Patent Description:
As the power output of the engine increases, the exhaust temperature will typically also increase. While increases in the temperature of the exhaust represent additional energy that might be recaptured, higher temperatures may approach or exceed the operating limits of the materials of the exhaust components or of the turbocharger. Thus, the turbocharger cannot be operated where the exhaust temperature exceeds an operating threshold, which puts a limit on the overall power output of the engine.

Unless otherwise indicated herein, the description provided in this section is not prior art to the claims and is not admitted to be prior art by inclusion in this section. <CIT> discloses an engine exhaust component including a plurality of coolant passages having parallel coolant flows, each coolant passage at least partially surrounding a respectively corresponding exhaust runner. The engine exhaust manifold further includes a coolant inlet manifold coupled to each of the coolant passages and a coolant outlet manifold coupled to each of the coolant passages. <CIT> discloses an exhaust pipe for a combustion engine, the pipe having combustion cylinders provided with exhaust outlets. Multiple spacer segments are formed in an exhaust gas passage. The exhaust gas passage is in contact with a coolant passage. An exhaust gas inlet is sealed with the exhaust gas passage and the spacer segments. Exhaust gas discharge openings are provided in a combustion engine. A cooling system is provided with a coolant inlet and a coolant outlet. A closed refrigerant circuit is provided in the spacer segments. <CIT> discloses a modular exhaust manifold comprising a plurality of exhaust manifold segments connected to one another along a common axis. The exhaust manifold segments include a water jacket tube defining a liquid coolant passage around each of the plurality of exhaust manifold segments. An internal combustion engine has a connecting assembly for connecting adjacent exhaust manifold segments. The connector assembly includes a plurality of annular sealing devices configured to fit into a first set of grooves formed at an end portion of a first exhaust manifold segment. The connecting assembly also includes a spacer sleeve configured to be attached to the end portion of the first exhaust manifold segment for connecting the first exhaust manifold segment and the second exhaust manifold segment and to be connected to a fixed radial flange formed on an opposite end portion of a second exhaust manifold segment. <CIT> discloses a segmented three-walled exhaust gas line comprising a flame tube for guiding the exhaust gas arranged in an intermediate piece. The connecting site of a manifold with a further flame tube lies opposite the intermediate piece with the flame tube. The intermediate piece comprises a first flange and a second flange for positioning on the corresponding first manifold section or second manifold section and a first insertion tube and a second insertion tube for introducing water and the flame tube. <CIT> discloses a removable collector for liquid cooled exhaust that includes a retention member, a coolant transfer plate and a collector housing. The retention member fits between at least two exhaust jacket pipes and is attached thereto. Holes are formed through the coolant transfer plate to receive the at least two exhaust jacket pipes and exhaust pipes. The coolant transfer plate is secured to the retention member with fasteners. At least one coolant opening is formed through each exhaust jacket pipe at substantially an end thereof, adjacent a coolant passage cavity in the coolant transfer plate. The collector housing is attached to the coolant transfer plate. Coolant flows between the exhaust pipes and exhaust jacket pipes; through the coolant transfer plate; and through the collector housing. The removable collector for liquid cooled exhaust may be removed from the exhaust pipes by removing the fasteners. The exhaust pipes may be retained in a line. <CIT> discloses a marine conversion of a "Duramax" V8 diesel engine, in which each bank of cylinders has a jacketed exhaust manifold comprising a solid elongated casting including coolant galleries and a central exhaust duct. Recirculating coolant cools each cylinder then enters the exhaust manifold through separate apertures aligned with openings made by removal of a frost plug. Each manifold coolant aperture has a controlled diameter, ensuring most of the coolant passes along the length of the engine then along the manifold yet enough coolant cools each cylinder. The coolant then traverses and cools a manifold extension and a turbocharger.

The present disclosure describes implementations that relate to a fluid-cooled manifold. Beneficially, embodiments described herein may provide the ability to increase the power output of an engine without damaging exhaust components of the engine or a turbocharger associated with the engine.

According to a first aspect of the invention, there is provided a fluid-cooled manifold for cooling exhaust from an engine. The fluid-cooled manifold includes a plurality of exhaust runners including a first exhaust runner and a second exhaust runner, where the first exhaust runner is detached from the second exhaust runner. Each of the plurality of exhaust runners includes a runner body having an inlet end and an outlet end, an exhaust conduit extending through the runner body from an exhaust inlet opening at the inlet end of the runner body to an exhaust outlet opening at the outlet end of the runner body, and a coolant passage extending through the runner body from a coolant inlet opening to a coolant outlet opening. The fluid-cooled manifold also includes an exhaust collection manifold including a plurality of inlets. Each inlet of the exhaust collection manifold is coupled to the exhaust outlet opening of a respective one of the plurality of exhaust runners. Further, the fluid-cooled manifold also includes a coolant feed pipe and a coolant exit pipe. The coolant feed pipe includes a plurality of outlets, where each outlet of the coolant feed pipe is coupled to the coolant inlet of a respective one of the plurality of exhaust runners. The coolant exit pipe includes a plurality of inlets, where each inlet of the coolant exit pipe is coupled to the coolant outlet of a respective one of the plurality of exhaust runners. Each exhaust runner of the plurality of exhaust runners has the same shape as the other exhaust runners of the plurality of exhaust runners.

In an embodiment of the fluid-cooled manifold, for each exhaust runner of the plurality of exhaust runners, the coolant passage is concentrically disposed around the exhaust conduit.

