Engine Intake Device EGR Mixing via Chamber Edge Segmentation

Solution Overview

Problem

The existing intake devices for engines suffer from irregular flow of intake air through the intercooler, leading to inefficient mixing of EGR gas with intake air, resulting in uneven distribution to engine cylinders.

Innovation Solution

The intake device features a chamber with an intake-air supply opening smaller than the intercooler core's downstream face, an extension passage portion that extends upwardly, and strategically positioned EGR introduction ports to ensure proper mixing of EGR gas with the intake air by creating a main stream that swirls and directs the EGR gas effectively into the intake air flow.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If the chamber outlet is opened widely to allow intake air to flow freely from the chamber to the downstream portion, then the intake air flow capacity is improved, but the flow becomes irregular and mixing with EGR gas becomes insufficient

Engineering Contradiction:

Improveintake air flow capacityVSAvoidflow uniformity

Core Design Contradiction:

ProductivityVSStability of the object's composition

Solution Approach 1:

The chamber outlet is segmented into multiple opening edges (first opening edge, second opening edge, third opening edge) that create separate flow paths. This segmentation organizes the previously random flow into structured streams, allowing each edge to guide a specific portion of intake air in a controlled manner toward the downstream portion, thus maintaining flow capacity while improving uniformity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different opening edges are positioned at different locations and orientations to create locally optimized flow patterns. The first opening edge creates a first stream, the second opening edge creates a second stream, and the third opening edge creates a third stream, each with specific flow characteristics tailored to its position. This local differentiation ensures comprehensive and uniform mixing with EGR gas across the entire downstream cross-section.

Inventive Principle:

Principle #3Local quality

2Ease of manufacture

If the chamber outlet is opened widely, then the ease of manufacture is improved, but the mixing of EGR gas with intake air becomes insufficient

Engineering Contradiction:

Improvechamber outlet structureVSAvoidmixing uniformity

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The chamber outlet is segmented into multiple opening edges (first opening edge, second opening edge, third opening edge) that create separate flow paths. This segmentation organizes the previously random flow into structured streams, allowing each edge to guide a specific portion of intake air in a controlled manner toward the downstream portion, thus maintaining flow capacity while improving uniformity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different opening edges are positioned at different locations and orientations to create locally optimized flow patterns. The first opening edge creates a first stream, the second opening edge creates a second stream, and the third opening edge creates a third stream, each with specific flow characteristics tailored to its position. This local differentiation ensures comprehensive and uniform mixing with EGR gas across the entire downstream cross-section.

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 ensures orderly flow of intake air and effective mixing of EGR gas, ensuring even distribution to engine cylinders, thereby improving combustion stability.

Implementation Method 1

an upper edge portion which is configured to separate the intake air flowing from the chamber into the extension passage portion from the inside wall part and to form a main stream of flowing of the intake air inside the extension passage portion

Methodology Applied

Scientific EffectFlow separation and swirling: Vortex Ring

Implementation Method 2

the outside wall part of the extension passage portion includes an EGR introduction port to join the EGR passage to the downstream-side intake passage, the EGR introduction port being arranged at a position capable of supplying the EGR gas toward the main stream of flowing of the intake air

Methodology Applied

Scientific EffectGas mixing: Turbulence

Data Source

PatentUS11280301B2Intake device of engine

Publication Date: 2022.03.22 MAZDA MOTOR CORP

AI summary

An intake device of an engine comprises an intercooler, an intake passage including a downstream-side intake passage, and an EGR passage recirculating exhaust gas to the downstream-side intake passage. An intake-air supply opening having an opening area smaller than an area of a downstream-side face of an intercooler core is provided at a downstream side wall of a chamber. The downstream-side intake passage includes an extension passage portion extending upwardly along the downstream side wall. The intake-air supply opening includes an upper edge portion which separates the intake air flowing from an inside wall face of the extension passage portion and forms flowing main streams of the intake air inside the extension passage portion. EGR introduction ports are arranged at positions capable of supplying the EGR gas toward the flowing main streams.