Intake Manifold Reinforcing Bracket Pre-Mounting

Solution Overview

Problem

In vehicle direct injection engines, the intake manifold module is prone to damage during collisions, causing fuel leakage and potential fires due to its interaction with the injector, and existing solutions increase manufacturing costs and assembly complexity.

Innovation Solution

An intake manifold module with a pre-mounted reinforcing bracket using various joining members, such as bushings, welding grooves, and insert molding, to secure the bracket around the injector, reducing assembly time and preventing damage to the module during collisions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a reinforcing bracket is mounted between the intake manifold and the injector in the engine assembling line, then the injector is protected from damage during collisions, but the assembly time increases and piping components may be broken due to interference

Engineering Contradiction:

Improveinjector protectionVSAvoidassembly time

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The reinforcing bracket is pre-mounted on the intake manifold module in a process line before the engine assembly line, rather than being installed during engine assembly. This preliminary action protects the injector during collisions while avoiding interference with piping components and reduces assembly time in the engine assembly line.

Inventive Principle:

Principle #10Preliminary action

2Reliability

If a reinforcing bracket is mounted in the engine assembling line, then the injector is protected from damage, but the manufacturing cost increases due to assembly time delay

Engineering Contradiction:

Improveinjector protectionVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The reinforcing bracket is pre-mounted on the intake manifold module in a process line before the engine assembly line, rather than being installed during engine assembly. This preliminary action protects the injector during collisions while avoiding interference with piping components and reduces assembly time in the engine assembly line.

Inventive Principle:

Principle #10Preliminary action

3Reliability

If the reinforcing bracket is mounted after piping components are assembled, then the injector is protected, but the piping components may be broken due to interference

Engineering Contradiction:

Improveinjector protectionVSAvoidpiping component damage

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The reinforcing bracket is pre-mounted on the intake manifold module in a process line before the engine assembly line, rather than being installed during engine assembly. This preliminary action protects the injector during collisions while avoiding interference with piping components and reduces assembly time in the engine assembly line.

Inventive Principle:

Principle #10Preliminary action

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

The solution effectively reduces manufacturing costs and assembly complexity while preventing fuel leakage and injector damage by securely mounting the reinforcing bracket before engine assembly, thus enhancing safety and efficiency.

Implementation Method 1

The joining member may include a bushing that press-fits and is fixed into the coupling holes formed on the both-end mounting plates, and the bushing may press-fit and be fixed into a stud bolt hole formed on the mount section.

Methodology Applied

Scientific EffectPress-fit: Mechanical Fastener

Implementation Method 2

A welding groove may be formed in each of the coupling holes of the both mounting plates and the welding groove and the bushing may be welded to each other.

Methodology Applied

Scientific EffectWelding: Welding

Data Source

PatentUS8677972B2Intake manifold module for preventing fuel leakage of vehicle and manufacturing method thereof

Publication Date: 2014.03.25 HYUNDAI MOTOR CO LTD

AI summary

An intake manifold module for preventing fuel leakage of a vehicle, may include a runner unit where a runner may be formed, a mount section connected with the runner unit and mounted at an intake port of a cylinder head, and a reinforcing bracket mounted at an edge around an injector installed on the cylinder head in the mount section, wherein the reinforcing bracket may be pre-mounted in a process line prior to an engine assembly line by using a joining member.