In another embodiment of the fluid-cooled manifold, for each exhaust runner of the plurality of exhaust runners, the coolant passage has an annular cross section that surrounds the exhaust conduit and that extends along a majority of a length the exhaust conduit.

In another embodiment of the fluid-cooled manifold, for each exhaust runner of the plurality of exhaust runners, the coolant inlet opening is disposed at the inlet end of the exhaust runner and the coolant outlet opening is disposed at the outlet end of the exhaust runner.

In another embodiment of the fluid-cooled manifold, for each exhaust runner of the plurality of exhaust runners, the coolant inlet opening is disposed at the outlet end of the exhaust runner and the coolant outlet opening is disposed at the inlet end of the exhaust runner.

In another embodiment of the fluid-cooled manifold, the plurality of exhaust runners includes a third exhaust runner and a fourth exhaust runner.

In another embodiment of the fluid-cooled manifold, each exhaust runner of the plurality of exhaust runners is detached from the other exhaust runners of the plurality of exhaust runners.

In another embodiment of the fluid-cooled manifold, the coolant feed pipe and the coolant exit pipe have the same shape.

In a second aspect of the invention, the disclosure describes an engine system. The engine system includes a plurality of exhaust ports including a first group of exhaust ports. The engine system also includes a first fluid-cooled manifold according to the first aspect coupled to the engine configured to receive exhaust from the first group of exhaust ports. The first fluid-cooled manifold includes a first group of exhaust runners including a first exhaust runner and a second exhaust runner. The first exhaust runner is detached from the second exhaust runner. Each of the first group of exhaust runners includes a runner body having an inlet end and an outlet end, an exhaust conduit extending through the runner body from an exhaust inlet opening at the inlet end of the runner body to an exhaust outlet opening at the outlet end of the runner body, wherein the exhaust inlet is coupled to a respective exhaust port of the first group of exhaust ports, and a coolant passage extending through the runner body from a coolant inlet opening to a coolant outlet opening. The first fluid-cooled manifold also includes an exhaust collection manifold including a plurality of inlets. Each inlet of the exhaust collection manifold is coupled to the exhaust outlet opening of a respective one of the first group of exhaust runners. The first fluid-cooled manifold also includes a coolant feed pipe including a plurality of outlets and a coolant exit pipe including a plurality of inlets. Each outlet of the coolant feed pipe is coupled to the coolant inlet of a respective one of the first group of exhaust runners. Each inlet of the coolant exit pipe is coupled to the coolant outlet of a respective one of the first group of exhaust runners.

In an embodiment of the engine system, for each exhaust runner of the first group of exhaust runners of the first fluid-cooled manifold, the coolant passage is concentrically disposed around the exhaust passage.

In another embodiment of the engine system, for each exhaust runner of the first group of exhaust runners of the first fluid-cooled manifold, the coolant passage has an annular cross section that surrounds the exhaust passage and that extends along a majority of the exhaust passage.

In another embodiment of the engine system, the engine system further includes a turbocharger, where the first fluid-cooled manifold is coupled to the turbocharger and is configured to deliver cooled exhaust to the turbocharger.

In another embodiment of the engine system, the plurality of exhaust ports of the engine further includes a second group of exhaust ports and the engine system further includes a second fluid-cooled manifold. The second fluid-cooled manifold includes a second group of exhaust runners. Each exhaust runner of the second group of exhaust runners including an exhaust inlet coupled to a respective exhaust port of the second group of exhaust ports.

In another embodiment of the engine system, each of the exhaust runners of the first group of exhaust runners and the second group of exhaust runners has the same shape.

In addition to the illustrative aspects, implementations, and features described above, further aspects, implementations, and features will become apparent by reference to the figures and the following detailed description.

The accompanying drawings, which are included to provide a further understanding of the disclosure, are incorporated in and constitute a part of this specification, illustrate embodiments of the disclosure, and together with the detailed description serve to explain the principles of the disclosure. No attempt is made to show structural details of embodiments of the disclosure in more detail than may be necessary for a fundamental understanding of the embodiments of the disclosure and various ways in which it may be practiced.

Exemplary apparatus and systems are described herein. It should be understood that the word "exemplary" is used herein to mean "serving as an example, instance, or illustration. " Any embodiment or feature described herein as "exemplary" or an "example" is not necessarily to be construed as preferred or advantageous over other embodiments or features. The exemplary embodiments described herein are not meant to be limiting. It will be readily understood that certain aspects of the disclosed apparatus and systems can be arranged and combined in a wide variety of different configurations, all of which are contemplated herein.

<FIG> illustrates a fluid-cooled manifold <NUM> in accordance with example embodiment of the disclosure that is configured to receive and cool exhaust from an engine. An exploded view of the fluid-cooled manifold <NUM> is shown in <FIG>. The fluid-cooled manifold <NUM> includes a plurality of exhaust runners 102A-102D, including a first exhaust runner 102A, a second exhaust runner 102B, a third exhaust runner 102C, and a fourth exhaust runner 102D. The exhaust runners 102A-102D may be disposed in a line, as shown in <FIG>, where the first exhaust runner 102A and the second exhaust runner 102B are positioned toward the center of the fluid-cooled manifold <NUM>, whereas the third exhaust runner 102C and the fourth exhaust runner 102D are positioned on the periphery of the fluid-cooled manifold. As discussed in more detail below, the first exhaust runner 102A and the second exhaust runner 102B are detached from one another.

