Integrated EGR Heat Exchanger in Engine Block Cavity
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Solution Overview
Problem
Existing EGR systems face space constraints and complexity in integrating heat exchangers due to the need for separate components and conduits, which complicates engine assembly and maintenance.
Innovation Solution
A heat exchange device is integrated into the engine block's cavity, where the liquid coolant flows through, eliminating the need for coolant inlet and outlet conduits and allowing the heat exchanger to be housed within the engine block, with a structural element comprising a plate and supports that absorb thermal stresses without additional structural elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a heat exchanger is integrated into the engine block cavity, then space usage is reduced and device complexity is reduced, but the structural element must withstand thermal stresses from the bundle of tubes
Solution Approach 1:
The patent merges the heat exchanger device with the engine block by integrating it into a cavity of the engine block. The structural element of the heat exchanger is directly installed within the engine block cavity, eliminating the need for separate mounting structures and reducing overall space usage while maintaining structural integrity to handle thermal stresses.
Solution Approach 2:
The heat exchanger is segmented into a structural element comprising a plate and supports, with a bundle of tubes arranged between the supports. This segmentation allows the thermal stresses to be distributed and absorbed by the structural element rather than concentrating on a single component, resolving the stress issue while maintaining compact integration.
2Device complexity
If a heat exchanger is installed as a separate device, then it requires coolant inlet and outlet conduits taking up space, but integrating it into the engine block eliminates these fluid connections
Solution Approach 1:
The heat exchanger is merged with the engine block's coolant system by utilizing the engine block's existing coolant flow path. The liquid coolant flows directly through the engine block cavity where the heat exchanger is installed, eliminating the need for separate coolant inlet and outlet conduits and reducing space in the engine bay.
3Reliability
If additional components are added to the EGR system, then heat exchange functionality is improved, but the packaging requirements complicate engine assembly and maintenance
Solution Approach 1:
The heat exchanger is combined with the engine block structure, eliminating the need for separate mounting operations and reducing the number of assembly steps. The integrated design allows the heat exchanger to be installed as part of the engine block assembly process, simplifying both manufacturing and maintenance operations.
Solution Approach 2:
The engine block serves multiple functions: it provides structural support for the engine, houses the coolant flow path, and contains the cavity for the heat exchanger. This multi-functionality reduces the need for additional components and simplifies the overall engine assembly process.
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 configuration reduces space usage, eliminates fluid connections, and prevents cooled gas outlet conduits, enhancing compact integration and simplifying engine assembly and maintenance while maintaining effective heat exchange performance.
Implementation Method 1
The recirculated gas must be pretreated to prevent it from having dirt particles and to prevent its temperature from being high... The heat exchanger cooling the exhaust gas to adapt it to the intake temperature
Implementation Method 2
A liquid coolant evacuating heat from the hot gas is allowed to pass between the shell and the bundle of tubes cooling the tubes of the bundle of tubes
Implementation Method 3
a structural element which in turn comprises a plate, a first support and a second support... The assembly forms a device which is housed in the engine bay... the structural element comprises a plate and supports that absorb thermal stresses
Data Source
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AI summary
The present invention relates to a heat exchange device suitable for cooling recirculated exhaust gases in an EGR (Exhaust Gas Recirculation) system. The invention is characterized by a configuration which allows integrating the heat exchanger in a cavity of the engine block of an internal combustion engine with fluid communication with the liquid coolant.