JP2004263651A

JP2004263651A - Intake manifold made of resin

Info

Publication number: JP2004263651A
Application number: JP2003056630A
Authority: JP
Inventors: Mitsutake Yasuda; 光毅安田
Original assignee: Aisan Industry Co Ltd
Current assignee: Aisan Industry Co Ltd
Priority date: 2003-03-04
Filing date: 2003-03-04
Publication date: 2004-09-24

Abstract

<P>PROBLEM TO BE SOLVED: To facilitate vibration welding work by securing mutual airtightness of intake passages by mutual vibration welding of only outside components without vibration welding of an inside component, in an intake manifold having a plurality of intake passages formed of the outside components and the inside component included in the outside components. <P>SOLUTION: The resin-made inside component 8 is disposed in the resin-made outside components 7 and 9 forming an outer peripheral wall, and the plurality of intake passages 2-4 are formed of the outside components 7 and 9 and the inside component 8. The outside components 7 and 9 are divided into a plurality of outside components in the circumferential direction, the divided outside components 7 and 9 are fixed by vibration welding, and the inside component 8 is held air-tightly without vibration welding to the outside components 7 and 9. <P>COPYRIGHT: (C)2004,JPO&NCIPI

Description

【０００１】
【発明の属する技術分野】
本発明は樹脂製インテークマニホールドに関する。
【０００２】
【従来の技術】
エンジンへ吸気を供給する樹脂製のインテークマニホールドにおいて、複数の吸気通路を形成するために、分割された外側部品内に内側部品を配置し、これら部品を振動溶着法により溶着して、各吸気通路を独立して形成することが考えられる。
【０００３】
このような外側部品内に内側部品を配置して通路を形成する方法として、例えば図１４に示すように、シール面１０１を有する樹脂製の第１のケーシング部分１０２と、シール面１０３を有する樹脂製の第２のケーシング部分１０４と、シール面１０５を有し、前記第１のケーシング部分１０２内に挿入する挿入部分１０６を設け、挿入部分１０６を第１のケーシング部分１０２内に挿入するとともに第１のケ−シング部分１０２のシール面１０１に第２ケーシング部分１０４のシール面１０３を接合してこれらの部材のシール面を振動溶着法により溶着する方法が知られている（例えば特許文献１参照）。
【０００４】
【特許文献１】
特開平８−２５２８６４号公報（第２頁、図１）
【０００５】
【発明が解決しようとする課題】
前記のような分割された外側部品内に内側部品を配置して例えば３本の吸気通路を形成するインテークマニホールドを製造するために、前記従来の特許文献１に記載の技術を用いて製造すると、図１５乃至図１８に示すような方法になる。なお、この図１５乃至図１８に示す構造及びその製造方法は本発明を説明するために仮定したものであり、公知のものではない。
【０００６】
図１５乃至図１８に示すインテークマニホールド２０１は、第１の吸気通路２０２、第２の吸気通路２０３、第３の吸気通路２０４を一体的に形成し、これらの一端に、サージタンク２０５を有し、他端にフランジ２０６を有する例である。
【０００７】
このインテークマニホールド２０１を構成する部品は、図１６に示すように、樹脂製の第１の外側部品（アッパピース）２０７と樹脂製の内側部品（インナピース）２０８と樹脂製の第２の外側部品（ロアーピース）２０９とからなる。第１の外側部品２０７は、横断面形状において、第１の吸気通路２０２の上半分を形成する部分２１０と、内側部品２０８を嵌入する嵌合面２１１と、第２の吸気通路２０３の上部を形成する部分２１２と、第３の吸気通路２０４の上部を形成する部分２１３と、振動溶着面２１４を有する。
【０００８】
内側部品２０８は、前記嵌合面２１１に嵌合する嵌合部２１５と、第１の吸気通路２０２の下半部を形成する部分２１６と、第１及び第２の吸気通路２０３、２０４の上部を形成する部分２１７，２１８と、振動溶着面２１９を有する。
【０００９】
第２の外側部品２０９は、第１及び第２の吸気通路２０３，２０４の下半部を形成する部分２２０，２２１と、前記第１の外側部品２１０の振動溶着面２１４に対応する振動溶着面２２２と、前記内側部品２０８の振動溶着面２１９に対応する振動溶着面２２３を有する。
【００１０】
そして、先ず、図１７に示すように、内側部品２０８を第１の外側部品２０７の嵌合面２１１に嵌合し、次に、第２の外側部品２０９の振動溶着面２２２を第１の外側部品２０７の振動溶着面２１４に接合させるとともに振動溶着面２２３を内側部品２０８の振動溶着面２１９に接合させる。
【００１１】
そして、第２の外側部品２０９を振動しないように固定し、振動溶着法により第１の外側部品２０７と内側部品２０８を振動させて３箇所の振動溶着面を同時に溶着し、図１８に示すような外側部品２０７，２０９に内側部品２０８が内包され、かつ、これら３部品が一体化したインテークマニホールド２０１を製造する。
【００１２】
しかし、このような製造方法によると次のような問題がある。
前記内側部品２０８の振動溶着面２１９と第２の外側部品２２１の振動溶着面２２３を振動溶着するには、該内側部品２０８を第１の外側部品２０７とともに振動溶着に必要な振動幅で振動させなければならない。
【００１３】
しかし、前記の構造においては、内側部品２０８を振動治具で直接振動させることはできない。そのため、第１の外側部品２０７の振動を内側部品２０８に伝達させて内側部品２０８を振動させなければならないが、第１の外側部品２０７と内側部品２０８との嵌合隙間などにより第１の外側部品２０７の振動が内側部品２０８に伝達されにくいことから、内側部品２０８の振動溶着面２１９と第２の外側部品２０９の振動溶着面２２３との振動溶着が困難な問題がある。特に、インテークマニホールドのように長い振動溶着面を有する場合には、溶着面相互の接触抵抗が大きくなり、振動溶着が期待できない。
【００１４】
また、外側部品に内側部品を内包することなく図１９に示すように、樹脂製の第１の部品３０１に樹脂製の第２の部品３０２を溶着面３０３，３０４で振動溶着し、該第２の部品３０２に樹脂製の第３の部品３０５を溶着面３０６〜３０８で振動溶着して、前記のような３本の吸気通路２０２〜２０４を形成することも考えられる。なお、この図１９に示す構造は本発明を説明するものであって公知のものではない。
【００１５】
しかし、前記図１９に示す構造においては、振動溶着作業が２回必要になる問題がある。
【００１６】
そこで本発明は、前記のような内側部品の振動溶着をやめ、外側部品相互は振動溶着するが、内側部品と外側部品とは嵌合構造で対応することにして、前記の問題を解決する樹脂製インテークマニホールドを提供することを目的とするものである。
【００１７】
【課題を解決するための手段】
前記の課題を解決するために、請求項１記載の発明は、外周壁を形成する樹脂製の外側部品内に樹脂製の内側部品を配設して、これら外側部品と内側部品の間で複数の吸気通路を形成するようにし、前記外側部品を、周方向において複数の外側部品に分割するとともにこの分割された外側部品相互を振動溶着で固着して形成し、前記内側部品を前記外側部品に振動溶着することなく気密的に嵌合して保持させたことを特徴とするものである。
【００１８】
請求項２記載の発明は、前記請求項１記載の発明において、前記内側部品と外側部品との嵌合部を、その一方の部品側を他方の部品側に嵌合し、その嵌合部にシール部材を介在して構成したものである。
【００１９】
請求項３記載の発明は、前記請求項２記載の発明において、前記シール部材を、外側部品と内側部品のいずれか一方の部材に設けた可撓性のシール片とし、該シール片を他方の部材の嵌合面に圧接するようにしたものである。
【００２０】
請求項４記載の発明は、前記請求項２記載の発明において、前記シール部材を、外側部品と内側部品のいずれか一方の部材に設けた弾性材料からなる弾性部材とし、該弾性部材を他方の部材の嵌合面に圧接するようにしたものである。
【００２１】
請求項５記載の発明は、前記請求項１乃至４のいずれかに記載の発明において、前記嵌合部に、内側部品と外側部品相互の嵌合位置を定める位置決め手段を設けたものである。
【００２２】
請求項６記載の発明は、前記請求項１乃至５のいずれかに記載の発明において、前記内側部品と外側部品との嵌合状態を仮保持する仮保持手段を設けたものである。
【００２３】
請求項７記載の第７の発明は、３本の吸気通路を一体的に形成する樹脂製のインテークマニホールドであって、周方向において２個に分割された樹脂製の第１の外側部品及び樹脂製の第２の外側部品と、これらの外側部品内に配置される樹脂製の内側部品とからなり、
横断面形状において、前記第１の外側部品は、第１の吸気通路の略半分を形成する第１通路形成部と、該第１通路形成部の両端の先部に延設した嵌合面と、該両嵌合面の先端に延設して第２の吸気通路を形成する略１／４円の第２通路形成部及び第３の吸気通路を形成する略１／４円の第３通路形成部と、該両通路形成部の先端に形成した溶着面を有し、
前記内側部品は、前記第１の吸気通路の略半分を形成する第１通路形成部と、前記第２の吸気通路を形成する略１／４円の第２通路形成部と、前記第３の吸気通路を形成する略１／４円の第３通路形成部と、前記第１の外側部品の前記嵌合面に嵌合する嵌合部と、前記第２の外側部品に嵌合する嵌合部を有し、
前記第２の外側部品は、前記第２の吸気通路の略半分を形成する第２通路形成部と、前記第３の吸気通路の略半分を形成する第３通路形成部と、両側に設けた前記第１の外側部品の溶着面に対応する溶着面と、前記内側部品の嵌合部に対応する嵌合面を有し、
前記内側部品の各嵌合部には、該各嵌合部と対応する前記嵌合面に圧接するシール部材を設け、
前記内側部品を前記第１の外側部品に嵌合し、前記第２の外側部品を、その嵌合面に前記内側部品の嵌合部を嵌合するとともに該第２の外側部品の溶着面を前記第１の外側部品の溶着面に振動溶着して第１の外側部品に固着したことを特徴とするものである。
【００２４】
請求項８記載の発明は、前記請求項７記載の発明において、前記シール部材を外側に開く可撓性のシール片で形成したものである。
【００２５】
請求項９記載の発明は、前記請求項７記載の発明において、前記シール部材を弾性材料からなる弾性部材で形成したものである。
【００２６】
請求項１０記載の発明は、前記請求項７乃至９のいずれかに記載の発明において、前記内側部品と第１の外側部品の相互の嵌合位置を定める位置決め手段を設けたものである。
【００２７】
請求項１１記載の発明は、前記請求項７乃至１０のいずれかに記載の発明において、前記内側部品と第１の外側部品の相互の嵌合位置を仮保持する仮保持手段を設けたものである。
【００２８】
【発明の実施の形態】
本発明の好ましい実施の形態を図１乃至図１１に示す実施例に基づいて説明する。
【００２９】
先ず、図１乃至図６に示す第１実施例について説明する。
図に示す実施例は、本発明を３気筒のエンジンに使用する樹脂製インテークマニホールドに適用したものである。すなわち、第１の吸気通路２と第２の吸気通路３と第３の吸気通路４を一体的に設け、一端に前記各吸気通路２〜４に共通して連通するサージタンク５とフランジ６ａを一体的に設け、他端にフランジ６ｂを一体的に設けて樹脂製のインテークマニホールド１を形成したものである。なお、前記フランジ６ａは図示しないスロットルボデー側に取り付けられ、前記フランジ６ｂは図示しないエンジン側へ取り付けられて、前記各吸気通路２〜４がエンジンの気筒に連通される。
【００３０】
前記樹脂製のインテークマニホールド１は、図２に示すように、外周壁を形成する樹脂製の第１の外側部品（アッパーピース）７と、外周壁を形成する樹脂製の第２の外側部品（ロアーピース）９と、これらの外側部品７，９に内包される樹脂製の内側部品（インナピース）８とからなる。なお、前記各部品７〜９の材料は、ポリアミド系樹脂などの熱可塑樹脂で成形され、振動溶着法によって溶着する樹脂が使用されている。
【００３１】
前記第１の外側部品７は、横断面形状において、第１の吸気通路２の略上半部を形成する略半円状の第１通路形成部１０と、該第１通路形成部１０の両端から両側へ突出する段部１１，１２と、該段部１１，１２から垂下状態に延設された嵌合部１３，１４と、該嵌合部１３の下端から外側へ突出するように延設した第２通路形成部１５と、前記嵌合部１４の下端から外側へ突出するように延設した第３通路形成部１６と、前記第２通路形成部１５の先端（下端）に形成した溶着部１７と、前記第３通路形成部１６の先端（下端）に形成した溶着部１８とからなり、これらが樹脂で一体成形されている。
【００３２】
また、前記両段部１１，１２の内面には位置決め穴１９，２０が、第１の外側部品７の軸方向、すなわち前記第１の吸気通路２の軸方向において適宜間隔を有して複数形成されている。
【００３３】
更に、前記嵌合部１３，１４の内面で形成される嵌合面２１，２２は平面で形成されているとともに、該嵌合面２１と２２との間の距離Ｌ１は所定寸法に設定されている。また、該嵌合面２１，２２の入口部である下端部には内側へ突出する係止突部２３，２４が形成されている。
【００３４】
更に、前記第２通路形成部１５は、前記第２の吸気通路３の上側部分でかつ、外側部分を形成する略１／４円で形成されている。また、前記第３通路形成部１６は、第３の吸気通路４の上側部分でかつ、外側部分を形成する略１／４円で形成されている。
【００３５】
更に、前記両溶着部１７，１８は第１の外側部品７の全長にわたって形成されているとともに、その下面は平面からなる溶着面１７ａ，１８ａに形成されている。なお、溶着部１７，１８には溶着時にバリが内外へ出ることを防止する片２５，２６が形成されている。
【００３６】
前記内側部品８は、横断面形状において、前記第１の吸気通路２の略下半分を形成する略半円状の第１通路形成部２７と、該第１通路形成部２７の両側に形成した上側嵌合部２８，２９と、前記第１通路形成部２７の中心より一方の側において、前記第２の吸気通路３の上側部分でかつ、内側部分を形成する略１／４円で形成された第２通路形成部３０と、第１通路形成部２７の中心より他方の側において、前記第３の吸気通路４の上側部分でかつ、内側部分を形成する略１／４円で形成された第３通路形成部３１と、前記第２通路形成部３０と第３通路形成部３１の間における下部に形成された下側嵌合部３２からなり、これらが樹脂で一体成形されている。
【００３７】
前記上側嵌合部２８，２９の上面３３，３４は前記第１の外側部品７における段部１１，１２の内面に当接するように形成されているとともに、該上面３３，３４には、前記位置決め穴１９，２０に挿入する位置決め突部３５，３６が突設されている。該位置決め突部３５，３６は、位置決め穴１９，２０と同数、同位置に対応して設けられている。これら位置決め穴１９，２０と位置決め突部３５，３６により位置決め手段を形成している。
【００３８】
前記両上側嵌合部２８，２９の外側面で形成した嵌合面３７と３８との間の距離Ｌ２は、前記第１の外側部品７の嵌合面２１，２２間の距離Ｌ１よりも若干短く設定され、上側嵌合部２８，２９が嵌合面２１，２２内に挿入嵌合できるようになっている。
【００３９】
