JP2017066985A

JP2017066985A - Resin intake manifold

Info

Publication number: JP2017066985A
Application number: JP2015193752A
Authority: JP
Inventors: 智志榎田; Tomoshi Enokida; 建司藤本; Kenji Fujimoto
Original assignee: DaikyoNishikawa Corp
Current assignee: DaikyoNishikawa Corp
Priority date: 2015-09-30
Filing date: 2015-09-30
Publication date: 2017-04-06

Abstract

PROBLEM TO BE SOLVED: To prevent an inner member from being floated out of an inner surface of a surge tank part by enabling a location that is hardly fused and fixed in vibration against a surge tank part to be rigidly fixed to the surge tank without being dependent on the vibration fusion and adhering.SOLUTION: Partition wall parts 52 of an inner member 50 are provided with engaging recesses 52b. A middle member 20 is provided with engaging salients 23b that are engaged under a state in which they are inserted into the engaging recesses 52b. The extremity end part of the engaging salients 23b in their protruding direction are provided with enlarged parts 23c as compared with that of the base ends. The enlarged parts 23c are engaged with the inner surfaces of the engaging recesses 52b.SELECTED DRAWING: Figure 4

Description

本発明は、エンジンの吸気ポートに連通する吸気パイプ部とサージタンク部とが一体化されたサージタンク一体型の樹脂製インテークマニホールドに関し、特に、樹脂製インテークマニホールドが複数の溶着可能な樹脂製部材で構成された構造の技術分野に属する。 TECHNICAL FIELD The present invention relates to a surge tank-integrated resin intake manifold in which an intake pipe portion communicating with an intake port of an engine and a surge tank portion are integrated. In particular, the resin intake manifold has a plurality of weldable resin members. Belongs to the technical field of structure composed of

従来より、この種のサージタンク一体型のインテークマニホールド構造としては、気筒列方向に並ぶ複数の吸気パイプ部と、該吸気パイプ部の上流端が接続されたサージタンク部とを有するものが知られている（例えば、特許文献１、２参照）。 Conventionally, as this type of intake manifold structure integrated with a surge tank, one having a plurality of intake pipe portions arranged in the cylinder row direction and a surge tank portion to which an upstream end of the intake pipe portion is connected is known. (For example, see Patent Documents 1 and 2).

特許文献１のインテークマニホールドのサージタンク部は第１部材と第２部材とに分割されており、該サージタンク部の内部には各吸気パイプ部の上流端部を区画するための樹脂製の区画部材が挿入されている。区画部材は、吸気パイプ部の並び方向に長く形成されており、第２部材に溶着される溶着部と、各吸気パイプ部の上流端部を区画する複数の区画壁部とが一体成形されたものである。各区画壁部の上部及び下部には、それぞれ上側及び下側突条部が形成されている。一方、サージタンク部の内面には、上記各区画壁部の上側及び下側突条部がそれぞれ嵌合する上側及び下側凹条部が形成されている。 The surge tank portion of the intake manifold of Patent Document 1 is divided into a first member and a second member, and a resin compartment for partitioning an upstream end portion of each intake pipe portion inside the surge tank portion. A member is inserted. The partition member is formed long in the arrangement direction of the intake pipe portions, and a weld portion welded to the second member and a plurality of partition wall portions partitioning the upstream end portion of each intake pipe portion are integrally formed. Is. Upper and lower protrusions are formed on the upper and lower portions of each partition wall. On the other hand, on the inner surface of the surge tank portion, there are formed upper and lower concave ridge portions into which the upper and lower ridge portions of the partition wall portions are respectively fitted.

また、特許文献２のインテークマニホールドのサージタンク部は第１ケーシングピースと第２ケーシングピースとに分割されており、該サージタンク部の内部には樹脂製のインナーピースが挿入されている。インナーピースは、サージタンク部の内部において各吸気パイプ部の上流端部を区画するためのものである。インナーピースは、第１ケーシングピースと第２ケーシングピースとの分割面からサージタンク部の下方へ延びるように湾曲した円弧部を備えている。また、インナーピースの円弧部の下部には、突条部が形成されている。一方、サージタンク部の底壁部には、インナーピースの突条部が嵌合する凹条部が形成されている。インナーピースの突条部とサージタンク部の凹条部とは、レーザー光の照射によって互いに溶着されている。 Moreover, the surge tank part of the intake manifold of patent document 2 is divided | segmented into the 1st casing piece and the 2nd casing piece, and the resin-made inner piece is inserted in the inside of this surge tank part. The inner piece is for defining an upstream end portion of each intake pipe portion inside the surge tank portion. The inner piece includes an arc portion that is curved so as to extend downward from the surge tank portion from the dividing surface of the first casing piece and the second casing piece. Further, a ridge portion is formed at the lower portion of the arc portion of the inner piece. On the other hand, the bottom wall part of the surge tank part is formed with a recessed line part into which the protruding part of the inner piece is fitted. The protrusions of the inner piece and the recesses of the surge tank are welded together by laser light irradiation.

特開２００８−２０８７７０号公報JP 2008-208770 A 特開２００３−３２８８８１号公報JP 2003-328881 A

ところで、設備費や量産性等の生産性の観点から、樹脂製インテークマニホールドを製造する場合には複数の樹脂製部材を振動溶着することによって接合したいという要求がある。 By the way, from the viewpoint of productivity such as equipment costs and mass productivity, when manufacturing a resin intake manifold, there is a demand to join a plurality of resin members by vibration welding.

特許文献１の場合、第１部材と第２部材とを振動溶着する際、区画壁部の上側及び下側突条部が、サージタンク部の内面の上側及び下側凹条部に嵌合している。これにより、区画壁部を上下両方から挟持することができるので、振動溶着時の区画壁部の浮き上がりを防止することができ、振動溶着を適用することができると考えられる。 In the case of Patent Document 1, when the first member and the second member are vibration welded, the upper and lower protrusions of the partition wall are fitted to the upper and lower recesses of the inner surface of the surge tank. ing. Thereby, since a partition wall part can be clamped from both upper and lower sides, it can be considered that the partition wall part can be prevented from being lifted during vibration welding, and vibration welding can be applied.

ところが、樹脂製インテークマニホールドの構造は様々あり、例えば特許文献２のように、インナーピースの形状を、第１及び第２ケーシングピースの分割面からサージタンク部の内方へ向かって分割面から離れる方向へ延びる形状とせざるを得ない場合がある。この場合、インナーピースをケーシングピースに固定する構造が問題となる。つまり、第１及び第２ケーシングピースの分割面においては、インナーピースを第１ケーシングピースや第２ケーシングピースに振動溶着することができる一方、インナーピースの円弧部はサージタンク部の内方へ向かって分割面から離れる方向に延びているので、当該円弧部には振動溶着時の圧着力を作用させることができず、振動溶着が困難である。そのため、特許文献２ではインナーピースの円弧部にレーザー光を照射してケーシングピースに溶着するようにしている。しかしながら、特に円弧部は複数あるので、レーザー光の照射による溶着は振動溶着に比べて生産性が悪いという問題がある。 However, the structure of the resin-made intake manifold is various. For example, as in Patent Document 2, the shape of the inner piece is separated from the dividing surface from the dividing surface of the first and second casing pieces toward the inside of the surge tank portion. In some cases, the shape must extend in the direction. In this case, the structure of fixing the inner piece to the casing piece becomes a problem. That is, on the dividing surface of the first and second casing pieces, the inner piece can be vibration welded to the first casing piece or the second casing piece, while the arc portion of the inner piece faces inward of the surge tank portion. Therefore, it is difficult to apply vibration bonding to the arc portion due to vibration welding, and vibration welding is difficult. For this reason, in Patent Document 2, laser light is applied to the arc portion of the inner piece to weld it to the casing piece. However, since there are a plurality of arc portions in particular, there is a problem that welding by laser light irradiation is less productive than vibration welding.

本発明は、かかる点に鑑みてなされたものであり、その目的とするところは、サージタンク部の内部にインナー部材を配設し、該サージタンク部に対して振動溶着するのが困難な部位がインナー部材に存在する場合に、当該部位を振動溶着によらずサージタンク部に強固に固定できるようにしてサージタンク部の内面から浮き上がらないようにすることにある。 The present invention has been made in view of the above points, and the object of the present invention is to provide an inner member inside the surge tank portion and to make it difficult to vibrate and weld to the surge tank portion. Is present in the inner member, the portion can be firmly fixed to the surge tank portion without depending on vibration welding so as not to float from the inner surface of the surge tank portion.

上記目的を達成するために、本発明では、インナー部材の区画壁部をサージタンク部の壁部に係合させるようにした。 In order to achieve the above object, in the present invention, the partition wall portion of the inner member is engaged with the wall portion of the surge tank portion.