Each of the exhaust runners 102A-102D may be configured to attach to an engine in order to receive exhaust from the engine, as described in more detail below. For example, each exhaust runner 102A-102D is configured to attach an exhaust port associated with a cylinder of the engine. In some embodiments the fluid-cooled manifold is configured such that each exhaust runner 102A-102D is paired with one cylinder of the engine. In other embodiments, each of the exhaust runners may be associated with more than one cylinder of the engine. On the other hand, in other embodiments, more than one exhaust runner may be associated with a cylinder of the engine. For example, in some embodiments, two exhaust runners may be associated with each cylinder of the engine. In such embodiments, an adapter may be positioned between the fluid-cooled manifold and the exhaust ports of the engine in order to combine or divide exhaust from the exhaust ports for introduction into the fluid-cooled manifold.

The fluid-cooled manifold <NUM> also includes an exhaust collection manifold <NUM> that receives exhaust from the exhaust runners 102A-102D and directs the exhaust downstream, as explained in more detail below. The exhaust collection manifold <NUM> includes a plurality of inlets 142A-142D, as shown in <FIG>, that are respectively coupled to the exhaust runners 102A-102D. Further, the fluid-cooled manifold <NUM> also includes a coolant feed pipe <NUM> and a coolant exit pipe <NUM>. The coolant feed pipe <NUM> includes a plurality of outlets 152A-152D, as shown in <FIG>, that are respectively coupled to the exhaust runners 102A-102D. Likewise, the coolant exit pipe <NUM> includes a plurality of inlets 156A-156D, also shown in <FIG>, that are respectively coupled to the exhaust runners 102A-102D. The coolant feed pipe <NUM> and coolant exit pipe <NUM> may be part of a coolant circulation system that is configured to circulate a coolant through the fluid-cooled manifold, as explained in more detail below. Accordingly, the coolant feed pipe <NUM> may include an inlet 158A for receiving coolant that is circulated through the coolant circulation system. Further, the coolant feed pipe <NUM> may be configured to deliver the coolant to the exhaust runners 102A-102D through the feed pipe outlets 152A-152D. Likewise, the coolant exit pipe <NUM> may be configured to receive the coolant from the exhaust runners 102A-102D via the exit pipe inlets 156A-156D and include an outlet 158B to continue circulation of the coolant through the coolant circulation system.

A side cross-sectional view of one of the exhaust runners <NUM> (e.g., exhaust runner 102A) of fluid-cooled manifold <NUM> is shown in <FIG>. As explained in more detail below, the exhaust runners all have a similar configuration. As shown in <FIG>, exhaust runner <NUM> includes a runner body <NUM> having an inlet end <NUM> and an outlet end <NUM>. The inlet end <NUM> may include a first attachment surface <NUM> configured to be secured against the engine so as to surround an exhaust port of the engine. Further, the inlet end <NUM> may also include an exhaust inlet opening <NUM> that provides fluid access to an exhaust conduit <NUM> that extends through the runner body <NUM>. The exhaust inlet opening <NUM> extends through the first attachment surface <NUM>. The outlet end <NUM> may include a second attachment surface <NUM> that is attached to a respective inlet 142A-142D of the inlets of the exhaust collection manifold <NUM>. In various embodiments, a seal, such as a gasket, may be included between the second attachment surface <NUM> and the respective inlet 142A-142D of the exhaust collection manifold <NUM>. The outlet end <NUM> of each exhaust runner may also include an exhaust outlet opening <NUM> that extends through the second attachment surface <NUM> and provides fluid access to the exhaust conduit <NUM>. Thus, the exhaust conduit <NUM> may run through the runner body <NUM> from the exhaust inlet opening <NUM> at the inlet end <NUM> to the exhaust outlet opening <NUM> at the outlet end <NUM>.

The exhaust runner <NUM> also includes a coolant passage <NUM> that extends through the runner body <NUM> from a coolant inlet opening <NUM> to a coolant outlet opening <NUM>. To receive coolant from the coolant feed pipe <NUM>, the coolant inlet opening <NUM> may be coupled to a respective one of the feed pipe outlets 152A-152D (as shown in <FIG>). After passing through the exhaust runner <NUM> the coolant may exit the coolant passage <NUM> via the coolant outlet opening <NUM> and flow into the coolant exit pipe <NUM> via a respective one of the exit pipe inlets 156A-156D (as shown in <FIG>).

With further reference to <FIG>, in some embodiments, the coolant passage <NUM> of each of the exhaust runners <NUM> may be concentrically disposed around the exhaust conduit <NUM>. For example, the exhaust conduit <NUM> of each exhaust runner <NUM> may extend from the inlet end <NUM> to the outlet end <NUM> along a path through the runner body <NUM>, and the coolant passage <NUM> may concentrically surround the exhaust conduit <NUM> along the path from the inlet end <NUM> to the outlet end <NUM>. Moreover, the exhaust conduit <NUM> may be defined within an interior wall <NUM> that is formed by a portion of the runner body <NUM>. The interior wall <NUM> may then be surrounded by an exterior wall <NUM> of the runner body <NUM>, thereby defining the coolant passage <NUM> between the interior wall <NUM> and the exterior wall <NUM>. Accordingly, the coolant passage <NUM> is positioned concentrically around the exhaust conduit <NUM>. Having the coolant passage <NUM> be concentrically disposed around the exhaust conduit <NUM> allows a large area of heat transfer between the exhaust conduit <NUM> and the coolant passage <NUM>. Accordingly, such a configuration may provide more heat transfer from the exhaust within the exhaust conduit <NUM> to the coolant in the coolant passage <NUM> than a coolant passage without a concentric configuration operating under similar conditions.

