Exhaust Manifold Flow Guide Element for Turbocharger and EGR

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Solution Overview

Problem

Existing exhaust manifolds for internal combustion engines with exhaust turbocharging and recirculation devices face challenges in maintaining optimal flow conditions, particularly during non-steady engine operation, which affects turbine pressurization and exhaust gas recirculation efficiency.

Innovation Solution

Incorporating a flow guide element in the header pipe near outlet openings for targeted division of exhaust gas flow, allowing for improved pressurization of the exhaust turbocharger and variable arrangement without the need for flutter valves, by deflecting exhaust gas flows onto outlet openings in a fluidically favorable manner.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a dual-flow exhaust manifold is used with separate outlet openings for exhaust gas recirculation and exhaust turbocharger, then exhaust gas recirculation can be achieved, but flow conditions are difficult to control and turbulence increases

Engineering Contradiction:

Improveexhaust gas recirculation capabilityVSAvoidflow control complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The exhaust manifold is segmented into multiple flow paths with separate outlet openings for exhaust gas recirculation and exhaust turbocharger, allowing independent control of each flow while maintaining overall system integration

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A flow guide element is introduced as an intermediary component between the exhaust gas flow and the outlet openings, serving as a mediator that directs and controls the flow distribution without requiring complex control mechanisms

Inventive Principle:

Principle #24Intermediary (Mediator)

2Volume of moving object

If outlet openings are positioned diametrically opposed in the header pipe, then compact arrangement is achieved, but flow resistance increases

Engineering Contradiction:

Improveexhaust manifold compactnessVSAvoidflow resistance

Core Design Contradiction:

Volume of moving objectVSObject-generated harmful factors

Solution Approach 1:

Curved flow channels are introduced between the diametrically opposed outlet openings, allowing the exhaust gas to follow a curved path that reduces abrupt directional changes and minimizes flow resistance while maintaining compact arrangement

Inventive Principle:

Principle #14Spheroidality (Curvature)

Solution Approach 2:

The flow guide element changes the flow parameters by directing the exhaust gas flow at specific angles toward the outlet openings, optimizing the flow distribution and reducing resistance despite the diametrically opposed positioning

Inventive Principle:

Principle #35Parameter changes

3Productivity

If high exhaust gas recirculation rates are required, then emission control is improved, but turbine pressurization is reduced

Engineering Contradiction:

Improveexhaust gas recirculation rateVSAvoidturbine pressurization

Core Design Contradiction:

ProductivityVSStress or pressure

Solution Approach 1:

The flow guide element is designed to dynamically adjust the flow distribution between exhaust gas recirculation and exhaust turbocharger based on operating conditions, allowing high recirculation rates while maintaining adequate turbine pressurization through optimized flow paths

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

Different flow paths with different resistance characteristics are provided for exhaust gas recirculation and exhaust turbocharger, allowing each function to operate optimally under different local flow conditions while maintaining overall system balance

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 solution enables effective pressurization of the exhaust turbocharger, supports high exhaust gas recirculation rates, and reduces turbulence and flow resistance, enhancing the response behavior of the exhaust turbocharger and minimizing backpressure at high engine speeds.

Implementation Method 1

the flow guide element arranged between the adjacent inflow openings deflects the opposing exhaust gas flows onto the outlet openings

Methodology Applied

Scientific EffectFluid flow deflection:

Implementation Method 2

an effective pressurization of the exhaust turbocharger connected to the exhaust manifold can be achieved

Methodology Applied

Scientific EffectPressure differential: Pressure Gradient

Data Source

PatentUS9109543B2Exhaust manifold for an internal combustion engine, in particular in motor vehicles

Publication Date: 2015.08.18 MAN TRUCK & BUS SE

AI summary

An exhaust manifold for an internal combustion engine with exhaust turbocharging and an exhaust gas recirculation device, includes a header pipe with several inflow openings connected with the combustion chambers of the internal combustion engine via connecting pieces, and outlet openings branching from the header pipe via connecting branches for the exhaust gas recirculation and the exhaust turbocharger. To achieve a high exhaust gas recirculation rate and an effective pressurization of the exhaust turbocharger with exhaust gas, at least one flow guide element is arranged in the header pipe close to the outlet openings which divides the exhaust gas flow onto the two outlet openings in a targeted manner.