Integrated PCV Channel in Air Intake Manifold

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Solution Overview

Problem

Existing positive crankcase ventilation (PCV) systems for internal combustion engines face challenges in integrating a compact and efficient design within under-hood space limitations, often requiring additional parts and manufacturing steps, while ensuring uniform distribution of blow-by gases to engine cylinders.

Innovation Solution

A PCV channel is integrated into the structural weld seam of an air intake manifold, allowing blow-by gases to be ported from the crankcase and uniformly mixed with air flow, eliminating the need for extra parts and manufacturing steps by forming the channel along a pre-existing weld line between shells.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a separate external conduit and PCV channel are used to route blow-by gases, then the PCV system can function properly, but the device complexity and number of parts increase

Engineering Contradiction:

ImprovePCV system functionalityVSAvoidnumber of parts

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines the PCV channel with the air induction manifold into a single integrated component. The PCV channel is formed as an internal passage within the manifold structure itself, eliminating the need for separate external conduits and reducing the total number of parts while maintaining proper blow-by gas routing functionality

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The air induction manifold is designed to serve multiple functions: it distributes intake air to cylinders and simultaneously routes blow-by gases through its internal PCV channel. This multi-functionality reduces the need for dedicated separate components for each function

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If additional PCV parts and manufacturing steps are used, then the PCV system can be implemented, but manufacturing complexity and costs increase

Engineering Contradiction:

ImprovePCV system implementationVSAvoidmanufacturing steps

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The PCV channel is integrated into the manifold structure and formed during the same manufacturing process (injection molding) as the manifold itself. This eliminates separate manufacturing steps for producing distinct PCV components and reduces assembly operations

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The PCV channel is built into the manifold structure during its initial formation process. The manifold is injection molded with internal cavities that define the PCV channel passages, so the channel structure is already in place before the manifold is assembled or installed

Inventive Principle:

Principle #10Preliminary action

3Productivity

If blow-by gases are not uniformly distributed to cylinders, then the PCV system can operate, but fuel efficiency and combustion performance deteriorate

Engineering Contradiction:

Improvefuel efficiencyVSAvoiduniform gas distribution

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The manifold is designed with multiple separate outlet passages that distribute blow-by gases to different cylinder groups. Each outlet is positioned and sized to ensure appropriate local distribution characteristics, achieving uniform overall distribution across all cylinders

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The PCV channel system is divided into multiple outlet passages that separately serve different cylinder banks or groups. This segmentation allows independent optimization of gas flow to each cylinder group, improving uniformity of distribution

Inventive Principle:

Principle #1Segmentation

4Device complexity

If under-hood space is not constrained, then larger PCV components can be used, but available installation space is exceeded

Engineering Contradiction:

ImprovePCV component sizeVSAvoidunder-hood space

Core Design Contradiction:

Device complexityVSVolume of moving object

Solution Approach 1:

The PCV channel is nested within the internal structure of the air induction manifold. The channel passages are formed as hollow cavities inside the manifold body, utilizing the existing structural volume rather than requiring additional external space

Inventive Principle:

Principle #7Nested doll (Nesting)

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 provides a cost-effective, compact PCV system that ensures uniform distribution of blow-by gases to engine cylinders, minimizing damage and unburned fuel discharge, while adhering to under-hood space constraints and reducing manufacturing complexity.

Implementation Method 1

With respect to the gas pressure in the crankcase, a relative negative pressure in the air intake is typically used to draw blow-by gases out of crankcase and into the air intake

Methodology Applied

Scientific EffectNegative pressure: Pressure Gradient

Implementation Method 2

Blow-by gases can be ported from the crankcase to the PCV channel where they can be uniformly mixed with the flow of air through the air induction system

Methodology Applied

Scientific EffectGas mixing: Diffusion

Data Source

PatentUS7827973B2Integrated positive crankcase ventilation channel

Publication Date: 2010.11.09 MANN HUMMEL GMBH

AI summary

An integrated positive crankcase ventilation (PCV) channel is formed along a structural weld line between two shell components that are welded together to form an air intake manifold. The integrated PCV channel can be used to uniformly distribute blow-by gases from the crankcase of an internal combustion engine to a plurality of combustion chambers via the air intake manifold.