Intake Manifold Inner Joint Arrangement for Stress Relief
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Solution Overview
Problem
The existing intake manifold design is susceptible to stress concentration and low compressive strength at the welded parts due to increased pressure from backfire, which can lead to deformation and failure.
Innovation Solution
The intake manifold design includes a surge tank formed by two members joined by vibration welding, with a passage wall portion that extends inwardly to form a gas passage, where the inner joint portion is arranged closer to the middle part of the gas passage than the division point, reducing stress concentration and enhancing compressive strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the welded parts are arranged close to the base part of the passage wall portion, then the manufacturing is simplified, but the compressive strength and stress resistance are reduced
Solution Approach 1:
The invention moves the welded parts from a two-dimensional arrangement at the base of the passage wall portion to a three-dimensional arrangement that extends along the longitudinal direction of the passage wall portion. This dimensional change allows the welded parts to be distributed over a larger area, reducing stress concentration while maintaining manufacturing simplicity.
Solution Approach 2:
The passage wall portion is divided into multiple segments with welded parts arranged at different positions along its length. Instead of having all welded parts concentrated at the base, they are segmented and distributed along the longitudinal direction, which reduces stress concentration at any single location and improves overall compressive strength.
2Ease of operation
If the welded parts are arranged close to the base part of the passage wall portion, then the assembly process is simplified, but the reliability under backfire pressure is reduced
Solution Approach 1:
The welded parts are arranged not only at the base but also extending along the longitudinal direction of the passage wall portion. This spatial distribution in multiple dimensions maintains assembly simplicity while significantly improving reliability by preventing stress concentration at critical locations during backfire events.
Solution Approach 2:
The distributed arrangement of welded parts along the passage wall portion acts as a preemptive measure against backfire pressure. By spreading the welded parts over a larger area, the structure is beforehand prepared to withstand pressure increases, preventing deformation and failure before they can occur.
3Strength
If the passage wall portion is positioned to reduce stress concentration, then the compressive strength is improved, but the structural complexity increases
Solution Approach 1:
The passage wall portion is segmented into multiple sections with welded parts distributed along its length. This segmentation approach improves compressive strength by reducing stress concentration while maintaining a relatively simple overall structure that follows the natural geometry of the surge tank and gas passage.
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 effectively relieves stress and enhances the compressive strength of the passage wall portion, preventing deformation and ensuring reliable operation under increased pressure conditions.
Implementation Method 1
the first member passage wall portion and the second member passage wall portion are joined with each other by vibration welding
Data Source
AI summary
An intake manifold includes a passage wall portion having a first member passage wall portion provided at a first member, a second member passage wall portion provided at a second member, and an inner joint portion including a division point at which an inner joint portion is divided from an outer peripheral joint portion, the inner joint portion at which the first member passage wall portion and the second member passage wall portion are joined with each other. At least a part of the inner joint portion except for the division point is arranged at a height position closer to a middle part of a gas passage than the division point in a first direction in which the first member and the second member are opposed with each other.