JP2012193631A - Air intake duct - Google Patents

Abstract

PROBLEM TO BE SOLVED: To improve mountability for an engine compartment of a vehicle, by reducing the size of an intercooler duct 4.SOLUTION: An inside burr sump 41 and a communication passage 42, which are formed between first and second flanges 21 and 31 of first and second duct half bodies A and B, that is to say, the inside burr sump 41 and the communication passage 42, which are adjacently formed on both the sides of a duct body 17, are used as a resonant chamber and a communication pipe for resonators 18 and 19, respectively. In addition, the volumetric capacity of the inside burr sump 41 is set as a volumetric capacity calculated by using a formula expressing resonance frequencies of the resonators 18 and 19, with respect to a target silencing frequency. Thus, the intercooler duct 4 with a compact silencing function can be obtained only by finely adjusting the volumetric capacity of the inside burr sump 41 without newly providing a special resonant chamber for the intercooler duct 4 having the duct body 17.

Description

  The present invention relates to an intake duct having a Helmholtz type resonator that silences intake noise of an internal combustion engine by a resonance action, and in particular, resonates intake noise generated in a duct body that forms an intake passage through which intake air sucked into the internal combustion engine flows. The present invention relates to an intake silencer for an internal combustion engine that silences by action.

[Conventional technology]
In recent years, there has been an increasing demand for reduction of outside noise to automobiles, and the intake noise generated in the intake system of the engine, which is one of the noises of the internal combustion engine (engine), is also the subject. As an intake silencer for reducing intake noise, a resonance silencer (a resonator or a side branch) that silences the intake sound by a resonance action is known.
As one of the resonators, there is known a Helmholtz type resonator in which a resonance chamber is connected to an intake passage inside an intake duct with a communication pipe having a smaller flow path cross-sectional area than the resonance chamber. It is known that the resonance frequency (f) of this resonator is expressed by the following formula (Helmholtz equation).

[Equation 1]
f = {c / (2π)} · {S / (V · L)} ^1/2
Here, c is the speed of sound (m / s), S is the cross-sectional area (m ² ) of the communication tube, V is the volume (m ³ ) of the resonance chamber, and L is the total length (m) of the communication tube.
Then, by appropriately adjusting the volume (V) of the resonance chamber of the resonator, the total length (L) of the communication pipe, or the diameter of the communication pipe (or the flow path cross-sectional area S of the communication pipe), intake air having a specific resonance frequency Sound can be reduced.

Here, an intake silencer in which a resonator is integrated with a duct body of an engine intake system is known (see, for example, Patent Documents 1 and 2).
First, as shown in FIGS. 4 to 6, the air intake duct is formed by integrally forming duct halves 101 and 102, which are semi-cylindrical bodies vertically divided into two in the duct axial direction, with a synthetic resin material, respectively. Concave side protrusions 103 and 104 are provided on the lateral sides of the half bodies 101 and 102, flanges 105 and 106 facing each other are provided on the peripheral edges of the side protrusions 103 and 104, and the flanges 105 and 106 are abutted against each other. By vibration welding, the resonators 107 and 108 and the side branch 109 are joined and integrated on both sides of the cylindrical duct body 110 to produce a synthetic resin intake duct.

The synthetic resin intake duct (conventional example 1) shown in FIGS. 4 and 5 protrudes on both sides of the duct body 110 from the opposite side of the flange 105 to the upper side of the opposite side surface (upper end surface). A lower convex portion projecting downward from the opposite side surface (lower end surface) to the opposing surface of the upper convex portion and the flange 106, and a volume between the inner surface of the upper convex portion and the lower convex portion. Spaces 111 to 120 are provided, and these volume spaces 111 to 120 are used as resonance chambers for the resonators 107 and 108.
In addition, notches 121 to 130 are provided in a partition wall that partitions the resonators 107 and 108 and the duct body 110, and these notches 121 to 130 are used as communication pipes for the resonators 107 and 108.
The spaces 111 to 120 are partitioned by a partition wall. Thereby, it can respond to a plurality of resonance frequencies.

  However, in the intake duct of the first conventional example, the cylindrical duct body 110 is arranged at the center in the width direction, and is configured by a plurality of spaces 111 to 120 and a plurality of notches 121 to 130 on both sides in the width direction. The plurality of resonators 107 and 108 are joined and integrated. In order to form the plurality of resonators 107 and 108 on both sides of the duct body 110, the upper and lower end surfaces of the flanges 105 and 106 are directed upward and downward. Since the protruding upper and lower convex portions are provided, the size of the intake duct, in particular, the size of the silencing function portions (resonators 107 and 108) on both sides of the duct main body 110 is increased. Accordingly, as the size of the intake duct is increased, for example, it is a factor that deteriorates the mountability of the intake duct on the vehicle.

On the other hand, the intake duct (conventional example 2) made of synthetic resin shown in FIG. 6 is provided with a porous resonator 107 as a resonance silencer and two side branches 109 on both sides of the duct body 110.
This is because the duct body 110 is halved in the direction of the duct axis and at the same time the porous resonator 107 and the two side branches 109 are halved in the direction of the duct axis so that the first and second ducts The flanges 105 and 106 of the half bodies 101 and 102 are brought into contact with each other and vibration-welded so as to be joined and integrated.
Note that the resonator 107 and the side branch 109 are, as in the intake duct of the first conventional example, an upper convex portion protruding upward from the upper end surface of the flange 105 and a lower side of the lower end surface of the flange 106. A protruding lower convex portion is provided, and volume spaces 111, 116, and 117 are provided between the inner surface of the upper convex portion and the lower convex portion.

