Shear Catch Manages Intake Manifold Collision Forces
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Solution Overview
Problem
Existing vehicle intake systems face challenges in managing shear forces during collisions, leading to potential shearing of the joint between the upper and lower intake manifolds, which can result in disengagement and increased production costs or weight through additional structural modifications.
Innovation Solution
A shear catch system is introduced, comprising upper and lower components mounted on the intake manifold and cam cover, respectively, that engage to manage shear forces by transferring loads to intermediate components, reducing the risk of joint failure and allowing for deformation, thereby mitigating impact and load transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional structural features or components are added to the intake manifold to increase structural rigidity or guide collision forces, then crash robustness is improved, but production costs and overall weight increase
Solution Approach 1:
A shear catch component is introduced as an intermediary element between the upper intake manifold and the cam cover. This intermediate component absorbs and redirects shear forces during collisions, protecting the intake manifold joint from direct impact while avoiding the need for extensive structural modifications to the manifold itself, thus minimizing weight increase.
Solution Approach 2:
The collision force management function is extracted from the intake manifold structure itself and placed into a separate, dedicated shear catch component. This allows the intake manifold to remain lightweight while the specialized shear catch component handles the crash forces, separating the structural integrity function from the collision protection function.
2Strength
If additional mounting hardware is added to strengthen the joint between upper and lower intake manifolds, then joint strength is improved, but device complexity and production costs increase
Solution Approach 1:
The shear catch component combines multiple functions into a single element: it strengthens the joint between upper and lower intake manifolds, guides collision forces away from the joint, and provides structural support during impact. This integration avoids the need for multiple separate mounting hardware components, reducing device complexity while maintaining joint strength.
3Reliability
If a rigid body is added to the side of the intake manifold opposite the cam cover to guide collision forces, then force guidance is improved in some scenarios, but it provides little protection against shearing forces directed at the intake manifold
Solution Approach 1:
Instead of adding a rigid body to the far side of the intake manifold to guide forces, the shear catch is positioned between the intake manifold and the cam cover. This inverted approach allows the shear catch to directly intercept and manage shear forces at their source, providing comprehensive protection against shearing forces from multiple directions rather than only guiding forces from one side.
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 shear catch system effectively reduces the risk of joint failure, decreases noise, vibration, and harshness (NVH) characteristics, and minimizes the need for additional crash brackets or fastening locations, thus reducing costs and weight while effectively managing engine component movement during collisions.
Implementation Method 1
The shear catch may manage the deformation of intermediate parts to reduce impact and load transfer into components proximate to the manifold during impact events
Implementation Method 2
In the event of a collision, the upper intake manifold may be subjected to excessive shear forces
Data Source
AI summary
Systems are disclosed to restrain movement of engine components in the event of a collision. A system may comprise an upper intake manifold; a cam cover; a shear catch located between the upper intake manifold and the cam cover; an upper component of the shear catch is arranged on the upper intake manifold; a lower component of the shear catch is arranged on the cam cover; and the upper component and the lower component are arranged opposite each other such that they engage when the upper intake manifold is subjected to shear forces. Variations to the size, arrangement, and shape of a shear catch are disclosed herein.