Patent Publication Number: US-2023134794-A1

Title: Flow control member for a vehicle

Description:
BACKGROUND 
     Technical Field 
     The present disclosure generally relates to a flow control member for a vehicle. More specifically, the present disclosure relates to a flow control member disposed between a throttle valve and an intake manifold to provide laminar flow characteristics to air flowing therethrough. 
     Background Information 
     An air intake system of a vehicle includes an air intake passage supplying air to an intake manifold of an internal combustion engine. A throttle valve is disposed in the air intake passage upstream of the air intake manifold. The throttle valve controls the flow of air into the intake manifold. The air passing through the throttle valve can become turbulent. The turbulent air flow reduces air flow distribution in the intake manifold, which results in a pressure loss and a decreased volumetric efficiency in the internal combustion engine, thereby reducing engine performance. 
     SUMMARY 
     A need exists for a flow control member for a vehicle that controls the flow of air downstream of a throttle valve of an air intake system. 
     In view of the state of the known technology, one aspect of the present disclosure is to provide a flow control member for a vehicle. The flow control member includes a body, a plurality of mounting tabs, and a panel member. The body has an outer surface and an inner surface. An air passage through the body is defined by the inner surface. A plurality of mounting tabs extends outwardly from the outer surface of the body. Each of the mounting tabs is configured to receive a fastener to connect the flow control member to an intake passage of the vehicle. A panel member is disposed in the air passage. The panel member has a plurality of openings extending therethrough. 
     Another aspect of the present disclosure is to provide an air intake system for a vehicle. The air intake system includes an intake manifold, an intake passage, a throttle valve, and a flow control member. The intake passage is configured to supply air to the intake manifold. The throttle valve is disposed in the intake passage. The flow control member is disposed between the throttle valve and the intake manifold. The flow control member includes a body having an outer surface and an inner surface. An air passage through the body is defined by the inner surface. A panel member is disposed in the air passage. The panel member has a plurality of openings extending therethrough. 
     Also other objects, features, aspects and advantages of the disclosed flow control member for a vehicle will become apparent to those skilled in the art from the following detailed description, which, taken in conjunction with the annexed drawings, discloses exemplary embodiments of the flow control member for a vehicle. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Referring now to the attached drawings which form a part of this original disclosure: 
         FIG.  1    is a perspective view of a flow control member connected to an intake manifold of a vehicle in accordance with an exemplary embodiment; 
         FIG.  2    is an elevational view in cross section of an air intake system taken along line  2 - 2  of  FIG.  1    in which the flow control member is disposed between a throttle valve and the intake manifold; 
         FIG.  3    is a perspective view in cross section of the air intake system of  FIG.  2   ; 
         FIG.  4    is a perspective view of the flow control member of  FIG.  2   ; 
         FIG.  5    is a front elevational view of the flow control member of  FIG.  4   ; 
         FIG.  6    is a side elevational view of the flow control member  FIG.  4   ; 
         FIG.  7    is an elevational view in cross section of a laminar air flow through the flow control member of  FIG.  2   ; 
         FIG.  8    is an elevational view in cross section of the air intake system taken along line  8 - 8  of  FIG.  1    illustrating the flow control member connected between the air intake passage and the air intake manifold; and 
         FIG.  9    is a rear perspective view of the flow control member connected to the air intake passage of  FIG.  3   . 
     
    
    
     DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS 
     Selected embodiments will now be explained with reference to the drawings. It will be apparent to those skilled in the art from this disclosure that the following descriptions of the embodiments are provided for illustration only and not for the purpose of limiting the invention as defined by the appended claims and their equivalents. 
     Referring initially to  FIGS.  1 - 3   , an air intake system  10  includes an air intake manifold  12 , an air intake passage  14 , a throttle valve  16 , and a flow control member  18 . The intake passage  14  is configured to supply air to the intake manifold  12 . The throttle valve  16  is disposed in the intake passage  14  to regulate, or control, the supply of air to the intake manifold  12 . The flow control member  18  is disposed between the throttle valve  16  and the intake manifold  12  to control the flow of air entering the intake manifold  12 . The flow control member  18  imparts laminar flow characteristics to the air passing through the flow control member  18 . 
