JP2012251518A - Resin intake manifold and method of manufacturing the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a resin intake manifold and a method of manufacturing the resin intake manifold, which can reduce the volume of a surge tank, while reducing manufacturing cost.SOLUTION: The resin intake manifold 1 includes a middle piece 12 and a lower piece 14, and forming the surge tank 18 between the middle piece 12 and the lower piece 14 and forming a branch passage 16 communicating with the surge tank 18. The lower piece 14 is an integral mold by resin, and has a curved pipe conduit 20 of a curved shape and constituting a part of the branch passage 16, and a wall part 52 formed toward the middle piece 12 side from a passage port 34 between the curved pipe conduit 20 and the surge tank 18 on the inner peripheral side of the curved shape of the curved pipe conduit 20 and constituting a sidewall of the surge tank 18.

Description

  The present invention relates to an intake manifold provided in an intake system of an engine, and more particularly, to a resin-made resin intake manifold and a method for manufacturing the resin-made intake manifold.

  Patent Document 1 discloses a technique of a molding die having a rotatable slide core as a molding die for a resin molded product having a curved tube portion. In the technique of Patent Document 1, a space is provided in the mold by lowering the mold clamping disk after molding the molded product and separating the support from the slide core, and the slide core is rotated inside the space. Yes. After that, the molded product is pushed out from the main board.

  Patent Document 2 discloses a technique of a molding die that enables extraction of a molded product having an arcuate cylindrical portion and a method of extracting the molded product from the molding die.

JP 2002-067088 A JP 2007-307713 A

  However, in the technique of Patent Document 1, since a space necessary for rotating the slide core is formed inside the mold, the strength of the mold is reduced. In addition, when using an ejector mechanism to push out the molded product from the main board, the ejector mechanism and the rotating mechanism that rotates the slide core may interfere with each other during operation. It is difficult to do. Therefore, it is necessary to provide an ejector mechanism outside the range of operation of the rotating mechanism. Therefore, the molded product formed by the technique of Patent Document 1 is necessarily increased in size.

  Here, as an example of a resin molded product having such a curved pipe portion, there is a lower piece that constitutes a resin intake manifold provided in an intake system of an engine. And if this lower piece enlarges, the volume of the surge tank of the resin intake manifold will increase more than necessary. As a result, engine responsiveness decreases.

  Moreover, in the technique of patent document 2, the molded product extraction body for extracting the circular arc cylindrical part of a molded product is needed, and a manufacturing cost will increase.

  Accordingly, the present invention has been made to solve the above-described problems, and a resin intake manifold capable of reducing the volume of the surge tank while reducing the manufacturing cost, and a method for manufacturing the resin intake manifold are provided. It is an issue to provide.

  One aspect of the present invention made to solve the above-described problems includes a first piece and a second piece, and a surge tank is formed between the first piece and the second piece, and the surge tank In the resin intake manifold in which a branch passage communicating with the second passage is formed, the second piece is an integrally molded product made of resin, and a curved conduit that forms a part of the branch passage, and the curved conduit A wall portion that is formed toward the first piece side from a connection port between the curved pipe line and the surge tank on an inner peripheral side of the curved shape, and that constitutes a side wall of the surge tank. To do.

  According to this aspect, the second piece is formed from the connection port between the curved conduit and the surge tank toward the first piece on the inner peripheral side of the curved shape of the curved conduit, and constitutes the side wall of the surge tank. A wall is provided. Thereby, the side wall of the surge tank is formed directly from the connection port between the curved conduit and the surge tank on the inner peripheral side of the curved conduit. Therefore, the volume of the surge tank can be reduced.

  The second piece is an integrally molded product made of resin. Therefore, compared with the case where the second piece is formed by joining a plurality of pieces, the step of joining the plurality of pieces can be omitted. Therefore, the manufacturing cost can be reduced.

  In the above aspect, it is preferable that a plurality of the curved ducts are arranged, and the wall portion is formed in a linear shape in the arrangement direction of the curved ducts.

  According to this aspect, the wall portion is formed in a straight line shape in the arrangement direction of the plurality of curved ducts. Thereby, the volume of a surge tank can be reduced more reliably.

  In the above aspect, the second piece includes a curved rotary core that forms the curved conduit, a first mold that is disposed outside the outer peripheral surface of the rotary core, and an inner peripheral surface of the rotary core. It is formed by injecting resin into the cavity formed between the second mold placed inside and the rotary core is separated from the second mold while being held by the rotary core. It is preferable that they are manufactured after being relatively rotated and then taken out from the rotating core.

