JP2002106431A - Air intake duct and its manufacturing method - Google Patents
Air intake duct and its manufacturing methodInfo
- Publication number
- JP2002106431A JP2002106431A JP2000299843A JP2000299843A JP2002106431A JP 2002106431 A JP2002106431 A JP 2002106431A JP 2000299843 A JP2000299843 A JP 2000299843A JP 2000299843 A JP2000299843 A JP 2000299843A JP 2002106431 A JP2002106431 A JP 2002106431A
- Authority
- JP
- Japan
- Prior art keywords
- porous sheet
- intake duct
- divided
- divided body
- mold
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
Classifications
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y02T10/00—Road transport of goods or passengers
- Y02T10/10—Internal combustion engine [ICE] based vehicles
- Y02T10/12—Improving ICE efficiencies
Landscapes
- Injection Moulding Of Plastics Or The Like (AREA)
Abstract
Description
【０００１】[0001]
【発明の属する技術分野】本発明は、エンジンに空気を
供給する通路としての吸気ダクトおよびその製造方法に
関し、詳しくは吸気時の騒音が低減された吸気ダクトお
よびその製造方法に関する。BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an intake duct as a passage for supplying air to an engine and a method of manufacturing the same, and more particularly, to an intake duct with reduced noise during intake and a method of manufacturing the same.
【０００２】[0002]
【従来の技術】自動車エンジンの吸気系では、吸気時に
吸気ダクトから騒音が発生するという問題がある。この
吸気騒音は、特にエンジンの低速回転時に耳障りであ
る。そこで従来より、図８に示すように、吸気ダクト１
にサイドブランチ１０１および／またはレゾネータ１０
２を設け、ヘルムホルツの共鳴理論等に基づいて計算さ
れる特定周波数の騒音を低減することが行われている。2. Description of the Related Art In an intake system of an automobile engine, there is a problem that noise is generated from an intake duct during intake. This intake noise is particularly harsh when the engine is running at a low speed. Therefore, conventionally, as shown in FIG.
Side branch 101 and / or resonator 10
2, the noise of a specific frequency calculated based on Helmholtz's resonance theory or the like is reduced.
【０００３】しかしサイドブランチ１０１は長いもので
約３０ｃｍほどにもなり、レゾネータ１０２は大きいも
ので１４×１０-3ｍ3ほどにもなる。このため、これら
の吸音装置のエンジンルーム内に占めるスペースが大き
くなり、他の部品の搭載の自由度が低くなるという不具
合が生じていた。However, the length of the side branch 101 is as long as about 30 cm, and the size of the resonator 102 is as large as about 14 × 10 −3 m 3 . For this reason, the space occupied by these sound absorbing devices in the engine room becomes large, and the degree of freedom in mounting other components is reduced.
【０００４】そこで、省スペース化のため、本出願人が
特願２０００−１５６４２０号において紹介した吸気ダ
クトが開発された。図９に示すように、この吸気ダクト
１はブロー成形により成形した吸気ダクト本体１０の開
口１１に、多孔質シートとしての不織布シート１２を溶
着したものである。この吸気ダクト１は、サイドブラン
チやレゾネータを有しないためエンジンルーム内に占め
るスペースは小さい。In order to save space, an intake duct introduced by the present applicant in Japanese Patent Application No. 2000-156420 has been developed. As shown in FIG. 9, the intake duct 1 is obtained by welding a nonwoven fabric sheet 12 as a porous sheet to an opening 11 of an intake duct body 10 formed by blow molding. Since this intake duct 1 does not have a side branch or a resonator, the space occupied in the engine room is small.
【０００５】[0005]
【発明が解決しようとする課題】（１）上記特願２００
０−１５６４２０号において紹介した吸気ダクトはブロ
ー成形法により製造される。ブロー成形法は、半溶融状
態の熱可塑性樹脂からなる中空円筒状のパリソン（予備
成形体）をブロー成形型で挟持し、その内部に空気を圧
入することによりパリソンを膨らませ成形型内面に押し
つけることにより、所望の形状の成形品を得る成形方法
である。Problems to be Solved by the Invention (1) The above-mentioned Japanese Patent Application No. 200
The intake duct introduced in No. 0-156420 is manufactured by a blow molding method. In the blow molding method, a hollow cylindrical parison (preformed body) made of a thermoplastic resin in a semi-molten state is sandwiched by a blow molding die, and air is pressed into the parison to expand the parison and press it against the inner surface of the molding die. Is a method for obtaining a molded article having a desired shape.
【０００６】しかし、このブロー成形法は以下の問題点
を有する。まず、成形品である吸気ダクト本体の肉厚が
変わりやすいという問題点がある。パリソンは半溶融状
態であるため自重により垂れ下がり肉厚が変わるおそれ
がある。パリソンの肉厚が変わると成形品である吸気ダ
クト本体の肉厚も変わるおそれがある。また、ブロー成
形型内でパリソンを膨らませる際においても型までの距
離が遠い部位の肉厚は必然的に薄くなってしまう。設計
通りの肉厚が得られないと吸気ダクトが所望の強度を有
しないおそれがある。また、設計通りの肉厚を得るため
には、パリソン自体の肉厚を調整する必要があり、煩雑
である。However, this blow molding method has the following problems. First, there is a problem that the thickness of the intake duct body, which is a molded product, tends to change. Since the parison is in a semi-molten state, it may hang down due to its own weight and its thickness may change. If the thickness of the parison changes, the thickness of the molded intake duct body may also change. Further, even when the parison is expanded in the blow molding die, the thickness of the portion far from the die is inevitably thin. If the designed thickness is not obtained, the intake duct may not have the desired strength. Further, in order to obtain the designed thickness, it is necessary to adjust the thickness of the parison itself, which is complicated.