     The intake manifold  12 , as shown in  FIGS.  1  and  3   , receives air from the intake passage  14  and transmits the air to the engine cylinders for combustion with fuel. An air inlet  20  is disposed in an axial face  22  of the intake manifold  12 . A circumferential groove  24  is disposed in the axial face  22  of the intake manifold  12 . The circumferential groove  24  completely surrounds the inlet  20 , and is configured to receive a first sealing member  26 , such as a gasket. The intake manifold  12  includes a plurality of mounting tabs  28  disposed outwardly of the air inlet  20 . Each mounting tab  28  has a fastener opening  30  configured to receive a fastener  32 , as shown in  FIG.  7   . 
     The air intake passage, or air intake tube,  14  supplies air to the throttle valve  16  disposed upstream of the inlet  20  of the intake manifold  12 , as shown in  FIGS.  2 ,  3 ,  7  and  8   . The air intake passage  14  has an outer surface  14 A and an inner surface  14 B. The inner surface  14 B defines an air passage  14 C through which the air is supplied to the intake manifold  12 . A flange  34  is disposed at an end of the intake passage  14 , as shown in  FIGS.  2  and  9   . The flange  34  has an axial face  36 . A plurality of fastener openings  38  are disposed in the axial face  36 . 
     The throttle valve  16  includes a throttle body  40  fixed to a shaft  42 , as shown in  FIGS.  2  and  3   . The shaft  42  is rotatably mounted in the intake passage  14 . The shaft  42  extends in a direction substantially perpendicular to a longitudinal axis A of the intake passage  14 . The throttle body  40  is a substantially planar member fixed to the throttle shaft  42  in any suitable manner such that the throttle body  40  rotates with the shaft  42 . The throttle valve  16  is configured to be moved from a closed position in which air is substantially prevented from passing through the throttle valve  16  to an open position in which the amount of air flowing to the intake manifold  12  is regulated. Referring to  FIG.  2   , the throttle body  40  is positioned substantially vertically to close the air passage  14 C in the air intake passage  14  to substantially prevent the flow of air to the intake manifold. The shaft  42  rotates in a counter-clockwise direction to allow air to pass through the throttle valve  16  to regulate the supply of air to the intake manifold  12 . The throttle valve  16  is controlled in a conventional to regulate the supply of air to the intake manifold  12 . 
     The flow control member  18  is disposed between the throttle valve  16  and the intake manifold  12 , as shown in  FIGS.  2 ,  3 ,  7  and  8   . The flow control member  18  includes a body  44 , a panel member  46 , and a plurality of mounting tabs  48 . The flow control member  18  is preferably integrally formed as a one-piece member. In other words, the body  44 , the panel member  46  and the plurality of mounting tabs  48  are integrally formed as a one-piece member. The body  44 , the panel member  46  and the mounting tabs  48  of the flow control member  18  are made of any suitable material, such as a plastic material. Preferably, the flow control member is made of a thermoplastic, such as a glass fiber reinforced polyamide resin. The flow control member  18  is preferably made by injection molding as a one-piece member. 
     The body  44  of the flow control member  18  has an outer surface  50  and an inner surface  52 , as shown in  FIGS.  4 - 6   . An air passage  54  through the body  44  of the flow control member  18  is defined by the inner surface  52 . The inner surface  52  preferably defines a substantially circular air passage  54  when viewed in the direction of the longitudinal axis A, as shown in  FIGS.  2  and  5   . The air passage  54  extends from a first axial facing surface  56  of the body  44  to a second axial facing surface  58 . 
     The panel member  46  of the flow control member  18  is disposed in the air passage  54  of the flow control member  18 , as shown in  FIGS.  4 - 6   . The panel member  46  has a plurality of openings  60  disposed therein. The panel member  46  is formed of a plurality of panels  62  connected together to form the plurality of openings  60  through the panel member  46 . The plurality of openings  60  preferably have a substantially hexagonal shape. 
