DE102020205558A1 - Air duct for the intake tract of an internal combustion engine - Google Patents

Abstract

The invention relates to an air line (100) for the intake tract of an internal combustion engine, having a first air line section (110) and a second air line section (120), the first air line section (110) being a polyalkylene terephthalate and the second air line section (120) being a polymer blend Polyalkylene terephthalate, and / or a polyalkylene terephthalate copolymer. The invention also relates to a method for producing an air duct (100).

Description

AREA OF APPLICATION AND STATE OF THE ART

The invention relates to an air line, in particular a clean air line, for the intake tract of an internal combustion engine and to a method for producing an air line.

Conventional air lines for motor vehicles are used, for example, to connect a turbocharger, part of an internal combustion engine or another motor vehicle device with an increased operating temperature to a component such as an air filter. Corresponding air lines usually consist of a hard component and an elastomer hose as the soft component. Instead of an elastomer hose, the air lines can also have a bellows as a separate component. The hard component can be connected to the elastomer hose or the bellows in a form-fitting manner, mechanically via a separate clamping element or by means of a joining process. Air lines for motor vehicles are for example from the WO 2019/214937 A1 as WO 2019/214959 A1 known.

A problem with the conventional air lines for the motor vehicle sector is, in particular, the requirement for assembly steps in the production of air lines that are composed, in particular, of form-fitting assemblies. Another problem that exists in particular with materially joined air lines relates to the risk of leaks due to imperfect joints.

TASK AND SOLUTION

The technical problem underlying the invention is the provision of an air line, in particular a clean air line, for the intake tract of an internal combustion engine and the provision of a method for producing such an air line, which at least partially or completely avoid disadvantages known from the prior art in connection with generic air lines.

The invention solves this problem by an air line having the features of independent claim 1 and by a method according to claim 13. Preferred embodiments of the invention are the subject matter of the dependent claims. The wording of all claims is hereby made part of the content of the description by express reference.

According to a first aspect, the invention relates to an air line for the intake tract of an internal combustion engine.

The air line has a first air line section and a second air line section.

The first air line section has a polyalkylene terephthalate or consists of a polyalkylene terephthalate. The second air line section has a polymer blend (polyblend) or consists of a polymer blend, the polymer blend comprising a polyalkylene terephthalate. Alternatively or in combination, the second air line section has a polyalkylene terephthalate copolymer or consists of a polyalkylene terephthalate copolymer.

The air line according to the invention is preferably a so-called clean air line.

In the context of the present invention, the expression “clean air line” should be understood to mean an air line via which cleaned air is transported from an air filter to a turbocharger in an intake tract of an internal combustion engine.

The air line is preferably tubular and / or preferably has a cornerless, in particular circular, cross section. The air line is particularly preferably designed in the shape of a round tube. Accordingly, the first air line section and the second air line section are each preferably tubular and / or preferably each have a cornerless, in particular circular, cross section. Particularly preferably, the first air line section and the second air line section are each designed in the shape of a round tube.

Alternatively, the air line can have a polygonal, for example triangular, square, pentagonal or hexagonal cross section. Correspondingly, the first air line section and the second air line section can each have a polygonal, for example triangular, square, pentagonal or hexagonal cross section.

Furthermore, the air line can have a general wall thickness or wall thickness of 0.5 mm to 5 mm.

The expression “polymer blend” or “polyblend” in the context of the present invention is intended to mean a mixture of a polyalkylene terephthalate, preferably polybutylene terephthalate, and at least one further polymer are understood.

In the context of the present invention, the expression “polyalkylene terephthalate copolymer” is to be understood as meaning a copolymer whose polymer chain or polymer backbone has at least one section or one block of polyalkylene terephthalate. In the context of the present invention, the polyalkylene terephthalate copolymer is therefore preferably a block copolymer (so-called polyalkylene terephthalate block copolymer).

• - Durch die Verwendung eines Polyalkylenterephthalats als Hartkomponente und eines Polymerblends, welches ein Polyalkylenterephthalat aufweist, oder eines Polyalkylenterephthalat-Copolymers als Weichkomponente ist ein besonders optimales, d.h. festes und dichtes, stoffschlüssiges Verbinden oder Fügen entsprechend gestalteter oder zusammengesetzter Luftleitungsabschnitte zu einer Luftleitung erzielbar, wodurch vorzeitige Verschleißerscheinungen, insbesondere Undichtigkeiten im Verbindungs- oder Fügebereich, vermieden werden können.
• - Ferner ist von Vorteil, dass sich die erfindungsgemäße Luftleitung durch ein stoffschlüssiges Fügeverfahren, insbesondere durch ein Spritzgussverfahren, herstellen lässt, wodurch Montageschritte, wie sie bei konventionellen und insbesondere formschlüssig zusammengesetzten Luftleitungen bekannt sind, und insbesondere das Erfordernis zusätzlicher Verbindungselemente, insbesondere von Spannelementen, entfallen.

