Intake manifold secondary gas distribution via structural posts

Patent metadata

Field	Value
Publication number	US-9541044-B2
Application number	US-201514606090-A
Country	US
Kind code	B2
Filing date	Jan 27, 2015
Priority date	Jan 27, 2015
Publication date	Jan 10, 2017
Grant date	Jan 10, 2017

Abstract

An intake manifold for an internal combustion engine comprises upper and lower shell members with outer flanges. The shell members define a manifold cavity having a plenum and a plurality of runners. The upper shell includes an upper post formed as an indentation into the plenum with a tunnel wall and a terminus wall. The lower shell includes a lower post formed as an indentation into the plenum with a tunnel wall and a terminus wall. The terminus walls are attached to provide a brace across the plenum. One of the posts includes an orifice penetrating the tunnel wall. A sealed coupler extends from the one post and is adapted to receive a secondary gas for mixing within the plenum. Thus, secondary gases can be introduced without additional structures that could impede gas flow and could increase manufacturing cost.

First claim

What is claimed is:

1. An intake manifold comprising:
an upper shell member with an outer flange;
a lower shell member with an outer flange joined to the outer flange of the upper shell member to define a manifold cavity having a plenum and a plurality of runners, wherein the upper shell includes an upper post formed as an indentation into the plenum with a tunnel wall and a terminus wall, wherein the lower shell includes a lower post formed as an indentation into the plenum with a tunnel wall and a terminus wall, wherein the terminus walls are attached to provide a brace across the plenum, and wherein one of the posts includes an orifice penetrating the tunnel wall; and
a sealed coupler extending from the one post and adapted to receive a secondary gas for mixing within the plenum.

2. The manifold of claim 1 wherein the coupler is comprised of a separate unit sealed to the tunnel wall by an O-ring, wherein the orifice is disposed intermediate of the O-ring and the terminus wall.

3. The manifold of claim 2 further comprising a bracket mounting the coupler onto the shell member and compressing the O-ring.

4. The manifold of claim 1 wherein the upper and lower shell members are comprised of molded polymeric material, and wherein the outer flanges and the terminus walls are joined by friction welding.

5. The manifold of claim 1 wherein the one post is the upper post.

6. The manifold of claim 1 further comprising a flow guide on a plenum side of the tunnel wall of the one post to deflect secondary gas passing through the orifice into the plenum.

7. A method of manufacturing an intake manifold for an internal combustion engine, comprising the steps of:
molding a polymeric upper shell member having an outer flange and an upper post section formed as an indentation with a tunnel wall and a terminus wall;
molding a polymeric lower shell member having an outer flange and a lower post section formed as an indentation with a tunnel wall and a terminus wall;
friction welding the upper and lower shell members at the outer flanges and at the terminus walls to define a plenum with the joined post sections providing a brace across the plenum reducing vibrations, wherein the tunnel wall of one of the shell members includes an orifice; and
mounting a sealed coupler extending from the post section of the one shell member adapted to convey a secondary gas through the orifice for mixing within the plenum.

Assignees

• Ford Global Tech Llc

Inventors

• Host Ray
• Kulkarni Milind B
• Tran Calvin C
• Simon Joshua D

Classifications

• F02M26/17

  in relation to the intake system · CPC title

• F02M35/10321

  Plastics; Composites; Rubbers · CPC title

• F02M35/10222

  Exhaust gas recirculation [EGR]; Positive crankcase ventilation [PCV]; Additional air admission, lubricant or fuel vapour admission · CPC title

• F02M35/1036 Primary

  by welding, bonding or the like (welding plastic materials together in general B29C65/02) · CPC title

• F02M35/10347

  Moulding, casting or the like · CPC title