Intake Manifold Welding Stability via Middle Member Ribs
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Solution Overview
Problem
Intake manifolds with multiple intake passages arranged in a straight line during welding face challenges in maintaining stable welding conditions due to bending and deformation of resin members under pressure, leading to unstable welded portions.
Innovation Solution
The intake manifold incorporates a middle member with ribs that support the welded portions, ensuring they are held in fixed positions during vibration welding, preventing bending and allowing for secure joining of resin segments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple intake passages are arranged in a straight line in the welding pressure direction, then the degree of freedom in designing piping is increased, but the resin members are susceptible to bending and deformation under pressure during welding
Solution Approach 1:
The patent applies preliminary action by providing support jigs that are positioned in advance at the welded portions before welding begins. These support jigs pre-establish the correct positioning and prevent bending deformation during the welding process, allowing the intake passages to be arranged in a straight line in the welding pressure direction without compromising welding stability.
2Ease of operation
If support jig is inserted into empty spaces between middle member components, then positioning is possible, but the complicated piping routes make it difficult to insert the support jig
Solution Approach 1:
The patent applies dimensionality change by transitioning from lateral insertion of support jigs into empty spaces to approach from the upstream end along the linear arrangement of intake passages. This changes the insertion direction from a constrained lateral path to an open longitudinal path, making it easier to position support jigs even with complicated piping routes.
Solution Approach 2:
The support jigs are designed to be positioned in advance at the welded portions before welding begins. By preliminarily establishing the correct positioning using the linear intake passage arrangement, the welding process can proceed without bending deformation, eliminating the need to navigate complex empty spaces.
3Adaptability or versatility
If welded portions are not directly held between upper and lower jigs, then the structure can accommodate straight-line intake passages, but the resin members are susceptible to bending and deformation under pressure
Solution Approach 1:
The patent introduces support jigs as intermediary elements between the upper and lower welding jigs. These support jigs directly hold the welded portions at the intake passages, acting as mediators that transmit and stabilize the positioning force, thereby preventing bending deformation while maintaining the straight-line configuration of intake passages.
Solution Approach 2:
The support jigs are positioned in advance to directly hold the welded portions before welding pressure is applied. This preliminary positioning ensures that when welding pressure is applied, the welded portions remain stable and do not bend, maintaining manufacturing precision in the straight-line intake passage configuration.
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 stabilizes the welding process, enabling secure and stable connection of the intake manifold segments, enhancing the structural integrity and layout flexibility according to engine requirements.
Implementation Method 1
the upper member 71 and the middle member 73 are joined together by frictional heat by vibrating the upper member 71 laterally under vertical pressure
Implementation Method 2
the middle member 73 and the lower member 72 are likewise joined together by vibration welding
Data Source
AI summary
The present intake manifold consists of segments including an upper member, a lower member, and a middle member that is interposed between these members to demarcate and form intake passages so that the intake passages are arranged in a straight line, and has first welded portions at which the upper member and the middle member are welded together, and second welded portions at which the middle member and the lower member are welded together. The first welded portions are extended outward from the intake passage formed by the upper member and the middle member, and the second welded portions are extended outward from the intake passage formed by the middle member and the lower member. The middle member is provided with ribs holding the first welded portions and the second welded portions in one piece.