更に、前記上側嵌合部２８，２９の外側面には、上側が外側へ開いた状態の舌片状のシール片３９，４０が樹脂により内側部品７と一体成形されており、該シール片３９，４０は可撓性を有する。該シール片３９の先端部３９ａとシール片４０の先端部４０ａとの間の距離Ｌ３は、嵌合前において、前記嵌合面２１，２２間の距離Ｌ１よりも若干長くなるように設定されており、嵌合した場合に、両シール片３９，４０の先端部３９ａ，４０ａが、その弾性による復元力によって前記嵌合面２１，２２に圧接するようになっている。このシール片３９，４０は内側部品８の全長にわたって形成されている。
【００４０】
前記嵌合面３７，３８の下部には、前記上側嵌合部２８，２９を嵌合面２１，２２に嵌合した場合に、前記第１の外側部品７に形成した係止突部２３，２４がスナップフィットにより嵌入係止する係止穴４１，４２が形成されている。該係止突部２３，２４と係止穴４１，４２は、内側部品８の軸方向全長にわたって設けられている。該係止穴部２３，２４と係止穴４１，４２により仮保持手段を形成している。
【００４１】
前記下側嵌合部３２は、両側に段部４３，４４を形成して下方への突出部を形成するとともに、この下方への突出部の両側に、下側が外側へ開いた状態の舌片状のシール片４５，４６を樹脂により内側部品７と一体に成形して構成されている。前記シール片４５，４６は可撓性を有する。該シール片４５の先端部４５ａとシール片４６の先端部４６ａとの間の距離Ｌ４は、嵌合前において、後述する第２の外側部品９における嵌合凹部５１の嵌合面間距離Ｌ５よりも若干長くなるように設定されており、嵌合部３２を嵌合凹部５１に嵌合した場合に、両シール片４５，４６の先端部４５ａ，４６ａが、その弾性による復元力によって嵌合凹部５１の嵌合面５４，５５に圧接するようになっている。このシール片４５，４６は内側部品の全長にわたって形成されている。
【００４２】
前記第２の外側部品９は、横断面形状において、前記第２の吸気通路３の略下半部を形成する略半円状の第２通路形成部４７と、前記第３の吸気通路４の略下半部を形成する略半円状の第３通路形成部４８と、該両通路形成部４７，４８の外側に位置して前記第１の外側部品７における溶着面１７ａ，１８ａに対応する溶着面４９，５０と、両通路形成部４７，４８の内側の中央部に位置して前記内側部品８における嵌合部３２が嵌合する嵌合凹部５１からなり、これらが樹脂で一体成形されている。
【００４３】
前記嵌合凹部５１を形成する両側壁の上面５２，５３は前記内側部品８の段部４３，４４に当接するように形成され、嵌合面５４，５５は図６に示すように若干上方が開くようなテーパ面に形成されている。
【００４４】
なお、前記内側部品８は図１においてＢの範囲で示す一部分に配置され、図１に示すフランジ６ａは前記第２の外側部品９に一体成形され、サージタンク５は前記第１の外側部品７と第２の外側部品９で分割して形成され、各吸気通路２〜４の下流側部２ａ〜４ａは前記第１の外側部品７と第２の外側部品９で分割して形成され、前記フランジ６ｂは前記第２の外側部品９に一体成形されている。
【００４５】
次に、前記３部品によってインテークマニホールド１を製造する方法について説明する。
【００４６】
先ず、図２に示すように分割成形された第１の外側部品７の嵌合面２１，２２に、分割成形された内側部品８の上側嵌合部２８，２９を挿入して、図３に示すように嵌合する。この嵌合時において位置決め突部３５，３６を位置決め穴１９，２０に挿入することにより、内側部品８を第１の外側部品７に対して設定位置に配置することができる。更に、この嵌合により、第１の外側部品７に形成した係止突部２３，２４が内側部品８の係止穴４１，４２にスナップフィットにより嵌合係止し、第１の外側部品７に対する内側部品８の嵌合状態が仮保持される。
【００４７】
更に、内側部品８に設けたシール片３９，４０の先端部３９ａ，４０ａが、その弾性復元力によって図３及び図５に示すように嵌合面２１，２２に圧接する。
【００４８】
次に、図３に示すように、第２の外側部品９の両溶着面４９，５０を第１の外側部品７における両溶着面１７ａ，１８ａに接触させるとともに第２の外側部品９の嵌合凹部５１を内側部品８の下側嵌合部３２に対向させて第２の外側部品９を配置する。
【００４９】
次に、振動溶着法により、一方、例えば第２の外側部品９を治具により不動に固定し、他方、例えば第１の外側部品７を、第２の外側部品９側へ押圧しつつ矢印Ｃ−Ｄ方向へ振動させ、溶着面１７ａ，１８ａと溶着面４９，５０に生じる摩擦熱により溶着面を溶融させて、図４に示すように、溶着面１７ａ，１８ａと溶着面４９，５０を固着して第１の外側部品７と第２の外側部品９を一体化させる。
【００５０】
また、前記の振動溶着により溶着面が溶けることにより、図４及び図６に示すように、第１の外側部品７の下側嵌合部３２が第２の外側部品９の嵌合凹部５１内に嵌入する。この嵌入により、内側部品８に設けたシール片４５，４６の先端部４５ａ，４６ａが、その弾性復元力によって図６に示すように嵌合面５４，５５に圧接する。
【００５１】
以上によって、第１の外側部品７と第２の外側部品９が振動溶着で固着され、内側部品８が、第１の外側部品と第２の外側部品９にシールされた嵌合状態で収納配置されたインテークマニホールド１が製造される。
【００５２】
以上のように組み付けられたインテークマニホールド１をエンジンに取り付けて使用した場合について説明する。
【００５３】
図示しないエアクリーナからスロットルボデーを経てインテークマニホールド１におけるサージタンク５内に導入された吸気は、サージタンク５から分流して各吸気通路２〜４に導入され、各吸気通路２〜４を通り、フランジ６ｂ部に形成された流出口からエンジン側へ供給される。
【００５４】
このとき、第１の外側部品７と第２の外側部品９との接合部は、溶着面１７ａ，４９及び１８ａ，５０で溶着されて密閉され、また、第１の吸気通路２を形成する第１の外側部品９と内側部品８との嵌合部はシール片３９，４０が嵌合面２１，２２に圧着して密閉され、更に、第２の吸気通路３と第３の吸気通路４を形成する第２の外側部品９と内側部品８との嵌合部はシール片４５，４６が嵌合面５４，５５に圧着して密閉される。したがって、各吸気通路２〜４は外部との気密性が保持されるとともに各吸気通路２〜４の相互においても気密性が保持される。
【００５５】
また、第１の外側部品７における嵌合面２１，２２と内側部品８の嵌合面３７，３８との間には、図５に示すように、嵌合するための若干の隙間ｄを形成し、内側部品８における嵌合部２８，２９の上面３３，３４を段部１１，１２の内面に密着させることにより、第２の吸気通路３内の吸気負圧がシール片３９の外側面に作用し、また、第３の吸気通路４の吸気負圧がシール片４０の外側面に作用し、両シール片３９，４０が、その内側と外側の差圧によって外側、すなわち嵌合面２１，２２側へ引き寄せられて変形し、嵌合面２１，２２に圧接する。そのため、シール片３９，４０による気密性が前記のようなシール片３９，４０自体の弾性による嵌合面２１，２２への圧接作用と前記吸気負圧による嵌合面２１，２２への圧接作用によって一層高められる。
【００５６】
また、内側部品８の段部４３，４４と第２の外側部品９の上面５２，５３との間に隙間が生じている場合には、第２の吸気通路２と第３の吸気通路４内の吸気負圧がシール片４５，４６の外側に作用し、シール片４５，４６が嵌合面５４，５５側に引き寄せられて変形し、嵌合面５４，５５に圧接する。そのため、シール片４５，４６による気密性が、前記のようなシール片４５，４６自体の弾性による嵌合面５４，５５への圧接作用と、前記吸気負圧による嵌合面５４，５５への圧接作用によって一層高められる。
【００５７】
また、前記のように、内側部品８と第１の外側部品７との嵌合部及び内側部品８と第２の外側部品９との嵌合部の気密性を確保できることにより、この嵌合部を振動溶着にて固着する必要がない。そのため、内側部品８に、第１の外側部品７を介して振動溶着に必要な振動を付与する必要がない。したがって、前記図１３乃至図１６で例示した製造方法の問題を解決することができる。
【００５８】
また、前記図１７で例示した構造のものに比べ、振動溶接作業の回数が１回減少し、製造コストの低減を図ることができる。
【００５９】
図７乃至図１０は第２実施例を示す。
本第２実施例は、前記第１実施例におけるシール片３９，４０に代えて弾性材料、例えばゴム、或いはシリコン、ＦＩＰＣなどの樹脂などで形成した弾性部材６０，６１を使用し、また、前記第１実施例におけるシール片４５，４６に代えて弾性材料、例えばゴム、或いはシリコン、ＦＩＰＣなどの樹脂などで形成した弾性部材６２，６３を使用したものである。
【００６０】
前記弾性部材６０，６１の外側面は前記第１実施例における内側部品８の嵌合面３７，３８より外側へ突出して形成され、前記第１実施例における第１の外側部品７における嵌合面２１，２２に圧接するように形成されている。
【００６１】
また、前記弾性部材６２，６３の外側面は、前記第１実施例における第２の外側部品９の嵌合面５４，５５に圧接するように形成されている。
【００６２】
前記弾性部材６０〜６３は、流体状のものを付設面に塗布して形成してもよく、成形品を付設面に焼き付けて設けてもよく、更に、付設面に差し込み部を形成して該差し込み部に成形品を差し込んで設けてもよい。
【００６３】
その他の構造は前記第１実施例と同様であるため、前記と同一部分には同一符号を付してその説明を省略する。
【００６４】
本第２実施例においても前記第１実施例と同様の嵌合及び振動溶着により組み付けるものであり、図７に示す分離状態から、内側部品８を第１の外側部品７に嵌合するとともに第２の外側部品９を第１の外側部品７と内側部品８に接合し、次で前記と同様に振動溶着法により第１の外側部品７と第２の外側部品９を溶着して図８に示すように組み付ける。
【００６５】
本第２実施例においても前記弾性部材６０〜６３によりシールされ、前記第１実施例と同様の効果を発揮できる。
【００６６】
なお、前記内側部品８における第１の外側部品７とのシール部と内側部品８における第２の外側部品９とのシール部を、そのいずれか一方を前記第１実施例のようにシール片で形成し、他方を前記第２実施例のような弾性部材で形成してもよい。図７は、内側部品８における第１の外側部品７とのシール部を前記第１実施例のシール片３９，４０とし、内側部品８における第２の外側部品９とのシール部を前記第２実施例の弾性部材６２，６３とした第３実施例である。
【００６７】
更に、前記シール片３９，４０，４５，４６及び弾性部材６０〜６３を外側部品側に設けてもよい。
【００６８】
また、前記各実施例は、３本の吸気通路を有するインテークマニホールドに本発明を適用した例であるが、本発明は、このような３本の吸気通路を有するインテークマニホールドに限るものではなく、外側部品に内側部品を内包して複数の吸気通路を形成するインテークマニホールドに適用できるものである。
【００６９】
例えば、図１２の第４実施例に示すように、第１の外側部品７に、前記各実施例のような第１通路形成部１０と同様の第４通路形成部１０Ａを連設し、また、内側部品８に、前記各実施例のような第１通路形成部２７と同様の第４通路形成部２７Ａを連設して第４の吸気通路２Ａを形成する。更に、前記内側部品８に、前記各実施例のような第２通路形成部３０と第３通路形成部３１と同様の第３通路形成部３０Ａと第５通路形成部３１Ａを連設し、また、第２の外側部品９に、前記第３通路形成部４８と同様な第５通路形成部４８Ａを連設して第５の吸気通路４Ａを形成する。
【００７０】
なお、該第４実施例における第１の外側部品７と第２の外側部品９との接合及び第１の外側部品７と内側部品８との接合、更には、第２の外側部品９と内側部品８との接合は、前記第１乃至第３実施例で示した構造を採用している。これらの接合構造は前記の説明で明らかであるため、その説明は省略する。
【００７１】
本第４実施例は吸気通路を３本以上の奇数本設ける場合の配置例である。
また、３本以上の偶数本の吸気通路を設ける場合には、例えば図１３に示すように配置する。
【００７２】
すなわち、前記図１２に示す実施例の第１の外側部品７に、前記第４通路形成部１０Ａと同様の第６通路形成部１０Ｂを連設し、また、前記図１２に示す実施例の内側部品８に、前記第４通路形成部２７Ａと同様の第６通路形成部２７Ｂを連設して第６の吸気通路２Ｂを形成する。更に、前記図１２に示す実施例の内側部品８における前記第５通路形成部３１Ａを略半円状に形成するとともに、第２の外側部品９に一体に接続用の部品７０を連設する。
【００７３】
なお、該第５実施例における第１の外側部品７と第２の外側部品９との接合及び第１の外側部品７と内側部品８との接合、第２の外側部品９と内側部品８との接合は、前記第１乃至第３実施例で示した構造を採用する。これらの接合構造は前記の説明で明らかであるため、その説明は省略する。
【００７４】
本第５実施例では６本の吸気通路が形成される。
前記第４及び第５実施例においても、前記第１実施例と同様の嵌合及び振動溶着により組み付けるものであり、これにより、前記第１実施例と同様の作用、効果が得られる。
【００７５】
【発明の効果】
以上のようであるから、本発明によれば、内側部品を外側部品に気密的に嵌合して保持するようにしたので、該内側部品と外側部品とを振動溶着で固着することなく該嵌合部での各吸気通路間の気密性を確保できる。
【００７６】
したがって、振動溶着は、分割された外側部品相互において行えばよく、前記の問題を解決することができる。
【００７７】
また、請求項５記載の発明においては、３本の吸気通路を一体に有する樹脂製のインテークマニホールドを気密性を確保して容易に製造できる。
【００７８】
また、シール部材としてシール片を用いることにより、該シール片に吸気負圧を作用させて嵌合面側へ圧接することができ、一層シール効果を高めることができる。
【００７９】
また、嵌合位置を定める位置決め手段を設けることにより、内側部品を所定の位置に確保できるとともにシール性も確保できる。
【００８０】
また、内側部品を一方の外側部品に嵌合した状態を仮保持する仮保持手段を設けることにより、内側部品を一方の外側部品に嵌合した状態で一方の外側部品と他方の外側部品とを振動溶着する作業が容易に行える。
【図面の簡単な説明】
【図１】本発明を３本の吸気通路を有するインテークマニホールドに適用した第１実施例を示す平面図。
【図２】図１の部品を分解した状態の横断面図。
【図３】図２の状態から内側部品を第１の外側部品に嵌合し、第２の外側部品を第１の外側部品に接合した状態の横断面図。
【図４】図３の状態から、両外側部品を相互に振動溶着して組み付けた横断面図で、図１におけるＡ−Ａ線断面図。
【図５】図４における内側部品と第１の外側部品との接合部を示す拡大横断面図。
【図６】図４における内側部品と第２の外側部品との接合部を示す拡大横断面図。
【図７】本発明の第２実施例を示すもので、部品を分解した状態の横断面図。
【図８】図７の第２実施例における組付状態の横断面図。
【図９】図７における内側部品の上側嵌合部を示す拡大横断面図。
【図１０】図７における内側部品の下側嵌合部を示す拡大横断面図。
【図１１】本発明の第３実施例を示すもので、部品を分解した状態の横断面図。
【図１２】本発明の第４実施例を示す組付状態の横断面図。
【図１３】本発明の第５実施例を示す組付状態の横断面図。
【図１４】従来の技術を示す部品を分解した側面図。
【図１５】本発明を説明するために例示したインテークマニホールドの平面図。
【図１６】図１５における部品を分解した状態の横断面図。
【図１７】図１６の状態から内側部品を第１の外側部品に嵌合し、第２の外側部品を第１の外側部品に接合した状態の横断面図。
【図１８】図１７の状態から、両外側部品相互を振動溶着して組み付けた横断面図。
【図１９】本発明を説明するために例示した他のインテークマニホールドの横断面図。
【符号の説明】
１樹脂製のインテークマニホールド
２〜４，２Ａ，２Ｂ，４Ａ吸気通路
７第１の外側部品
８内側部品
９第２の外側部品
１０第１通路形成部
１３，１４嵌合部
１５第２通路形成部
１６第３通路形成部
１７，１８溶着部
１７ａ，１８ａ溶着面
１９，２０位置決め手段の穴
２１，２２嵌合面
２３，２４仮保持手段の係止突部
２７第１通路形成部
２８，２９嵌合部
３０第２通路形成部
３１第３通路形成部
３２嵌合部
３５，３６位置決め手段の突部
３７，３８嵌合面
３９，４０，４５，４６シール片
４１，４２仮保持手段の係止穴
４７第２通路形成部
４８第３通路形成部
４９，５０溶着面
５１嵌合凹部
５４，５５嵌合面
６０〜６３弾性部材
１０Ａ，２７Ａ第４通路形成部
３１Ａ，４８Ａ第５通路形成部
１０Ｂ，２７Ｂ第６通路形成部[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a resin intake manifold.
[0002]
[Prior art]
In a resin intake manifold that supplies intake air to the engine, in order to form a plurality of intake passages, inner parts are arranged in divided outer parts, and these parts are welded by a vibration welding method, and each intake passage is welded. May be formed independently.
