Classifications

• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
  • F02M—SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
  • F02M35/00—Combustion-air cleaners, air intakes, intake silencers, or induction systems specially adapted for, or arranged on, internal-combustion engines
  • F02M35/10—Air intakes; Induction systems
  • F02M35/104—Intake manifolds
  • F02M35/112—Intake manifolds for engines with cylinders all in one line
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
  • F02M—SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
  • F02M35/00—Combustion-air cleaners, air intakes, intake silencers, or induction systems specially adapted for, or arranged on, internal-combustion engines
  • F02M35/10—Air intakes; Induction systems
  • F02M35/10006—Air intakes; Induction systems characterised by the position of elements of the air intake system in direction of the air intake flow, i.e. between ambient air inlet and supply to the combustion chamber
  • F02M35/10026—Plenum chambers
  • F02M35/10039—Intake ducts situated partly within or on the plenum chamber housing
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
  • F02M—SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
  • F02M35/00—Combustion-air cleaners, air intakes, intake silencers, or induction systems specially adapted for, or arranged on, internal-combustion engines
  • F02M35/10—Air intakes; Induction systems
  • F02M35/10091—Air intakes; Induction systems characterised by details of intake ducts: shapes; connections; arrangements
  • F02M35/10111—Substantially V-, C- or U-shaped ducts in direction of the flow path
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
  • F02M—SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
  • F02M35/00—Combustion-air cleaners, air intakes, intake silencers, or induction systems specially adapted for, or arranged on, internal-combustion engines
  • F02M35/10—Air intakes; Induction systems
  • F02M35/10314—Materials for intake systems
  • F02M35/10321—Plastics; Composites; Rubbers
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
  • F02M—SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
  • F02M35/00—Combustion-air cleaners, air intakes, intake silencers, or induction systems specially adapted for, or arranged on, internal-combustion engines
  • F02M35/10—Air intakes; Induction systems
  • F02M35/1034—Manufacturing and assembling intake systems
  • F02M35/10347—Moulding, casting or the like
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
  • F02M—SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
  • F02M35/00—Combustion-air cleaners, air intakes, intake silencers, or induction systems specially adapted for, or arranged on, internal-combustion engines
  • F02M35/10—Air intakes; Induction systems
  • F02M35/1034—Manufacturing and assembling intake systems
  • F02M35/10354—Joining multiple sections together
  • F02M35/1036—Joining multiple sections together by welding, bonding or the like
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
  • F02M—SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
  • F02M35/00—Combustion-air cleaners, air intakes, intake silencers, or induction systems specially adapted for, or arranged on, internal-combustion engines
  • F02M35/10—Air intakes; Induction systems
  • F02M35/10006—Air intakes; Induction systems characterised by the position of elements of the air intake system in direction of the air intake flow, i.e. between ambient air inlet and supply to the combustion chamber
  • F02M35/10078—Connections of intake systems to the engine
  • F02M35/10085—Connections of intake systems to the engine having a connecting piece, e.g. a flange, between the engine and the air intake being foreseen with a throttle valve, fuel injector, mixture ducts or the like
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
  • F02M—SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
  • F02M35/00—Combustion-air cleaners, air intakes, intake silencers, or induction systems specially adapted for, or arranged on, internal-combustion engines
  • F02M35/10—Air intakes; Induction systems
  • F02M35/10209—Fluid connections to the air intake system; their arrangement of pipes, valves or the like
  • F02M35/10216—Fuel injectors; Fuel pipes or rails; Fuel pumps or pressure regulators
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
  • F05C—INDEXING SCHEME RELATING TO MATERIALS, MATERIAL PROPERTIES OR MATERIAL CHARACTERISTICS FOR MACHINES, ENGINES OR PUMPS OTHER THAN NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES
  • F05C2225/00—Synthetic polymers, e.g. plastics; Rubber
  • F05C2225/08—Thermoplastics

Definitions

• the invention relates to an intake manifold for an internal combustion engine fitted with a fuel supply installation preferably by injection, in particular of the so-called "multipoint" type, comprising, for each cylinder of the engine, at least one injector which injects fuel into a suction duct from the air intake manifold to the engine, directly upstream of the engine cylinder head and of the corresponding cylinder intake valve (s).
