Intake Manifold Cover Braces for NVH Reduction
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Solution Overview
Problem
Existing composite intake manifold assemblies face challenges in mitigating noise and vibration due to pressure pulsations, particularly the rocking mode, which is difficult to address with traditional ribs and external brackets that are heavy, increase part count, and complicate underhood packaging.
Innovation Solution
The integration of braces within the intake manifold assembly, extending from its external surface, which are formed integrally with the assembly through vibration welding, providing additional support and reducing the need for external bracing by incorporating flanges and weld beads for enhanced rigidity and reduced part count.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If external brackets are provided to enhance external stiffness, then noise and vibration are reduced, but weight increases, part count increases, assembly complexity increases, and underhood packaging is interfered with
Solution Approach 1:
The brace is merged with the cover to form a single integral component. The cover includes a shell, flanges, and braces all formed as one piece, eliminating the need for separate external brackets and reducing part count while maintaining stiffness and reducing NVH effects
Solution Approach 2:
The cover structure serves multiple functions simultaneously: it encloses the cavity, provides flanges for joining, and incorporates braces for stiffness enhancement. This multi-functional design eliminates the need for dedicated external bracing components
2Object-affected harmful factors
If external brackets are provided to enhance external stiffness, then noise and vibration are reduced, but weight increases
Solution Approach 1:
The brace is merged with the cover to form a single integral component. The cover includes a shell, flanges, and braces all formed as one piece, eliminating the need for separate external brackets and reducing part count while maintaining stiffness and reducing NVH effects
3Object-affected harmful factors
If ribs are used to mitigate NVH effects, then some vibration is reduced, but the rocking mode remains difficult to mitigate
Solution Approach 1:
The brace extends outwardly from the cover in a direction perpendicular to the plenum shell, creating a three-dimensional bracing structure. This outward extension provides additional support against rocking motion that cannot be achieved with ribs alone, effectively mitigating the rocking mode while maintaining NVH reduction
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 solution effectively reduces noise and vibration while being lighter, cheaper, and easier to assemble, eliminating the rocking mode and minimizing the need for external bracing, thus improving the structural integrity and NVH performance of the intake manifold.
Implementation Method 1
The weld beads of the pieces that are to be coupled together are brought in contact with each other and then vibrated by a welder causing the weld beads to melt
Data Source
AI summary
A composite material intake manifold cover includes braces integral to the outside surface of the cover to stiffen the cover and reduce noise and vibration associated with the cover. The cover has a flange around the periphery with a raised weld bead, the weld bead provided for welding the cover to a mating piece. The flange extends outwardly from the cover for a first distance over most of the periphery and a second distance to support the braces over the remainder of the periphery. The braces extend upwardly from the upper surface of the flange at the sections of the flange extending out the second distance and may be placed between adjacent intake runner ports. By providing portions of the flange extending out a greater distance, a more substantial brace can be supported, thereby improving the noise and vibration characteristics relative to conventional stiffening ribs.