第１の発明は、
吸気パイプ部（２）と、該吸気パイプ部（２）の上流端が接続されたサージタンク部（３）とを有するサージタンク一体型の樹脂製インテークマニホールド（１）において、
少なくとも上記サージタンク部（３）が、樹脂製の第１分割体（２０）及び第２分割体（４０）を振動溶着してなり、
上記サージタンク部（３）の内部には、樹脂製のインナー部材（５０）が設けられ、
上記インナー部材（５０）は、上記第１分割体（２０）及び上記第２分割体（４０）に挟持されて少なくとも一方に振動溶着される挟持部（５１）と、該挟持部（５１）から上記サージタンク部（３）の内部へ向けて延び、上記吸気パイプ部（２）の上流端部を区画するための区画壁部（５２）とを備え、
上記区画壁部（５２）と、上記サージタンク部（３）の壁部との一方には係合凹部（５２ｂ）が設けられ、他方には上記係合凹部（５２ｂ）に挿入された状態で係合する係合凸部（２３ｂ）が設けられ、
上記係合凸部（２３ｂ）の突出方向先端側には、基端側に比べて拡大した拡大部（２３ｃ）が設けられ、該拡大部（２３ｃ）が上記係合凹部（５２ｂ）の内面に係合することを特徴とする。 The first invention is
In a surge tank integrated resin intake manifold (1) having an intake pipe portion (2) and a surge tank portion (3) to which the upstream end of the intake pipe portion (2) is connected,
At least the surge tank part (3) is formed by vibration welding the first divided body (20) and the second divided body (40) made of resin,
Inside the surge tank portion (3), a resin inner member (50) is provided,
The inner member (50) includes a sandwiching portion (51) sandwiched between the first divided body (20) and the second divided body (40) and vibration welded to at least one of the sandwiched portion (51). A partition wall (52) for extending toward the inside of the surge tank (3) and partitioning the upstream end of the intake pipe (2);
One of the partition wall (52) and the wall of the surge tank (3) is provided with an engagement recess (52b), and the other is inserted into the engagement recess (52b). An engagement convex part (23b) to be engaged is provided,
An enlarged portion (23c) enlarged as compared with the base end side is provided on the distal end side in the protruding direction of the engaging convex portion (23b), and the enlarged portion (23c) is formed on the inner surface of the engaging concave portion (52b). It is characterized by engaging.

この構成によれば、サージタンク部の内部に配設されたインナー部材により、サージタンク部の内部に吸気パイプ部の上流端部が区画形成される。インテークマニホールドを製造する際には、第１分割体と第２分割体の間にインナー部材の挟持部を配置し、第１分割体及び第２分割体を振動溶着すると、インナー部材の挟持部が第１分割体と第２分割体の少なくとも一方に溶着されるとともに、第１分割体と第２分割体に挟持されて強固に固定される。一方、インナー部材の区画壁部とサージタンク部の壁部との一方に設けられた係合凸部を他方に設けられた係合凹部に挿入すると、係合凸部の先端側の拡大部が係合凹部の内面に係合する。これにより、係合凸部が係合凹部から抜け難くなるので、従来のようにレーザー光による溶着をすることなく、インナー部材の区画壁部がサージタンク部の壁部に強固に固定される。 According to this configuration, the upstream end portion of the intake pipe portion is partitioned and formed inside the surge tank portion by the inner member disposed inside the surge tank portion. When the intake manifold is manufactured, the inner member clamping portion is disposed between the first divided body and the second divided body, and when the first divided body and the second divided body are vibration welded, the inner member clamping portion is While being welded to at least one of the first divided body and the second divided body, it is sandwiched and fixed firmly between the first divided body and the second divided body. On the other hand, when the engaging convex portion provided on one of the partition wall portion of the inner member and the wall portion of the surge tank portion is inserted into the engaging concave portion provided on the other side, the enlarged portion on the tip side of the engaging convex portion is Engages with the inner surface of the engaging recess. As a result, the engagement convex portion is unlikely to come out of the engagement concave portion, so that the partition wall portion of the inner member is firmly fixed to the wall portion of the surge tank portion without welding with a laser beam as in the prior art.

第２の発明は、第１の発明において、
上記第１分割体（２０）の内部には、上記インナー部材（５０）の上記挟持部（５１）を上記第２分割体（４０）とは反対側から受ける受け部（２５）が設けられ、
上記受け部（２５）と上記インナー部材（５０）の上記挟持部（５１）との一方に嵌合凸部（５１ａ）が形成され、他方に該嵌合凸部（５１ａ）が嵌合する嵌合凹部（２５ａ）が形成されていることを特徴とする。 According to a second invention, in the first invention,
Inside the first divided body (20) is provided a receiving portion (25) for receiving the clamping portion (51) of the inner member (50) from the side opposite to the second divided body (40),
A fitting projection (51a) is formed on one of the receiving portion (25) and the clamping portion (51) of the inner member (50), and the fitting projection (51a) is fitted on the other. A joint recess (25a) is formed.

この構成によれば、インナー部材の挟持部を第１分割体の受け部によってしっかりと受けることが可能になるので、インナー部材の挟持部が第１分割体や第２分割体に強固に振動溶着される。 According to this configuration, since the holding portion of the inner member can be firmly received by the receiving portion of the first divided body, the holding portion of the inner member is firmly vibration welded to the first divided body and the second divided body. Is done.

第１の発明によれば、サージタンク部の内部に設けられるインナー部材に、サージタンク部の第１分割体及び第２分割体に挟持される挟持部と、該挟持部からサージタンク部の内部へ向けて延びる区画壁部とを設け、区画壁部と、サージタンク部の壁部との一方に係合凹部を設け、他方に係合凸部を設け、係合凸部の突出方向先端側に設けた拡大部を係合凹部の内面に係合させるようにしている。したがって、第１分割体及び第２分割体を振動溶着すると、インナー部材の挟持部を第１分割体と第２分割体で挟持して強固に固定できる。また、係合凸部の拡大部を係合凹部に挿入して該係合凹部の内面に係合させると係合凸部が係合凹部から抜け難くなるので、従来のようにレーザー光による溶着をすることなく、インナー部材の区画壁部をサージタンク部の壁部に強固に固定することができ、サージタンク部の内面から浮き上がらないようにすることができる。 According to the first invention, the inner member provided inside the surge tank portion includes the sandwiching portion sandwiched between the first split body and the second split body of the surge tank portion, and the inside of the surge tank portion from the sandwiching portion. A partition wall portion extending toward the wall, an engagement concave portion provided in one of the partition wall portion and the wall portion of the surge tank portion, an engagement convex portion provided in the other, and a protruding direction front end side of the engagement convex portion The enlarged portion provided on the inner surface is engaged with the inner surface of the engaging recess. Therefore, when the first divided body and the second divided body are vibration welded, the sandwiching portion of the inner member can be firmly fixed by being sandwiched between the first divided body and the second divided body. In addition, when the enlarged portion of the engaging convex portion is inserted into the engaging concave portion and engaged with the inner surface of the engaging concave portion, the engaging convex portion becomes difficult to come off from the engaging concave portion. Therefore, the partition wall portion of the inner member can be firmly fixed to the wall portion of the surge tank portion, and can be prevented from floating from the inner surface of the surge tank portion.

第２の発明によれば、第１分割体の内部に、インナー部材の挟持部を受ける受け部を設け、受け部とインナー部材の挟持部との一方に嵌合凸部を形成し、他方に該嵌合凸部が嵌合する嵌合凹部を形成したので、インナー部材の挟持部を第１分割体の受け部によってしっかりと受けることができ、第１分割体や第２分割体に強固に振動溶着できる。 According to the second invention, the receiving portion for receiving the holding portion of the inner member is provided inside the first divided body, the fitting convex portion is formed on one of the receiving portion and the holding portion of the inner member, and the other is formed on the other side. Since the fitting concave portion into which the fitting convex portion is fitted is formed, the sandwiching portion of the inner member can be firmly received by the receiving portion of the first divided body, and the first divided body and the second divided body are firmly Vibration welding is possible.