• the invention relates to such an intake manifold, more particularly intended to equip a spark-ignition engine, and which comprises:
• an envelope delimiting a plenum intended to be supplied with air supplying the engine, in general by a variable flow valve such as a throttle body, and provided with at least one flange for fixing to at least one cylinder head of the engine, the said flange (s) having at least one supply opening for each cylinder of the engine, each supply opening opening, on the one hand, into the casing and, on the other hand, into a fixing face of the flange on said cylinder head, and - curved air suction tubes, in number at least equal to that of the engine cylinders, and mounted in the casing, so that each tube supplies a corresponding cylinder with air that it receives by its entry into the plenum and which it transmits to a corresponding opening of a flange by its outlet connected by sealed connection means to said supply opening.
• a variable flow valve such as a throttle body
• the inner part of all the air tubes is formed by the bottom molded molded cavities in at least two molded inserts, generally made of the same material as the half-shells, for example in moldable synthetic material, preferably thermoplastic, such as polyamide, and which can be loaded with reinforcing fibers, and each fitted in one of the half-shells respectively, so that the imprints of the inserts also extend during of the joining of the half-shells against each other.
• This process therefore makes it possible to form the tubes by cooperation of surfaces presented by at least four molded parts (two half-shells and two inserts) which are associated.
• a manifold thus produced is suitable for equipping a diesel engine, because of the low pressure gradient between the atmosphere and the plenum of the manifold, depending on the engine.
• the basic problem of the invention is to propose a manifold of an economical embodiment, essentially in thermomouldable synthesis, and semi-modular, because acoustically adaptable to a whole family of engines of different displacements by dimensional adjustment, in particular the diameter and length of the air tubes.
• each tube is a one-piece tube, with corrugated external face, preferably with parallel rings, and face smooth internal delimiting a central passage of constant cross section in shape and surface, so that the tube has great flexibility or transverse flexibility, but low flexibility or axial flexibility.
• the rings of the external corrugated face of such tubes make it possible to maintain constant the shape and the surface of the cross section of the central passage, while helping to maintain the acoustic impedance of the tubes, while providing good flexibility or suppleness. in the radial or transverse direction, making it possible to bend the tubes in the desired manner, while their smooth internal surface limits the pressure losses and gives the tubes a low flexibility or axial flexibility, necessary for maintaining their acoustic impedance.
• each tube is made of synthetic material, preferably moldable, such as thermoplastic, and cut, perpendicular to its longitudinal axis, to the desired length, to give the collector an impregnation.
• annular conformation of the external face of the tube can be defined by one or more helical ribs wound in the external face of the tube, from its entry to its exit, the annular external face of each tube is advantageously a surface of cylindrical revolution with corrugated generator before the tube is bent to the desired shape, to simultaneously benefit from great transverse flexibility but very little axial flexibility.
• the collector casing can consist, in a known manner, of two half-shells of complementary shapes corresponding to the shape of the casing and molded, preferably made of moldable synthetic material, preferably thermoplastic, with flanges for joining on their peripheral edges in a joint plane, the half-shells being closed and fixed one against the other at their joining flanges, for example by welding, preferably by vibration, in which case it is advantageous that each tube is fixed only by its ends to the half-shells.
• each tube is advantageously fixed to a half-shell using a sleeve which is partly force-fitted into the corresponding end of the tube and retained on said half shell by a part of sleeve external to the tube.
• the sleeve to have, on the external face of its part which fits into a corresponding end of the tube, at least one peripheral anchoring redent, which is formed at the axial end, facing said end of the tube, of a surface which is substantially frustoconical with small base facing the central part of the tube, several axially offset redents being preferably formed in this way on the sleeve.
• the latter advantageously comprises at least one abutment projecting substantially radially outwards to limit its fitting in a corresponding end of the tube.
• the sleeve or each of the two connecting sleeves of a tube is molded from a synthetic material, which is preferably a thermosetting material.
• an air inlet sleeve fitted into an inlet end of a tube, is shaped, in its external part, to said inlet end of the tube, in a tulip converging towards the inside of the tube and provided with at least one fixing lug to that of the two half-shells which is not provided with the fixing flange having the supply opening to which said tube is connected by its output, the fixing being for example ensured by heat sealing or by bolting at the level of the fixing lug (s).
