INDUCTION ASSEMBLY AND SYSTEM FOR A SUPERCHARGED INTERNAL COMBUSTION ENGINE, AND METHOD FOR ASSEMBLY FOR THE SAME

Abstract

An induction system for a supercharged internal V-type combustion engine includes a monolithic continuous unitary casting housing a supercharger with a rotor and gear assembly operative to discharge pressurized air to a common bounding receiving plenum, through a first slidably-removable intercooler providing a first cooling, and then to a pair of second side intercoolers providing a second cooling within the bounded plenum and in fluid communication therewith. First and second intercoolers are secured within the monolithic housing. The monolithic housing provides a robust and stable housing of light weight and allows an exterior air cooling as well. Side walls of the supercharger are separate from and are spaced from air intake runners of a cylinder block. Air in the plenum is additionally cooled by convective surface cooling while being guided in an appropriate direction. The intercoolers are plumbed in parallel allowing for enhanced temperature management of the air flow in combination with the convective cooling. The monolithic housing includes rib elements for sound attenuation and strength while minimizing weight. This arrangement allows for enhanced cooling, and simplifies manufacture and service.

Claims

1. An induction assembly for a supercharged internal combustion engine of a vehicle, said induction assembly comprising: a monolithic unitary housing member; said monolithic housing member bounding a bounded super charger rotor portal, a super charger access portal, a first central intercooler portal, and opposed second and third intercooler portals; said monolithic housing member forming a bounded air distribution plenum in a flow communication from said super charger rotor portal through said super charger access portal into said first central intercooler portal and to each said second and third intercooler portal; a super charger having a rotor assembly operative to produce a pressurized air through said super charger access portal; a first central intercooler assembly in said air distribution plenum receiving said pressurized air and passing a first cooled air to said air distribution plenum; said air distribution plenum splitting and passing said first cooled air to a second side intercooler assembly and an opposed third side intercooler assembly; said second and said third side intercooler assemblies passing a second cooled air to opposed air inlet members external to said monolithic unitary housing member; and a central air guidance rib projecting inwardly along an airflow pathway from an inner surface of said monolithic housing member and relative to said first central intercooler assembly operative to split a laminar airflow toward respective said second and said third side intercooler assemblies

2. (canceled)

3. The induction assembly, according to claim 1, further comprising: an operative water flow system in a parallel flow communication with each said first central intercooler assembly, said second side intercooler assembly, and said third side intercooler assembly.

4. The induction assembly, according to claim 1, wherein: said first central intercooler assembly is operatively slidably removable from said bounded continuous plenum through said first central intercooler portal, whereby an assembly and maintenance burden of said induction assembly is improved.

5. The induction assembly, according to claim 1, further comprising: a plurality of lateral air guidance ribs projecting inwardly along said airflow pathway, and perpendicular to said central air guidance rib, being operative for guiding a laminar airflow from said first central intercooler to respective said second and third side intercooler assemblies.

6. The induction assembly, according to claim 1, further comprising: at least one through bolt hole having a continuous defined side wall extending from a top surface to a bottom surface of said induction assembly and through said airflow pathway, whereby said monolithic induction assembly is secured during an installation thereof without disturbance of said laminar air flow.

7. The induction assembly system, according to claim 1, further comprising: said first central intercooler assembly is operatively slidably removable from said bounded plenum through said first central intercooler portal.

8. The induction assembly system, according to claim 1, further comprising: a plurality of undulations on an exterior surface of said monolithic unitary housing member.

9. The induction assembly system, according to claim 1, further comprising: a vehicle hood of said vehicle having a bounded opening proximate said monolithic unitary housing member, said plurality of undulations on said exterior surface of said monolithic unitary housing member extending through said bounded opening; whereby during a movement of said vehicle an airflow over said exterior surface is improved.

