Plastic Intake Distributor With Anchored Metal Lining
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Solution Overview
Problem
Current solutions for protecting plastic air intake distributors in vehicles from the high temperatures and soot/tar deposits caused by exhaust gas recirculation in internal combustion engines are either costly, heavy, or prone to thermal detachment, failing to provide adequate mechanical and thermal resistance.
Innovation Solution
A thermoplastic intake distributor composed of two rigid shells with a preformed metallic sheet internally secured using anchoring sites and self-drilling screws, where the anchoring sites are integrated into the thermoplastic material and located outside the internal volume to avoid direct thermal exposure, and the metallic sheet has lateral tabs for secure attachment without additional connecting pieces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a plastic distributor is used, then cost and weight are reduced, but thermal resistance deteriorates under high EGR temperatures
Solution Approach 1:
The patent combines thermoplastic material and metallic material to create a composite distributor structure. The plastic distributor body provides lightweight and cost-effective construction, while the attached metallic sheet provides thermal resistance against EGR temperatures up to 400°C. This composite approach resolves the contradiction by integrating materials with complementary properties.
2Temperature
If a metallic coating is applied by electrodeposition, then thermal resistance is improved, but manufacturing cost increases
Solution Approach 1:
Instead of using expensive electrodeposited metallic coatings, the patent employs a metallic sheet that is mechanically attached to the plastic distributor body. This approach uses more economical materials and attachment methods while achieving the required thermal resistance, thereby reducing manufacturing cost.
3Temperature
If metal sheet is fixed with rivets, then thermal resistance is improved, but assembly complexity and cost increase
Solution Approach 1:
The patent extracts the fastening elements from the internal volume of the distributor by positioning anchoring sites and fastening means at the external periphery. This eliminates the need for complex internal assembly operations and reduces assembly complexity while maintaining thermal resistance through the metallic sheet attachment.
4Strength
If fixing studs are used to attach metal sheet, then mechanical strength is improved, but thermal resistance deteriorates due to low resistance at fastening points
Solution Approach 1:
The patent introduces anchoring sites as intermediary structures that mediate between the metallic sheet and the plastic distributor body. These anchoring sites are positioned at the external periphery where they are not directly exposed to high-temperature gases, allowing the use of mechanical fastening means without compromising thermal resistance in the internal volume.
5Strength
If fastening means are positioned inside the internal volume, then mechanical strength is improved, but thermal resistance deteriorates due to direct thermal exposure
Solution Approach 1:
The patent moves the fastening means from the internal volume (three-dimensional space exposed to hot gases) to the external periphery (different spatial dimension). This dimensional relocation allows the fastening means to be positioned in a region with lower thermal exposure while maintaining their mechanical function, thereby preserving thermal resistance in the internal volume.
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 configuration enhances thermal resistance, mechanical strength, and assembly efficiency while maintaining a lightweight and cost-effective design, ensuring the distributor's integrity under high-temperature conditions and reducing heat transmission to the fixing means.
Implementation Method 1
said or each metallic sheet being mechanically and rigidly bonded to the shell concerned, distributor characterized in that the shell or each shell comprises anchoring sites for attached fastening means, designed to directly secure the metal sheet or sheets to this shell
Data Source
Figure 1A
Figure 1B
Figure 2A
AI summary
The present invention concerns an intake distributor or manifold (1) made from thermoplastic material constituted by two shells (2, 2') assembled together rigidly at respective circumferential peripheral edges (3, 3') and together constituting a distributor body defining a hollow internal space, at least one of the shells (2, 2') comprising a fitted sheet or plate (4, 4') made from metal material, at least partially covering the inner face of the wall of the or each shell (2, 2') in question and preformed so as to substantially conform to the shape of the wall of this shell at least locally, in the manner of a skin, the or each metal sheet (4, 4') being mechanically and rigidly secured to the shell (2, 2') in question. The distributor (1) is characterised in that the or each shell (2, 2') comprises anchoring sites (6) for anchoring attachment means (7) for attaching the or each metal sheet (4, 4') with this shell (2, 2'), these anchoring sites (6) being located in formations (8) made from thermoplastic material situated at the circumferential edge (3, 3') and extending outwards from the wall.