JP2008025354A - Weld joining structure and weld joining method of intake manifold - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To materialize stable high joining strength by regulating slippage to the outside of the split body substantially along an inclination direction of an inclined part and suppressing variation of welding strength even when both split bodies include curved parts having inclined parts inclined to a pressing direction at vibration welding when forming an intake manifold of a pair of synthetic resin made split bodies which keeps intake pipe parts of an intake manifold respectively containing split surfaces substantially along an axial line of an intake passage and joining the split bodies by a vibration welding method. <P>SOLUTION: A receiving part 21 which is substantially orthogonal to an inclination direction of an inclined part in a split surface and which receives a force to the inside of the split body substantially along the inclination direction is provided on a back side of the split surface of an upper side split body 15 in an intake pipe part 10. The upper side split body 15 and lower side split 16 are joined to each other by a vibration welding method with a force to the inside of the split body substantially along the inclined direction acting on the receiving part. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention comprises an intake volume part and a synthetic resin intake pipe part, and the intake pipe part is composed of a pair of split bodies each having a split surface substantially along the axis of the intake passage, The present invention relates to a welded joint structure and a welded joint method for an intake manifold that are welded and joined at an abutting portion of the divided surface by a vibration welding method.

  2. Description of the Related Art Conventionally, as an intake manifold attached to an engine of a vehicle such as an automobile, there are an intake volume portion communicating with an intake air supply source, and a plurality of intake passages with one end communicating with the intake volume portion and the other end communicating with an engine cylinder. A pair of divided bodies (a first divided body and a second divided body) each having a divided surface substantially along the axis of the intake passage. It is known that both of these divided bodies are welded and joined at the abutting portions of the divided surfaces by a vibration welding method (see, for example, Patent Document 1).

  In relation to the size and shape of the intake manifold, the length of the intake passage of the intake manifold is secured to a required length in accordance with the space saving of the engine room, or the length of a plurality of intake passages. There is a demand for further compactness while setting the lengths to be as equal as possible. For this reason, the shape of the intake pipe portion needs to be devised such as changing from a relatively straight straight pipe to a bent pipe having a curved portion.

FIG. 10 is an overall perspective view showing an example of a conventional intake manifold, and FIG. 11 is a longitudinal sectional explanatory view taken along line Y11-Y11 in FIG.
As shown in these drawings, the intake manifold Ma according to this conventional example has four intake passages 62 having one end communicating with a surge tank 51 (intake volume portion) and the other end communicating with a cylinder of an engine (not shown). A pair of divided bodies 65 and 66 (first divided parts) each having a split surface 65f and 66f substantially along the axis of the intake passage 62. Body and second divided body). Then, these two divided bodies 65 and 66 are welded and joined by the vibration welding method at the abutting portions where the respective divided surfaces 65f and 66f are abutted, whereby an integrated intake manifold Ma is obtained.

When the first divided body 65 and the second divided body 66 are welded by vibration, the two divided surfaces 65f and 66 are brought into contact with each other by dividing surfaces 65f and 66f, and as shown by an arrow A10 in FIG. , 66f in a state of being pressurized through the jig from the back side, vibration is applied in the direction indicated by the reciprocating arrow B10 in FIG. 10 to weld the two divided bodies 65, 66 at the abutting portion.
The intake pipe portion 60 of the intake manifold Ma has a curved portion curved so as to bulge upward in order to secure the length of the intake passage 62 at a required length even in a relatively small installation space. This curved portion has left and right inclined portions 63 that are inclined with respect to the pressing direction during vibration welding.
JP 2002-364470 A

  In the case where the first divided body 65 and the second divided body 66 are vibration welded, when the both inclined portions 65f and 66f are pressurized from the back side of the respective divided surfaces 65f, 66f due to the presence of the inclined portion 63, the inclined portion 63 is provided. In the portion 63, for example, the right inclined portion 63 in FIG. 11 will be described as an example. The applied pressure F1 acting on the first divided body 65 is perpendicular to the tangent lines of the divided surfaces 65f and 66f (that is, the inclined portion 63 is inclined). A vertical component force Fv acting in a direction (perpendicular to the direction) and applying a surface pressure between the two split surfaces 65f and 66f, and a direction along the tangent line of the split surfaces 65f and 66f (that is, along the tilt direction of the tilt portion 63). The inclined component force Fk is generated, and the inclined component force Fk acts to slide the right inclined portion 63 of the first divided body 65 outward in the right direction along the inclination direction. Similarly, a force for sliding leftward outwardly acts on the left inclined portion 63 of the first divided body 66.