10. A method for assembly of an induction system for a supercharged internal combustion engine, comprising the steps of: providing a monolithic unitary housing member, said monolithic housing member bounding a bounded super charger rotor portal, a super charger access portal, a first central intercooler portal, and opposed second and third intercooler portals; said monolithic housing member and forming a bounded air distribution plenum in a flow communication from said super charger portal through said super charger access portal and to each said second and third intercooler portal; said monolithic housing member having a central air guidance rib projecting inwardly along an airflow pathway from an inner surface of said monolithic housing member and toward said first central intercooler assembly operative to split a laminar airflow toward respective said second and said third side intercooler assemblies; providing a first central intercooler assembly in said first central intercooler portal; providing a second and a third side intercooler assembly in said respective second and third intercooler portals; and inserting a surer charger having a rotor assembly into said supercharger rotor portal being operative to produce a pressurized air through said super charger access portal; inserting a first central intercooler assembly in said air distribution plenum through a bounded first intercooler access portal and operative for receiving said pressurized air and passing a first cooled air to said bounded air distribution plenum; inserting a second and a third opposed intercooler assembly in said air distribution plenum through opposed intercooler portals; operating said rotor assembly and producing said pressurized air through said supercharger access portal and through said first central intercooler assembly and passing said first cooled air to said bounded air distribution plenum; splitting said first cooled air along a central rib member and passing a laminar first cooled air to a second side intercooler assembly and an opposed third side intercooler assembly; and operating said second and said third side intercooler assemblies and cooling said first cooled air into a second cooled air and passing said second cooled air in a laminar manner to opposed sets of a plurality of air inlet members external to said monolithic unitary housing member.

11. (canceled)

12. The method for assembly of an induction system, according to claim 10, further comprising the steps of: providing an operative water flow system in a parallel flow communication with each said first central intercooler assembly, said second side intercooler assembly, and said third side intercooler assembly, thereby providing a cooling to each respective intercooler assembly.

13. (canceled)

14. An induction assembly for a supercharged internal combustion engine of a vehicle, said induction assembly comprising: a monolithic unitary housing member; said monolithic housing member bounding a bounded super charger rotor portal, a super charger access portal, a first central intercooler portal parallel to a rotational axis of a rotor assembly, and opposed second and third intercooler portals; said monolithic housing member forming a bounded air distribution plenum in a flow communication from said super charger rotor portal through said super charger access portal into said first central intercooler portal and to each said second and third intercooler portal; a super charger having said rotor assembly operative to produce a pressurized air through said super charger access portal during a use; a first central intercooler assembly in said air distribution plenum receiving said pressurized air and passing a first cooled air to said air distribution plenum; said first intercooler assembly slidably removably accessable from said first central intercooler portal in a direction parallel to said rotational axis of said rotor assembly thereby providing a reduced profile to said induction assembly; said air distribution plenum splitting and passing said first cooled air to a second side intercooler assembly and an opposed third side intercooler assembly; and said second and said third side intercooler assemblies passing a second cooled air to opposed air inlet members external to said monolithic unitary housing member; and at least one air guidance rib projecting inwardly along an airflow pathway from an inner surface of said monolithic housing member and relative to said first central intercooler assembly operative to split a laminar airflow toward respective said second and said third side intercooler assemblies.

15. The induction assembly, according to claim 14, further comprising: an operative cooling flow system in a parallel flow communication with each said first central intercooler assembly, said second side intercooler assembly, and said third side intercooler assembly.

16. The induction assembly, according to claim 14, further comprising: a plurality of lateral air guidance ribs projecting inwardly along said airflow pathway, and perpendicular to said central air guidance rib, being operative for guiding a laminar airflow from said first central intercooler to respective said second and third side intercooler assemblies.

17. The induction assembly, according to claim 14, further comprising: at least one through bolt hole having a continuous defined side wall extending from a top surface to a bottom surface of said induction assembly and through said airflow pathway, whereby said monolithic induction assembly is secured during an installation thereof without disturbance of said laminar air flow.

18. The induction assembly system, according to claim 14, further comprising: a plurality of undulations on an exterior surface of said monolithic unitary housing member.

19. The induction assembly system, according to claim 14, further comprising: a vehicle hood of said vehicle having a bounded opening proximate said monolithic unitary housing member, and said plurality of undulations on said exterior surface of said monolithic unitary housing member extending through said bounded opening; whereby during a movement of said vehicle an airflow over said exterior surface is improved.

