Vehicle Intake Structure Heat Exchange with Power Control Unit
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Solution Overview
Problem
Existing intake structures for internal combustion engines face challenges in cooling intake air without direct access to fresh cooling air and require a large number of additional component parts, especially when space is limited in the engine room.
Innovation Solution
An intake structure that utilizes an onboard device with a built-in cooling device, such as a power control unit, to cool both the device and the intake passage member, allowing for heat exchange without additional cooling devices, and features a curved intake passage design to maximize heat transfer and minimize noise and friction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If an air-cooled air cooler is positioned near the front grill to cool intake air, then the intake air temperature is reduced, but the device complexity and space requirements increase due to the need for additional cooling components and direct access to fresh air
Solution Approach 1:
The intake passage member is designed to serve dual functions: as part of the intake system and as a heat exchange surface. By positioning it near the power control unit, it utilizes the cooling device already present for the power control unit to also cool the intake air, eliminating the need for a separate air cooler system
Solution Approach 2:
The cooling function for both the power control unit and the intake air is merged into a single system. The cooling device serves both components simultaneously, and the intake passage member acts as both an air conduit and a heat exchanger, reducing overall system complexity
2Temperature
If an air-cooled air cooler is positioned near the front grill to cool intake air, then the intake air temperature is reduced, but the device complexity increases due to the need for additional component parts
Solution Approach 1:
The intake passage member serves multiple functions including air conduction and heat exchange, while the cooling device serves both the power control unit and the intake air, reducing the total number of components needed
Solution Approach 2:
The cooling systems for the power control unit and intake air are combined into one system, and the intake passage member is designed to function as both an air passage and a heat exchanger, minimizing the quantity of separate parts
3Temperature
If the intake passage member is placed close to the power control unit for heat exchange, then cooling efficiency is improved, but thermal expansion and contraction may cause relative movement and friction
Solution Approach 1:
A flexible seal member is introduced between the intake passage member and the power control unit. This flexible element accommodates thermal expansion and contraction of both components while maintaining the heat exchange relationship and preventing friction and noise
Solution Approach 2:
The flexible seal member acts as an intermediary between the intake passage member and the power control unit, absorbing the effects of thermal expansion and contraction while maintaining the necessary thermal contact for heat exchange
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 effectively cools intake air without requiring direct fresh cooling air and minimizes the number of additional component parts, enhancing heat transfer efficiency while reducing noise and assembly complexity.
Implementation Method 1
the intake passage member is provided in proximity of the onboard device... the heat can be exchanged between the intake passage member and the onboard device over a large area so that the heat transfer between the two parts can be maximized
Data Source
AI summary
An intake structure for an internal combustion engine of a vehicle comprises an intake passage member (25) internally defining an intake passage (40) having an air inlet (40A) and an air outlet (40B); and a PCU (14) provided in an engine room of the vehicle and provided with a cooling device for cooling the PCU (14). The intake passage member is provided in proximity of the onboard device for favorable heat transfer between the PCU and the intake passage member.