The present subject matter described herein, relates to an arrangement of an Exhaust Gas Recirculation (EGR) cooler. More particularly, to an effective layout of an EGR cooler.

BACKGROUND

Background description includes information that may be useful in understanding the present invention. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed invention, or that any publication specifically or implicitly referenced is prior art.
[0003] EGR system has been in use as a part of Internal Combustion Engines from several years to improve fuel efficiency and reduce harmful emissions (NOx) from the engine. Generally, the exhaust gases either from exhaust manifold or turbocharger or catalytic converter are adapted to pass through the EGR cooler which acts as a heat exchanger and in turn supplies cooled air to the engine.
[0004] Referring to fig. 1(a) and 1(b), there is provided an EGR system 100 for internal combustion engine. The EGR system 100 comprises an EGR cooler (not shown in the figure), a casing 102, a plurality of pipes/hoses 104 and an EGR valve 106. The casing houses an EGR cooler having openings (01 and 02) at extreme ends for intake of the exhaust air from the engine and exit of the cooled air to the engine. The casing 102 is also provided with an inlet pipe HI and an exit pipe H2 for circulation of coolant in the space provided in between the air passage pipes of the EGR cooler and the casing 102. The casing 102 of the EGR cooler includes an integrally formed bracket Bl at its bottom to facilitate in mounting of the EGR cooler on a transmission case 108 with the help of bolts. The coolant is drawn from the engine into the casing 102 of the EGR cooler and exited out from the casing 102 of the EGR cooler to a reservoir with the help of the pipes 104(a) and 104(b) respectively. The exhaust air is drawn after a catalytic converter 110

into the EGR cooler and the air after cooling exits out to a gallery G provided inside a cylinder head 112 of the engine through the pipes 104(c) and 104(d) respectively. The entry of the cooled air from the gallery G to an intake manifold 114 of the engine is facilitated through the pipe 104(e). The rate of flow of the cooled air from the gallery G into the intake manifold 114 of the engine is controlled by an EGR valve 106 mounted on the cylinder head 112 of the engine.
[0005] Technical Problem: The mounting arrangement of the EGR cooler as shown in the fig 1(a) and 1(b) has its own limitations: a) As the EGR cooler is mounted close to the catalytic converter 110, the efficiency of thermal management of the EGR cooler may come down due to radiation, b) As the length of the piping circuit is more, the pressure at which the cooled air enters the intake manifold 114 is less and pumping of the cooled air becomes difficult. Further, there are chances of the cooled air for catching up of heat again as it passes through the gallery G inside the cylinder head 112 of the engine, c) The mounting arrangement of the EGR cooler calls in for more packaging space.
[0006] Therefore, an EGR system for an internal combustion engine is required to achieve effective packaging space and thermal management.
OBJECTS OF THE DISCLOSURE
[0007] Some of the objects of the present disclosure, which at least one embodiment herein satisfy, are listed herein below.
[0008] The principal object of the present invention is to provide an EGR system for effective thermal management of an EGR cooler.
[0009] Another object of the present invention is to provide an EGR system to meet space constraints.
[0010] One more object of the present invention is to provide an efficient piping layout of an EGR system to minimize losses.
[0011] Still another object of the present invention is to provide an ideal location for an EGR cooler and an EGR Valve to withstand thermal fatigue and vibration from an engine.