[0003]
As a method of forming a passage by arranging an inner part in such an outer part, for example, as shown in FIG. 14, a resin first casing part 102 having a sealing surface 101 and a resin having a sealing surface 103 A second casing portion 104, a sealing surface 105, and an insertion portion 106 for insertion into the first casing portion 102. The insertion portion 106 is inserted into the first casing portion 102 and A method is known in which the sealing surface 103 of the second casing portion 104 is joined to the sealing surface 101 of the first casing portion 102 and the sealing surfaces of these members are welded by a vibration welding method (for example, see Patent Document 1). ).
[0004]
[Patent Document 1]
JP-A-8-252864 (page 2, FIG. 1)
[0005]
[Problems to be solved by the invention]
When manufacturing using the technique described in the above-mentioned conventional patent document 1, in order to manufacture an intake manifold in which the inner part is arranged in the divided outer part as described above to form, for example, three intake passages, The method is as shown in FIGS. The structures shown in FIGS. 15 to 18 and the manufacturing method thereof are assumed to explain the present invention and are not publicly known.
[0006]
The intake manifold 201 shown in FIGS. 15 to 18 integrally forms a first intake passage 202, a second intake passage 203, and a third intake passage 204, and has a surge tank 205 at one end thereof. And a flange 206 at the other end.
[0007]
As shown in FIG. 16, the components constituting the intake manifold 201 include a first outer component (upper piece) 207 made of resin, an inner component (inner piece) 208 made of resin, and a second outer component (made of resin). 209). The first outer part 207 has, in cross-sectional shape, a part 210 forming the upper half of the first intake passage 202, a fitting surface 211 into which the inner part 208 is fitted, and an upper part of the second intake passage 203. A portion 212 to be formed, a portion 213 to form an upper portion of the third intake passage 204, and a vibration welding surface 214 are provided.
[0008]
The inner part 208 includes a fitting portion 215 that fits into the fitting surface 211, a portion 216 that forms the lower half of the first intake passage 202, and upper portions of the first and second intake passages 203 and 204. Are formed, and a vibration welding surface 219.
[0009]
The second outer part 209 includes a portion 220, 221 that forms the lower half of the first and second intake passages 203, 204, and a vibration welding surface corresponding to the vibration welding surface 214 of the first outer component 210. 222, and a vibration welding surface 223 corresponding to the vibration welding surface 219 of the inner part 208.
[0010]
First, as shown in FIG. 17, the inner part 208 is fitted to the fitting surface 211 of the first outer part 207, and then the vibration welding surface 222 of the second outer part 209 is fitted to the first outer part 209. The vibration welding surface 223 of the inner component 208 is bonded together with the vibration welding surface 214 of the component 207.
[0011]
Then, the second outer part 209 is fixed so as not to vibrate, and the first outer part 207 and the inner part 208 are vibrated by the vibration welding method to simultaneously weld three vibration welding surfaces, as shown in FIG. The intake manifold 201 in which the inner component 208 is included in the outer components 207 and 209 and the three components are integrated is manufactured.
[0012]
However, such a manufacturing method has the following problems.
To vibration-weld the vibration welding surface 219 of the inner part 208 and the vibration welding surface 223 of the second outer part 221, the inner part 208 is vibrated together with the first outer part 207 at a vibration width required for vibration welding. There must be.
[0013]
However, in the above structure, the inner component 208 cannot be directly vibrated by the vibration jig. Therefore, the vibration of the first outer component 207 must be transmitted to the inner component 208 to cause the inner component 208 to vibrate. Since the vibration of the component 207 is not easily transmitted to the inner component 208, there is a problem that the vibration welding between the vibration welding surface 219 of the inner component 208 and the vibration welding surface 223 of the second outer component 209 is difficult. In particular, in the case of having a long vibration welding surface such as an intake manifold, contact resistance between the welding surfaces becomes large, and vibration welding cannot be expected.
[0014]
Further, as shown in FIG. 19, the second part 302 made of resin is vibration-welded to the first part 301 made of resin at the welding surfaces 303 and 304 without enclosing the inner part in the outer part. It is also conceivable to form a three-part intake passage 202 to 204 as described above by vibration-welding a third part 305 made of resin to the part 302 at the welding surfaces 306 to 308. The structure shown in FIG. 19 explains the present invention and is not a known structure.
[0015]
However, the structure shown in FIG. 19 has a problem that the vibration welding operation is required twice.
[0016]
In view of the above, the present invention provides a resin that solves the above-mentioned problem by stopping the vibration welding of the inner part and the outer parts being vibration-welded to each other. It is an object of the present invention to provide an intake manifold.
[0017]
[Means for Solving the Problems]
In order to solve the above-mentioned problem, the invention according to claim 1 disposes a resin inner part in a resin outer part forming an outer peripheral wall, and provides a plurality of parts between the outer part and the inner part. The outer part is divided into a plurality of outer parts in the circumferential direction, and the divided outer parts are fixed to each other by vibration welding, and the inner part is formed on the outer part. It is characterized by being fitted and held in an airtight manner without vibration welding.
[0018]
According to a second aspect of the present invention, in the first aspect of the present invention, a fitting portion between the inner component and the outer component is fitted with one component side to the other component side, and is fitted to the fitting portion. It is configured with a seal member interposed.
[0019]
According to a third aspect of the present invention, in the second aspect of the present invention, the sealing member is a flexible sealing piece provided on one of an outer part and an inner part, and the sealing piece is the other. It is configured to be in pressure contact with the fitting surface of the member.
[0020]
According to a fourth aspect of the present invention, in the second aspect of the invention, the seal member is an elastic member made of an elastic material provided on one of the outer part and the inner part, and the elastic member is the other. It is configured to be in pressure contact with the fitting surface of the member.
[0021]
According to a fifth aspect of the present invention, in the first aspect of the present invention, the fitting portion is provided with positioning means for determining a fitting position between the inner part and the outer part.
