CN108953016A - 用于内燃机的进气通道部件 - Google Patents

用于内燃机的进气通道部件 Download PDF

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CN108953016A
CN108953016A CN201810497507.0A CN201810497507A CN108953016A CN 108953016 A CN108953016 A CN 108953016A CN 201810497507 A CN201810497507 A CN 201810497507A CN 108953016 A CN108953016 A CN 108953016A
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layer
sound
wall portion
absorbing layer
sound absorbing
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犬塚義则
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Toyota Boshoku Corp
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Abstract

内燃机的空气滤清器的第一壳体包括减音壁部，该减音壁部包括不透气的泡沫层以及由无纺布制成的透气的吸音层，该不透气的泡沫层由闭孔泡沫塑料制成并且固定于吸音层的外表面。

Description

用于内燃机的进气通道部件
技术领域
本发明涉及用于内燃机的进气通道部件。
背景技术
该类型的进气通道部件包括例如用于内燃机的空气滤清器。
日本特开2000-110682号公报所公开的空气滤清器包括由硬塑料和吸音材料制成的壳体。吸音材料由例如无纺布、玻璃棉、石棉或泡沫塑料组成并且安装到空气滤清器壳体的壁部的内表面。
日本特开2002-21660号公报所公开的空气滤清器的壳体的壁部由诸如滤纸、无纺布、开孔海绵等的多孔吸音材料形成。
在日本特开2000-110682号公报所公开的空气滤清器中，进气噪音通过被吸音材料吸收而降低。然而，除了由硬塑料制成以外，壳体包括吸音材料。不期望地，这增加了壳体的重量。
在日本特开2002-21660号公报所公开的空气滤清器中，由于空气滤清器的壁部由多孔吸音材料形成，所以能够减小壳体的重量。然而，仅通过多孔材料的相对小的传输损耗对于穿过壁部漏到壳体外侧的传输噪音的降低存在限制。因而不能充分降低传输噪音。
发明内容
因此，本发明的目的是提供同时减小进气噪音和重量的用于内燃机的空气滤清器。
为了实现前述目的，提供了用于内燃机的进气通道部件。进气通道部件构成内燃机的进气通道的壁并且包括减音壁部。减音壁部包括由多孔材料制成的透气的吸音层，以及由闭孔泡沫塑料制成且固定到吸音层外表面的不透气的泡沫层。
附图说明
图1是示出空气滤清器整体结构的根据一个实施方式的用于内燃机的进气通道部件的立体图。
图2是沿着图1的线2-2截取的截面图。
图3是沿着图2的线3-3截取的截面图。
图4是示出相同实施方式中的第一壳体的降噪壁部的层叠结构的示意图。
图5是示出变型例中的第一壳体的降噪壁部的层叠结构的示意图。
具体实施方式
现在将参照图1至图4说明一个实施方式。
图1至图3中示出的空气滤清器配置于车载内燃机的进气通道并且包括具有入口18的第一壳体10和具有出口28的第二壳体20。
如图2和图3所示，第一壳体10包括底壁13和围绕上开口11的周壁12。向外延伸的凸缘16绕着上开口11的整个周缘设置。入口18从周壁12的外表面突出。
第二壳体20包括顶壁23和围绕下开口21的周壁22。向外延伸的凸缘26绕着下开口21的整个周缘设置。出口28从周壁22的外表面突出。
