Method and system for manufacturing a family of intake manifolds for a family of internal combustion engines

Patent metadata

Field	Value
Publication number	US-2019107086-A1
Application number	US-201816213105-A
Country	US
Kind code	A1
Filing date	Dec 7, 2018
Priority date	Mar 15, 2017
Publication date	Apr 11, 2019
Grant date	—

Abstract

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.

First claim

What is claimed is:

1 . A system for manufacturing a family of intake manifolds including at least a first intake manifold and a second intake manifold for a family of engines including at least a first engine and a second engine,
the first engine including a first number of cylinders, the second engine including a second number of cylinders, the second number being smaller than the first number, the second number being at least one,
the system comprising:
a first intake mold for molding a first portion of any one of the family of intake manifolds including a first portion of a plenum chamber;
a second intake mold for molding a second portion of any one of the family of intake manifolds including a second portion of the plenum chamber,
one of the first and second intake molds comprising an outlet insert for use with one of the first and second intake molds for forming at least one outlet,

wherein, when manufactured by the system,
the first intake manifold comprises:
the plenum chamber,
a plenum chamber air inlet;
the first number of intake runner passages; and
the first number of outlets, each of the outlets being fluidly connected to a corresponding one of the first number of intake runner passages and being configured for fluid connection to a corresponding one of the first number of cylinders; and

the second intake manifold comprises:
the plenum chamber;
the plenum chamber air inlet;
the first number of intake runner passages; and
the second number of outlets, each of the second number of outlets being fluidly connected to a corresponding one of the first number of intake runner passages and being configured for fluid connection to a corresponding one of the second number of cylinders, at least one of the first number of intake runner passages of the second intake manifold not being fluidly connected to any one of the second number of outlets of the second intake manifold.

2 . The system of claim 1 , wherein:
one of the first and second intake molds further comprises a fuel injector port insert for forming at least one fuel injector port; and when manufactured by the system:
the first intake manifold comprises the first number of fuel injector ports, each of the fuel injector ports being fluidly connected to a corresponding one of the first number of intake runner passages; and
the second intake manifold comprises at least the second number of fuel injector ports, each of the fuel injector ports being fluidly connected to a corresponding one of the first number of intake runner passages,
at least one of the first intake manifold and the second intake manifold having been formed by using the fuel injector port insert.

3 . The system of claim 2 , wherein the fuel injector port insert is integrated with the outlet insert.

4 . The system of claim 1 , wherein:
one of the first and second intake molds further comprises a flange insert for forming at least one mounting hole in a mounting flange; and when manufactured by the system:
the first intake manifold comprises a first mounting flange having a first pattern of mounting holes, the first mounting flange being configured for mounting the first intake manifold to the first engine having the first number of cylinders; and
the second intake manifold comprises a second mounting flange having a second pattern of mounting holes, the second pattern of holes being different from the first pattern of holes, the second mounting flange being configured for mounting the second intake manifold to the second engine having the second number of cylinders,
at least one of the first and second mounting flanges having been formed using the flange insert.

5 . The system of claim 4 , wherein the flange insert is integrated with the outlet insert.

6 . The system of claim 1 , wherein:
one of the first and second intake molds further comprises a slider for forming at least one portion of the first intake manifold and the second intake manifold; and when manufactured by the system:
the first intake manifold comprises the at least one portion; and
the second intake manifold comprises the at least one portion.

Assignees

• Brp Rotax Gmbh & Co Kg

Inventors

• Schallauer Martin
• Stiebinger Christian
• Neubacher Hermann
• Sauer Michael

Classifications

• F02M35/112

  for engines with cylinders all in one line · CPC title

• B29C45/2673

  with exchangeable mould parts, e.g. cassette moulds (B29C45/1756 takes precedence) · CPC title

• B29C65/06

  using friction, e.g. spin welding {(non-plastics elements to plastic elements B29C65/645)} · CPC title

• B29L2031/7492

  Intake manifold · CPC title

• F02M35/10072

  Intake runners · CPC title