In some embodiments, the coolant passage <NUM> of each exhaust runner <NUM> has an annular cross section that surrounds the exhaust conduit <NUM> and extends along a majority of a length of the exhaust conduit <NUM>. In other words, in some embodiments, the coolant passage <NUM> completely surrounds the exhaust conduit <NUM> without any connection between interior wall <NUM> and the exterior wall <NUM> of the runner body. Moreover, in some embodiments, the annular cross section of the coolant passage <NUM> extends over substantially the entire exhaust conduit <NUM>, except at the ends of the exhaust runner <NUM> around the exhaust inlet opening <NUM> and the exhaust outlet opening <NUM>. In other embodiments, partitions may extend between the interior wall <NUM> and the exterior wall <NUM> such that the coolant passage <NUM> is not completely annular along a majority of the exhaust conduit <NUM>. Such partitions may provide added stability or control the flow direction of any coolant running through the coolant passage <NUM>.

In some embodiments, the coolant inlet opening <NUM> of the coolant passage <NUM> of each exhaust runner <NUM> may be disposed at the inlet end <NUM> of the exhaust runner <NUM> and the coolant outlet opening <NUM> may be disposed at the outlet end <NUM> of the exhaust runner <NUM>. In such a configuration, the exhaust and the coolant will run in parallel through the exhaust runner <NUM>. In other embodiments, the coolant inlet opening <NUM> of the coolant passage <NUM> of each exhaust runner <NUM> may be disposed at the outlet end <NUM> of the exhaust runner <NUM> and the coolant outlet opening <NUM> may be disposed at the inlet end <NUM> of the exhaust runner, such that the exhaust and coolant run in counter flow. Providing the coolant inlet opening <NUM> and the coolant outlet opening <NUM> at the ends of the exhaust runner <NUM> allows for a greater area of thermal contact between the exhaust conduit <NUM> and the coolant passage <NUM>. Still, in other embodiments, due to geometric or other constraints, the coolant inlet opening <NUM> and/or the coolant outlet opening <NUM> may be disposed at another location, such as toward the center of the exhaust runner <NUM>.

In some embodiments, the coolant inlet opening <NUM> is configured such that coolant flowing through the coolant inlet opening <NUM> flows perpendicular to the interior wall <NUM> that defines the exhaust conduit <NUM> so as to impinge upon the interior wall <NUM>. Further, in some embodiments the coolant passage <NUM> is configured so as to form a swirling flow of coolant within the coolant passage <NUM>, such that the coolant swirls around the exhaust conduit <NUM>. These and other configurations of the flow pattern of coolant within the coolant passage <NUM> can assist in promoting heat transfer between the exhaust and the coolant.

In some embodiments, the fluid-cooled manifold includes four exhaust runners. For example, the fluid-cooled manifold <NUM> shown in <FIG> has four exhaust runners 102A-102D arranged in a row. The first exhaust runner 102A and second exhaust runner 102B are positioned toward the center of the row of exhaust runners 102A-102D, while the third exhaust runner 102C and fourth exhaust runner 102D are positioned at the ends of the row of exhaust runners 102A-102D. A schematic depiction of fluid-cooled manifold <NUM> is also shown in <FIG> for comparison to schematic depictions of other fluid-cooled manifolds discussed below. <FIG> illustrates the four exhaust runners 102A-102D. Each of the exhaust runners 102A-102D delivers exhaust from the engine to the exhaust collection manifold <NUM>. As the exhaust passes through the exhaust runners 102A-102D it is cooled by the coolant that is circulated through the exhaust runners 102A-102D. Further, the coolant is received in the exhaust runners 102A-102D from a coolant feed pipe <NUM> that is coupled to each of the exhaust runners 102A-102D. Likewise, the coolant returns to the coolant circulation system via the coolant exit pipe <NUM>, which is also coupled to each of the exhaust runners 102A-102D.

In other embodiments, the fluid-cooled manifold includes a different number of exhaust runners. Accordingly, such embodiments may be configured to operate with engines having a different number of exhaust ports. For example, <FIG> shows a schematic depiction of a fluid-cooled manifold <NUM> that includes only two exhaust runners, including first exhaust runner 502A and second exhaust runner 502B. Both the first exhaust runner 502A and the second exhaust runner 502B deliver exhaust from the engine to the exhaust collection manifold <NUM>. Again, as the exhaust passes through the exhaust runners 502A-502B it is cooled by the coolant that is circulated through the exhaust runners 502A-502B. A coolant feed pipe <NUM> is coupled to both the first exhaust runner 502A and the second exhaust runner 502B in order to deliver coolant to both exhaust runners 502A-502B. Likewise, the coolant returns to the coolant circulation system via the coolant exit pipe <NUM>, which is also coupled to both of the exhaust runners 502A-502B.