実施形態に係る樹脂製インテークマニホールドの斜視図である。It is a perspective view of the resin-made intake manifold which concerns on embodiment. インテークマニホールドの縦断面図である。It is a longitudinal cross-sectional view of an intake manifold. アッパー部材を省略して示すインテークマニホールドの斜視図である。It is a perspective view of an intake manifold which omits and shows an upper member. インナー部材を取り外した状態の分解斜視図である。It is a disassembled perspective view of the state which removed the inner member. ロアー部材とミドル部材とを一体化した状態の斜視図である。It is a perspective view of the state which integrated the lower member and the middle member. ミドル部材を前方から見た斜視図である。It is the perspective view which looked at the middle member from the front. 図６におけるVII−VII線断面図である。It is the VII-VII sectional view taken on the line in FIG. ミドル部材に通路形成部材を配置した状態の斜視図である。It is a perspective view of the state where the passage formation member has been arranged in the middle member. 図８におけるIX−IX線断面図である。It is the IX-IX sectional view taken on the line in FIG. インナー部材を下方から見た斜視図である。It is the perspective view which looked at the inner member from the lower part. インナー部材に通路形成部材を組み付けた状態を下方から見た斜視図である。It is the perspective view which looked at the state which assembled | attached the channel | path formation member to the inner member from the downward direction. インナー部材を前方から見た斜視図である。It is the perspective view which looked at the inner member from the front. 通路形成部材を上方から見た斜視図である。It is the perspective view which looked at the channel formation member from the upper part. 通路形成部材を下方から見た斜視図である。It is the perspective view which looked at the passage formation member from the lower part. 通路形成部材の接続筒部近傍を拡大して示す斜視図である。It is a perspective view which expands and shows the connection cylinder part vicinity of a channel | path formation member. 通路形成部材を上方から見た斜視図である。It is the perspective view which looked at the channel formation member from the upper part.

以下、本発明の実施形態を図面に基づいて詳細に説明する。尚、以下の好ましい実施形態の説明は、本質的に例示に過ぎず、本発明、その適用物或いはその用途を制限することを意図するものではない。 Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. It should be noted that the following description of the preferred embodiment is merely illustrative in nature, and is not intended to limit the present invention, its application, or its use.

（樹脂製インテークマニホールドの全体構成）
図１は、本発明の実施形態に係る樹脂製インテークマニホールド１を上方から見た斜視図である。樹脂製インテークマニホールド１は、４本の吸気パイプ部２、２、…と、該吸気パイプ部２、２、…の上流端が接続されたサージタンク部３とを有するサージタンク一体型のインテークマニホールドである。インテークマニホールド１は、自動車に搭載される直列４気筒エンジン（図示せず）に装着されるようになっており、エンジンへの装着状態で上になる側を単に「上」といい、下になる側を単に「下」というものとする。また、図１において右になる側を単に「右」といい、左になる側を単に「左」というものとする。また、図１に示すように前側及び後側を定義する。尚、前後左右の各方向は車両への搭載状態とは必ずしも一致しないが、説明の便宜上、上記のように定義する。 (Overall structure of resin intake manifold)
FIG. 1 is a perspective view of a resin intake manifold 1 according to an embodiment of the present invention as viewed from above. The resin intake manifold 1 is a surge tank integrated intake manifold having four intake pipe portions 2, 2,... And a surge tank portion 3 to which the upstream ends of the intake pipe portions 2, 2,. It is. The intake manifold 1 is mounted on an in-line four-cylinder engine (not shown) mounted on an automobile, and the upper side when mounted on the engine is simply referred to as “upper” and is lower. The side is simply called “bottom”. In FIG. 1, the right side is simply referred to as “right”, and the left side is simply referred to as “left”. Also, the front side and the rear side are defined as shown in FIG. Note that the front, rear, left and right directions do not necessarily match the mounting state on the vehicle, but are defined as described above for convenience of explanation.

サージタンク部３は、インテークマニホールド１の前側に設けられており、左右方向に長い形状となっている。吸気パイプ部２、２、…は、左右方向に並んでいる。図２に示すように、吸気パイプ部２、２、…の上流端はサージタンク部３の下側に接続されている。吸気パイプ部２、２、…は、サージタンク部３の下側からサージタンク部３の下方を後側へ向かって斜め上方へ延び、その後、下流側が下方へ延びるように全体として湾曲している。図３等に示すように、吸気パイプ部２、２、…の左右方向の間隔は、下流側が上流側に比べて広くなっている。 The surge tank portion 3 is provided on the front side of the intake manifold 1 and has a shape that is long in the left-right direction. The intake pipe portions 2, 2, ... are arranged in the left-right direction. As shown in FIG. 2, the upstream ends of the intake pipe portions 2, 2,... Are connected to the lower side of the surge tank portion 3. The intake pipe portions 2, 2,... Are curved as a whole so as to extend obliquely upward from the lower side of the surge tank portion 3 downward to the rear side of the surge tank portion 3, and then extend downward on the downstream side. . As shown in FIG. 3 etc., the intervals in the left-right direction of the intake pipe portions 2, 2,... Are wider on the downstream side than on the upstream side.

図２等にも示すように、インテークマニホールド１は、上下方向に３つの部材に分割されるとともに、その内部には更に別の部材が配設されることによって構成されている。すなわち、インテークマニホールド１は、ロアー部材１０と、ミドル部材２０と、アッパー部材４０と、インナー部材５０と、通路形成部材６０とを有している。ロアー部材１０、ミドル部材２０、アッパー部材４０、インナー部材５０及び通路形成部材６０は、全て溶着可能な樹脂材であり、その材料は従来から周知の熱可塑性樹脂を挙げることができる。 As shown in FIG. 2 and the like, the intake manifold 1 is divided into three members in the vertical direction, and another member is disposed inside the intake manifold 1. That is, the intake manifold 1 includes a lower member 10, a middle member 20, an upper member 40, an inner member 50, and a passage forming member 60. The lower member 10, the middle member 20, the upper member 40, the inner member 50, and the passage forming member 60 are all resin materials that can be welded, and examples of the materials include conventionally known thermoplastic resins.

ロアー部材１０は、吸気パイプ部２、２、…の周壁部のうち下側部分を構成するものである。ミドル部材２０は、本発明の第１分割体に相当する部材であり、サージタンク部３の周壁部の下側部分と、吸気パイプ部２、２、…の周壁部のうち下側部分を構成するものである。アッパー部材４０は、本発明の第２分割体に相当する部材であり、サージタンク部３の周壁部の上側部分を構成するものである。 The lower member 10 constitutes a lower portion of the peripheral wall portions of the intake pipe portions 2, 2,. The middle member 20 is a member corresponding to the first divided body of the present invention, and constitutes the lower part of the peripheral wall part of the surge tank part 3 and the peripheral wall part of the intake pipe parts 2, 2,. To do. The upper member 40 is a member corresponding to the second divided body of the present invention, and constitutes the upper part of the peripheral wall portion of the surge tank portion 3.

（ロアー部材の構成）
ロアー部材１０は、吸気パイプ部２、２、…の周壁部の下側部分となる４つの下側湾曲板部１１、１１、…と、下側湾曲板部１１、１１、…の後端部同士を連結するように左右方向に延びる締結フランジ１２とを有しており、下側湾曲板部１１、１１、…と締結フランジ１２とは一体成形されている。各下側湾曲板部１１は、前後方向に長く延びるように形成されており、その左右方向中央部が最も下に位置するように湾曲している。各下側湾曲板部１１の周縁部には、全周に亘ってロアー側溶着フランジ１１ａが外方へ延出するように形成されている。ロアー側溶着フランジ１１ａは、後述するミドル部材２０に振動溶着法によって溶着される部分である。締結フランジ１２は、インテークマニホールド１をエンジンのシリンダヘッド（図示せず）に対してボルト等の締結部材（図示せず）によって締結固定するためのものである。 (Configuration of lower member)
The lower member 10 includes four lower curved plate portions 11, 11,... And rear end portions of the lower curved plate portions 11, 11,. It has the fastening flange 12 extended in the left-right direction so that they may be connected, and the lower curved board part 11, 11, ... and the fastening flange 12 are integrally molded. Each lower curved plate portion 11 is formed so as to extend long in the front-rear direction, and is curved so that the center portion in the left-right direction is located at the lowest position. A lower welding flange 11a is formed on the peripheral edge of each lower curved plate portion 11 so as to extend outward over the entire circumference. The lower welding flange 11a is a portion that is welded to a middle member 20 described later by a vibration welding method. The fastening flange 12 is used to fasten and fix the intake manifold 1 to a cylinder head (not shown) of the engine with a fastening member (not shown) such as a bolt.