The invention is based in particular on the following advantages:

• - By using a polyalkylene terephthalate as the hard component and a polymer blend which has a polyalkylene terephthalate, or a polyalkylene terephthalate copolymer as the soft component, a particularly optimal, ie firm and tight, cohesive connection or joining of appropriately designed or assembled air line sections to form an air line can be achieved, which leads to premature Signs of wear, in particular leaks in the connection or joining area, can be avoided.
• - It is also advantageous that the air line according to the invention can be produced by a material-locking joining process, in particular by an injection molding process, whereby assembly steps as are known in conventional and, in particular, positively assembled air lines, and in particular the need for additional connecting elements, in particular clamping elements, omitted.

As a result, both a weight reduction of the air line and a cost reduction in the manufacture of the air line can advantageously be achieved.

In an embodiment of the invention, the first air line section and the polymer blend of the second air line section each have the same polyalkylene terephthalate. As a result, a particularly optimized material connection between the first air line section and the second air line section can be achieved with particular advantage.

In a further embodiment of the invention, the first air line section and the polyalkylene terephthalate copolymer of the second air line section each have the same polyalkylene terephthalate. The advantage mentioned in the previous paragraph applies accordingly.

In a further embodiment of the invention, the polyalkylene terephthalate is polybutylene terephthalate. The advantages according to the invention are particularly evident in the case of polybutylene terephthalate.

Alternatively, the polyalkylene terephthalate can be polyethylene terephthalate.

Furthermore, the first air line section can have a different polyalkylene terephthalate than the polymer blend of the second air line section. For example, the polyalkylene terephthalate of the first air line section can be polybutylene terephthalate and the polyalkylene terephthalate of the polymer blend of the second air line section can be polyethylene terephthalate. Alternatively, the polyalkylene terephthalate of the first air line section can be, for example, polyethylene terephthalate and the polyalkylene terephthalate of the polymer blend of the second air line section can be polybutylene terephthalate.

Furthermore, the first air line section can have a different polyalkylene terephthalate than the polyalkylene terephthalate copolymer of the second air line section. For example, the polyalkylene terephthalate of the first air line section can be polybutylene terephthalate and the polyalkylene terephthalate of the polyalkylene terephthalate copolymer of the second air line section can be polyethylene terephthalate. Alternatively, the polyalkylene terephthalate of the first air line section can be polyethylene terephthalate and the polyalkylene terephthalate of the polyalkylene terephthalate copolymer of the second air line section can be polybutylene terephthalate.

Furthermore, the first air duct section can have a polymer blend, comprising or consisting of different polyalkylene terephthalates, or consist of such a polymer blend. For example, the first air duct section can have a polymer blend, comprising or consisting of polybutylene terephthalate and polyethylene terephthalate, or consist of such a polymer blend.

Furthermore, the polymer blend of the second air line section can have different polyalkylene terephthalates, in particular polybutylene terephthalate and polyethylene terephthalate.

Furthermore, the polyalkylene terephthalate copolymer of the second air line section can contain different polyalkylene terephthalate blocks, in particular at least one polybutylene terephthalate block and at least one block of polyethylene terephthalate.

In a further embodiment of the invention, the first air duct section also has a reinforcing means, in particular in the form of fibers, i.e. so-called reinforcing fibers, and / or in the form of particles, i.e. so-called reinforcing particles. As a result, the strength, in particular tensile strength, of the first air duct section can be increased with particular advantage.

The fibers or reinforcing fibers can in principle be selected from the group consisting of inorganic fibers, metallic fibers, organic fibers, natural fibers and mixtures of at least two of the aforementioned fibers.

In a further embodiment of the invention, the fibers or reinforcing fibers are selected from the group consisting of glass fibers, basalt fibers, boron fibers, ceramic fibers, silica fibers, steel fibers, polyamide fibers, aramid fibers, carbon fibers, carbon fibers, nylon fibers, polyethylene fibers, plexiglass fibers, flax fibers, hemp fibers, wood fibers, sisal fibers and mixtures of at least two of the aforesaid fibers.

Glass fibers are particularly preferred according to the invention.

The fibers or reinforcing fibers can also be present in particular in the form of long and / or short fibers.

