JP2000161157A - Structure of inertia supercharging intake manifold for use in multiple cylinder internal combustion engine - Google Patents

Abstract

PROBLEM TO BE SOLVED: To fabricate through the injection molding of a synthetic resin an entire inertia supercharging intake manifold comprising a surge tank for introducing intake from an air cleaner and long branch pipes connecting cylinders together, when each branch pipe is curved to surround the circumference of the surge tank. SOLUTION: Each branch pipe is divided into an upstream branch pipe 7a on the side of a surge tank 6 and a downstream branch pipe 7b on the side of an internal combustion engine and the surge tank 6 is divided into two halved surge tank pieces 6a, 6b on a dividing plane D. Both the upstream and downstream branch pipes 7a, 7b are divided into respective two halved pipe pieces 7a, 7b and two halved pipe pieces 7b', 7b" on respective dividing planes E, F. Both of the halved surge tank pieces 6a, 6b and both of the halved pipe pieces 7a, 7b and 7b', 7b" can be injection molded from a thermoplastic synthetic resin.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a multi-cylinder internal combustion engine such as a four-cylinder internal combustion engine, in which, among intake manifolds for distributing intake air from an air cleaner to each cylinder, supercharging is performed by an inertia effect. The present invention relates to a structure of an intake manifold.

[0002]

2. Description of the Related Art In general, in this type of inertia supercharged intake manifold for a multi-cylinder internal combustion engine, each cylinder is independently provided between a surge tank into which intake air from an air cleaner is introduced and an intake port of each cylinder. By connecting via branch pipes, the length of each of the branch pipes is made considerably long, so that the intake air is supercharged by the inertia effect. In other words, the connection between each cylinder and the surge tank is made. Since each branch pipe between them has to be considerably long, the size of the intake manifold is greatly increased.

In recent years, therefore, a surge tank has been disposed at a position adjacent to a longitudinal side surface of an internal combustion engine so as to extend in the axial direction of a crankshaft. Each connected branch pipe extends laterally through the upper side of the surge tank as viewed from the axial direction of the crankshaft, curves downwardly outside the surge tank and then toward the internal combustion engine below the surge tank. There has been proposed an inertia supercharged intake manifold configured to bend inward and further upward and then connect to the lower surface of the surge tank.

[0004]

As described above, each branch pipe connected to the flange attached to the longitudinal side face of the internal combustion engine passes through the upper side of the surge tank when viewed from the axial direction of the crankshaft. When it is configured to extend sideways, curve downward on the outside of the surge tank, then curve inward toward the internal combustion engine below the surge tank, curve further upward, and then connect to the lower surface of the surge tank. Since each long branch pipe can be arranged around the surge tank so as to surround it, there is an advantage that the intake manifold can be reduced in size.

However, on the other hand, the bending angle of each of the branch pipes becomes so large as to be about 270 degrees. Therefore, when manufacturing the branch pipes, each branch pipe is made of a metal pipe. Must be bent as described above, or the whole must be made of cast aluminum or its alloy, but in the former, in addition to making each branch pipe made of metal pipe, Since the flange for mounting to the surge tank and internal combustion engine to which each branch pipe is connected must also be made of metal, not only the weight of the entire intake manifold is significantly increased, but also material and processing costs are increased, and the price is increased. There was also a problem that it would be significantly up.

When the entire intake manifold is made of aluminum or an alloy thereof, as in the latter case, the weight and the price are similarly increased. There is a problem that the flow resistance of the intake air is large due to the rough surface roughness on the inner surface, which causes a decrease in output. SUMMARY OF THE INVENTION It is a technical object of the present invention to provide a structure of an intake manifold having the above-described configuration, which can be entirely manufactured by injection molding of a thermoplastic hard synthetic resin.

