Marine Engine Supercharger Inward Discharge and Integrated Cooling

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Solution Overview

Problem

Conventional supercharged marine engines with outward-facing discharge ports for charge air are not conducive to a small package size, as charge air needs to be ducted around the engine block, leading to inefficiencies and increased size.

Innovation Solution

A marine engine design with a supercharger that discharges charge air towards the engine block and cylinder heads, utilizing a central duct through both the supercharger and crankcase cover for a more direct route, and incorporating charge air coolers with recirculation passages to manage charge air flow efficiently.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If charge air is discharged outwardly from the supercharger, then the discharge port is easily accessible, but the package size increases and ducting becomes complex

Engineering Contradiction:

Improvepackage sizeVSAvoidducting complexity

Core Design Contradiction:

Volume of moving objectVSDevice complexity

Solution Approach 1:

The patent inverts the conventional discharge direction by directing charge air inwardly toward the engine block rather than outwardly. This allows the charge air to be delivered directly to the cylinder heads through integrated passages, eliminating the need for complex external ducting and reducing overall package size.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The supercharger discharge passages are merged with the engine block intake passages, creating an integrated flow path. The charge air cooler is also integrated into the engine block, combining multiple functions (cooling, discharge, and delivery) into a single unified structure that reduces complexity and space requirements.

Inventive Principle:

Principle #5Merging (Combining)

2Temperature

If charge air coolers are added to cool the charge air, then overheating is reduced, but the device complexity increases

Engineering Contradiction:

Improvecharge air temperatureVSAvoidsystem complexity

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The charge air coolers are integrated directly into the engine block structure, merging the cooling function with the engine's existing cooling system. The coolers utilize the engine block's cooling passages and water jacket, eliminating the need for separate external cooling systems and reducing overall system complexity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The engine block's cooling system serves multiple functions: it cools the engine cylinders and simultaneously cools the charge air through the integrated charge air coolers. This multi-functionality reduces the need for additional dedicated cooling systems and simplifies the overall thermal management architecture.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Productivity

If a central duct through the crankcase cover is used, then charge air delivery efficiency improves, but manufacturing complexity increases

Engineering Contradiction:

Improvecharge air delivery efficiencyVSAvoidmanufacturing complexity

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

The central duct is segmented into multiple sections: a first section in the supercharger, a second section through the crankcase cover, and integration points with the engine block. This segmentation allows each component to be manufactured separately using conventional processes, then assembled together, reducing overall manufacturing complexity while maintaining efficient charge air delivery.

Inventive Principle:

Principle #1Segmentation

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 configuration allows for a smaller package size while maintaining efficient charge air delivery and cooling, improving engine performance and reducing overheating risks.

Implementation Method 1

first and second charge air coolers configured to cool the charge air

Methodology Applied

Scientific EffectHeat exchange: Heat Exchanger

Implementation Method 2

a recirculation passage coupled to the first charge air cooler, the recirculation passage conveying the portion of the charge air from the bypass port of the first charge air cooler back to the supercharger

Methodology Applied

Scientific EffectFluid flow:

Data Source

PatentUS10975762B1Marine engines having a supercharger and charge air coolers

Publication Date: 2021.04.13 BRUNSWICK CORP

AI summary

A marine engine has first and second banks of cylinders; a supercharger configured to supply charge air for combustion in the first and second banks of cylinders; first and second charge air coolers configured to cool the charge air, wherein the first and second charge air coolers each have an upstream inlet that receives the charge air from the supercharger, a downstream outlet that discharges the charge air for combustion in the marine engine, and a bypass port for conveying a portion of the charge air, the bypass port being located downstream of the inlet and upstream of the outlet; a recirculation passage coupled to the first charge air cooler, the recirculation passage conveying the portion of the charge air from the bypass port of the first charge air cooler back to the supercharger; and a mounting plate coupled to the second charge air cooler, the mounting plate preventing flow of the portion of charge air through the bypass port of the second charge air cooler.