Intake Duct Segments Hard-Soft Material Joining
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Solution Overview
Problem
Existing intake ducts for internal combustion engines face challenges in forming a satisfactory seal between segments, particularly when using a fibrous body material, as they require precise positioning and deformation to avoid deformation and ensure accurate joining, making the assembly process time-consuming and prone to errors.
Innovation Solution
The intake duct is designed with a first segment made of harder material and a second segment made of elastic material, featuring a groove with projections and a rib that can be elastically deformed to fit into the groove, allowing for easier and more accurate coupling without the need for precise alignment, enhancing the seal at the joined portion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a soft fibrous body segment is used for noise reduction, then noise reducing property is improved, but manufacturing precision deteriorates due to deformation during joining
Solution Approach 1:
The patent changes the material parameter of the first segment from soft fibrous body to hard material, making it resistant to deformation during joining while the second segment remains soft for noise reduction. This parameter differentiation resolves the contradiction by assigning different material properties to different segments.
Solution Approach 2:
The intake duct is divided into two segments with different material properties: the first segment (hard) provides structural stability for precise joining, while the second segment (soft fibrous body) provides noise reduction. This segmentation allows each part to fulfill its specific function without compromising the other.
2Object-affected harmful factors
If a soft fibrous body segment is used, then noise reducing property is improved, but device complexity increases due to need for dedicated joining jig
Solution Approach 1:
By changing the material parameter of the first segment to hard material, the patent eliminates the need for complex dedicated joining jigs. The hard first segment maintains its shape during joining, allowing for simpler assembly processes while the soft second segment still provides noise reduction.
3Object-affected harmful factors
If soft fibrous body segment is used, then noise reducing property is improved, but productivity decreases due to time-consuming assembly process
Solution Approach 1:
The patent improves productivity by changing the material parameter of the first segment to hard material, which resists deformation and enables faster, more reliable joining without requiring time-consuming adjustments or dedicated jigs. The soft second segment maintains its noise reduction function.
4Manufacturing precision
If hard material is used for both segments, then manufacturing precision is improved, but noise reducing property deteriorates
Solution Approach 1:
The patent applies parameter differentiation by making the first segment hard for precision joining while keeping the second segment soft for noise reduction. This selective parameter assignment resolves the contradiction by optimizing each segment for its primary function.
Solution Approach 2:
The intake duct is segmented into two parts with different material properties: the hard first segment for structural precision and the soft second segment for acoustic performance. This segmentation allows both requirements to be satisfied simultaneously in different parts of the same component.
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 design facilitates easier assembly and improves the seal quality by allowing the ribs to be easily fitted into the grooves, reducing the impact of manufacturing errors and ensuring a consistent planar pressure, thus enhancing the overall assembly efficiency and seal integrity.
Implementation Method 1
The second segment is formed from a material that allows for elastic deformation. The rib is fitted into the groove so that the projections locally compress the rib in a width direction of the groove.
Data Source
AI summary
An intake duct for an internal combustion engine includes a plurality of segments coupled together into a tubular shape. The segments include at least a first segment and a second segment. The first segment is formed from a material harder than the second segment. The first segment includes a groove that extends in the extending direction in a portion coupled to the second segment and projections that project from one of two inner surfaces of the groove. The second segment is formed from a material that allows for elastic deformation. The second segment includes a rib. The rib extends in the extending direction and has a projection width that is less than the opening width of the groove. The rib is fitted into the groove so that the projections locally compress the rib in the width direction of the groove.