In the context of the present invention, the expression “long fibers” preferably means fibers with a length> 6 mm, in particular 7 mm to 50 mm, preferably 7 mm to 20 mm, more preferably 7 mm to 15 mm, particularly preferably 8 mm to 10 mm to be understood.

In the context of the present invention, the expression “short fibers” should preferably be understood to mean fibers with a length of 6 mm, in particular <6 mm. Preferably, the term “short fibers” in the context of the present invention should be understood to mean fibers with a length of 2 mm to 6 mm, more preferably 4 mm to 6 mm, particularly preferably 4 mm to 5 mm.

The particles or reinforcing particles mentioned above in connection with the reinforcing agent can also be spherical or non-spherical, in particular polyhedral, for example cube-shaped and / or cuboid and / or prism-shaped and / or pyramidal and / or truncated pyramidal and / or conical and / or truncated and / or tetrahedral and / or spatulate be designed.

The particles or reinforcing particles can furthermore be, in particular, filler particles, for example made of calcium carbonate, calcium sulfate, kaolin, mica, silicates, talc or quartz.

In a further embodiment of the invention, the polymer blend also has, ie in addition to the polyalkylene terephthalate, at least one further polymer which is selected from the group consisting of polycarbonate, polyether ester, polyester, thermoplastic polyester elastomers, thermoplastic copolyester elastomers and combinations of at least two of the aforementioned polymers .

The polycarbonate is preferably an aromatic polycarbonate. In particular, the polycarbonate can be a polycarbonate which can be obtained by polycondensation of phosgene with an aromatic diol or by reaction of an aromatic diol with diphenyl carbonate (so-called transesterification). The aromatic diol is preferably selected from the group consisting of bisphenol A, bisphenol S, dihydroxydiphenyl sulfide, tetramethylbisphenol A, 1,1-bis (4-hydroxyphenyl) -3,3,5-trimethylcyclohexane (BPTMC), 1,1,1- Tris (4-hydroxyphenyl) ethane (THPE) and combinations of at least two of the aforementioned aromatic diols.

The polyesters, thermoplastic polyester elastomers or thermoplastic copolyester elastomers can in particular be selected from the group consisting of ... and combinations of at least two of the aforementioned polyesters, thermoplastic polyester elastomers or thermoplastic copolyester elastomers.

In a further embodiment of the invention, the polyalkylene terephthalate copolymer has at least one further polymer which is selected from the group consisting of polycarbonate, polyetherester, polyester, thermoplastic polyester elastomers, thermoplastic copolyester elastomers and combinations of at least two of the aforementioned polymers.

In particular, the polyalkylene terephthalate copolymer has at least one further polymer section or at least one further polymer block along its polymer chain, the polymer section or block preferably being selected from the group consisting of polycarbonate section or block, polyetherester section or block, polyester section or block, thermoplastic Polyester elastomer section or block, thermoplastic copolyester elastomer section or block, and combinations of at least two of the aforesaid polymer sections or blocks.

In a further embodiment of the invention, the second air duct section is free from a reinforcing agent, in particular free from a reinforcing agent in the form of fibers, ie free from reinforcing fibers, and / or free from a reinforcing agent in the form of particles, ie free from reinforcing particles.

Alternatively, the second air line section can have a reinforcing means, in particular in the form of fibers and / or particles. If necessary, however, it is preferred if the second air line section has a lower proportion of reinforcing agent, in particular fiber and / or particle content, than the first air line section. With regard to suitable reinforcing means, in particular in the form of fibers and / or particles, for the second air line section, to avoid repetition, reference is made in full to the reinforcing means disclosed in connection with the first air line section. The reinforcement means described there can in principle also be used for the second air line section.

In a further embodiment of the invention, the air line is designed at least in sections, in particular only in sections or continuously (completely), linear or straight, i.e. not curved.

Alternatively, the air line can be curved or bent.

In a further embodiment of the invention, the second air line section has a bellows section. As a result, a tolerance compensation between components of an internal combustion engine to be connected to the air line, in particular a motor vehicle device, for example between an air filter and a turbocharger, can be (additionally) optimized. The bellows sub-section can comprise the polymer blend comprising a polyalkylene terephthalate and / or the polyalkylene terephthalate copolymer or consist of the polymer blend comprising a polyalkylene terephthalate and / or the polyalkylene terephthalate copolymer.

Alternatively, the second air line section or the air line can be free of a bellows section. In other words, the second air line section or the air line can be designed to be free of folds or folds.

