Polyphenylene Sulfide Sleeve for Nylon Coolant Cross-Over

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Solution Overview

Problem

Existing air intake manifolds for engines are costly and heavy due to metal production methods, and polymer alternatives degrade when exposed to engine coolant, requiring additional manufacturing steps for metal coolant cross-overs.

Innovation Solution

A polymer air intake manifold with a polyaromatic sulfide sleeve that separates the coolant from the polymer, preventing degradation and reducing production costs and weight by using a polymer coolant cross-over.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a metal air intake manifold with integrally formed coolant cross-over is used, then durability and resistance to coolant degradation are improved, but weight and production cost increase

Engineering Contradiction:

Improveresistance to coolant degradationVSAvoidweight of air intake manifold

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The air intake manifold is divided into separate components: a polymer body and a separate coolant cross-over assembly. This segmentation allows each component to be optimized independently - the polymer body for weight reduction and the metal coolant cross-over for durability where it contacts coolant.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A polymer coolant cross-over is introduced as an intermediary component between the metal cross-over and the engine coolant. This intermediary protects the polymer material from direct contact with degrading coolant while allowing thermal management to function.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Weight of moving object

If a polymer air intake manifold is used, then weight and production cost are reduced, but resistance to coolant degradation deteriorates

Engineering Contradiction:

Improveweight of air intake manifoldVSAvoidresistance to coolant degradation

Core Design Contradiction:

Weight of moving objectVSReliability

Solution Approach 1:

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

A polymer sleeve or coating is applied to the metal coolant cross-over to create a protective barrier. This thin film prevents direct contact between the coolant and polymer materials, eliminating chemical degradation while maintaining the benefits of polymer construction.

Inventive Principle:

Principle #30Flexible shells and thin films

3Reliability

If a metal coolant cross-over is mechanically attached to a polymer air intake manifold, then resistance to coolant degradation is improved, but production complexity and cost increase

Engineering Contradiction:

Improveresistance to coolant degradationVSAvoidmanufacturing operations

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The polymer body and coolant cross-over are combined into a single integrally formed polymer component through injection molding. This merging eliminates the need for separate metal cross-over parts and mechanical attachment operations, reducing manufacturing complexity while maintaining durability through the polymer sleeve design.

Inventive Principle:

Principle #5Merging (Combining)

4Strength

If casting and milling operations are used to produce a metal air intake manifold, then structural strength is improved, but production cost and manufacturing complexity increase

Engineering Contradiction:

Improvestructural strength of air intake manifoldVSAvoidproduction cost

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

Traditional mechanical manufacturing processes (casting and milling) are replaced with injection molding technology. This substitution enables integrally forming complex three-dimensional polymer components with high strength-to-weight ratio, eliminating costly multi-step metal fabrication while maintaining structural integrity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 reduces the overall weight and production costs of the air intake manifold, enhancing fuel efficiency by using a polymer coolant cross-over resistant to physical, thermal, and chemical degradation, while minimizing manufacturing operations.

Implementation Method 1

The sleeve comprises a polyaromatic sulfide and is disposed within the passage for separating the engine coolant and the polymer which forms the coolant cross-over to prevent degradation of the polymer by the engine coolant

Methodology Applied

Scientific EffectChemical resistance:

Data Source

PatentUS8156913B2Polyphenylene sulfide sleeve in a nylon coolant cross-over of an air intake manifold

Publication Date: 2012.04.17 SYENSQO SA

AI summary

The subject invention provides a coolant cross-over for circulating an engine coolant between a first engine component, e.g., a first cylinder head, and a second engine component, e.g., a second cylinder head. The coolant cross-over defines a first outlet in fluid communication with the first engine component, a second outlet in fluid communication with second engine component, and further defines a passage interconnecting the first outlet and the second outlet. The coolant cross-over comprises a polymer. A sleeve comprises polyaromatic sulfide and is disposed within the passage for separating the engine coolant from the nylon which forms the coolant cross-over to prevent physical, thermal and/or chemical degradation of the polymeric coolant cross-over by the engine coolant.