[0022]
According to a sixth aspect of the present invention, in the invention of any one of the first to fifth aspects, a temporary holding means for temporarily holding a fitting state between the inner part and the outer part is provided.
[0023]
According to a seventh aspect of the present invention, there is provided a resin-made intake manifold integrally forming three intake passages, wherein the resin-made first outer part and the resin-made first outer part are divided into two parts in a circumferential direction. A second outer component, and a resin inner component disposed in these outer components,
In the cross-sectional shape, the first outer part includes a first passage forming portion that forms substantially half of the first intake passage, and a fitting surface that extends to a front end of both ends of the first passage forming portion. A second passage forming portion extending substantially at the ends of the two fitting surfaces to form a second intake passage, and a third passage having a substantially quarter circle forming a third intake passage. Forming portion, having a welding surface formed at the tip of the both passage forming portion,
The inner part includes a first passage forming portion that forms substantially a half of the first intake passage, a second passage forming portion having a substantially quarter circle that forms the second intake passage, and the third passage forming portion. A substantially 1/4 circle third passage forming portion forming an intake passage, a fitting portion fitted to the fitting surface of the first outer component, and a fitting fitted to the second outer component. Part
The second outer part is provided on both sides of a second passage forming portion forming substantially half of the second intake passage, and a third passage forming portion forming substantially half of the third intake passage. A welding surface corresponding to the welding surface of the first outer component, and a fitting surface corresponding to a fitting portion of the inner component,
Each fitting portion of the inner part is provided with a seal member that presses against the fitting surface corresponding to each fitting portion,
The inner part is fitted to the first outer part, and the second outer part is fitted to the fitting part of the inner part on the fitting surface and the welding surface of the second outer part is fitted. A vibration welding is performed on a welding surface of the first outer component, and the first outer component is fixed to the first outer component.
[0024]
According to an eighth aspect of the present invention, in the invention of the seventh aspect, the seal member is formed of a flexible seal piece that opens outward.
[0025]
According to a ninth aspect of the present invention, in the invention of the seventh aspect, the seal member is formed of an elastic member made of an elastic material.
[0026]
According to a tenth aspect of the present invention, in any one of the seventh to ninth aspects, a positioning means for determining a mutual fitting position of the inner part and the first outer part is provided.
[0027]
An eleventh aspect of the present invention is the invention according to any one of the seventh to tenth aspects, further comprising provisional holding means for temporarily holding a mutual fitting position between the inner part and the first outer part. is there.
[0028]
BEST MODE FOR CARRYING OUT THE INVENTION
A preferred embodiment of the present invention will be described based on an embodiment shown in FIGS.
[0029]
First, a first embodiment shown in FIGS. 1 to 6 will be described.
In the embodiment shown in the drawings, the present invention is applied to a resin intake manifold used for a three-cylinder engine. That is, the first intake passage 2, the second intake passage 3, and the third intake passage 4 are integrally provided, and the surge tank 5 and the flange 6 a commonly communicating with the intake passages 2 to 4 are provided at one end. The intake manifold 1 made of resin is formed by integrally providing a flange 6b at the other end. The flange 6a is attached to a throttle body (not shown), and the flange 6b is attached to an engine (not shown), so that the intake passages 2 to 4 communicate with the cylinders of the engine.
[0030]
As shown in FIG. 2, the resin intake manifold 1 includes a first resin outer part (upper piece) 7 that forms an outer peripheral wall, and a second resin outer part (an upper part) that forms an outer peripheral wall. A lower part 9 and a resin inner part (inner piece) 8 included in the outer parts 7 and 9. The material of each of the components 7 to 9 is formed of a thermoplastic resin such as a polyamide resin, and a resin that is welded by a vibration welding method is used.
[0031]
The first outer component 7 has a substantially semicircular first passage forming portion 10 that forms a substantially upper half of the first intake passage 2 in a cross-sectional shape, and both ends of the first passage forming portion 10. Steps 11 and 12 projecting from both sides from the bottom, fitting portions 13 and 14 extending from the step portions 11 and 12 in a hanging state, and extending so as to project outward from the lower end of the fitting portion 13. A second passage forming portion 15, a third passage forming portion 16 extending so as to protrude outward from a lower end of the fitting portion 14, and welding formed at a tip (lower end) of the second passage forming portion 15. A portion 17 and a welded portion 18 formed at the tip (lower end) of the third passage forming portion 16 are integrally formed of resin.
[0032]
A plurality of positioning holes 19 and 20 are formed in the inner surfaces of the two step portions 11 and 12 at appropriate intervals in the axial direction of the first outer component 7, that is, in the axial direction of the first intake passage 2. Have been.
[0033]
Further, the fitting surfaces 21 and 22 formed by the inner surfaces of the fitting portions 13 and 14 are formed as flat surfaces, and the distance L1 between the fitting surfaces 21 and 22 is set to a predetermined size. I have. In addition, locking projections 23 and 24 projecting inward are formed at lower ends of the fitting surfaces 21 and 22 which are entrances.
[0034]
Further, the second passage forming portion 15 is formed in a substantially quarter circle which forms an upper portion and an outer portion of the second intake passage 3. Further, the third passage forming portion 16 is formed in a substantially 1/4 circle forming an upper portion and an outer portion of the third intake passage 4.
[0035]
Further, the welding portions 17, 18 are formed over the entire length of the first outer part 7, and the lower surfaces thereof are formed on flat welding surfaces 17a, 18a. The welding portions 17 and 18 are formed with pieces 25 and 26 for preventing burrs from coming in and out during welding.
[0036]