【０００７】また、袋部のカット、バリ取りという工程
が、別途必要になるという問題点がある。ブロー成形法
においては、成形型でパリソンを挟持する際にパリソン
の両端部が封止されるため、成形後の吸気ダクト本体の
両端部に袋部が形成されることになる。また、成形型か
らはみ出したパリソンを形成する樹脂がバリとなって吸
気ダクト本体の側面にひだ状に残る。このため、袋部の
カット、バリ取りという工程が別途必要になるまた、ブ
ロー成形法により吸気ダクト本体を成形し、袋部のカッ
ト、バリ取りを終えた後でも、吸気ダクト本体に多孔質
シートを設置するための開口を形成する工程、および吸
気ダクト本体と多孔質シートとを昇温し、形成した開口
を塞ぐように多孔質シートを溶着する工程が必要になる
という問題点がある。There is another problem that a step of cutting and deburring the bag portion is required separately. In the blow molding method, both ends of the parison are sealed when the parison is sandwiched by the mold, so that the bag portions are formed at both ends of the intake duct body after molding. In addition, the resin forming the parison protruding from the mold becomes burrs and remains in a pleated shape on the side surface of the intake duct body. For this reason, a step of cutting and deburring the bag part is required separately.Also, after the air intake duct body is formed by the blow molding method and the bag part is cut and deburred, the porous sheet is formed on the air intake duct body. In addition, there is a problem that a step of forming an opening for installing the sheet and a step of heating the air intake duct body and the porous sheet and welding the porous sheet so as to close the formed opening are required.
【０００８】さらに、図１０に示すように、多孔質シー
ト１２を溶着するためには、予めブロー成形時に吸気ダ
クト本体１０に受け面１３を形成しておく必要があると
いう問題点もある。また、吸気ダクト本体１０と多孔質
シート１２とは受け面１３を介して、二次元的に接合さ
れているだけである。このため、吸気ダクト本体１０と
多孔質シート１２との間に隙間ができやすく、吸気ダク
トの接合性が悪くなるおそれがある。特に、吸気ダクト
本体の肉厚が薄い場合は、受け面の面積、すなわち接合
面積も狭くなり、かつダクト自身の剛性が不足し、溶着
時に必要な押付圧力が得られないため一層接合性が悪く
なるおそれがある。Further, as shown in FIG. 10, in order to weld the porous sheet 12, there is another problem that the receiving surface 13 must be formed on the intake duct body 10 at the time of blow molding. Further, the intake duct body 10 and the porous sheet 12 are only two-dimensionally joined via the receiving surface 13. For this reason, a gap is likely to be formed between the intake duct main body 10 and the porous sheet 12, and there is a possibility that the joinability of the intake duct is deteriorated. In particular, when the thickness of the intake duct body is small, the area of the receiving surface, that is, the joining area is also small, and the rigidity of the duct itself is insufficient, and the necessary pressing pressure at the time of welding cannot be obtained, so that the joining property is further deteriorated. Could be.
【０００９】（２）また、製造された吸気ダクトも、上
記製造方法に起因する以下の問題点を有する。まず、吸
気ダクト本体が一体成形されているため、内部のメンテ
ナンスがしにくいという問題点を有する。また、吸気ダ
クトの一部が破損しても、全体を交換しなければならな
いため交換コストが高いという問題点を有する。また、
ダクト本体が所望の肉厚を有さず、強度的に劣るおそれ
があるという問題点を有する。さらに、受け面に対する
多孔質シートの接合性が悪いおそれがあるという問題点
を有する。(2) The manufactured intake duct also has the following problems caused by the above manufacturing method. First, since the intake duct body is integrally formed, there is a problem that internal maintenance is difficult. In addition, even if a part of the intake duct is damaged, the entire unit must be replaced, so that the replacement cost is high. Also,
There is a problem that the duct body does not have a desired thickness and may be inferior in strength. Furthermore, there is a problem that the bonding property of the porous sheet to the receiving surface may be poor.
【００１０】（３）上記、吸気ダクトおよびその製造方
法の問題点に鑑み、本発明者が鋭意研究を行った結果、
吸気ダクトを構成する分割体の成形と同時に多孔質シー
トをこの分割体に接合（インサート成形）することで、
上記製造方法に関する問題点を解決できるとの知見を得
た。また、吸気ダクトを複数の分割体から構成すること
で、上記吸気ダクトに関する問題点を解決できるとの知
見を得た。(3) In view of the above-mentioned problems of the intake duct and the method of manufacturing the same, as a result of intensive studies made by the present inventors,
By joining a porous sheet to this divided body (insert molding) at the same time as forming the divided body constituting the intake duct,
It has been found that the problems relating to the above manufacturing method can be solved. In addition, it has been found that the problem related to the intake duct can be solved by forming the intake duct from a plurality of divided bodies.
【００１１】本発明の吸気ダクトの製造方法は、上記製
造方法に関する知見に基づき完成されたものであり、肉
厚制御しやすく、袋部カット、バリ取り、開口形成、溶
着等の工程が不要で生産性に優れ、製造コストが低く、
また溶着用の受け部の形成も必要としない製造方法を提
供することを課題とする。The method of manufacturing an intake duct according to the present invention has been completed based on the knowledge of the above-described manufacturing method. It is easy to control the wall thickness and does not require steps such as bag cutting, deburring, opening formation, welding and the like. Excellent productivity, low production cost,
Another object of the present invention is to provide a manufacturing method that does not require the formation of a receiving portion for welding.
【００１２】また、本発明の吸気ダクトは、上記吸気ダ
クトに関する知見に基づき完成されたものであり、メン
テナンスしやすく、交換コストが低く、所望の肉厚を有
し、多孔質シートの接合性が良好で信頼性の高い吸気ダ
クトを提供することを課題とする。Further, the intake duct of the present invention has been completed based on the knowledge of the above-mentioned intake duct, is easy to maintain, has a low replacement cost, has a desired thickness, and has good bonding properties of the porous sheet. It is an object to provide a good and highly reliable intake duct.