（ミドル部材の構成）
ミドル部材２０は、吸気パイプ部２、２、…の周壁部の上側部分となる４つの上側湾曲板部２１、２１、…と、サージタンク部３の周壁部の下側部分となる下側周壁部２２とを有しており、上側湾曲板部２１、２１、…と下側周壁部２２とは一体成形されている。各上側湾曲板部２１は、前後方向に長く延びるように形成されており、その左右方向中央部が最も上に位置するように湾曲している。また、各上側湾曲板部２１は、後側へ行くほど下に位置するように延びている。上側湾曲板部２１、２１、…の前側は互いに左右方向に連続しており、サージタンク部３の底壁部を構成している。各上側湾曲板部２１の周縁部には、全周に亘ってミドル側溶着フランジ２１ａが外方へ延出するように形成されている。ミドル側溶着フランジ２１ａがロアー側溶着フランジ１１ａに振動溶着される。 (Configuration of middle member)
The middle member 20 includes four upper curved plate portions 21, 21,... Which are upper portions of the peripheral wall portions of the intake pipe portions 2, 2... And a lower peripheral wall which is a lower portion of the peripheral wall portion of the surge tank portion 3. The upper curved plate portions 21, 21,... And the lower peripheral wall portion 22 are integrally molded. Each upper curved plate portion 21 is formed so as to extend long in the front-rear direction, and is curved so that the center portion in the left-right direction is located at the top. Moreover, each upper curved board part 21 is extended so that it may be located below, so that it goes to the rear side. The front sides of the upper curved plate portions 21, 21,... Are continuous in the left-right direction and constitute the bottom wall portion of the surge tank portion 3. On the peripheral edge of each upper curved plate portion 21, a middle-side welding flange 21a is formed to extend outward over the entire circumference. The middle welding flange 21a is vibration welded to the lower welding flange 11a.

下側周壁部２２は、サージタンク部３の周壁部の下側部分を構成している。図７に示すように、下側周壁部２２の下部には、吸気パイプ部２の上流端部となる４つの上流開口部２２ａ、２２ａ、…が左右方向に並ぶように形成されている。隣り合う上流開口部２２ａ、２２ａの間には、隣り合う上流開口部２２ａ、２２ａの間を仕切るように前後方向に延びるタンク側壁部２３（図４〜図６に示す）が設けられている。このサージタンク部３に形成されたタンク側壁部２３は中空状である。各タンク側壁部２３の上面は、前後方向に延び、かつ、前側へ行くに従って上に位置するように湾曲した円弧面で構成されている。 The lower peripheral wall portion 22 constitutes a lower portion of the peripheral wall portion of the surge tank portion 3. As shown in FIG. 7, four upstream openings 22 a, 22 a, which are upstream ends of the intake pipe portion 2 are formed in the lower portion of the lower peripheral wall portion 22 so as to be aligned in the left-right direction. Between the adjacent upstream openings 22a and 22a, a tank side wall portion 23 (shown in FIGS. 4 to 6) extending in the front-rear direction so as to partition the adjacent upstream openings 22a and 22a is provided. The tank side wall portion 23 formed in the surge tank portion 3 is hollow. The upper surface of each tank side wall part 23 is comprised by the circular arc surface extended so that it might be located up as it goes to the front side, and goes to the front side.

タンク側壁部２３の上面には、前後方向に延びる溝２３ａが形成されている。溝２３ａの前端部は、タンク側壁部２３の上面の前端部よりも後に位置している。また、タンク側壁部２３の上面の前部には、係合凸部２３ｂが該上面から突出するように設けられている。図７に示すように、係合凸部２３ｂの突出方向先端側には、基端側に比べて拡大した拡大部２３ｃが設けられている。具体的には、拡大部２３ｃは、係合凸部２３ｂの基端側に対して左右両方向に拡大している。また、拡大部２３ｃは、その先端側へ行くほど左右方向の寸法が短くなるように先細形状となっている。拡大部２３ｃの先端の左右方向の寸法は、係合凸部２３ｂの基端側の左右方向の寸法と略同程度、あるいは拡大部２３ｃの先端の方が若干長く設定されている。 A groove 23 a extending in the front-rear direction is formed on the upper surface of the tank side wall portion 23. The front end portion of the groove 23 a is located behind the front end portion of the upper surface of the tank side wall portion 23. Further, an engaging convex portion 23 b is provided at the front portion of the upper surface of the tank side wall portion 23 so as to protrude from the upper surface. As shown in FIG. 7, an enlarged portion 23c that is larger than the proximal end side is provided on the distal end side in the protruding direction of the engaging convex portion 23b. Specifically, the enlarged portion 23c is enlarged in both the left and right directions with respect to the proximal end side of the engaging convex portion 23b. Further, the enlarged portion 23c has a tapered shape so that the dimension in the left-right direction becomes shorter toward the tip side. The size in the left-right direction at the distal end of the enlarged portion 23c is set to be approximately the same as the size in the left-right direction on the proximal end side of the engaging convex portion 23b, or slightly longer at the distal end of the enlarged portion 23c.

また、下側周壁部２２の左右両側壁部の内面には、サージタンク部３の内方へ膨出する膨出部２４がそれぞれ設けられている。膨出部２４の上面は、前後方向に延び、かつ、前側へ行くに従って上に位置するように湾曲した円弧面で構成されている。膨出部２４の上面には、前後方向に延びる溝２４ａが形成されている。溝２４ａの前端部は、膨出部２４の上面の前端部よりも後に位置している。 Further, on the inner surfaces of the left and right side wall portions of the lower peripheral wall portion 22, bulge portions 24 that bulge inward of the surge tank portion 3 are respectively provided. The upper surface of the bulging portion 24 is configured by an arc surface that extends in the front-rear direction and is curved so as to be positioned upward as it goes to the front side. A groove 24 a extending in the front-rear direction is formed on the upper surface of the bulging portion 24. The front end portion of the groove 24 a is located behind the front end portion of the upper surface of the bulging portion 24.

図６に示すように、下側周壁部２２の内面の前後方向中間部には、左右方向に延びる横溝２２ｂが形成されている。横溝２２ｂは、左側の膨出部２４の上面の後部から右側の膨出部２４の上面の後部に亘って延びている。横溝２２ｂの中途部には、各タンク側壁部２３の上面に形成された溝２３ａの後端部が連続している。 As shown in FIG. 6, a lateral groove 22 b extending in the left-right direction is formed in the middle portion in the front-rear direction of the inner surface of the lower peripheral wall portion 22. The lateral groove 22 b extends from the rear part of the upper surface of the left bulge part 24 to the rear part of the upper surface of the right bulge part 24. The rear end portion of the groove 23a formed on the upper surface of each tank side wall portion 23 is continuous with the middle portion of the horizontal groove 22b.

ミドル部材２０の下側周壁部２２の上端部は略全体が開放されており、この開放部分の周縁部には、全周に亘って連続する溶着用突条部２２ｃが形成されている。ミドル部材２０の下側周壁部２２の左右両側面には、サージタンク部３の外方へ向けて窪むことによって形成された段部２２ｄが設けられている。 The upper end portion of the lower peripheral wall portion 22 of the middle member 20 is substantially entirely open, and a welding protrusion 22c that is continuous over the entire circumference is formed at the peripheral portion of the open portion. On both left and right side surfaces of the lower peripheral wall portion 22 of the middle member 20, a step portion 22 d formed by being recessed outward of the surge tank portion 3 is provided.

図６に示すように、ミドル部材２０の下側周壁部２２の内面には、インナー部材５０の挟持部５１（後述する）をアッパー部材４０とは反対側、即ち下側から受ける複数の受け部２５、２５、…が設けられている。受け部２５は、下側周壁部２２の内面における後側と左右両側とに、それぞれ該下側周壁部２２の周方向に互いに間隔をあけて配置されており、上下方向に延びる板状をなしている。図７及び図９に拡大して示すように、受け部２５の上端部には、嵌合凹部２５ａが形成されている。嵌合凹部２５ａは、受け部２５の上端部の一部を切り欠くことによって形成されたものであり、インナー部材５０の挟持部５１（後述する）が嵌合する部分である。 As shown in FIG. 6, on the inner surface of the lower peripheral wall portion 22 of the middle member 20, a plurality of receiving portions that receive a clamping portion 51 (described later) of the inner member 50 from the side opposite to the upper member 40, that is, the lower side. 25, 25,... Are provided. The receiving portion 25 is disposed on the rear side and the left and right sides of the inner surface of the lower peripheral wall portion 22 at intervals in the circumferential direction of the lower peripheral wall portion 22 and has a plate shape extending in the vertical direction. ing. As shown in enlarged views in FIGS. 7 and 9, a fitting recess 25 a is formed at the upper end of the receiving portion 25. The fitting recess 25a is formed by cutting out a part of the upper end portion of the receiving portion 25, and is a portion into which a clamping portion 51 (described later) of the inner member 50 is fitted.

図６に示すように、吸気パイプ部２の周壁部を構成するミドル部材２０の上側湾曲板部２１には、連通孔２１ｂが該上側湾曲板部２１を貫通するように形成されている。この連通孔２１ｂは、下側周壁部２２で囲まれた領域に位置しており、吸気パイプ部２の内部に連通している。連通孔２１ｂの周囲には、上方へ突出する環状突部２１ｃが形成されている。 As shown in FIG. 6, a communication hole 21 b is formed in the upper curved plate portion 21 of the middle member 20 constituting the peripheral wall portion of the intake pipe portion 2 so as to penetrate the upper curved plate portion 21. The communication hole 21 b is located in a region surrounded by the lower peripheral wall portion 22 and communicates with the inside of the intake pipe portion 2. An annular protrusion 21c that protrudes upward is formed around the communication hole 21b.

