diameter of the channel 304 are.
[0066] The PCV device 300 or sections of it, such as the casing 302 and the holes 310 , can be integral components of the intake manifold 238 be educated. The diversion device 308 can either be an integral part of the intake manifold 238 or formed separately and placed in the canal 304 be used.
[0067] In a further alternative embodiment, the one-piece intake manifold can 238 an EGR device 316include the EGR device. 316 It serves as a nitrogen oxide reduction device, capable of recirculating a portion of the engine exhaust gas back to the engine cylinders. The gas that passes through the intake manifold... 238 The flowing air is enriched with combustion-inert gases, which act as an absorber for combustion heat, thus reducing peak temperatures in the cylinders.
[0068] The typical EGR inlet port is located within the intake manifold inlet, downstream of the throttle body. Like the PCV inlet port, this port is typically machined, leaving an opening with sharp edges. When the EGR system is active, exhaust gas is therefore introduced through this port into the intake manifold's gas flow, potentially disrupting the flow. Furthermore, the mixing of this exhaust gas with the gas in the swan neck pipe is a concern. 284 The amount of gas present is minimal due to the single opening.
[0069] To prevent the mixing of the exhaust gas with the gas in the swan neck pipe 284 To improve the existing gas as well as the overall performance and engine efficiency, the EGR device is used. 316 revealed. The EGR device 316 , depicted in the Fig. 9, Fig. 11 and Fig. 13, includes a pipe 318 , which is attached to the outer section of the swan neck pipe 284 borders and / or extends from an outer section of the swan neck pipe 284 extends outwards. The pipe 318 It has a helical shape. The tube 318 It can have a shape other than a spiral. The pipe 318 It can generally have a circular, oval, rectangular, square, regular, or irregular cross-section. The pipe 318 is hollow to allow exhaust gas flow through the pipe 318 to enable the pipe 318It can have a uniform or uneven diameter. The pipe 318 The pipe can have uniform dimensions along its entire length. 318 It could be a section of the swan neck pipe 284 The number of turns in the helix can be 1, 2, 3, 4, 5, 6, 7, 8, 9, 10 or more.
[0070] The pipe 318 includes one or more holes 320 , which the pipe 318 with an inner section of the swan neck pipe 284 connect the holes 320 They can be elongated slits. Alternatively or additionally, they can be holes. 320 They may be of various shapes, such as circular, square, oval, the like, or a combination thereof. The holes 320 can be along the length of the pipe 318 The holes may be distributed regularly or irregularly. 320 enable the exhaust gas to spread along the length of the pipe318 , so that the mixing of exhaust gas and gas in the swan neck pipe 284 This will be done gradually and more efficiently.
[0071] In at least one embodiment, the EGR device 316 adjacent to the PCV device 300 or the case 302 be arranged. Both the EGR device 316 as well as the PCV device 300 can affect the thoracic body 286 It should be arranged downstream. The PCV device 300 can be adjacent to two wound sections or coils of the EGR pipe 318 be arranged.
[0072] A method for forming the intake manifold 238is also disclosed herein. The prerequisite for the production of the disclosed intake manifold, which has unique structural features illustrated in the figures and described above, can be additive manufacturing. Additive manufacturing processes refer to technologies that create 3D objects by adding material layer by layer. The material can be plastic, metal, concrete, or the like. Additive manufacturing encompasses a range of technologies such as 3D printing, rapid prototyping, direct manufacturing, layer-by-layer fabrication, additive manufacturing, bath photopolymerization including stereolithography (SLA) and digital light processing (DLP), material blasting, binder blasting, material extrusion, powder bed fusion, sheet lamination, directed energy deposition, and the like.
[0073] Early additive manufacturing focused on pre-production visualization models, prototype production, and similar applications. The quality of the manufactured items determined their use, and vice versa. Early items produced through additive manufacturing were generally not designed to withstand long-term use. Additive manufacturing equipment was also expensive, and speed was a barrier to widespread adoption of additive manufacturing for high-volume production. However, more recently, additive manufacturing processes have become faster and more cost-effective. Additive manufacturing technologies have also improved in terms of the quality of the manufactured items.