[0007]

In order to achieve this technical object, a first aspect of the present invention is to provide a method for manufacturing a vehicle in which a surge tank for introducing intake air from an air cleaner is provided near a longitudinal side surface of an internal combustion engine. The branch pipes arranged for each cylinder and connected to the flange portion attached to the longitudinal side surface of the internal combustion engine for each cylinder, pass sideways through the upper side of the surge tank when viewed from the axial direction of the crankshaft. An intake manifold that extends downward, curves downward on the outside of the surge tank, then curves inward toward the internal combustion engine below the surge tank, further curves upward, and then connects to the lower surface of the surge tank. Each of the branch pipes is connected to an upstream branch pipe at a portion between the downward curved portion and the inward curved portion of the branch pipe. And flop, in the structure in which bonding is divided into the downstream side of the branch pipe, while each integrating each downstream branch pipe to the mounting flange portion,
The surge tank is configured by combining two half-segmented surge tank pieces that are horizontally divided by a substantially horizontal dividing plane, and each of the downstream branch pipes and the upstream branch pipes is divided into planes each including an axis thereof. It is characterized in that it is constituted by combining two half-split pipe pieces which are vertically split in. Is the thing.

[0008] Claim 2 of the present invention (second invention)
`` A surge tank for introducing intake air from an air cleaner is disposed in a portion adjacent to a longitudinal side surface of an internal combustion engine, and each branch connected to a flange portion attached to the longitudinal side surface of the internal combustion engine for each cylinder. A pipe extends laterally through the upper side of the surge tank and curves downwardly outside the surge tank, as viewed from the axial direction of the crankshaft, and then curves inwardly toward the internal combustion engine below the surge tank. In the intake manifold connected to the lower surface of the surge tank after being further curved upward, each of the branch pipes is connected to an upstream branch in a portion between the downwardly curved portion and the inwardly curved portion of the branch pipe. A pipe and a branch pipe on the downstream side are divided and joined to each other. While integrating the side branch pipe and the mounting flange portion, the surge tank is configured by combining two half-split surge tank pieces that are horizontally divided by a substantially horizontal dividing plane, and the respective downstream branch pipes and the respective Each of the upstream branch pipes is configured by combining two half-split pipe pieces vertically divided by a split plane including the axis thereof. "

[0009]

According to the first aspect of the invention, each branch pipe is formed by joining an upstream branch pipe and a downstream branch pipe integrated with a mounting flange portion. The surge tank is formed by combining two half-segmented surge tank pieces obtained by dividing the surge tank by a substantially horizontal divided plane, and each of the downstream branch pipes and the upstream branch pipes is defined by an axis thereof. By combining the two half pipe pieces vertically divided by the divided plane including the two, the two half surge tank pieces constituting the surge tank, and the two half pipe pieces constituting each of the downstream branch pipes Split pipe pieces, and each of the two half-split pipe pieces that constitute each upstream branch pipe, are made of thermoplastic hard using at least one pair of molding dies. It can be made by the synthetic resin injection molding.

[0010] Then, after the two half-split surge tank pieces are joined together, they are integrally joined by an adhesive, heat welding or fusion by vibration, or a molten synthetic resin is injected into the joining surface. By assembling them together into a surge tank, the two half pipe pieces constituting each of the downstream branch pipes are combined with each other, and then fused by an adhesive, heat fusion, or vibration as described above. By assembling integrally with each other, or by injecting molten synthetic resin into the mating surface and integrally joining, assembling with each downstream branch pipe, further configuring each of the upstream branch pipes After the two halved pipe pieces are joined together, they are joined together by an adhesive or heat fusion or vibration fusion as described above, or they are joined together. By assembling integrally by injecting molten synthetic resin into the surface, assembling into each upstream branch pipe, then each downstream branch pipe for each upstream branch pipe, with respect to the surge tank The upstream branch pipes can be assembled to the intake manifold by bonding them with an adhesive, heat fusion, fusion by vibration, or the like, as described above.

Further, according to the second invention, two half-split tank pieces constituting the surge tank, two half-pipe pieces constituting each of the downstream branch pipes, and each of the upstream branches Each of the two half-split pipe pieces constituting the pipe, as in the first aspect,
It can be manufactured by an injection molding method of a thermoplastic hard synthetic resin using at least a pair of molding dies,
After the two half-split surge tank pieces are joined together, they are joined together by an adhesive or heat fusion or vibration fusion as described above, or by injecting a molten synthetic resin into the joint surface. By joining them together, they are assembled into a surge tank having a mounting flange portion, while the two half pipe pieces constituting each of the downstream branch pipes are joined together, and then an adhesive or heat is applied in the same manner as described above. Assembling into each downstream branch pipe by integrally joining by fusion or vibration fusion or by injecting molten synthetic resin into the mating surface to assemble each downstream branch pipe, After joining the two halved pipe pieces constituting the side branch pipe to each other, they are integrally joined by adhesive or heat fusion or fusion by vibration as described above. Or, by integrally injecting by injecting a molten synthetic resin into the mating surface, assembling each upstream branch pipe, and for each upstream branch pipe, each downstream branch pipe, By joining each upstream branch pipe to the surge tank and each downstream branch pipe to the mounting flange by adhesive or heat fusion or fusion by vibration, as described above, It can be assembled into an intake manifold.

