Manifold With Integrated Diffuser for Lower Turbomachine Pressure Loss

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Solution Overview

Problem

Manifolds in internal combustion engines experience significant pressure losses, particularly downstream from turbines, leading to increased exhaust effort and reduced engine efficiency, especially when used in turbochargers.

Innovation Solution

A manifold design featuring a centrally arranged diffuser section integrated with the wall, which minimizes pressure loss and recirculation, and includes a curved geometry to enhance flow guidance, optionally using additive manufacturing for complex geometries.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If a conventional manifold is used in the exhaust tract, then the manifold structure is simple, but pressure loss increases and engine efficiency deteriorates

Engineering Contradiction:

Improvepressure lossVSAvoidmanifold structure

Core Design Contradiction:

Loss of energyVSDevice complexity

Solution Approach 1:

The manifold is divided into functionally distinct sections: a diffuser section for reducing pressure loss and a recirculation section for minimizing recirculation effects. This segmentation allows each section to be optimized for its specific function while working together to reduce overall pressure loss and improve engine efficiency.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The manifold incorporates curved geometries in the diffuser and recirculation sections to guide flow smoothly and reduce turbulence. The curved design in the diffuser section gradually expands the flow area to reduce pressure loss, while the curved recirculation section minimizes recirculation effects, thereby reducing overall pressure loss and improving engine efficiency.

Inventive Principle:

Principle #14Spheroidality (Curvature)

2Loss of energy

If the diffuser section is arranged centrally on the inlet side, then pressure loss is reduced and flow guidance is optimized, but manufacturing complexity increases

Engineering Contradiction:

Improvepressure lossVSAvoidmanufacturing complexity

Core Design Contradiction:

Loss of energyVSEase of manufacture

Solution Approach 1:

The diffuser section and recirculation section are merged into a single integrated manifold component. This merging allows the centrally arranged diffuser section to be manufactured as one piece with the recirculation section, reducing the need for separate manufacturing processes and assembly operations while maintaining the optimized flow guidance and pressure loss reduction benefits.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The manifold design utilizes additive manufacturing technology to produce complex geometries that would be difficult to manufacture using traditional methods. This parameter change in the manufacturing approach enables the centralized diffuser section and integrated recirculation section to be manufactured as a single complex component, achieving optimized flow guidance without proportionally increasing manufacturing complexity.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If the diffuser section is designed as a single component with the wall, then flow guidance is optimized and recirculation is minimized, but device complexity increases

Engineering Contradiction:

Improveflow guidanceVSAvoidmanifold structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The diffuser section is merged with the manifold wall as a single integrated component rather than a separate element. This merging ensures optimal flow guidance and recirculation minimization while reducing the number of parts and assembly steps. The integrated design maintains structural integrity and flow optimization benefits without requiring multiple separate components.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The integrated manifold structure serves multiple functions simultaneously: it guides flow through the diffuser section, creates the recirculation section, and provides structural support. This multi-functionality reduces the need for separate components and assembly operations while maintaining optimal flow guidance and recirculation characteristics, thereby improving reliability without proportionally increasing device complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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

The design reduces pressure loss, minimizes flow separation, and enhances containment properties, thereby increasing the efficiency of internal combustion engines and turbochargers.

Implementation Method 1

a diffuser section which is centrally arranged in the flow volume on the inlet side

Methodology Applied

Scientific EffectDiffusion: Diffusion

Implementation Method 2

flow separation can be at least largely avoided, optionally prevented

Methodology Applied

Scientific EffectFlow separation: Flow Separation

Data Source

PatentUS12416256B2Manifold, a turbomachine including such a manifold, a turbocharger including such a turbomachine, and an internal combustion engine including such a manifold

Publication Date: 2025.09.16 ROLLS ROYCE SOLUTIONS GMBH

AI summary

A manifold for deflecting a flow of a medium flowing through the manifold from an inlet side of the manifold to an outlet side of the manifold includes: the inlet side; a wall at least partially defining and thereby restricting a flow volume of the manifold; and a diffuser section arranged centrally in the flow volume on the inlet side, the diffuser being a single component with the wall.