  According to this aspect, in a state where the second piece formed by injecting the resin is held by the rotating core, the rotating core is relatively rotated after being separated from the second mold. Therefore, the rotating core can be reliably rotated without being blocked by the second mold, and the second piece can be reliably taken out from the rotating core. In this way, the second piece can be manufactured as an integrally molded product made of resin.

  Another aspect of the present invention made to solve the above-described problems includes a first piece and a second piece, and a surge tank is formed between the first piece and the second piece, and the surge In the method of manufacturing a resin intake manifold in which a branch passage communicating with the tank is formed, the second piece is an integrally molded product made of resin, and a curved curved pipe line forming a part of the branch passage; A wall portion that is formed from the connection port between the curved pipe line and the surge tank toward the first piece side on the inner peripheral side of the curved shape of the curved pipe line and that constitutes the side wall of the surge tank. A curved rotary core forming the curved duct, a first mold placed outside the outer peripheral surface of the rotary core, and a second mold placed inside the inner peripheral surface of the rotary core; Cavite formed between Forming the second piece by injecting a resin into the interior of the mold, separating the rotary core from the second mold while holding the second piece on the rotary core, A step of rotating the rotary core relative to two pieces, a step of taking out the second piece from the rotary core, and a step of joining the second piece and the first piece taken out from the rotary core It is characterized by having.

  According to this aspect, the method includes the step of separating the rotary core from the second molding die in a state where the second piece formed of resin is held by the rotary core. Accordingly, in the step of rotating the rotary core relative to the second piece, the rotary core can be reliably rotated without being blocked by the second mold, and the second piece can be reliably removed from the rotary core. It can be taken out. Therefore, the 2nd piece which can reduce the volume of a surge tank can be manufactured as an integrally molded article by resin. Therefore, compared with the case where the second piece is formed by joining a plurality of pieces, the step of joining the plurality of pieces can be omitted. Therefore, the manufacturing cost can be reduced.

  According to the resin intake manifold and the method of manufacturing the resin intake manifold according to the present invention, the volume of the surge tank can be reduced while reducing the manufacturing cost.

It is a front view of a resin-made intake manifold. It is a right view of the resin-made intake manifold shown in FIG. It is an exploded view of a resin intake manifold. It is AA sectional drawing of FIG. It is a front view of a lower piece. It is BB sectional drawing of FIG. It is explanatory drawing of the mold clamping process in the manufacturing method of a lower piece. It is explanatory drawing of a mold opening process in the manufacturing method of a lower piece. It is explanatory drawing of a rotation unit raising process in the manufacturing method of a lower piece. It is explanatory drawing of a core rotation process in the manufacturing method of a lower piece. It is explanatory drawing of the molded article taking-out process in the manufacturing method of a lower piece.

  DESCRIPTION OF EXEMPLARY EMBODIMENTS Hereinafter, embodiments of the invention will be described in detail with reference to the accompanying drawings.

[Description of resin intake manifold]
As shown in FIGS. 1 to 3, the resin-made intake manifold 1 includes an upper piece 10, a middle piece 12, a lower piece 14, and the like. Further, as shown in FIG. 4, the upper piece 10 is arranged on the upper side of the middle piece 12 and constitutes an upper half shell portion of each branch passage 16 located on the upper side of the drawing. The middle piece 12 is arranged on the lower side of the drawing with respect to the upper piece 10 and constitutes the upper half shell portion of the surge tank 18 and also the lower half shell portion of each branch passage 16 located on the upper side of the surge tank 18 in the drawing. Configure. Further, the lower piece 14 is arranged on the lower side of the drawing with respect to the middle piece 12 and constitutes a lower half shell portion of the surge tank 18 and constitutes each branch passage 16 positioned on the lower side of the surge tank 18 in the drawing. The upper piece 10, the middle piece 12, and the lower piece 14 are each formed into a predetermined shape by injection molding using a synthetic resin as a material.

  1 is a front view of the resin intake manifold 1, FIG. 2 is a right side view of the resin intake manifold 1 shown in FIG. 1, and FIG. 3 is an exploded view of the resin intake manifold 1. 4 is a cross-sectional view taken along the line AA of FIG. The middle piece 12 is an example of the “first piece” in the present invention, and the lower piece 14 is an example of the “second piece” in the present invention.

  The branch passage 16 communicates with the surge tank 18, branches from the surge tank 18, has a curved shape, and is formed in a plurality. Here, as an example, four branch passages 16 are formed. A portion of the branch passage 16 located on the lower side of the drawing in FIG. 4 with respect to the surge tank 18 is formed by a curved conduit 20 provided in the lower piece 14. Further, in the branch passage 16, a portion located on the upper side of the drawing in FIG. 4 with respect to the surge tank 18 is formed by the upper piece 10 and the middle piece 12. As shown in FIG. 4, the surge tank 18 is formed between the middle piece 12 and the lower piece 14 and is disposed so as to be enclosed inside the curved branch passage 16.

