Integrated Composite Throttle Body and Intake Manifold

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Solution Overview

Problem

The existing intake manifold systems for internal combustion engines often suffer from misaligned seals and loose bolts between the throttle body and intake manifold, leading to increased system costs and potential engine degradation.

Innovation Solution

A short fiber reinforced polymer composite intake manifold and throttle body housing are integrated, eliminating the need for bolts and gaskets by being molded over an aluminum cylinder and welded together, forming a single unit.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If bolts and gaskets are used to connect the throttle body and intake manifold, then the connection is secure, but the system cost increases and the risk of misaligned seal and loose bolts increases

Engineering Contradiction:

Improveconnection reliabilityVSAvoidnumber of fastening components

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The throttle body and intake manifold are merged into a single integrated component made of short fiber reinforced polymer composite material. This eliminates the need for separate fastening components (bolts and gaskets) by creating a unified structure where the throttle body is molded directly onto the intake manifold, thereby reducing device complexity while maintaining connection reliability through the inherent structural integration

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent utilizes short fiber reinforced polymer composite material for both the throttle body and intake manifold. This composite material provides sufficient structural strength and rigidity to maintain a secure connection without requiring additional fastening hardware, thus resolving the contradiction between connection reliability and device complexity

Inventive Principle:

Principle #40Composite materials

2Ease of manufacture

If bolts and gaskets are used to connect the throttle body and intake manifold, then the connection can be assembled, but the system cost increases

Engineering Contradiction:

Improveassembly capabilityVSAvoidnumber of parts

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The throttle body and intake manifold are combined into a single molded part, eliminating multiple components (bolts, gaskets, separate throttle body, separate intake manifold). This integration reduces the total number of parts while maintaining manufacturability through injection molding processes that can create complex integrated structures in one operation

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

While the main bodies are integrated, the patent maintains functional segmentation by keeping the throttle plate, bearing holders, and other functional elements as distinct components that can be assembled into the integrated housing. This allows for modular assembly of internal components while the external structure remains unified, balancing ease of manufacture with reduced part count

Inventive Principle:

Principle #1Segmentation

3Reliability

If a traditional throttle body with bolts and gasket is used, then the sealing can be provided, but the weight of the air intake system increases

Engineering Contradiction:

Improvesealing reliabilityVSAvoidair intake system weight

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The patent employs short fiber reinforced polymer composite material for the integrated throttle body and intake manifold. This composite material provides high strength-to-weight ratio and excellent sealing properties through its molecular structure and fiber reinforcement, achieving reliable sealing without the additional weight of metal bolts and gaskets that would be required in a traditional design

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

By merging the throttle body and intake manifold into a single monolithic structure, the patent eliminates the need for separate sealing components (gaskets) and fastening components (bolts). The integrated design creates inherent sealing surfaces through the molding process, reducing the overall weight while maintaining sealing reliability

Inventive Principle:

Principle #5Merging (Combining)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This solution reduces system costs, minimizes the risk of engine emissions degradation, and decreases the weight of the engine air intake system while ensuring a secure seal.

Implementation Method 1

a short fiber reinforced polymer composite throttle body housing molded over an aluminum cylinder that includes two bearing holders

Methodology Applied

Scientific EffectMolding:

Implementation Method 2

a composite throttle body housing may be welded to a composite intake manifold to eliminate bolts and gaskets between the components

Methodology Applied

Scientific EffectWelding: Welding

Data Source

PatentUS11821393B1Integrated intake manifold

Publication Date: 2023.11.21 FORD GLOBAL TECH LLC

AI summary

Systems and methods for directing and controlling air flow into an internal combustion engine are presented. In one example, an aluminum cylinder with two welded bearing holders is over molded with a short fiber reinforced polymer composite throttle body housing. The short fiber reinforced polymer composite throttle body housing may be welded to an engine intake manifold or it may be part of the engine intake manifold.