One-Piece Charge Fluid Intake Housing Integrating Heat Exchanger
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Solution Overview
Problem
Existing charge fluid intake modules for internal combustion engines have elaborate and costly connections between the charge fluid intake module and the heat exchanger, which are susceptible to breakdown, and lack flexible integration of exhaust gas cooling and recirculation systems.
Innovation Solution
A one-piece housing design for the charge fluid intake module that integrates a heat exchanger for exhaust gas cooling and a connection piece for gaseous charge fluid, allowing for a reduced and flexible connection to the charge fluid intake tract, with optional separate exhaust gas recirculation pipes, and using less heat-resistant materials for the second housing portion to accommodate the heat exchanger.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a separate heat exchanger is connected to the charge fluid intake module via external pipes or flanges, then the heat exchanger can be provided as a separate unit, but the connection becomes elaborate and costly and is susceptible to breakdown
Solution Approach 1:
The patent integrates the heat exchanger directly into the housing of the charge fluid intake module, merging two previously separate components into a unified structure. This eliminates external connections via pipes or flanges, reducing connection complexity and potential failure points while maintaining the functionality of separate heat exchanger units.
2Device complexity
If the heat exchanger is integrated into the charge fluid intake tract, then connection elaborateness is reduced, but the heat exchanger must be provided together with the charge fluid intake tract and cannot be separately configured
Solution Approach 1:
The housing is divided into a first housing portion and a second housing portion, with the heat exchanger integrated into the second portion. This segmentation allows the heat exchanger to be provided as a separate unit that is subsequently integrated into the housing, combining the benefits of reduced connection complexity with the flexibility of separate configuration.
3Device complexity
If the housing is constructed in one piece, then connection complexity is reduced and assembly is simplified, but the housing must be made from heat-resistant materials throughout
Solution Approach 1:
The housing is constructed with different material properties in different regions: the first housing portion is made from heat-resistant material to withstand high temperatures, while the second housing portion containing the heat exchanger can use less heat-resistant, more cost-effective materials. This local differentiation reduces overall manufacturing costs while maintaining necessary thermal resistance where required.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design reduces connection complexity and costs, enhances flexibility, and ensures effective exhaust gas cooling and recirculation, while allowing for a more integrated and space-efficient assembly of the heat exchanger and charge fluid intake tract components.
Implementation Method 1
a heat exchanger for an exhaust gas (45)
Implementation Method 2
cooling fluid connections to the cover are arranged such that cooling fluid can flow into the further cooling channel
Implementation Method 3
a further cooling channel is provided to isolate the exhaust gas recirculation pipe from the charge air intake pipe. Cooling fluid connections to the cover are arranged such that cooling fluid can flow into the further cooling channel
Data Source
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AI summary
The invention concerns a charge fluid intake module (1) for an internal combustion engine (11) having a housing (2) which forms a flow path for a gaseous charge fluid (13, 17), in particular air, a gas and/or an air/gas mixture. According to the concept of the invention, it is provided that the housing (2) is designed to receive a heat exchanger (31) for an exhaust gas (45) and substantially in one piece with two housing portions, a connection piece (7) for the charge fluid on the first housing portion (3) being designed for connection to an inlet manifold (83) of a charge fluid intake tract (10).