Multifunctional Engine Module With Thermoplastic Heat Exchanger
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Solution Overview
Problem
The limited space under the bonnet of vehicles requires integration of multiple engine functions into a single compact unit while maintaining reliability, reducing the number of parts and assembly processes, and accommodating rapid engine heating after a cold start without additional support structures.
Innovation Solution
A multifunctional module integrating the engine cooling circuit and exhaust gas recirculation functions, featuring a heat exchanger with a thermoplastic tank and a sub-module for pneumatic energy, allowing direct fixation to the engine block and optimized space usage, with components made from synthetic materials to withstand high temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If multiple engine functions are integrated into a single compact unit, then space under the bonnet is reduced and the number of parts is decreased, but the structural complexity of the module increases
Solution Approach 1:
The patent combines the heat exchanger for cooling exhaust gases and the thermostat housing for regulating cooling liquid circulation into a single integrated multifunctional module. This merging of previously separate components reduces the overall space requirement under the bonnet while consolidating multiple engine functions into one structural unit, directly addressing the contradiction between space reduction and structural complexity.
Solution Approach 2:
The multifunctional module is designed to perform multiple functions simultaneously: cooling exhaust gases through the heat exchanger, regulating cooling liquid flow through the thermostat, and providing structural support. This multi-functionality allows a single component to replace what would traditionally require multiple separate parts, reducing the number of assembly processes and fitting operations while maintaining comprehensive engine management capabilities.
2Productivity
If functions are integrated into a single unit, then the number of assembly and fitting processes is reduced, but the manufacturing complexity of individual components increases
Solution Approach 1:
By merging the heat exchanger and thermostat housing into a single integrated module, the patent reduces the number of separate assembly and fitting processes required during engine assembly. The integrated design allows for fewer connection points and interfaces, streamlining the assembly workflow and improving productivity despite the increased complexity of manufacturing the integrated component itself.
3Device complexity
If the module is designed to be fixed directly to the engine block, then additional support structures are eliminated, but the mounting requirements and precision increase
Solution Approach 1:
The integration of multiple functions into a single compact module reduces the number of separate components that would otherwise require individual mounting, thereby eliminating the need for additional support structures. The direct mounting design simplifies the overall installation architecture, though it does require precise alignment during assembly.
4Ease of manufacture
If thermoplastic materials are used for the heat exchanger tank, then manufacturing cost is reduced, but temperature resistance requirements increase
Solution Approach 1:
The patent specifies that the heat exchanger tank is made from a synthetic thermoplastic material capable of withstanding elevated temperatures. This represents a parameter change in material selection, choosing a thermoplastic with sufficient thermal resistance for the application. The material must maintain its structural integrity and functional performance at the operating temperatures encountered in the engine cooling and exhaust gas recirculation systems.
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 solution achieves a compact, reliable, and efficient integration of engine functions, reducing the number of parts and assembly processes, enabling rapid engine heating and eliminating the need for additional support structures, while maintaining performance and financial efficiency.
Implementation Method 1
incorporating, on the one hand, at least a portion of an exhaust gas recirculation circuit and a heat exchanger (2) for cooling said gases
Implementation Method 2
heat exchanger (2) for cooling said gases
Implementation Method 3
allowing rapid heating of the engine, for example, to be achieved after a cold start
Implementation Method 4
regulating, at least in part, the circulation flows in the cooling circuit of said engine
Data Source
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AI summary
The present invention relates to a multifunctional module (1) for an internal-combustion engine, forming a structural assembly and incorporating the functions of cooling the exhaust gases, regulating the re-injection of the exhaust gases and regulating, at least in part, the circulation flows in the cooling circuit of said engine, said structural assembly being in the form of a constructional and functional unit (1) intended to be fitted to the engine block and incorporating, on the one hand, at least a portion of an exhaust gas recirculation circuit and a heat exchanger (2) for cooling said gases and, on the other hand, at least a portion of the engine cooling circuit, with at least the water-outlet housing (3), multifunctional module characterised in that the heat exchanger (2) has a tank (6) arranged in the region of an end of the constructional and functional unit (1) and made from a synthetic thermoplastic material.