[0012] These and other objects and advantages will become more apparent when reference is made to the following description and accompanying drawings.
SUMMARY
[0013] This summary is provided to introduce concepts related to a bracket member for improving tactile vibration in a vehicle. The concepts are further described below in the detailed description. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter.
[0014] In an embodiment, the present disclosure relates to an EGR system comprising an integrally formed housing provided adjacent to an integrally formed reservoir on a transmission case. The integrally formed housing accommodates the EGR cooler and has an opening to establish fluid communication between the EGR cooler and the integrally formed reservoir. An EGR valve is mounted on the integrally formed reservoir to control the rate of flow of gases into an intake manifold. The integrally formed housing also includes two integrally formed or coupled pipes for the circulation of coolant.
[0015] Various objects, features, aspects, and advantages of the inventive subject matter will become more apparent from the following detailed description of preferred embodiments, along with the accompanying drawing figures in which like numerals represent like components.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] The illustrated embodiments of the subject matter will be best understood by reference to the drawings, wherein like parts are designated by like numerals throughout. The following description is intended only by way of example, and simply illustrates certain selected embodiments of devices, systems, and methods that are consistent with the subject matter as claimed herein, wherein:

[0017] Figure 1(a) illustrates a perspective view of an EGR system mounted adjacent to an Internal Combustion Engine according to the prior art;
[0018] Figure 1(b) illustrates an enlarged view of mounting arrangement of an EGR cooler of figure 1(a);
[0019] Figure 2 illustrates a perspective view of an EGR system of an Internal Combustion Engine, in accordance with an embodiment of the present disclosure;
[0020] Figure 3 illustrates an exploded view of an EGR cooler being inserted into a transmission case of figure 2;
[0021] Figure 4 illustrates a perspective view of an EGR cooler looking from the direction 'A' of figure 3;
[0022] Figure 5 illustrates a perspective view of an EGR cooler looking from the direction 'B' of figure 3;
[0023] Figure 6 illustrates a perspective view of a transmission case looking from the direction 'C of figure 2;
[0024] Figure 7 illustrates a perspective view of a transmission case looking from the direction 'D' of figure 2;
[0025] Figure 8(a) illustrates a side view of a transmission case of figure 6; and
[0026] Figure 8(b) illustrates a cross-section view along the line X-X of a transmission case of figure 8(a).
[0027] The figures depict embodiments of the present subject matter for the purposes of illustration only. A person skilled in the art will easily recognize from the following description that alternative embodiments of the structures and methods illustrated herein may be employed without departing from the principles of the disclosure described herein.
DETAILED DESCRIPTION

[0028] The detailed description of various exemplary embodiments of the disclosure is described herein with reference to the accompanying drawings. It should be noted that the embodiments are described herein in such details as to clearly communicate the disclosure. However, the amount of details provided 5 herein is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the scope of the present disclosure as defined by the appended claims.
[0029] It is also to be understood that various arrangements may be devised 10 that, although not explicitly described or shown herein, embody the principles of the present disclosure. Moreover, all statements herein reciting principles, aspects, and embodiments of the present disclosure, as well as specific examples, are intended to encompass equivalents thereof.
[0030] The terminology used herein is for the purpose of describing particular 15 embodiments only and is not intended to be limiting of example embodiments. As used herein, the singular forms “a",” “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises,” “comprising,” “includes” and/or “including,” when used herein, specify the presence of stated features, integers, 20 steps, operations, elements and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components and/or groups thereof.
[0031] It should also be noted that in some alternative implementations, the functions/acts noted may occur out of the order noted in the figures. For example, 25 two figures shown in succession may, in fact, be executed concurrently or may sometimes be executed in the reverse order, depending upon the functionality/acts involved.
[0032] In addition, the descriptions of "first", "second", and the like in the
present invention are used for the purpose of description only, and are not to be
30 construed as indicating or implying their relative importance or implicitly
6