20. An induction assembly for a supercharged internal combustion engine of a vehicle, said induction assembly comprising: a monolithic unitary housing member; said monolithic housing member bounding a bounded super charger rotor portal, a super charger access portal, a first central intercooler portal parallel to a rotational axis of a rotor assembly, and opposed second and third intercooler portals; said monolithic housing member forming a bounded air distribution plenum in a flow communication from said super charger rotor portal through said super charger access portal into said first central intercooler portal and to each said second and third intercooler portal; a super charger having said rotor assembly operative to produce a pressurized air through said super charger access portal during a use; a first central intercooler assembly in said air distribution plenum receiving said pressurized air and passing a first cooled air to said air distribution plenum; said first intercooler assembly slidably removably accessable from said first central intercooler portal in a direction parallel to said rotational axis of said rotor assembly thereby providing a reduced profile to said induction assembly; said air distribution plenum splitting and passing said first cooled air to a second side intercooler assembly and an opposed third side intercooler assembly; and said second and said third side intercooler assemblies passing a second cooled air to opposed air inlet members external to said monolithic unitary housing member; and at least one air guidance rib projecting inwardly along an airflow pathway from an inner surface of said monolithic housing member operative to guide a laminar airflow toward respective said second and said third side intercooler assemblies.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0023] FIG. 1 is a perspective view of the proposed inventive housing positioned relative to a vehicle hood having an air cooling portal.

[0024] FIG. 2 is a rear elevation view of a monolithic block assembly and a portion of an engine, and cylinder head, and intake runners noting a rear access portal to the intercooler and supercharger arrangement.

[0025] FIG. 3 is a side elevation view taken along section line 3-3 in FIG. 1, noting the relative positions of the vehicle hood, fire wall structure, and the monolithic continuous unitary casting.

[0026] FIG. 4 is a perspective top front view of a monolithic continuous unitary casting housing a supercharger with a rotor and gear assembly operative to discharge pressurized air to a common bounding receiving plenum mounted with related components.

[0027] FIG. 5 is a perspective top rear view of a monolithic continuous unitary casting housing a supercharger as shown in FIG. 4.

[0028] FIG. 6 is a partially exploded top rear view of FIG. 5 noting removal of the central intercooler.

[0029] FIG. 7 is top plan view of the monolithic continuous unitary casting housing a supercharger.

[0030] FIG. 8 is a partial sectional view along section line 8-8 in FIG. 7.

[0031] FIG. 9 is a partial sectional view along section line 9-9 in FIG. 7.

[0032] FIG. 10 is a partial sectional view illustrating air flow from a supercharger through a top intercooler and two side intercoolers.

[0033] FIG. 11 front perspective view of the monolithic continuous unitary casting noting air flow and coolant (water) flow.

[0034] FIG. 12 is a side elevation view of FIG. 11 noting the arrangement of strengthening ribs.

[0035] FIG. 13 is a front elevation view of FIG. 11 of the monolithic continuous unitary casting.

[0036] FIG. 14 is a rear elevation view of FIG. 11 of the monolithic continuous unitary casting noting the easy access to the intercooler and supercharger features.

[0037] FIG. 15 is a bottom rear perspective view of FIG. 11 noting air flow access and the interior internal geometry of the monolithic casting with ribs assisting laminar flow.

[0038] FIG. 16 is a bottom rear perspective view of FIG. 15 of the monolithic continuous unitary casting further noting the laminar air flow for cooling and operation.

[0039] FIG. 17 is a side rear perspective view of FIG. 16 noting the interior geometry for air flow as unrestricted.

[0040] FIG. 18 is a front perspective bottom view of FIG. 17 noting the interior geometry of air flow as unrestricted.

[0041] FIG. 19 is a bottom perspective view along section line 19-19 in FIG. 2 noting the interior ribbing and air flow structure for illustrating the continuous air flow to the side intercooler receivers from the plenum and the internal surface profile thereof.

[0042] FIG. 20 is a rear elevation exploded view of the monolithic continuous unitary casting and assembly as in FIG. 2 noting the central intercooler portal and rear access to the super charger portal.

[0043] FIG. 21 is a top rear perspective exploded and partial sectional view of FIG. 20 noting the positioning and arrangement of intercoolers.