【００１３】[0013]
【課題を解決するための手段】（１）上記課題を解決す
るため、本発明の吸気ダクトの製造方法は、自動車の外
気取り入れ口とエンジンのインテークマニホールドとの
間に配置され部分的に多孔質シートで覆われた窓部を管
壁に持つ吸気ダクトの製造方法であって、それぞれ凸型
と凹型とを備える複数の分割体型の少なくとも一つの該
凸型または該凹型の表面に該多孔質シートを配置して該
分割体型を閉型する多孔質シート配置工程と、閉型され
た複数の該分割体型のキャビティ内に溶融状態の熱可塑
性樹脂を注入し冷却し離型し複数の分割体を得る分割体
成形工程と、該複数の分割体を接合し吸気ダクトを得る
分割体接合工程と、を有し、該分割体成形工程におい
て、該凸型または該凹型の表面に該多孔質シートが配置
された分割体型のキャビティ内に熱可塑性樹脂を注入
し、該多孔質シートの外縁部に熱可塑性樹脂を含浸さ
せ、接合部を形成することにより、該多孔質シートの該
外縁部が接合された窓部を持つ分割体を得ることを特徴
とする。(1) In order to solve the above-mentioned problems, a method of manufacturing an intake duct according to the present invention is characterized in that the method is provided between an outside air intake of an automobile and an intake manifold of an engine and is partially porous. A method of manufacturing an intake duct having a window covered with a sheet on a pipe wall, wherein the porous sheet is provided on at least one of the convex or concave surfaces of a plurality of divided body types each having a convex shape and a concave shape. A porous sheet disposing step of disposing the divided body molds and injecting a thermoplastic resin in a molten state into the cavities of the closed plurality of divided body molds, cooling and releasing the molds to form a plurality of divided bodies. Obtaining a divided body, and a divided body joining step of joining the plurality of divided bodies to obtain an intake duct. In the divided body forming step, the porous sheet is formed on the surface of the convex or concave mold. A split body key placed Injecting a thermoplastic resin into the cavity, impregnating the outer edge of the porous sheet with the thermoplastic resin, and forming a joining portion, thereby dividing the porous sheet into a window having the joined outer edge. It is characterized by gaining a body.
【００１４】つまり、本発明の吸気ダクトの製造方法
は、分割型を複数用いて射出成形等により吸気ダクトの
分割体を成形し、これを合体させて吸気ダクトを作るも
のである。複数の分割型は、それぞれ凸型と凹型とを備
える。多孔質シートを配置した分割体を成形する場合
は、予め凸型または凹型の表面に多孔質シートをセット
し、少なくとも外縁部の一部をリング状に両型の型面で
挟持し、その後キャビティ内に溶融状態の熱可塑性樹脂
を注入する。注入された樹脂は、多孔質シートの外縁部
に含浸し、外縁部を形成する繊維等の隙間に侵入する。
隙間に侵入した溶融樹脂がこの状態のまま冷却固化する
と、樹脂と繊維等とが複雑に絡み合い離れなくなる。こ
のようにして接合部が形成され、多孔質シートは分割体
に接合される。That is, in the method of manufacturing an intake duct of the present invention, a divided body of the intake duct is formed by injection molding or the like using a plurality of split dies, and these are combined to form an intake duct. The plurality of split molds each include a convex mold and a concave mold. When forming a divided body on which a porous sheet is arranged, the porous sheet is set in advance on a convex or concave surface, and at least a part of the outer edge portion is sandwiched between the mold surfaces in a ring shape, and then the cavity is formed. A molten thermoplastic resin is injected into the inside. The injected resin impregnates the outer edge of the porous sheet and penetrates into gaps such as fibers forming the outer edge.
When the molten resin that has entered the gaps is cooled and solidified in this state, the resin and the fibers and the like are not entangled in a complicated manner and cannot be separated. In this way, a joint is formed, and the porous sheet is joined to the divided body.
【００１５】従来は、吸気ダクト本体の受け面に多孔質
シートを、二次元的に接合していたため、接合性が悪い
場合があった。一方、本発明の製造方法は、分割体成形
時に多孔質シートの外縁部に樹脂が含浸した接合部を形
成することにより、分割体に多孔質シートを、三次元的
に接合するものである。このため、例えば分割体の肉厚
が薄い場合であっても、接合部の幅を大きく取ることに
より所望の接合性を確保することができる。Conventionally, the porous sheet is two-dimensionally joined to the receiving surface of the intake duct main body, so that the joining property may be poor. On the other hand, in the production method of the present invention, the porous sheet is three-dimensionally joined to the divided body by forming a joint portion impregnated with resin on the outer edge of the porous sheet at the time of forming the divided body. Therefore, for example, even when the thickness of the divided body is thin, a desired joining property can be ensured by increasing the width of the joining portion.
【００１６】このように、本発明の吸気ダクトの製造方
法によると、吸気ダクトの分割体の成形と多孔質シート
の接合とが同時にできる。しかも受け面を形成する必要
がない。また、多孔質シートとして熱可塑性樹脂に溶着
しない材料も使用することができる。また、分割体の肉
厚に関係なく多孔質シートの接合性を高くすることがで
きる。As described above, according to the method of manufacturing the intake duct of the present invention, the formation of the divided body of the intake duct and the joining of the porous sheet can be simultaneously performed. Moreover, there is no need to form a receiving surface. Further, a material that does not adhere to the thermoplastic resin can be used as the porous sheet. Further, the bonding property of the porous sheet can be increased regardless of the thickness of the divided body.
【００１７】さらに、従来のブロー成形法を用いた吸気
ダクトの製造方法と比較して、本発明の吸気ダクトの製
造方法は、肉厚制御しやすく、袋部カット、バリ取り、
開口形成、溶着等の工程が不要であり生産性が高く、製
造コストも低い製造方法である。Furthermore, as compared with the conventional method of manufacturing an intake duct using a blow molding method, the method of manufacturing an intake duct of the present invention facilitates wall thickness control, cuts a bag portion, removes burrs,
This is a manufacturing method in which steps such as opening formation and welding are not required, productivity is high, and manufacturing cost is low.