Therefore, according to the present invention, the entire intake manifold having a plurality of branch pipes bent at a large angle, a flange portion for mounting to an internal combustion engine, and a surge tank is manufactured by injection molding of a thermoplastic hard synthetic resin. Can greatly reduce the weight of the intake manifold, achieve a significant reduction in price, and
Since the inner surface of each branch pipe formed by injection molding of a synthetic resin is smooth, there is an effect that the flow resistance of intake air is small and the output can be improved.

[0013]

Embodiments of the present invention will be described below with reference to the drawings. 1 to 16 show a first embodiment. In this figure, reference numeral 1 denotes four cylinders A1, A
2 shows a four-cylinder internal combustion engine in which two cylinders A1, A2 and A4 are arranged in series along the direction of the axis 2 of the crankshaft.
3, the intake port 4 to A4 is open.

Reference numeral 5 denotes an inertia supercharging type intake manifold for the internal combustion engine 1. The intake manifold 5 is provided with a surge tank 6 at a portion close to the longitudinal side surface 3 of the internal combustion engine 1 and a long length. Four branch pipes 7 and a plurality of bolts (not shown) on the longitudinal side surface 3 of the internal combustion engine 1 for connecting each of the branch pipes 7 to the intake port 4 of the internal combustion engine 1. ), And an intake inlet pipe 9 for introducing intake air from an air cleaner (not shown) into the surge tank 6 protrudes upward from the upper surface of the surge tank 6. Are provided integrally.

As shown in FIG. 2, each branch pipe 7 in the intake manifold extends laterally from the mounting flange 8 above the surge tank 6 as viewed from the direction of the axis 2 of the crankshaft. Extending downwardly outside the surge tank 6, then inwardly below the surge tank 6 toward the internal combustion engine 1 and further upwardly, and then connecting to the lower surface of the surge tank 6. Is configured.

In the case of the present embodiment, the connecting portion of the branch pipe 7 to the cylinders A1 and A4 with respect to the surge tank 6 is provided on the outer side of the branch pipe 7 at a position remote from the internal combustion engine 1 on the lower surface of the surge tank 6. While setting, the cylinders A2, A
By setting the connecting portion of the branch pipe 7 to the surge tank 6 with respect to the surge tank 6 at a position near the internal combustion engine 1 on the lower surface of the surge tank 6, the length of each branch pipe 7 is made substantially equal. .

As shown in FIGS. 4 and 5, each branch pipe 7 in the intake manifold 5 is connected to an upstream branch in a portion between the downwardly curved portion and the inwardly curved portion of the branch pipe 7. A pipe 7a,
The upstream branch pipe 7a is divided into two parts, the downstream branch pipe 7b and the upstream branch pipe 7a.
And the mounting flange 8 is integrated with each downstream branch pipe 7b.

As shown in FIGS. 4 and 6, the surge tank 6 is divided into upper and lower parts by a substantially horizontal dividing plane D, so that a half-divided surge tank piece having an intake inlet pipe 9 on the upper surface is provided. 6a and a half surge tank piece 6a having a connection portion for each branch pipe 7 on the lower surface.
By dividing the surge tank 6 in this way, each of the two half-split surge tank pieces 6a and 6b is
As shown in FIG. 12, it can be manufactured by injection molding of a thermoplastic synthetic resin using two molding dies A1, A2 and A3, A4.

On the other hand, each of the downstream branch pipes 7b integrally provided with the mounting flange portions 8 is shown in FIGS.
9, the pipe is divided into two half-split pipe pieces 7 b ′ and 7 b ″ which are vertically divided by a split plane E including the axis. Each of the downstream branch pipes 7 b with the mounting flange portion 8 is thus divided. Of the two half pipe pieces 7b 'and 7b ".
b ′, as shown in FIG. 13, three molding dies B1, B
By injection molding of thermoplastic synthetic resin using 2, B3,
As shown in FIG. 14, the other half pipe piece 7b "can be manufactured by injection molding of a thermoplastic synthetic resin using two molding dies B4 and B5.

