This application relates in general to intake manifolds for vehicle engines that utilize a coolant fluid, and more particularly, to inserts positionable between the manifold and/or coolant crossover or other cooling passage, plug, connector, or connection and the cylinder heads, where the inserts are each configured to hold a gasket seal and are made of a material that is chemically resistant to coolant fluid.
In automotive engines, coolant crossovers are commonly present on V-type internal combustion engine. Coolant crossovers carry the engine coolant fluid from one bank or side of the engine to the opposite bank for cooling during engine operation. The coolant crossover is typically a separate component attached or mounted to an intake manifold by a plurality of fasteners, such as bolts. One example of an intake manifold and coolant crossover assembly is disclosed in U.S. Pat. No. 6,945,199.
Turning now to
Referring again to U.S. Pat. No. 6,945,199, one approach to solve this problem is presented, best seen in
Another attempted solution is presented in U.S. Pat. No. 8,156,913, which molds a sleeve of polyphenylene sulfide inside the water crossover's main passage 46, best seen in
There is a need for a solution the forms the innermost wall of the seal seat of a chemically resistant material without requiring a redesign of the coolant crossover, so that expensive aluminum coolant crossovers can be retained during repair of the intake manifold. The solution presented herein protects all the coolant passage seal supports from exposure to coolant fluid and provides a design for reuse of aluminum coolant crossovers and in the future.
In a first aspect, intake manifolds for an internal combustion engine are disclosed that include a first insert configured as a port cap having a bottom surface defining a first perimeter recess configured to receive a first sealing member, a second insert configured as a port cap and having a bottom surface defining a second perimeter recess configured to receive a second sealing member, and a main body having a first set of runners extending in a first direction therefrom and a second set of runners extending in an opposite direction therefrom, wherein both the first set of runners and the second set of runners each terminate at a back end with a flange that defines a socket configured to receive one of the first and second inserts, respectively, and in which one of the first insert and second insert are seated. The first insert and the second insert are made of a material that is chemically resistant to coolant fluid, for example, polyphenylene sulfide or a metal or metal alloy. The main body can be made of a polyamide or polypropylene.
In one embodiment, the first insert has a top surface from which an elongate spout extends and from which a fastener post extends. The flange of the first set of runners includes a mating hole for receipt of the fastener post for a deformation fit therewith. The elongate spout can be open for fluid flow therethrough. In the same or a different embodiment, the bottom surface of the second insert has an outer wall having a beginning and an end and an endless inner wall defining the recess for a second sealing member.
In another aspect, the intake manifold described above can additionally have both the first set of runners and the second set of runners each terminating at a front end with a flange that defines a socket configured to receive a third insert and a fourth insert, respectively. The third insert is seated in the flange of the first set of runners and defines an open port, has a top surface defining a third perimeter recess about the open port configured to receive a third sealing member, and has a bottom surface defining a fourth perimeter recess about the open port configured to receive a fourth sealing member. The fourth insert is seated in the flange of the second set of runners and defines a dual port, has a top surface defining a fifth perimeter recess about the dual ports configured to receive a fifth sealing member, and has a bottom surface defining a sixth perimeter recess that surrounds and extends between the ports of the dual port configured to receive a sixth sealing member. The third insert and the fourth insert are made of a material that is chemically resistant to coolant fluid, for example, polyphenylene sulfide or a metal or metal alloy. The main body can be made of a polyamide or polypropylene.
The third insert and the fourth insert can each have a key-keyway or keyway-key connection to the respective socket. Separately or in addition to key-keyway connection, the third insert and the fourth insert can have a deformation fit in their respective socket.
In all embodiments, the top surface of the third insert and the fourth insert and a top surface of their respective flanges of the intake manifold are configured to mate with a coolant crossover.
In another aspect, the intake manifold described above can include a coolant crossover juxtaposed to and attached or integral with the main body thereof. The coolant crossover has a first end more proximate the first set of runners and a second end more proximate the second set of runners. The intake manifold includes a first interface spacer attached to the first end of the coolant crossover, and a second interface spacer attached to the second end of the coolant crossover. The first interface spacer and the second interface spacer are each made of a material that is chemically resistant to coolant fluid, for example, polyphenylene sulfide or a metal or metal alloy. The main body can be made of a polyamide or polypropylene.
The first interface spacer defines a through-port and has a top surface defining a third perimeter recess about the through-port configured to receive a third sealing member and a bottom surface defining a fourth perimeter recess about the through-port configured to receive a fourth sealing member. The second interface spacer defines dual through-ports and has a top surface defining a fifth perimeter recess about and between the dual through-ports configured to receive a fifth sealing member and a bottom surface defining a sixth perimeter recess that about and between the dual through-ports configured to receive a sixth sealing member.
