Charge motion control valve seal and method of assembly

Patent metadata

Field	Value
Publication number	US-10087899-B2
Application number	US-201514966594-A
Country	US
Kind code	B2
Filing date	Dec 11, 2015
Priority date	Dec 11, 2015
Publication date	Oct 2, 2018
Grant date	Oct 2, 2018

Abstract

In an intake manifold that has charge-motion-control valves (CMCVs), a gap exists between the flapper valves and the wall of the intake runners. Although the gap is maintained as small as practical, it cannot be eliminated because manufacturing tolerances and temperature variations to which the intake manifold is subjected must be accommodated to prevent binding of the flapper valves. Some flow makes an end run through the gap leading to undesirable fluid mechanics. Disclosed herein is a seal that is positioned to rest gently upon the flapper valve near the gap such that the gap is substantially sealed off while applying a modest force on the CMCV so that the actuation torque is minimally impacted. The seal has a press-in-place portion inserted into a pocket formed in the manifold to hold it in place and a lip portion that extends out from the press-in-place portion to obstruct the gap.

First claim

We claim:

1. An intake manifold, comprising:
a lower intake manifold section defining an intake runner and a pocket;
a rotatable shaft passing through the intake runner;
a flapper valve coupled to the rotatable shaft; and
a seal disposed between a side of the runner proximate the shaft and the flapper valve coupled to the shaft wherein the seal has a press-in portion having retention ribs; and the press-in portion is pressed into the pocket.

2. The intake manifold of claim 1 wherein:
the seal has two portions: the press in portion and a lip portion.

3. The intake manifold of claim 2 wherein:
the press-in-place portion of the seal has at least one pilot tab extending outwardly from a surface of the press-in-place portion of the seal;
the pocket has at least one notch defined therein; and
the pilot tab engages with the notch when the seal is installed in the pocket to thereby ensure that the seal is installed in the proper orientation.

4. The intake manifold of claim 2 wherein the thickness of the lip portion of the seal is less than the thickness of the press-in-place portion of the seal.

5. The intake manifold of claim 2 wherein the lip portion of the seal touches the flapper valve proximate where the shaft passes through the flapper valve.

6. The intake manifold of claim 2 wherein:
the seal is fabricated of a flexible material; and
a tip of the lip portion of the seal interferes with flapper valve proximate where the shaft passes through the flapper valve such that the lip portion of the seal bends and thereby presses against the flapper valve.

7. The intake manifold of claim 1 wherein:
the seal has two portions: a thicker portion and a thinner lip portion;
the thicker portion engages with the lower intake manifold section; and
the lip portion presses against the flapper valve proximate where the shaft passes through the flapper valve.

8. An intake manifold for an internal-combustion engine, comprising:
a lower intake manifold section having a plurality of intake runners, one intake runner leading toward each cylinder of the engine;
a rotatable shaft passing through at least two of the intake runners with the shaft being substantially perpendicular to the direction of flow in the runners;
flapper valves coupled to the rotatable shaft with one flapper valve disposed in each of the at least two of the intake runners through with the rotatable shaft passes; and
a seal provided behind each of the flapper valves in the at least two intake runners wherein each seal has a portion that engages the lower intake manifold section and a portion that is biased against the flapper valve proximate where the shaft passes through the flapper valve.

9. The intake manifold of claim 8 wherein:
the lower intake manifold section defines a pocket associated with each of the at least two runners; and
the portion of the seal that engages with the lower intake manifold section has a plurality of retention ribs that extend outwardly from the seal and press against the pocket when installed.

10. The intake manifold of claim 9 wherein:
the portion of the seal that engages with the lower intake manifold section has at least one pilot tab extending outwardly from its surface;
the pocket has at least one notch defined therein; and
the pilot tab engages with the notch when the seal is installed in the pocket to thereby ensure that the seal is installed in the proper orientation.

11. The intake manifold of claim 8 wherein:
a gap associated with each of the at least two intake runners exists between a wall of the intake runner and an end of the flapper valve through which the rotatable shaft passes; and
the portion of the seal biased against the flapper valve largely obstructs the gap.

12. The intake manifold of claim 8 wherein:
the lower intake manifold section is made of a material with a predetermined color; and
the seals are made of a material that has a color that contrasts with the predetermined color.

13. The intake manifold of claim 8 , further comprising:
an upper intake manifold section affixed to the lower intake manifold section wherein when the upper intake manifold section is affixed to the lower intake manifold section, the rotatable shaft with the flapper valves coupled to the rotatable shaft and the seals are captured in place.

14. An intake manifold, comprising:
a molded lower intake manifold section having: a plurality of intake ducts; and a plurality of retention features each adapted to accept a portion of a seal;
a plurality of molded seals with the seals engaged into the retention features in the lower intake manifold wherein:
the lower manifold section is provided with at least one notch proximate each of the retention features for the seals;
each seal has at least one pilot tab that protrudes outwardly from a side of the seal; and

the pilot tabs of the seals engage with the notches.

15. The intake manifold of claim 14 , further comprising: a charge-motion-control valve assembly that is secured into the lower intake manifold section.

16. The intake manifold of claim 15 wherein the CMCV assembly is secured into the lower intake manifold section after the seals are engaged with the retention features in the lower intake manifold section.

17. The intake manifold of claim 15 , further comprising: a molded upper intake manifold section that is welded onto the lower upper intake manifold section.

18. The intake manifold of claim 14 , wherein:
the retention features are channels formed in a wall of the lower intake manifold section; and
the seals have a protruding member that engages with the channels, the intake manifold further comprising:
a molded upper intake manifold section affixed to the lower intake manifold section wherein an open end of the channels in the lower intake manifold section is closed off when the upper intake manifold section is welded to the lower intake manifold section such that the seals are captured between the upper and lower intake manifold sections.

Assignees

• Ford Global Tech Llc

Inventors

• Tomlinson Samuel Jeffrey
• Snow Christopher
• Newman Christopher William

Classifications

• F02M35/10354

  Joining multiple sections together (joining plastic materials together in general B29C65/00) · CPC title

• F02M35/104 Primary

  Intake manifolds · CPC title

• F02M35/10347

  Moulding, casting or the like · CPC title

• F02M35/10262

  Flow guides, obstructions, deflectors or the like (for generating a charge motion in the cylinder F02B31/00; for re-atomising condensed fuel or homogenising fuel-air mixture F02M29/00) · CPC title

• F02D9/1045

  for sealing of the flow in closed flap position, e.g. the housing forming a valve seat · CPC title