ミドル部材２０の下側周壁部２２の右側には、図示しないエンジンのブローバイガスをインテークマニホールド１に導入するためのブローバイガス導入筒部２６が設けられている。ブローバイガス導入筒部２６は、ミドル部材２０の下側周壁部２２の右側から突出している。ブローバイガス導入筒部２６には、図示しないが、エンジンから延びるブローバイガス配管の下流側が接続されるようになっている。本実施形態において、ブローバイガスは吸気パイプ部２、２、…に混合する気体である。尚、ブローバイガス以外の気体を吸気パイプ部２、２、…に混合するようにしてもよい。 On the right side of the lower peripheral wall portion 22 of the middle member 20, a blow-by gas introducing cylinder portion 26 for introducing an engine blow-by gas (not shown) into the intake manifold 1 is provided. The blow-by gas introducing cylinder portion 26 protrudes from the right side of the lower peripheral wall portion 22 of the middle member 20. Although not shown, the blow-by gas introduction cylinder portion 26 is connected to a downstream side of a blow-by gas pipe extending from the engine. In this embodiment, the blow-by gas is a gas mixed in the intake pipe portions 2, 2,. A gas other than blow-by gas may be mixed in the intake pipe portions 2, 2,.

（アッパー部材の構成）
アッパー部材４０は、ミドル部材２０の下側周壁部２２の開放部分を覆うように形成されており、サージタンク部３の上壁部を構成している。アッパー部材４０の周縁部には、ミドル部材２０の溶着用突条部２２ｃに溶着される被溶着部４０ａが全周に亘って形成されている。また、アッパー部材４０の後側には、吸気をサージタンク部３に導入するための吸気導入筒部４１が形成されている。吸気導入筒部４１には、図示しないがエアクリーナによって濾過された吸気が導入されるようになっている。 (Configuration of upper member)
The upper member 40 is formed so as to cover the open portion of the lower peripheral wall portion 22 of the middle member 20 and constitutes the upper wall portion of the surge tank portion 3. A welded portion 40 a to be welded to the welding protrusion 22 c of the middle member 20 is formed on the peripheral edge of the upper member 40 over the entire circumference. Further, an intake air introduction cylinder portion 41 for introducing intake air into the surge tank portion 3 is formed on the rear side of the upper member 40. Although not shown, intake air filtered by an air cleaner is introduced into the intake air introduction cylinder portion 41.

（通路形成部材の構成）
通路形成部材６０は、吸気パイプ部２、２、…の周壁部の一部であるミドル部材２０の上側湾曲板部２１とインナー部材５０との間に設けられており、インナー部材５０と共にブローバイガス通路Ｒをインテークマニホールド１に区画形成するためのものである。通路形成部材６０は、図１３、図１４等に示すように左右方向に長い形状とされており、インナー部材５０側に開放して下方に窪む凹状をなす開放部６１と、連通孔２１ｂに接続される接続孔６２とを有している。開放部６１の右側には、ブローバイガス導入筒部２６に接続される接続筒部６６が右側へ突出するように形成されている。接続筒部６６は、図１６に示すように左側に開口しており、上流側へ向かって径が拡大している。この接続筒部６６は、インナー部材５０とミドル部材２０とで挟持される。また、図２に示すように、ブローバイガス通路Ｒの下壁は、前側へ向かって下降傾斜している。 (Configuration of passage forming member)
The passage forming member 60 is provided between the upper curved plate portion 21 of the middle member 20 that is a part of the peripheral wall portion of the intake pipe portions 2, 2,... And the inner member 50. This is for partitioning the passage R into the intake manifold 1. The passage forming member 60 has a shape that is long in the left-right direction as shown in FIGS. 13, 14, and the like, and is formed in an open portion 61 that is open to the inner member 50 side and is recessed downward, and the communication hole 21b. And a connection hole 62 to be connected. On the right side of the open part 61, a connection cylinder part 66 connected to the blow-by gas introduction cylinder part 26 is formed so as to protrude to the right side. As shown in FIG. 16, the connecting tube portion 66 is open on the left side, and the diameter increases toward the upstream side. The connecting tube portion 66 is sandwiched between the inner member 50 and the middle member 20. Further, as shown in FIG. 2, the lower wall of the blow-by gas passage R is inclined downward toward the front side.

開放部６１は、接続筒部６６に連通しており、この接続筒部６６に連通する部分から左側へ向けてインテークマニホールド１の左右方向中央部近傍まで延びた後、前側へ延びてから左側及び右側へそれぞれ延び、その左側及び右側下流部分においてさらに左右に分岐している。つまり、開放部６１は、１箇所から流入したブローバイガスを４本の吸気パイプ部２、２、…に分流して流すことができるように形状設定されている。開放部６１の上端部には、該開放部６１を全周に亘って囲むように屈曲しながら延びる溝６１ａが形成されている。開放部６１は、非溶着部分である。 The open portion 61 communicates with the connecting cylinder portion 66, extends from the portion communicating with the connecting cylinder portion 66 toward the left side to the vicinity of the central portion in the left-right direction of the intake manifold 1, extends to the front side, and then extends to the left side and the left side. Each extends to the right, and further branches left and right at the left and right downstream portions. That is, the open portion 61 is shaped so that blow-by gas flowing in from one place can be divided and flowed to the four intake pipe portions 2, 2,. A groove 61 a that extends while being bent so as to surround the entire open portion 61 is formed at the upper end portion of the open portion 61. The open part 61 is a non-welded part.

開放部６１におけるブローバイガスの流れ方向下流端部に対応する４箇所には、それぞれ下方へ突出する突出筒部６３が形成されている。突出筒部６３の内部には、上記接続孔６２が形成されており、この接続孔６２の上端部（上流端部）が開放部６１の内部に連通している。突出筒部６３の下端部には、環状溝６３ａが形成されている。環状溝６３ａには、ミドル部材２０の環状突部２１ｃが挿入されるようになっている。これにより、環状溝６３ａによって形成された凹に、環状突部２１ｃによって形成された凸が挿入されて気体の漏れを抑制することができるシール構造、即ち、ラビリンス構造を、通路形成部材６０の接続孔６２と、連通孔２１ｂとの間に設けることができる。突出筒部６３は非溶着部分である。 At four locations corresponding to the downstream end portion in the flow direction of the blow-by gas in the open portion 61, projecting cylindrical portions 63 that project downward are formed. The connecting hole 62 is formed inside the protruding cylindrical portion 63, and the upper end portion (upstream end portion) of the connecting hole 62 communicates with the inside of the open portion 61. An annular groove 63 a is formed at the lower end portion of the protruding cylinder portion 63. The annular protrusion 21c of the middle member 20 is inserted into the annular groove 63a. As a result, a seal structure, that is, a labyrinth structure, in which the protrusion formed by the annular protrusion 21c is inserted into the recess formed by the annular groove 63a to suppress gas leakage, is connected to the passage forming member 60. It can be provided between the hole 62 and the communication hole 21b. The protruding cylinder part 63 is a non-welded part.

図１５に拡大して示すように、突出筒部６３の内面の下流側には、湾曲面６３ｂが設けられている。湾曲面６３ｂは、図９に示すように下方へ行くほど吸気の流れ方向（矢印Ａで示す）下流側に位置するように湾曲しており、これにより、接続孔６２を流通したブローバイガスを吸気パイプ部２に向けてスムーズに流すことができるとともに、ブローバイガスの流れの方向を吸気パイプ部２内の吸気の流れ方向に近づけてブローバイガスを効率良く吸気に混合させることができる。 As shown in an enlarged view in FIG. 15, a curved surface 63 b is provided on the downstream side of the inner surface of the protruding cylindrical portion 63. As shown in FIG. 9, the curved surface 63 b is curved so as to be positioned downstream of the flow direction of the intake air (indicated by an arrow A) as it goes downward, and as a result, the blow-by gas flowing through the connection hole 62 is taken into the intake air. While being able to flow smoothly toward the pipe part 2, the flow direction of the blow-by gas can be brought close to the flow direction of the intake air in the intake pipe part 2, so that the blow-by gas can be efficiently mixed with the intake air.