过滤进气的过滤元件30配置于第一壳体10的上开口11与第二壳体20的下开口21之间。过滤元件30具有过滤部31和环状密封部32。通过使例如滤纸或无纺布等的过滤介质片打褶形成过滤部31。密封部32由诸如聚氨酯等的闭孔泡沫塑料制成并且设置于过滤部31的外周缘。
通过第一壳体10的凸缘16和第二壳体20的凸缘26保持密封部32。这密封了第一壳体10与第二壳体20之间的间隙。
现在将说明第一壳体10的结构。
如图1至图3所示，第一壳体10具有由硬塑料制成的成形塑料部15和由例如无纺布制成的减音壁部14。
成形塑料部15是构成凸缘16、入口18和部分周壁12的部件。成形塑料部15由凸缘16的外表面、位于凸缘16与入口18之间的塑料壁部17以及从塑料壁部17的外表面突出的肋19构成。肋19在周向上间隔配置。
减音壁部14由底壁13和除了成形塑料部15之外的周壁12构成。
通过嵌入成形，成形塑料部15与减音壁部14形成为一体。
现在将说明减音壁部14的截面结构。
如图2和图3所示，减音壁部14包括由无纺布制成的透气的吸音层41、由闭孔泡沫塑料制成的不透气的泡沫层42和由透气材料制成的内层43。利用粘接剂使泡沫层42固定到吸音层41的外表面。利用粘接剂使内层43固定到吸音层41的内表面。与吸音层41相比，内层43具有较低的透气度。
<吸音层41>
如图4所示，通过层叠两片无纺布形成吸音层41。无纺布片均由已知的鞘-芯双组份纤维组成(均未示出)，该鞘-芯双组份纤维包括由例如聚对苯二甲酸乙二醇酯(PET)制成的芯以及由改性PET制成的鞘，其中改性PET的熔点低于芯的PET的熔点。
层叠无纺布片的每单位面积的重量优选地为300g/m2至1500g/m2。
在本实施方式中，一个无纺布片的每单位面积的重量为600g/m2，并且两个无纺布片的每单位面积的重量(总值)被设定为1200g/m2。
通过对总厚度为例如30mm至100mm的两个层叠无纺布片进行热压形成图2和图3中示出的吸音层41。吸音层41具有厚部41a、薄部41b和渐变部41c。薄部41b具有比厚部41a的压缩度高的压缩度并且比厚部41a薄。渐变部41c位于厚部41a与薄部41b之间，并且厚度从厚部41a朝向薄部41b逐渐减小。
如图2所示，厚部41a设置于第一壳体10的底壁13的相对于中央距入口18更远的范围内(位于图2中的右侧)。厚部41a的厚度优选地为5mm至50mm。
薄部41b遍及减音壁部14的整个周缘地设置。通过成形塑料部15的保持部15a从厚度方向上的相反两侧保持减音壁部14的周缘。这使减音壁部14和成形塑料部15一体化。薄部41b的厚度优选地为1mm至3mm。
<泡沫层42>
泡沫层42由闭孔泡沫塑料组成，闭孔泡沫塑料由例如PET制成。
泡沫层42的每单位面积的重量优选地为30g/m2至500g/m2。
在本实施方式中，泡沫层42的每单位面积的重量被设定为100g/m2。
泡沫层42的厚度优选地为1.0mm至10mm。
<内层43>
内层43包括透气片43b和由无纺布制成的透气内覆盖层43a，其中透气片43b配置于内覆盖层43a与吸音层41之间并且具有比内覆盖层43a的透气度低的透气度。
构成内覆盖层43a的无纺布由鞘-芯双组份纤维组成，鞘-芯双组份纤维包括由例如PET制成的芯以及由改性PET制成的鞘，其中改性PET的熔点低于芯的PET的熔点。
内覆盖层43a的每单位面积的重量优选地为10g/m2至300g/m2。
在本实施方式中，内覆盖层43a的每单位面积的重量被设定为50g/m2。
片43b是由例如PP制成的膜并且具有大量排气孔(未示出)。
片43b的每单位面积的重量优选地为10g/m2至300g/m2。
在本实施方式中，片43b的每单位面积的重量被设定为100g/m2。
通过排气孔的数量和尺寸控制片43b的透气度并因此控制内层43的透气度。