Furthermore, the second air duct section can have an unfolded section, preferably an unfolded section formed directly adjacent to the bellows section. The unfolded subsection can comprise the polymer blend comprising a polyalkylene terephthalate and / or the polyalkylene terephthalate copolymer or consist of the polymer blend comprising a polyalkylene terephthalate and / or the polyalkylene terephthalate copolymer.

In a further embodiment of the invention, the first air line section and the second air line section are materially connected to one another, preferably in the radial direction.

In a further embodiment of the invention, the air line is designed as a one-piece injection-molded part, in particular a one-part multi-component injection-molded part, preferably a one-part two-component injection-molded part.

In a further embodiment of the invention, an upstream end of the air line, in particular of the first air line section, is set up to connect the air line to a cold component of the internal combustion engine, in particular an air filter. For this purpose, the upstream end of the air line can be designed, for example. The expression “upstream end” is to be understood in this context as an end of the air line, in particular of the first air line section, through the opening of which air, preferably cleaned air (by means of an upstream air filter), enters the air line, in particular the first air line section .

In a further embodiment of the invention, a downstream end of the air line, in particular of the second air line section, is set up to connect the air line to a hot component of the internal combustion engine, such as a turbocharger. The expression “downstream end” is to be understood in this context as an end of the air line, in particular of the second air line section, through the opening of which air exits the air line, in particular the second air line section, preferably in the direction of a turbocharger.

According to a second aspect, the invention relates to a method for producing an air line, in particular a clean air line, according to the first aspect of the invention.

In the process, the air duct is manufactured by means of injection molding, i.e. in an injection molding process.

In a further embodiment of the invention, the air line is produced by means of multi-component injection molding, in particular two-component injection molding, preferably by means of bi-injection.

With regard to further features and advantages of the method, full reference is made to the statements made in connection with the first aspect of the invention, which also apply mutatis mutandis to the method according to the second aspect of the invention.

Further features and advantages emerge from the following description of a preferred embodiment on the basis of a figure and the associated description of the figures. The embodiment described below serves only to further explain the invention without restricting it thereto. Individual features can be implemented individually or in combination with one another.

Figure list

• 1: eine Ausführungsform einer erfindungsgemäßen Luftleitung.

In the only one 1 the following is shown schematically:

• 1 : an embodiment of an air duct according to the invention.

DETAILED DESCRIPTION OF THE FIGURES

1 shows schematically an embodiment of an air line according to the invention 100 .

The air duct 100 is expediently tubular, in particular round tubular.

The air duct 100 has a first air duct section 110 and a second air duct section 120 on. The first air duct section 110 comprises a polyalkylene terephthalate or consists of a polyalkylene terephthalate. The polyalkylene terephthalate is preferably polybutylene terephthalate. Furthermore, the first air line section 110 a reinforcing agent, in particular in the form of fibers.

The second air duct section 120 comprises a polymer blend or consists of a polymer blend, the polymer blend comprising a polyalkylene terephthalate, preferably polybutylene terephthalate. In addition to the polyalkylene terephthalate, preferably polybutylene terephthalate, the polymer blend can in particular have at least one further polymer selected from the group consisting of polycarbonate, polyether ester, polyester, thermoplastic polyester elastomers, thermoplastic copolyester elastomers and combinations of at least two of the aforementioned polymers.

The polymer blend of the second air line section can, for example, have polybutylene terephthalate and a polycarbonate or consist of these polymers. Alternatively, the polymer blend can comprise polybutylene terephthalate and a polyether ester or consist of these polymers. Alternatively, the polymer blend can have, for example, polybutylene terephthalate and a thermoplastic polyester elastomer or consist of these polymers. Alternatively, the polymer blend can, for example, comprise polybutylene terephthalate and a thermoplastic copolyester elastomer or consist of these polymers.

Alternatively, the second air line section 120 comprise a polyalkylene terephthalate copolymer or consist of such a copolymer. In addition to a section or block made of polyalkylene terephthalate, the polymer can have a section or block made of polycarbonate and / or polyetherester and / or polyester and / or a thermoplastic polyester elastomer and / or a thermoplastic copolyester elastomer or consist of corresponding polymer sections or blocks.

In principle, the second air line section can (also) 120 a reinforcing agent, in particular in the form of fibers, such as glass fibers. Assign both the first duct section 110 as well as the second air duct section 120 each have a reinforcing means, in particular as described above, it is preferred if the second air line section 120 has a lower proportion of reinforcing agent than the first air line section 110 .

According to the invention, however, it is particularly preferred if the second air line section 120 is free of a reinforcing agent, in particular in the form of fibers and / or particles.