  As a result, as a whole, as shown by an arrow A11 in FIG. 11, a force in a direction to open the left and right lower portions outwardly acts on the first divided body 65, and the divided surfaces 65f and 66f of both the divided bodies 65 and 66 are applied. It is difficult to obtain a uniform and sufficient pressing force over the entire surface, particularly a pressing force perpendicular to the dividing surfaces 65f and 66f that contributes to strong welding (the vertical component force Fv). For this reason, there is a problem that the welding strength easily varies along the axis of the intake passage 62 and it is difficult to stably obtain a sufficient welding strength.

  Accordingly, the present invention relates to an intake manifold in which at least a part of the intake pipe portion is formed by welding and joining a pair of synthetic resin divided bodies each having a divided surface substantially along the axis of the intake passage by a vibration welding method. Even when the split surfaces of the two split bodies are provided with a curved portion having an inclined portion inclined with respect to the pressurizing direction during vibration welding, the split bodies slide substantially along the inclined direction of the inclined portion. By restricting, the basic purpose is to suppress the dispersion of the welding strength and to achieve a stable high bonding strength.

For this reason, the welding connection structure of the intake manifold according to the present invention has an intake volume portion communicating with an intake air supply source, and a plurality of intake passages having one end communicating with the intake volume portion and the other end communicating with a cylinder of the engine. An intake pipe portion made of a synthetic resin, and at least a part of the intake pipe portion includes a first divided body and a second divided body each having a divided surface substantially along the axis of the intake passage. The manifold is a welded joint structure of an intake manifold in which both of these divided bodies are welded and joined by vibration welding at an abutting portion where the respective divided surfaces are abutted.
The dividing surfaces of the two divided bodies are provided with a curved shape portion having an inclined portion inclined with respect to the pressurizing direction during vibration welding, and on the back side of the inclined portion of the dividing surface in the first divided body, A receiving portion that receives a force in a direction substantially perpendicular to the inclined direction of the inclined portion and substantially along the inclined direction is provided, and the second divided body comes into contact with the receiving portion when the divided surfaces collide with each other. A contact part is provided, and the first divided body and the second part are applied to the receiving part through the contact part in a state in which an opposing force is applied to the receiving part, which opposes the pressure component substantially along the tilt direction. The divided body is joined by a vibration welding method.

  In this case, it is preferable that the contact portion is formed in a plate shape and is disposed in a direction substantially orthogonal to the vibration direction at the time of vibration welding.

  Further, in the above case, the intake pipe part is configured by a plurality of intake pipes at least partially separated from each other, and at least one of the receiving part and the contact part connects the separated intake pipes It is more preferable.

An intake manifold welding and joining method according to the present invention comprises a synthetic resin having an intake volume portion communicating with an intake air supply source, and a plurality of intake passages having one end communicating with the intake volume portion and the other end communicating with an engine cylinder. An intake manifold, wherein at least a part of the intake pipe is composed of a first divided body and a second divided body each having a divided surface substantially along the axis of the intake passage. A method for welding and joining intake manifolds, in which the two divided bodies are welded and joined by vibration welding at the abutting portions where the divided surfaces abut each other.
The dividing surfaces of the two divided bodies are provided with a curved shape portion having an inclined portion inclined with respect to the pressurizing direction during vibration welding, and on the back side of the inclined portion of the dividing surface in the first divided body, A receiving portion is provided to receive a force in a direction substantially along the inclination direction substantially orthogonal to the inclination direction of the inclination portion, and is opposed to a pressure component force substantially along the inclination direction with respect to the receiving portion. The first divided body and the second divided body are welded and joined by a vibration welding method in a state where an opposing force is applied.