• each tube is advantageously connected by an air outlet sleeve, fitted in the outlet end of the tube, to that of the half-shells which is provided with said fixing flange having said supply opening to which said tube is connected in a leaktight manner by its outlet, said sealed connection means comprising a tubular manifold tip, projecting from said flange on the side opposite to the cylinder head, in the extension of said corresponding supply opening, and in which end piece a part of said outlet sleeve, which is external to the tube, is retained with the interposition of at least one flexible seal between said external part of the outlet sleeve and said manifold end piece.
• each manifold end piece comprises:
• a cradle molded in one piece with said half-shell and said corresponding fixing flange, and of substantially semi-cylindrical shape, the internal end of said half-shell has a U-shaped bottom forming a stop in protruding towards the inside of the cradle, and
• a good seal can be ensured using a single flexible seal for each tube, if this seal, mounted around the part of the corresponding outlet sleeve which is external to the tube and retained in the tip.
• corresponding collector is molded in shape, preferably in elastomer, with a cross section corresponding to that of the space available between, on the one hand, said outlet sleeve, and, on the other hand, said cradle and said cover , and so that the seal is compressed radially between these three elements.
• the corresponding manifold tip advantageously has a substantially cross section of the same shape. than that of said supply opening, and the corresponding outlet sleeve has a central passage having a cross section of evolutive shape, progressively varying from the section shape of the manifold tip, in the part of the outlet sleeve which is external to the tube, in the shape of a section of the tube, in the part of the outlet sleeve which is fitted in the outlet end of this tube, so that the sleeve outlet constitutes an adapter sleeve ensuring the transition between the shapes of the sections of the manifold end piece and the air tube.
• the tubes can be grouped at least by pairs of tubes joined over at least part of their length, and, in order to limit the transverse displacements of the tubes or groups of tubes joined in the envelope, housings can be delimited by recesses in the internal face of the envelope, and parts of tubes or contiguous parts of tubes can be housed in these recesses, possibly bordered by ribs projecting from the internal face of one at least half-shells constituting the envelope.
• FIG. 1 is a cross-sectional view of a manifold for an in-line four-cylinder engine, the section being substantially perpendicular to the axis of the engine,
• FIG. 2 is a half-view partly in elevation in plan and partly in section of the downstream half-shell of the collector of Figure 1, with one of the two pairs of tubes which are grouped and retained in this half -shell by their outlet end,
• FIGS. 3 and 4 are cross sections respectively on III-III and IV-IV of FIG. 1, and
• FIG. 5 is a partial view in axial section and on a larger scale of a detail of Figure 2.
• the manifold of Figures 1 and 2 for a four-cylinder in-line engine, comprises a rigid casing 1, made of material synthetic moldable and heat sealable such as a polyamide possibly reinforced with reinforcing fibers, and made up of two half-shells 2 and 3, each molded in this material, having complementary shapes which correspond to the shape of the envelope 1.
• the two half shells 2 and 3 close against each other, by their peripheral edges, to reconstitute the shape of the envelope 1, and are secured to each other in a joint plane P, defined by flanges 4 and 5, projecting outwards on their edges, by vibration welding at these flanges 4 and 5, after mounting in the half-shells 2 and 3 of four air suction tubes (one by engine cylinder), grouped in two pairs of joined tubes, as shown in Figure 2, and their sleeves as described below.
• the flange 6 has, for each cylinder of the engine, an opening supply 7, molded, of circular or oblong cross section, which opens on one side into the flat face 8 for fixing the flange 6 on the cylinder head of the engine and, on the other side, inside of the half-shell 3, lower in FIG.
• the flange 6 also has, for each cylinder, a housing 9 for a fuel injector, this housing 9 opening in the face 10 of the flange 6 which is opposite to the face 8 of attachment to the cylinder head, and to the outside of the half-shell 3, on the one hand, and, on the other hand, each housing 9 opens into a corresponding supply opening 7.
• the flange 6 finally has holes 11, also coming from molding like the openings 7 and housings 9, for the passage of elements for fixing the manifold to the cylinder head.
• the collector also includes a curved tube air intake for each cylinder, that is, as already mentioned, four air tubes grouped in two pairs of tubes joined over a part of their length.
