Cargo movement flap seal and assembly method

Abstract

Inlet manifold (40), comprising: a lower intake manifold section (44) defining an intake pipe (70) and a pocket (122); a rotatable shaft (100) extending through the inlet pipe (70); a flap valve (102) coupled to the rotatable shaft (100); and a seal (110) arranged between one side of the tube (70) near the shaft (100) and the flap valve (102) coupled to the shaft (100), wherein the seal (110) has a press-fit part (144) with retaining ribs (146) and a lip part (142); and the press-in part (144) of the seal (110) is pressed into the pocket (122), characterized by the fact that the press-fit part (144) of the seal (110) has at least one guide lug (148) which extends outwards from a surface of the press-fit part (144) of the seal (110); the pocket (122) has at least one defined notch (160) therein; and the guide nose (148) engages the notch (160) when the seal (110) is installed in the pocket (122) to ensure that the seal (110) is installed in the correct orientation.

Description

Area

[0001] The present disclosure relates to charge motion control in the intake of internal combustion engines. background

[0002] More than a quarter of a century ago, spark-ignition engines tended to have only a single intake valve. To improve breathing and thus the peak power achievable from a given reciprocating engine, two intake valves became the norm in engine design. However, it has been found that two intake valves result in less mixture movement under low-torque conditions than a single intake valve, resulting in a deterioration in idle quality. If the cross-sectional area of ​​the port is reduced under low-torque conditions, the velocity of the flow past such a reduced area is increased. Valves placed in ports in the intake manifold can be held open under high-torque operating conditions but moved to a closed position under low-torque operating conditions.In addition, the contours of the valves are carefully designed to promote flow characteristics that lead to tumble and / or swirl.

[0003] Document DE 697 00 746 T2 discloses an intake manifold comprising a lower intake manifold section defining an intake pipe and a pocket, a rotatable shaft extending through the intake pipe, a flap valve coupled to the rotatable shaft, and a seal arranged between a side of the intake pipe near the shaft and the flap valve coupled to the shaft, the seal being pressed into the pocket. Document DE 19 05 009 A discloses a seal for machine parts having a press-fit part with retaining ribs and a lip part, and which is particularly suitable for compensating manufacturing tolerances. Further prior art relating to the background of the invention is provided by documents US 2014 / 0 230 781 A1 and JP 2011-74 760 A.

[0004] Charge motion control valves (CMCVs), such as those in our own US patent US 8 056 534 B2, are used in some engines to close off secondary intake ports of an intake system. The CMCVs in US 8 056 534 B2 use a butterfly valve similar to a throttle valve used to control the amount of air supplied to the engine. The CMCV actuator shaft extends through the center of the intake manifold as well as through the center of the inlet pipes of the primary intake ports. The CMCV stems, which extend through the center of the secondary intake pipes, interact with flow under high-torque conditions, causing a pressure drop and disturbing fluid mechanics. Even more problematic is when the stem also extends through the primary ports, thereby negatively affecting flow in those ports as well.

[0005] To overcome this problem, the butterfly valve was replaced with a flap valve connected to a stem extending through one edge of the channel. It was found that a portion of the flow passes through the channel behind the flap valve, i.e., a gap located between the CMCV stem and the edge of the channel near the CMCV stem. Such a gap allows flow when the CMCV should be closed, thereby negating some of the benefits of the CMCV and causing undesirable effects on fluid mechanics. Even when the CMCV is open, flow through the gap has a negative impact on fluid mechanics.

[0006] In a prior art seal disclosed in WO 2013 / 137349 A1, a centrally positioned stem has seals attached to the tips of the butterfly valve. Such seals, attached to the moving part of the valve, only have a significant effect when the valve is closed or nearly closed. Such a seal does not solve the problem of sealing the undesired flow path when the valve is open. Furthermore, it would not solve the problem of flow behind the butterfly valve in any valve position. Summary

[0007] The seal prevents unwanted flow behind the flap valve. Locating lugs on the seal prevent incorrect installation. Retaining ribs hold the seal in position after installation. By manufacturing the lip portion of the seal from a thin, flexible material, the amount of pressure exerted by the lip portion on the flap valve is large enough to essentially close the gap, yet small enough to only minimally increase the actuating force required to rotate the stem and thus the flap valves. Short description of the drawings Fig. 1 is an isometric view of the intake manifold; Fig. 2 is a part of an isometrically shown intake manifold, Fig. Figure 3 is an isometric view of a CMCV stem assembly; Fig. 4 is an illustration of a flap valve coupled to a CMCV stem and a flap seal; Fig. 5 is a representation of the flap seal of Fig. 4; Fig. 6 is a view of the flap seal of the Fig. 4 and Fig. 5, as installed in an intake manifold; Fig. 7 is a flow diagram of a method for assembling an intake manifold having a seal behind the flapper valve; Fig. Figure 8 is an illustration of an alternative flap seal in which the lip portion is arranged symmetrically with respect to the press-fit portion; Fig. Figures 9-11 are illustrations of an alternative flap seal that engages grooves in the manifold. Detailed description

