[001] The present subject matter described herein, relates to an air intake manifold structure for a vehicle and, in particular, to the intake manifold for exhaust gas recirculation system for an internal combustion engine.
BACKGROUND OF THE INVENTION:
[002] Exhaust gas recirculation (EGR) is an emission control technology allowing significant NOx emission reductions from engines: from light-duty engines through medium- and heavy-duty engine applications. The air fuel mixture is conducted to the intake valves of the engine through an air intake manifold.
[003] Generally, to recirculate the exhaust gas from an exhaust pipe to the internal combustion engine an Exhaust Gas Recirculation system is provided that reintroduces the exhaust gasses with combination of air to combustion chamber of the internal combustion engine. A passage is provided separately that connects the exhaust gas gallery from the cylinder head to the air intake manifold for mixing the air with the exhaust gasses.
[004] In existing layout of the exhaust gas system where a separate pipe connects the air intake manifold with the exhaust gas gallery provided in the cylinder head. A first end of an EGR pipe is connected with an EGR cooler and a second end of the EGR pipe is connected with a surge tank. The EGR pipe is provided to transport exhaust gases from the exhaust manifold to the air intake manifold.
[005] The technical problem associated with the existing structure is that the separately provided EGR pipe is very long thus, resultantly increases the overall occupant space of the EGR system.
[006] Another technical problem associated with the existing structure is the rigidity of the EGR pipe is very low due to excessive vibration at the time of operation. The excessive vibration and the low rigidity of the EGR pipe causes wear and tear and further decreases life span and efficiency of the EGR pipe.
[007] Another technical problem is improper mixing of air and the exhaust gases coming through the exhaust pipe which is connected to the surge tank in offset direction.
[008] Therefore, there is a need in the art to provide an alternative provision that reduces the number of members involved in the assembly and transfers exhaust gases from the cylinder head gallery to surge tank without any pipe that creates above mentioned technical problems. Also, the efficiency of the exhaust gas recirculation system is enhanced, problems such as loosening of pipe due to vibration can be eliminated, and sealing performance can be ensured.
OBJECTS OF THE INVENTION:
[009] Some of the objects of the present disclosure, which at least one embodiment herein satisfy, are listed herein below.
[0010] The principal object of the present invention is to provide an air intake manifold with an integrated Exhaust Gas Recirculation gallery that eliminates the use of a separate EGR pipe.
[0011] Another object of the present subject matter is to provide the air intake manifold with integrated EGR gallery that provides rigidity to the EGR system during working conditions.
[0012] Another object of the present subject matter is to provide an EGR system where the EGR gallery is integrated with the air intake manifold that is more durable and has a better efficiency in terms of exhaust gas handling by homogeneously mixing the exhaust gas with the air.
[0013] Another object of the present subject matter is to provide an air intake manifold with the integrated EGR gallery that occupies less space in engine room.
[0014] Another object of the present subject matter is to provide an air intake manifold that provides better acidic resistance in order to increase life span and the performance of the EGR system.
[0015] Another object of the present subject matter is to increase the rigidity of the EGR pipe/EGR gallery during crash.
[0016] Yet another object of the present subject matter is to provide an integrated EGR gallery in the air intake manifold of upward type layout.
[0017] These and other objects and advantages will become more apparent when reference is made to the following description and accompanying drawings.
SUMMARY OF THE INVENTION:
[0018] This summary is provided to introduce concepts related to layout of an Exhaust Gas Recirculation (EGR) pipe in the 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.
[0019] In an embodiment, the present disclosure relates to an air intake manifold structure for an internal combustion engine of a vehicle. The air intake manifold structure comprising a surge tank connected with throttle body to receive fresh air from the environment and a plurality of air runners connected with the surge tank at one end and configured to connect with cylinder head of the internal combustion engine at other end to allow passage of air from the surge tank to combustion chamber of the internal combustion engine. Further, an Exhaust Gas Recirculation (EGR) gallery integrally provided along the plurality of air runners, where one end of the integrated EGR gallery is directly connected to an EGR gallery of the cylinder head and other end of the integrated EGR gallery connects with the surge tank.
[0020] In an aspect, the integrated EGR gallery opens adjacent to a throttle body of the surge tank to provide homogenous mixture of air and EGR gases.
[0021] In an aspect, the integrated EGR gallery opens adjacently to a throttle opening of the surge tank followed by the plurality of air runners.
[0022] In an aspect, the air intake manifold defines an upward type layout.
[0023] In an aspect, the integrated EGR gallery defines outward extending flanges that connects with the EGR gallery of the cylinder head by fastening and sealing means.
[0024] In an aspect, material of the air intake manifold is selected from but not limited to metal, or resin, etc.
[0025] In an aspect, the integrated EGR gallery is provided during manufacturing process of the air intake manifold structure.
[0026] In an aspect, the air intake manifold structure is manufactured by casting process or by injection molding process or by molding process.