Each of the upstream branch pipes 7a
As shown in FIGS. 4, 8 and 10, two half-split pipe pieces 7a ',
7a ". Each of the upstream branch pipes 7a is divided in this manner, so that the two half pipe pieces 7a are separated.
Each of a ′ and 7a ″ can be manufactured by injection molding of a thermoplastic synthetic resin using two molding dies C1, C2 and C3, C4 as shown in FIGS.

Then, after the two half-split surge tank pieces 6a and 6b constituting the surge tank 6 are joined together, they are joined together by an adhesive, heat welding or fusion by vibration, or they are joined together. By injecting molten synthetic resin into the surfaces and integrally joining them, the assembly is assembled to the surge tank 6 shown in FIG. On the other hand, both the half pipe pieces 7 constituting the downstream branch pipe 7b
b ', 7b "are joined together, and then joined together by an adhesive or heat fusion or vibration fusion as described above, or by injecting a molten synthetic resin into the joint surface. FIGS. 4 and 5
As shown in (1), it is assembled to the downstream branch pipe 7b integrally provided with the mounting flange portion 8.

Further, after the two half pipe pieces 7a 'and 7a "constituting the upstream branch pipe 7a are joined together, they are integrally formed by an adhesive or heat fusion or vibration fusion as described above. Or by integrally injecting a molten synthetic resin into the mating surface to assemble them into an upstream branch pipe 7a shown in FIG.

Next, each of the upstream branch pipes 7a
Then, each downstream branch pipe 7b is bonded to the surge tank 6 with an adhesive or heat fusion or fusion by vibration in the same manner as described above.
1, 2 and 3 by bonding to each of the connecting portions on the lower surface of the same by an adhesive or heat fusion or fusion by vibration in the same manner as described above. 5 can be assembled.

Next, FIGS. 17 to 25 show a second embodiment of the present invention. In the second embodiment, like the intake manifold in the first embodiment, each branch pipe 17 in the intake manifold 15 for the internal combustion engine 1 is viewed from the direction of the crankshaft axis 2 as shown in FIG. As shown in FIG. 5, the mounting flange 15 for the internal combustion engine 1 extends laterally through the upper side of a surge tank 16 having an intake inlet pipe 19, curves downwardly outside the surge tank 16, and then extends downward. On the lower side, is bent inward toward the internal combustion engine 1 and further bent upward, and then connected to the lower surface of the surge tank 16. The mounting flange portion 18 for connection is integrated with the surge tank 16.

That is, as shown in FIG. 20, each branch pipe 17 in the intake manifold 15 is connected to an upstream branch pipe 17a at a portion between the downward curved portion and the inward curved portion of the branch pipe 17.
And a downstream branch pipe 17b. Each of the upstream branch pipes 17a is separated from the surge tank 16, and the mounting flange portion 18 is separated from the downstream branch pipe 17b. It is integrated with the tank 16.

As shown in FIGS. 20 and 21, the surge tank 16 provided with the mounting flange portion 18 is divided into two upper and lower sides by a substantially horizontal dividing plane D 'as shown in FIG. It is divided into a half split surge tank piece 16a having an intake inlet pipe 19 and a half split surge tank piece 16a having a connection portion for each branch pipe 17 on the lower surface.

By dividing the surge tank 16 in this manner, two half-split surge tank pieces 16a, 16b
One of the half surge tank pieces 16a can be manufactured by injection molding of a thermoplastic synthetic resin using three molding dies A1 ', A2', and A3 'as shown in FIG. , The other half split surge tank piece 16b,
As in the case of FIG. 12 in the first embodiment, it can be manufactured by injection molding of a thermoplastic synthetic resin.

