INTAKE MANIFOLD WITH INTEGRATED WATER INJECTION NOZZLE

Abstract

An intake manifold for an internal combustion engine, comprising: a at least one air intake opening connected to an inner chamber, and a plurality of outlet pipes connected to the inner chamber, wherein each outlet pipe is provided with an outlet opening adapted for a sealed connection with a cylinder head of an internal combustion engine, wherein the intake manifold is injection moulded in a plastic material, wherein the intake manifold comprises at least one water injection nozzle moulded into the intake manifold. The advantage of the invention is that a cost-efficient water injection system for a combustion engine is provided.

Claims

1. An intake manifold for an internal combustion engine, comprising: at least one air intake opening connected to an inner chamber, and a plurality of outlet pipes connected to the inner chamber, where each outlet pipe is provided with an outlet opening adapted for a sealed connection with a cylinder head of an internal combustion engine, wherein the intake manifold is injection moulded in a plastic material, wherein the intake manifold comprises at least one water injection nozzle moulded into the intake manifold.

2. The intake manifold according to claim 1, wherein the water injection nozzle is made from a metal.

3. The intake manifold according to claim 1, wherein the intake manifold further comprises a first water conduit integrated in the body of the intake manifold, wherein the first water conduit is connected to the water injection nozzle.

4. The intake manifold according to claim 1, wherein the intake manifold comprises a single water injection nozzle arranged in the inner chamber.

5. The intake manifold according to claim 1, wherein each outlet pipe comprises a water injection nozzle.

6. The intake manifold according to claim 1, wherein the intake manifold further comprises at least one water injection valve interface adapted to hold a water injection valve.

7. The intake manifold according to claim 3, wherein the intake manifold further comprises a second water conduit integrated in the body of the intake manifold which is connected to the water injection valve interface.

8. The intake manifold according to claim 7, wherein the second water conduit is connected to an interface adapted to hold a water pump.

9. The intake manifold according to claim 1, wherein the intake manifold is made from at least two separate parts which are assembled to each other.

10. An internal combustion engine, wherein the internal combustion engine comprises an intake manifold according to claim 1.

11. A vehicle, wherein the vehicle comprises an internal combustion engine according to claim 10.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0010] The invention will be described in greater detail in the following, with reference to the attached drawings, in which:

[0011] FIG. 1 shows a first example of an intake manifold according to the invention,

[0012] FIG. 2 shows a second example of an intake manifold according to the invention,

[0013] FIG. 3 shows a third example of an intake manifold according to the invention,

[0014] FIG. 4 shows a cut view of an intake manifold according to the invention, and

[0015] FIG. 5 shows a vehicle comprising an intake manifold according to the invention.

DESCRIPTION OF EMBODIMENTS

[0016] The embodiments of the invention with further developments described in the following are to be regarded only as examples and are in no way to limit the scope of the protection provided by the patent claims.

[0017] FIGS. 1 to 4 show examples of an intake manifold 1 which comprises at least one embedded water injection nozzle. FIG. 5 shows a vehicle comprising an intake manifold.

[0018] The intake manifold 1 is adapted to receive and distribute the intake air from the air filter to the combustion engine. The intake manifold may also comprise other components, such as an air cooler or an exhaust gas recirculation system. In some engines, one or more fuel injectors are also comprised in the intake manifold. The intake manifold 1 comprises for this reason an air intake opening 2 which is connected to e.g. an air filter by an air conduit. The air intake opening 2 leads to an inner chamber 3 of the intake manifold, which often resembles a larger tube extending over at least part of the length of the combustion engine, especially for a straight combustion engine. The inner chamber ends in a plurality of outlet pipes 4 which are adapted to lead the air from the inner chamber to the inlet ports of the combustion engine. In a four cylinder combustion engine, the inner chamber may end in either two intermediate outlet pipes (as shown in FIG. 2), where each intermediate outlet pipe will end in two separate outlet pipes, or may end directly in four separate outlet pipes (as shown in FIG. 1). Each outlet pipe ends in an outlet opening 5 which is adapted to be connected to an inlet port of a cylinder head, close to the inlet valve of the cylinder.

[0019] The intake manifold is produced from a plastic material. In modern vehicles, an intake manifold is often produced by injection moulding a plastic material. The plastic material is preferably a composite plastic material comprising reinforcement fibres. Injection moulding will allow for an easy and reliable forming of the various chambers and pipes of the intake manifold. The intake manifold may be produced as a single part or may be assembled from several parts.

[0020] In the shown intake manifold, one or more water injection nozzles 6 are embedded in the plastic material of the intake manifold. The water injection nozzle is positioned in the mould prior to moulding, and is embedded into a wall of the intake manifold during the injection moulding of the intake manifold. In this way, the water injection nozzle is mounted in a secure and gas tight manner with a proper alignment and spray direction. The intake manifold will further comprise a first water conduit 7 which ends at the water injection nozzle. The first water conduit 7 is adapted to supply the water injection nozzle with pressurized water and is connected to a water pump. The water pump will be able to deliver a suitable pressure, e.g. in the range of 10-14 bars. The first water conduit 7 is also integrated in the intake manifold and is created in the injection moulding process.

