Intake Manifold PCV Check Valve Retainer Design
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Solution Overview
Problem
Check valves in intake manifolds of certain engines, such as those in the Chevrolet Cruz and Buick Encore, have a high failure rate due to dislodging from their intended position, leading to improper engine operation and backflow of gases, with existing solutions either requiring skilled modification or potentially voiding warranties.
Innovation Solution
An insert is designed to secure the check valve in its proper location within the manifold, maintaining the original equipment manufacturer's design and using a retainer that is heat-staked between manifold sections, ensuring the check valve remains in place without interfering with its operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the check valve is retained only by a press fit nipple, then the manifold design remains simple and easy to manufacture, but the check valve has a high failure rate and can be dislodged from its intended position
Solution Approach 1:
The retainer is divided into a first portion that receives the nipple and a second portion that engages the manifold body, allowing each section to perform its specific function independently while working together to secure the check valve
Solution Approach 2:
The nipple is nested within the first portion of the retainer, and the entire retainer assembly is then installed within the manifold body, creating a nested structure that secures the check valve without adding external complexity
2Reliability
If modification kits are used to secure the check valve, then the check valve retention is improved, but the manufacturer's warranty may be voided and skilled modification is required
Solution Approach 1:
The retainer is pre-formed with the nipple receiving portion and engagement features during manufacturing, eliminating the need for field modifications or complex installation procedures
Solution Approach 2:
The retainer acts as an intermediary component between the nipple and the manifold body, providing a secure connection without requiring direct modification of the original manifold structure
3Reliability
If a retainer is heat-staked between manifold sections, then the check valve is securely fixed in position, but the manufacturing process becomes more complex
Solution Approach 1:
The retainer material is selected to undergo thermal expansion and plastic deformation during heat staking, allowing it to be formed into the manifold sections and creating a permanent mechanical lock
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 prevents the check valve from dislodging, ensuring proper engine operation by maintaining the OEM design and avoiding unintended modifications that could void warranties.
Implementation Method 1
The preferred retainer is heat staked and held in place between the sections of manifold
Data Source
AI summary
An intake manifold with an internal check valve that operates in coordination with a Positive Crankcase Valve has a check valve retainer that is mounted within the manifold and contacts the check valve to maintains the check valve in position and avoid dislodgement.