The inner part 8 has a substantially semicircular first passage forming portion 27 that forms a substantially lower half of the first intake passage 2 in a cross-sectional shape, and is formed on both sides of the first passage forming portion 27. On one side from the center of the upper fitting portions 28 and 29 and the center of the first passage forming portion 27, the upper portion is formed in a substantially 1/4 circle forming the upper portion and the inner portion of the second intake passage 3. On the other side of the center of the second passage forming portion 30 and the first passage forming portion 27, the upper portion of the third intake passage 4 is formed in a substantially 1/4 circle forming the inner portion. A third passage forming portion 31 and a lower fitting portion 32 formed at a lower portion between the second passage forming portion 30 and the third passage forming portion 31 are integrally formed of resin.
[0037]
The upper surfaces 33 and 34 of the upper fitting portions 28 and 29 are formed so as to abut against the inner surfaces of the step portions 11 and 12 of the first outer component 7, and the upper surfaces 33 and 34 are provided with the positioning. Positioning protrusions 35 and 36 to be inserted into the holes 19 and 20 are provided in a protruding manner. The positioning projections 35 and 36 are provided in the same number and at the same positions as the positioning holes 19 and 20. These positioning holes 19 and 20 and the positioning projections 35 and 36 form a positioning means.
[0038]
The distance L2 between the fitting surfaces 37 and 38 formed on the outer surfaces of the upper fitting portions 28 and 29 is slightly larger than the distance L1 between the fitting surfaces 21 and 22 of the first outer component 7. The length is set short so that the upper fitting portions 28 and 29 can be inserted and fitted into the fitting surfaces 21 and 22.
[0039]
Further, on the outer side surfaces of the upper fitting portions 28, 29, tongue-shaped sealing pieces 39, 40 with the upper side opened outward are integrally formed with the inner part 7 by resin. , 40 are flexible. The distance L3 between the tip 39a of the sealing piece 39 and the tip 40a of the sealing piece 40 is set to be slightly longer than the distance L1 between the fitting surfaces 21 and 22 before fitting. When fitted, the distal end portions 39a, 40a of both seal pieces 39, 40 are pressed against the fitting surfaces 21, 22 by a restoring force due to their elasticity. These sealing pieces 39 and 40 are formed over the entire length of the inner part 8.
[0040]
When the upper fitting portions 28 and 29 are fitted to the fitting surfaces 21 and 22, the locking projections 23 formed on the first outer component 7 are provided below the fitting surfaces 37 and 38. Engagement holes 41 and 42 are formed in the engagement holes 24 by snap fitting. The locking projections 23 and 24 and the locking holes 41 and 42 are provided over the entire length of the inner component 8 in the axial direction. The locking holes 23 and 24 and the locking holes 41 and 42 form temporary holding means.
[0041]
The lower fitting portion 32 has stepped portions 43 and 44 formed on both sides to form a downwardly projecting portion, and a tongue piece having a lower side opened outward on both sides of the downwardly projecting portion. The seal pieces 45 and 46 are formed integrally with the inner part 7 by resin. The seal pieces 45 and 46 have flexibility. The distance L4 between the tip 45a of the seal piece 45 and the tip 46a of the seal piece 46 is smaller than the distance L5 between the fitting surfaces of the fitting recesses 51 of the second outer component 9 described later before fitting. Are slightly longer, and when the fitting portion 32 is fitted into the fitting recess 51, the distal end portions 45a and 46a of the two seal pieces 45 and 46 are resiliently restored by the elasticity of the fitting pieces 32 and 46. The fitting surfaces 54 and 55 of the fitting 51 are pressed against each other. These sealing pieces 45, 46 are formed over the entire length of the inner part.
[0042]
The second outer component 9 has a substantially semicircular second passage forming portion 47 that forms a substantially lower half of the second intake passage 3 in a cross-sectional shape, and a second passage forming portion 47 that defines the third intake passage 4. A substantially semicircular third passage forming portion 48 that forms a substantially lower half portion, and is located outside the two passage forming portions 47 and 48 and corresponds to the welding surfaces 17a and 18a of the first outer component 7. It is composed of welding surfaces 49, 50 and a fitting concave portion 51 which is located at the center of the inside of both passage forming portions 47, 48 and into which the fitting portion 32 of the inner part 8 fits, and these are integrally formed of resin. ing.
[0043]
The upper surfaces 52, 53 of both side walls forming the fitting concave portion 51 are formed so as to abut the step portions 43, 44 of the inner part 8, and the fitting surfaces 54, 55 are slightly upward as shown in FIG. The opening is formed on a tapered surface.
[0044]
The inner part 8 is disposed in a part indicated by a range B in FIG. 1, the flange 6a shown in FIG. 1 is integrally formed with the second outer part 9, and the surge tank 5 is formed as the first outer part 7 And the second outer part 9 are formed separately, and the downstream portions 2a to 4a of the intake passages 2 to 4 are formed by being divided by the first outer part 7 and the second outer part 9, The flange 6b is formed integrally with the second outer part 9.
[0045]
Next, a method of manufacturing the intake manifold 1 from the three components will be described.
[0046]
First, as shown in FIG. 2, the upper fitting portions 28 and 29 of the divided inner component 8 are inserted into the fitting surfaces 21 and 22 of the first outer component 7 which is divided and formed. Fit as shown. By inserting the positioning projections 35 and 36 into the positioning holes 19 and 20 at the time of this fitting, the inner component 8 can be arranged at a set position with respect to the first outer component 7. Further, by this fitting, the locking projections 23 and 24 formed on the first outer component 7 are fitted and locked into the locking holes 41 and 42 of the inner component 8 by snap fit. Is temporarily held.
[0047]
Further, the distal end portions 39a, 40a of the seal pieces 39, 40 provided on the inner part 8 are pressed against the fitting surfaces 21, 22 by the elastic restoring force as shown in FIGS.
[0048]
Next, as shown in FIG. 3, both welding surfaces 49, 50 of the second outer component 9 are brought into contact with both welding surfaces 17a, 18a of the first outer component 7, and the second outer component 9 is fitted. The second outer component 9 is arranged with the concave portion 51 facing the lower fitting portion 32 of the inner component 8.
[0049]
Next, by means of the vibration welding method, for example, the second outer component 9 is fixed immovably by a jig, and the other, for example, the first outer component 7 is pressed against the second outer component 9 while the arrow C is pressed. By vibrating in the −D direction, the welding surfaces 17a, 18a and the welding surfaces 49, 50 are melted by frictional heat generated between the welding surfaces 17a, 18a, and the welding surfaces 17a, 18a and the welding surfaces 49, 50 are fixed as shown in FIG. Then, the first outer component 7 and the second outer component 9 are integrated.
[0050]
Further, the welding surface is melted by the vibration welding, so that the lower fitting portion 32 of the first outer component 7 is in the fitting recess 51 of the second outer component 9 as shown in FIGS. To fit. By this fitting, the tip portions 45a, 46a of the seal pieces 45, 46 provided on the inner part 8 are pressed against the fitting surfaces 54, 55 by the elastic restoring force as shown in FIG.