【００１８】（２）また、上記課題を解決するため、本
発明の吸気ダクトは、自動車の外気取り入れ口とエンジ
ンのインテークマニホールドとの間に配置される吸気ダ
クトであって、熱可塑性樹脂製であって各々の断面が弧
状をなす複数の分割体と、該分割体の少なくとも一つの
壁面に部分的に形成された開口部を覆って一体となって
接合され外縁部に前記熱可塑性樹脂が含浸した接合部を
有する多孔質シートと、を備えることを特徴とする。(2) In order to solve the above-mentioned problems, the intake duct of the present invention is an intake duct disposed between an outside air intake of an automobile and an intake manifold of an engine, and is made of a thermoplastic resin. A plurality of divided bodies each having an arc-shaped cross section, and integrally joined to cover an opening partly formed in at least one wall surface of the divided body and impregnated with the thermoplastic resin at an outer edge part And a porous sheet having a bonded portion.
【００１９】つまり、本発明の吸気ダクトは複数の分割
体が一体となって形成されている。このため、一部の分
割体を外すだけで吸気ダクト内部のメンテナンスをする
ことができる。また、一部の部品が破損した場合でも、
吸気ダクト全体を交換する必要はなく、破損した部品を
有する分割体だけを交換すればよい。例えば、多孔質シ
ートを交換したい場合は多孔質シートを有する分割体だ
けを交換すればよい。That is, the intake duct of the present invention is formed by integrating a plurality of divided bodies. Therefore, maintenance of the inside of the intake duct can be performed only by removing some of the divided bodies. Also, even if some parts are damaged,
It is not necessary to replace the entire intake duct, only the divided body having the damaged part. For example, when it is desired to replace the porous sheet, only the divided body having the porous sheet may be replaced.
【００２０】また、本発明の吸気ダクトは、ブロー成形
法により作製されていないため、複雑な形状であっても
各々の部位が所望の肉厚を有している。このため、強度
的に優れている。また、吸気ダクトを構成する分割体と
多孔質シートとは、上述したように接合部により接合さ
れている。このため、接合性に優れており信頼性が高
い。Further, since the intake duct of the present invention is not manufactured by the blow molding method, each part has a desired thickness even if it has a complicated shape. Therefore, the strength is excellent. Further, the divided body and the porous sheet constituting the intake duct are joined by the joint as described above. For this reason, the bonding property is excellent and the reliability is high.
【００２１】[0021]
【発明の実施の形態】以下、本発明の吸気ダクト及びそ
の製造方法の実施の形態について、本発明の吸気ダクト
の製造方法の代表的実施の形態、本発明の吸気ダクトの
代表的実施の形態の項目毎に説明する。BEST MODE FOR CARRYING OUT THE INVENTION Hereinafter, an embodiment of an intake duct and a method of manufacturing the same according to the present invention will be described with reference to a typical embodiment of a method of manufacturing an intake duct of the present invention and a representative embodiment of an intake duct of the present invention. Will be described for each item.
【００２２】〈本発明の吸気ダクトの製造方法の代表的
実施の形態〉本実施形態の吸気ダクトの製造方法は、多
孔質シートを分割体型のキャビティ内に配置し型を閉じ
る多孔質シート配置工程と、キャビテイ内に溶融樹脂を
注入し樹脂冷却後に分割体型を離型する分割体成形工程
と、成形された分割体を接合し吸気ダクトを得る分割体
接合工程とからなる。なお、本実施形態においては、分
割体および分割体型の数は二つであり、このうち一つの
分割体に一つだけ多孔質シートが配置されている。<Representative Embodiment of Manufacturing Method of Air Intake Duct of the Present Invention> The manufacturing method of the air intake duct of the present embodiment is a porous sheet arranging step of arranging a porous sheet in a cavity of a divided body and closing the mold. And a divided body molding step of injecting a molten resin into the cavity and releasing the divided mold after cooling the resin, and a divided body joining step of joining the molded divided bodies to obtain an intake duct. In the present embodiment, the number of divided bodies and the number of divided body types are two, and only one porous sheet is arranged in one of the divided bodies.
【００２３】（１）まず、多孔質シート配置工程につい
て説明する。本工程では、それぞれ凸型と凹型とを備え
る二つの分割体型のうち、一つの分割体型の凹型の表面
に多孔質シートを配置して分割体型を閉型する。(1) First, the porous sheet disposing step will be described. In this step, a porous sheet is arranged on the concave surface of one of the two divided bodies each having a convex shape and a concave shape, and the divided body is closed.
【００２４】まず、多孔質シートを配置した分割体型を
閉じる前の状態の拡大断面図を図１に示す。図１に示す
ように、分割体型２は、鋼製で半円柱状の凸部を有する
凸型２０と、同じく鋼製で半円柱状の凹部を有する凹型
２１とから構成される。また、凹型２１の表面にはＰＥ
Ｔ（ポリエチレンテレフタレート）製の不織布で長方形
板状の多孔質シート１２が配置されている。凸型２０の
表面にはシート固定部２２が形成されている。このシー
ト固定部２２は、長方形板状の多孔質シート１２の外縁
部に対応する位置に形成されており、長方形枠状を有す
る。First, FIG. 1 is an enlarged cross-sectional view showing a state before closing a divided body on which a porous sheet is arranged. As shown in FIG. 1, the split mold 2 includes a convex mold 20 made of steel and having a semi-cylindrical convex portion, and a concave mold 21 made of steel and having a semi-cylindrical concave portion. The surface of the concave mold 21 has PE
A rectangular plate-shaped porous sheet 12 made of a nonwoven fabric made of T (polyethylene terephthalate) is arranged. A sheet fixing portion 22 is formed on the surface of the convex 20. The sheet fixing portion 22 is formed at a position corresponding to the outer edge of the rectangular plate-shaped porous sheet 12, and has a rectangular frame shape.