• Each tube such as 12a or 12b of the pair of tubes of FIG. 2, is a curved tube, obtained by cutting, perpendicular to its longitudinal axis, a determined length, to give the tube 12a or 12b an acoustic impedance granted to the motor.
• thermoplastic tube having a smooth internal face 13, delimiting a central passage of cross section of constant shape and surface, for example circular, and a corrugated external face 14, with peripheral rings in substantially parallel planes between them and perpenicular to the axis of the tube, before the cut tube section is bent to the desired shape by closing the half-shells 2 and 3, to each of which each tube 12a or 12b is not fixed as by one respectively of its inlet ends such as 15a and outlet 16a or 16b.
• a light tube 12a or 12b is thus produced, with a thin and impermeable wall, having great flexibility or flexibility, transverse dirty or radial, and low flexibility or axial flexibility, so that it can be bent back to the desired shape without losing the constant shape and surface of the cross section of its central passage with smooth wall, and without varying appreciably in length, which ensures practically constant pressure losses and acoustic impedance.
• Each tube such as 12a or 12b is bent in an almost complete loop in the plane of FIG. 1, over a large part of its length substantially from its entry such as 15a, and its downstream part is moreover bent or counter-bent in a direction perpendicular to the plane of Figure 1, as shown in Figure 2.
• two tubes such as 12a and 12b grouped in a pair of tubes to supply each one of two adjacent cylinders respectively , can be joined over a large part of their length substantially from their inputs such as 15a, while their outputs 16a and 16b (see Figure 2) are spaced from each other to be each connected in a sealed manner to one respecti ⁇ vely, from two adjacent supply openings 7 one from the other in the flange 8 to supply the two corresponding contiguous cylinders.
• each tube 12a or 12b is fixed to the upstream half-shell 2 by an air inlet sleeve such as 17a, while the outlet end 16a or 16b of the tube is connected to the downstream half-shell 3 by an air outlet sleeve 18a or 18b, each of the sleeves 17a, 18a or 18b being preferably molded in a synthetic material, preferably thermosetting.
• the inlet sleeve 17a comprises a tubular part 19a which is force fitted into the inlet end 15a of the tube 12a, and which extends forwards, outside this inlet 15a, by a shaped part in volute or inlet tulip 20a converging towards the interior of the tube 12a and downstream.
• This inlet tulip 20a has a fixing lug 21a, by which the sleeve 17a is fixed to the half-shell 2 at at least one point, for example by heat sealing or by a rivet, as shown schematically in 22a.
• the internal face of the tubular part 19a is smooth, and substantially in the extension of the smooth internal face 13 of the tube 12a, while to ensure good axial fitting of the sleeve 17a in the inlet 15a of the tube 12a, the external face of the tubular part 19a has peripheral redents, as described below for the outlet sleeve 18a with reference to FIG. 5.
• Each outlet sleeve 18a or 18b comprises, as shown for the sleeve 18a in FIG. 5, a tubular part 23a which is force fitted into the outlet 16a of the tube 12a, and which extends rearward or downstream , outside this outlet 16a, by a tubular part 24a external to the tube 12a and retained on the half shell 3 while being connected with sealing to the corresponding opening 7 in the manner described below.
• the parts 23a and 24a between which the sleeve 18a has an annular abutment 25a projecting radially outwards to limit the fitting in the outlet 16a of the tube 12a, have an internal smooth surface, substantially in the extension of the smooth internal face 13 of the tube 12a, while the external face of the fitted part 23a has two peripheral and axially offset recesses 26a, each formed at the axial end, facing the stop 25a, with a substantially frustoconical surface 27a with a small base facing the end of the innermost part 23a of the tube 12a, so as to facilitate penetration at the emmanche ⁇ ment and to ensure good anchoring.
• This cradle 29a projects on the flange 6 on the side opposite to the cylinder head of the engine and has the shape substantially of a semi-cylinder open towards the joint plane P, with a cross section of U shape of substantially constant surface, delimiting a central duct which extends a corresponding opening 7 towards the inside of the half-shell 3.
• the cradle 29a has an annular chamber delimited by a U-shaped bottom 30a projecting radially towards the inside of cradle 29a to form a stop opposing the axial outlet of the seal 28 on the external part 24a of the sleeve 18a.
