Intake Manifold Intercooler Top Plate Thermal Deformation

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Solution Overview

Problem

The incorporation of an intercooler in the intake manifold leads to thermal contraction and expansion issues, potentially causing cracks and breakage due to the short distance between cooled and heated portions, affecting the product quality and fixing strength.

Innovation Solution

The intake manifold design includes a top plate with recess and groove portions to absorb deformation from thermal expansion and contraction, a gasket for enhanced sealing, and a thicker top plate than the flange for increased rigidity, along with a vacuum pipe and heater for improved control.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If an intercooler is incorporated in the intake manifold, then cooling efficiency is improved, but thermal contraction and expansion cause cracks and breakage

Engineering Contradiction:

Improvecooling efficiencyVSAvoidcrack resistance

Core Design Contradiction:

TemperatureVSReliability

Solution Approach 1:

The top plate is separated from the flange into two independent components. The flange remains fixed to the intake manifold while the top plate can move independently to accommodate thermal expansion and contraction, preventing crack formation at the connection point.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The thickness of the top plate is increased relative to the flange thickness. This parameter change provides greater rigidity to the top plate while still allowing controlled deformation, enabling it to absorb thermal stresses without compromising structural integrity.

Inventive Principle:

Principle #35Parameter changes

2Strength

If the top plate is made thicker for increased rigidity, then fixing strength is improved, but deformation absorption capability is reduced

Engineering Contradiction:

Improvefixing strengthVSAvoidthermal deformation tolerance

Core Design Contradiction:

StrengthVSStability of the object's composition

Solution Approach 1:

By separating the top plate from the flange, the system allows the thicker top plate to move independently relative to the flange. This segmentation enables the top plate to maintain its rigidity and fixing strength while still accommodating thermal deformation through relative movement between the two components.

Inventive Principle:

Principle #1Segmentation

3Reliability

If the flange is fixed tightly to ensure sealing, then sealing performance is improved, but thermal stress concentration increases

Engineering Contradiction:

Improvesealing performanceVSAvoidthermal stress

Core Design Contradiction:

ReliabilityVSStress or pressure

Solution Approach 1:

The separation of the top plate from the flange creates a deformation absorption zone. The gasket maintains sealing between these two separate components, allowing each to move independently under thermal stress while maintaining the seal, thus reducing stress concentration.

Inventive Principle:

Principle #1Segmentation

4Stability of the object's composition

If recess and groove portions are added to the top plate, then deformation absorption is improved, but manufacturing complexity increases

Engineering Contradiction:

Improvethermal deformation absorptionVSAvoidmanufacturing complexity

Core Design Contradiction:

Stability of the object's compositionVSEase of manufacture

Solution Approach 1:

Instead of making the entire top plate complex, recess portions and groove portions are added only at specific locations where thermal deformation occurs. This localized approach provides deformation absorption capability while minimizing the increase in manufacturing complexity.

Inventive Principle:

Principle #3Local quality

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 design allows for controlled thermal deformation, preventing cracks and enhancing the product quality and fixing strength while maintaining desired fastening pressure, and improves the cooling efficiency and mixing of EGR gas with intake air.

Implementation Method 1

the recess portion and the groove portion function to absorb a deformation of the flange that is generated as a result of thermal expansion and thermal contraction of the flange

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Implementation Method 2

the recess portion and the groove portion function to absorb a deformation of the flange that is generated as a result of thermal expansion and thermal contraction of the flange

Methodology Applied

Scientific EffectThermal contraction: Thermal Contraction

Implementation Method 3

an intercooler is incorporated in an intake manifold for cooling compressed charge (intake air) entering the engine... By adopting a cooling construction like this, refrigerant piping in the intercooler can be shortened and simplified

Methodology Applied

Scientific EffectHeat exchange: Heat Exchanger

Data Source

PatentEP3112655B1Intake manifold

Publication Date: 2018.11.28 MITSUBISHI MOTORS CORP

Figure 1~2
Figure 3
Figure 4~5

AI summary

In an intake manifold 1 that incorporates an intercooler 10 that cools intake air entering an engine 30, an opening portion 2 is provided through which a core 20 of the intercooler 10 is inserted. A flange 11 is caused to extend from an end face of the core 20 that is inserted through the opening portion 2 into a flat surface-like shape and is attached to an external surface of an edge portion 3 of the opening portion 2. A top plate 12 is prepared which is formed separately from the flange 11, and the flange 11 is fixed to the external surface of the edge portion 3.