indicating the number of technical features indicated. Thus, features defining "first" and "second" may include at least one of the features, either explicitly or implicitly.
[0033] Unless otherwise defined, all terms (including technical and scientific 5 terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which example embodiments belong. It will be further understood that terms, e.g., those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly 10 formal sense unless expressly so defined herein.
[0034] These and other advantages of the present subject matter would be described in greater detail with reference to the following figures. It should be noted that the description merely illustrates the principles of the present subject matter. It will thus be appreciated that those skilled in the art will be able to devise 15 various arrangements that, although not explicitly described herein, embody the principles of the present subject matter and are included within its scope.
[0035] To this as shown in figure 2 and 3, there is provided an EGR system (800) of an Internal Combustion Engine comprising an EGR cooler 200, a transmission case 300, a plurality of pipes/hoses 400, an EGR valve 500 and a 20 plurality of bolts 600.
[0036] Generally, the transmission case 300 is made through casting, bolted to an internal combustion engine of the vehicle and houses a transmission unit which facilitates in transmission of mechanical power in to motion of the vehicle. But, in the present invention, the transmission case 300 also houses an EGR cooler 200.
25 [0037] Referring to fig. 4 and 5, the EGR cooler 200 comprises an inlet gas box 212 and an outlet gas box 214 defining a plurality of passages 216 in between therein. The inlet gas box 212 and the outlet gas box 214 includes a plurality of openings 212(a) and 214(a) at their ends for the intake of the gases into the EGR cooler 200 and exit of the gases from the EGR cooler 200 respectively. A flange
7

218 having an opening 218(a) defined therein is coupled to the inlet gas box 212 and provided with a plurality of gaskets/O-rings 220 in between therein. The flange 218 is drilled with a plurality of holes 218(b) and a plurality of holes 218(c) on its opposite ends. A flange 222 having an opening 222(a) defined 5 therein with an extended rim 222(b) on its one face is coupled to the outlet gas box 214 and sealed with a plurality of gaskets/O-rings 220.
[0038] In an aspect, plurality of holes (218(b) and 218(c)) of the flange 218 and the plurality of holes 222(c) of the flange 222 can be provided horizontally, vertically or at any inclined angle.
10 [0039] In an aspect, the the EGR cooler 200 is of circular or rectangular or square cross-section.
[0040] Referring to figure 6, 7, 8(a) and 8(b), the transmission case 300 comprises an integrally formed housing 302 and an integrally formed reservoir 304 positioned adjacent to each other establishing a fluid connection from inside
15 as shown in the figure 8(b). The integrally formed housing 302 is provided with a slot 302(a) defining an opening 302(b) therein at one end. The integrally formed housing 302 includes a flange 302(c) integrally formed and extending around the circumference at the other end. A plurality of holes 302(d) are provided at the opposite ends of the flange 302(c). The integrally formed housing 302 includes
20 two integrally formed or coupled pipes (302(e) and 302(f)) for the inlet and outlet of a coolant. The integrally formed reservoir 304 provided with one hole 304(a) on its operative top and another hole 304(e) opening to an integrally formed or coupled flange 304(b). The integrally formed reservoir 304 is drilled with a plurality of holes 304(c) at opposite ends of its top surface. The integrally formed
25 or coupled flange 304(b) is provided with a plurality of holes 304(d) therein.
[0041] In an aspect, the integrally formed housing 302 is of circular or rectangular or square cross-section.
[0042] Referring to the figures 2, 3, 4, 5, 6, 7, 8(a) and 8(b), the configuration of the EGR system 800 is as follows: The EGR cooler 200 adapted to insert into
8