  As shown in FIGS. 1 and 2, the resin intake manifold 1 is formed with a flange 22 for fixing a throttle device (not shown). The flange 22 is formed with an intake inlet 24 that communicates with the internal surge tank 18. As shown in FIG. 2, a flange 26 for attaching an EGR pipe (not shown) is formed in the resin intake manifold 1. The flange 26 is formed with an EGR gas inlet 28 leading to the internal surge tank 18.

  As shown in FIGS. 1 and 2, the resin intake manifold 1 is formed with a pipe joint 30 for attaching a blow-by gas reducing pipe (not shown). This pipe joint 30 leads to the internal surge tank 18. Further, as shown in FIG. 1, the resin intake manifold 1 is formed with a pipe joint 32 for attaching a negative pressure pipe (not shown) for supplying a negative pressure to a brake booster (not shown). This pipe joint 32 leads to the internal surge tank 18.

  In the resin intake manifold 1 having such a structure, intake air filtered by an air cleaner (not shown) is introduced into the surge tank 18 from an intake inlet 24 through a throttle device (not shown). The intake air introduced into the surge tank 18 is distributed to each branch passage 16 and supplied to each cylinder (not shown) of the engine through each branch passage 16.

  In addition, the resin intake manifold 1 having such a structure is manufactured by combining the upper piece 10, the middle piece 12, and the lower piece 14 together and joining them together by vibration welding.

  In addition, the case where the piece by which the upper piece 10 and the middle piece 12 were integrally molded is also considered. In this case, the piece in which the upper piece 10 and the middle piece 12 are integrally formed is an example of the “first piece” in the present invention.

[Description of the structure of the lower piece]
Next, the lower piece 14 among the pieces constituting such a resin intake manifold 1 will be described. As shown in FIGS. 5 and 6, the lower piece 14 has a passage port 34 formed in one opening portion of the curved conduit 20 and a passage port 36 formed in the other opening portion of the curved conduit 20. And the part formed in the passage port 34 side of the lower piece 14 comprises the lower half shell part corresponding to the upper half shell part of the surge tank 18 formed in the middle piece 12. The passage opening 36 of the lower piece 14 is joined to a passage opening 38 formed in the middle piece 12 (see FIG. 4). The four curved conduits 20 are arranged side by side in the longitudinal direction of the surge tank 18, that is, the flow direction of the intake air introduced into the surge tank 18, and the passage ports 34 of the four curved conduits 20. And passage openings 36 are arranged side by side. 5 is a front view of the lower piece 14, and FIG. 6 is a cross-sectional view taken along the line BB of FIG. The passage port 34 is an example of the “connection port” in the present invention.

  Moreover, the lower piece 14 is provided with the surrounding wall 40 provided so that it may stand toward the middle piece 12 side from the channel | path opening 34, as shown in FIG.4 and FIG.6. The peripheral wall 40 constitutes a part of the side wall of the surge tank 18 and is formed so as to surround the surge tank 18 as shown in FIG.

  And as shown in FIG. 5, the welding line 42 is formed in the front end surface at the side of the middle piece 12 of the surrounding wall 40 along the shape of the surrounding wall 40. As shown in FIG. The welding line 42 is welded in contact with a welding line 44 (see FIG. 4) formed on the middle piece 12. A welding line 48 is formed in the flange portion 46 formed around the passage opening 36. The welding line 48 is welded in contact with a welding line 50 (see FIG. 4) formed on the middle piece 12.

  The lower piece 14 having such a structure is an integrally molded product made of resin as will be described later. Therefore, the process of welding a plurality of pieces, which was necessary when manufacturing a conventional lower piece made up of a plurality of pieces, becomes unnecessary.

  Further, as shown in FIGS. 4 to 6, the lower piece 14 of the present embodiment is formed as a part of the peripheral wall 40 from the passage opening 34 (the upper piece 10 and the middle) on the inner circumferential side of the curved pipe 20. For the arrangement direction of the piece 12 and the lower piece 14), a wall 52 is provided so as to rise toward the middle piece 12 side. The wall portion 52 is formed upright from the passage opening 34 toward the middle piece 12 side. Thereby, the part used as the bottom wall of the surge tank 18 is not formed in the inner peripheral side of the curved duct 20. In this way, the wall 52 directly forms the side wall of the surge tank 18 from the passage opening 34. Therefore, compared with the conventional lower piece in which the bottom wall of the surge tank is formed, the lower piece 14 of the present embodiment can reduce the width of the surge tank 18 in the short direction (left and right direction in FIGS. 4 to 6). . Therefore, according to the lower piece 14 of the present embodiment, the volume of the surge tank 18 can be reduced.

