Intake Manifold Cover Sandwiched Between Flanges
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Solution Overview
Problem
The existing intake manifold designs, such as Japanese Patent No. 3960101, require complex molding processes and impose limitations on shape design due to the integral molding of the cover with other components, restricting the flexibility in designing the surge tank and branch pipes.
Innovation Solution
The intake manifold is composed of resin pieces with a first piece, a second piece, and a cover, where the cover is sandwiched between flanges of the first and second pieces, allowing for independent molding and reducing design constraints, with a gas passage defined by the cover and the inner surface of the surge tank to facilitate blow-by gas flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the cover is integrally molded with the first piece, then the structure is simplified, but the molding process becomes complicated and design flexibility is limited
Solution Approach 1:
The intake manifold is divided into separate components: the first piece, second piece, and cover are molded independently and then assembled together using flanges and fasteners. This segmentation allows each component to be manufactured separately with standard molding processes, avoiding the complications of integral molding while maintaining structural integrity through the flange connections.
2Device complexity
If the cover is integrally molded with the first piece, then assembly is simplified, but design flexibility of the first piece and cover is limited
Solution Approach 1:
By separating the cover from the first piece and connecting them via flanges, the design allows independent optimization of each component's shape and function. The cover can be designed specifically for its sealing and structural role, while the first piece can be optimized for its intake and blow-by gas handling functions, providing greater overall design flexibility.
Solution Approach 2:
The flange connection system serves multiple functions: it provides structural attachment between components, enables disassembly for manufacturing and assembly, and allows for potential variations in cover and first piece designs while maintaining the same connection interface, enhancing design adaptability.
3Device complexity
If the cover is integrally molded with the first piece, then the number of parts is reduced, but the molding process becomes more complicated
Solution Approach 1:
The cover and first piece are manufactured as separate components using standard injection molding or similar resin molding processes, which are well-established and straightforward techniques. After molding, the components are assembled using flanges and fasteners. This approach trades a small increase in part count for a significant simplification of the molding process, allowing each component to be produced with conventional, efficient molding methods.
Data Source
AI summary
A first piece forms a part of a surge tank. A second piece forms the surge tank together with the first piece. The first piece includes an introduction hole through which blow-by gas is introduced. The first piece includes a first flange fixed to the second piece. The second piece includes a second flange fixed to the first flange. A cover is located inside the surge tank. The cover defines, together with an inner surface of the surge tank, a gas passage extending from the introduction hole into the branch pipe. A part of the cover is sandwiched between the first flange and the second flange.