[0008] It will be apparent to one of ordinary skill in the art that various features of the embodiments illustrated and described with reference to any of the figures may be combined with features illustrated in one or more other figures to create alternative embodiments not explicitly illustrated or described. The combinations of illustrated features provide representative embodiments for typical applications. Various combinations and modifications of the features consistent with the teachings of the present disclosure may, however, be desirable for particular applications or implementations. One of ordinary skill in the art may recognize similar applications or implementations whether or not explicitly described or illustrated.

[0009] An intake manifold 40 is Fig. 1. An upper manifold section 42 includes a top shell 52 coupled to an upper center shell. Alternatively, the upper shell 52 and the upper center shell 54 may be integrally formed. A lower manifold section 44 includes a lower center shell 56 coupled to a chamber section 58. Alternatively, the lower center shell 56 and the chamber section 58 are integrally formed. The intake manifold 40 includes an inlet 60 to the lower manifold section 44, which may be coupled to the throttle body (not shown).

[0010] The lower manifold section 44 is Fig. 2. Several flap valves 102 are provided in inlet pipes 70. The flap valves 102 are Fig. 2 in an open position. When folded upward, the flap valves 102 partially block the inlet pipes 70.

[0011] A CMCV arrangement 98 is used in Fig. 3. Bearing blocks are placed on a stem 100, after which the flaps 102 are molded onto the stem 100. A vacuum actuator (not shown) is coupled to the end 106 of the stem 100; the vacuum actuator can rotate the stem 100 to actuate the CMCV assembly 98. An element 108 includes a clamp, block rings, and a seal to prevent leaks and hold the CMCV assembly 98 longitudinally in position after installation. The bearing blocks are clamped into the lower manifold section and hold the CMCV assembly 98 in alignment after installation in the manifold.

[0012] In Fig. 4 shows a close-up view of a flap valve 102 near an interface 120 between an upper center shell 54 and a lower center shell 56. The flap valve 102 is molded onto the stem 100. A seal 110 is installed in a pocket 122 molded into the lower center shell 56. The seal 110 includes a lip portion 142 and a press-fit portion 144. The lip portion 142 blocks a gap 124 between the flap valve 102 and the lower center shell 56. The gap 124 is in position to ensure that the flap valve 102 does not stick against the center shell portion 56 in the face of manufacturing tolerances and relative movement of the parts due to temperature extremes. The flap valve 102 includes a tip 116. A cut-out section is located near the curve 118.Thus, when the flap valve 102 is in a flow blocking position, a majority of the flow passes through the cutout near the curve 118. Furthermore, the flap valve 102 has a curved portion 114 to direct flow to provide the desired fluid mechanics in the cylinder.

[0013] In Fig. 5, a seal 110 is shown with a lip portion 142 having a thickness D1 and a press-in-place (PIP) portion 144 having a thickness D2. The PIP portion 144 is the portion that fits into the pocket 122 (in Fig. 4). The PIP portion 144 has a plurality of retaining ribs 146 that cause the seal to remain in position, as is known in PIP seals. Optionally, the seal 110 further includes guide lugs 148. Now Fig. Referring to Figure 6, the tabs 148 on one side of the seal 110 fit into notches 160 on one side of the pocket 122. The seal 110 can only be installed one way. If it were installed the wrong way, the guide tabs 148 would interfere with the pocket 122, preventing improper installation. The guide tabs 148 also prevent the seal 110 from moving out of the pocket 122 through a designed interference with the flapper 102.

[0014] In Fig. 7, processes by which an intake manifold may be manufactured are shown. In block 200, the lower and upper intake manifold sections are manufactured by any suitable process, such as injection molding. The pocket 122 is formed in the lower intake manifold section. Flexible seals are formed or manufactured in any suitable manner in block 202. The CMCV assembly is assembled in block 204. Sealing members, clamps, bearing blocks, and flapper valves are arranged on the stem. In block 206, the seals 110 manufactured in block 202 are pressed into pockets formed in the lower manifold section. In block 208, the CMCV stem assembly manufactured in block 204 is placed into the lower manifold section. In some embodiments, the seals 110 are arranged in position such that they cannot be removed.It is desirable to prevent the seals 110 from becoming loose and entering the engine. In some embodiments, bearing blocks are snapped into openings provided in the lower manifold section.