As another example, <FIG> shows a schematic depiction of a fluid-cooled manifold <NUM> that includes six exhaust runners. Similar to fluid-cooled manifold <NUM>, fluid-cooled manifold <NUM> includes a first exhaust runner 602A and a second exhaust runner 602B that are located at the center of a row of exhaust runners 602A-602F. Further, a third exhaust runner 602C and a fourth exhaust runner 602D are disposed at the end of the row of exhaust runners 602A-602F. In addition, a fifth exhaust runner 602E and a sixth exhaust runner 602F are located at intermediate positions between the center and the ends of the row. Each of the exhaust runners 602A-602D delivers exhaust from the engine to the exhaust collection manifold <NUM>. As the exhaust passes through the exhaust runners 602A-602D it is cooled by coolant being circulated through the exhaust runners 602A-602F. Further, the coolant is received in the exhaust runners 602A-602F from a coolant feed pipe <NUM> that is coupled to each of the exhaust runners 602A-602F. Likewise, the coolant returns to the coolant circulation system via the coolant exit pipe <NUM>, which is coupled to each of the exhaust runners 602A-602F.

In some embodiments, the first exhaust runner is detached from the second exhaust runner. For example, in each of the embodiments of the fluid-cooled manifold <NUM>, <NUM>, <NUM> shown in <FIG>, the first exhaust runner 102A, 502A, 602A is detached from the respective second exhaust runner 102B, 502B, 602B. The term "detached," as used herein, refers to a situation where two components are neither directly coupled to one another, nor part of a larger construction formed as a single integral piece. Thus, the detached first and second exhaust runners, e.g., 102A, 102B, are neither directly coupled to one another, nor are they part of a larger construction that includes the exhaust runners, e.g., 102A, 102B, in a single integral piece. Further, in some embodiments, the detached exhaust runners are separated from one another by a space. In other embodiments, the detached exhaust runners may abut one another while not being directly coupled to one another.

In some embodiments, each of the exhaust runners 102A-102D is detached from all of the other exhaust runners 102A-102D of the fluid-cooled manifold <NUM>. For example, in fluid-cooled manifold <NUM>, exhaust runners 102A-102D are arranged in a row, but none of the exhaust runners 102A-102D are attached to one another. In contrast, each exhaust runner 102A-102D is detached from the others. Instead, the exhaust runners 102A-102D are connected to one another via their attachment to the exhaust collection manifold <NUM>, coolant feed pipe <NUM> and coolant exit pipe <NUM>.

The use of exhaust runners 102A-102D that are detached from one another allows the portion of the fluid-cooled manifold <NUM> that includes two different fluid paths, i.e., the exhaust runners 102A-102D that include both the exhaust conduit <NUM> and the coolant passage <NUM>, to be manufactured as a group of smaller individual components. Including separate passages that accommodate different fluids within the body of a manifold is complicated. Further, providing a single large manifold with various passages for different exhaust streams as well as additional passages for coolant channels that cool the exhaust streams would add considerable complexity. By designing the manifold as several different components, including individual and detached exhaust runners that each include a single exhaust conduit <NUM>, the manufacturing can be simplified.

In other embodiments, at least some of the exhaust runners are attached to one another. For example, <FIG> depicts an embodiment of a fluid-cooled manifold <NUM> that includes four exhaust runners 702A-702D arranged in a row, similar to the fluid-cooled manifold <NUM> shown in <FIG>. The first exhaust runner 702A and second exhaust runner 702B are positioned toward the center of the row, while the third exhaust runner 702C and fourth exhaust runner 702D are positioned at the ends of the row. As with the previously described embodiments, each of the exhaust runners 702A-702D delivers exhaust from the engine to the exhaust collection manifold <NUM>, receives coolant from a coolant feed pipe <NUM> and returns the coolant to a coolant exit pipe <NUM>. Similar to the other embodiments, the first exhaust runner 702A is detached from the second exhaust runner 702B. However, the first exhaust runner 702A is attached to third exhaust runner 702C, as identified in regions 703A. In particular, the first exhaust runner 702A is attached to third exhaust runner 702C at the inlet end and at the outlet end. For example, the first exhaust runner 702A may be formed in a single integral piece with the third exhaust runner 702C. The second exhaust runner 702B may also be attached to the fourth exhaust runner 702D, as identified in regions 703B. For example, the second exhaust runner 702B may be formed in a single integral piece with the fourth exhaust runner 702D, as shown in <FIG>. In some embodiments, the exhaust runners are attached to one another in pairs, allowing a fluid-cooled manifold to be constructed with any even number of exhaust runners.

In contrast to the embodiment of <FIG>, where all of the exhaust runners 102A-102D are detached from one another, and the embodiment of <FIG>, where some of the exhaust runners 702A-702D are attached to one another, in other embodiments, all of the exhaust runners are attached to one another. For example, in some embodiments, all of the exhaust runners of the fluid-cooled manifold are formed in a single integral piece.

Each of the exhaust runners 102A-102D have the same shape. For example, each of exhaust runners 102A-102D in fluid-cooled manifold <NUM>, shown in <FIG> and <FIG> have the same shape. Two components that have the "same shape," as the phrase is used herein, refers to components that are manufactured using the same method or tools, such that the components are interchangeable. For example, two components having the same shape may be molded or cast in the same die. Differences between components having the same shape may be based on manufacturing tolerances or variations caused by installation.

