Air Intake Manifold with Nested Blow-By Gas Passage

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Solution Overview

Problem

The existing air intake apparatuses for internal combustion engines face challenges in downsizing and reducing the number of components due to protruding distribution passages for blow-by gas, which increase the overall size and component count.

Innovation Solution

An air intake apparatus with an integrated external gas passage formed by bonding multiple pieces along a split plane, eliminating the need for external connectors and allowing the blow-by gas passage to be enclosed within the main body, reducing size and component count, while optimizing gas flow and heat retention to prevent condensation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If the distribution passage for introducing blow-by gas projects outward from the outer wall surface of the manifold main body, then the connector can be easily connected to the cylinder head, but the entire manifold increases in size

Engineering Contradiction:

Improveease of connectionVSAvoidsize of manifold

Core Design Contradiction:

Ease of operationVSVolume of stationary object

Solution Approach 1:

The distribution passage is nested inside the manifold main body rather than projecting outward. The passage is formed as an internal cavity within the molded manifold structure, allowing the blow-by gas to be distributed to air intake pipes without requiring external protruding components. This nesting approach maintains ease of connection while significantly reducing the overall size of the manifold.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The distribution passage and the manifold main body are merged into a single integrated component. The passage is formed directly within the manifold structure during the molding process, eliminating the need for separate external distribution components. This merging reduces the number of parts and minimizes the overall manifold size while maintaining functional connectivity to the cylinder head.

Inventive Principle:

Principle #5Merging (Combining)

2Ease of operation

If the distribution passage projects outward from the manifold main body, then the connector can be accessed for connection, but the number of components increases

Engineering Contradiction:

Improveease of connectionVSAvoidnumber of components

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The distribution passage is merged with the manifold main body as an internal feature rather than a separate component. The passage is formed as an integral part of the molded manifold structure, eliminating the need for external distribution tubes or separate connector housings. This merging reduces the component count while maintaining accessibility for connection to the cylinder head.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The manifold main body serves multiple functions: it acts as both the structural housing and contains the distribution passage internally. The integrated structure performs both containment and distribution functions simultaneously, reducing the need for separate specialized components and simplifying the overall assembly.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Volume of stationary object

If the external gas passage is enclosed inside the air intake apparatus main body, then the size is reduced and components are minimized, but the gas may be influenced by outside air temperature

Engineering Contradiction:

Improvesize of apparatusVSAvoidinfluence of outside air temperature

Core Design Contradiction:

Volume of stationary objectVSObject-affected harmful factors

Solution Approach 1:

The external gas passage is nested within the air intake apparatus main body, utilizing the internal volume of the manifold structure. By nesting the passage inside the existing housing, the overall size is reduced without requiring additional external space. The enclosure also provides thermal protection from outside air while maintaining gas flow functionality.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The air intake apparatus main body creates a relatively isolated environment for the external gas passage, shielding it from direct exposure to outside air temperature variations. This enclosure acts as a thermal buffer, reducing the harmful influence of extreme outside temperatures on the blow-by gas and EGR gas flowing through the passage.

Inventive Principle:

Principle #39Inert atmosphere (Inert environment)

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 downsizes the air intake apparatus, reduces component count, minimizes external influences, and prevents condensation and freezing of blow-by gas, ensuring efficient gas mixing and improved mountability in engine rooms.

Implementation Method 1

a manifold main body (air intake apparatus main body) including four air intake pipes is configured by bonding a first member and a second member (a plurality of pieces) each having a half structure to each other by vibration welding

Methodology Applied

Scientific EffectVibration welding: Ultrasonic Vibration

Data Source

PatentUS10612499B2Air intake apparatus

Publication Date: 2020.04.07 AISIN SEIKI KK

AI summary

This air intake apparatus includes an air intake apparatus main body including a plurality of pieces bonded to each other along a split plane and an external gas passage formed inside the air intake apparatus main body by bonding the plurality of pieces to each other and including an external gas receiving port that directly receives external gas from a cylinder head and an external gas introduction port that introduces the external gas into a surge tank.