[0044] FIG. 22 is a rear top perspective exploded and partial sectional view as in FIG. 21 noting the ease of accessibility and maintenance and improved air flow.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0045] Reference will now be made in detail to embodiments of the invention. Wherever possible, same or similar reference numerals are used in the drawings and the description to refer to the same or like parts or steps. The drawings are in simplified form and are not to precise scale. The word ‘couple’ and similar terms do not necessarily denote direct and immediate connections, but also include connections through intermediate elements or devices. For purposes of convenience and clarity only, directional (up/down, etc.) or motional (forward/back, etc.) terms may be used with respect to the drawings. These and similar directional terms should not be construed to limit the scope in any manner. It will also be understood that other embodiments may be utilized without departing from the scope of the present invention, and that the detailed description is not to be taken in a limiting sense, and that elements may be differently positioned, or otherwise noted as in the appended claims without requirements of the written description being required thereto.

[0046] Various operations may be described as multiple discrete operations in turn, in a manner that may be helpful in understanding embodiments of the present invention; however, the order of description should not be construed to imply that these operations are order dependent.

[0047] Referring now to FIGS. 1-10 the present invention involves an induction assembly and system 1 for a supercharged internal combustion engine having a v-type configuration (engine partially shown, but understood by those of skill in the art). As noted, a monolithic continuous unitary casting 2 housing a super charger assembly rotor assembly 6 (See FIG. 1) positioned relative to an automobile hood 3 (car not shown). The hood 3 includes a set of initial hood vents 3A (see FIG. 1) and a hood opening 3B bounding an upper portion of monolithic continuous unitary casting 2. Hood 3 operates relative to a fire wall structure 8 within an engine cavity of the vehicle and a particular improvement of the present invention is to enable an operative positioning of all components within the engine cavity while allowing for maintenance without comprehensive disassembly of the vehicle engine.

[0048] As will be noted from the figures, rotor assembly and super charger 11 includes a nose drive assembly 15 operative to receive a driving force from the internal combustion engine for operative rotation.

[0049] During a use, an air intake 16 receives an air flow via hood vents 3A and ambient atmosphere and the intake air flow is pressurized forcefully through supercharger rotor assembly 11 within monolithic continuous unitary casting 2, and is transmitted through an access portal 11A (See FIGS. 15-17) as will be discussed herein.

[0050] Monolithic unitary casting 2 includes a left side 20A and a right side 20b intercooler portal for receiving respective ones of a pair of side intercooler assemblies 13, 13 before joining to respective side air intake runners 12, 12 for transferring cooled pressurized air to the cylinder heads of the internal combustion engine. Casting 2 includes a central intercooler portal 20C (FIG. 10) and a continuously bound plenum including left and right intercooler portals 20A, 20B as well as a central intercooler portal 23 on a rear side thereof shaped to slidably-receive a central intercooler 14 from the rear side (see FIG. 5). A super charger portal 24″ is part of the monolithic construction and is shaped to slidingly-receive the super charger rotor assembly 11, as shown, from a rear side, and a super charger air intake portal 24′ is shaped on a front side of the monolithic housing 2. It will be understood that the super charger rotor assembly includes a nose drive assembly 15 for receiving a driving force for operation, and a rear cover door 15A.

[0051] During an operation a water flow operates in parallel to the central intercooler assembly 14 and to each respective side intercooler assembly 13, 13. Water flows from a heat exchanger 6 operative to exchange heat with an ambient air, through a water pump assembly 4, and a reservoir system 5 via a plurality of outgoing and return tubing 7 (shown respectively) to each respective intercooler assembly 13, 13, 14. At a front portion of the monolithic casting 2, a water cross over manifold 10 receives and transmits cooling water in parallel from either side intercooler assembly 13, 13 and links with a water manifold assembly 9 for regulating an in/out flow of cooling water between each intercooler assembly 13, 13, 14 and the other respective elements in the water flow system 30. As is shown particularly in FIGS. 1, 3, 4, and 5 tubing elements 7 for the central intercooler assembly 14 are shown for convenience. It will be understood by those of skill in the art of automotive engineering, after study of the present disclosure that the flow elements of water flow system 30 may be modified and positioned differently and remain within the scope and spirit of the present invention. The present arrangement shown provides an improved convenience but is not limited thereto. For example, additional pumps, different reservoirs, and different pumps, cross-over manifolds and other separate manifolds may be used without departing from the present invention.