     A lowermost panel  64  extends across an entirety of the air passage  54  in the flow control member  18 , as shown in  FIGS.  4  and  5   . The lowermost panel  64  separates a first portion  54 A of the air passage  54  from a second portion  54 B of the air passage  54 . The panel member  46  is disposed in the first portion  54 A of the air passage  54 . The second portion  54 B of the air passage  54  does not have the panel member  46  disposed therein. The panel member  46  covers approximately fifty percent of the air passage  54 . In other words, the panel member  46  is disposed in an upper half of the air passage  54 , and the lower half of the air passage  54  does not have the panel member  46  disposed therein. 
     Each of the plurality of mounting tabs  48  of the flow control member  18  extends outwardly from the outer surface  50  of the body  44 , as shown in  FIGS.  4 - 6   . A fastener opening  66  is disposed in each of the mounting tabs  48  and is configured to receive the fastener  32  to connect the flow control member  18  to the intake passage  14  of the vehicle. Each fastener opening  66  extends from the first axial facing surface  56  to the second axial facing surface  58 . 
     A groove  68  is disposed in the first axially facing surface  56  of the body  44  of the flow control member  18 , as shown in  FIG.  5   . The groove  56  surrounds an entirety of the air passage  54  in the body  44  of the flow control member  18 . The groove  68  has a first portion  68 A that is substantially circular and a second portion  68 B that extends radially outwardly from the first portion  68 A of the groove  68 . The second portion  68 B of the groove  68  extends radially from the first portion  68 A to an outer peripheral edge  56 A of the first axially facing surface  56  of the body  44  of the flow control member  18 . 
     A second sealing member  70  is disposed in the groove  68  in the first axially facing surface  56  of the body  44  of the flow control member  18 , as shown in  FIGS.  2 - 4  and  7 - 9   . The second sealing member  70  has a first portion  70 A that is substantially circular and a second portion  70 B that extends radially outwardly from the first portion  70 A of the first sealing member  70 . The first portion  70 A of the second sealing member  70  is received by the first portion  68 A of the groove  68 . The second portion  70 B of the second sealing member  70  is received by the second portion  70 B of the groove  68 . The second portion  70 B of the first sealing member  70  is a tab that extends outwardly beyond the outer peripheral edge  56 A of the first axially facing surface  56  of the body  44 . The first sealing member  26  is preferably substantially identical to the second sealing member  70 . The first and second sealing members  26  and  70  are made of any suitable material, such as a rubber material. The first and second sealing members  26  and  70  are preferably made of a nitrile rubber. 
     As shown in  FIGS.  2 ,  3 ,  7  and  8   , the flow control member  18  is disposed between the intake passage  14  and the intake manifold  12  in the air flow direction Fr. The flow control member  18  is disposed between the throttle valve  16  and the intake manifold  12  in the air flow direction. 
     The flow control member  18  is connected to an end of the intake passage  14 , as shown in  FIGS.  2 ,  3  and  7 - 9   . A first axial facing surface  56  of the flow control member  18  is positioned to face the axial face  36  of the flange  34  at the end of the intake passage  14 . The plurality of fastener openings  66  in the mounting tabs  18  of the flow control member  18  are aligned with the plurality of fastener openings  38  in the flange  34  of the intake passage  14 . 
     The second axial facing surface  58  of the flow control member  18  is positioned to face the axial face  22  at the inlet  20  of the intake manifold  12 , as shown in  FIGS.  1 - 3 ,  7  and  8   . The plurality of fastener openings  66  in the mounting tabs  18  of the flow control member  18  are aligned with the plurality of fastener openings  30  in the mounting tabs  28  of the intake manifold  12 . 
     The fastener openings  38  in the flange  34  of the intake passage  14 , the fastener openings  66  in the mounting tabs  18  of the flow control member  18 , and the fastener openings  30  in the mounting tabs  28  of the intake manifold  12  are aligned to receive the fasteners  32  to secure the air intake passage  14  to the intake manifold  12  with the flow control member  18  disposed therebetween. Collars  72  and collars  74  may be disposed in the fastener openings  66  in the mounting tabs  18  of the flow control member  18  and in the fastener openings  30  in the mounting tabs  28  of the intake manifold  12 , respectively, to facilitate receiving the fasteners  32 . A threaded insert  78  is disposed in the fastener opening  30  in the fastener opening  30  in the mounting tab  28  of the intake manifold  12  to receive a threaded portion of the fastener  32 . 
