Engine Intake Duct Self-Positioning Assembly
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Solution Overview
Problem
Existing intake duct structures for internal combustion engines are difficult to assemble to the vehicle body efficiently, requiring manual holding during fastening, which hampers assembly efficiency.
Innovation Solution
The intake duct structure features a passage portion with a bottom surface that rests on a structural member and a resonator portion with a vertical surface, allowing it to be self-stably positioned, minimizing the need for manual holding during assembly. This configuration includes a semi-cylindrical bottom surface and a vertically elongated resonator portion to enhance stability and space efficiency, with components designed for easy molding and assembly, such as a tubular air outlet and a combination of hard and soft materials for impact absorption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the intake duct structure is designed with a partition wall part joining three parts by welding, then the ease of manufacture is improved, but the ease of assembling to the vehicle body deteriorates requiring manual holding during fastening
Solution Approach 1:
The patent applies preliminary action by providing a positioning structure with a bottom surface that rests on the vehicle body and vertical surfaces that engage with the vehicle body structure before the actual fastening operation. This preliminary positioning eliminates the need for manual holding during assembly, as the structure self-positions through the geometric engagement features.
Solution Approach 2:
The intake duct structure performs self-service by incorporating geometric features (bottom surface and vertical surfaces) that automatically position and stabilize the structure on the vehicle body without requiring additional manual intervention. The structure uses its own geometric properties to achieve proper alignment and stability during assembly.
2Volume of moving object
If the resonator portion is positioned behind the structural member, then the space efficiency of the engine room is improved, but the stability of the intake duct structure deteriorates
Solution Approach 1:
The patent resolves the stability-space contradiction by utilizing the vertical dimension. The resonator portion extends vertically behind the structural member with vertical surfaces that engage with the vehicle body structure. This vertical arrangement provides both stability through geometric engagement and space efficiency by utilizing the vertical space rather than horizontal space.
Solution Approach 2:
The positioning structure is designed with vertical surfaces that preliminarily engage with the vehicle body structure, providing stability before the final fastening. This preliminary geometric engagement ensures the structure remains stable even with the resonator portion positioned behind the structural member for space efficiency.
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
Facilitates easier and more stable assembly of the intake duct structure, improving assembly efficiency and reducing the risk of instability or air leakage, while maintaining space efficiency and protecting the resonator from radiator heat.
Implementation Method 1
the bottom surface (28G) of the passage portion (28) is configured to rest on an upper surface of the structural member (40, 11B)
Implementation Method 2
the resonator portion (29) is provided with a vertical surface (29C) opposing a vertical surface of the structural member (40, 11B)
Implementation Method 3
a resonator portion (29) depending from the downstream end part of the passage portion (28) and internally defining a resonator chamber (35)
Data Source
AI summary
An intake duct structure (22) of an engine intake system for an internal combustion engine of a vehicle includes a passage portion (28) internally defining an air passage having an air inlet (22A) located in an upstream end part of the passage portion and an air outlet (22B) located in a downstream end part of the passage portion, and extending above a structural member (40, 11B) of a vehicle body, and a resonator portion (29) depending from the downstream end part of the passage portion and internally defining a resonator chamber (35). The passage portion is provided with a bottom surface (28G) configured to rest on an upper surface of the structural member, and the resonator portion is provided with a vertical surface (29C) opposing a vertical surface of the structural member.