[0051]
As described above, the first outer part 7 and the second outer part 9 are fixed by vibration welding, and the inner part 8 is housed and arranged in a fitted state sealed with the first outer part and the second outer part 9. The manufactured intake manifold 1 is manufactured.
[0052]
A case where the intake manifold 1 assembled as described above is used by being attached to an engine will be described.
[0053]
The intake air introduced into the surge tank 5 of the intake manifold 1 from the air cleaner (not shown) via the throttle body is divided from the surge tank 5 and introduced into each of the intake passages 2 to 4, passes through each of the intake passages 2 to 4, and flows through the flange. It is supplied to the engine side from the outlet formed in the portion 6b.
[0054]
At this time, the joint between the first outer component 7 and the second outer component 9 is welded and sealed at the welding surfaces 17a, 49 and 18a, 50, and the first air inlet passage 2 is formed. The fitting portion between the outer part 9 and the inner part 8 is sealed by sealing pieces 39 and 40 being pressed against the fitting surfaces 21 and 22, and furthermore, the second intake passage 3 and the third intake passage 4 are closed. The fitting portion between the second outer component 9 and the inner component 8 to be formed is hermetically sealed by sealing pieces 45 and 46 pressed against the fitting surfaces 54 and 55. Therefore, each of the intake passages 2 to 4 maintains the airtightness with the outside and also maintains the airtightness of each of the intake passages 2 to 4.
[0055]
Further, between the fitting surfaces 21 and 22 of the first outer component 7 and the fitting surfaces 37 and 38 of the inner component 8, as shown in FIG. By bringing the upper surfaces 33 and 34 of the fitting portions 28 and 29 of the inner part 8 into close contact with the inner surfaces of the steps 11 and 12, the intake negative pressure in the second intake passage 3 is applied to the outer surface of the seal piece 39. In addition, the negative pressure of the third intake passage 4 acts on the outer surface of the seal piece 40, and the two seal pieces 39, 40 are moved outward, that is, the fitting surfaces 21, It is drawn to the side 22 and deformed, and presses against the fitting surfaces 21 and 22. Therefore, the hermeticity of the seal pieces 39, 40 is such that the elasticity of the seal pieces 39, 40 themselves as described above exerts a pressing action on the fitting surfaces 21, 22 and a pressing action on the fitting faces 21, 22 due to the negative pressure of the intake air. Is further enhanced by:
[0056]
If there is a gap between the step portions 43 and 44 of the inner component 8 and the upper surfaces 52 and 53 of the second outer component 9, the inside of the second intake passage 2 and the third intake passage 4 Acts on the outside of the seal pieces 45, 46, and the seal pieces 45, 46 are drawn toward the fitting surfaces 54, 55 to be deformed and pressed against the fitting surfaces 54, 55. Therefore, the airtightness of the seal pieces 45, 46 is caused by the elasticity of the seal pieces 45, 46 itself as described above, and the press-fitting action on the fitting surfaces 54, 55, and by the suction negative pressure on the fitting surfaces 54, 55. It is further enhanced by the pressing action.
[0057]
Further, as described above, the airtightness of the fitting portion between the inner component 8 and the first outer component 7 and the fitting portion between the inner component 8 and the second outer component 9 can be ensured. Need not be fixed by vibration welding. Therefore, it is not necessary to apply vibration necessary for vibration welding to the inner part 8 via the first outer part 7. Accordingly, the problem of the manufacturing method illustrated in FIGS. 13 to 16 can be solved.
[0058]
Also, as compared with the structure illustrated in FIG. 17, the number of times of the vibration welding operation is reduced by one, and the manufacturing cost can be reduced.
[0059]
7 to 10 show a second embodiment.
The second embodiment uses elastic members 60 and 61 made of an elastic material, for example, rubber, or a resin such as silicon or FIPC, instead of the seal pieces 39 and 40 in the first embodiment. Instead of the sealing pieces 45 and 46 in the first embodiment, elastic members 62 and 63 formed of an elastic material, for example, rubber, or a resin such as silicon or FIPC are used.
[0060]
The outer surfaces of the elastic members 60 and 61 are formed so as to protrude outward from the fitting surfaces 37 and 38 of the inner part 8 in the first embodiment, and the fitting surfaces of the first outer part 7 in the first embodiment. It is formed so as to be pressed against 21 and 22.
[0061]
The outer surfaces of the elastic members 62 and 63 are formed so as to be in pressure contact with the fitting surfaces 54 and 55 of the second outer component 9 in the first embodiment.
[0062]
The elastic members 60 to 63 may be formed by applying a fluid-like material to the attachment surface, or may be provided by baking a molded product on the attachment surface, and further forming an insertion portion on the attachment surface. A molded article may be inserted into the insertion portion.
[0063]
Since other structures are the same as those of the first embodiment, the same parts as those described above are denoted by the same reference numerals and the description thereof will be omitted.
[0064]
The second embodiment is also assembled by the same fitting and vibration welding as in the first embodiment. From the separation state shown in FIG. The second outer part 9 is joined to the first outer part 7 and the inner part 8 and then the first outer part 7 and the second outer part 9 are welded by the vibration welding method in the same manner as described above. Assemble as shown.
[0065]
Also in the second embodiment, the sealing is performed by the elastic members 60 to 63, and the same effects as in the first embodiment can be exhibited.
[0066]
In addition, one of the sealing part of the inner part 8 with the first outer part 7 and the sealing part of the inner part 8 with the second outer part 9 is a sealing piece as in the first embodiment. And the other may be formed of an elastic member as in the second embodiment. FIG. 7 shows that the sealing portion of the inner part 8 with the first outer part 7 is the sealing piece 39, 40 of the first embodiment, and the sealing part of the inner part 8 with the second outer part 9 is the second part. This is a third embodiment in which the elastic members 62 and 63 of the embodiment are used.
[0067]
Further, the seal pieces 39, 40, 45, 46 and the elastic members 60 to 63 may be provided on the outer component side.
[0068]
Further, each of the above embodiments is an example in which the present invention is applied to an intake manifold having three intake passages. However, the present invention is not limited to such an intake manifold having three intake passages. The present invention can be applied to an intake manifold in which an inner part is included in an outer part to form a plurality of intake passages.
[0069]