[0074] Any additive manufacturing technique can be used to create the revealed intake manifold. 238to produce, since additive manufacturing technologies operate on a similar principle. The process can involve the use of a computer, 3D modeling software (computer-aided design or CAD), a machine capable of applying material to produce the layered intake manifold, and the layering material. An example process might also involve creating a virtual design of the intake manifold in a CAD file using a 3D modeling program or with the aid of a 3D scanner, which creates a 3D digital copy of the intake manifold, for example, from a previously manufactured intake manifold. The process can involve slicing the digital file, with each slice containing data, so that the intake manifold can be built layer by layer. The process can involve reading each slice by a machine that applies the layering material.The process can involve adding successive layers of the layering material in liquid, powder, or sheet form and forming the intake manifold by bonding each layer to the next, so that there are hardly any visually discernible signs of the discretely applied layers. The layers form the three-dimensional solid intake manifold described above, with a chamber housing containing a gas inlet. The housing includes a plurality of resonating tubes, each resonating tube terminating in an opening that leads to a gas distribution channel with a gas outlet at its opposite end, so that the additive manufacturing process results in a single, unified piece. The process can also incorporate additional features as integral components of the intake manifold. 238 through additive manufacturing, for example the EGR device 316 , the PCV device 300 , the fuel injection292 , the throttle body 286 , the like, or at least a part thereof. The material used may be metal, plastic, composite material, the like, or a combination thereof.
[0075] The additively manufactured intake manifold 238 It may require one or more post-processing steps to obtain the final 3D object, such as stabilization. Stabilization refers to adjusting, modifying, improving, altering, securing, maintaining, preserving, balancing, or changing one or more properties of the additively manufactured intake manifold so that the resulting intake manifold meets specified standards after manufacturing.
[0076] The stabilized intake manifold remains in compliance with various standards for several hours, days, weeks, months, years, and / or decades after manufacturing. The property to be modified can relate to physical, chemical, optical, and / or mechanical properties. These properties can include dimensional stability, functionality, durability, wear resistance, lightfastness, chemical resistance, water resistance, ultraviolet (UV) resistance, heat resistance, shape memory, desired gloss, color, mechanical properties such as toughness, strength, flexibility, elongation, and the like, or a combination thereof.
[0077] Additive manufacturing enables the creation of complex shapes, wave-like forms, smooth contours, and gradual transitions between adjacent segments or parts of the one-piece intake manifold, resulting in a more uniform distribution of intake gases to the engine. The intake manifold produced according to the method described above 238 can be free of fasteners, adhesives, or other types of connections typical of traditional intake manifold manufacturing.
[0078] Although exemplary embodiments are described above, it is not intended that these embodiments describe all possible forms of the disclosure. Rather, the words used in the description are descriptive rather than limiting, and it is understood that several modifications can be made without deviating from the essence and scope of the disclosure. Furthermore, features of different embodiments can be combined to form further embodiments of the disclosure.
[0079] According to the present invention, a machine component is provided comprising: an intake manifold made of layered strata defining a plurality of vibrating tubes, each having a gas outlet leading to a cylinder head, and a chamber with partial walls forming channels that share a common gas inlet extending into a gooseneck pipe, with a throttle body integrated therein, so that the gooseneck pipe transitions into the channels and vibrating tubes without a seal.
[0080] According to one embodiment, the throttling body comprises a shaft integrated into the gooseneck pipe and a valve configured to restrict the gas flow in the gooseneck pipe.
[0081] According to one embodiment, the wave extends from a first side of the gooseneck cable to a second side of the gooseneck cable.
[0082] According to one embodiment, the throttle body is arranged adjacent to an opening located on the opposite side of the gooseneck pipe from the gas inlet.
[0083] According to one embodiment, the throttle body is fully integrated into the gooseneck pipe.
[0084] According to one embodiment, the partial walls form an endoskeleton structure configured to support the intake manifold.
[0085] According to one embodiment, the partial walls project inwards from opposite sides of the chamber.
[0086] According to one embodiment, the partial walls have a greater thickness than the rest of the chamber.
[0087] According to the present invention, an engine system is provided comprising: a cylinder head; and layered material defining an intake manifold, with a plurality of tuned tubes, each having a gas outlet connected to the cylinder head, and a chamber with an endoskeletal support structure forming channels extending from a common gas inlet, the gas inlet extending outwards into a gooseneck pipe having built-in fuel injection and gradually transitioning into the channels and tuned tubes, so that there is no seal between the gooseneck pipe, the chamber and the tuned tubes.
[0088] According to one embodiment, the fuel injection system comprises a pipe that tapers from a first end into a nozzle section at a second end.
[0089] According to one embodiment, the gooseneck pipe includes a section of increased thickness which is arranged as a support for the fuel injection, the support extending outwards from an outer layer of the gooseneck pipe.
[0090] According to one embodiment, the fuel injection extends from an outside of the gooseneck line to an inside of the gooseneck line.
[0091] According to one embodiment, the nozzle section projects from an outside of the swan neck pipe into an inside of the swan neck pipe in the immediate vicinity of an opening of the swan neck pipe.
