Unified Intake Manifold Gas Flow Path for Engine Torque

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Solution Overview

Problem

The existing intake manifolds for vehicles experience flow resistance and freezing issues due to separate inlets for blow-by gas and fuel evaporation gas, which hinder smooth air supply and increase manufacturing complexity.

Innovation Solution

A unified gas flow path is introduced in the intake manifold, where blow-by gas and fuel evaporation gas flow through a single inlet, reducing flow resistance and preventing freezing by integrating the PCV and PCSV connectors with a gas cap member, and using an anti-backflow wall to guide gases effectively.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If separate inlets are used for blow-by gas and fuel evaporation gas, then the gases can be received through dedicated connectors, but flow resistance increases and external air cannot flow smoothly into the surge tank

Engineering Contradiction:

Improvegas reception reliabilityVSAvoidpressure loss

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The patent merges the separate blow-by gas inlet and evaporation gas inlet into a unified inlet structure. The PCV valve connector and PCSV connector are integrated to share a common external air inlet, allowing blow-by gas and evaporation gas to enter through the same opening. This eliminates the need for multiple separate inlets, reducing flow resistance and preventing pressure loss while maintaining reliable gas reception functionality.

Inventive Principle:

Principle #5Merging (Combining)

2Stability of the object's composition

If separate inlets are spaced apart to allow mixing, then gas mixing can occur, but flow resistance increases and external air supply is insufficient

Engineering Contradiction:

Improvegas mixture uniformityVSAvoidair supply efficiency

Core Design Contradiction:

Stability of the object's compositionVSProductivity

Solution Approach 1:

The patent combines multiple gas inlets into a unified inlet structure where blow-by gas, evaporation gas, and external air all enter through the same opening. The internal flow paths are designed to allow these gases to mix naturally within the surge tank while maintaining high flow efficiency. This resolves the contradiction by achieving both uniform gas mixing and high air supply efficiency simultaneously.

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If blow-by gas inlet is positioned separately, then blow-by gas can be received, but condensate water freezes and blocks the inlet in winter

Engineering Contradiction:

Improveblow-by gas receptionVSAvoidfreezing blockage

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent integrates the blow-by gas inlet with the external air inlet, so that warm external air enters simultaneously with the blow-by gas. The mixed gases maintain a higher temperature that prevents condensate water from freezing and blocking the inlet during winter conditions. This unified inlet design eliminates the freezing blockage problem while ensuring reliable blow-by gas reception.

Inventive Principle:

Principle #5Merging (Combining)

4Reliability

If multiple separate connectors are used, then specific gas paths can be defined, but manufacturing complexity increases

Engineering Contradiction:

Improvegas path definitionVSAvoidconnector structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges the PCV valve connector and PCSV connector into a single integrated connector structure that shares a common external air inlet. While the internal flow paths remain distinctly defined for different gases, the external structure is simplified to a unified design. This reduces manufacturing complexity and the number of separate components while maintaining reliable gas path definition through internal flow path design.

Inventive Principle:

Principle #5Merging (Combining)

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 enhances air supply efficiency, reduces pressure loss, increases engine torque, and simplifies manufacturing by minimizing condensate water freezing and reducing manufacturing costs.

Implementation Method 1

flow resistance when external air flows into the surge tank

Methodology Applied

Scientific EffectFlow resistance: Drag

Implementation Method 2

high-temperature blow-by gas is supplied into the surge tank unit through the blow-by gas inlet, condensate water is produced in the blow-by gas inlet when the high-temperature blow-by gas is mixed with cold external air in winter

Methodology Applied

Scientific EffectThermal mixing: Mixed Convection

Data Source

PatentUS10006418B2Intake manifold for vehicle with unified gas flow path

Publication Date: 2018.06.26 HYUNDAI KEFICO CORP

AI summary

Disclosed is an intake manifold for a vehicle with a unified flow path. The intake manifold has a plurality of branch pipes connected to intake ports of cylinders of an automotive engine, and a surge tank unit connected to the branch pipes and having an external air inlet formed at a side to receive external air, in which the surge tank unit has a unified gas inlet formed at the external air inlet so that blow-by gas an fuel evaporation gas both flows inside. Accordingly, flow resistance when external air flows inside is reduced and freezing at the blow-by gas inlet is prevented in winter. Therefore, the amount of air mixture to be supplied into the cylinders is increased, whereby the volume efficiency of the cylinders is improved and engine torque is increased.