【００２５】次に、多孔質シートを配置した分割体型を
閉じた後の状態の拡大断面図を図２に示す。図２に示す
ように、凹型２１の上方から凸型２０が接近することに
より分割体型２は閉じる。このとき、凸型２０表面のシ
ート固定部２２は、多孔質シート１２の外縁部の内周側
の部分を圧迫し凹型２１に押さえつける。こうして多孔
質シート１２は分割体型２の中に固定される。Next, FIG. 2 is an enlarged sectional view showing a state after the divided body on which the porous sheet is arranged is closed. As shown in FIG. 2, the divided mold 2 closes when the convex mold 20 approaches from above the concave mold 21. At this time, the sheet fixing portion 22 on the surface of the convex 20 presses the inner peripheral portion of the outer edge of the porous sheet 12 and presses it against the concave 21. Thus, the porous sheet 12 is fixed in the divided body 2.
【００２６】なお、多孔質シートを有しないもう一方の
分割体を作製する場合は、本工程は単に分割体型を閉じ
る工程となる。また、凸型の表面にはシート固定部は形
成されていない。In the case of producing another divided body having no porous sheet, this step is simply a step of closing the divided body mold. Also, no sheet fixing portion is formed on the convex surface.
【００２７】（２）次に、分割体成形工程について説明
する。本工程では、射出成形機を用いて、分割体型のキ
ャビテイ内に溶融樹脂を注入し、樹脂冷却後に分割体型
を離型する。(2) Next, the divided body forming step will be described. In this step, the molten resin is injected into the cavity of the divided mold using an injection molding machine, and after the resin is cooled, the divided mold is released.
【００２８】まず、多孔質シートを配置した分割体型の
キャビティ内に溶融樹脂を注入した状態の拡大断面図を
図３に示す。溶融したＰＰ（ポリプロピレン）である溶
融樹脂１４は、図示しない射出成形機のスクリューによ
り分割体型２のキャビティ内に注入される。このとき多
孔質シート１２はシート固定部２２と凹型２１の壁面と
により挟持されているため溶融樹脂１４により動かされ
ることはない。溶融樹脂１４は多孔質シート１２の外縁
部からシート内部に徐々に含浸するが、外縁部の内周側
はシート固定部２２により押さえられている。この押さ
えられている部分は、圧縮され密度が高くなっているた
め、この部分からシート内周部に樹脂が含浸することは
ない。多孔質シート１２の外縁部の外周側部分に溶融樹
脂１４が含浸した状態で冷却すると、溶融樹脂１４は多
孔質シート１２を形成するＰＥＴ繊維間に侵入した状態
で固化し、接合部が形成される。本実施例においては、
多孔質シート１２の外縁部の内周側部分がシート固定部
２２により押さえられているため、接合部の体積は大き
くなり、また接合力も強くなる。こうして、多孔質シー
ト１２は、固化した樹脂からなる分割体と接合される。First, FIG. 3 is an enlarged cross-sectional view showing a state in which a molten resin is injected into a cavity of a divided body in which a porous sheet is arranged. The molten resin 14 that is a molten PP (polypropylene) is injected into the cavity of the split mold 2 by a screw of an injection molding machine (not shown). At this time, the porous sheet 12 is not moved by the molten resin 14 because it is sandwiched between the sheet fixing portion 22 and the wall surface of the concave mold 21. The molten resin 14 gradually impregnates the inside of the porous sheet 12 from the outer edge thereof, but the inner peripheral side of the outer edge is pressed by the sheet fixing portion 22. Since the pressed portion is compressed and has a high density, the resin does not impregnate the inner peripheral portion of the sheet from this portion. When the outer peripheral portion of the outer edge portion of the porous sheet 12 is cooled while being impregnated with the molten resin 14, the molten resin 14 solidifies in a state where the molten resin 14 enters between the PET fibers forming the porous sheet 12, and a joint is formed. You. In this embodiment,
Since the inner peripheral side portion of the outer edge of the porous sheet 12 is pressed by the sheet fixing portion 22, the volume of the joining portion increases, and the joining force also increases. Thus, the porous sheet 12 is joined to the divided body made of the solidified resin.
【００２９】次に、樹脂冷却後に分割体型を分割体から
離型した状態の拡大断面図を図４に示す。分割体型２の
凸型２０は閉型の際とは逆方向に移動し、分割体１５か
ら離型される。冷却固化した断面が半円弧状の分割体１
５は、多孔質シート１２と接合部１６を介して接合され
ている。Next, FIG. 4 is an enlarged sectional view showing a state in which the divided mold is released from the divided body after the resin is cooled. The convex mold 20 of the split mold 2 moves in the direction opposite to the direction when the mold is closed, and is released from the split body 15. Cooled and solidified divided body 1 whose cross section is semicircular.
5 is joined to the porous sheet 12 via a joint 16.
【００３０】次に、成形後の多孔質シートを有する分割
体の拡大断面図を図５に示す。従来の製造方法では、図
１０に示したように、多孔質シート１２を溶着するため
に予めブロー成形時に吸気ダクト本体１０に受け面１３
を形成しておく必要があった。また、受け面の面積が狭
い場合、すなわちダクト本体１０に肉厚が薄い場合は接
合性が悪くなるおそれがあった。本発明の製造方法によ
ると図５に示すように受け面を形成する必要がない。Next, FIG. 5 is an enlarged cross-sectional view of the divided body having the formed porous sheet. In the conventional manufacturing method, as shown in FIG. 10, in order to weld the porous sheet 12, the receiving surface 13
Had to be formed. In addition, when the area of the receiving surface is small, that is, when the thickness of the duct body 10 is small, there is a possibility that the joining property is deteriorated. According to the manufacturing method of the present invention, it is not necessary to form the receiving surface as shown in FIG.
【００３１】なお、多孔質シートを有しないもう一方の
分割体を作製する場合も、本工程と同様の手順で成形が
行われる。When another divided body having no porous sheet is produced, molding is performed in the same procedure as in this step.
【００３２】（３）次に、分割体接合工程について説明
する。本工程では、多孔質シートを有する分割体と、も
う一方の多孔質シートを有しない分割体とを接合し、吸
気ダクトを作製する。(3) Next, the divided body joining step will be described. In this step, the divided body having the porous sheet and the other divided body having no porous sheet are joined to produce an intake duct.
