Clamped Repair Boot for Air Intake Leak and Vibration Fatigue
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Air intake assemblies experience leaks due to fatigue from heat changes and vibrations, which necessitate costly repairs or replacement of the entire assembly.
Innovation Solution
A new air intake boot with a clamp and flexible corrugated body is designed to fit over the existing air intake tube, providing secure attachment and preventing leaks through a clamp mechanism that fits over a circumferential flange, allowing for easy installation and compatibility with the original system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If adhesive or sonic welding is used to secure the boot to the air intake tube, then the boot is initially sealed, but over time heat changes and vibrations cause fatigue and leakage
Solution Approach 1:
The patent replaces the chemical bonding method (adhesive) or high-frequency welding (sonic welding) with a mechanical clamping system. The clamp applies continuous mechanical pressure to secure the boot to the air intake tube, eliminating the fatigue issues associated with adhesive degradation and weld cracking under thermal and vibrational stress.
Solution Approach 2:
The invention changes the attachment mechanism from a permanent bond (adhesive/weld) that degrades over time to an adjustable mechanical clamp that maintains consistent clamping force. The clamp's design allows it to accommodate thermal expansion and contraction while maintaining secure attachment, thereby extending service life.
2Reliability
If a new air intake assembly is purchased to repair leaks, then leakage is eliminated, but repair cost increases significantly
Solution Approach 1:
The invention separates the boot replacement function from the entire air intake assembly replacement. By creating a standalone boot repair kit with a clamp and new boot, only the leaking components are replaced rather than the entire assembly, significantly reducing repair costs while eliminating leakage.
Solution Approach 2:
The clamp acts as an intermediary component that secures the new boot to the air intake tube without requiring replacement of the entire assembly. This intermediate fixing mechanism enables cost-effective repair by isolating and replacing only the failed boot component.
3Reliability
If the boot is securely attached to prevent leaks, then engine air intake control is maintained, but the attachment mechanism must withstand heat changes and vibrations
Solution Approach 1:
The clamp design incorporates flexible elements that can accommodate thermal expansion and contraction of the boot and air intake tube. The flexible construction allows the clamp to maintain secure attachment while flexing with temperature changes and vibrations, preventing fatigue failure.
Solution Approach 2:
The clamp mechanism is designed to be dynamic rather than rigid, allowing it to adjust and accommodate movements caused by thermal expansion and vibrational forces. This dynamic attachment maintains secure sealing while withstanding environmental stressors that cause fatigue in static bonding methods.
Data Source
AI summary
A repair boot for an air intake assembly having an air intake duct. The repair boot is open between its ends and has a collar with a first interior dimension that is selected to complement the air intake duct and a second interior diameter that is selected to engage a surrounding flange on the exterior of air intake duct.