Intake Manifold Expansion Cooling for Supercharged Engines
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Solution Overview
Problem
Supercharged internal combustion engines face challenges in reducing charge air temperature effectively, leading to increased knocking combustion and inefficiencies due to the heating of air during compression, which existing cooling methods struggle to mitigate without adding structural complexity.
Innovation Solution
The air intake system is designed to allow air to be sucked into the combustion chamber during an expansion phase, with a distributor pipe length that reduces charge pressure and achieves targeted expansion, cooling the air without additional moving components, optimizing air intake for both Otto and diesel engines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a larger intercooler is used to reduce charge air temperature, then the cooling effectiveness is improved, but the structural complexity and space requirements increase
Solution Approach 1:
The intake manifold is designed to perform dual functions: distributing charge air to cylinders and simultaneously cooling it through controlled expansion. The expansion of charge air within the intake manifold creates a cooling effect that reduces the need for additional cooling components, making the system self-sufficient for both distribution and temperature reduction.
Solution Approach 2:
The intake manifold is transformed from a single-function component (air distribution) to a multi-functional component that combines air distribution with charge air cooling. By designing the manifold with specific volume and expansion characteristics, it serves both as a distribution network and as a heat exchanger through expansion cooling.
2Productivity
If compression is increased to improve supercharging effect, then the air intake efficiency is improved, but the air temperature increases leading to knocking combustion
Solution Approach 1:
The system changes the thermodynamic parameters of charge air by controlling its expansion within the intake manifold. By adjusting the timing and degree of expansion, the system reduces charge air temperature while maintaining the benefits of compression, effectively changing the pressure-temperature trajectory of the intake air.
Solution Approach 2:
The expansion cooling is synchronized with the engine cycle, creating periodic expansion events that coincide with intake phases. This periodic expansion action temporarily reduces temperature during critical intake periods while allowing compression to occur during other phases of the cycle.
3Temperature
If expansion devices are added downstream of the intercooler to reduce combustion air temperature, then the temperature reduction is improved, but the device complexity increases
Solution Approach 1:
The patent extracts the expansion cooling function from separate downstream expansion devices and integrates it directly into the intake manifold structure. By taking out the cooling function and combining it with the distribution function in a single component, the system eliminates the need for additional standalone expansion devices.
4Productivity
If resonance supercharging is used to improve air intake, then the air intake efficiency is improved, but the charge air temperature increases causing knocking tendencies
Solution Approach 1:
The system dynamically controls the expansion process within the intake manifold to counteract the temperature-raising effects of resonance supercharging. By adjusting expansion timing and characteristics, the system creates dynamic cooling that adapts to the resonant pressure waves, maintaining efficient air intake while preventing excessive temperature rise.
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 results in a significant reduction of charge air temperature, enabling a more efficient combustion process with improved fuel efficiency, reduced knocking tendencies, and lower exhaust gas temperatures, allowing for earlier ignition and optimized engine performance.
Implementation Method 1
the air intake into the combustion chamber takes place during an expansion phase of the air mass in the air intake system
Implementation Method 2
the compression of the intake air results in an increase in air temperature
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
The internal-combustion engine has multiple cylinders, an air suction unit (3), a compressor for promotion of the combustion air, and a combustion chamber arranged in the cylinder. The air suction unit is formed in such a manner that a part of air mass flows into the combustion chamber of the internal-combustion engine during expansion phase of air mass in the air suction unit.