Overmolded Structural Support for Composite Intake Manifolds

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Solution Overview

Problem

Composite intake manifolds made from materials like plastics and polymers lack sufficient structural support, leading to issues with noise, vibration, harshness, durability, and strength, particularly in regions without adequate structural elements, which can increase weight and decrease fuel efficiency when thickness is increased or additional structural elements are introduced.

Innovation Solution

An overmolded supporting member with greater tensile strength than the composite material is integrated into the upper outer wall of the intake manifold, enhancing structural integrity without increasing wall thickness or adding internal structural elements, thereby improving air flow performance and reducing material and part costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If the thickness of the outer walls of a composite intake manifold is increased, then the structural integrity is improved, but the weight of the manifold increases

Engineering Contradiction:

Improvestructural integrityVSAvoidweight of manifold

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The patent applies composite materials by integrating a supporting member made of a second material with greater tensile strength into the composite intake manifold made of a first material. This composite structure enhances structural integrity without requiring increased wall thickness, thereby avoiding the weight penalty associated with thicker walls while maintaining strength through material property optimization.

Inventive Principle:

Principle #40Composite materials

2Strength

If additional structural elements are introduced within the hollow body of the manifold, then the structural integrity is improved, but the air flow performance degrades

Engineering Contradiction:

Improvestructural integrityVSAvoidair flow performance

Core Design Contradiction:

StrengthVSProductivity

Solution Approach 1:

The supporting member is strategically positioned within the composite intake manifold to provide localized structural reinforcement only where needed. This local quality approach enhances structural integrity in specific critical areas without introducing structural elements throughout the entire hollow body, thereby preserving air flow performance in regions where flow is critical while providing strength where structurally necessary.

Inventive Principle:

Principle #3Local quality

3Strength

If additional structural elements are introduced within the hollow body of the manifold, then the structural integrity is improved, but the part cost increases

Engineering Contradiction:

Improvestructural integrityVSAvoidpart cost

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The supporting member is integrated into the composite intake manifold as a unified structure, merging the structural reinforcement function with the manifold body. This integration eliminates the need for separate structural elements and assembly operations, thereby reducing part count and manufacturing complexity while achieving the desired structural integrity, which ultimately lowers part cost compared to introducing additional separate structural components.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS8651081B2Intake manifold with overmolded structural enhancement

Publication Date: 2014.02.18 FORD GLOBAL TECH LLC

AI summary

A composite intake manifold coupled to a V-engine is provided. The composite intake manifold includes a supporting member overmolded in an unsupported region of the composite intake manifold.