The use of exhaust runners 102A-102D that have the same shape simplifies manufacturing, as a smaller, less complicated component can be reproduced several times to form a substantial portion of the fluid-cooled manifold <NUM>. Moreover, in fluid-cooled manifolds where each of the exhaust runners has the same shape, the fluid-cooled manifold can be redesigned by adding or removing one or more exhaust runner. Accordingly, accommodating engines with different numbers of cylinders can be achieved without redesigning the entire manifold.

Although there are advantages in having each exhaust runner have the same shape, in some unclaimed embodiments, the exhaust runners 102A-102D may have different configurations and different shapes. For example, in some unclaimed embodiments, the exhaust runners 102A-102D may bend at different angles, or have bends with different radiuses of curvature. Other aspects of the shape and configuration of the exhaust runners 102A-102D may also differ. Differences in the geometries of the exhaust runners may be beneficial to meet space constraints or for other reasons.

In some embodiments, each exhaust runner <NUM> has a symmetrical configuration and is substantially symmetrical about a central plane of the exhaust runner. For example, the exhaust conduit <NUM> may follow the central plane of the exhaust runner <NUM> and be surrounded by the coolant passage <NUM> on both sides of the central plane. Further, in some embodiments, both the coolant inlet opening <NUM> and the coolant outlet opening <NUM> may be positioned on the central plane of the exhaust runner <NUM>. By providing the exhaust runners 102A-102D with a symmetrical configuration, the exhaust runners 102A-102D may operate independently of the overall orientation and position of the fluid-cooled manifold with respect to the engine. Thus, the exhaust runners 102A-102D can be implemented in a fluid-cooled manifold <NUM> configured to couple to the right side of an engine, or the same exhaust runners 102A-102D can be implemented in a fluid-cooled manifold <NUM> configured to couple to the left side of an engine.

In some embodiments, the central plane of each of the exhaust runners 102A-102D may be parallel within the fluid-cooled manifold <NUM>. By providing the exhaust runners 102A-102D with a parallel alignment throughout the fluid-cooled manifold <NUM>, the size of the fluid-cooled manifold <NUM> can be modified to cooperate with engines having more or fewer cylinders simply by adding or removing exhaust runners. The relative position or angle of one exhaust runner does not need to be modified with respect to neighboring exhaust runners as the number of exhaust runners changes, since the respective orientation is always parallel.

In some embodiments, the coolant feed pipe <NUM> and the coolant exit pipe <NUM> may have the same shape. Such a configuration simplifies manufacture of the fluid-cooled manifold <NUM>, since both the coolant feed pipe <NUM> and the coolant exit pipe <NUM> can be formed by the same part, similar to the various exhaust runners 102A-102D.

The above-described components of the fluid-cooled manifold <NUM> may be composed of a variety of different materials. For example, the components may be formed of metal, such as steel or aluminum. Likewise the above-described components may be formed of a plastic material. Further, in some embodiments, different components are formed of different materials. For example, in some embodiments, the exhaust runners 102A-102D may be formed of steel, while the coolant feed pipe <NUM> and the coolant exit pipe <NUM> are formed of plastic. The fluid-cooled manifold <NUM> may include additional components to those that have been described, such as fasteners, seals, sensors or any other components that may be advantageous.

The fluid-cooled manifold <NUM> may be manufactured using a variety of different methods. For example, the exhaust runners <NUM> may be molded or cast. Likewise, the exhaust collection manifold <NUM>, coolant feed pipe <NUM>, and coolant exit pipe <NUM> may also be molded or cast. Further, each of these components can be machined from a block of material, or manufactured by an additive manufacturing process. Other methods of manufacture are also possible.

In another aspect, the disclosure provides an engine system. <FIG> illustrates an engine system <NUM> according to an embodiment of the disclosure. The engine system <NUM> includes an engine <NUM>, at least one fluid-cooled manifold <NUM>, a turbocharger <NUM>, and a radiator <NUM>. A schematic depiction of the engine system <NUM> is shown in <FIG> to illustrate various features of the depicted embodiment. Engine system <NUM>, as shown in <FIG>, includes an engine <NUM> that includes a plurality of exhaust ports 864A-<NUM>, including a first group of exhaust ports 864A-864D. A first fluid-cooled manifold <NUM> is coupled to the engine <NUM> and configured to receive exhaust from the first group of exhaust ports 864A-864D. The first fluid-cooled manifold <NUM> may be configured according to any of the above-described embodiments. For example, the first fluid-cooled manifold <NUM> may include a first group of exhaust runners 802A-802D that are detached from one another. Each of the first group of exhaust runners 802A-802D of the first fluid-cooled manifold <NUM> is coupled to a respective one of the first group of exhaust ports 864A-864D of the engine <NUM>.

The first fluid-cooled manifold <NUM> also includes an exhaust collection manifold <NUM> including a plurality of inlets 842A-842D, where each inlet 842A-842D of the exhaust collection manifold <NUM> is coupled to an exhaust outlet opening of a respective one of the first group of exhaust runners 802A-802D. The first fluid-cooled manifold <NUM> also includes a coolant feed pipe <NUM> and a coolant exit pipe <NUM>. As described above with respect to various embodiments of the fluid-cooled manifold, the coolant feed pipe <NUM> is configured to supply coolant to the first group of exhaust runners 802A-802D and the coolant exit pipe <NUM> is configured to receive coolant from the first group of exhaust runners 802A-802D.