[0015] In block 210, the upper and lower intake manifold sections are brought together and welded together. In some embodiments, the intake manifold sections are formed from polyamide material with mating raised beads. The beads are welded together by friction welding, butt welding, or gas welding. Alternatively, the intake manifold sections are bonded or secured together by another technique. With the intake manifold sections secured together, the CMCV valve assembly is held in position.

[0016] In some embodiments, the gaskets are installed into the lower intake manifold section by an operator. If the manifold is black and the gaskets are black, this provides only minimal visual confirmation that all gaskets have been installed. By manufacturing the gaskets with a contrasting color, the operator can easily see that the appropriate number of gaskets has been installed. Such color contrast can also prove useful for machine visual confirmation in an automated assembly process.

[0017] In Fig. 8, an alternative embodiment, a symmetrical seal 310, is shown in an end view. The seal 310 has a press-fit portion 312 that is thicker than the lip portion 318. Retaining ribs 316 are provided on the sides so as to interfere with the pocket into which the press-fit portion 312 is installed to prevent loosening of the seal 310. The seal 310 is symmetrical about a plane crossing the seal 310, as shown by line 320. In some intake manifolds, the symmetrical seal 310 can be accommodated. The seal 310 of Fig. 9 makes the guide lugs 148, which are attached to the Fig. 4 shown seal 110 are superfluous.

[0018] At the Fig. In the embodiment shown in Figure 5, the lip portion 142 of the seal 110 extends upward from the PIP portion 144. However, in an alternative embodiment, a seal may extend downward and be installed in the lower center shell or in the upper center shell. Such an alternative is shown in Figures Fig. 9-11. A portion of a lower center shell 350 has re-entry grooves 352 extending from a top surface 354 to bottoms 356 of the grooves 352. The grooves 352 are open at the top end of the lower center shell 350. In Fig. 9 shows a seal 360 having fitting ribs 362 for insertion into the grooves 352. The seal 360 is made of a flexible material having a part with a thickness D3, which imparts stability to the seal 360, and a lip part 364 with a thickness D4, which can be pressed with a small amount of force against the flap valve (in the Fig. 9-11 not shown): this is sufficient to maintain contact with the flap valve to block the gap, but is small enough that the actuating force is only slightly affected. The tip 366 of the seal 360 can move on the flap valve as it moves in response to rotation of the stem. Another view of the seal 360 is shown in Fig. 11, which shows that ribs 362 extend downward along a portion of the seal 360. The tips 376 of the ribs 362, after installation, abut lower ends 356 of the grooves 352 (in Fig. 9). When the upper intake manifold section is coupled to the lower intake manifold section, the ribs 362 are engaged, thereby gripping the gasket 360 to prevent its release.

[0019] The terms "lower manifold section" and "upper manifold section" are used herein. Although "upper" and "lower" are used herein as identifiers for the two sections, such terms are not intended to be limiting and could refer to any orientation.

[0020] Although the best mode has been described in detail with reference to specific embodiments, those skilled in the art will recognize various alternative designs and embodiments within the scope of the following claims. While various embodiments may be described as offering advantages or being preferred over other embodiments with respect to one or more desired characteristics, as will be apparent to those skilled in the art, one or more characteristics may be compromised to achieve the desired system characteristics, depending on the particular application and implementation. These characteristics include, but are not limited to, cost, strength, durability, life cycle cost, marketability, appearance, packaging, size, serviceability, weight, manufacturability, ease of assembly, etc.Embodiments described herein that are described as less desirable than other embodiments or prior art implementations with respect to one or more characteristics are not outside the scope of the disclosure and may be desirable for certain applications.