the integrally formed housing 302 of the transmission case 300 such that the extended rim 222(b) of the flange 222 of the EGR cooler 200 surrounded by a gasket 220 gets inserted into the slot 302(a) of the integrally formed housing 302. The EGR cooler 200 is bolted to the integrally formed housing 302 of the
5 transmission case 300 by means of a plurality of bolts 600 passing through the plurality of holes 218(b) of the flange 218 and the plurality of holes 302(d) of the flange 302(c). A pipe/hose 402 provided with flanges on either ends is coupled to the EGR cooler 200 at one end by means of a plurality of bolts 600 passing through the plurality of holes 218(c) of the flange 218 and to a catalytic converter
10 900 at the other end. A pipe/hose 404 provided with flanges on either ends is coupled to the flange 304(b) of the integrally formed reservoir 304 at one end by means of a plurality of bolts 600 passing through the plurality of holes 304(d) and to an intake manifold 1000 at the other end. The EGR valve 500 is mounted on the integrally formed reservoir 304 and bolted by means of a plurality of bolts 600
15 passing through the EGR valve 500 and the plurality of holes 304(c) of the integrally formed reservoir 304. A pipe/hose 406 is coupled to the internal combustion engine at one end and to the integrally formed or coupled pipe 302(e) of the integrally formed housing 302 of the transmission case 300 at the other end. A pipe/hose 408 is coupled to the integrally formed or coupled pipe 302(f) of the
20 integrally formed housing 302 of the transmission case 300 at one end and to a coolant reservoir at the other end.
[0043] Referring to the figures 2, 3, 4 and 6, the method of working of the EGR system 800 is as follows: Firstly, the gases are drawn after a catalytic converter 900 into the EGR cooler 200 through the pipe/hose 402. Secondly, the
25 coolant is drawn from the internal combustion engine through the pipe/hose 406 into the integrally formed housing 302 of the EGR cooler 200 which circulates around the plurality of passages 216 containing the gases resulting in the heat transfer between the gases and the coolant through convection. Thirdly, the coolant that got heated up exits from the integrally formed housing 302 of the
30 EGR cooler 200 to the coolant reservoir through the pipe/hose 408. Fourthly, the gases that got cooled up enters into the integrally formed reservoir 304 from the
9

EGR cooler 200. Finally, the gases from the integrally formed reservoir 304 enters into the intake manifold 1000 through the pipe/hose 404 and the rate of flow of the gases from the integrally formed reservoir 304 to the intake manifold 1000 is controlled through opening and closing of the EGR valve 500.
5 [0044] The mounting of the EGR cooler 200 inside the integrally formed housing 302 of the transmission case 300 facilitates in achieving compact internal combustion engine, effective thermal management and efficient piping layout. Also, the said mounting arrangement of the EGR cooler reduces the effect of vibration and radiation from the internal combustion engine.
10 [0045] It will be understood by those within the art that, in general, terms used herein, and especially in the appended claims (e.g., bodies of the appended claims) are generally intended as “open” terms (e.g., the term “including” should be interpreted as “including but not limited to,” the term “having” should be interpreted as “having at least,” the term “includes” should be interpreted as
15 “includes but is not limited to,” etc.). It will be further understood by those within the art that if a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation no such intent is present. For example, as an aid to understanding, the following appended claims may contain usage of the introductory phrases “at least
20 one” and “one or more” to introduce claim recitations. However, the use of such phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles “a” or “an” limits any particular claim containing such introduced claim recitation to inventions containing only one such recitation, even when the same claim includes the introductory phrases “one or more” or “at least
25 one” and indefinite articles such as “a” or “an” (e.g., “a” and/or “an” should typically be interpreted to mean “at least one” or “one or more”); the same holds true for the use of definite articles used to introduce claim recitations. In addition, even if a specific number of an introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should typically be
30 interpreted to mean at least the recited number (e.g., the bare recitation of “two
10

recitations," without other modifiers, typically means at least two recitations, or two or more recitations). Furthermore, in those instances where a convention analogous to "at least one of A, B, and C, etc." is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., "a system having at least one of A, B, and C" would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). In those instances where a convention analogous to "at least one of A, B, or C, etc." is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., "a system having at least one of A, B, or C" would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). It will be further understood by those within the art that virtually any disjunctive word and/or phrase presenting two or more alternative terms, whether in the description, claims, or drawings, should be understood to contemplate the possibilities of including one of the terms, either of the terms, or both terms. For example, the phrase "A or B" will be understood to include the possibilities of "A" or "B" or "A and B."
[0046] While the foregoing describes various embodiments of the invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof. The scope of the invention is determined by the claims that follow. The invention is not limited to the described embodiments, versions or examples, which are included to enable a person having ordinary skill in the art to make and use the invention when combined with information and knowledge available to the person having ordinary skill in the art.

