EGR Plenum Integration with Intake Manifold Runners

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Internal combustion engine systems face challenges with packaging space and EGR imbalance due to the positioning of EGR conduits, which increase the complexity of integrating exhaust gas recirculation systems with intake manifolds, leading to inefficiencies and potential coking issues.

Innovation Solution

The introduction of an EGR plenum fluidly coupled to the intake manifold allows for the recirculation of exhaust gases between or directly into intake runners, reducing packaging size and minimizing EGR imbalance through strategically located apertures and flanges, enabling better control and distribution of exhaust gases.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If EGR conduits are integrated with intake manifolds using conventional positioning, then exhaust gas recirculation can be achieved, but packaging space increases and EGR imbalance occurs

Engineering Contradiction:

ImproveEGR distribution balanceVSAvoidpackaging space

Core Design Contradiction:

ReliabilityVSVolume of moving object

Solution Approach 1:

The patent merges the EGR plenum with the intake manifold by forming the plenum as an integral part of the manifold structure. The plenum is positioned within the manifold housing and shares the same structural space, eliminating the need for separate EGR conduits and reducing overall packaging volume while maintaining proper EGR distribution to all cylinders

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent repositions the EGR plenum from a conventional external conduit arrangement to an internal positioning within the manifold housing. By utilizing the vertical and lateral space within the manifold structure itself, the design achieves three-dimensional space optimization that reduces packaging requirements while improving EGR distribution balance

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Reliability

If conventional EGR conduit positioning is used, then exhaust gas recirculation is possible, but device complexity increases

Engineering Contradiction:

Improveexhaust gas recirculation functionVSAvoidintegration complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The EGR plenum is merged with the intake manifold as a single integrated structure. The plenum is formed as part of the manifold housing with direct fluid communication between the plenum and intake runners, eliminating the need for separate conduits, flanges, and connection points that would increase assembly complexity

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The intake manifold is segmented into functional zones including the EGR plenum region and intake runner regions. The plenum is positioned to receive exhaust gas separately while maintaining independent flow paths to each cylinder, allowing for modular manufacturing and simplified assembly while maintaining EGR recirculation function

Inventive Principle:

Principle #1Segmentation

3Reliability

If EGR conduits are positioned conventionally, then exhaust gas recirculation can be implemented, but coking issues occur

Engineering Contradiction:

Improveexhaust gas recirculation efficiencyVSAvoidcoking risk

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent implements different flow characteristics in different regions of the EGR plenum. The apertures are strategically positioned and sized to create optimal flow patterns that prevent stagnant zones where coking could occur. The plenum geometry is designed to maintain uniform exhaust gas distribution that prevents localized overheating and carbon deposition

Inventive Principle:

Principle #3Local quality

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 decreases packaging size, enhances control over recirculated exhaust, and minimizes EGR imbalance within the intake manifold, improving engine efficiency and reducing the risk of coking and other inefficiencies.

Implementation Method 1

a plenum that includes a flange configured to receive exhaust from an exhaust gas recirculation (EGR) valve of the vehicle, that is fixed to the intake manifold, and that includes apertures configured to flow exhaust from the plenum into the intake manifold

Methodology Applied

Scientific EffectFluid flow through apertures:

Implementation Method 2

the lower portion is vibration welded to the middle portion, and the upper portion is vibration welded to the middle portion

Methodology Applied

Scientific EffectVibration welding:

Data Source

PatentUS11852109B1Vehicle gas distribution to intake manifold runners

Publication Date: 2023.12.26 GM GLOBAL TECHNOLOGY OPERATIONS LLC

AI summary

An intake system of an internal combustion engine of a vehicle includes: an intake manifold configured to be fluidly coupled to a throttle valve and including intake runners for cylinders, respectively, of the internal combustion engine; and a plenum that includes a flange configured to receive gas from a valve of the vehicle, that is fixed to the intake manifold, and that includes apertures configured to flow gas from the plenum into the intake manifold one of: between ones of the intake runners; and directly into the intake runners.