  However, in the intake duct of the conventional example 2, as in the intake duct of the conventional example 1, in order to configure the resonator 107 and the side branch 109 on both sides of the duct body 110, the upper and lower sides from the upper and lower end surfaces of the flanges 105, 106 Since the upper and lower convex portions projecting toward the front are provided, the size of the intake duct, in particular, the size of the silencing function portions (resonator 107 and side branch 109) on both sides of the duct body 110 is increased. Accordingly, as the size of the intake duct is increased, for example, it is a factor that deteriorates the mountability of the intake duct on the vehicle.

European Patent Application No. 1553284 European Patent Application No. 15548701

  An object of the present invention is to provide an intake duct (intake silencer for an internal combustion engine) that can reduce the size of the intake duct with a silencing function and improve the mountability.

The invention described in claim 1 is a synthetic resin intake duct having a cylindrical duct main body that forms an intake passage of an internal combustion engine, and a resonator that silences the intake noise generated in the duct main body by resonance.
The intake duct (the duct body and the resonator) has first and second flanges facing each other at the periphery of the first and second duct halves (the first and second divided bodies made of synthetic resin) divided into at least two parts. The first and second duct halves are joined by providing the first and second welds that are welded to the first and second flanges, respectively, and welding the first and second welds together. It is formed integrally.

The intake duct (the duct main body and the resonator) includes an inner wall body, an inner burr pool, and a communication path.
The inner wall body is disposed closer to the duct body (inner side) than the first and second welded portions of the first and second duct halves. The inner wall body projects from at least one flange of the first and second flanges toward at least the other flange side of the first and second flanges.
The inner burr pool is formed between the first and second welded portions of the first and second duct halves and the inner wall body. This inner burr pool is a space for storing weld burrs generated when the first and second welds are welded.

The communication path includes an inner wall provided on a flange of at least one of the first and second duct halves and a flange of at least the other duct half of the first and second duct halves. Is formed between. The communication passage communicates the intake passage and the inner burr pool.
The resonator is constituted by an inner burr pool and a communication path. That is, the inner burr pool and the communication path formed between the first and second flanges of the first and second duct halves are used as a resonator that silences the intake sound generated in the duct body by resonance.

According to the first aspect of the present invention, since the resonator is constituted by the inner burr pool and the communication path, the first and second welded portions to be welded to each other and the cylindrical duct main body that forms the intake passage inside A resonator is provided between the two. Accordingly, a compact resonance silencer (Helmholtz resonator) can be obtained without newly providing a special resonance chamber and communication pipe for the intake duct having the duct body.
Thereby, the physique of the air intake duct (duct body and resonator) with a silencing function is made lower than the conventional example (that is, the upper convex portion projecting upward from the upper end surface of the flange 105 and the lower end surface of the flange 106). Mute on both sides of the duct body 110 by providing a lower convex portion projecting toward the upper surface and providing volume spaces 111 to 120 and notches 121 to 130 between the inner surface of the upper convex portion and the lower convex portion. Compared to the conventional example 1 and 2 intake duct with a silencing function) in which the functional part protrudes in the vertical direction from the flanges 105 and 106, the silencing function formed between the first and second flanges on both sides of the duct body Since the physique of the part (resonator) can be greatly reduced, for example, the mounting property on the vehicle can be improved.

According to the second aspect of the present invention, a special resonance chamber (resonator volume) is newly provided for the intake duct having the duct body by using the inner burr pool as the resonance chamber of the resonator. In addition, it is possible to obtain a compact resonance silencer (helmholtz resonator) simply by finely adjusting the volume of the inner burr pool.
According to the third aspect of the invention, the volume of the inner burr pool is set to a volume calculated using a formula (general formula, Helmholtz formula) representing the resonance frequency of the resonator with respect to the target silencing frequency. Has been.
This makes it possible to make a compact resonance silencer (Helmholtz type) by simply adjusting the volume of the inner burr pool without providing a new special resonance chamber (resonator volume) for the intake duct with the duct body. Can be obtained.
Here, the volume of the inner burr pool is set to the volume (V) defined (defined) by the above equation 1, that is, the general equation of the resonance frequency of the resonator.

According to the invention described in claim 4, by using the communication path as a communication pipe of the resonator, the flow of the communication path can be reduced without providing a new special communication pipe for the intake duct having the duct body. A compact resonant silencer (Helmholtz type resonator) can be obtained simply by finely adjusting the road cross-sectional area or the total length.
According to the fifth aspect of the invention, the flow path cross-sectional area of the communication path is calculated using a formula (general formula, Helmholtz formula) representing the resonance frequency of the resonator with respect to the target silencing frequency. It is set to the original.
This makes it possible to make a compact resonance silencer (helmholtz resonator) by simply fine-tuning the cross-sectional area of the communication path without providing a new special communication pipe for the intake duct with the duct body. Can be obtained.
Here, the flow path cross-sectional area of the communication path is set to the flow path cross-sectional area (S) defined (defined) by the above equation 1, that is, the general expression of the resonance frequency of the resonator.

According to the invention described in claim 6, the total length of the communication path is set to specifications calculated using a formula (general formula, Helmholtz formula) representing the resonance frequency of the resonator with respect to the target silencing frequency. Has been.
This makes it possible to obtain a compact resonance silencer (helmholtz resonator) by simply fine-tuning the overall length of the communication path without providing a new special communication pipe for the intake duct having the duct body. Can do.
Here, the total length of the communication path is set to the total length (L) defined (defined) by the above equation 1, that is, the general expression of the resonance frequency of the resonator.

According to invention of Claim 7, it is applied to the intercooler duct connected to the exit of a compressor as an intake duct.
According to the invention described in claim 8, a frequency (for example, 2 to 3 kHz) included in the high frequency band is used as a target silencing frequency (frequency to be silenced). In the case of a frequency included in this high frequency band, the volume of the inner burr pool can be reduced. Further, the overall length of the communication path can be shortened. Further, the total length of the communication path may be shortened while reducing the volume of the inner burr pool. In addition, the flow path cross-sectional area of the communication path may be increased simultaneously with shortening the overall length of the communication path.