[0092] According to one embodiment, the nozzle section comprises a tip with a plurality of apertures for spraying gas into the gooseneck pipe.
[0093] According to one embodiment, the invention is further characterized by a throttling element located in a cavity of the swan neck pipe.
[0094] According to one embodiment, the throttle body and the fuel injection are adjacent to each other, such that the nozzle section is configured to expel fuel towards a flap of the throttle body to prevent gas from entering the gooseneck pipe.
[0095] According to the present invention, a method comprises the following: forming material layers by additive manufacturing that define an intake manifold for internal combustion engines with a plurality of resonating tubes, each having a gas outlet leading to a cylinder head, and a chamber with partial walls forming channels that create a common gas inlet extending outwards into a gooseneck pipe with a fuel injection, throttle body, or both, wherein the gooseneck pipe transitions into the channels and resonating tubes so that there is no seal between the gooseneck pipe, chamber, and resonating tubes, and the partial walls form an endoskeleton structure configured to support the intake manifold.
[0096] According to one embodiment, the invention is further characterized by forming a support for the fuel injection in an outer layer of the swan neck line.
[0097] According to one embodiment, the forming involves shaping the fuel injection as a tube that is partially located on the outside of the gooseneck pipe and extends into an interior of the gooseneck pipe.
[0098] According to one embodiment, the forming involves forming a fuel injection tip comprising a plurality of apertures.
Claims
[1] Engine component, comprising: an intake manifold made of layered strata defining a multitude of tuned tubes, each having a gas outlet leading to a cylinder head, and a chamber with partial walls forming channels that share a common gas inlet extending into a gooseneck pipe with an integrated throttle body, so that the gooseneck pipe transitions into the channels and tuned tubes without a seal. [2] Engine component according to claim 1, wherein the throttle body comprises a shaft integrated into the gooseneck line and a valve configured to restrict the gas flow in the gooseneck line. [3] Engine component according to claim 1 or 2, wherein the throttle body is arranged adjacent to an opening located on the opposite side of the gooseneck pipe from the gas inlet. [4] Engine component according to any of the preceding claims, wherein the partial walls form an endoskeleton structure configured to support the intake manifold. [5] Motor component according to one of the preceding claims, wherein the partial walls of opposite surfaces of the chamber project inwards. [6] Motor component according to one of the preceding claims, wherein the partial walls have a greater thickness than the remainder of the chamber. [7] Engine system, comprising: a cylinder head; and layered material that defines an intake manifold which has the following features a multitude of vibration tubes, each having a gas outlet connected to the cylinder head, and a chamber with an endoskeletal support structure forming channels radiating from a common gas inlet, the gas inlet extending outwards into a gooseneck pipe incorporating built-in fuel injection and gradually transitioning into the channels and vibrating tubes, so that there is no seal between the gooseneck pipe, the chamber and the vibrating tubes. [8] Engine system according to claim 7, wherein the fuel injection comprises a pipe that tapers from a first end into a nozzle section at a second end. [9] Engine system according to claim 7 or 8, wherein the gooseneck line comprises a section with increased thickness which is arranged as a support for the fuel injection, the support extending outwards from an outer layer of the gooseneck line. [10] Engine system according to one of claims 7-9, wherein the fuel injection extends from an outer gooseneck line to an inner gooseneck line. [11] Motor system according to one of claims 7-10, wherein the nozzle section projects from an outside of the gooseneck pipe into an inside of the gooseneck pipe in the immediate vicinity of an opening of the gooseneck pipe. [12] Engine system according to one of claims 7-11, wherein the throttle body and the fuel injection are adjacent to each other, such that the nozzle section is configured to expel fuel towards a flap of the throttle body to prevent gas from entering the gooseneck line. [13] Procedures, including: Forming material layers by additive manufacturing that define an intake manifold for internal combustion engines with a plurality of resonating tubes, each having a gas outlet leading to a cylinder head, and a chamber with partial walls forming channels that create a common gas inlet extending outwards into a gooseneck pipe with a fuel injection, throttle body, or both, the gooseneck pipe transitioning into the channels and resonating tubes so that there is no seal between the gooseneck pipe, chamber, and resonating tubes, and the partial walls forming an endoskeletal structure configured to support the intake manifold. [14] Method according to claim 13, further comprising forming a support for fuel injection in an outer layer of the swan neck line. [15] Method according to claim 13 or 14, wherein the forming includes shaping the fuel injection as a tube which is partially located on the outside of the gooseneck line and extends into an interior of the gooseneck line.