[0021] FIG. 1 shows an example of an intake manifold 1 comprising a single water injection nozzle 6. Here, the water injection nozzle is positioned close to the air intake opening 2 such that the water spray will be able to mix in the inner chamber before the air/water spray mixture is forwarded to the four separate outlet pipes 4.

[0022] FIG. 2 shows an example of an intake manifold 1 comprising two intermediate outlet pipes, where each intermediate outlet pipe comprises a water injection nozzle 6. Each intermediate outlet pipe bifurcate into two separate outlet pipes 4. The injected water will mix with the air in the intermediate outlet pipe before the air/water spray mixture enters the two outlet pipes.

[0023] FIG. 3 shows an example of an intake manifold 1 where the inner chamber ends in four separate outlet pipes. Each outlet pipe 4 is provided with a water injection nozzle 6. Here, a water injection nozzle is positioned close to the outlet opening 5 of each outlet pipe, close to the intake valve of the combustion engine.

[0024] The number and position of water injection nozzles in the intake manifold is adapted to the various requirements and specifications of the combustion engine. Some combustion engines use water injection for enhancing the power output of the combustion engine, and in this case, the water injection can be positioned further away from the air intake of the combustion engine to reduce intake air temperature before entering the combustion chamber. In this way, the injected water is used to reduce the temperature of the intake air before entering the combustion chamber and the water injection nozzle can be arranged closer to the air intake of the intake manifold. Some combustion engines use water injection to improve fuel efficiency by replacing fuel enrichment and/or to reduce knock. In this case, the water injection may be performed closer to the air intake of the combustion engine, and the water injection nozzles may be positioned closer to the air intake of the combustion engine, close to the intake valves.

[0025] FIG. 4 shows a cut view of an intake manifold 1. The outlet opening 5 of the outlet pipe 4 is connected to an inlet port 19 of a cylinder head 17 of a combustion engine. The water injection nozzle 6 is here embedded in the wall of the outlet pipe 4, close to the outlet opening 5. This allows for water injection into the combustion chamber 18 when the intake valve 16 is open. The water injection nozzle 6 is connected to a water injection valve interface 8 through a first water conduit 7. The water injection valve interface 8 is also embedded in the wall of the outlet pipe, and may e.g. comprise a threaded member. In the water injection valve interface 8, an injection valve 9 is mounted. The injection valve 9 is preferably an electrically controlled injection valve. The injection valve will open or close the first water conduit 7 in order to inject water into the air intake of the combustion engine. The injection valve 9 is preferably arranged relatively close to the water injection nozzle 6.

[0026] A second water conduit 10 connects the injection valve to a water pump 11. The second water conduit is preferably also integrated in the body of the intake manifold, e.g. in a wall of the intake manifold. An interface for the water pump may also be embedded in the body of the intake manifold. Since only one water pump is required, the water pump may well be arranged outside of the intake manifold. In an intake manifold comprising more than one water injection nozzle, the second water conduit may branch of such that one water conduit leads to each injection valve. By integrating all water conduits in the intake manifold body together with the water injection nozzles and interfaces for the injection valves, a cost-efficient solution which requires fewer parts than conventional solutions is obtained.

[0027] The intake manifold is in the shown example provided with an embedded injection valve interface 8 adapted to hold a water injection valve 9. The water injection valve is preferably an on/off valve, e.g. an electromechanical solenoid valve adapted to open and close the water conduit 7 to the water injection nozzle 6. The injection valve interface 8 is adapted to the injection valve 9 that is to be used. The injection valve interface may e.g. comprise a water inlet and a water outlet which both connect to the valve, where the injection valve uses a built-in valve seat for opening and closing the water supply to the water injection nozzle. The interface may also comprise a valve seat against which the injection valve opens and closes the water supply to the water injection nozzle. The interface may be formed solely in the plastic material of the intake manifold or may comprise a metallic insert, e.g. a threaded part, adapted for the mounting of the injection valve.

[0028] The intake manifold comprises in the shown example a second water conduit 10 adapted to supply water from a water pump 11. It would be possible to embed an interface for the water pump in the intake manifold. The water pump supplies the water injection nozzles with pressurized water through the injection valve. By integrating the second water conduit in the intake manifold, only one water connection must be made, from the water pump to the water inlet to the intake manifold. By integrating the second water conduit leading from the water pump to the injection valves, the assembly of the water injection system is simplified since fewer components are used and since fewer connections must be made. Further, the space requirement for the water injection system in the engine compartment is reduced.

[0029] The water pump draws water for the water injection system from a water tank 14. The water pump may be arranged in the water tank or may be arranged outside of the water tank.

[0030] FIG. 5 shows a vehicle 30 comprising an internal combustion engine 31 comprising an intake manifold 1 according to the invention. The internal combustion engine is a spark-ignited gasoline engine which may be charged with a turbo or a supercharger.

[0031] The invention is not to be regarded as being limited to the embodiments described above, a number of additional variants and modifications being possible within the scope of the subsequent patent claims.