According to the ninth aspect of the present invention, the first welded portion is provided with the protruding rib extending from the first flange toward the second flange side and extending in the intake flow direction of the intake passage.
According to the tenth aspect of the present invention, the second weld portion is provided with the protruding rib that protrudes from the second flange toward the first flange and extends in the intake flow direction of the intake passage.
In addition, the rib rib of the 1st welding part and the rib rib of the 2nd welding part are mutually joined by welding.

According to the eleventh aspect of the present invention, the first duct half is arranged on the top side in the top and bottom direction with respect to the second duct half.
The inner wall body projects from the second flange toward the first flange.
The communication path is formed between the first flange and the inner wall body.
The front end position of the inner wall body or the opening position of the communication path is located on the top side in the top-to-bottom direction with respect to the position of the joint surface between the first welded portion and the second welded portion.
As a result, when the first and second welded portions are welded, weld burrs generated at the joint surface between the first welded portion and the second welded portion are blocked by the inner wall body, so that the weld burrs protrude from the intake passage side. Can be prevented. As a result, it is possible to suppress the occurrence of a problem that the protruding portion becomes an obstacle and the flow resistance (pressure loss) of the intake air is deteriorated or sucked into the engine.

According to the twelfth aspect of the present invention, the intake duct (the duct main body and the resonator) includes the inner wall body, the inner burr pool, the communication path, the outer wall body, and the outer burr pool. The outer side wall body is disposed on the opposite side (outside) with respect to the intake passage side with respect to the first and second welded portions. The outer wall projects from at least one of the first and second flanges toward at least the other flange of the first and second flanges.
The outer burr pool is formed between the first and second welded portions and the outer wall body. This outer burr pool is a space for storing weld burrs generated when the first and second welds are welded.

1 is a configuration diagram showing a representative control device (engine control system) for an internal combustion engine (Example 1); FIG. It is the perspective view which showed the intercooler duct with a muffling function (Example 1). (A) is sectional drawing which showed the intercooler duct with a silencing function, (b) is an enlarged view of (a) (Example 1). It is the perspective view which showed the intake duct (conventional example 1). It is sectional drawing which showed the intake duct (conventional example 1). (A), (b) is the perspective view which showed the intake duct (conventional example 2).

Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings.
The present invention reduces the size of the intake duct with a silencing function to improve the mountability, effectively reduces the intake noise of the target silencing frequency, and causes welding burrs generated during vibration welding to flow into the intake passage. In order to prevent this, the inner burr pool and communication passage formed between the first and second flanges of the first and second duct halves are silenced by resonance action in the duct body. Realized by using as a resonator.
This makes it possible to provide a compact resonance type for an intake duct having a duct body, without newly providing a special resonance chamber and communication pipe, for example, without providing a protruding portion that forms a large resonator space on the side of the duct body. A silencer (Helmholtz type resonator) can be obtained.

[Configuration of Example 1]
1 to 3 show a first embodiment of the present invention. FIG. 1 is a view showing an engine control system, and FIGS. 2 and 3 are views showing an intercooler duct with a silencing function.

The control device (engine control system) for the internal combustion engine of the present embodiment has a turbocharger that supercharges (compresses) intake air (intake air) using the pressure of exhaust gas (exhaust gas) of the internal combustion engine (engine 1). A supercharging system (supercharging device for an internal combustion engine) and an intake silencer that silences the intake noise generated in the intake pipe of the engine 1 by resonance (intake of an intake silencer for an internal combustion engine, an intercooler duct with a silencing function, etc.) And an intake control device that controls intake air supplied to the engine 1 (intake control device for an internal combustion engine).
Here, the engine 1 is a multi-cylinder gasoline engine (for example, an in-line four-cylinder engine) having a plurality of cylinders (cylinder bores). However, it is not limited to a multi-cylinder gasoline engine, and a multi-cylinder diesel engine may be applied. The engine 1 is installed together with a turbocharger in an engine room of a vehicle such as an automobile.

The engine 1 is equipped with an air cleaner 2, a turbocharger, an electronic throttle device, a fuel injection device, and the like.
Here, the air cleaner 2 has a filter element (filtering element) that filters outside air (intake air) introduced into the air introduction channel from an outside air introduction port opened at an upstream end of the inlet duct (outside air introduction duct). .
The outlet end of the air cleaner 2 is connected to the compressor housing of the turbocharger via an intake duct that forms an intake passage through which intake air that has passed through the air cleaner 2 flows.
The outlet end of the compressor housing is connected to the intercooler 5 via an intake duct (including the intercooler duct 4) that forms an intake passage through which intake air flowing out from the compressor impeller 3 flows. The outlet end of the intercooler 5 is connected to the throttle body of the electronic throttle device via an intake duct that forms an intake passage through which intake air that has passed through the intercooler 5 flows. Note that the arrangement of the intercooler and the electronic throttle device may be reversed, and further, the electronic throttle device may not be provided.

Here, the electronic throttle device includes a throttle body, a throttle valve 6 and an electric actuator 7. This electronic throttle device is an air flow rate adjusting device that adjusts the flow rate of intake air by opening and closing the throttle valve 6.
The shaft that supports the throttle valve 6 is driven in the rotational direction by an electric actuator 7. The electric actuator 7 includes a motor that drives the throttle valve 6 in the valve opening direction or the valve closing direction, and a speed reduction mechanism that reduces the rotation of the motor and transmits it to the shaft. The motor is electrically connected to a battery mounted on a vehicle such as an automobile via a motor drive circuit electronically controlled by the ECU.

