Engine Cylinder Head Gas Distribution Manifold with Integrated Injection Spout
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Solution Overview
Problem
Current heat exchanger systems for automotive engines are complex and costly to manufacture, requiring multiple steps and a foundry process with core molding for recirculated exhaust gas injection, leading to increased manufacturing time and cost, and are not compact enough to be integrated optimally near the engine.
Innovation Solution
A compact gas mixing device for automotive engines that integrates a distribution manifold without tubular pipes for exhaust gas injection, using a die-casting process without cores, featuring a half-shell injection chute oriented to create turbulence for improved gas mixing, and allowing the injection of recirculated exhaust gases directly into the intake gas flow before it enters the engine cylinders.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a foundry process with sand core molding is used to manufacture the mixing device with recirculated gas injection pipes, then the device can be manufactured with complex internal cavities, but the manufacturing time and cost increase significantly
Solution Approach 1:
The invention extracts and eliminates the sand core from the foundry process. Instead of using traditional sand core molding that requires multiple steps (positioning core, filling mold, unmolding, removing core), the patent uses a die-casting process that directly forms the complex internal cavities and injection pipes without requiring removable cores, thereby significantly reducing manufacturing time and complexity
Solution Approach 2:
The invention replaces the mechanical sand core molding process with a die-casting process. The die-casting method uses a rigid mold with pre-formed cavities that directly shape the metal alloy, eliminating the need for flexible sand cores and multiple manual operations, thus improving productivity while maintaining manufacturing capability for complex geometries
2Ease of operation
If recirculated exhaust gas is injected independently into each outlet pipe through separate injection pipes, then the gas distribution can be controlled precisely, but the device volume and structural complexity increase
Solution Approach 1:
The invention merges the recirculated gas injection function directly into the outlet manifold structure. Instead of having separate injection pipes attached to each outlet pipe, the manifold itself incorporates integrated injection ports and internal channels that distribute recirculated gas directly into each outlet passage, reducing the number of separate components while maintaining precise gas distribution control
Solution Approach 2:
The outlet manifold is designed to perform multiple functions simultaneously: it serves as both the gas distribution manifold and the recirculated exhaust gas injection system. The manifold structure includes integrated injection channels and ports that enable it to distribute both fresh charge air and recirculated exhaust gas through the same component, eliminating the need for separate injection piping systems
3Reliability
If the heat exchanger is positioned far from the engine, then the heat exchange efficiency can be optimized, but the overall system compactness and integration are reduced
Solution Approach 1:
The invention implements a nested integration where the heat exchanger is positioned within or adjacent to the engine block structure. The outlet manifold serves as both a structural component of the engine and as the housing for the heat exchanger, with the heat exchange channels integrated into the manifold walls. This nesting arrangement allows the heat exchanger to be in close proximity to the engine cylinders for efficient heat recovery while maintaining a compact overall system volume
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 reduces manufacturing time and cost, enhances gas mixing homogeneity through turbulence, and allows for a more compact and efficient integration of the heat exchanger near the engine, improving engine performance while simplifying the manufacturing process.
Implementation Method 1
The exchange elements of the bundle are hollow and conduct a heat transfer fluid, intended to exchange heat with the flow of gas to be cooled circulating in the fluid conduct channels and thus cool it
Implementation Method 2
the injection chute is oriented to create turbulence for improved gas mixing
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to a gas distribution manifold (3) in the cylinder head of a heat engine of a motor vehicle, said manifold (3) comprising a manifold housing (31) provided with an inflow face for the inflow of an admission gas (G) and an outflow face (3B) entering the cylinder head of the engine, and an injection spout (6) for injecting a recirculated exhaust gas flow (H) of the engine into the admission gas flow (G), the manifold housing (31) and the injection spout (6) forming a single component. As the injection spout (6) comprises an open face, the manifold (3) is configured such that said open face is closed by an element outside the manifold (3), especially the cylinder head, in such a way as to form a tubular injection pipeline.