通路形成部材６０の外面には、複数の係合片６４が互いに間隔をあけて形成されている。係合片６４は、通路形成部材６０の外面から外方へ突出した後、上方へ屈曲したフック状に形成されている。係合片６４には、係合孔６４ａが形成されている。 A plurality of engagement pieces 64 are formed on the outer surface of the passage forming member 60 at intervals. The engaging piece 64 is formed in a hook shape that protrudes outward from the outer surface of the passage forming member 60 and then bends upward. An engagement hole 64 a is formed in the engagement piece 64.

（インナー部材の構成）
図４に示すように、インナー部材５０はミドル部材２０の下側周壁部２２の内部に配設されるものであり、ミドル部材２０及びアッパー部材４０に挟持されてアッパー部材４０に振動溶着される挟持部５１と、該挟持部５１からサージタンク部３の内部へ向けて延び、吸気パイプ部２、２、…の上流端部を区画するための３つの区画壁部５２、５２、５２とを備えている。インナー部材５０の左右両側は、それぞれ、ミドル部材２０の段部２２ｄに嵌まるように形成されている。 (Configuration of inner member)
As shown in FIG. 4, the inner member 50 is disposed inside the lower peripheral wall portion 22 of the middle member 20, and is sandwiched between the middle member 20 and the upper member 40 and vibration welded to the upper member 40. A sandwiching portion 51 and three partition wall portions 52, 52, 52 extending from the sandwiching portion 51 toward the inside of the surge tank portion 3 and partitioning the upstream end portions of the intake pipe portions 2, 2,. I have. The left and right sides of the inner member 50 are formed so as to fit into the stepped portion 22d of the middle member 20, respectively.

挟持部５１は、インナー部材５０の後縁部から左右両側縁部に亘って設けられており、ミドル部材２０及びアッパー部材４０によって該挟持部５１の厚み方向、即ち上下方向に挟持される。この挟持部５１には、図１０〜図１２に示すように、下方へ突出する板状の嵌合凸部５１ａが形成されている。嵌合凸部５１ａは、インナー部材５０の後縁部から左右両側縁部に亘って連続して延びており、ミドル部材２０の嵌合凹部２５ａに上方から挿入されて嵌合する。 The clamping part 51 is provided from the rear edge part of the inner member 50 to the left and right side edge parts, and is clamped by the middle member 20 and the upper member 40 in the thickness direction of the clamping part 51, that is, in the vertical direction. As shown in FIGS. 10 to 12, the sandwiching portion 51 is formed with a plate-like fitting convex portion 51 a that protrudes downward. The fitting convex portion 51a extends continuously from the rear edge portion of the inner member 50 to the left and right side edge portions, and is inserted into the fitting concave portion 25a of the middle member 20 from above to fit.

区画壁部５２は、前後方向に長く延びるように形成されている。区画壁部５２の下面は、ミドル部材２０のタンク側壁部２３の上面に接触するように、前側へ行くに従って上に位置するように湾曲した円弧面で構成されている。インナー部材５０の区画壁部５２がミドル部材２０のタンク側壁部２３に接触することで、隣り合う吸気パイプ部２の上流開口部２２ａの間が仕切られることになる。 The partition wall 52 is formed to extend long in the front-rear direction. The lower surface of the partition wall part 52 is comprised by the circular arc surface curved so that it might be located up as it goes to the front side so that the upper surface of the tank side wall part 23 of the middle member 20 may be contacted. When the partition wall portion 52 of the inner member 50 contacts the tank side wall portion 23 of the middle member 20, the upstream opening 22a of the adjacent intake pipe portions 2 is partitioned.

図１２に示すように、インナー部材５０の区画壁部５２の下面には、ミドル部材２０のタンク側壁部２３の溝２３ａに挿入される突条部５２ａが形成されている。インナー部材５０の区画壁部５２の下面の前部には、係合凹部５２ｂが設けられている。係合凹部５２ｂには、ミドル部材２０の係合凸部２３ｂが挿入された状態で係合する。すなわち、係合凹部５２ｂの内面は係合凸部２３ｂの左右両側面に沿うように形成されており、従って、各係合凹部５２ｂの内面には、係合凸部２３ｂの左右両側面の突出方向中間部に嵌まるように、係合凹部５２ｂの内方へ突出する突起５２ｃ、５２ｃ（図１２にのみ示す）が形成されている。突起５２ｃ、５２ｃの形成により、係合凸部２３ｂの上下方向中間部の幅が狭くなり、これにより、係合凹部５２ｂに挿入した係合凸部２３ｂが係合凹部５２ｂから抜け難くなる。 As shown in FIG. 12, a protrusion 52 a to be inserted into the groove 23 a of the tank side wall 23 of the middle member 20 is formed on the lower surface of the partition wall 52 of the inner member 50. An engagement recess 52 b is provided in the front portion of the lower surface of the partition wall portion 52 of the inner member 50. The engagement recess 52b engages with the engagement protrusion 23b of the middle member 20 inserted. That is, the inner surface of the engaging recess 52b is formed along both the left and right side surfaces of the engaging convex portion 23b. Therefore, the left and right side surfaces of the engaging convex portion 23b protrude from the inner surface of each engaging concave portion 52b. Protrusions 52c and 52c (shown only in FIG. 12) projecting inward from the engaging recess 52b are formed so as to fit in the middle portion in the direction. By forming the protrusions 52c and 52c, the width of the intermediate portion in the vertical direction of the engagement convex portion 23b is narrowed, so that the engagement convex portion 23b inserted into the engagement concave portion 52b is difficult to be removed from the engagement concave portion 52b.

インナー部材５０の左右両側の下面は、ミドル部材２０の膨出部２４の上面に沿って延び、該上面に接触するようになっている。インナー部材５０の左右両側の下面には、ミドル部材２０の膨出部２４の溝２４ａに挿入される突条部５０ａが前後方向に延びるように形成されている。また、インナー部材５０の下面には、ミドル部材２０の横溝２２ｂに挿入される突条部５０ｂが形成されている。突条部５０ｂは、左右方向に延びており、突条部５０ｂの中途部には、突条部５２ａの後端部が連続している。 The lower surfaces of the left and right sides of the inner member 50 extend along the upper surface of the bulging portion 24 of the middle member 20 and come into contact with the upper surface. On the lower surfaces of the left and right sides of the inner member 50, ridges 50a inserted into the grooves 24a of the bulging portion 24 of the middle member 20 are formed so as to extend in the front-rear direction. Further, on the lower surface of the inner member 50, a protruding portion 50b to be inserted into the lateral groove 22b of the middle member 20 is formed. The ridge 50b extends in the left-right direction, and the rear end of the ridge 52a is continuous with the middle of the ridge 50b.

また、インナー部材５０の突条部５０ｂよりも後側には、後述する通路形成部材６０と共にブローバイガス通路Ｒを区画形成するための通路区画部５３が設けられている。この通路区画部５３は、通路形成部材６０の開放部６１を上方から覆って閉塞する板状をなしている。図１０に示すように、通路区画部５３の周縁部には、通路形成部材６０の溝６１ａに挿入される突条部５３ａが形成されている。通路区画部５３の突条部５３ａは、通路形成部材６０の溝６１ａに一致するように、通路区画部５３を全周に亘って囲むように延びている。通路区画部５３の突条部５３ａを通路形成部材６０の溝６１ａに挿入することにより、溝６１ａによって形成された凹に、突条部５３ａによって形成された凸が挿入されて気体の漏れを抑制することができるシール構造、即ち、ラビリンス構造を、通路形成部材６０の開放部６１と、インナー部材５０との間に設けることができる。 Further, a passage partitioning portion 53 for partitioning the blowby gas passage R together with a passage forming member 60 described later is provided on the rear side of the protrusion 50b of the inner member 50. The passage partition 53 has a plate shape that covers and closes the opening 61 of the passage forming member 60 from above. As shown in FIG. 10, a ridge 53 a to be inserted into the groove 61 a of the passage forming member 60 is formed at the peripheral edge of the passage partition 53. The protrusion 53a of the passage partition 53 extends to surround the passage partition 53 over the entire circumference so as to coincide with the groove 61a of the passage forming member 60. By inserting the protrusion 53a of the passage partition 53 into the groove 61a of the passage forming member 60, the protrusion formed by the protrusion 53a is inserted into the recess formed by the groove 61a, thereby suppressing gas leakage. A seal structure that can be formed, that is, a labyrinth structure, can be provided between the opening 61 of the passage forming member 60 and the inner member 50.

インナー部材５０の下面には、係合爪５５が下方へ突出するように形成されている。係合爪５５は、通路形成部材６０の係合片６４の形成箇所に対応するように配置されており、係合片６４の係合孔６４ａに挿入された状態で該係合孔６４ａの周縁部に係合するようになっている。 An engaging claw 55 is formed on the lower surface of the inner member 50 so as to protrude downward. The engaging claw 55 is disposed so as to correspond to the position where the engaging piece 64 of the passage forming member 60 is formed, and the periphery of the engaging hole 64a is inserted in the engaging hole 64a of the engaging piece 64. It engages with the part.

