Longitudinal Engine Intake Manifold with Variable Rigidity Couplings

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Solution Overview

Problem

Existing engine intake manifold structures do not effectively prevent interference between the intake manifold and fuel pipes during a vehicle front collision when the engine is longitudinally mounted in the engine room.

Innovation Solution

The intake manifold is designed with independent intake pipe portions arranged in the vehicle front-rear direction, featuring varying coupling portions with reduced rigidity on the front side to absorb collision loads, thereby minimizing deformation and preventing interference with fuel pipes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If the intake manifold is designed with uniform high rigidity throughout, then structural strength is improved, but collision load absorption is worsened causing interference with fuel pipes

Engineering Contradiction:

Improvestructural strengthVSAvoidcollision load interference

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The patent applies local quality by creating different rigidity characteristics in different portions of the intake manifold. Specifically, the front-side coupling portion is designed with lower rigidity (through reduced wall thickness or structural features) while the rear-side coupling portion maintains higher rigidity. This allows the front portion to deform and absorb collision loads while the rear portion remains structurally sound, preventing interference with fuel pipes arranged on the vehicle rear side.

Inventive Principle:

Principle #3Local quality

2Object-affected harmful factors

If the coupling portion rigidity is reduced to absorb collision loads, then collision load absorption is improved, but overall structural strength is worsened

Engineering Contradiction:

Improvecollision load absorptionVSAvoidoverall structural strength

Core Design Contradiction:

Object-affected harmful factorsVSStrength

Solution Approach 1:

The patent resolves this contradiction by applying local quality - the front-side coupling portion has reduced rigidity for collision absorption while the rear-side coupling portion maintains high rigidity for structural strength. This localized differentiation allows each portion to fulfill its specific function without compromising the other.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The intake manifold is segmented into front-side and rear-side coupling portions with distinct rigidity characteristics. This segmentation allows the front portion to specialize in collision load absorption while the rear portion specializes in maintaining structural integrity, preventing the need to compromise overall strength when reducing rigidity for collision absorption.

Inventive Principle:

Principle #1Segmentation

3Object-affected harmful factors

If the intake manifold is positioned to avoid fuel pipe interference, then collision interference is prevented, but engine room layout flexibility is worsened

Engineering Contradiction:

Improvefuel pipe interference preventionVSAvoidengine room layout flexibility

Core Design Contradiction:

Object-affected harmful factorsVSAdaptability or versatility

Solution Approach 1:

The patent changes the rigidity parameter of the coupling portions to enable the intake manifold to adapt its deformation characteristics based on collision conditions. This allows the fuel pipe arrangement to remain on the vehicle rear side (maintaining layout flexibility) while the front-side low-rigidity coupling portion deforms during collision to prevent interference, rather than requiring fixed positioning constraints.

Inventive Principle:

Principle #35Parameter changes

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 configuration effectively absorbs collision loads on the front side, reducing the load on the rear side and preventing deformation, thus avoiding interference between the intake manifold and fuel pipes during a vehicle front collision.

Implementation Method 1

the independent intake pipe portions on the vehicle front side deform and absorb the collision load

Methodology Applied

Scientific EffectDeformation: Deformation

Implementation Method 2

the collision load can be absorbed as much as possible

Methodology Applied

Scientific EffectEnergy absorption: Absorption (physical)

Data Source

PatentUS20220381208A1Intake manifold structure

Publication Date: 2022.12.01 MAZDA MOTOR CORP

AI summary

Interference between an intake manifold and a fuel pipe during a vehicle front collision is prevented in an engine which is longitudinally mounted in an engine room. A vehicle component is arranged on the front side of the intake manifold, and the fuel pipe is arranged on the rear side of the intake manifold. The intake manifold includes a plurality of independent intake pipe portions arranged side by side in the vehicle front-rear direction which branch for each of the cylinders of the engine; and a plurality of coupling portions that each couple adjacent independent intake pipe portions to each other in an integral manner A first coupling portion of the plurality of coupling portions positioned on the frontmost side has a lower rigidity than a third coupling portion of the plurality of coupling portions positioned the rearmost side.