We claim:

An Exhaust Gas Recirculation(EGR) system(800) for an Internal
Combustion Engine, said EGR system (800) comprising:
a) an integrally formed housing (302) accommodating an EGR cooler (200) on a transmission case (300) with an opening 302(b) to an integrally formed reservoir (304) to establish fluid communication between said EGR cooler (200) and said integrally formed reservoir (304), said integrally formed housing (302) includes two integrally formed or coupled pipes (302(e) and 302(f)) for the inlet and outlet of a coolant; and
b) an EGR valve (500) coupled to said integrally formed reservoir (304) on its operative top.

2) The EGR system (800) as claimed in claim 1, wherein said integrally formed housing (302) and said integrally formed reservoir (304) are placed adjacent to each other on said transmission case (300).
3) The EGR system (800) as claimed in claim 1, wherein said EGR cooler (200) comprises an inlet gas box (212) and an outlet gas box (214) defining a plurality of passages (216) in between therein.
4) The EGR system (800) as claimed in claim 3, wherein said inlet gas box (212) and said outlet gas box (214) includes a plurality of openings (212(a)) and (214(a)) at their ends.
5) The EGR system (800) as claimed in claim 3, wherein a flange (218) having an opening (218(a)) defined therein is coupled to said inlet gas box (212) of said EGR cooler (200).

6) The EGR system (800) as claimed in claim 3, wherein a flange (222) having an opening 222(a) defined therein with an extended rim (222(b)) on its one face is coupled to said outlet gas box (214).
7) The EGR system (800) as claimed in claim 1, wherein a slot (302(a)) is provided inside said integrally formed housing (302) defining said opening (302(b)) therein.
8) The EGR system (800) as claimed in claim 6, wherein said extended rim (222(b)) of said flange (222) sits inside said slot (302(a)) of said integrally formed housing (302) in assembled condition.
9) The EGR system (800) as claimed in claim 1, wherein said integrally formed reservoir (304) is provided with an integrally formed or coupled flange (304(b)) on its side face therein in fluid communication with said integrally formed reservoir (304).
10) The EGR system (800) as claimed in claim 1, wherein said integrally formed housing (302) is provided with a flange (302(c)) integrally formed and extending around its circumference.
11) The EGR system (800) as claimed in claim 10, wherein said flange (302(c)) of said integrally formed housing (302) is provided with a plurality of holes (302(d)) on its opposite ends.
12) The EGR system (800) as claimed in claim 5, wherein said flange (218) of said EGR cooler (200) is drilled with a plurality of holes (218(b)) and a plurality of holes (218(c)) on its opposite ends.
13) The EGR system (800) as claimed in claim 5, wherein a pipe or hose (402) provided with flanges on either ends is coupled to said flange (218) of said

EGR cooler (200) at one end and to a catalytic converter (900) at the other end.
14) The EGR system(800) as claimed in claim 1, wherein a pipe or hose (406) is coupled to the internal combustion engine at one end and to said integrally formed or coupled pipe (302(e)) of said integrally formed housing (302 )of said transmission case (300) at the other end.
15) The EGR system (800) as claimed in claim 9, wherein a pipe or hose (408) provided with flanges on either ends is coupled to said flange (304(b)) of said integrally formed reservoir (304) at one end and to an intake manifold (1000) at the other end.
16) The EGR system (800) as claimed in claim 1, wherein said integrally formed housing (302) is of circular or rectangular or square cross section.
17) The EGR system (800) as claimed in claim 1, wherein said EGR cooler (200) is of circular or rectangular or square cross-section.
18) The EGR system (800) as claimed in claim 9, wherein said integrally
formed reservoir (304) is provided with one hole 304(e) opening to said
integrally formed or coupled flange (304(b)).