Resin Intake Manifold Pillar Shape for Strength and Low Pressure Loss

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Solution Overview

Problem

Intake manifolds made of resin in large engines face challenges in achieving sufficient pressure resisting strength while maintaining low pressure loss due to increased size, and existing reinforcement methods disturb the intake flow.

Innovation Solution

The intake manifold features a pillar portion with an oval cross-section elongated in the intake air direction, reinforced by a plate-shaped rib, enhancing strength and reducing pressure loss by minimizing flow disturbance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If the intake manifold size is increased for large engines, then the engine capacity is improved, but the pressure resisting strength is insufficient

Engineering Contradiction:

Improveintake manifold sizeVSAvoidpressure resisting strength

Core Design Contradiction:

Volume of moving objectVSStrength

Solution Approach 1:

The pillar portion is designed with an asymmetric oval cross-section where the longitudinal dimension (in the intake air flow direction) is greater than the lateral dimension. This asymmetric geometry optimizes both the structural strength to resist pressure and the aerodynamic characteristics to minimize flow disturbance, resolving the contradiction between size and pressure resisting strength.

Inventive Principle:

Principle #4Asymmetry

2Strength

If a pillar is added to enhance pressure resisting strength, then the strength is improved, but the intake flow is disturbed and pressure loss increases

Engineering Contradiction:

Improvepressure resisting strengthVSAvoidpressure loss

Core Design Contradiction:

StrengthVSLoss of energy

Solution Approach 1:

The pillar cross-sectional parameters are optimized by making it oval-shaped with specific dimensional ratios. The longitudinal dimension is made larger than the lateral dimension, which changes the geometric parameters to reduce flow disturbance while maintaining sufficient structural strength, thus resolving the contradiction between strength enhancement and pressure loss.

Inventive Principle:

Principle #35Parameter changes

3Ease of manufacture

If a pillar with circular cross-section is used, then the manufacturing is simple, but the pressure resisting strength is insufficient and flow disturbance occurs

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidpressure resisting strength

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The pillar transitions from a conventional circular cross-section to an asymmetric oval cross-section. This asymmetric shape provides superior pressure resisting strength and reduced flow disturbance compared to circular sections, while still being manufacturable using standard molding techniques, thus resolving the contradiction between manufacturing simplicity and performance.

Inventive Principle:

Principle #4Asymmetry

Data Source

PatentUS12571363B2Intake manifold

Publication Date: 2026.03.10 MIKUNI CORP

AI summary

In an intake manifold made of a resin and including: a surge tank 2 applied to an engine, an intake air flowing into the surge tank 2; and branch pipes 3a and 3b branched from the surge tank 2 and connected to intake ports of the engine, a pillar portion 20 penetrating through an internal space of the surge tank 2 and connecting an inner wall 12 and an outer wall 13 facing each other is included, and a cross section perpendicular to an extending direction of the pillar portion 20 has an oval shape elongated in an passing direction of the intake air inside the surge tank 2.