Resin Intake Manifold Vibration Welding Alignment

Solution Overview

Problem

Resin injection molding of intake manifolds faces challenges in forming hollows and flow paths, often requiring separate pieces to be integrated through vibration welding, which can result in misalignment and interference during the process.

Innovation Solution

The intake manifold is designed with a first piece having a branch pipe half and an intake air introducing portion, and a second piece with a branch pipe half and an additional body connected by a connecting portion, allowing for vibration-welding without relative movement, thus maintaining a predetermined distance and reducing interference.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If multiple pieces are integrated by vibration welding to form hollows and flow paths, then the manufacturing flexibility and weight reduction are improved, but the alignment precision and welding reliability deteriorate due to misalignment and interference during the welding process

Engineering Contradiction:

Improvemanufacturing flexibilityVSAvoidalignment precision

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The intake manifold is divided into multiple separately molded resin pieces (first piece, second piece, third piece) that are subsequently integrated through vibration welding. This segmentation allows each piece to be manufactured independently with optimized mold design, improving manufacturing flexibility while enabling weight reduction through resin material selection.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent positions the welded end faces of adjacent pieces at different positions in the direction perpendicular to the vibrating direction, creating a stepped configuration. This dimensional arrangement allows the welded surfaces to be adjacent in the vibrating direction without interfering with each other, thereby resolving the alignment precision issue while maintaining manufacturing flexibility.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Weight of moving object

If multiple pieces are integrated by vibration welding, then the weight and cost are reduced, but the welding process complexity and time increase due to multiple welding operations

Engineering Contradiction:

Improveintake manifold weightVSAvoidwelding process complexity

Core Design Contradiction:

Weight of moving objectVSDevice complexity

Solution Approach 1:

The intake manifold is divided into multiple separately molded resin pieces (first piece, second piece, third piece) that are subsequently integrated through vibration welding. This segmentation allows each piece to be manufactured independently with optimized mold design, improving manufacturing flexibility while enabling weight reduction through resin material selection.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent designs the pieces such that their welded end faces are positioned to be adjacent to each other in the vibrating direction before the welding process begins. This preliminary positioning arrangement simplifies the welding operation by eliminating the need for complex alignment procedures during welding, thereby reducing welding process complexity while still enabling multi-piece construction for weight reduction.

Inventive Principle:

Principle #10Preliminary action

3Shape

If the welded end faces are positioned at the same position perpendicular to the vibrating direction, then the pieces can be continuously formed in the same plane, but the welding reliability decreases due to interference between adjacent pieces

Engineering Contradiction:

Improvepiece continuityVSAvoidwelding reliability

Core Design Contradiction:

ShapeVSReliability

Solution Approach 1:

The patent positions the welded end faces of adjacent pieces at different positions in the direction perpendicular to the vibrating direction, creating a stepped configuration. This dimensional arrangement allows the welded surfaces to be adjacent in the vibrating direction without interfering with each other, thereby resolving the alignment precision issue while maintaining manufacturing flexibility.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

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 enables smooth vibration welding, reducing the number of welding operations and parts, while ensuring strong and aligned connections between the branch pipe and additional body, enhancing the manufacturing efficiency and integrity of the manifold.

Implementation Method 1

The second piece is connected to the first piece by vibration-welding

Methodology Applied

Scientific EffectVibration welding: Vibration

Data Source

PatentUS8683971B2Intake manifold

Publication Date: 2014.04.01 HONDA MOTOR CO LTD

AI summary

An intake manifold includes a first piece and a second piece. The first piece includes a first branch pipe half portion and an intake air introducing portion. The second piece is connected to the first piece by vibration-welding and includes a second branch pipe half portion, an additional body, and a connecting portion. The second branch pipe half portion is connected to the first branch pipe half portion. The additional body is connected to the intake air introducing portion. The second branch pipe half portion and the additional body are spaced apart from each other at a predetermined distance. The connecting portion connects the second branch pipe half portion to the additional body.