Air Intake Manifold Runner Assembly Segmentation
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Solution Overview
Problem
Existing air intake manifolds are costly to manufacture, lack portability between engine types, and have complex internal passageways that are difficult for end users to modify, leading to restricted airflow and reduced volumetric efficiency.
Innovation Solution
An air intake manifold design featuring upper and lower shells with permanently attached runner assemblies, where the runner components are connected via a support member and welded to the lower shell, allowing for improved structural robustness and user-accessible modification of airflow characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If air intake manifolds use complex curved internal passageways to fit within OEM space limitations, then the manifold can be compact and functional, but the passageways become difficult for end users to modify due to complexity and size
Solution Approach 1:
The manifold is divided into multiple removable components including a manifold body, runner assembly, and plenum chamber that can be separated and reconfigured. This segmentation allows users to access and modify internal passageways without dealing with a single complex curved structure, while still maintaining a compact overall size when assembled.
Solution Approach 2:
The manifold transitions from a fixed curved structure to a dynamic reconfigurable system where runners can be removed, repositioned, or replaced. This allows the internal geometry to be dynamically adjusted by users to optimize airflow characteristics for different applications while maintaining space efficiency.
2Ease of operation
If air intake manifolds use modular assemblies with individually removable runners, then disassembly and interchangeability are easier, but the manifolds lack the structural robustness found in traditional integrated cast, molded or welded manifolds
Solution Approach 1:
The removable runners are permanently attached to the manifold body through welding or adhesive bonding, merging the modular runner components with the main structure. This creates a hybrid design that combines the ease of modular disassembly with the structural robustness of a permanently bonded assembly, eliminating the weakness of purely bolted modular designs.
3Strength
If air intake manifolds are designed as traditional integrated cast, molded or welded structures, then structural robustness is achieved, but interchangeability and ease of modification are reduced
Solution Approach 1:
The integrated structure is segmented into removable runner assemblies that can be interchangeably swapped between different manifold bodies or engine applications. This segmentation provides versatility and adaptability while the welded or bonded connections maintain structural robustness comparable to traditional integrated designs.
4Volume of moving object
If air intake manifolds use complex curved internal passageways, then the manifold fits within OEM space limitations, but manufacturing costs increase
Solution Approach 1:
The complex curved passageways are segmented into separate runner components that can be manufactured using simpler, more cost-effective processes such as injection molding or machining of individual parts. These pre-manufactured runners are then assembled into the final manifold structure, reducing overall manufacturing complexity and cost while maintaining the compact curved geometry needed for OEM space limitations.
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 design enhances airflow efficiency, reduces manufacturing costs, and allows for user modifications while maintaining structural integrity and OEM compatibility, resulting in improved engine performance and efficiency.
Implementation Method 1
the first and second runner shell halves are welded at the first and second mating faces
Implementation Method 2
a single, threaded support member joining together the support member apertures on each runner component to form the runner assembly and provide cantilever force support
Implementation Method 3
a plenum assembly seal that is positioned between the upper and lower shells before attaching them to one another... injector seals that are tethered to the plenum assembly seals at injector positions
Data Source
AI summary
An air intake manifold for an internal combustion engine having a top shell and a base weldment. The base weldment is formed by permanent joining of a bottom shell having a plurality of air outlets with a runner assembly having a plurality of runner components each having an air inlet and an air outlet, wherein the plurality of runner components are attached to one another via a support member to form the runner assembly.