[0027] To further understand the characteristics and technical contents of the present subject matter, a description relating thereto will be made with reference to the accompanying drawings. However, the drawings are illustrative only but not used to limit scope of the present subject matter.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] It is to be noted, however, that the appended drawings illustrate only typical embodiments of the present subject matter and are therefore not to be considered for limiting of its scope, for the invention may admit to other equally effective embodiments. The detailed description is described with reference to the accompanying figures. In the figures, the left-most digit(s) of a reference number identifies the figure in which the reference number first appears. The same numbers are used throughout the figures to reference like features and components. Some embodiments of system or methods in accordance with embodiments of the present subject matter are now described, by way of example, and with reference to the accompanying figures, in which:
[0029] Fig. 1 illustrates an air intake manifold structure with an integrated EGR gallery connected with an EGR gallery of cylinder head and a surge tank, in accordance with an embodiment of the present subject matter;
[0030] Figure. 2 illustrates a perspective view where the air intake manifold structure is connected with the cylinder head of the engine, in accordance with an embodiment of the present subject matter;
[0031] Figure. 3 illustrates an air intake manifold structure of fig. 1;
[0032] Figure. 4a illustrates opening of the integrated EGR gallery toward the cylinder head along with openings of a plurality of air runners of the air intake manifold, in accordance with an embodiment of the present subject matter; and
[0033] Figure. 4b illustrates throttle opening of the surge tank of the air intake manifold, in accordance with an embodiment of the present subject matter,
[0034] 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.
DESCRIPTION OF THE PREFERRED EMBODIMENTS:
[0035] 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 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.
[0036] It is also to be understood that various arrangements may be devised 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.
[0037] The terminology used herein is for the purpose of describing particular 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 tennis “comprises,” “comprising,” “includes” and/or “including,” when used herein, specify the presence of stated features, integers, 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.
[0038] 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, 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.
[0039] Unless otherwise defined, all terms (including technical and scientific 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 formal sense unless expressly so defined herein.
[0040] 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 various arrangements that, although not explicitly described herein, embody the principles of the present subject matter and are included within its scope.
[0041] Referring to figure. 1 that illustrates structure of an intake manifold structure 200 connected with a cylinder head 300 by known fastening means, such as nut-bolt and rubber seal in between the intake manifold structure 200 and the cylinder head 300 to provide leakage proof connection. In an Exhaust Gas Recirculation (EGR) system exhaust gases are circulated from exhaust manifold to combustion chamber of the internal combustion engine. In the cylinder head 300, an EGR gallery 301 is provided to receive exhaust gas from the exhaust manifold.
[0042] The present intake manifold structure 200 comprises a surge tank 201 connected with a throttle opening 206 to receive fresh air from the environment and a plurality of intake runner 202, 203, 204. The plurality of intake runners 202, 203, 204 connect the surge tank 201 with the cylinder head 300. The plurality of intake runners 202, 203, 204 connected with the surge tank 201 at one end and configured to connect with cylinder head 300 of the internal combustion engine at other end. The plurality of intake runners 202, 203, 204 are coupled with inlet valve of the combustion chamber to deliver air-fuel mixture. Further, connection of the intake manifold structure 200 with the combustion chamber of the internal combustion engine is well known to a person skilled in the art to avoid any ambiguity for the subject matter as claimed in present application detailed explanation and working of the same is not elaborated. The number of intake runners in the intake manifold depends upon number of combustion cylinders in the internal combustion engine. For example, the present drawings show three intake runners which means that internal combustion engine has three combustion cylinder. However, the present subject matter is not limited only to intake manifold having three intake runners but also to all intake manifold without any limitation to number of intake runners.
[0043] The air intake manifold structure 200 comprises an Exhaust Gas Recirculation (EGR) gallery 205 integrally provided along the plurality of intake runners 202, 203, 204. The gallery means a hollow provision provided in a solid part or component that allow passage of fluids from one end to other end. The integrated EGR gallery 205 longitudinally extends along the length of the intake manifold structure 200. One end 205a of the integrated EGR gallery 205 is directly connected to the EGR gallery 301 of the cylinder head 300 by known fastening means and other end 205b of the integrated EGR gallery 205 integrally connects with the surge tank 201.
[0044] In an embodiment, the other end 205b the integrated EGR gallery 205 opens adjacently to a throttle opening 206 of the surge tank 201 to provide homogenous mixture of air and exhaust gases. The integrated EGR gallery 205 is positioned at closed proximity of throttle opening 206 in the surge tank 201 or just after the throttle opening 206 in the surge tank 201 so that a maximum homogenous air and exhaust gas mixture is achieved.
[0045] In another embodiment, the integrated EGR gallery 205 may be provided at any location in the surge tank 201 from where homogenous air and exhaust gases mixture is achieved.
[0046] In yet another embodiment, the integrated EGR gallery 205 may open adjacently to the throttle opening 206 of the surge tank 201 followed by opening of the plurality of intake runners 202, 203, 204.
[0047] Referring to figure. 2 that illustrates joining of the intake manifold structure 200 with the cylinder head 300. As shown in the figure 3, the EGR gallery 301 of the cylinder head 300 is leak proof connection with the integrated EGR gallery 205 of the intake manifold structure 200.