尚、図示しないが、インナー部材５０に係合孔を設け、通路形成部材６０に、インナー部材５０の係合孔に係合する係合爪部を設けてもよい。 Although not shown, the inner member 50 may be provided with an engagement hole, and the passage forming member 60 may be provided with an engagement claw portion that engages with the engagement hole of the inner member 50.

（インテークマニホールドの製造要領）
次に、インテークマニホールド１の製造要領について説明する。ロアー部材１０及びミドル部材２０を周知の振動溶着機（図示せず）にセットし、ロアー部材１０のロアー側溶着フランジ１１ａの上面と、ミドル部材２０のミドル側溶着フランジ２１ａの下面とを振動溶着する。 (Intake manifold manufacturing procedure)
Next, the manufacturing procedure of the intake manifold 1 will be described. The lower member 10 and the middle member 20 are set in a known vibration welding machine (not shown), and the upper surface of the lower welding flange 11a of the lower member 10 and the lower surface of the middle welding flange 21a of the middle member 20 are vibration welded. To do.

また、図１１に示すように、インナー部材５０に通路形成部材６０を組み付けておく。このとき、通路形成部材６０の溝６１ａに、インナー部材５０の突条部５３ａを挿入するとともに、インナー部材５０の係合爪５５を通路形成部材６０の係合孔６４ａに挿入して係合させる。これにより、通路形成部材６０がインナー部材５０に固定され、通路形成部材６０の開放部６１がインナー部材５０の通路区画部５３によって閉塞されてブローバイガス通路Ｒが区画形成される。尚、ロアー部材１０及びミドル部材２０を溶着する工程と、インナー部材５０に通路形成部材６０を組み付ける工程とは、どちらかを先に行ってもよいし、並行して行ってもよい。 Further, as shown in FIG. 11, the passage forming member 60 is assembled to the inner member 50. At this time, the protrusion 53a of the inner member 50 is inserted into the groove 61a of the passage forming member 60, and the engaging claw 55 of the inner member 50 is inserted into the engaging hole 64a of the passage forming member 60 to be engaged. . As a result, the passage forming member 60 is fixed to the inner member 50, the opening 61 of the passage forming member 60 is closed by the passage partition 53 of the inner member 50, and the blow-by gas passage R is formed. Note that either the step of welding the lower member 10 and the middle member 20 and the step of assembling the passage forming member 60 to the inner member 50 may be performed first or in parallel.

その後、通路形成部材６０が組み付けられたインナー部材５０をミドル部材２０に組み付ける。すなわち、インナー部材５０をミドル部材２０の下側周壁部２２の内部に挿入していく。このとき、ミドル部材２０の各係合凸部２３ｂが、インナー部材５０の各係合凹部５２ｂにそれぞれ挿入されていき、インナー部材５０をミドル部材２０に対して挿入方向に強く押し付けることで、係合凸部２３ｂの拡大部２３ｃが係合凹部５２ｂの突起５２ｃ、５２ｃを弾性変形させながら乗り越えて突起５２ｃ、５２ｃよりも上方に位置すると、突起５２ｃ、５２ｃの形状が復元する。これにより、拡大部２３ｃが係合凹部５２ｂの内面に係合して強固に固定される。 Thereafter, the inner member 50 to which the passage forming member 60 is assembled is assembled to the middle member 20. That is, the inner member 50 is inserted into the lower peripheral wall portion 22 of the middle member 20. At this time, each engaging convex portion 23b of the middle member 20 is inserted into each engaging concave portion 52b of the inner member 50, and the inner member 50 is strongly pressed against the middle member 20 in the inserting direction. When the enlarged portion 23c of the mating convex portion 23b moves over the projections 52c and 52c of the engagement concave portion 52b while elastically deforming and is positioned above the projections 52c and 52c, the shapes of the projections 52c and 52c are restored. As a result, the enlarged portion 23c engages with the inner surface of the engaging recess 52b and is firmly fixed.

尚、図示しないが、上述した場合とは逆に、インナー部材５０に係合凸部を形成し、ミドル部材２０に係合凹部を形成してもよい。 Although not shown, contrary to the case described above, an engagement convex portion may be formed on the inner member 50 and an engagement concave portion may be formed on the middle member 20.

同時に、インナー部材５０の突条部５２ａがミドル部材２０の溝２３ａに挿入され、インナー部材５０の突条部５０ａがミドル部材２０の溝２４ａに挿入され、インナー部材５０の突条部５０ｂがミドル部材２０の横溝２２ｂに挿入される。これにより、インナー部材５０がミドル部材２０に対して位置ずれし難くなる。また、インナー部材５０の左右両側がそれぞれミドル部材２０の段部２２ｄに嵌まる。 At the same time, the protrusion 52a of the inner member 50 is inserted into the groove 23a of the middle member 20, the protrusion 50a of the inner member 50 is inserted into the groove 24a of the middle member 20, and the protrusion 50b of the inner member 50 is inserted into the middle 50. It is inserted into the lateral groove 22b of the member 20. Thereby, the inner member 50 is less likely to be displaced with respect to the middle member 20. Further, the left and right sides of the inner member 50 are fitted into the stepped portions 22d of the middle member 20, respectively.

さらに、インナー部材５０の挟持部５１の嵌合凸部５１ａがミドル部材２０の受け部２５の嵌合凹部２５ａに挿入されて嵌合する。尚、図示しないが、上述した場合とは逆に、インナー部材５０に嵌合凹部を形成し、ミドル部材２０に嵌合凸部を形成してもよい。 Furthermore, the fitting convex part 51a of the clamping part 51 of the inner member 50 is inserted and fitted into the fitting concave part 25a of the receiving part 25 of the middle member 20. Although not shown, contrary to the case described above, a fitting recess may be formed in the inner member 50 and a fitting protrusion may be formed in the middle member 20.

次いで、上記振動溶着機を用いて、ミドル部材２０の溶着用突条部２２ｃにアッパー部材４０の被溶着部４０ａを溶着する。ミドル部材２０とアッパー部材４０を振動溶着機の治具に保持する。このとき、インナー部材５０の挟持部５１がミドル部材２０の受け部２５によって下方から支持されるとともに、嵌合凸部５１ａが嵌合凹部２５ａに嵌合しているので、インナー部材５０の挟持部５１がミドル部材２０に対してしっかりと固定されることになる。従って、振動溶着時に、インナー部材５０がミドル部材２０に対して位置ずれし難くなるので、ミドル部材２０とアッパー部材４０とを振動溶着機で相対的に振動させる際、インナー部材５０とアッパー部材４０も相対的に振動させることができる。これにより、インナー部材５０の挟持部５１をアッパー部材４０の被溶着部４０ａに確実に溶着することができる。そして、インナー部材５０の挟持部５１がミドル部材２０とアッパー部材４０とに挟持される。 Next, the welded portion 40 a of the upper member 40 is welded to the welding protrusion 22 c of the middle member 20 using the vibration welding machine. The middle member 20 and the upper member 40 are held by a jig of a vibration welding machine. At this time, the holding portion 51 of the inner member 50 is supported from below by the receiving portion 25 of the middle member 20, and the fitting convex portion 51a is fitted into the fitting concave portion 25a. 51 is firmly fixed to the middle member 20. Accordingly, since the inner member 50 is less likely to be displaced with respect to the middle member 20 during vibration welding, when the middle member 20 and the upper member 40 are caused to vibrate relatively with the vibration welding machine, the inner member 50 and the upper member 40. Can also be vibrated relatively. Thereby, the clamping part 51 of the inner member 50 can be reliably welded to the welded part 40 a of the upper member 40. Then, the sandwiching portion 51 of the inner member 50 is sandwiched between the middle member 20 and the upper member 40.

尚、インナー部材５０の挟持部５１をミドル部材２０に予め溶着してもよい。また、インナー部材５０の挟持部５１をミドル部材２０とアッパー部材４０の両方に溶着してもよい。また、溶着順序は適宜設定することができ、上述した順序に限られるものではない。 Note that the clamping portion 51 of the inner member 50 may be welded to the middle member 20 in advance. Further, the sandwiching portion 51 of the inner member 50 may be welded to both the middle member 20 and the upper member 40. Further, the welding order can be set as appropriate, and is not limited to the order described above.