  According to the welded joint structure of the intake manifold according to the present invention, with respect to the receiving portion provided in the first divided body, in the inclination direction of the inclined portion of the dividing surface via the contact portion provided in the second divided body. The first divided body and the second divided body are welded and joined by a vibration welding method in a state in which an opposing force that opposes the substantially pressing force component is applied. Therefore, even when both the divided bodies are provided with a curved portion having an inclined portion inclined with respect to the pressurizing direction at the time of vibration welding, the first division substantially along the inclined direction of the inclined portion. The body slip can be effectively controlled. Thereby, the dispersion | variation in welding intensity | strength can be suppressed and realization of the stable high joint strength can be aimed at.

  In this case, preferably, the contact portion is formed in a plate shape and disposed in a direction orthogonal to the vibration direction at the time of vibration welding, so that the contact portion is in contact with the receiving portion. Can be prevented from being easily melted during vibration welding, and the sliding of the first divided body substantially along the inclined direction can be more effectively regulated.

  In the above case, more preferably, the intake pipe part is configured by a plurality of intake pipes at least partially separated from each other, and at least one of the receiving part and the contact part is the separated intake pipe. Since the pipes are connected together, the separation interval between the separated intake pipes is widened by pressurization during vibration welding, and the welding balance is impaired. Can prevent.

  According to the method for welding and joining an intake manifold according to the present invention, the opposing force that opposes the pressure component force substantially along the inclination direction of the inclined portion of the dividing surface acts on the receiving portion provided in the first divided body. In this state, the first divided body and the second divided body are welded and joined by the vibration welding method. Therefore, even when both the divided bodies have a curved shape portion having at least two inclined portions inclined with respect to the pressurizing direction at the time of vibration welding, the first division substantially along the inclined direction is provided. The body slip can be effectively controlled. Thereby, the dispersion | variation in welding intensity | strength can be suppressed and realization of the stable high joint strength can be aimed at.

Hereinafter, embodiments of the present invention will be described with reference to the accompanying drawings.
1 is an overall perspective view of an intake manifold according to an embodiment of the present invention, FIG. 2 is a perspective view showing an upper divided body (first divided body) of the intake manifold, and FIG. 3 is a lower divided body of the intake manifold (first divided body). FIG. 4 is a plan view of the lower divided body, FIG. 5 is a longitudinal sectional view of the intake manifold taken along line Y5-Y5 of FIG. 1, and FIG. It is a cross-sectional explanatory drawing of the said intake manifold along the Y6-Y6 line of 1. FIG.

  As shown in these drawings, the intake manifold M1 according to the present embodiment includes a surge tank 1 as an intake volume communicating with an intake supply source, and one end communicating with the surge tank 1 and the other end being an engine cylinder ( And an intake pipe portion 10 having a plurality of (four in this embodiment) intake passages 15 communicating with each other. The other end of the intake pipe portion 10 is preferably coupled to the cylinder side of the engine via a mounting flange 5 made of synthetic resin. The mounting flange 5 is provided with a plurality of bolt insertion holes 7 having metal bushes 6 through which mounting bolts (not shown) to the engine are inserted. The surge tank 1 is preferably made of synthetic resin, and is formed by joining the upper half 2 and the lower half 3 together by welding, for example.

  The intake pipe portion 10 is made of a synthetic resin and includes a plurality (four) of intake pipes 11 at least partially separated from each other. Specifically, the intake pipe portion 10 is branched from the other end into four intake pipes 11 separated from each other, and the terminal side of the branched intake pipe 11 is connected to the mounting flange 5. Instead of this, it is possible to adopt a configuration in which there is no intake pipe separated from the intake pipe portion.