For example, as shown in a fourth embodiment in FIG. 12, a fourth passage forming portion 10A similar to the first passage forming portion 10 as in each of the above embodiments is continuously provided on the first outer part 7, and A fourth passage forming portion 27A similar to the first passage forming portion 27 as in each of the above-described embodiments is connected to the inner part 8 to form a fourth intake passage 2A. Further, a third passage forming portion 30A and a fifth passage forming portion 31A similar to the second passage forming portion 30 and the third passage forming portion 31 as in the above embodiments are continuously provided on the inner part 8, and A fifth passage forming portion 48A similar to the third passage forming portion 48 is connected to the second outer component 9 to form a fifth intake passage 4A.
[0070]
In the fourth embodiment, the first outer part 7 and the second outer part 9 are joined together, the first outer part 7 and the inner part 8 are joined together, and the second outer part 9 and the inner part 8 are joined together. The connection with the component 8 employs the structure shown in the first to third embodiments. Since these joining structures are clear in the above description, the description is omitted.
[0071]
The fourth embodiment is an arrangement example in which three or more odd-numbered intake passages are provided.
When three or more intake passages are provided, they are arranged, for example, as shown in FIG.
[0072]
That is, a sixth passage forming portion 10B similar to the fourth passage forming portion 10A is continuously connected to the first outer part 7 of the embodiment shown in FIG. 12, and the inside of the embodiment shown in FIG. A sixth passage forming portion 27B similar to the fourth passage forming portion 27A is connected to the component 8 to form a sixth intake passage 2B. Further, the fifth passage forming portion 31A of the inner part 8 of the embodiment shown in FIG. 12 is formed in a substantially semicircular shape, and a connecting part 70 is integrally connected to the second outer part 9.
[0073]
In the fifth embodiment, the first outer part 7 and the second outer part 9 are joined together, the first outer part 7 and the inner part 8 are joined together, and the second outer part 9 and the inner part 8 are joined together. The structure shown in the first to third embodiments is employed for the bonding. Since these joining structures are clear in the above description, the description is omitted.
[0074]
In the fifth embodiment, six intake passages are formed.
Also in the fourth and fifth embodiments, they are assembled by the same fitting and vibration welding as in the first embodiment, whereby the same operations and effects as in the first embodiment can be obtained.
[0075]
【The invention's effect】
As described above, according to the present invention, the inner component is airtightly fitted to and held by the outer component, so that the inner component and the outer component can be fitted without being fixed by vibration welding. Airtightness between the intake passages at the joint can be ensured.
[0076]
Therefore, the vibration welding may be performed between the divided outer parts, and the above problem can be solved.
[0077]
According to the fifth aspect of the invention, a resin-made intake manifold integrally having three intake passages can be easily manufactured while ensuring airtightness.
[0078]
In addition, by using a seal piece as a seal member, it is possible to apply an intake negative pressure to the seal piece and press the seal piece against the fitting surface, thereby further enhancing the sealing effect.
[0079]
Further, by providing the positioning means for determining the fitting position, the inner part can be secured at a predetermined position and the sealing property can be secured.
[0080]
Further, by providing temporary holding means for temporarily holding a state in which the inner component is fitted to the one outer component, one outer component and the other outer component can be connected in a state where the inner component is fitted to the one outer component. Vibration welding can be easily performed.
[Brief description of the drawings]
FIG. 1 is a plan view showing a first embodiment in which the present invention is applied to an intake manifold having three intake passages.
FIG. 2 is a cross-sectional view of the disassembled part of FIG. 1;
FIG. 3 is a cross-sectional view showing a state where the inner part is fitted to the first outer part and the second outer part is joined to the first outer part from the state shown in FIG. 2;
4 is a cross-sectional view in which both outer parts are assembled by vibration welding from each other from the state of FIG. 3, and is a cross-sectional view taken along line AA in FIG. 1;
FIG. 5 is an enlarged cross-sectional view showing a joint between the inner part and the first outer part in FIG. 4;
FIG. 6 is an enlarged cross-sectional view showing a joint between the inner part and the second outer part in FIG. 4;
FIG. 7 is a cross-sectional view showing a second embodiment of the present invention, in which parts are disassembled.
FIG. 8 is a cross-sectional view of the assembled state in the second embodiment of FIG. 7;
FIG. 9 is an enlarged cross-sectional view showing an upper fitting portion of the inner part in FIG. 7;
FIG. 10 is an enlarged cross-sectional view showing a lower fitting portion of the inner part in FIG. 7;
FIG. 11 shows a third embodiment of the present invention, and is a cross-sectional view of a state where components are disassembled.
FIG. 12 is a cross-sectional view of an assembled state showing a fourth embodiment of the present invention.
FIG. 13 is a cross-sectional view of an assembled state showing a fifth embodiment of the present invention.
FIG. 14 is an exploded side view of a part showing a conventional technique.
FIG. 15 is a plan view of an intake manifold illustrated to explain the present invention.
FIG. 16 is a transverse cross-sectional view of a state where the components in FIG. 15 are disassembled.
FIG. 17 is a cross-sectional view of the state in which the inner part is fitted to the first outer part and the second outer part is joined to the first outer part from the state shown in FIG. 16;
18 is a cross-sectional view in which both outer parts are assembled by vibration welding from the state of FIG. 17;
FIG. 19 is a cross-sectional view of another intake manifold illustrated to explain the present invention.
[Explanation of symbols]
1 Intake manifold made of resin
2-4, 2A, 2B, 4A Intake passage
7 First outer part
8 Inside parts
9 The second outer part
10 1st passage formation part
13, 14 fitting part
15 2nd passage formation part
16 3rd passage formation part
17, 18 welding part
17a, 18a welding surface
19,20 Hole for positioning means
21,22 mating surface
23, 24 locking projection of temporary holding means
27 1st passage formation part
28, 29 Fitting part
30 2nd passage formation part
31 3rd passage formation part
32 fitting part
35, 36 Projection of positioning means
37, 38 mating surface
39, 40, 45, 46 Seal pieces
41, 42 Locking holes of temporary holding means
47 2nd passage formation part
48 Third passage forming part
49,50 welding surface
51 Fitting recess
54, 55 mating surface
60-63 elastic member
10A, 27A 4th passage formation part
31A, 48A Fifth passage forming portion
10B, 27B 6th passage formation part