[0048] Figure. 3, 4a and 4b, the integrated EGR gallery 205 longitudinally extends along the length of the plurality of intake runners 202, 203, 204 of the intake manifold structure 200 which is an upward type layout of intake manifold. The integrated EGR gallery 205 with the intake manifold structure 200 forms a single structure rather than an individual component as already discussed in the background of the present application. The present integrated structure provides better stability and high rigidity to the integrated EGR gallery 205 as well as the intake manifold structure 200. Also, the present integrated structure reduces the overall requirement of pipes and fasteners associated with them in order to control the issue faced with the EGR pipe movement.
[0049] As shown in figure 4a, the integrated EGR gallery 205 defines a flange portion 205c outwardly extending from opening for mounting of the same on the cylinder head 300. The flange portion 205c has mounting provision, such as mounting hole 205d and sealing provision 205e to receive seal that sandwiches in between the flange portion 205c of the intake manifold structure 200 and the cylinder head 300. The flange portion 205c helps in increasing the rigidity of the intake manifold structure 200 with the cylinder head 300. Figure 4b shows adjacent opening of the other end 205b of the EGR gallery 205 to the throttle opening 206 in the surge tank 201.
[0050] The integrated EGR gallery 205 is provided integrally during manufacturing process of the intake manifold structure 200. The material of the intake manifold structure 200 is selected from but not limited to metal, or resin, etc. The intake manifold structure 200 is manufactured by casting process or by injection molding process or by molding process.
[0051] With the integrated EGR gallery 205 in the intake manifold structure 200, overall space requirement and occupancy of the entire EGR system is reduced when compared to its conventional counterparts.
[0052] The stability of the integrated EGR gallery 205 as well as the intake manifold structure 200 also improves the vibrational characteristics of the entire EGR system which includes exhaust manifold, EGR cooler, valve, internal combustion engine, and intake manifold.
[0053] As the EGR gallery is provided along the intake runners carrying the fresh air which improves the temperature of the EGR gallery and EGR gases available in the EGR gallery that controls the acidic resistance of gallery. The EGR gasses contain sulphates, nitrates, etc., which, while passing through the EGR cooler cools and gets combined with the moisture present in the EGR pipes (eliminated in the present application) which results in the formation of acids and leads to corrosion.
Technical advantages: there are a number of technical advantages which arise from the integrated EGR gallery integrally provided along the plurality of intake runners of the air intake manifold structure.
? Durability of EGR system has increased as all the parts are joined directly without any extra part, such as EGR pipe.
? With present integration of EGR gallery in the intake manifold structure, the vibration has decreased as no separate handling parts or pipes.
? No of pipes and fasteners has reduced due to integration.
? Shortest path for recirculation of exhaust gases is achieved.
? Cost has been reduced with high durability and stability.
? Better crash performances as there is no separate or hanging part.
? Compact space in the engine room as no extra pipe is provided.
? Acidic resistance of EGR gallery is controlled as temperature of the exhaust gases is maintained by intake runners.
[0054] 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 “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 one” and “one or more” to introduce claim recitations.
[0055] 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 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 interpreted to mean at least the recited number (e.g., the bare recitation of “two recitations,” without other modifiers, typically means at least two recitations, or two or more recitations).
[0056] 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.).
[0057] 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.”
[0058] 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.

Claims:We claim:
1. An intake manifold structure (200) for an internal combustion engine of a vehicle, the intake manifold structure (200) comprising:
a surge tank (201);
a plurality of intake runners (202, 203, 204) connected with the surge tank (201) at one end and configured to connect with cylinder head (300) of an internal combustion engine at other end;
characterized in that
an Exhaust Gas Recirculation (EGR) gallery (205) integrally provided along the plurality of intake runners (202, 203, 204), where one end of the integrated EGR gallery (205) is directly connected to an EGR gallery (301) of the cylinder head (300) and other end of the integrated EGR gallery (205) connects with the surge tank (201).
2. The intake manifold structure (200) as claimed in claim 1, wherein the integrated EGR gallery (205) opens adjacent to a throttle opening (206) of the surge tank (201).
3. The intake manifold structure (200) as claimed in claim 1, wherein the integrated EGR gallery (205) opens adjacent to a throttle opening (206) of the surge tank (201) followed by the plurality of intake runners (202, 203, 204).
4. The intake manifold structure (200) as claimed in claim 1, wherein the intake manifold structure (200) defines an upward type layout.
5. The intake manifold structure (200) as claimed in claim 1, wherein the integrated EGR gallery (205) defines outward extending flanges (205c) that connects with the EGR gallery (301) of the cylinder head by fastening and sealing means.
6. The intake manifold structure (200) as claimed in claim 1, wherein material of the intake manifold structure (200) is selected from but not limited to metal, resin, etc.
7. The intake manifold structure (200) as claimed in claim 1, wherein the integrated EGR gallery (205) is provided during manufacturing process of the intake manifold structure (200).