On the other hand, each downstream branch pipe 17b is
As shown in FIGS. 20 and 23, two half-split pipe pieces 17b 'and 17
b ". By dividing each downstream branch pipe 17b in this way, the two half-split pipe pieces 1
7b ', 17b ", one half of the pipe piece 17b'
As shown in FIG. 25, three molding dies B1 ′, B1
2 'and B3' can be manufactured by injection molding of a thermoplastic synthetic resin, while the other half pipe piece 1
7b ″ can be manufactured by injection molding of a thermoplastic synthetic resin, similarly to FIG. 14 in the first embodiment.

In this case, each of the downstream branch pipes 1
At the lower end of 7b, a flange 1 connecting these components to each other is provided.
7c is provided integrally. Further, similarly to the first embodiment, each of the upstream branch pipes 17a is also divided into two half-split pipe pieces 17a 'and 17a "which are vertically divided by a division plane F' including the axis thereof. These two half pipe pieces 17a 'and 17a "are manufactured by injection molding of a thermoplastic synthetic resin.

Next, after the two half-split surge tank pieces 16a, 16b constituting the surge tank 16 are joined together, they are joined together by an adhesive, heat welding or fusion by vibration, or they are joined together. By injecting a molten synthetic resin into the surfaces and joining them together, they are assembled into a surge tank 16 shown in FIG. on the other hand,
After the two half pipe pieces 17b 'and 17b "constituting the downstream branch pipe 17b are joined together, they are integrally joined by an adhesive or heat fusion or vibration fusion in the same manner as described above. By injecting molten synthetic resin into the mating surface and joining them together,
It is assembled to the downstream branch pipe 17b shown in FIGS.

Further, the two half pipe pieces 17a ', 17a "constituting the upstream branch pipe 17a are joined together, and then integrally formed with an adhesive or by heat fusion or vibration fusion in the same manner as described above. 20 or by integrally injecting molten synthetic resin into the mating surface to assemble it into the upstream branch pipe 17a shown in FIG.

Next, each of the downstream branch pipes 17
b, the mounting flange 1 integrated with the surge tank 16
8 and connected by an adhesive or thermal fusion or fusion by vibration as described above, and each downstream branch pipe 17b is bonded to each downstream branch pipe 17b in the same manner as described above. After joining with an agent or heat fusion or fusion by vibration or the like, each upstream branch pipe 17a is connected to each connection portion on the lower surface of the surge tank 16 with an adhesive or heat fusion in the same manner as described above. Alternatively, by joining by fusion or the like by vibration, FIGS.
9 can be assembled to the intake manifold 15 having the configuration shown in FIG.

[Brief description of the drawings]

FIG. 1 is a plan view of an intake manifold according to a first embodiment of the present invention.

FIG. 2 is a side view taken along the line II-II of FIG.

FIG. 3 is a side view taken along the line III-III of FIG. 1;

FIG. 4 is a side view showing a state where the intake manifold is divided into a surge tank, an upstream branch pipe, and a downstream branch pipe.

FIG. 5 is a perspective view showing the downstream branch pipe.

FIG. 6 is a side view showing a state where the surge tank is divided into two parts.

FIG. 7 is a side view showing a state where the downstream branch pipe is divided into two parts.

FIG. 8 is a side view showing a state in which the upstream branch pipe is divided into two.

FIG. 9 is an enlarged cross-sectional view taken along the line IX-IX of FIG. 7;

FIG. 10 is an enlarged sectional view taken along line XX of FIG. 8;

FIG. 11 is a view showing a state in which one half of a surge tank piece constituting the surge tank is injection-molded.

FIG. 12 is a view showing a state in which the other half split surge tank piece constituting the surge tank is injection-molded.

FIG. 13 is a view showing a state in which one half of a pipe piece constituting the downstream branch pipe is injection-molded.

FIG. 14 is a view showing a state in which the other half pipe piece constituting the downstream side branch pipe is injection-molded.

FIG. 15 is a view showing a state in which one half of a pipe piece constituting the upstream branch pipe is injection-molded.

FIG. 16 is a view showing a state in which the other half-split pipe piece constituting the upstream branch pipe is injection-molded.

FIG. 17 is a plan view of an intake manifold according to a second embodiment of the present invention.

FIG. 18 is a side view taken along the line XVIII-XVIII in FIG. 17;

FIG. 19 is a side view taken along XIX-XIX in FIG. 17;

FIG. 20 is a side view showing a state where the intake manifold is divided into a surge tank, an upstream branch pipe, and a downstream branch pipe.