In some embodiments of the engine system <NUM>, the engine <NUM> includes a second group of exhaust ports 864E-<NUM>. A second fluid-cooled manifold <NUM> may be coupled to the engine <NUM> and configured to receive exhaust from the second group of exhaust ports 864E-<NUM>. The second fluid-cooled manifold <NUM> may be configured according to any of the above-described embodiments. For example, each of the second group of exhaust runners 802E-<NUM> of the second fluid-cooled manifold <NUM> may be coupled to a respective one of the second group of exhaust ports 864E-<NUM> of the engine <NUM>. Further, the second fluid-cooled manifold <NUM> may also include an exhaust collection manifold <NUM> including a plurality of inlets 843A-843D, where each inlet 843A-843D of the exhaust collection manifold <NUM> is coupled to an exhaust outlet opening of a respective one of the second group of exhaust runners 802E-<NUM>. The second fluid-cooled manifold <NUM> may also include a coolant feed pipe <NUM> and a coolant exit pipe <NUM>. As described above with respect to various embodiments of the fluid-cooled manifold, the coolant feed pipe <NUM> may be configured to supply coolant to the second group of exhaust runners 802E-<NUM> and the coolant exit pipe <NUM> may be configured to receive coolant from the first group of exhaust runners 802E-<NUM>. A second fluid-cooled manifold <NUM> may be particularly useful where the exhaust ports 864A-<NUM> of the engine <NUM> are disposed in two groups, for example in a V8 engine, where the exhaust ports 864A-<NUM> are disposed on either side of the engine <NUM>.

In some embodiments of the engine system, each of the exhaust runners 802A-<NUM> of both the first group and the second group has the same configuration. Accordingly, the first fluid-cooled manifold <NUM> and the second fluid-cooled manifold <NUM> may be formed from eight exhaust runners <NUM> that are all manufactured as the same part. Likewise, in some embodiments the exhaust collection manifold <NUM> of the first fluid-cooled manifold <NUM> and the exhaust collection manifold <NUM> of the second fluid-cooled manifold <NUM> may have the same shape and be manufactured as the same part. Further, in some embodiments, the coolant feed pipe <NUM> of the first fluid-cooled manifold <NUM> and the coolant feed pipe <NUM> of the second fluid-cooled manifold <NUM> may have the same shape and be manufactured as the same part. Similarly, in some embodiments, the coolant exit pipe <NUM> of the first fluid-cooled manifold <NUM> and the coolant feed pipe <NUM> of the second fluid-cooled manifold <NUM> may also have the same shape and be manufactured as the same part. Indeed, in some embodiments, each of the coolant feed pipe <NUM> of the first fluid-cooled manifold <NUM>, the coolant feed pipe <NUM> of the second fluid-cooled manifold <NUM>, the coolant exit pipe <NUM> of the first fluid-cooled manifold <NUM>, and the coolant feed pipe <NUM> of the second fluid-cooled manifold <NUM>, may have all the same shape and be manufactured as the same part. The similarity of the shape of these components and the ability to use the same part in both manifolds and/or as more than one component of both manifolds simplifies manufacturing, as the overall list of components is reduced and the complexity of each part is also reduced. Rather than a system having more unique components, or larger more complex components, the system can be fabricated from the reuse of several smaller, simpler components.

In some embodiments, the engine system <NUM> may include a turbocharger <NUM>, where the first fluid-cooled manifold <NUM> is coupled to the turbocharger <NUM> and is configured to deliver cooled exhaust to the turbocharger <NUM>. By cooling the exhaust prior to delivering the exhaust to the turbocharger <NUM>, the engine <NUM> may be run at higher power loads. In contrast, if the exhaust is delivered directly to the turbocharger <NUM> when the engine <NUM> is operating at high loads, the exhaust temperature may be high enough to damage components of the turbocharger <NUM>. For example, in some instances, when an engine <NUM> is operated with a turbocharger <NUM> at high loads, the exhaust temperature may be higher than <NUM>. Many materials commonly used in turbochargers cannot withstand such high temperatures and will begin to crack or melt. Reducing the temperature of the exhaust allows the engine to continue running at high loads without damaging the engine or turbocharger.

In some embodiments, the fluid-cooled manifolds <NUM>, <NUM> may reduce the temperature of the exhaust by more than <NUM>. Such a decrease in temperature can allow the engine to be run at high power output without damaging the turbocharger. As an example, an <NUM> V8 engine operated while using a turbocharger and a pair of the fluid-cooled manifolds of the disclosure can be operated at over 200kW without damaging the turbocharger.

In some embodiments, the engine system <NUM> may include a radiator <NUM>. The radiator <NUM> can be used to reduce the temperature of the coolant coming from the exhaust runners 802A-<NUM> and allow lower temperature coolant to be recirculated back to the exhaust runners 802A-<NUM>. The lower temperature of the coolant allows the coolant to remove a greater amount of energy from the exhaust within the fluid-cooled manifolds <NUM>, <NUM>.

In another aspect not according to the invention, the disclosure provides a coolant circulation system for an engine. <FIG> illustrates a schematic depiction of a coolant circulation system <NUM>. The coolant circulation system <NUM> may include a pump <NUM> configured to circulate coolant through the coolant circulation system <NUM>. The coolant circulation system <NUM> may also include a first cooling line <NUM> that is in fluid communication with the pump <NUM>. The first cooling line <NUM> may include engine coolant passages <NUM> extending through a portion of an engine <NUM>, such as the engine block <NUM> and the engine head <NUM>. The first cooling line <NUM> may lead to a first junction <NUM> where a first thermostat <NUM> is disposed. The first thermostat <NUM> may be configured to direct a portion of flow from the first cooling line <NUM> to a first cold return line <NUM> or a first hot return line <NUM>. The first cold return line <NUM> may extend from the first junction <NUM> back to the pump <NUM>. On the other hand, the first hot return line <NUM> may extend from the first junction <NUM> through a heat exchanger <NUM>, such as a radiator, that is configured to cool the coolant in the first hot return line <NUM>.