内层43的透气度(根据JIS L 1096，A-方法(Frazier方法)测量)优选地为3cm3/cm2·s以上、更优选地为5cm3/cm2·s以上。内层43的透气度优选地为50cm3/cm2·s以下、更优选地为20cm3/cm2·s以下。
在本实施方式中，内层43的透气度被设定为5cm3/cm2·s至20cm3/cm2·s。
内层43的厚度优选地为1μm至500μm。本实施方式的内层43的厚度为例如10μm至15μm。
通过使作为内覆盖层43a的材料的无纺布、作为片43b的材料的膜、作为吸音层41的材料的两片无纺布和作为泡沫层42的材料的闭孔泡沫塑料层叠形成基部。预先对基部加热。然后，对加热了的基部进行冷压以使上述减音壁部14形成为预定形状。然后，在进行裁切处理之后，通过将减音壁部14插入成形模具进行注射成形，从而使成形塑料部15与减音壁部14一成形为一体的。
现在将说明第二壳体20的结构。
如图1至图3所示，第二壳体20具有由硬塑料制成的成形塑料部25和由例如无纺布制成的压缩壁部24。
成形塑料部25是构成凸缘26、出口28和部分周壁22的部件。成形塑料部25由凸缘26的外表面、位于凸缘26与出口28之间的塑料壁部27以及从塑料壁部27的外表面突出的肋29构成。肋29在周向上间隔配置。
压缩壁部24由顶壁23和除了成形塑料部25以外的周壁22构成。
通过嵌入成形，成形塑料部25与压缩壁部24形成为一体。
现在将说明压缩壁部24的截面结构。
如图2和图3所示，压缩壁部24包括压缩层51、外层52和内层53。压缩层51由无纺布制成。利用粘接剂使外层52固定到压缩层51的外表面。利用粘接剂使内层53固定到压缩层51的内表面。
压缩层51由与减音壁部14的吸音层41相同的无纺布制成。通过对厚度为例如30mm至100mm的无纺布进行热压形成压缩层51。压缩层51的厚度优选地为1mm至3mm。
例如，外层52是由PP制成的防水膜。
内层53由与减音壁部14的内层43相同的材料制成。
通过成形塑料部25的保持部25a从厚度方向上的相反两侧保持压缩壁部24的周缘。这使压缩壁部24和成形塑料部25一体化。
现在将说明本实施方式的操作。
当进气噪音进入内层43时，通过噪音的具有与内层43的共振频率相同的频率的分量引起内层43的共振。振动能量使固定于内层43的吸音层41振动，并且振动能量通过被转换成吸音层41的摩擦热而被消耗。
随着被内层43阻断的空气的质量增加、即随着内层43的透气度降低，内层43的共振频率降低。
在本实施方式中，内层43由透气材料制成，该透气材料具有比吸音层41的透气度低的透气度。因而，与未设置内层43的构造、或者所具有的透气度大于或等于吸音层的透气度的层设置于吸音层41的内表面的构造相比，低频范围的进气噪音降低(操作1)。
另外，减音壁部14具有由无纺布制成的透气的吸音层41。因此，进气噪音在穿过吸音层41的部分时被吸收，特别地，进气噪音在穿过厚部41a和渐变部41c的厚度相对大的部分时被吸收。即，通过进气噪音使吸音层41振动，并且振动能量通过被转换成吸音层41的摩擦热而被消耗(操作2)。
由闭孔塑料泡沫制成的不透气泡沫层42固定于吸音层41的外表面。因此，当进气噪音经由吸音层41进入泡沫层42时，通过噪音的具有与泡沫层42的共振频率相同的频率的分量引起泡沫层42的共振。振动能量使固定于泡沫层42的吸音层41振动，并且振动能量通过被转换成吸音层41的摩擦热而被消耗。
随着被泡沫层42阻断的空气的质量增加、即随着泡沫层42的透气度降低，泡沫层42的共振频率降低。
如上所述，泡沫层42是不透气的。因而，与未设置泡沫层42的构造、或者具有透气度的层设置于吸音层41的外表面的构造相比，较低频率范围的进气噪音降低(操作3)。
泡沫层42由闭孔塑料泡沫制成。因此，泡沫层42内捕获的大量气泡吸收或反射进气噪音，从而降低穿过泡沫层42的传输噪音(操作4)。