FIG. 21 is a side view showing a state where the surge tank is divided into two parts.

FIG. 22 is a perspective view showing the downstream branch pipe.

FIG. 23 is a side view showing a state where the downstream branch pipe is divided into two parts.

FIG. 24 is a diagram showing a state in which one half of a surge tank piece constituting the surge tank is injection molded.

FIG. 25 is a view showing a state in which one half of a pipe piece constituting the downstream branch pipe is injection-molded.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 1 Internal combustion engine 2 Axis line of a crankshaft 3 Longitudinal side surface 4 Intake port 5, 15 Intake manifold 6, 16 Surge tank 6a, 6b, 16a, 16b Half split surge tank piece 7, 17 Branch pipe 7a, 17a Upstream branch pipe 7b, 17b Downstream branch pipe 7a ', 7a ", 17a', 17a" Half-split pipe piece 7b ', 7b ", 17b', 17b" Half-split pipe piece 8, 18 Mounting flange part 9, 19 Intake inlet pipe D, D ', E, E', F, F 'division plane

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[Procedure amendment]

[Submission date] December 1, 1998 (1998.12.
1)

[Procedure amendment 1]

[Document name to be amended] Drawing

[Correction target item name] FIG.

[Correction method] Change

[Correction contents]

FIG.

[Procedure amendment 2]

[Document name to be amended] Drawing

[Correction target item name] FIG.

[Correction method] Change

[Correction contents]

FIG.

 ──────────────────────────────────────────────────続 き Continuing on the front page (72) Inventor Yoshihiro Kimoto 2-1-1 Taoyuan, Ikeda-shi, Osaka Daihatsu Industry Co., Ltd. (72) Inventor Takeharu Suga 175, Omotohara, Hachihonmatsu-cho, Higashihiroshima-shi, Hiroshima No. 1 Daikyo Co., Ltd. (72) Inventor Nobuyuki Homi, No. 175 Daiyakuhara, Hachihonmatsucho, Higashihiroshima City, Hiroshima Prefecture

Claims (2)

[Claims] 1. A surge tank for introducing intake air from an air cleaner is disposed in a portion adjacent to a longitudinal side surface of an internal combustion engine, and is connected for each cylinder to a flange portion attached to the longitudinal side surface of the internal combustion engine. Each branch pipe extends laterally through the upper side of the surge tank, curved downwardly outside the surge tank and then inwardly toward the internal combustion engine below the surge tank, as viewed from the axial direction of the crankshaft. In the intake manifold connected to the lower surface of the surge tank after being bent upward and further upward, each of the branch pipes is located at an upstream side in a portion between the downwardly curved portion and the inwardly curved portion of the branch pipe. Of the downstream branch pipe and the downstream branch pipe. And the surge tank is integrated with each of the mounting flange portions, and the surge tank is formed by combining two half-segmented surge tank pieces that are horizontally divided by a substantially horizontal dividing plane, and each of the downstream branch pipes and each of the upstream branch pipes is formed. The structure of an inertia supercharged intake manifold in a multi-cylinder internal combustion engine, wherein each of the side branch pipes is constituted by combining two half pipe pieces vertically divided by a division plane including an axis thereof. 2. A surge tank for introducing intake air from an air cleaner is disposed at a position adjacent to a longitudinal side surface of the internal combustion engine, and is connected for each cylinder to a flange portion attached to the longitudinal side surface of the internal combustion engine. Each branch pipe extends laterally through the upper side of the surge tank, curved downwardly outside the surge tank and then inwardly toward the internal combustion engine below the surge tank, as viewed from the axial direction of the crankshaft. In the intake manifold connected to the lower surface of the surge tank after being bent upward and further upward, each of the branch pipes is located at an upstream side in a portion between the downwardly curved portion and the inwardly curved portion of the branch pipe. Into a branch pipe and a branch pipe on the downstream side. While each upstream branch pipe and the mounting flange portion are integrated, the surge tank is configured by combining two half-split surge tank pieces that are horizontally divided by a substantially horizontal dividing plane,
Inertia in a multi-cylinder internal combustion engine, wherein each of the downstream branch pipes and each of the upstream branch pipes are configured by combining two half-split pipe pieces which are vertically divided by a division plane including an axis thereof. Supercharged intake manifold structure.