In another aspect, kits are disclosed herein that include a first insert configured as a port cap having a bottom surface defining a first perimeter recess configured to receive a first scaling member, a second insert configured as a port cap and having a bottom surface defining a second perimeter recess configured to receive a second sealing member, and an intake manifold comprising a main body having a first set of runners extending in a first direction therefrom and a second set of runners extending in an opposite direction therefrom. Both the first set of runners and the second set of runners each terminate at a back end with a flange that defines a socket configured to receive one of the first and second inserts, respectively. The first insert and the second insert are made of a material that is chemically resistant to coolant fluid, for example, polyphenylene sulfide or a metal or metal alloy. The main body can be made of a polyamide or polypropylene.
In one embodiment, the first insert has a top surface from which an elongate spout can extends, the elongate spout being open or closed.
The kit can also include the first sealing member and the second sealing member.
In one embodiment, both the first set of runners and the second set of runners of the intake manifold terminate at a front end with a flange that defines a socket configured to receive a third insert and a fourth insert, respectively. The kit also includes the third insert which defines an open port, has a top surface defining a third perimeter recess about the open port configured to receive a third sealing member, and has a bottom surface defining a fourth perimeter recess about the open port configured to receive a fourth sealing member. The kit also include the fourth insert which defines a dual port, has a top surface defining a fifth perimeter recess about the dual ports configured to receive a fifth sealing member, and has a bottom surface defining a sixth perimeter recess that surrounds and extends between the ports of the dual port configured to receive a sixth sealing member. The third insert and the fourth insert are made of a material that is chemically resistant to coolant fluid, for example, polyphenylene sulfide or a metal or metal alloy.
The kit can also include the third sealing member through a sixth sealing member.
In another embodiment, the kit can include a coolant crossover attachable or integral with the main body of the intake manifold, a first spacer attachable to a first end of the coolant crossover, and a second spacer attachable to the second end of the coolant crossover. The first interface spacer and second interface spacer are each made of a material that is chemically resistant to coolant fluid. The first spacer defines a through-port, has a top surface defining a third perimeter recess about the through-port configured to receive a third sealing member, and has a bottom surface defining a fourth perimeter recess about the through-port configured to receive a fourth sealing member. The second spacer defines dual through-ports, has a top surface defining a fifth perimeter recess about and between the dual through-ports configured to receive a fifth sealing member, and has a bottom surface defining a sixth perimeter recess that about and between the dual through-ports configured to receive a sixth sealing member.
The kit also includes a plurality of sealing members, one each configured to seat in one of the first through sixth perimeter recesses.
The following detailed description will illustrate the general principles of the invention, examples of which are additionally illustrated in the accompanying drawings. In the drawings, like reference numbers indicate identical or functionally similar elements.
As used herein, “fluid” means any liquid, suspension, colloid, gas, plasma, or combinations thereof.
A basic internal combustion engine system 100 is configured for combusting fuel vapor accumulated in at least one component thereof and includes a multi-cylinder internal combustion engine 110. The engine system 100 receives air from an air intake 112, which may include an air filter 113 and may include a turbocharger (or a supercharger). The compressor of the turbocharger receives air from the air intake 112, compresses the air, and directs a flow of compressed air (or boosted air) downstream through a charge air cooler or intercooler and then to a throttle. The throttle controls fluid communication between the compressor and the intake manifold of the engine. The throttle is operable using known techniques to vary an amount of intake air provided to the intake manifold and the cylinders of the engine. The intake manifold is configured to supply intake air or an air-fuel mixture to a plurality of combustion chambers of engine located within the engine block. The combustion chambers are typically arranged above a lubricant-filled crankcase such that reciprocating pistons of the combustion chambers rotate a crankshaft located in the crankcase. In some engines, a first cylinder block and a second cylinder block and heads form a valley, often referred to as a V-engine. The valley is an open space beneath the intake manifold which, in some examples, may be used for various engine components, such as air, exhaust, and/or engine coolant conduits. Additionally, open space in the valley may assist in cooling of the engine.
Each cylinder may receive intake air from the intake manifold via an intake port located on the cylinder head and may exhaust combustion gases via an exhaust port located on the cylinder head. Thus, each cylinder head includes a plurality of exhaust ports and a plurality of intake ports. The exhaust ports are positioned on sides of the cylinder heads opposing the valley in an outbound configuration. For example, outbound exhaust manifolds leading to a tail pipe may be coupled to the exhaust ports on cylinder heads of the banks. The intake ports are positioned on the sides of the cylinder heads adjacent to the valley in an inbound configuration.
Referring to
Intake manifold 100 may be mechanically coupled to the intake ports on the cylinder head(s) using mechanical fasteners. For example, intake manifold 100 may be attached to the cylinder heads by a plurality of attachments 115 located adjacent to outer edges of intake manifold. Intake manifold 100 may further include various mounting components, outlets, etc. which may be coupled to various engine sensors, serve as a mounts for engine components, or secure the intake manifold to the engine. For example, a carburetor, throttle body, coolant crossover, fuel injectors and/or other components of the engine may be fastened to the intake manifold, e.g., via mounting holes shown in the figures. As another example, a manifold absolute pressure (MAP) sensor, a mass air flow (MAF) sensor, an air/fuel sensor, and/or other engine diagnostic devices may be coupled to the intake manifold.