【００３３】分割体を接合する様子を図６に示す。図６
に示すように、多孔質シート１２を有する分割体１５の
接合面側には嵌合枠１７が四つ形成されている。一方、
多孔質シート１５を有しない分割体１５の接合面側に
は、嵌合枠１７に対応する位置に嵌合爪１８が四つ形成
されている。嵌合爪１８が嵌合枠１７に圧入されること
により両分割体１５が接合され、吸気ダクト１となる。
ここに示す嵌合爪および嵌合枠の個数および位置は任意
に設定可能となっている。FIG. 6 shows how the divided bodies are joined. FIG.
As shown in (4), four fitting frames 17 are formed on the joining surface side of the divided body 15 having the porous sheet 12. on the other hand,
On the joining surface side of the divided body 15 having no porous sheet 15, four fitting claws 18 are formed at positions corresponding to the fitting frames 17. When the fitting claw 18 is pressed into the fitting frame 17, the two divided bodies 15 are joined to form the intake duct 1.
The number and positions of the fitting claws and fitting frames shown here can be set arbitrarily.
【００３４】（４）以上、本発明の吸気ダクトの製造方
法の代表的実施の形態について説明した。本実施形態に
おいては、多孔質シートを形成する材料としてＰＥＴを
使用したが、多孔質シートを形成する材料は特に限定し
ない。溶融樹脂が多孔質シートの繊維に含浸すればよ
く、例えば、ＰＰ、ＰＥ（ポリエチレン）等を使用する
形態で実施することもできる。なお、本実施形態では、
多孔質シートとして不織布を用いた。不織布は、従来か
ら用いられているスパンボンド法、ニードルパンチ法等
により作製すればよい。また、不織布に限らず、例えば
ＰＵＲ（ポリウレタン）フォーム等の連泡発泡体を用い
る態様で実施することもできる。(4) The representative embodiment of the method of manufacturing an intake duct according to the present invention has been described above. In the present embodiment, PET is used as a material for forming the porous sheet, but the material for forming the porous sheet is not particularly limited. What is necessary is just to impregnate the fiber of the porous sheet with the molten resin, and for example, it can be carried out in a form using PP, PE (polyethylene) or the like. In the present embodiment,
A nonwoven fabric was used as the porous sheet. The nonwoven fabric may be produced by a conventionally used spun bond method, needle punch method or the like. Further, the present invention is not limited to the nonwoven fabric, and may be implemented in a mode using an open-cell foam such as PUR (polyurethane) foam.
【００３５】また、本実施形態においては、長方形板状
の多孔質シートを設置したが、多孔質シートの形状（厚
さを含む）は特に限定するものではない。吸気時の騒音
を低減する効果の高い形状にして実施すればよい。ま
た、本実施形態においては、単一の多孔質シートを、一
つの分割体の中央部に設置したが、多孔質シートの個
数、配置部位についても特に限定するものではない。騒
音低減効果、エンジンルームに搭載される他の部品との
位置関係等を考慮して決定すればよい。In this embodiment, a rectangular plate-like porous sheet is provided, but the shape (including the thickness) of the porous sheet is not particularly limited. What is necessary is just to implement it in the shape which has the high effect of reducing the noise at the time of intake. Further, in the present embodiment, a single porous sheet is provided at the center of one divided body, but the number and arrangement of the porous sheets are not particularly limited. It may be determined in consideration of the noise reduction effect, the positional relationship with other components mounted in the engine room, and the like.
【００３６】また、本実施形態においては、分割体を形
成する溶融樹脂としてＰＰを使用したが、他のＰＥ、Ｐ
Ａ（ポリアミド）等の熱可塑性樹脂を用いて実施する形
態もある。Further, in this embodiment, PP is used as the molten resin forming the divided body.
There is also an embodiment in which a thermoplastic resin such as A (polyamide) is used.
【００３７】多孔質シートの接合力を調節する方法とし
て、分割体型のシート固定部の位置を変える方法がある
（図３参照）。シート固定部が多孔質シート内周部側に
位置するほど、溶融樹脂の含浸量が増え、多孔質シート
全体積に対する接合部の体積の割合が増えるため、より
強固な接合力を得ることができる。As a method of adjusting the joining force of the porous sheet, there is a method of changing the position of the divided body type sheet fixing portion (see FIG. 3). As the sheet fixing portion is located closer to the inner peripheral side of the porous sheet, the amount of impregnation of the molten resin increases, and the ratio of the volume of the joining portion to the entire volume of the porous sheet increases, so that a stronger joining force can be obtained. .
【００３８】また、本実施形態においては、シート固定
部は分割体型の凸型側に形成したが、凹型側でもよい。
また、図７に示すように、シート固定部２２を分割体型
２の凸型２０および凹型２１の両型に形成する形態で実
施することもできる。シート固定部２２を両型に形成す
ると、多孔質シート１２内への含浸に加えて、多孔質シ
ート１２の外縁部の両面側から溶融樹脂が回り込み、接
合部１６を挟み込むように樹脂が固化するため、接合性
がより向上する。なお、シート固定部は分割体型の一部
として形成しても、別途作製し分割体型に設置してもよ
い。Further, in the present embodiment, the sheet fixing portion is formed on the convex side of the divided body, but may be formed on the concave side.
Further, as shown in FIG. 7, the sheet fixing portion 22 may be formed in both a convex shape 20 and a concave shape 21 of the divided body 2. When the sheet fixing portion 22 is formed in both molds, in addition to impregnation into the porous sheet 12, the molten resin flows around from both sides of the outer edge of the porous sheet 12, and the resin is solidified so as to sandwich the joint 16. Therefore, the joining property is further improved. The sheet fixing portion may be formed as a part of the divided body, or may be separately manufactured and installed on the divided body.
【００３９】また、本実施形態においては、スクリュー
式の射出成形機を用いたが、トーピード式等他の方式の
射出成形機を使用する形態で実施することもできる。さ
らに、射出成形機以外の、プレス成形機、トランスファ
成形機等の割型に溶融樹脂を注入する機構を有する成形
機を用いる形態で実施することもできる。In this embodiment, a screw-type injection molding machine is used. However, it is also possible to use another type of injection molding machine such as a torpedo type. Further, the present invention can be implemented by using a molding machine having a mechanism for injecting a molten resin into a split mold such as a press molding machine or a transfer molding machine other than the injection molding machine.