  In the present embodiment, at least a part of the intake pipe portion 10 has an upper divided body 15 and a lower divided body 16 each having divided surfaces 15f and 16f substantially along the axis L12 (see FIG. 5) of the intake passage 12. After the two divided bodies 15 and 16 are brought into contact with each other at the divided surfaces 15f and 16f, as shown by an arrow A1 in FIG. 1 and FIG. 5, from the back side of the divided surfaces 15f and 16f. In a state of being pressurized through a jig (not shown), vibrations of a predetermined frequency and amplitude are applied in the direction indicated by the reciprocating arrow B1 in FIG. 1 to weld the two divided bodies 15 and 16 at the abutting portion. Thereby, the integral intake manifold M1 is obtained. The lower divided body 16 is preferably integrally formed with the upper half 2 of the surge tank 1 and the mounting flange 5.

  The upper and lower divided bodies 15 and 16 of the intake pipe portion 10 have welding protrusions P (see FIGS. 3, 4 and 6) that are melted and welded by vibration welding, and an excessive molten resin. When this occurs, a resin reservoir groove G (see FIG. 6) is provided to prevent this from protruding to the inside and outside of the abutting portion. In FIGS. 3 and 4, the display of the groove portion G is omitted in order to avoid an excessively complicated drawing.

  The intake pipe portion 10 of the intake manifold M1 has a curved portion curved so as to bulge upward in order to ensure the length of the intake passage 12 at a required length even in a relatively small installation space. This curved portion has left and right inclined portions 13 (see FIG. 5) that are inclined with respect to the pressurizing direction (see arrow A1 in FIGS. 1 and 5) during vibration welding.

In the present embodiment, even when both the divided bodies 15 and 16 are provided with curved portions having left and right inclined portions 13 inclined with respect to the pressurizing direction at the time of vibration welding, the dividing surfaces 15f are provided. , 16f along the tangent line (that is, along the inclination direction of the inclined portion 13), the upper divided body 15 is inclined to the upper divided body 15 so as to be restricted from sliding in the left-right direction. A receiving portion 21 is provided which receives a force toward the inside of the divided body substantially perpendicular to the direction and substantially along the inclined direction.
The receiving portion 21 is provided on the back side (upper side) of the dividing surface 15 f in the upper divided body 15, and has a plate-like leg portion 23 whose lower end side is connected to the upper side of the divided body 15, and the upper end of the leg portion 23. It is comprised with the plate-shaped pressure receiving plate 22 extended in the direction substantially orthogonal to the inclination direction.

  In this example, as described above, the intake pipe portion 10 is branched into four separate intake pipes 11 on the side close to the end connected to the mounting flange 5, and the receiving portion 21 is separated. It is provided on both sides of each intake pipe 11. Of the five receiving portions 21, three central receiving portions 21 located between the intake pipes 11 are formed so as to connect the separated intake pipes 11 to each other. These three connection receiving portions 21 include a pair of plate-like leg portions 23, and the lower ends of the plate-like leg portions 23 are respectively connected to the upper sides of the divided bodies 15 of the intake pipes 11 on both sides.

  As described above, the receiving portion 21 is formed by connecting the separated intake pipes 11, so that the separation interval between the separated intake pipes 11 is widened by pressurization during vibration welding, and the welding balance is impaired. This can be prevented with a compact structure without the need for providing a special mechanism.

Out of the five receiving portions 21, the outer two receiving portions 21 positioned at the end of the intake pipe 11, not between the intake pipes 11, have one plate-like leg portion 23. The lower end portion is connected to the upper side of the divided body 15 of the intake pipe 11 at the end.
In the case where the intake pipe portion 10 has no separated intake pipe and is integrated, only the two outer receiving portions 21 positioned at the end of the intake pipe 11 are provided.

  On the other hand, the lower divided body 16 is provided with an abutting portion 26 that abuts on the receiving portion 21 provided on the upper divided body 15 (specifically, abuts on the pressure receiving plate 22). The contact portion 26 includes a plate-shaped substrate portion 28, and a plate-shaped contact plate 27 that contacts the pressure receiving plate 22 of the receiving portion 21 is provided on the substrate portion 28.

