Intake Member Annular Step for Fuel Accumulation Prevention
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Solution Overview
Problem
Existing intake manifolds with resin components face challenges in accurately aligning core end portions, leading to fuel accumulation issues due to eccentricities, which increases production costs and time when machining is required to rectify the problem.
Innovation Solution
A straddled vehicle design featuring an intake member with an annular step on its inner wall, where the connecting wall portion is directed downstream, preventing fuel accumulation and eliminating the need for machining, thus reducing fuel accumulation and manufacturing time and effort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the end portions of the first core and the second core are butted against each other to form the intake manifold, then the intake manifold can be manufactured using molding, but eccentricity between the core end portions creates steps on the inner wall that cause fuel accumulation
Solution Approach 1:
The patent applies preliminary action by designing the first core and second core with predetermined dimensions and shapes before the molding process. The first core is designed with a first end portion having a specific outer diameter, and the second core is designed with a second end portion having a larger outer diameter. This preliminary design ensures that when the cores are butted against each other, they form an annular step with a specific geometry that prevents fuel accumulation, rather than requiring post-manufacturing adjustments or achieving perfect alignment.
Solution Approach 2:
The patent applies asymmetry by intentionally designing the first core and second core with different outer diameters at their end portions. The second end portion of the second core has a larger outer diameter than the first end portion of the first core. This asymmetric design creates an annular step with a connecting wall portion that has a specific inclination, transforming the potentially harmful eccentricity into a beneficial geometric feature that directs fuel away from accumulation zones.
2Object-affected harmful factors
If machining such as shot peening is performed to remove the step on the inner wall, then fuel accumulation is prevented, but production cost and production time increase
Solution Approach 1:
The patent applies the blessing in disguise principle by converting the potentially harmful step formed by eccentric core alignment into a beneficial geometric feature. Instead of viewing the step as a defect to be eliminated through machining, the invention designs the step with specific characteristics: the connecting wall portion has an inclination such that its downstream end is positioned more outwardly than its upstream end. This configuration causes the step to function as a fuel redirector, guiding fuel away from accumulation zones and toward the engine, thereby preventing fuel accumulation without requiring any post-manufacturing machining operations.
3Object-affected harmful factors
If machining is added to remove the step, then fuel accumulation is reduced, but the amount of work and time required to manufacture the intake member increases
Solution Approach 1:
The patent applies the blessing in disguise principle by converting the potentially harmful step formed by eccentric core alignment into a beneficial geometric feature. Instead of viewing the step as a defect to be eliminated through machining, the invention designs the step with specific characteristics: the connecting wall portion has an inclination such that its downstream end is positioned more outwardly than its upstream end. This configuration causes the step to function as a fuel redirector, guiding fuel away from accumulation zones and toward the engine, thereby preventing fuel accumulation without requiring any post-manufacturing machining operations.
Solution Approach 2:
The patent applies self-service by designing the annular step with inherent geometric features that automatically prevent fuel accumulation. The connecting wall portion's inclination creates a self-draining effect where fuel naturally flows along the wall toward the engine rather than accumulating at the step. This self-service mechanism eliminates the need for external intervention through machining operations, allowing the intake manifold to function optimally straight out of the molding process without additional time-consuming steps.
Data Source
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AI summary
An annular step (73) is formed on an inner wall (51) of an intake member (50). The annular step (73) includes an upstream wall portion (74), a downstream wall portion (76), and a connecting wall portion (75). The connecting wall portion (75) connects a first connecting end (75a) of the upstream wall portion (74) and a second connecting end (75b) of the downstream wall portion (76) with each other. The second connecting end (75b) of the downstream wall portion (76) is disposed at a more outward position than the first connecting end (75a) of the upstream wall portion (74) in a radial direction (Dr) of the intake member (50), and the connecting wall portion (75) extends outwardly in the radial direction (Dr) of the intake member (50) from the first connecting end (75a) toward the second connecting end (75b).