• the seal 28 around the sleeve 18a is compressed radially between the sleeve 18a and the cradle 29a.
• This cover 31a is molded in synthetic material, preferably thermo ⁇ plastic, and preferably welded by ultrasound on its periphery on the edges of the cradle 29a. Maintaining the sleeve 18a and sealing its connection to the corresponding opening 7 are thus ensured by virtue of the sealing joint 28 and a tubular collector nozzle, formed by the cradle 29a and the corresponding cover 31a. As shown by the section of FIG. 4, the seal 28 is molded with a cross-sectional shape such that it occupies radially all the space available between the part 24a of the sleeve 18a, in the center, and the cradle 29a and the cover 31a , at the periphery, being compressed radially between these parts.
• the part 24a of the sleeve 18a is extended by an end in the form of a half-cylinder open towards the bottom of the cradle 29a which receives it, and having, as shown on the section of the FIG. 3, a recess complementary to that of the cradle 29a to define a conduit of progressively variable section connecting the outlet, for example circular, 16a of the tube 12a to the section, for example oblong, of the corresponding opening 7, as shown in the drawings.
• the outlet sleeve 18a is molded so that its central passage has this corresponding change in section, the section of the end of the sleeve 18a fitted into the tube 12a always having the same shape as the section of the tube 12a, and the section of the end of the sleeve 18a facing the opening 7 having, alone or with the section complementary to the bottom of the cradle 29a which receives it, the same shape as the section of the opening 7.
• the outlet sleeve 18b of the tube 12b is mounted in the same way with a seal such as 28 in a manifold end piece consisting of a similar cradle 29b closed by a corresponding similar cover.
• the two tubes 12a and 12b are also arranged, by their adjoining parts, in a housing defined in the downstream half-shell 3 by a recess between ribs 33 projecting from the internal face of this half-shell 3.
• the tubes 12a and 12b can be joined so that the rings of the external face of one are engaged between the rings of the other, and, optionally, the ribs 33 bordering the housings can have projections engaging between the outer rings of the tubes 12a, 12b to better position them in the casing 1.
• the sleeves 17a and 18a are mounted to give the tubes a general radius of curvature which is slightly less than the radius of curvature of the parts rounded half-shells 2 and 3 of the envelope 1.
• the transverse flexibility of the tubes allows, during the assembly of the half-shells 2 and 3, small alternating relative displacements of the latter in the direction perpendicular to the radius of curvature of the tubes, thus offering the possibility of perform the assembly of the half-shells 2 and 3 for example by vibration welding.
• a collector is thus obtained, the envelope 1 of which delimits an internal chamber 34, called the plenum, which is supplied with air supplying the engine by an opening (not shown) for example formed in an end face of the envelope 1 parallel to the plane of Figure 1, this opening being connected to a butterfly body.
• Each tube such as 12a or 12b mounted in the casing 1 sucks in the air in the plenum 34 by its inlet such as 15a and transmits this air by its outlet 16a or 16b to a supply opening 7 of the flange 6 to supply a corresponding cylinder.
• the envelope 1 contains, in its half not shown in Figure 2, two other symmetrical air suction tubes of the tubes 12a and 12b and mounted in the same way.

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• Engineering & Computer Science (AREA)
• Chemical & Material Sciences (AREA)
• Combustion & Propulsion (AREA)
• Mechanical Engineering (AREA)
• General Engineering & Computer Science (AREA)
• Manufacturing & Machinery (AREA)
• Exhaust Silencers (AREA)
• Lining Or Joining Of Plastics Or The Like (AREA)
• Characterised By The Charging Evacuation (AREA)

Applications Claiming Priority (3)

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• 1995
  • 1995-05-23 FR FR9506119A patent/FR2734603B1/fr not_active Expired - Fee Related
• 1996
  • 1996-05-20 DE DE69607752T patent/DE69607752T2/de not_active Expired - Lifetime
  • 1996-05-20 EP EP96917521A patent/EP0827567B1/de not_active Expired - Lifetime
  • 1996-05-20 WO PCT/FR1996/000750 patent/WO1996037696A1/fr active IP Right Grant
  • 1996-05-20 US US08/945,319 patent/US5964194A/en not_active Expired - Fee Related

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