Of the five abutting portions 26, the three abutting portions 26 on the center side located between the intake pipes 11 are formed so as to connect the separated intake pipes 11 to each other. In these three connecting contact portions 26, both end portions of the substrate portion 28 are connected to the divided bodies 16 of the intake pipes 11 on both sides.
As described above, the contact portion 26 is formed by connecting the separated intake pipes 11, so that the separation interval between the separated intake pipes 11 is widened by pressurization during vibration welding, and the welding balance is lost. This can be prevented with a compact structure without the need for providing a special mechanism.

  During vibration welding, the upper and lower divided bodies 15 and 16 that are brought into contact with each other are pressurized from above and below, so that they are substantially aligned in the inclination direction of the inclined portion 13 via the contact plate 27 of the contact portion 26. A force toward the inside of the divided body is applied to the pressure receiving plate 22 of the receiving portion 21.

  Thus, according to the present embodiment, a state in which a force toward the divided body substantially along the inclination direction of the inclined portion 13 is applied to the pressure receiving plate 22 of the receiving portion 21 provided in the upper divided body 15. Thus, the upper divided body 15 and the lower divided body 16 are joined by the vibration welding method. Therefore, even if both the divided bodies 15 and 16 are provided with curved portions having left and right inclined portions 13 inclined with respect to the pressurizing direction during vibration welding, the inclination direction of the inclined portion 13 is It is possible to effectively regulate the sliding of the upper divided body 15 substantially along the left and right outwards. Thereby, the dispersion | variation in welding strength can be suppressed and the realization of the stable high joint strength can be aimed at.

In this case, the contact plate 27 of the contact portion 26 is formed in a plate shape as described above, and is disposed in a direction substantially orthogonal to the vibration direction at the time of vibration welding.
Thereby, it can prevent that the said contact plate 27 contact | abutted with the said pressure receiving plate 22 of the receiving part 21 melts | dissolves easily at the time of vibration welding, and the left-right outer side of the upper side division body 15 along the inclination direction of the said inclination part 13 substantially. Can be more effectively regulated.

  In the present embodiment, the upper divided body is applied to the pressure receiving plate 22 of the receiving portion 21 provided in the upper divided body 15 in order to apply a force toward the divided body along the inclined direction of the inclined portion 13. The contact portion 26 having the contact plate 27 that contacts the pressure receiving plate 22 of the 15 receiving portions 21 is provided in the lower divided body 16, but instead of the upper and lower divided bodies at the time of vibration welding. Of the jigs (not shown) for pressurizing 15, 16, a protrusion is provided on the jig for holding the lower divided body 16, and this protrusion is attached to the pressure receiving plate 22 of the receiving part 21 of the upper divided body 15. By abutting, it is also possible to configure the pressure receiving plate 22 to apply a force toward the inside of the divided body substantially along the inclination direction of the inclined portion 13.

  7 to 9 show modifications in which the shape of the anti-slip portion is mainly different from the above-described embodiment (the embodiment shown in FIGS. 1 to 6). In the description of this modification, the same components as those in the above-described embodiment are denoted by the same reference numerals, and further description thereof is omitted.

  In the intake manifold M2 according to this modification, the receiving portion 31 provided on the back side of the dividing surface 15f in the upper divided body 15 is substantially orthogonal to the inclined direction of the inclined portion 13, and is divided into the divided body inside along the inclined direction. The end of the plate 31 is connected to the divided body 16 of the intake pipe 11. That is, the plate material 31 performs the functions of the pressure receiving plate 22 and the leg portion 23 in the above-described embodiment. The contact portion 26 provided in the lower divided body 16 is the same as that in the above-described embodiment.

  Needless to say, the present invention is not limited to the above embodiments, and various changes and modifications can be made without departing from the scope of the present invention.

  The present invention includes an intake volume part and a synthetic resin intake pipe part, and the intake pipe part is constituted by a pair of split bodies each having a split surface substantially along the axis of the intake passage, and the split bodies are vibrated. The present invention relates to a welded joint structure of an intake manifold that is joined at the divided surface by a welding method, and both the divided bodies are provided with a curved portion having an inclined portion that is inclined with respect to a pressurizing direction during vibration welding. Even in this case, by restricting the sliding of the inclined portion outward along the inclined direction of the inclined portion, it is possible to suppress a variation in welding strength and achieve a stable high bonding strength. It can be effectively used as a welded joint structure of an intake manifold attached to the engine.

