Resin Intake Manifold Structure for Simpler Engine Assembly
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Solution Overview
Problem
Conventional intake systems for engines, particularly those on vehicles like snowmobiles, have complex structures with numerous components and require complicated assembly, leading to increased costs.
Innovation Solution
An intake manifold made of resin with integrated surge tank, branch pipes, and linking parts, featuring reinforcement ribs and a two-part molding structure, simplifies assembly by integrating key components and enhancing mechanical strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple separate components (surge tank, branch pipes, linking parts) are used in the intake manifold, then assembly flexibility and component replacement are improved, but the number of components increases and assembly complexity increases
Solution Approach 1:
The patent combines the surge tank, multiple branch pipes, and linking parts into a single integrally molded resin manifold. This merging eliminates the need for separate components and their associated connections, directly reducing the total component count while maintaining the functional flexibility needed for assembly and replacement.
2Ease of operation
If multiple separate components are used with spigot joints and bands, then ease of assembly and disassembly is improved, but assembly time and labor cost increase
Solution Approach 1:
By integrating all manifold components into a single molded piece, the patent eliminates multiple assembly steps involving spigot joints and bands. The single-component design allows for faster installation and removal as a complete unit, significantly reducing assembly time and labor requirements.
3Ease of repair
If multiple separate components are used, then ease of repair and replacement is improved, but manufacturing cost and assembly complexity increase
Solution Approach 1:
The integrally molded manifold reduces the system to a single replaceable component. When repair or replacement is needed, the entire manifold is replaced as one unit rather than assembling or disassembling multiple parts, simplifying the repair process despite the initial higher manufacturing cost of the integrated design.
4Ease of manufacture
If resin material is used for the intake manifold, then manufacturing cost and weight are reduced, but mechanical strength and durability may be compromised
Solution Approach 1:
The patent employs resin as the manifold material, leveraging its advantages of low cost, light weight, and corrosion resistance. The integral molding process and design optimizations compensate for any perceived strength limitations, achieving a balance between manufacturing economy and mechanical performance suitable for the application.
5Device complexity
If integrally molded structure is used, then component count and assembly complexity are reduced, but manufacturing precision and molding complexity increase
Solution Approach 1:
The patent successfully integrates multiple manifold components into a single molded piece, achieving the desired component reduction. The molding process and design considerations address the increased manufacturing precision requirements inherent in integral molding, balancing the benefits of fewer parts with the challenges of complex mold fabrication and production precision.
Data Source
AI summary
An intake manifold made of resin applied to an engine includes: a surge tank that defines an internal space temporarily storing intake air, an inlet, and a flange part configured to fix a throttle body around the inlet; multiple branch pipes that are integrally molded with the surge tank and include tubular fitting parts at respective tip regions; and a linking part integrally molded with the multiple branch pipes to link the multiple branch pipes to each other upstream of the tubular fitting parts.