Integrated EGR Cooler and Compressor Housing
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Solution Overview
Problem
Existing exhaust gas recycling systems for internal combustion engines have a high number of structural components, leading to increased space requirements, weight, and manufacturing costs, and do not effectively utilize positive thermodynamic and engineering interactions between the exhaust gas heat exchanger and compressor.
Innovation Solution
A device integrating an exhaust gas heat exchanger and compressor into a single, cohesive housing element, constructed from a minimal number of components using materials like aluminum, which reduces weight and manufacturing complexity, and allows for efficient cooling and compression of exhaust gas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If exhaust gas heat exchanger and compressor are constructed as separate components, then each component can be optimized independently, but the overall system requires more space, has higher weight, and increased manufacturing costs
Solution Approach 1:
The patent combines the exhaust gas heat exchanger and compressor into a single integrated device with a common housing. The heat exchanger core, compressor, and associated components are merged into one unit, reducing the total number of separate structural components while maintaining the functional independence of each subsystem.
Solution Approach 2:
The common housing serves multiple functions: it encloses both the heat exchanger and compressor, provides structural support for the entire assembly, and facilitates mounting to the exhaust system. This multi-functional design reduces the need for separate housings and mounting structures.
2Weight of moving object
If exhaust gas heat exchanger and compressor are constructed as separate components, then assembly and disassembly are straightforward, but the overall assembly requires more space and results in higher weight
Solution Approach 1:
By merging the heat exchanger and compressor into a single integrated unit, the patent eliminates the weight of separate housings, mounting brackets, and connection components. The combined device requires fewer fasteners and less structural material overall, reducing total weight despite the increased complexity of the integrated assembly.
3Area of stationary object
If traditional exhaust gas heat exchanger design is used, then cooling function is provided, but additional components and housing are required increasing space requirements
Solution Approach 1:
The compressor is positioned within or adjacent to the heat exchanger housing, with the exhaust gas flow path arranged to pass through the heat exchanger core first and then into the compressor. This nested arrangement allows the exhaust gas to be cooled and compressed in a compact sequence, minimizing the overall footprint while maintaining effective cooling.
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
The integrated design minimizes structural components, reduces weight and space, lowers manufacturing and assembly costs, and enhances the efficiency of the internal combustion engine by improving fuel consumption and reducing emissions.
Implementation Method 1
the exhaust gas is cooled off prior to the admixture in a heat exchanger, referred to as an exhaust gas heat exchanger or exhaust gas recycling cooler
Implementation Method 2
The coolant flows around the tubes or conduits on their outside so that the mass flow of the coolant flows in an intermediate space formed by a housing and the tubes or conduits
Implementation Method 3
a compressor for compressing the cooled exhaust gas before being fed into the fresh air current taken in by the internal combustion engine
Data Source
AI summary
A device for the recycling of exhaust gas of an internal combustion engine in a motor vehicle. The device comprises an exhaust gas heat exchanger constructed with a first housing element with an inlet and an outlet for the exhaust gas and at least one inlet and at least one outlet for a coolant, and a compressor which is constructed with a second housing element with an inlet and an outlet for the exhaust gas. The first housing element of the exhaust gas heat exchanger and the second housing element of the compressor are constructed as a housing connected to a cohesive, compact component so that the exhaust gas heat exchanger and the compressor are arranged inside the housing.