1 is an overall perspective view of an intake manifold according to an embodiment of the present invention. It is a perspective view which shows the upper side division body of the said intake manifold. It is a perspective view which shows the lower side division body of the said intake manifold. It is a plane explanatory view of the lower divided body. FIG. 5 is a longitudinal cross-sectional explanatory view of the intake manifold taken along line Y5-Y5 of FIG. It is a cross-sectional explanatory drawing of the said intake manifold along the Y6-Y6 line | wire of FIG. It is a whole perspective view of the intake manifold which concerns on the modification of the said embodiment. It is a perspective view of the upper side division body of the intake manifold which concerns on the said modification. It is a perspective view of the lower part division body of the intake manifold which concerns on the said modification. It is a whole perspective view of the intake manifold which concerns on a prior art example. It is longitudinal cross-sectional explanatory drawing of the intake manifold which concerns on the said prior art example along the Y11-Y11 line | wire of FIG.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Surge tank 10 Intake pipe part 11 Intake pipe 12 Intake passage 13 Inclination part 15 Upper division body 15f (Upper division body) Dividing surface 16 Upper division body 16f (Upper division body) Dividing surface 21,31 Receiving part 26 Contact M1, M2 Intake manifold

Claims (4)

An intake volume portion communicating with an intake air supply source, and a synthetic resin intake pipe portion having a plurality of intake passages having one end communicating with the intake volume portion and the other end communicating with a cylinder of the engine. At least a portion of the intake manifold formed of a first divided body and a second divided body each having a divided surface substantially along the axis of the intake passage. A weld joint structure of an intake manifold that is welded and joined by a vibration welding method at an abutted joint part,
The split surfaces of the two split bodies include a curved shape portion having an inclined portion inclined with respect to the pressurizing direction during vibration welding,
On the back side of the inclined portion of the dividing surface in the first divided body, a receiving portion is provided that receives a force in a direction substantially perpendicular to the inclined direction of the inclined portion and substantially along the inclined direction,
The second divided body is provided with a contact portion that comes into contact with the receiving portion at the time of the collision of the divided surfaces,
The first divided body and the second divided body are vibration welded in a state in which an opposing force that opposes the pressure component force substantially along the inclination direction is applied to the receiving portion via the contact portion. Joined by,
This is a welded joint structure for intake manifolds.   2. The intake manifold weld joint structure according to claim 1, wherein the contact portion is formed in a plate shape and disposed in a direction substantially orthogonal to a vibration direction at the time of vibration welding.   The intake pipe part is constituted by a plurality of intake pipes at least partially separated from each other, and at least one of the receiving part and the contact part connects the separated intake pipes. A welded joint structure for an intake manifold according to claim 1 or 2. An intake volume portion communicating with an intake air supply source, and a synthetic resin intake pipe portion having a plurality of intake passages having one end communicating with the intake volume portion and the other end communicating with a cylinder of the engine. At least a portion of the intake manifold formed of a first divided body and a second divided body each having a divided surface substantially along the axis of the intake passage, the two divided bodies are divided into the divided surfaces. A method of welding and joining an intake manifold that welds and joins by a vibration welding method at the abutted contact portion,
The split surfaces of the two split bodies include a curved shape portion having an inclined portion inclined with respect to the pressurizing direction during vibration welding,
On the back side of the inclined portion of the dividing surface in the first divided body, a receiving portion is provided that receives a force in a direction substantially perpendicular to the inclined direction of the inclined portion and substantially along the inclined direction,
The first divided body and the second divided body are welded and joined to each other by a vibration welding method in a state in which an opposing force that opposes the pressure component force substantially along the tilt direction is applied to the receiving portion.
Intake manifold welding method characterized by the above.

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