Intake Manifold Baffle for Exhaust Gas Recirculation Mixing
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Solution Overview
Problem
Existing intake manifolds for internal combustion engines face issues with carbon deposits from recirculated exhaust gases causing valve malfunctions and efficiency reduction, leading to costly and complex solutions.
Innovation Solution
An intake manifold design with a baffle that separates the flow of recirculated exhaust gases and intake air, directing the exhaust gases to pass in the same direction as the air flow, avoiding soiling of the butterfly valve and sensor, ensuring uniform mixing and maintaining efficiency throughout the engine's life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the butterfly valve is placed in the air inlet conduit of the intake manifold, then the air flow can be regulated effectively, but the valve becomes subject to carbon deposits from recirculated exhaust gases causing malfunctions and efficiency reduction
Solution Approach 1:
The intake manifold chamber is segmented into a first chamber portion and a second chamber portion by a baffle. The first chamber portion receives both intake air and recirculated exhaust gases, while the second chamber portion directs the mixed flow to outlets. This segmentation allows the butterfly valve to regulate air flow in the first chamber portion without being exposed to carbon deposits that accumulate in the exhaust gas recirculation path, thereby maintaining valve reliability while preserving regulatory function.
2Manufacturing precision
If a baffle is added to separate and direct flows for uniform mixing, then mixing efficiency improves, but device complexity increases
Solution Approach 1:
The baffle is positioned extending from the end wall opposite the air inlet towards the exhaust gas inlet, creating a three-dimensional flow separation within the manifold chamber. This spatial arrangement directs exhaust gases to enter the first chamber portion and mix with air in a controlled manner before flowing into the second chamber portion, achieving uniform mixing without requiring complex multi-component structures.
Solution Approach 2:
The baffle serves multiple functions simultaneously: it segments the manifold chamber into distinct flow zones, directs the mixing of air and exhaust gases, and positions the exhaust gas inlet to optimize flow patterns. This multi-functionality achieves improved mixing uniformity without proportionally increasing device complexity, as a single structural element performs multiple critical roles.
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 prevents valve malfunctions and maintains constant efficiency by isolating carbon deposits from the butterfly valve and sensor, ensuring effective mixing and reducing production costs while maintaining performance over the engine's life.
Implementation Method 1
a baffle extending within said chamber and which defines a first chamber portion in communication with said inlet and with said conduit and a second chamber portion in communication with said plurality of outlets
Implementation Method 2
configured for receiving and mixing a flow of recirculated exhaust gases and a flow of intake air
Data Source
Figure 1
Figure 2
AI summary
An intake manifold unit (1) for an internal combustion engine of a motor-vehicle is configured for receiving and mixing a flow of recirculated exhaust gases and a flow of intake air. The unit (1) comprises a manifold hollow body which defines a chamber (C) which communicates with a conduit (2) for introducing the flow of recirculated exhaust gases within the chamber (C), with an inlet (3) for the intake air of the engine and a plurality of outlets (4) in communication with the cylinders of the engine for directing the mixed flow of air and recirculated exhaust gases towards the cylinders of the engine. The unit (1) further comprises a baffle (5) extending within the chamber (C) and defining a first chamber portion (7) and a second chamber portion (8). The conduit (2) of the recirculated exhaust gases has a terminal end portion (20) which is internal to the first chamber portion (7) and which is directed transversally to the direction of the flow of intake air within the first chamber portion (7). The terminal portion (20) of the conduit (2) has a closed end wall (21) and a lateral wall (22) with an opening (23) provided on an opposite side with respect to the air inlet (3).