     As shown in  FIGS.  2  and  7   , a first sealing member  26  is disposed between the axial face  22  of the intake manifold  12  and the second axial facing surface  58  of the flow control member  18 . A second sealing member  70  is disposed between the first axial facing surface  56  of the flow control member  18  and the axial face  36  of the flange  34  of the intake passage  14 . The first and second sealing members  26  and  70  are compressed between the respective mating surfaces as the fasteners  32  are tightened in the respective fastener openings  38 ,  66  and  30  in the intake passage  14 , the flow control member  18  and the intake manifold  12  to substantially prevent leakage of air flowing through the intake passage  14 , the flow control member  18  and the intake manifold  12 . The second portion  70 B of the second sealing member  70  extends externally of the body  44  of the flow control valve, as shown in  FIGS.  1 ,  4  and  9   , to properly position the sealing member  70  in the groove  68  ( FIG.  5   ) of the flow control valve  18  and to indicate that the sealing member  70  is disposed in the flow control member  18  when the flow control member  18  is connected between the intake passage  14  and the intake manifold  12 . The second sealing member  26  has a similar tab, as shown in  FIG.  1   . As shown in  FIG.  2   , a diameter of the air passage  14 C of the intake passage  14 , a diameter of the air passage  54  of the flow control member  18  and a diameter of the air inlet  20  of the intake manifold  12  are substantially equal proximate the flow control member  18 . 
     The position of the throttle body  40  of the throttle valve  16  is adjusted in a conventional manner to control the flow of air to the intake manifold  12 . The air flowing through the panel member  46  of the flow control member  18  is provided with laminar flow characteristics, as indicated by flow arrows  76  in  FIG.  7   , to the air flowing into the inlet of the intake manifold  12 . In other words, the turbulence of the air flowing through the throttle valve  16  is substantially reduced by the flow control member  18 . By providing laminar flow characteristics to the air flowing to the intake manifold  12 , the pressure loss is reduced and the volumetric efficiency is increased in the internal combustion engine, thereby improving engine performance. 
     General Interpretation of Terms 
     In understanding the scope of the present invention, the term “comprising” and its derivatives, as used herein, are intended to be open ended terms that specify the presence of the stated features, elements, components, groups, integers, and/or steps, but do not exclude the presence of other unstated features, elements, components, groups, integers and/or steps. The foregoing also applies to words having similar meanings such as the terms, “including”, “having” and their derivatives. Also, the terms “part,” “section,” “portion,” “member” or “element” when used in the singular can have the dual meaning of a single part or a plurality of parts. Also as used herein to describe the above embodiment(s), the following directional terms “forward”, “rearward”, “above”, “downward”, “vertical”, “horizontal”, “below” and “transverse” as well as any other similar directional terms refer to those directions of a vehicle equipped with the hybrid door seal. Accordingly, these terms, as utilized to describe the present invention should be interpreted relative to a vehicle equipped with the flow control member. 
     The terms of degree such as “substantially”, “about” and “approximately” as used herein mean a reasonable amount of deviation of the modified term such that the end result is not significantly changed. 
     While only selected embodiments have been chosen to illustrate the present invention, it will be apparent to those skilled in the art from this disclosure that various changes and modifications can be made herein without departing from the scope of the invention as defined in the appended claims. For example, the size, shape, location or orientation of the various components can be changed as needed and/or desired. Components that are shown directly connected or contacting each other can have intermediate structures disposed between them. The functions of one element can be performed by two, and vice versa. The structures and functions of one embodiment can be adopted in another embodiment. It is not necessary for all advantages to be present in a particular embodiment at the same time. Every feature which is unique from the prior art, alone or in combination with other features, also should be considered a separate description of further inventions by the applicant, including the structural and/or functional concepts embodied by such feature(s). Thus, the foregoing descriptions of the embodiments according to the present invention are provided for illustration only, and not for the purpose of limiting the invention as defined by the appended claims and their equivalents.