The outlet end of the throttle body is connected to an intake port for each cylinder of the engine via an intake manifold that forms an intake passage through which intake air that has passed through the throttle valve 6 flows.
By these intake duct, compressor housing, intercooler duct 4, intercooler 5, intake duct, throttle body, intake manifold, and the like, an intake pipe that forms an intake passage 11 through which intake air drawn into the combustion chamber of each cylinder of the engine flows is formed. (Intake pipe and intake duct of an internal combustion engine) are configured.
An intake passage 11 formed inside the intake pipe communicates with a combustion chamber and an intake port for each cylinder of the engine 1.

On the other hand, the outlet end of the exhaust port of each cylinder of the engine 1 is connected to the turbine housing of the turbocharger via an exhaust manifold that forms an exhaust passage through which exhaust gas flowing out from the combustion chamber of each cylinder of the engine flows. Yes. The outlet end of the turbine housing is connected to an exhaust purification device (catalyst) via an exhaust duct that forms an exhaust passage through which exhaust gas flowing out from the turbine wheel 8 flows. The outlet end of the exhaust gas purification apparatus is connected to a muffler 9 that is an exhaust silencer through an exhaust duct that forms an exhaust passage through which exhaust gas that has passed through the catalyst flows.
An exhaust pipe that forms an exhaust passage 12 through which exhaust gas flowing out from the combustion chamber of each cylinder of the engine flows is constituted by the exhaust manifold, the turbine housing, the exhaust duct, the exhaust purification device, the exhaust duct, the exhaust silencer muffler 9 and the like. (Exhaust pipe and exhaust duct of an internal combustion engine) are configured.
An exhaust passage 12 formed inside the exhaust pipe communicates with a combustion chamber and an exhaust port for each cylinder of the engine 1.

The turbocharger includes a compressor provided in the middle of the intake pipe of the engine 1 and a turbine provided in the middle of the exhaust pipe of the engine 1, and the intake air flowing through the intake pipe is compressed by the compressor, and compressed compressed air (intake air) ) To the combustion chamber for each cylinder of the engine 1.
In this turbocharger, when a turbine wheel (turbine wheel) 8 is rotationally driven by exhaust gas, a turbine shaft 10 connected to the wheel 8 and a compressor impeller (compressor impeller) 3 also rotate, and the impeller 3 compresses intake air. To do.

The turbine includes a wheel 8 and a turbine housing. The wheel 8 has a plurality of turbine blades (blades) in the circumferential direction and is rotationally driven by the exhaust pressure of the engine 1. The wheel 8 is directly connected to the impeller 3 of the compressor via the turbine shaft 10 to rotationally drive the impeller 3 (direct drive).
A wheel housing space for rotatably housing the wheel 8 is formed at the center of the turbine housing. An exhaust introduction flow path through which exhaust flows into the wheel 8 from the outside is formed at the inlet of the turbine housing. Further, an exhaust outlet passage for exhausting the exhaust from the wheel 8 to the outside is formed at the outlet of the turbine housing.

The compressor includes an impeller 3 and a compressor housing. The impeller 3 has a plurality of impeller blades (blades) in the circumferential direction, and is connected to a wheel 8 via a turbine shaft 10 to be rotationally driven (directly connected).
An impeller housing space for rotatably housing the impeller 3 is formed at the center of the compressor housing. An intake air introduction flow path through which intake air flows into the impeller 3 from the outside is formed at the inlet of the compressor housing. In addition, an intake outlet passage for discharging intake air from the impeller 3 to the outside is formed at the outlet portion of the compressor housing.
The intercooler 5 is an air cooler (heat exchanger) that cools compressed air (intake) that has been compressed by the impeller 3 of the compressor to become high pressure and the intake air temperature has risen.

Here, the engine body (cylinder block and cylinder head) of the engine 1 is formed with an intake port opened and closed by an intake valve 13 and an exhaust port opened and closed by an exhaust valve 14.
A spark plug 15 is attached to the cylinder head of the engine 1 so that the tip end portion is exposed in the combustion chamber of each cylinder. The cylinder head is provided with an injector (electromagnetic fuel injection valve) that injects fuel into each intake port at an optimal timing.
In the cylinder block of the engine 1, for example, in a four-cylinder engine, four combustion chambers (cylinder bores) are formed in the cylinder arrangement direction. Further, in each cylinder bore of the cylinder block, a piston 16 connected to the crankshaft is supported via a connecting rod so as to be slidable in the reciprocating sliding direction.

[Features of Example 1]
Next, details of the intercooler duct 4 of the present embodiment will be briefly described with reference to FIGS.
The intercooler duct 4 includes a rectangular tube-shaped duct body 17 having an intake passage 11 formed therein, and a resonance-type intake silencer (Helmholtz-type resonator 18) that silences intake sound generated in the duct body 17 by resonance. , 19), an intake duct (intake duct).
The intercooler duct 4 is formed by integrally molding the first and second duct halves A and B, which are half-divided tubular bodies (half-divided rectangular tubular bodies) vertically divided into two in the duct axis direction, using a synthetic resin material. The first and second duct halves A and B are arranged so that the inner surfaces thereof face each other, and the welded portions of the first and second duct halves A and B are vibration welded to be joined and integrated. .

The first duct half A is formed by integral molding with a heat-resistant synthetic resin material (for example, a thermoplastic resin such as polyamide resin (PA)).
The first duct half A is disposed on the top side in the top-down direction with respect to the second duct half B at the time of manufacturing including at least the vibration welding process.
On the periphery of the first duct half A (the left and right edges in the circumferential direction), the intake air flow direction (the flow direction of the intake air flowing through the intake passage 11 of the duct body 17), which is the same direction as the duct axis direction of the intercooler duct 4, Two first flanges 21 projecting outward in a direction perpendicular to the direction of the intake passage 11 (in the direction perpendicular to the intake passage 11) are integrally provided. These first flanges 21 extend straight along the axial direction of the intake passage 11.
The two first flanges 21 are formed with opposing surfaces that are opposed to the second flange of the second duct half B by a predetermined distance.