Furthermore, the second air line section 120 a bellows section 123 exhibit. As a result, an (improved) tolerance compensation between components of an internal combustion engine, in particular a motor vehicle device, which is connected to the air line is particularly advantageous 100 are to be connected, achievable.

Furthermore, the second air line section 120 an unfolded section 125 have, which is directly attached to the bellows section 123 is formed adjacent.

The first air line section is preferred 110 and the second air duct section 120 materially connected to one another, in particular in the radial direction. The material connection between opposite end regions of the first air line section is preferred 110 and the second air duct section 120 educated. Such a material connection is preferred by means of injection molding, in particular multi-component injection molding Two-component injection molding, in particular by means of bi-injection, achieved.

Accordingly, it is preferred that the air duct 100 is designed as a one-piece injection-molded part, in particular a one-part multi-component injection-molded part, preferably a one-part two-component injection-molded part.

Furthermore, it can be preferred that an upstream end 111 the air duct 100 is set up to connect the air line 100 with a cold component of an internal combustion engine, in particular with an air filter.

It may also be preferred that a downstream end 121 the air duct 100 is set up to connect the air line 100 with a hot component of an internal combustion engine, in particular a turbocharger.

The air duct 100 can also have a wall thickness of 0.5 mm to 5 mm.

With the air line 100 it is preferably a so-called clean air line.

An air line according to the present invention has the particular advantage that, due to its special combination of materials (for the first line section and the second line section), it enables weight reductions and consequently cost reductions. Furthermore, the production of the air line in the injection molding process, in particular in multi-component injection molding, preferably two-component injection molding, allows a material fit, which eliminates complex and, in particular, error-prone assembly steps. By using a polyalkylene terephthalate, preferably polybutylene terephthalate, both for the first air conduit section and for the second air conduit section, the cohesive joining step can be additionally optimized.

QUOTES INCLUDED IN THE DESCRIPTION

This list of the documents listed by the applicant was generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Patent literature cited

• WO 2019/214937 A1 [0002]
• WO 2019/214959 A1 [0002]

Claims (14)

Air line (100) for the intake tract of an internal combustion engine, comprising a first air line section (110) and a second air line section (120), characterized in that the first air line section (110) is a polyalkylene terephthalate and the second air line section (120) is a polymer blend, comprising a polyalkylene terephthalate , and / or a polyalkylene terephthalate copolymer. Air line (100) Claim 1 , characterized in that the first air line section (110) and the polymer blend and / or the polyalkylene terephthalate copolymer of the second air line section (120) each have the same polyalkylene terephthalate. Air line (100) Claim 1 or 2 , characterized in that the polyalkylene terephthalate is polybutylene terephthalate. Air line (100) according to one of the preceding claims, characterized in that the first air line section (110) furthermore has a reinforcing means, in particular in particular in the form of fibers. Air line (100) Claim 4 , characterized in that the fibers are selected from the group consisting of glass fibers, basalt fibers, boron fibers, ceramic fibers, silica fibers, steel fibers, polyamide fibers, aramid fibers, carbon fibers, carbon fibers, nylon fibers, polyethylene fibers, plexiglass fibers, flax fibers, hemp fibers, wood fibers, sisal fibers and mixtures of sisal fibers at least two of the aforementioned fibers. Air duct (100) according to one of the preceding claims, characterized in that the polymer blend and / or the polyalkylene terephthalate copolymer furthermore at least one further polymer selected from the group consisting of polycarbonate, polyetherester, polyester, thermoplastic polyester elastomers, thermoplastic copolyester elastomers and combinations of at least two of the aforementioned polymers. Air line (100) according to one of the preceding claims, characterized in that the second air line section (120) is free of a reinforcing agent. Air line (100) according to one of the preceding claims, characterized in that the air line (100) is designed to be linear at least in sections. Air line (100) according to one of the preceding claims, characterized in that the second air line section (120) has a bellows section (123). Air line (100) according to one of the preceding claims, characterized in that the first air line section (110) and the second air line section (120) are materially connected to one another. Air line (100) according to one of the preceding claims, characterized in that the air line (100) is designed as a one-piece injection-molded part, in particular a one-part multi-component injection-molded part. Air line (100) according to one of the preceding claims, that an upstream end of the air line (100) is set up to effect a connection of the air line (100) to an air filter and a downstream end of the air line (100) is set up to connect to effect the air line (100) with a turbocharger. Method for producing an air line (100) according to one of the preceding claims, characterized in that the air line (100) is produced by means of injection molding. Method (100) according to Claim 13 , characterized in that the air line (100) is carried out by means of multi-component injection molding, in particular by means of bi-injection.

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