【００４０】また、本実施形態においては、分割体同士
を接合する機構として、爪嵌合を用いたが、例えば、ピ
ンと孔、クリップと孔、ボルトとナット等による他の嵌
合機構で接合する形態もある。また、分割体同士を溶着
する形態で実施することもできる。Further, in the present embodiment, the claw fitting is used as a mechanism for joining the divided bodies. However, for example, the divided bodies are joined by another fitting mechanism such as a pin and a hole, a clip and a hole, a bolt and a nut, or the like. There is also a form. Further, the present invention can be implemented in a form in which the divided bodies are welded to each other.
【００４１】また、本実施形態においては、分割体の個
数は二つとした。分割体により吸気ダクトを構成できる
最小限の個数であるため、より工数の少ない実施形態で
ある。ただし、型数も特に限定するものではない。In this embodiment, the number of the divided bodies is two. This is an embodiment in which the number of man-hours is smaller because the number of divided ducts is the minimum number that can constitute the intake duct. However, the number of types is not particularly limited.
【００４２】〈本発明の吸気ダクトの代表的実施の形
態〉上述した製造方法により製造された本実施形態の吸
気ダクトは、図６に示すように、各々の断面が半円弧状
をなす二つの分割体１５と、分割体１５の一つの壁面に
部分的に形成された開口部１９を覆って一体となって接
合され外縁部に樹脂が含浸した接合部を有する多孔質シ
ート１２とを備える。<Representative Embodiment of Intake Duct of the Present Invention> As shown in FIG. 6, the intake duct of the present embodiment manufactured by the above-described manufacturing method has two sections each having a semicircular arc shape. The porous body 12 includes a divided body 15 and a porous sheet 12 which is integrally joined so as to cover an opening 19 partially formed on one wall surface of the divided body 15 and has a joint portion impregnated with a resin at an outer edge portion.
【００４３】二つの分割体１５は、嵌合枠１７と嵌合爪
１８とにより接合されている。本実施形態の吸気ダクト
を構成する分割体、多孔質シート等も、種々の形態で実
施することができる。The two divided bodies 15 are joined by a fitting frame 17 and a fitting claw 18. The divided body, the porous sheet, and the like constituting the intake duct of the present embodiment can be implemented in various forms.
【００４４】すなわち、多孔質シートを形成する材料、
多孔質シートの形状（厚さを含む）、個数、配置部位に
ついては特に限定するものではない。また、分割体を形
成する熱可塑性樹脂、分割体の個数についても特に限定
するものではない。さらに、多孔質シートに対する接合
部の体積割合、接合部に対する樹脂の回り込み具合につ
いても特に限定するものではない。That is, a material for forming the porous sheet,
The shape (including the thickness), number, and location of the porous sheet are not particularly limited. Also, there is no particular limitation on the thermoplastic resin forming the divided body and the number of divided bodies. Furthermore, there is no particular limitation on the volume ratio of the joint to the porous sheet and the degree of the resin flowing around the joint.
【００４５】[0045]
【発明の効果】（１）本発明の吸気ダクトの製造方法に
よると、吸気ダクトの分割体の成形と多孔質シートの接
合とが同時にできる。しかも受け面を形成する必要もな
い。また、分割体の肉厚に関係なく接合部の接合性を良
くすることができる。また、多孔質シートとして熱可塑
性樹脂に溶着しない材料も使用することができる。さら
に、肉厚制御しやすく、袋部カット、バリ取り、開口形
成、溶着等の工程が不要であり生産性が上がり、製造コ
ストも低くなる。(1) According to the method of manufacturing the intake duct of the present invention, the formation of the divided body of the intake duct and the joining of the porous sheet can be performed at the same time. Moreover, there is no need to form a receiving surface. In addition, it is possible to improve the joining property of the joining portion regardless of the thickness of the divided body. Further, a material that does not adhere to the thermoplastic resin can be used as the porous sheet. Further, the thickness can be easily controlled, and steps such as bag cutting, deburring, forming an opening, and welding are not required, so that productivity is increased and manufacturing cost is reduced.
【００４６】（２）本発明の吸気ダクトによると、一部
の分割体を外すだけでメンテナンスをすることができ
る。また、一部の分割体が破損した場合でも、吸気ダク
ト全体を交換する必要はなく、破損した部品だけを交換
すればよい。(2) According to the intake duct of the present invention, maintenance can be performed only by removing a part of the divided bodies. Further, even when some of the divided bodies are damaged, it is not necessary to replace the entire intake duct, and only the damaged parts need be replaced.
【００４７】また、本発明の吸気ダクトによると、複雑
な形状であっても各々の部位が所望の肉厚を有している
ため、強度的に優れている。また、吸気ダクトを構成す
る分割体と多孔質シートとは、接合部により接合されて
いるため、接合性に優れており信頼性が高い。Further, according to the intake duct of the present invention, even if it has a complicated shape, each part has a desired thickness, and therefore, is excellent in strength. Further, since the divided body and the porous sheet constituting the intake duct are joined at the joining portion, the joining properties are excellent and the reliability is high.
【図１】分割体型を閉じる前の状態の拡大断面図であ
る。FIG. 1 is an enlarged sectional view of a state before a divided body is closed.
【図２】分割体型を閉じた後の状態の拡大断面図であ
る。FIG. 2 is an enlarged cross-sectional view of a state after a divided body is closed.
【図３】分割体型のキャビティ内に溶融樹脂を注入した
状態の拡大断面図である。FIG. 3 is an enlarged cross-sectional view showing a state in which a molten resin is injected into a cavity of a split mold.
【図４】分割体型を分割体から離型した状態の拡大断面
図である。FIG. 4 is an enlarged cross-sectional view showing a state in which a split mold is released from the split body.