At the intermediate portion in the projecting direction of the two first flanges 21, there are provided first ridge-like welds that are vibration welded to the second welds of the second duct half B. Each of the two first welded portions has a weld rib rib 22 projecting from the opposing surface of the first flange 21 toward the second flange side of the second duct half B. The two welding protrusion ribs 22 extend straight along the axial direction of the intake passage 11.
The two first flanges 21 are provided with outer wall bodies 23 on the opposite side (outside) from the first and second welded portions of the first and second duct halves A and B with respect to the intake passage side. It has been. The two outer wall bodies 23 are outer ribs that protrude from the facing surface of the first flange 21 toward the second flange side of the second duct half B. These outer wall bodies 23 extend straight along the axial direction of the intake passage 11.

Similar to the first duct half A, the second duct half B is configured by integral molding with a heat-resistant synthetic resin material (for example, a thermoplastic resin such as polyamide resin (PA)).
Projecting toward the outer side in the direction perpendicular to the direction of the intake air flow (the axial direction of the intake passage 11) flowing through the intake passage 11 at the periphery of the second duct half B (the left and right edges in the circumferential direction) 2 Two second flanges 31 are integrally provided. These second flanges 31 extend straight along the axial direction of the intake passage 11.
The two second flanges 31 are formed with opposing surfaces that are opposed to the first flange 21 of the first duct half A by a predetermined distance. Thereby, the 1st, 2nd flanges 21 and 31 are arrange | positioned mutually opposing at a predetermined distance.

At the intermediate part in the projecting direction of the two second flanges 31, there are respectively provided ridge-like second welded portions that are vibration welded to the first welded portion (welded ridge rib 22) of the first duct half A. ing. The two second welds protrude from the facing surface of the second flange 31 toward the first flange (particularly, the first weld) of the first duct half A, and the first duct half A is welded. Each has ribs 32 that are welded to the ribs 22 by vibration welding. The two welding protrusion ribs 32 extend straight along the axial direction of the intake passage 11.
The two second flanges 31 are respectively provided with outer wall bodies 33 on the opposite side (outer side) with respect to the intake passage side of the first and second duct halves A and B with respect to the welding rib ribs 22 and 32, respectively. It has been. The two outer wall bodies 33 are outer ribs that protrude from the facing surface of the second flange 31 toward the outer wall body side of the first flange 21. These outer wall bodies 33 extend straight along the axial direction of the intake passage 11. The outer wall bodies 23 and 33 are arranged to face each other with the opening 34 therebetween.

Here, in the first and second flanges 21 and 31 of the present embodiment, an outer space is formed between the welding protrusion ribs 22 and 32 and the outer wall bodies 23 and 33. This outer space is used as an outer burr pool 35 for accumulating welding burrs generated during vibration welding of the welding ribs 22 and 32. The outer burr pool 35 includes the facing surface of the first flange 21 of the first duct half A, the outer surface of the weld rib rib 22, the burr pool side of the outer wall 23, and the second flange of the second duct half B. It is surrounded by the opposing surface of 31, the outer surface of the welding rib 32, and the burr pool side of the outer wall 33. As a result, when the welding protrusion ribs 22 and 32 are vibrated and welded, the welding burrs flow out to the outside of the joining surface (joining line) of the welding protrusion ribs 22 and 32. It is blocked by the bodies 23 and 33 and stored in the outer burr pool 35.
The two second flanges 31 are each provided with an inner wall body 36 on the intake passage side (inner side) with respect to the welding protrusion ribs 22 and 32 of the first and second duct halves A and B. The two inner wall bodies 36 are inner ribs that protrude from the opposing surface of the second flange 31 toward the first flange side. These inner wall bodies 36 extend straight along the axial direction of the intake passage 11. The inner wall body 36 is disposed to face the facing surface of the first flange 21 with a predetermined gap (communication path 42) therebetween.

Here, in the first and second flanges 21 and 31 of the present embodiment, an inner space is formed between the welding ribs 22 and 32 and the inner wall body 36. This inner space is used as an inner burr pool 41 for accumulating welding burrs generated during vibration welding of the welding ribs 22 and 32. Thus, when the welding protrusion ribs 22 and 32 are welded by vibration, they become welding burrs and flow out to the inside of the bonding surfaces (bonding lines) of the welding protrusion ribs 22 and 32. It is blocked by the body 36 and stored in the inner burr pool 41.
Further, the front end position of the inner wall body 36 or the opening position H of the communication passage 42 is located in the vertical direction more than the position G of the joint surface between the welding rib rib 22 and the welding rib rib 32 as shown in FIG. Located on the heaven side.

Here, the intercooler duct 4 is formed by injection molding the first and second duct halves A and B with a resin mold, so that the peripheral edges of the first and second duct halves A and B, that is, the duct body 17 The first and second flanges 21 and 31 on both sides are provided with welding protrusion ribs 22 and 32 that are welded to each other by vibration, and the first and second duct halves A and B are arranged so that the inner surfaces thereof face each other. The first and second duct halves A and B are brought into contact with each other by butt welding the welding rib ribs 22 and 32 of the first and second flanges 21 and 31 and vibration welding the welding rib ribs 22 and 32 to each other. It is manufactured by joining and integrating so as to face each other.
The outer wall bodies 23 and 33 are outer partition walls that divide the outside (space) of the intercooler duct 4 and the outer burr pool 35 and restrict the welding burr from flowing out of the intercooler duct 4. It is an outside regulating wall body. The inner wall body 36 is an inner partition body that partitions the inside of the duct body 17 of the intercooler duct 4 (the intake passage 11) and the inner burr pool 41, so that the welding burr flows out into the intake passage 11. It is an inner regulation wall body to regulate.