Claims

A resin inner component is disposed within a resin outer component forming an outer peripheral wall, and a plurality of intake passages are formed between the outer component and the inner component. It is divided into a plurality of outer parts and the divided outer parts are fixed to each other by vibration welding to form an inner part, and the inner part is hermetically fitted and held without vibration welding to the outer part. Characterized resin intake manifold.

The resin intake manifold according to claim 1, wherein a fitting portion between the inner component and the outer component is configured such that one component side is fitted to the other component side and a sealing member is interposed between the fitting portions. .

3. The resin according to claim 2, wherein the sealing member is a flexible sealing piece provided on one of the outer component and the inner component, and the sealing piece is pressed against a fitting surface of the other component. Made intake manifold.

3. The resin according to claim 2, wherein the sealing member is an elastic member made of an elastic material provided on one of the outer component and the inner component, and the elastic member is pressed against a fitting surface of the other component. Made intake manifold.

The resin intake manifold according to any one of claims 1 to 4, wherein the fitting portion is provided with positioning means for determining a fitting position between the inner part and the outer part.

The resin intake manifold according to any one of claims 1 to 5, further comprising temporary holding means for temporarily holding the fitted state between the inner part and the outer part.

A resin-made intake manifold integrally forming three intake passages, wherein a first resin-made outer part and a second resin-made outer part are divided into two parts in a circumferential direction. It consists of a resin inner part placed inside the outer part,
In the cross-sectional shape, the first outer part includes a first passage forming portion that forms substantially half of the first intake passage, and a fitting surface that extends to a front end of both ends of the first passage forming portion. A second passage forming portion extending substantially at the ends of the two fitting surfaces to form a second intake passage, and a third passage having a substantially quarter circle forming a third intake passage. Forming portion, having a welding surface formed at the tip of the both passage forming portion,
The inner part includes a first passage forming portion that forms substantially a half of the first intake passage, a second passage forming portion having a substantially quarter circle that forms the second intake passage, and the third passage forming portion. A substantially 1/4 circle third passage forming portion forming an intake passage, a fitting portion fitted to the fitting surface of the first outer component, and a fitting fitted to the second outer component. Part
The second outer part is provided on both sides of a second passage forming portion forming substantially half of the second intake passage, and a third passage forming portion forming substantially half of the third intake passage. A welding surface corresponding to the welding surface of the first outer component, and a fitting surface corresponding to a fitting portion of the inner component,
Each fitting portion of the inner part is provided with a seal member that presses against the fitting surface corresponding to each fitting portion,
The inner part is fitted to the first outer part, and the second outer part is fitted to the fitting part of the inner part on the fitting surface and the welding surface of the second outer part is fitted. A resin intake manifold characterized by being vibration-welded to a welding surface of the first outer component and fixed to the first outer component.

The resin intake manifold according to claim 7, wherein the seal member is formed of a flexible seal piece that opens outward.

The resin intake manifold according to claim 7, wherein the seal member is formed of an elastic member made of an elastic material.

The resin intake manifold according to any one of claims 7 to 9, further comprising positioning means for determining a mutual fitting position of the inner component and the first outer component.

The resin intake manifold according to any one of claims 7 to 10, further comprising temporary holding means for temporarily holding a mutual fitting position between the inner component and the first outer component.