Integrated Metal Intake Manifold EGR Diffuser Design
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Solution Overview
Problem
Existing intake manifolds face challenges in optimal diffusion of exhaust gas recirculation (EGR) gases, with potential separation risks of metallic diffusers and high production costs, leading to suboptimal engine performance and safety concerns.
Innovation Solution
An integrated metal air intake manifold with a diffuser shaped to accelerate and direct EGR gases, featuring a section that decreases continuously and a flared portion to enhance gas distribution, eliminating the need for a separate diffuser and allowing for cost-effective production through molding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a separate metallic diffuser is used to protect the polymer intake manifold from EGR heat, then the manifold material protection is improved, but the device complexity and production cost increase
Solution Approach 1:
The diffuser function is merged with the intake manifold by integrating a metallic insert directly into the polymer manifold body. The insert is received within a cavity formed in the manifold and secured via ribs that engage with corresponding features on the insert, creating a unified structure that eliminates the need for a separate detachable diffuser while maintaining heat protection functionality.
2Object-affected harmful factors
If a metallic diffuser insert is used to prevent direct contact between EGR gases and polymer, then the thermal protection is improved, but the risk of diffuser separation and engine damage increases
Solution Approach 1:
The design incorporates preventive measures by integrating the metallic insert into the manifold structure before operation begins. The insert is received within a specifically formed cavity and secured with ribs that engage with corresponding features, preventing separation before it can occur. This prior cushioning approach eliminates the risk of diffuser detachment and subsequent engine damage.
3Productivity
If a frustoconical diffuser with protruding cylindrical part is used for EGR diffusion, then the gas diffusion function is achieved, but the risk of parts falling inside the intake manifold increases
Solution Approach 1:
The diffuser functionality is merged with the manifold structure through an integrated metallic insert that forms the diffuser passages directly within the manifold body. The insert includes internally formed passages with frustoconical sections that provide the necessary diffusion function while being permanently secured within the manifold cavity, eliminating protruding parts that could detach and fall into the intake manifold.
4Object-affected harmful factors
If a metallic diffuser is used to protect polymer from EGR heat, then the thermal resistance is improved, but the production cost increases
Solution Approach 1:
The metallic heat-resistant insert is merged with the polymer manifold in a single integrated component design. The insert is received within a cavity formed in the manifold and secured through integrated rib features, allowing the assembly to be produced as a unified structure. This merging approach simplifies manufacturing compared to assembling separate diffuser components and reduces overall production costs while maintaining the necessary heat resistance properties.
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 integrated diffuser design ensures improved gas distribution and reduced risk of engine failure by securely directing EGR gases to engine cylinders, while simplifying assembly and reducing production costs.
Implementation Method 1
a portion whose section decreases continuously from the external opening up to a restricted section... allowing the acceleration of the incoming gases
Implementation Method 2
The restricted section is shaped to direct a gas circulating in the passage (16) in the direction of the cylinders of the engine
Implementation Method 3
the passage may have a portion of flared shape between the restricted section and an internal end of said passage. Such a flared shape makes it possible to improve the redirection of the gases
Data Source
Figure 1~2
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AI summary
The invention relates to a metal air intake manifold (10) for supplying the cylinders of an internal combustion engine with air, said intake manifold (10) having an outer opening (14) which is intended to be connected to a pipe (12) for recirculating exhaust gases emitted by the engine, said outer opening (14) communicating with a passage (16) through a wall (18, 18') of said intake manifold (10) and leading into the inside of said manifold, characterised in that said passage (16) is shaped in order to distribute a gas from the outer opening (14) towards the inside of said intake manifold (10), said passage (16) having a portion (16a), the cross-section of which continuously decreases from the outer opening (14) to a narrowed cross-section (20) which is shaped in order to direct a gas circulating in said passage (16) in the direction of the cylinders of the engine to which cylinders said intake manifold is connected.