The intercooler duct 4 according to the present embodiment is an intake duct with a silencing function that silences the intake sound generated in the duct body 17 by a resonance action. Resonators 18 and 19 are provided on both sides of the duct body 17 in the duct axial direction.
The resonators 18 and 19 are constituted by an inner burr pool 41 and a communication path 42. That is, the inner burr pool 41 and the communication path 42 formed between the first and second flanges 21 and 31 of the first and second duct halves A and B are used as the resonators 18 and 19.
The resonators 18 and 19 include the above-described inner burr pool 41 and a communication path 42 that communicates the inside of the duct body 17 (the intake passage 11) with the inner burr pool 41.
When the volume of the inner burr pool 41 and the specifications of the communication path 42 are constant, the resonators 18 and 19 resonate with an intake sound of a specific frequency and mute (reducing) the intake sound of the specific frequency. It is a vessel.

The inner burr pool 41 is formed between the welding protrusion ribs 22 and 32 and the inner wall body 36 and is used as a resonance chamber for the resonators 18 and 19. The inner burr pool 41 includes the facing surface of the first flange 21 of the first duct half A, the inner surface of the welding rib rib 22, the facing surface of the second flange 31 of the second duct half B, and the welding rib rib. 32 and the burr pool side surface of the inner side wall body 36.
The volume of the inner burr pool 41 is set to a volume calculated using a formula (Helmholtz equation) representing the resonance frequency of the resonators 18 and 19 with respect to the target silencing frequency.
That is, the volume of the inner burr pool 41 is set to a volume defined by the following equation (2), that is, the resonance frequency of the resonators 18 and 19.
[Equation 2]
f = {c / (2π)} · {S / (V · L)} ^1/2
Here, c is the speed of sound (m / s), S is the flow path cross-sectional area (m ² ) of the communication passage 42 that is a communication pipe, V is the volume (m ³ ) of the inner burr pool 41 that is a resonance chamber, and L is the communication. This is the total length (m) of the passage 42.

The communication passage 42 is provided so as to extend straight along the axial direction of the intake passage 11. One end (inner end) of the communication passage 42 in the full length (perpendicular to the axis of the intake passage 11) direction is opened at the flow passage wall surface of the duct body 17. The other end (outer end) of the communication passage 42 in the full length (perpendicular to the axis of the intake passage 11) direction opens at the wall surface of the inner burr pool 41.
The communication path 42 is formed between the front end surface of the inner wall body 36 projecting upward from the facing surface of the first flange 21 of the first duct half A and the facing surface of the second flange 31 of the second duct half B. It is formed between them and is used as a communication pipe for the resonators 18 and 19. The channel cross-sectional area of the communication path 42 is set to specifications calculated using a formula representing the resonance frequency of the resonators 18 and 19 with respect to the target silencing frequency. That is, the flow path cross-sectional area of the communication path 42 is set to S defined (defined) by the above equation (2).
The total length of the communication path 42 is set to specifications calculated using a formula representing the resonance frequency of the resonators 18 and 19 with respect to the target silencing frequency. That is, the total length of the communication path 42 is set to L defined (defined) by the above equation (2).

Here, in this embodiment, the intake duct having a silencing function according to the present invention is applied to the intercooler duct 4 that connects the outlet of the compressor housing of the turbocharger and the inlet of the intercooler 5.
In the intercooler duct 4 that forms the intake passage 11 through which compressed air (intake) compressed to high pressure by the impeller 3 of the turbocharger compressor flows, as a target silencing frequency (frequency to be silenced), A frequency (for example, 2 to 3 kHz) included in the high frequency band is used. In the case of a frequency (for example, 2 to 3 kHz) included in this high frequency band, the volume of the inner burr pool 41 can be set small. Further, the overall length of the communication path can be shortened. Further, the total length of the communication path 42 may be shortened while the volume of the inner burr pool 41 is set small. In addition, the flow path cross-sectional area of the communication path 42 may be increased simultaneously with shortening the overall length of the communication path 42.
Thereby, the physique of the intercooler duct 4 with the silencing function, that is, the intercooler duct 4 having the resonators 18 and 19 becomes compact.

[Operation of Example 1]
Next, the operation of the engine control system of this embodiment will be briefly described with reference to FIGS.

Exhaust gas discharged from the combustion chamber of each cylinder of the engine 1 to the exhaust manifold flows into the wheel housing space from the exhaust introduction flow path which is the inlet portion of the turbine housing of the turbocharger, rotates the wheel 8, and the turbine housing Are discharged from the exhaust outlet flow path, which is the outlet portion.
When the rotation of the turbine wheel 8 is transmitted to the compressor impeller 3 via the turbine shaft 10, the compressor impeller 3 rotates.
Then, the intake air sucked into the intake passage 11 from the air cleaner 2 flows into the impeller accommodating space from the intake introduction flow path which is an inlet portion of the compressor housing. The intake air flowing into the impeller accommodating space is compressed by the impeller 3 that rotates as the wheel 8 rotates, and the pressure (supercharging pressure) increases. Then, the compressed air (intake air) whose pressure has increased is sent to the intercooler 5 through the intercooler duct 4 from the intake air outlet passage which is the outlet portion of the compressor housing, and is cooled. The intake air circulated from the intercooler 5 passes through the throttle valve 6 and the intake manifold and is sucked into the intake port and the combustion chamber for each cylinder of the engine 1.