The first thermostat <NUM> allows the coolant to continue circulating through the engine coolant passages <NUM> and returning to the pump <NUM> without passing through the heat exchanger <NUM> until the coolant reaches a predetermined temperature. Once the coolant temperature is at or above the predetermined temperature at the first thermostat <NUM>, the first thermostat <NUM> will route at least a portion of the coolant through the heat exchanger <NUM> before it is returned to the pump <NUM> and engine <NUM>.

The coolant circulation system <NUM> may also include a second cooling line <NUM> that is in fluid communication with the pump <NUM> and includes manifold coolant passages <NUM> extending through a first cooled exhaust manifold <NUM>. The second cooling line <NUM> may lead to a second junction <NUM> where a second thermostat <NUM> is disposed. The second thermostat <NUM> may be configured to direct a portion of flow from the second cooling line <NUM> to a second cold return line <NUM> or a second hot return line <NUM>. The second cold return line <NUM> may extend from the second junction <NUM> back to the pump <NUM>. On the other hand, the second hot return line <NUM> may extend from the second junction <NUM> through the heat exchanger <NUM> that is configured to cool the coolant in the second hot return line <NUM>.

Similar to the first thermostat <NUM>, the second thermostat <NUM> allows the coolant to continue circulating through the manifold coolant passages <NUM> and returning to the pump <NUM> without passing through the heat exchanger <NUM> until the coolant reaches a predetermined temperature. Once the coolant temperature is at or above the predetermined temperature at the second thermostat <NUM>, the second thermostat <NUM> will route at least a portion of the coolant through the heat exchanger <NUM> before it is returned to the pump <NUM> and the manifold coolant passages <NUM>.

The coolant can be any of a number of heat transfer fluids configured to circulate through the coolant circulation system and cool the exhaust. The coolant may be a liquid, a gas, or a two-phase flow. The coolant includes water. Further, the coolant may include additives, such as anti-corrosion additives and anti-freeze additives.

The second cooling line <NUM> may include engine coolant passages <NUM> in addition to the manifold coolant passages <NUM>. For example, the second cooling line <NUM> may include passages through the engine block <NUM> before the second cooling line <NUM> branches off to the manifold coolant passages <NUM> through the fluid-cooled manifold <NUM>.

The first cooling line <NUM> may have a first portion that includes the manifold coolant passages <NUM> extending through the first fluid-cooled manifold <NUM>. Further, the first cooling line <NUM> may also include a second portion that includes manifold coolant passages <NUM> extending through the second fluid-cooled manifold <NUM>. The first portion of the first cooling line <NUM> may run parallel to the second portion of the first cooling line <NUM>.

The coolant circulation system <NUM> may include an orifice downstream of the fluid-cooled manifold(s). The orifice may be configured to avoid diverting too much coolant from the engine and to increase coolant pressure in the fluid-cooled manifolds. Due to the higher coolant pressure, the boiling temperature of the coolant may be increased, such that phase change of the coolant is reduced and heat transfer to the coolant is enhanced.

Claim 1:
A fluid-cooled manifold (<NUM>) for cooling exhaust from an engine, the cooled manifold (<NUM>) comprising:
a plurality of exhaust runners (102A-102D) including a first exhaust runner (102A) and a second exhaust runner (102B), wherein the first exhaust runner (102A) is detached from the second exhaust runner (102B), each of the plurality of exhaust runners (102A-102D) comprising:
a runner body (<NUM>) having an inlet end (<NUM>) and an outlet end (<NUM>),
an exhaust conduit (<NUM>) extending through the runner body (<NUM>) from an exhaust inlet opening (<NUM>) at the inlet end (<NUM>) of the runner body (<NUM>) to an exhaust outlet opening (<NUM>) at the outlet end (<NUM>) of the runner body (<NUM>), and
a coolant passage (<NUM>) extending through the runner body (<NUM>) from a coolant inlet opening (<NUM>) to a coolant outlet opening (<NUM>);
an exhaust collection manifold (<NUM>) including a plurality of inlets (142A-142D), wherein each inlet of the exhaust collection manifold (<NUM>) is coupled to the exhaust outlet opening (<NUM>) of a respective one of the plurality of exhaust runners (102A-102D);
a coolant feed pipe (<NUM>) including a plurality of outlets (152A-152D), wherein each outlet of the coolant feed pipe (<NUM>) is coupled to the coolant inlet (<NUM>) of a respective one of the plurality of exhaust runners (102A-102D); and
a coolant exit pipe (<NUM>) including a plurality of inlets (156A-156D), wherein each inlet of the coolant exit pipe (<NUM>) is coupled to the coolant outlet (<NUM>) of a respective one of the plurality of exhaust runners (102A-102D),
wherein each exhaust runner of the plurality of exhaust runners (102A-102D) has the same shape as the other exhaust runners (102A-102D) of the plurality of exhaust runners (102A-102D).