Universal Intake Manifold Mold with Interchangeable Inserts
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Solution Overview
Problem
The manufacturing of intake manifolds for internal combustion engines is complex and costly due to the need for specific molds for each engine type, leading to increased time and complexity in assembly and installation.
Innovation Solution
A method and system for manufacturing a family of intake manifolds using shared molds with interchangeable inserts and sliders, allowing for the production of manifolds for engines with varying numbers of cylinders by forming two portions of the manifold and connecting them through friction welding, reducing the need for multiple molds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If different molds are used for different engine types, then manufacturing precision is improved, but device complexity and cost increase
Solution Approach 1:
A single universal mold is designed to manufacture intake manifolds for multiple engine types (4-cylinder, 6-cylinder, 8-cylinder). The mold includes a family of cavities that can form different manifold configurations, allowing one mold to serve multiple functions and produce manifolds adapted to various engine cylinder arrangements without requiring separate specialized molds for each engine type.
Solution Approach 2:
The universal mold is divided into multiple cavities, each capable of forming a portion of the intake manifold structure. By selectively using different cavity combinations and adjusting mold parameters, the system can produce manifolds with different numbers of outlets and configurations suitable for various engine types, thereby reducing the need for completely separate molds while maintaining manufacturing precision.
2Adaptability or versatility
If modular intake manifolds are used, then adaptability is improved, but assembly complexity and time increase
Solution Approach 1:
The intake manifold is designed as a universal component with a family of integrated cavities that can serve multiple engine types. The manifold structure includes multiple potential outlet locations and pathways that can be configured for 4-cylinder, 6-cylinder, or 8-cylinder engines, allowing a single manifold design to adapt to different engine configurations without requiring modular assembly or multiple separate components.
3Manufacturing precision
If specialized molds are used for each engine type, then manufacturing precision is improved, but loss of time increases
Solution Approach 1:
The patent employs a universal mold that can manufacture intake manifolds for multiple engine types without requiring retooling. The mold contains a family of cavities that can form different manifold configurations, allowing the same mold to produce manifolds for 4-cylinder, 6-cylinder, and 8-cylinder engines. This eliminates the time-consuming retooling process while maintaining manufacturing precision through the integrated cavity design.
Solution Approach 2:
The universal mold incorporates adjustable and reconfigurable elements that allow it to dynamically adapt to different production requirements. The mold can be configured to produce manifolds with different numbers of outlets and varying geometries by utilizing different cavity combinations, enabling rapid switching between product variants without physical retooling and maintaining precision across all configurations.
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 approach enables the cost-effective production of intake manifolds for different engines without retooling, simplifying the assembly and installation process while maintaining performance by using shared molds with interchangeable components.
Implementation Method 1
connecting them through friction welding
Data Source
AI summary
A system for manufacturing a family of intake manifolds includes first and second intake molds. One of the first and second intake molds includes an outlet insert. A first intake manifold includes: a plenum chamber, a plenum chamber air inlet; a first number of intake runner passages; and the first number of outlets. Each of the outlets is fluidly connected to a corresponding one of the first number of intake runner passages. The second intake manifold includes: the plenum chamber; the plenum chamber air inlet; the first number of intake runner passages; and a second number of outlets. Each of the second number of outlets is fluidly connected to a corresponding one of the first number of intake runner passages. At least one of the first number of intake runner passages is not fluidly connected to any one of the second number of outlets of the second intake manifold.