Blow-Molded Intake Duct With Integrated Vapor Trap
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Solution Overview
Problem
Existing methods for integrating hydrocarbon vapor traps in internal combustion engine intake ducts often require additional assembly steps and fasteners, which can complicate the manufacturing process and may not securely retain the trap within the duct, potentially affecting airflow and adsorption efficiency.
Innovation Solution
A hydrocarbon-adsorbing element is secured to a frame to form an insert, which is then surrounded by a plastic shell through a blow-molding process, ensuring the element is exposed to the duct's interior and securely retained without additional fasteners or assembly steps, utilizing thermoformed polymeric sheets impregnated with adsorption material and a blow-molding core for precise positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional fasteners and assembly steps are used to secure the HC vapor trap in the intake duct, then the trap can be retained securely, but the manufacturing process becomes more complex and time-consuming
Solution Approach 1:
The patent combines the HC vapor trap retention function directly into the intake duct structure by molding retention features (such as ribs, lugs, or clips) as integral parts of the duct during the blow-molding process. This eliminates the need for separate fasteners and reduces assembly steps while maintaining secure retention of the trap.
Solution Approach 2:
The retention features are pre-formed as part of the duct structure during the blow-molding process before the trap is installed. The duct is molded with built-in retention mechanisms that are ready to secure the trap in its correct position, eliminating the need for additional fastening operations during assembly.
2Reliability
If additional fasteners and assembly steps are used to secure the HC vapor trap, then retention can be improved, but the manufacturing time and cost increase
Solution Approach 1:
The retention function is merged into the duct manufacturing process itself through blow-molding with integrated retention features. This allows the trap to be secured during the single duct-forming operation rather than requiring separate fastening steps, thereby improving manufacturing efficiency and reducing production time.
Solution Approach 2:
The retention features are created in advance as part of the duct structure during the blow-molding process. This preliminary formation of retention mechanisms eliminates the need for subsequent fastening operations, streamlining the manufacturing process and increasing productivity.
3Reliability
If the HC-adsorbing element is fully enclosed in the duct, then protection is improved, but airflow restriction increases and adsorption efficiency decreases
Solution Approach 1:
The duct structure provides protection to the HC-adsorbing element through localized retention features (such as ribs or lugs) that secure the element in place without creating complete enclosure. These local structural features offer mechanical protection while maintaining open pathways for airflow to reach the adsorption material, thus preserving adsorption 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
This method allows for a secure, efficient, and cost-effective integration of hydrocarbon vapor traps within the engine intake duct, ensuring maximum adsorption capacity and minimal airflow restriction, while simplifying the manufacturing process by eliminating the need for additional assembly steps.
Implementation Method 1
an element that adsorbs HC vapors present in an air intake duct and which contact the element
Implementation Method 2
placing a molten plastic parison and mold around the insert and core, and blow-molding the parison to form the shell
Implementation Method 3
The HC-adsorbing element may be formed by thermoforming at least one sheet of polymeric material
Data Source
AI summary
An engine intake duct is formed by securing a hydrocarbon-adsorbing element to a frame to form an insert, positioning the insert in registry with a blow-molding core, placing a molten plastic parison and mold around the insert and core, and blow-molding the parison to form a shell engaging the frame to retain the insert with a surface of the insert exposed to a hollow interior of the shell.