  Further, as shown in FIG. 5, the wall 52 is formed in a linear shape in the longitudinal direction of the flow path of the surge tank 18 (that is, the arrangement direction of the four curved pipe lines 20). Thereby, about the longitudinal direction of the flow path of the surge tank 18, the width | variety of the transversal direction of the said flow path is constant. Therefore, according to the lower piece 14 of the present embodiment, the volume of the surge tank 18 can be effectively reduced.

[Explanation of lower piece manufacturing method]
Next, the manufacturing method of the lower piece 14 having such a structure will be described with reference to FIGS. As shown in FIG. 7, the manufacturing apparatus 54 for manufacturing the lower piece 14 includes a first mold 56, a rotary unit mold 58, a second mold 60, and the like. The rotary unit mold 58 includes a rotary core 62 and a slide mechanism 64. The rotary core 62 is a mold that has a curved portion and forms the curved conduit 20 as will be described later. The first mold 56 is disposed outside the outer peripheral surface 72 of the rotary core 62, and the second mold 60 is disposed inside the inner peripheral surface 70 of the rotary core 62.

  First, as a mold clamping process, as shown in FIG. 7, the first mold 56 and the second mold 60 are closed. At this time, the rotating core 62 is disposed between the concave portion 66 of the first mold 56 and the convex portion 68 of the second mold 60. And it forms with the inner surface of the recessed part 66 of the 1st shaping | molding die 56, the outer surface of the convex part 68 of the 2nd shaping | molding die 60, and the outer surface (inner peripheral surface 70, the outer peripheral surface 72, and both sides | surfaces (not shown) of the rotary core 62. The cavity 74 is formed on the surface to be formed. Then, the molten resin is injected into the cavity 74, and the resin is cooled to a predetermined temperature. Thus, the lower piece 14 having a predetermined shape is formed. At this time, the wall portion 52 of the lower piece 14 is formed by the second mold 60.

  Thus, the curved pipe 20 of the lower piece 14 is formed by the rotating core 62, the outer periphery of the lower piece 14 (curved pipe 20) is formed by the first mold 56, and the curved pipe 20 of the lower piece 14 is formed by the second mold 60. A part and the wall 52 are formed.

  Next, as a mold opening process, as shown in FIG. 8, the rotary unit mold 58 and the second mold 60 are moved down to separate the rotary unit mold 58 and the second mold 60 from the first mold 56. Let Note that the first mold 56 may be raised to separate the first mold 56 from the rotary unit mold 58 and the second mold 60.

  Next, as a rotating unit raising step, the slide mechanism 64 is raised relative to the second mold 60 as shown in FIG. 9 by an unillustrated ejector mechanism. As a result, the lower piece 14 formed in the mold clamping step together with the rotating unit mold 58 rises while being held by the rotating core 62, and the rotating core 62 and the lower piece 14 are separated from the second mold 60. A space 76 can be provided between the rotary core 62 and the second mold 60, specifically, between the wall portion 52 of the lower piece 14 held by the rotary core 62 and the second mold 60. Instead of raising the slide mechanism 64 relative to the second mold 60, the second mold 60 may be lowered relative to the slide mechanism 64.

  Next, as a core rotation process, as shown in FIG. 10, the rotary core 62 is rotated relative to the lower piece 14 while the lower piece 14 is held by the slide mechanism 64. As a result, the holding state of the lower piece 14 and the rotary core 62 is released. Here, as described above, the space 76 is provided in the rotating unit raising step. Therefore, the rotating core 62 can be rotated while moving a part of the rotating core 62 into the space 76. Therefore, the rotary core 62 can be reliably rotated relative to the lower piece 14 without the rotary core 62 being blocked by the second mold 60 that forms the wall portion 52 in the mold clamping step. .

  Next, as shown in FIG. 11, the lower piece 14 is taken out by rotating the lower piece 14 relative to the rotating core 62 while removing it from the slide mechanism 64 as shown in FIG. 11. Here, since the lower piece 14 is also separated from the second mold 60 together with the rotary core 62 in the rotating unit raising step as described above, the lower piece 14 can be easily taken out. Therefore, it is not necessary to provide an ejector mechanism for pushing out and taking out the lower piece 14. The lower piece 14 is manufactured as described above.

