Trough-Shaped Intake Flap with Eccentric Pivot for Reduced Airflow Interference
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Solution Overview
Problem
Existing flap devices for internal combustion engine intake systems face challenges in achieving high precision and low manufacturing costs, while minimizing the influence of flaps on airflow in their open position.
Innovation Solution
Designing trough-shaped flaps with a curved stirrup region and a shell region, actuated by a common metallic shaft with projections, allowing for precise control and reduced airflow interference by coordinating flap positions and shapes with inlet ducts, and using injection-molded plastic flaps with a metallic actuating shaft for cost-effectiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If flaps are configured as integral body with butterfly shape arranged centrally, then manufacturing is simplified, but manufacturing precision and operational precision are reduced
Solution Approach 1:
The flap assembly is segmented into separate components: individual flaps made by injection molding and a common actuating shaft made by metal deformation. This segmentation allows each component to be manufactured with optimized precision and then assembled, resolving the contradiction between manufacturing simplicity and precision.
Solution Approach 2:
The invention uses composite construction combining plastic injection-molded flaps with a metallic actuating shaft. This composite approach leverages the advantages of both materials: plastic for precise complex geometry and metal for structural strength and dimensional stability, thereby achieving both ease of manufacture and high precision.
2Stability of the object's composition
If flaps are arranged centrally with respect to flap pivot axis, then structural symmetry is achieved, but airflow influence in open position is increased
Solution Approach 1:
The flaps are designed with asymmetric geometry relative to the pivot axis, with different radii for the stirrup region and shell region. This asymmetric configuration allows the flaps to be positioned away from the central airflow path when open, reducing airflow obstruction while maintaining structural stability through the overall symmetric arrangement of the flap assembly.
3Device complexity
If common actuating shaft is used for all flaps, then device complexity is reduced, but manufacturing precision control becomes more difficult
Solution Approach 1:
The common actuating shaft serves as an intermediary component that connects and coordinates all individual flaps. The shaft features specifically designed projections that interface with corresponding receptacles on each flap, ensuring precise alignment and synchronized actuation. This intermediary structure simplifies the overall control mechanism while maintaining high manufacturing precision through standardized connection interfaces.
Data Source
AI summary
A valve device for an intake system of an internal combustion engine may include a housing and a flap arrangement. The housing may have one inlet duct per cylinder of the internal combustion engine. The flap arrangement may have a flap for each inlet duct for varying the cross-section of the respective inlet duct through which a flow can pass. The respective flap may be a trough-shaped flap having a curved stirrup region. The respective flap may be arranged between the stirrup ends eccentrically with respect to a flap pivot axis. The flap arrangement may have a common actuating shaft for the common pivoting of the flaps about the flap pivot axis. The actuating shaft may be coupled with an adjusting drive via a lever element having a metallic insert and a plastic body injected onto the insert.