Each insert described herein is made of a material that is chemically resistant to coolant fluid. Some non-limiting example materials include metal and/or metal alloys, such as aluminum or brass. The material can also be a synthetic polymer such as polyaromatic sulfide, for example, polyphenylene sulfide (PPS) and polyphenylene sulfide alloys, a polyphthalamide (PPA), a polybutylene terephthalate (PBT), or a polyoxymethylene (POM). Example polyphenylene sulfides are described in U.S. Pat. No. 8,156,913 and are incorporated herein by reference. Using such materials for the inserts enables the intake manifold to be molded of a more technically suitable material (one having a suitable elongation at rupture, transformation characteristics, etc.) and less expensive material, in particular, a polymeric material, such as, but not limited to, nylon 6, nylon 4/6, nylon 6/6, and/or other commercially available plastics that will provide fluid tight seal integrity at engine operational pressure differentials and are suitable for engine environmental conditions, such as temperatures between −40° C. to 120° C., as well as road and weather conditions and debris. In one embodiment, the intake manifold is made of a polyamide, such as a nylon. In another embodiment, the intake manifold is made of polypropylene. Typically, the polymers used for the intake manifold include fillers, such as glass fibers. The glass fibers can comprise 30% to 35% by weight of the polymer. In some examples, intake manifold may be formed at least partially from resin impregnated with a matrix material such a carbon fiber cloth. The composite intake manifold may be formed as one piece or as multiple pieces joined together in a post-process. For example, one or more pieces of the manifold may be formed using injection molding or blow-molding processes. The one or more pieces of the manifold may be joined together by a suitable welding process, e.g., using a vibration welding technique, and/or by using bolts, gaskets, or other suitable hardware.
Turning to
As seen in the figures, the port cap 122 includes a fastener post 132 extending outward away from the top surface 123. The fastener post 132 is configured to seat in a mating hole 134 (
In the assembled, cross-sectional view of
The first sealing member 190, shown in
Turning to
The intake manifold of
The first insert 220 may be the same the first insert 120 described above for the first embodiment. Alternately, the first insert 220 may be a port cap 222 only, i.e., no elongate spout is present. The first insert 220 include the other features of the first insert cap 120 of the first embodiment, such as the fastener post. Referring now to
The second insert 240 may be the same as the first insert 220 or the second insert 140 of the first embodiment discussed above.
Turning now to
Referring to
One or more fasteners (F) can fasten the intake manifold's flanges 215a, 215b, respectively, to the first end 252 and the second end 254 of the coolant crossover 250 through apertures 221a, 221b in the flanges 215a, 215b. As seen in
Each of the first through fourth inserts 220, 240, 260, and 280 can be molded, machined, thermoformed, 3-D printed, or made using sintering methods with any of the chemically resistant materials discussed above.
Turning now to
Turning to
Turning to
The second interface spacer 380 can include one or more registration tabs 329 configured to mate with a feature of the intake manifold or the coolant crossover to hold the interface spacer in a selected position during the fastening of the fastener (F), shown in
One or more fasteners (F) (labeled in
Each of the interface spacers 360 and 380 can be molded, machined, thermoformed, 3-D printed, or made using sintering methods with any of the chemically resistant materials discussed above.
The intake manifolds disclosed herein have several advantages. One advantage is that the chemically resistant material used for the inserts will prevent a coolant leak, the inserts will not erode from exposure to glycol. Another advantage is that the intake manifolds enable the reuse of the existing coolant crossover, which provides a cost savings during replacement of the intake manifold. Moreover, the inserts and interface spacers provide a simpler mold for the intake manifold and a completely separated interface for the water crossover requiring less geometrical tolerance precision for the intake manifold itself.
It should be noted that the embodiments are not limited in their application or use to the details of construction and arrangement of parts and steps illustrated in the drawings and description. Features of the illustrative embodiments, constructions, and variants may be implemented or incorporated in other embodiments, constructions, variants, and modifications, and may be practiced or carried out in various ways. Furthermore, unless otherwise indicated, the terms and expressions employed herein have been chosen for the purpose of describing the illustrative embodiments of the present invention for the convenience of the reader and are not for the purpose of limiting the invention.
Having described the invention in detail and by reference to preferred embodiments thereof, it will be apparent that modifications and variations are possible without departing from the scope of the invention which is defined in the appended claims.
This application claims the benefit of U.S. provisional Application No. 62/597,771, filed Nov. 10, 2023, which is incorporated herein by reference in its entirety.
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Number | Date | Country | |
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63597771 | Nov 2023 | US |