根据本实施方式的用于内燃机的空气滤清器实现了以下操作上的优势。
(1)内燃机的空气滤清器的第一壳体10包括减音壁部14，减音壁部14包括不透气泡沫层42和由无纺布制成的透气的吸音层41，其中不透气的泡沫层42由闭孔泡沫塑料制成并且固定于吸音层41的外表面。
由于该构造实现了操作2，所以进气通道内部的进气噪音的驻波的产生受到限制，这降低了来自进气通道入口的进气噪音。
另外，由于该构造实现了上述操作3和操作4，所以有效地抑制了穿过减音壁部14的进气噪音。
减音壁部14具有吸音层41和泡沫层42。因此，与吸音层固定于由硬塑料制成的壁部内表面的传统构造相比，减小了第一壳体10的重量。
因而减小了进气噪音和重量。
(2)由透气材料制成且具有比吸音层41的透气度低的透气度的内层43固定于吸音层41的内表面。
该构造实现了上述操作1，因而有效地减小了进气噪音的低频范围的分量。此外，能够通过改变内层43的透气度来改变进气噪音的可减小频率。
(3)第一壳体10的内表面由透气度比吸音层41的透气度低的内层43形成。
与未设置内层43的构造、即吸音层41露于第一壳体10的内部的构造相比，这增加了第一壳体10的内表面的平滑度。因此，空气沿着第一壳体10的内表面平滑地流动，并且减小了气流阻力。
(4)内层43的透气度被设定为5cm3/cm2·s至20cm3/cm2·s。
如果内层43的透气度低于5cm3/cm2·s，则内层43的共振频率进一步降低。这被认为减小了进气噪音的较低频率的分量。
然而，在该情况下，由于进气噪音几乎不到达吸音层41，所以通过吸音层41的吸音效果难以发挥。这具有不能容易地减小进气噪音的高频分量(例如，高于1kHz的分量)的缺点。
在该方面，根据上述构造，内层43的透气度在5cm3/cm2·s至20cm3/cm2·s的范围内。这防止了因内层43的透气度被设定得过低所导致的缺点。因此，进气噪音中的高频分量被吸音层41的吸音作用减小。此外，通过利用内层43的共振来减小进气噪音中的低频分量(例如，低于1kHz的分量)。因此，减小了进气噪音中较宽频率范围的分量。
(5)内层43包括由无纺布制成的透气的内覆盖层43a以及配置于内覆盖层43a与吸音层41之间且透气度低于内覆盖层43a的透气度的透气片43b。
该构造允许通过改变片43b的排气孔的数量和尺寸容易地改变内层43的透气度。
(6)利用粘接剂使内层43固定到吸音层41。因而，内层43容易且牢固地固定于吸音层41。这充分地防止内层43因操作内燃机期间产生的进气管负压而从吸音层41剥离。
(7)第一壳体10包括成形塑料部15，成形塑料部15构成凸缘16、入口18以及位于凸缘16与入口18之间的塑料壁部17。使成形塑料部15与减音壁部14一体化。
凸缘16是过滤元件30的密封部32所压靠的部分，因而凸缘16需要具有高的刚度。另外，入口18是连接入口管道(未示出)的部分，因而入口18需要具有高的刚度。
在该方面，尽管设置有减音壁部14，但是上述构造充分地防止第一壳体10具有不足的刚度。
(8)吸音层41具有厚部41a和薄部41b，薄部41b的无纺布具有比厚部41a的无纺布的压缩度高的压缩度，并且减音壁部14的薄部41b联接到成形塑料部15。
该构造利用薄部41b增加了减音壁部14的联接到成形塑料部15的部分的刚度，并且允许厚部41a充分发挥吸音效果。
(9)渐变部41c以厚度从厚部41a到薄部41b逐渐减小的方式设置于厚部41a与薄部41b之间。
利用该构造，不太可能在厚部41a与薄部41b之间形成吸音层41的厚度骤变的台阶。这允许进气在第一壳体10内部平滑地流动并且减小气流阻力。
(10)仅第一壳体10具有减音壁部14。
减音壁部14的厚部41a与薄部41b相比具有较低的刚度和较低的负压阻力。由于第一壳体10位于过滤元件30的上游侧，所以作用于第一壳体10的负压小于作用于第二壳体20的负压。