Claims

[1] Intake manifold (40), comprising: a lower intake manifold portion (44) defining an inlet tube (70) and a pocket (122); a rotatable shaft (100) extending through the inlet tube (70); a flap valve (102) coupled to the rotatable shaft (100); and a seal (110) arranged between a side of the tube (70) near the shaft (100) and the flap valve (102) coupled to the shaft (100), the seal (110) having a press-in part (144) with retaining ribs (146) and a lip part (142); and the press-in part (144) of the seal (110) is pressed into the pocket (122), characterized by , that the press-in part (144) of the seal (110) has at least one guide lug (148) extending outwardly from a surface of the press-in part (144) of the seal (110); the pocket (122) has at least one notch (160) defined therein; and the guide tab (148) engages the notch (160) when the seal (110) is installed in the pocket (122) to thereby ensure that the seal (110) is installed in the correct orientation. [2] Intake manifold (40) according to one of claims 1, wherein the thickness of the lip portion (142) of the seal (110) is less than the thickness of the press-fit portion (144) of the seal (110). [3] Intake manifold (40) according to one of claims 1 or 2, wherein the lip portion (142) of the seal (110) contacts the flap valve (102) near the point where the stem (100) extends through the flap valve (102). [4] Intake manifold (40) according to one of claims 1 to 3, wherein: the seal (110) is made of a flexible material; and a lip portion tip of the seal (110) near the point where the stem extends through the flap valve (102) interferes with the flap valve (102) so that the lip portion (142) of the seal (110) bends and thereby presses against the flap valve (102). [5] Intake manifold (40) according to one of claims 1 to 4, wherein: the seal (110) has two parts: a thicker part and a thinner lip part (142); the thicker part engages the lower intake manifold section (44); and the lip portion (142) presses against the flap valve (102) near the point where the stem (100) extends through the flap valve (102). [6] Intake manifold (40) for an internal combustion engine, comprising: a lower intake manifold section (44) having a plurality of intake pipes (70), one intake pipe (70) leading to each cylinder of the engine; a rotatable shaft (100) extending through at least two of the inlet tubes (70), the shaft (100) extending substantially perpendicular to the flow direction in the tubes (70); flap valves (102) coupled to the rotatable shaft (100), wherein a flap valve (102) is arranged in each of the at least two inlet pipes (70) through which the rotatable shaft (100) extends; and a seal (110) provided behind each of the flap valves (102) in the at least two inlet pipes (70), each seal (110) having a portion that engages the lower intake manifold section (44) and a portion that is biased against the flap valve (102) near the point where the stem extends through the flap valve (102). [7] Intake manifold (40) according to claim 6, wherein: the lower intake manifold section (44) defines a pocket (122) associated with each of the at least two tubes (70); and the portion of the gasket (110) engaging the lower intake manifold section (44) has a plurality of retaining ribs (146) that extend outwardly from the gasket (110) after installation and press against the pocket (122). [8] Intake manifold (40) according to claim 7, wherein: the portion of the seal (110) engaging the lower intake manifold section (44) has at least one guide tab (148) extending outwardly from its surface; the pocket (122) has at least one notch (160) defined therein; and the guide tab (148) engages the notch when the seal (110) is installed in the pocket (122) to thereby ensure that the seal (110) is installed in the correct orientation. [9] Intake manifold (40) according to one of claims 6 to 8, wherein: a gap (124) associated with each of the at least two inlet pipes (70) exists between a wall of the inlet pipe (70) and an end of the flap valve (102) through which the rotatable shaft (100) extends; and the part of the seal (110) prestressed against the flap valve (102) largely blocks the gap (124). [10] Intake manifold (40) according to one of claims 6 to 9, wherein: the lower intake manifold portion (44) is made of a material having a predetermined color; and the seals (110) are made of a material having a color that contrasts with the predetermined color. [11] Intake manifold (40) according to one of claims 6 to 10, further comprising: an upper intake manifold section (42) secured to the lower intake manifold section (44), wherein when the upper intake manifold section (42) is secured to the lower intake manifold section (44), the rotatable shaft (100) is held in position by the flap valves (102) and the seals (110) coupled to the rotatable shaft (100). [12] A method of manufacturing an intake manifold, comprising: Forming a lower intake manifold section (44) which: multiple inlet channels; and a plurality of retaining features each adapted to receive a portion of a seal (110); Forms of several seals (110); and Engaging one of the seals (110) in each of the retaining features in the lower intake manifold section (44), characterized by , that the lower manifold section (44) is provided with at least one notch (160) near each of the seal retention features (110); each seal (110) has at least one guide lug (148) projecting outwardly from one side of the seal (110); and the guide lugs (148) of the seals (110) engage with the notches (160). [13] The method of claim 12, further comprising: Mounting a charge movement valve (CMCV) assembly (98); and securing the CMCV assembly in the lower intake manifold section (44). [14] The method of claim 13, wherein the CMCV assembly (98) is placed into the lower intake manifold section (44) after engaging the seals (110) with the retention features in the lower intake manifold section (44). [15] The method of claim 13 or 14, further comprising: forming an upper intake manifold section (42); Placing the upper intake manifold section (42) onto the lower intake manifold section (44); and Welding the upper intake manifold section (42) to the lower intake manifold section (44). [16] A method according to any one of claims 12 to 15, wherein: the retaining features are grooves formed in a wall of the lower intake manifold section (44); and the seals (110) have a projecting member that engages the grooves, the method further comprising: forming an upper intake manifold section (42); and Attaching the upper intake manifold section (42) to the lower intake manifold section (44), wherein an open end of the throats in the lower intake manifold section (44) is closed when the upper intake manifold section (42) is welded to the upper intake manifold section (42) such that the seals (110) between the upper (42) and lower intake manifold sections (44) are engaged.

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