[0052] The interior surface of monolithic continuous unitary casting 2 includes a central rib member 21 (see FIGS. 10, 16 for example) to aid in directionally bifurcating the laminar pressurized air flow exiting intercooler 14. A plurality of lateral rib members 22 project generally perpendicularly away from central rib member 21 along the inside surface of casting 2 to further aid and generate laminar airflow to respective side intercooler assemblies 13, 13. It will be understood that internal ribs 21, 22 guide efficient pressurized laminar air flow, manage sound attenuation to reduce noise, and aid stiffening of casting 2.

[0053] At a bottom location of monolithic continuous unitary casting 2, below super charger rotor assembly 11 and super charger portals 24′, 24″ are provide a plurality of rotor support ribs 25 projecting outwardly therefrom (see FIGS. 12, 16, and 18). Ribs 25 provide an additional rigidity and thermal conduction to casting 2 while enabling a thin wall section in the casting for a substantial weight reduction.

[0054] Referring additionally to FIGS. 11-22 additional sectional views are provided to aid in comprehension of induction assembly and system 1, monolithic continuous induction housing 2, and the related positions of central intercooler 14 and side intercoolers 13, 13 relative to runners 12, 12.

[0055] As will well understood from the cross-sectional arrangements in FIGS. 8, 9, 10, 15, and 19, the induction housing 2 is continuous as a monolithic member having a thin wall thickness. In this matter, induction housing 2 can advantageously be assembled and removed from a set of cylinder heads 35, 35 and a respective cylinder block 40 provided for illustrative purposes and to illustrate an overall block assembly 41 containing these basic components. As a result, it will be recognized by those of skill in the art that induction assembly and system 1 may be readily incorporated with cylinder heads 35, 35 and cylinder block 40 and overall block assembly 41 having various geometries, within the scope and spirit of the present invention.

[0056] As will be understood from considering side elevation view of block assembly 41 in FIGS. 2, 21, there is enabled by the present invention, an air gap (shown) between the bottom super charger ribs 25 and the central portion of cylinder block 40, allowing for additional cooling, as well as other advantages in terms of efficiency and engine-component-arrangement.

[0057] It will be understood that monolithic continuous unitary casting 2 may be alternatively called a monolithic housing 2, for convenience without departing from the scope and spirit of the present invention.

[0058] It will be noted that side intercooler assemblies 13, 13 are provided within left and right intercooler portals 20A, 20B (see FIGS. 14, 15, 16), and are positioned within monolithic housing 2 allowing for easy access upon simple removal of monolithic housing 2 for maintenance. As will be noted, monolithic housing 2 contains a series of bolt holes (16 in total shown) respectively identified as openings 26. As will be appreciated from study of the figures, bolt holes 26 are continuous through monolithic housing 2 and extend through either side walls of the respective outer sides of monolithic housing 2 or are fully enclosed passages through the interior sides of the continuous bounded plenum within housing 2 (see for example, FIGS. 10, 16, 17, 18, where it can be seen that laminar air flows pass from central rib 21 region along lateral rib regions 22 directly to side intercooler assemblies 13, 13 and directly therethrough. It is noted that with the full enclosure of bolt holes 26 that tightening during assembly cannot distort unitary casting 2 because any bolt is continuously supported by the bolt-hole-side-wall (See FIG. 9)

[0059] As will be understood from the disclosure, and particularly from FIGS. 5 and 6, as a substantial convenience central intercooler 14 may be accessed in a slide-out manner from the rear of monolithic housing 2 without removal of monolithic housing 2 from any other engine component. In process, for assembly or disassembly, this is a substantial time savings and quality improvement. Specifically, there is no damage to any seal (which is not effective by sliding removal) between the monolithic housing 2, and runners 12, 12, or any other component. The rear door access portal 11A for supercharger rotor assembly 11 need not be opened for changing or inspecting central intercooler 14. Additionally, as a substantial benefit, side intercooler assemblies 13, 13 may also be inspected via angled viewing through (via) the central intercooler portal 23, providing an enhanced and very fast review. An inspection light (not shown) can be positioned within portal 23 (see FIG. 6) and each side intercooler 13, 13 can be inspected without the need to remove monolithic continuous unitary casting 2 unless necessary.