【図５】成形後の分割体の拡大断面図である。FIG. 5 is an enlarged sectional view of a divided body after molding.
【図６】分割体を接合する様子を示す斜視図である。FIG. 6 is a perspective view showing a state in which the divided bodies are joined.
【図７】シート固定部を分割体型の両型に形成し成形し
た状態の拡大断面図である。FIG. 7 is an enlarged cross-sectional view of a state in which the sheet fixing portion is formed and molded in both divided body molds.
【図８】サイドブランチおよびレゾネータを設けた従来
型吸気ダクトの斜視図である。FIG. 8 is a perspective view of a conventional intake duct provided with a side branch and a resonator.
【図９】ブロー成形により成形した従来型吸気ダクトを
分解した状態の斜視図である。FIG. 9 is an exploded perspective view of a conventional intake duct formed by blow molding.
【図１０】ブロー成形により成形した従来型吸気ダクト
の拡大断面図である。FIG. 10 is an enlarged sectional view of a conventional intake duct formed by blow molding.
１：吸気ダクト １０：吸気ダクト本体 １１：開口
１２：多孔質シート １３：受け面 １４：溶融樹脂 １５：分割体 １６：
接合部 １７：嵌合枠 １８：嵌合爪 １９：開口部 １０１：サイドブランチ
１０２：レゾネータ ２：分割体型 ２０：凸型 ２１：凹型 ２２：シート
固定部1: intake duct 10: intake duct body 11: opening
12: porous sheet 13: receiving surface 14: molten resin 15: divided body 16:
Joint 17: Fitting frame 18: Fitting claw 19: Opening 101: Side branch 102: Resonator 2: Split body 20: Convex 21: Concave 22: Seat fixing part
───────────────────────────────────────────────────── フロントページの続き (72)発明者 岩尾 裕 愛知県西春日井郡春日町大字落合字長畑１ 番地 豊田合成株式会社内 (72)発明者 伊藤 伸二 愛知県西春日井郡春日町大字落合字長畑１ 番地 豊田合成株式会社内 (72)発明者 林 和則 愛知県西春日井郡春日町大字落合字長畑１ 番地 豊田合成株式会社内 Ｆターム(参考） 4F206 AA11 AD08 AD17 AG08 AH16 JA07 JB12 JQ81 ──────────────────────────────────────────────────続 き Continuing on the front page (72) Inventor Hiroshi Iwao 1 Ochiai Nagahata, Kasuga-cho, Nishi-Kasugai-gun, Aichi Prefecture Inside Toyoda Gosei Co., Ltd. Within Toyoda Gosei Co., Ltd. (72) Inventor Kazunori Hayashi 1 Ochiai Ogata, Kasuga-cho, Nishikasugai-gun, Aichi F-term (reference) 4F206 AA11 AD08 AD17 AG08 AH16 JA07 JB12 JQ81
Claims (2)
ンテークマニホールドとの間に配置され部分的に多孔質
シートで覆われた窓部を管壁に持つ吸気ダクトの製造方
法であって、それぞれ凸型と凹型とを備える複数の分割
体型の少なくとも一つの該凸型または該凹型の表面に該
多孔質シートを配置して該分割体型を閉型する多孔質シ
ート配置工程と、 閉型された複数の該分割体型のキャビティ内に溶融状態
の熱可塑性樹脂を注入し冷却し離型し複数の分割体を得
る分割体成形工程と、 該複数の分割体を接合し吸気ダクトを得る分割体接合工
程と、を有し、 該分割体成形工程において、該凸型または該凹型の表面
に該多孔質シートが配置された分割体型のキャビティ内
に熱可塑性樹脂を注入し、該多孔質シートの外縁部に熱
可塑性樹脂を含浸させ、接合部を形成することにより、
該多孔質シートの該外縁部が接合された窓部を持つ分割
体を得ることを特徴とする吸気ダクトの製造方法。1. A method of manufacturing an air intake duct having a window partly disposed between an outside air intake of an automobile and an intake manifold of an engine and having a window partly covered with a porous sheet on a pipe wall, the method comprising: A porous sheet disposing step of disposing the porous sheet on at least one of the convex or concave surfaces of a plurality of divided molds including a mold and a concave mold to close the divided mold; A divided body molding step of injecting a molten thermoplastic resin into the cavity of the divided body mold, cooling and releasing the mold to obtain a plurality of divided bodies; and a divided body joining step of joining the plurality of divided bodies to obtain an intake duct. In the divided body forming step, a thermoplastic resin is injected into a cavity of the divided body mold in which the porous sheet is disposed on the surface of the convex or concave shape, and an outer peripheral portion of the porous sheet is formed. Impregnated with thermoplastic resin To form a joint,
A method of manufacturing an intake duct, comprising obtaining a divided body having a window portion to which the outer edge of the porous sheet is joined.
ンテークマニホールドとの間に配置される吸気ダクトで
あって、熱可塑性樹脂製であって各々の断面が弧状をな
す複数の分割体と、該分割体の少なくとも一つの壁面に
部分的に形成された開口部を覆って一体となって接合さ
れ外縁部に前記熱可塑性樹脂が含浸した接合部を有する
多孔質シートと、を備える吸気ダクト。2. An intake duct disposed between an outside air intake of an automobile and an intake manifold of an engine, wherein the plurality of divided bodies are made of a thermoplastic resin, and each of the divided bodies has an arc-shaped cross section. A porous sheet integrally joined to cover an opening partly formed on at least one wall surface of the body and having a joint part impregnated with the thermoplastic resin at an outer edge part thereof.
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|---|---|---|---|
| JP2000299843A JP3844191B2 (en) | 2000-09-29 | 2000-09-29 | Intake duct and manufacturing method thereof |
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2000299843A JP3844191B2 (en) | 2000-09-29 | 2000-09-29 | Intake duct and manufacturing method thereof |
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|---|---|
| JP2002106431A true JP2002106431A (en) | 2002-04-10 |
| JP3844191B2 JP3844191B2 (en) | 2006-11-08 |
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|---|---|---|---|
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