在该方面，根据上述构造，仅在第一壳体10中、而不在第二壳体20中设置减音壁部14。因此，能够同时确保第一壳体10和第二壳体20的负压抗力以及因减音壁部14的进气噪音的降低。
(11)不透气的泡沫层42设置于吸音层41的外表面。另外，不透气的外层52设置于压缩层51的外表面。这防止水进入空气滤清器的内部。
(12)部分第二壳体20由压缩壁部24形成，压缩壁部24具有外层52、内层53和由无纺布制成的压缩层51。
与第二壳体20由硬塑料制成的构造相比，利用该构造更容易减小第二壳体20的重量并且还减小空气滤清器的重量。
(13)成形塑料部15、25设置有保持部15a、25a以分别保持减音壁部14的周缘和压缩壁部24的周缘。
利用该构造，当成形塑料部15、25在减音壁部14和压缩壁部24中嵌入成形时，熔融的塑料渗透到减音壁部14的周缘和压缩壁部24的周缘中。这通过锚固效应使减音壁部14和压缩壁部24牢固地结合至成形塑料部15、25。
(14)通过使作为内覆盖层43a的材料的无纺布、作为片43b的材料的膜、作为吸音层41的材料的两片无纺布和作为泡沫层42的材料的闭孔泡沫塑料层叠形成基部。预先对基部加热。然后，对基部进行冷压以使减音壁部14形成为预定形状。
该制造方法可靠地固定吸音层41和泡沫层42并且可靠地固定吸音层41和内层43(内覆盖层43a和片43b)。这确保了利用泡沫层42的共振使吸音层41振动的上述操作3，并且还确保了利用内层43的共振使吸音层41振动的上述操作1。
<变型例>
上述实施方式可以作如下变型。
如图5所示，由诸如无纺布等的透气材料制成的外覆盖层44可以固定于泡沫层42的外表面。在该情况下，由于由无纺布制成的透气的外覆盖层44设置于泡沫层42的外表面，所以例如来自发动机室中其它音源的噪音被外覆盖层44吸收。因此，除了进气噪音之外，也降低了发动机室中的其它噪音。
由泡沫塑料制成的泡沫层42容易有刮痕。在该方面，上述构造具有由无纺布制成的外覆盖层44，外覆盖层44覆盖泡沫层42的外表面。这保护了泡沫层42。另外，由于外覆盖层44由无纺布制成，所以外覆盖层44自身抵抗刮痕。
整个第二壳体20可以由成形塑料部25形成。
在第二壳体20中能够设置与第一壳体10的减音壁部14相同的减音壁部。
能够省略吸音层41的渐变部41c。
还可以整个第一壳体10由减音壁部14形成。即，可以省略成形塑料部15。在该情况下，仅需要对应于成形塑料部15的部分由上述实施方式的薄部41b构成即可。
吸音层41可以由单片无纺布或层叠的两片以上的无纺布构成。
吸音层41可以由任意透气多孔材料制成。例如，吸音层41可以由开孔泡沫塑料制成。
内层43能够仅由内覆盖层43a或片43b构成。
能够省略内层43。即使在该情况下，也能够实现上述优势(1)。
例如，本发明能够应用于进气管道。

Claims (5)

1.一种用于内燃机的进气通道部件，其中，所述进气通道部件构成内燃机的进气通道的壁并且包括减音壁部，所述减音壁部包括：
透气的吸音层，其由多孔材料制成，以及
不透气的泡沫层，其由闭孔泡沫塑料制成并且固定于所述吸音层的外表面。
2.根据权利要求1所述的用于内燃机的进气通道部件，其特征在于，内层固定于所述吸音层的内表面，所述内层由透气材料制成且具有比所述吸音层的透气度低的透气度。
3.根据权利要求2所述的用于内燃机的进气通道部件，其特征在于，所述内层包括：
内覆盖层，其由透气材料制成，以及
透气片，其配置于所述内覆盖层与所述吸音层之间并且具有比所述内覆盖层的透气度低的透气度。
4.根据权利要求1至3中任一项所述的用于内燃机的进气通道部件，其特征在于，由透气材料制成的外覆盖层固定于所述泡沫层的外表面。
5.根据权利要求1至3中任一项所述的用于内燃机的进气通道部件，其特征在于，所述进气通道部件是空气滤清器的壳体。
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