[0060] Regarding the position of monolithic housing 2 positioned within hood opening 3B; during use, variable rate air flow flows over a pair of undulating outer surface region 27, 27 for monolithic housing 2, spaced by a smooth central surface region 28. Undulating outer surface regions 27, 27 receive deflected air flow from central surface region 28, which deflects laterally (to the side) due to a curved and slanted/angular arrangement. Additionally, any direct air flow (from the front of a vehicle) undulates over undulating out surface regions 27, 27 and mixes with the laterally deflected air flow. This combined air flow intermixes for an enhanced convection heat transfer from the surface of monolithic housing 2 during vehicle transfer.

[0061] Additionally, it will be understood that the rear-portion of monolithic housing 2 (see FIGS. 5, 6, 7, 12, 15-18, and 21-22) splits into two side ‘boot’ type portions (shown but not numbered) proximate the ends of relating left and right intercooler portals 20A, 20B and intakes and cylinders for the respective engine. In this way, it will be understood that the laminar air flow extends to the entire cylinder head bank and to the cylinder heads and is not detrimentally affected despite the split shape. This arrangement additionally allows a convenient sealing between respective air runners 12, 12 and monolithic housing 2, a convenient shape, and reduced weight for the overall engine and induction assembly 1.

[0062] It will be further understood that the proposed assembly and system, while maximizing the surface area for convective cooling and inner plenum surface for air flow and housing, the monolithic unitary housing may be formed in related, but different functional shapes without departing from the scope and spirit of the present invention. For example, external air-flow fins may be added to the external housing surface to provide more ambient air flow surface area during vehicle movement, and these air flow fins may be shaped in numerous ways, (parallel rows, series of irregular bumps, mixture of rows and ridges, etc.). For a second example, the monolithic unitary housing may be provided in differing widths and lengths to accommodate different engine block and intake arrangements or for use with different intercooler shapes. For a further example, the proposed monolithic unitary housing may be adapted to different cylinder arrangements (4-cylinder, 6-cylinder, 8, cylinder 10-cylinder, 12-cylinder, etc.) all within the scope and spirit of the present invention. As a result, there is no single exclusive outer surface shape or profile to the present, rather there are numerous alternatives that will meet the same functional claims and goals as noted herein.

[0063] Having described at least one of the preferred embodiments of the present invention with reference to the accompanying drawings, it will be apparent to those skills that the invention is not limited to those precise embodiments, and that various modifications and variations can be made in the presently disclosed system without departing from the scope or spirit of the invention. Thus, it is intended that the present disclosure cover modifications and variations of this disclosure provided they come within the scope of the appended claims and their equivalents.

REFERENCE DESIGNATOR LISTING

[0064] 1: induction assembly and system for a supercharged internal combustion engine [0065] 2: monolithic continuous unitary casting housing [0066] 3: hood [0067] 3A: hood vents [0068] 3B: hood opening [0069] 4: water pump [0070] 5: water/coolant reservoir [0071] 6: heat exchanger to ambient air [0072] 7: tubing [0073] 8: fire wall structure [0074] 9: water manifold [0075] 10: water cross over manifold [0076] 11: rotor assembly [0077] 11A: access portal (for pressurized air) [0078] 12, 12: runners (2) [0079] 13, 13 side intercooler assembly (2) [0080] 14: central intercooler assembly [0081] 15: nose drive assembly for super charger [0082] 15A: cover door [0083] 16: air intake [0084] 20A: 20B left side and right side intercooler portals [0085] 21: central rib interior [0086] 22: lateral ribs [0087] 22: lateral ribs interior [0088] 23: central intercooler portal [0089] 24′: super charger rotor portal [0090] 24″: super charger air intake portal [0091] 25: super charger rotor support ribs [0092] 26: bolt holes, collectively [0093] 27, 27: undulating outer surface region (2) [0094] 28: smooth central surface region [0095] 30: water flow system [0096] 35: cylinder head(s) [0097] 40: cylinder block [0098] 41: block assembly