[Effect of this embodiment]
According to the present embodiment, the lower piece 14 is formed from the passage port 34 between the curved pipe line 20 and the surge tank 18 toward the middle piece 12 side on the inner peripheral side of the curved pipe line 20, and the surge tank 18. The wall part 52 which comprises the side wall of this is provided. As a result, the side wall of the surge tank 18 is formed directly from the passage port 34 between the curved conduit 20 and the surge tank 18 on the inner peripheral side of the curved shape of the curved conduit 20. Therefore, the volume of the surge tank 18 can be reduced. In addition, the mold for forming the lower piece 14 can be reduced in size and the lower piece 14 can be reduced in weight.

  The lower piece 14 is an integrally molded product made of resin. Therefore, the process of joining a plurality of pieces can be omitted as compared with a conventional lower piece formed by joining a plurality of pieces. Therefore, the manufacturing cost can be reduced.

  Further, the wall 52 is formed in a linear shape in the arrangement direction of the plurality of curved ducts 20. Thereby, the volume of the surge tank 18 can be reduced more reliably.

  Further, there is a rotating unit raising step for separating the rotary core 62 from the second molding die 60 in a state where the lower piece 14 formed of resin is held by the rotary core 62. Thereby, in the core rotation process, the rotary core 62 can be reliably rotated without being obstructed by the second mold 60, and the lower piece 14 can be reliably removed from the rotary core 62. Therefore, the lower piece 14 capable of reducing the volume of the surge tank 18 can be reliably manufactured as an integrally molded product made of resin.

  Further, the space required for rotation inside the mold can be minimized. Therefore, since the strength of the mold is increased, it is possible to suppress the occurrence of defects such as burrs due to the deflection of the mold and to improve the life of the mold.

  Moreover, since it is not necessary to provide an ejector mechanism for pushing out and removing the lower piece 14, a space for providing the ejector mechanism can be omitted, and the enlargement of the lower piece 14 due to the provision of the ejector mechanism can be suppressed.

  It should be noted that the above-described embodiment is merely an example and does not limit the present invention in any way, and various improvements and modifications can be made without departing from the scope of the invention.

DESCRIPTION OF SYMBOLS 1 Resin intake manifold 10 Upper piece 12 Middle piece 14 Lower piece 16 Branch passage 18 Surge tank 20 Curved pipe 34 Passage port 36 Passage port 40 Peripheral wall 52 Wall part 54 Manufacturing apparatus 56 1st shaping | molding die 58 Rotary unit type 60 2nd shaping | molding die 62 Rotating core 64 Slide mechanism 74 Cavity 76 Space

Claims (4)

In a resin intake manifold having a first piece and a second piece, a surge tank is formed between the first piece and the second piece, and a branch passage communicating with the surge tank is formed.
The second piece is an integrally molded product made of resin, and the curved conduit that forms a part of the branch passage, the curved conduit on the inner peripheral side of the curved shape of the curved conduit, and the A wall portion formed from the connection port with the surge tank toward the first piece side and constituting a side wall of the surge tank;
Resin intake manifold featuring The resin intake manifold according to claim 1,
A plurality of the curved pipe lines are arranged,
The wall portion is formed in a linear shape in the arrangement direction of the curved ducts;
Resin intake manifold featuring The resin intake manifold according to claim 1 or 2,
The second piece includes a curved rotary core forming the curved duct, a first mold placed outside the outer peripheral surface of the rotary core, and a first die placed inside the inner peripheral surface of the rotary core. Formed by injecting resin into the cavity formed between the two molds and being rotated by the rotary core after being separated from the second mold while being held by the rotary core. , And thereafter being taken out of the rotating core and manufactured.
Resin intake manifold featuring A method of manufacturing a resin intake manifold having a first piece and a second piece, wherein a surge tank is formed between the first piece and the second piece, and a branch passage communicating with the surge tank is formed In
The second piece is an integrally molded product made of resin, and the curved conduit that forms a part of the branch passage, the curved conduit on the inner peripheral side of the curved shape of the curved conduit, and the A wall formed from the connection port with the surge tank toward the first piece side and constituting a side wall of the surge tank;
Between the curved-shaped rotary core forming the curved duct, the first mold placed outside the outer peripheral surface of the rotary core, and the second mold placed inside the inner peripheral surface of the rotary core Forming the second piece by injecting resin into the cavity formed by
Separating the rotary core from the second mold while holding the second piece on the rotary core;
Rotating the rotary core relative to the second piece;
Removing the second piece from the rotating core;
Joining the second piece and the first piece taken out from the rotating core,
A manufacturing method of a resin intake manifold characterized by

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