[Effect of Example 1]
As described above, in the intercooler duct 4 of the present embodiment, the inner burr pool 41 and the communication path formed between the first and second flanges 21 and 31 of the first and second duct halves A and B, respectively. 42, that is, the inner burr pool 41 and the communication passage 42 formed so as to be adjacent to both sides of the duct body 17 are used as the resonators 18 and 19 that mute the intake sound. That is, the silencing function part (resonator 18, 19) formed between the first and second flanges 21, 31 on both sides of the duct body 17 is opposite to the second flange side from the upper end surface of the first flange 21 ( There is no protrusion protruding upward). Moreover, the convex part which protrudes in the reverse side (downward side) with respect to the 1st flange side from the lower end surface of the 2nd flange 31 is not provided.
Further, the volume of the inner burr pool 41 is set to a volume calculated by using a formula representing the resonance frequency of the resonators 18 and 19 with respect to the target silencing frequency. Thus, a compact resonance-type noise reduction can be achieved by merely finely adjusting the volume of the inner burr pool 41 without providing a new special resonance chamber (resonator volume) for the intercooler duct 4 having the duct body 17. The intercooler duct 4 having a vessel (helmholtz type resonator) can be obtained.

In addition, the cross-sectional area of the communication passage 42 is set to specifications calculated using a formula representing the resonance frequency of the resonators 18 and 19 with respect to the target silencing frequency.
Further, the overall length of the communication path 42 is set to specifications calculated using a formula (general formula, Helmholtz formula) representing the resonance frequency of the resonators 18 and 19 with respect to the target silencing frequency.
As a result, the intercooler duct 4 having the duct body 17 is provided with a compact silencing function only by finely adjusting the cross-sectional area and the overall length of the communication passage 42 without newly providing a special communication pipe. The intercooler duct 4 can be obtained.
As a result, the intercooler duct 4 (duct main body 17 and resonators 18 and 19) having a silencing function is made to have a physique of conventional examples 1 and 2 (that is, an upper convex portion projecting upward from the upper end surface of the flange 105, and A lower convex portion protruding downward from the lower end surface of the flange 106 is provided, and volume spaces 111 to 120 and notches 121 to 130 are provided between the inner surface of the upper convex portion and the lower convex portion. In comparison with the conventional example 1 and 2 with a silencing function, the silencing function portions on both sides of the duct body 110 protrude in the vertical direction from the flanges 105 and 106, the first and Since the physique of the silencing function section (resonators 18 and 19) formed between the second flanges 21 and 31 can be greatly reduced, the mountability to the engine room of a vehicle such as an automobile is improved. Rukoto can. Therefore, it is possible to reduce the mounting space in a vehicle such as an automobile, particularly the mounting space in the engine room.

Further, the front end position of the inner wall body 36 or the opening position H of the communication passage 42 is located in the vertical direction more than the position G of the joint surface between the welding rib rib 22 and the welding rib rib 32 as shown in FIG. Located on the heaven side.
As a result, the welding burrs generated at the joint surface G between the welding projection ribs 22 and the welding projection ribs 32 are surely blocked by the inner wall body 36 at the time of vibration welding of the welding projection ribs 22, 32. It is possible to prevent burrs from protruding into the inside of the duct body 17 (the intake passage 11). As a result, it is possible to suppress the occurrence of a problem that the protruding portion becomes an obstacle and the flow resistance (pressure loss) of the intake air is deteriorated or sucked into the engine.

  Moreover, the welding protrusion rib 22 provided in the 1st flange 21 of the 1st duct half body A and the welding protrusion rib 32 provided in the 2nd flange 31 of the 2nd duct half body B are joined by vibration welding. . That is, the welding ridge rib 22 and the welding ridge rib 32 are sandwiched by a pair of welding jigs, and the bonding surfaces G of the welding ridge ribs 22 and 32 are relatively reciprocally slid, so that the vicinity of the bonding surface is obtained. The synthetic resin material is partially melted by frictional heat. And this welding part solidifies again, and each welding protrusion ribs 22 and 32 are joined. During such vibration welding, part of the molten synthetic resin material enters the outer burr pool 35 and the inner burr pool 41. Thereby, it is possible to prevent welding burrs from protruding outside the intercooler duct 4 and inside the duct body 17 (intake passage 11).

[Modification]
In this embodiment, the first and second duct halves A and B are half-angled cylindrical bodies (half-divided rectangular cylinders), but the first and second duct halves A and B are semi-cylindrical bodies ( A half cylindrical body) may also be used.
In this embodiment, the resonators 18 and 19 are disposed between the first and second flanges 21 and 31 on both sides of the duct body 17 (both sides perpendicular to the axial direction (intake flow direction) of the intake passage 11). Although provided respectively, a resonator may be provided only between the first and second flanges 21 and 31 on one side of the duct body 17.

Further, the intake duct of the present invention may be applied to intake ducts (intake ducts, surge tanks, intake manifolds) other than the intercooler duct 4.
Moreover, you may apply the air intake duct of this invention not only to the straight pipe part extended straightly but to the curved curved pipe part.
Further, the inner burr pool 41 and the communication path 42 may be divided into a plurality of resonance chambers (resonator volume portions) and a plurality of communication pipes by partitioning the inside of the inner burr pool 41 and the communication path 42 with a partition wall. In addition, by making the volumes of the plurality of resonance chambers and the specifications of the plurality of communication pipes different, it is possible to mute (reduce) the intake sound having a plurality of resonance frequencies.
Further, the length of the inner burr pool 41 (length in the axial direction (intake flow direction) of the intake passage 11) and the length of the communication passage 42 (length in the axial direction (intake flow direction) of the intake passage 11) are determined. It may be different.

In the present embodiment, the inner wall body 36 that protrudes from the facing surface of the second flange 31 toward the first flange side is provided, but the inner wall body 36 that protrudes from the facing surface of the first flange 21 toward the second flange side. A wall may be provided. Moreover, you may provide the inner wall body which protrudes toward the 2nd, 1st flange side so that it may mutually approach from the opposing surface of the 1st, 2nd flanges 21 and 31.
In the present embodiment, the outer wall body 23 protruding from the facing surface of the first flange 21 toward the second flange side is provided, but the outer wall body 23 may not be provided on the first flange side.
In the present embodiment, the outer wall body 33 that protrudes from the facing surface of the second flange 31 toward the first flange side is provided, but the outer wall body 33 may not be provided on the second flange side.

