Integral Cylinder Head with Exhaust Gas Recirculator
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Solution Overview
Problem
Traditional cylinder head manufacturing methods involve multiple parts and assembly steps, leading to complex geometries, potential leaks, and increased cycle time, while additive manufacturing enables the creation of integral cylinder heads with integrated fluid delivery ports that seamlessly transition into the cylinder head, reducing assembly complexity and improving fluid distribution efficiency.
Innovation Solution
The integration of a layered tubular exhaust gas recirculator with nozzles and diverters directly into the cylinder head, allowing for efficient exhaust gas recirculation and fluid distribution without seals, combined with additive manufacturing techniques to produce a unitary, complex geometry cylinder head with optimized fluid delivery systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional cylinder head manufacturing methods are used with multiple parts and assembly steps, then assembly flexibility is improved, but device complexity and potential leaks increase
Solution Approach 1:
The patent merges the exhaust gas recirculator and cylinder head into a single integral component manufactured via additive manufacturing. This eliminates separate assembly steps, reduces the number of parts, and removes the need for seals between components, directly resolving the contradiction by combining multiple parts into one while maintaining functional integration.
2Ease of repair
If traditional manufacturing methods are used with multiple parts, then ease of repair is improved, but reliability decreases due to potential leaks at seal interfaces
Solution Approach 1:
By integrating the exhaust gas recirculator directly into the cylinder head as a single additive-manufactured component, the patent eliminates seal interfaces that could leak, thereby improving reliability. The integral design ensures leak-free fluid delivery while maintaining the ability to replace the entire assembly as a unit.
3Manufacturing precision
If additive manufacturing is used to create integral cylinder heads, then manufacturing precision and fluid distribution efficiency are improved, but production time increases
Solution Approach 1:
The additive manufacturing process creates the complex internal fluid delivery channels and nozzle structures in a single build operation, preliminarily establishing the precise fluid distribution pathways before any assembly or post-processing is needed. This eliminates the need for separate machining or assembly steps to achieve the same precision.
4Weight of moving object
If integral cylinder heads with integrated fluid delivery ports are manufactured, then weight is reduced and fluid distribution efficiency is improved, but manufacturing complexity increases
Solution Approach 1:
The patent replaces traditional subtractive manufacturing and assembly processes with additive manufacturing technology. This substitution enables the creation of complex integral geometries with internal fluid channels that would be difficult or impossible to achieve with conventional methods, while actually simplifying the overall manufacturing process by eliminating multiple assembly steps.
Data Source
AI summary
A power train system includes an exhaust manifold having an exhaust flow and a control valve for releasing exhaust gas, and layered material defining an integrated engine cylinder head and an exhaust gas recirculator, connected to the exhaust flow and the valve, including a tubular inlet defining a plurality of branches around the cylinder head and having a plurality of nozzles extending into cavities of intake ports of the cylinder head. Each of the branches surrounding an exterior surface of one of the intake ports such that there is no seal between the recirculator and the cylinder head.