Intake Manifold Heat Exchanger Integration
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Solution Overview
Problem
Existing air intake modules for internal combustion engines with integrated heat exchangers face complexities in assembly, multiple sealing zones, modified manufacturing processes, and lack of precise positioning, leading to structural integrity issues and inefficient airflow channeling.
Innovation Solution
An air intake module design where the heat exchanger is mechanically connected to the manifold's constituent parts, using a cover with specific openings and cooperating means to ensure precise positioning and structural reinforcement, eliminating the need for separate fastening and reducing sealing zones, while maintaining the manifold's structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the heat exchanger is introduced into the hollow body of the collector after production through an opening, then the structural integrity of the collector is substantially retained, but multiple sealing zones and complex assembly operations are required
Solution Approach 1:
The heat exchanger is nested within the hollow body of the collector during the molding process itself. The heat exchanger is positioned in a receiving location formed in the collector mold, and both components are molded simultaneously as an integrated assembly, eliminating the need for separate introduction and sealing operations.
Solution Approach 2:
The manufacturing processes of the collector and heat exchanger are merged into a single molding operation. The collector and heat exchanger are produced together in one molding cycle, combining what were previously separate manufacturing steps into a unified process that reduces assembly complexity.
2Ease of manufacture
If the heat exchanger is mounted in the collector with separate assembly operations, then the collector manufacturing process is simplified, but precise positioning and reliable fixation are difficult to guarantee
Solution Approach 1:
The heat exchanger is nested within the hollow body of the collector during the molding process itself. The heat exchanger is positioned in a receiving location formed in the collector mold, and both components are molded simultaneously as an integrated assembly, eliminating the need for separate introduction and sealing operations.
Solution Approach 2:
The receiving location for the heat exchanger is pre-formed in the collector mold before the actual molding takes place. This preliminary structuring of the mold ensures that the heat exchanger will be precisely positioned during the molding process, eliminating positioning issues that would arise from post-manufacturing assembly.
3Strength
If the heat exchanger is used as an internal structural reinforcement element, then structural rigidity is enhanced, but complex fastening operations through the enclosure wall are required
Solution Approach 1:
The structural reinforcement function and the heat exchanger mounting function are merged into a single integrated molding operation. The heat exchanger is positioned in a receiving location formed in the collector mold, and both components are molded together, eliminating the need for separate fastening operations through the enclosure wall.
Solution Approach 2:
The heat exchanger is nested within the hollow body of the collector during the molding process itself. The heat exchanger is positioned in a receiving location formed in the collector mold, and both components are molded simultaneously as an integrated assembly, eliminating the need for separate introduction and sealing operations.
4Adaptability or versatility
If multiple separate parts are assembled to form the heat exchanger and manifold, then functional integration is achieved, but the number of sealing areas increases
Solution Approach 1:
The heat exchanger and collector are merged into a single integrated component through simultaneous molding. The receiving location for the heat exchanger is formed directly in the collector mold, creating a unified structure with minimal sealing requirements compared to assembling multiple separate parts.
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 design simplifies assembly, ensures precise and reliable positioning of the heat exchanger, enhances structural rigidity, and optimizes airflow through the exchanger, addressing the limitations of previous solutions by minimizing assembly complexity and maintaining the manifold's structural integrity.
Implementation Method 1
an air intake module (1) for an internal combustion engine, essentially consisting of a manifold (2) incorporating a heat exchanger (4) with fluid inlet and outlet nozzles (8) at one of its ends
Data Source
Figure 1~1B
Figure 1C~2
Figure 3
AI summary
The module (1) has a collector (2) comprising a body (2') that is provided with a side opening. The side opening is sealed by a lid (6). The side opening is arranged with a set of passage openings (7) for a set of input and output ends (8) of a heat exchanger (4). The heat exchanger is mechanically connected to a set of wall portions (3, 3') of the collector. The heat exchanger is placed approximately transversely with gas flow circulating in the collector, and divides the interior volume of the collector into two compartments. An independent claim is also included for a method for manufacturing an air intake module.