  In this embodiment, the first and second duct halves A and B are integrally molded (injection molding) with the same resin material or resin mold material, but the first and second duct halves A and B are different. You may integrally mold with a resin material or a resin mold material. The resin material forming the first and second duct halves A and B may contain (blend) a resin reinforcing material such as a fibrous filler. Further, as the molding method of the first and second duct halves A and B, extrusion molding or blow molding may be used in addition to injection molding.

In the present embodiment, the welding protrusion rib (first welding portion) 22 of the first flange 21 and the welding protrusion rib (second welding portion) 32 of the second flange 31 are brought into contact with each other to perform vibration welding. 1, the second duct halves A and B are joined and integrated to form an intercooler duct (suction duct) 4 made of synthetic resin. The first welded portion of the first flange 21 and the second flange 31 The two first and second duct halves A and B are joined and integrated by abutting with the two welded portions and welded using other welding methods such as heat welding and laser welding. It may be configured.
Alternatively, only the portions where the welding protrusion ribs 22 of the first flange 21 and the welding protrusion ribs 32 of the second flange 31 are brought into contact with each other and vibration welded to each other may be used as the first and second welding portions, respectively. For example, it is good also considering only the front-end | tip part of the welding protrusion rib 22 of the 1st flange 21 as a 1st welding part. Moreover, it is good also considering only the front-end | tip part of the welding protrusion rib 32 of the 2nd flange 31 as a 2nd welding part.

In this embodiment, the first and second duct halves A and B have substantially the same half cylinder shape, but the first and second duct halves A and B may have different partial cylinder shapes. . Further, instead of the rectangular tube shape, a cylindrical shape or an irregular shape may be used.
Further, the joining surface (joining line) between the first welded portion of the first flange 21 and the second welded portion of the second flange 31 is a predetermined angle with respect to the axial direction (intake flow direction) of the intake passage 11. It may be inclined.

A First duct half B Second duct half 1 Engine (internal combustion engine)
DESCRIPTION OF SYMBOLS 3 Compressor impeller 4 Intercooler duct 5 Intercooler 17 Duct body 18 Resonator 19 Resonator 21 First flange of first duct half body 22 Welding protrusion rib (first welded portion) of first flange
23 Outer wall body of first flange 31 Second flange of second duct half 32 Welding protrusion rib (second welding portion) of second flange
33 Outer wall body of second flange 35 Outer burr pool 36 Inner wall body of second flange 41 Inner burr pool (resonator resonance chamber)
42 Communication path (resonator communication pipe)

Claims (12)

A synthetic resin intake duct having a cylindrical duct main body that forms an intake passage through which intake air sucked into the internal combustion engine flows, and a resonator that silences the intake noise generated in the duct main body by resonance action,
First and second flanges facing each other are provided on the periphery of the first and second duct halves divided into at least two parts,
Providing first and second welded portions welded to the first and second flanges, respectively;
In the intake duct formed by joining and integrating the first and second duct halves by butting the first and second welding parts together,
(A) It is installed on the duct body side with respect to the first and second welded portions, and at least the other of the first and second flanges from at least one of the first and second flanges. An inner wall projecting toward the flange side;
(B) an inner burr pool formed between the first and second welded portions and the inner wall body for accumulating weld burrs generated during welding;
(C) a communication path formed between the inner wall body and the other flange and communicating the intake path and the inner burr pool;
The air intake duct, wherein the resonator is constituted by the inner burr pool and the communication path. Intake duct according to claim 1,
The air intake duct, wherein the inner burr pool is used as a resonance chamber of the resonator. In the intake duct according to claim 1 or 2,
The volume of the inner burr pool is
An intake duct having a volume calculated using a formula representing a resonance frequency of the resonator with respect to a target silencing frequency. In the intake duct according to any one of claims 1 to 3,
The air intake duct, wherein the communication path is used as a communication pipe of the resonator. In the intake duct according to any one of claims 1 to 4,
The cross-sectional area of the communication path is
An intake duct characterized by being set to specifications calculated using a formula representing a resonance frequency of the resonator with respect to a target silencing frequency. In the intake duct according to any one of claims 1 to 5,
The total length of the communication path is
An intake duct characterized by being set to specifications calculated using a formula representing a resonance frequency of the resonator with respect to a target silencing frequency. In the intake duct according to any one of claims 1 to 6,
An intake duct characterized by being applied to an intercooler duct connected to the outlet of a turbocharger compressor. The intake duct according to any one of claims 1 to 7,
An air intake duct, wherein the target muffle frequency is a frequency included in a high frequency band. In the intake duct according to any one of claims 1 to 8,
The intake duct according to claim 1, wherein the first welded portion has a protruding rib that protrudes from the first flange toward the second flange and extends in the intake flow direction of the intake passage. In the intake duct according to any one of claims 1 to 9,
The air intake duct, wherein the second welded portion has a protruding rib that protrudes from the second flange toward the first flange and extends in the intake air flow direction of the intake passage. In the intake duct according to any one of claims 1 to 10,
The first duct half is disposed on the top side in the vertical direction with respect to the second duct half, and the inner wall body protrudes from the second flange toward the first flange, The communication path is formed between the first flange and the inner wall body,
The front end position of the inner wall body or the opening position of the communication path is located on the top side in the top-to-bottom direction with respect to the position of the joint surface between the first weld portion and the second weld portion. Intake duct. In the intake duct according to any one of claims 1 to 11,
At least one of the first and second flanges is installed from at least one of the first and second flanges on the opposite side of the first and second welds with respect to the intake passage side. An outer wall projecting toward the other flange,
An air intake duct, comprising: an outer burr pool formed between the first and second welded portions and the outer wall body for accumulating weld burrs generated during welding.

Images