（実施形態の作用効果）
この実施形態では、インナー部材５０に、ミドル部材２０とアッパー部材４０とに挟持される挟持部５１と、該挟持部５１からサージタンク部３の内部へ向けて延びる区画壁部５２とを設け、サージタンク部３の壁部に係合凸部２３ｂを設け、区画壁部５２に係合凹部５２ｂを設け、係合凸部２３ｂの拡大部２３ｃを係合凹部５２ｂの内面に係合させるようにしている。これにより、係合凸部２３ｂが係合凹部５２ｂから抜け難くなるので、従来のようにレーザー光による溶着をすることなく、インナー部材５０の区画壁部５２をサージタンク部３の壁部に強固に固定することができ、サージタンク部３の内面から浮き上がらないようにすることができる。 (Effect of embodiment)
In this embodiment, the inner member 50 is provided with a sandwiching portion 51 sandwiched between the middle member 20 and the upper member 40, and a partition wall portion 52 extending from the sandwiching portion 51 toward the inside of the surge tank portion 3, An engagement convex portion 23b is provided on the wall portion of the surge tank portion 3, an engagement concave portion 52b is provided on the partition wall portion 52, and the enlarged portion 23c of the engagement convex portion 23b is engaged with the inner surface of the engagement concave portion 52b. ing. This makes it difficult for the engaging convex portion 23b to come out of the engaging concave portion 52b, so that the partition wall portion 52 of the inner member 50 is firmly attached to the wall portion of the surge tank portion 3 without welding by laser light as in the prior art. And can be prevented from floating from the inner surface of the surge tank portion 3.

また、ミドル部材２０の内部に、インナー部材５０の挟持部５１を受ける受け部２５を設け、受け部２５に嵌合凹部２５ａを形成し、挟持部５１に嵌合凸部５１ａを形成したので、インナー部材５０の挟持部５１をミドル部材２０の受け部２５によってしっかりと受けることができ、強固に振動溶着できる。 In addition, since the receiving portion 25 that receives the sandwiching portion 51 of the inner member 50 is provided inside the middle member 20, the fitting concave portion 25 a is formed in the receiving portion 25, and the fitting convex portion 51 a is formed in the sandwiching portion 51. The sandwiching portion 51 of the inner member 50 can be firmly received by the receiving portion 25 of the middle member 20, and vibration welding can be performed firmly.

また、ブローバイガス通路Ｒを形成するにあたり、ミドル部材２０及びアッパー部材４０とは別部材の通路形成部材６０を設けたので、ミドル部材２０及びアッパー部材４０の肉厚を厚くすることなく、ブローバイガス通路Ｒの形状を自由に設定してブローバイガスを吸気に混合させることができる。ミドル部材２０及びアッパー部材４０の肉厚を厚くせずに済むので熱収縮による変形が抑制され、ミドル部材２０及びアッパー部材４０を振動溶着したときのシール性を向上させることができる。 Further, when forming the blow-by gas passage R, since the passage forming member 60 is provided separately from the middle member 20 and the upper member 40, the blow-by gas is not increased without increasing the thickness of the middle member 20 and the upper member 40. The shape of the passage R can be freely set, and blow-by gas can be mixed with the intake air. Since it is not necessary to increase the thickness of the middle member 20 and the upper member 40, deformation due to heat shrinkage is suppressed, and the sealing performance when the middle member 20 and the upper member 40 are vibration welded can be improved.

また、インテークマニホールド１を使用する際には、エンジンのブローバイガスがミドル部材２０のブローバイガス導入筒部２６及び通路形成部材６０の接続筒部６６を介してブローバイガス通路Ｒに流入する。ブローバイガス通路Ｒに流入したブローバイガスは、ブローバイガス通路Ｒを下流側へ流れて各突出筒部６３の内部に形成されている接続孔６２を流通して各吸気パイプ部２に流入する。このとき、突出筒部６３の端部内面の近傍の少なくとも下流側の面に湾曲面６３ｂが設けられているので、ブローバイガスを吸気パイプ部２に向けてスムーズに流して効率良く吸気に混合させることができる。 Further, when the intake manifold 1 is used, the blowby gas of the engine flows into the blowby gas passage R through the blowby gas introduction cylinder portion 26 of the middle member 20 and the connection cylinder portion 66 of the passage formation member 60. The blow-by gas that has flowed into the blow-by gas passage R flows downstream through the blow-by gas passage R, flows through the connection holes 62 formed inside the protruding cylindrical portions 63, and flows into the intake pipe portions 2. At this time, since the curved surface 63b is provided at least on the downstream side surface in the vicinity of the inner surface of the end portion of the protruding cylindrical portion 63, the blow-by gas is smoothly flowed toward the intake pipe portion 2 to be efficiently mixed with the intake air. be able to.

また、通路形成部材６０の接続孔６２と、連通孔２１ｂとの間にラビリンス構造を設けているので、溶着することなく、接続孔６２を流通するブローバイガスが接続孔６２と連通孔２１ｂとの間から漏れにくくなる。 Further, since the labyrinth structure is provided between the connection hole 62 of the passage forming member 60 and the communication hole 21b, the blow-by gas flowing through the connection hole 62 without welding is formed between the connection hole 62 and the communication hole 21b. It becomes hard to leak from between.

また、通路形成部材６０の開放部６１と、インナー部材５０との間にラビリンス構造を設けているので、溶着することなく、ブローバイガス通路Ｒを流通するブローバイガスが開放部６１とインナー部材５０との間から漏れにくくなる。 Further, since the labyrinth structure is provided between the opening 61 of the passage forming member 60 and the inner member 50, the blow-by gas flowing through the blow-by gas passage R is not welded to the opening 61 and the inner member 50. It becomes hard to leak from between.

尚、上記実施形態では、直列４気筒エンジン用のインテークマニホールドについて説明したが、これに限らず、本発明は多気筒エンジン用のインテークマニホールドに適用することができる。 In the above embodiment, the intake manifold for an in-line four-cylinder engine has been described. However, the present invention is not limited to this, and the present invention can be applied to an intake manifold for a multi-cylinder engine.

上述の実施形態はあらゆる点で単なる例示に過ぎず、限定的に解釈してはならない。さらに、特許請求の範囲の均等範囲に属する変形や変更は、全て本発明の範囲内のものである。 The above-described embodiment is merely an example in all respects and should not be interpreted in a limited manner. Further, all modifications and changes belonging to the equivalent scope of the claims are within the scope of the present invention.

以上説明したように、本発明に係る樹脂製インテークマニホールドは、例えば自動車用エンジンのインテークマニホールドとして使用することができる。 As described above, the resin intake manifold according to the present invention can be used as, for example, an intake manifold of an automobile engine.

１樹脂製インテークマニホールド
２吸気パイプ部
３サージタンク部
１０ロアー部材
２０ミドル部材（第１分割体）
２３ｂ係合凸部
２３ｃ拡大部
２５受け部
２５ａ嵌合凹部
４０アッパー部材（第２分割体）
５０インナー部材
５１挟持部
５１ａ嵌合凸部
５２区画壁部
５２ｂ係合凹部
６０通路形成部材 DESCRIPTION OF SYMBOLS 1 Resin-made intake manifold 2 Intake pipe part 3 Surge tank part 10 Lower member 20 Middle member (1st division body)
23b Engaging convex part 23c Enlarged part 25 Receiving part 25a Fitting concave part 40 Upper member (second divided body)
50 Inner member 51 Clamping part 51a Fitting convex part 52 Partition wall part 52b Engaging concave part 60 Passage forming member

Claims

In a surge tank integrated resin intake manifold (1) having an intake pipe portion (2) and a surge tank portion (3) to which the upstream end of the intake pipe portion (2) is connected,
At least the surge tank part (3) is formed by vibration welding the first divided body (20) and the second divided body (40) made of resin,
Inside the surge tank portion (3), a resin inner member (50) is provided,
The inner member (50) includes a sandwiching portion (51) sandwiched between the first divided body (20) and the second divided body (40) and vibration welded to at least one of the sandwiched portion (51). A partition wall (52) for extending toward the inside of the surge tank (3) and partitioning the upstream end of the intake pipe (2);
One of the partition wall (52) and the wall of the surge tank (3) is provided with an engagement recess (52b), and the other is inserted into the engagement recess (52b). An engagement convex part (23b) to be engaged is provided,
An enlarged portion (23c) enlarged as compared with the base end side is provided on the distal end side in the protruding direction of the engaging convex portion (23b), and the enlarged portion (23c) is formed on the inner surface of the engaging concave portion (52b). A resin intake manifold (1) characterized by being engaged.

The resin intake manifold (1) according to claim 1,
Inside the first divided body (20) is provided a receiving portion (25) for receiving the clamping portion (51) of the inner member (50) from the side opposite to the second divided body (40),
A fitting projection (51a) is formed on one of the receiving portion (25) and the clamping portion (51) of the inner member (50), and the fitting projection (51a) is fitted on the other. A resin intake manifold (1) characterized in that a mating recess (25a) is formed.