JP2020033878A - Intake manifold - Google Patents

Abstract

To surely prevent burrs from being exposed to the outside from a joining region of first and second divided bodies which are vibration-welded, in an intake manifold.SOLUTION: An intake manifold 10 is constituted by the vibration-welding of a first flange part 26 of a first casing 12 composed of a resin-made material, and a second flange part 36 of a second casing 14 to each other. The second flange part 36 protrudes to the outside of a width direction, and comprises: a second base part 38; a welding wall 40 protruding to the first flange part 26 side with respect to the second base part 38, and welded to the first flange part 26 at its lower end part; one set of stopper walls 42a, 42b arranged outside the width direction and inside the radial direction of the welding wall 40 at the second base part 38, and extending toward the first flange part 26 side; and a guide part 44 which is circular in a cross section, and formed so as to straddle the other end part of the welding wall 40 and the second base part 38.SELECTED DRAWING: Figure 2

Description

  The present invention relates to an intake manifold made of a resin material for supplying intake air to a plurality of cylinder chambers of an internal combustion engine.

  2. Description of the Related Art Conventionally, in a multi-cylinder engine such as an automobile, an intake manifold is provided between an intake port of a cylinder head and a throttle valve for adjusting an intake air amount, and the intake air taken into the intake manifold is divided to divide each intake air. Allocated to ports.

  Such an intake manifold is formed by joining first to third divided pieces made of a resin material to each other, as disclosed in Patent Document 1, for example, and forms a surge tank and a bend from the surge tank. And a branch portion extending like this. The first divided piece forms the lower half when divided vertically along the central axis of the intake manifold, and the second divided piece forms the upper half with respect to the central axis.

  Then, ribs are respectively formed along the outer edges of the first and second divided pieces, and the ridges provided on the ribs of the second divided piece are inserted into the concave grooves provided on the ribs of the first divided piece. By applying vibration to the second divided pieces in a state where they are inserted and brought into contact with each other, the tips of the ridges are welded to the concave grooves and joined to each other.

JP-A-8-49610

  However, in the above-described intake manifold, for example, as shown in FIG. 8, burrs generated by melting the tips of the ridges at the time of vibration welding have cross sections provided on both sides in the width direction of the ridges. By extending toward the arc-shaped groove, the tip is guided to the widthwise outside and the widthwise inside on both sides of the second divided piece along the groove, respectively, so that the second divided piece and the It is apprehended that the air may protrude outside the intake manifold from the open gap with the one divided piece. If these burrs are exposed to the outside of the intake manifold, there is a problem that the quality is deteriorated.On the other hand, if they are exposed to the side of the passage inside the intake manifold, the burrs protrude into the passage and air is released. There is a problem that intake resistance when flowing to the internal combustion engine is generated.

  SUMMARY OF THE INVENTION The present invention has been made in consideration of the above-described problem, and provides an intake manifold that can surely prevent exposure of burrs to the outside from a joining portion of a first and a second divided body subjected to vibration welding. The purpose is to provide.

In order to achieve the above object, an aspect of the present invention comprises a first and a second divided body made of a resin material, and has a passage through which air flows inside, and a joining end of the first divided body. And the joining end of the second split body is joined to each other by vibration welding,
At the joint end of the first and second divided bodies, first and second joint flanges extending in a width direction substantially orthogonal to the extending direction of the passage are provided so as to face each other,
A base portion extending in the width direction;
A welding wall protruding toward the second joint flange side with respect to the base portion, one end of which is welded to the second joint flange;
A set of stopper walls provided at the base portion on the outer side in the width direction and the inner side in the width direction of the welding wall, and extending toward the second joint flange side;
A guide portion formed so as to connect the other end of the welding wall and the base portion, and extending in a direction away from the second joining flange toward the stopper wall from the welding wall;
Is provided.

  According to the present invention, in the intake manifold in which the first and second divided bodies made of a resin material are joined to each other by vibration welding, the first and second divided bodies extend in the width direction. The first joining flange is joined to the first joining flange via a base portion, a welding wall protruding toward the second joining flange side from the base portion and being welded at one end, and a welding wall at the base portion. And a stopper wall provided on the outer side in the width direction and the inner side in the width direction, and protruding toward the second joint flange, and a guide portion is formed so as to connect the other end of the welding wall and the base portion.

  Then, when the first joint flange of the first divided body and the second joint flange of the second divided body are vibration-welded, the other end of the welding wall is melted by frictional heat under the action of contact with the second joint flange. Then, even when the molten resin material is generated from the contact portion between the welding wall and the second joining flange as a burr toward the first joining flange, the tip of the burr comes into contact with the guide portion. It is locked by contacting the stopper wall after being suitably guided to the stopper wall side.

  As a result, the tip of the burr generated by the vibration welding is locked by the stopper wall of the first joint flange, so that the outer end in the width direction from the gap opened between the first joint flange and the second joint flange. In addition, it is possible to reliably prevent the projection from protruding inward in the width direction and being exposed.

  According to the present invention, the following effects can be obtained.

  That is, when the first joint flange of the first divided body and the second joint flange of the second divided body that constitute the intake manifold are vibration-welded, the welding wall formed on the first joint flange and the second joint flange are joined together. The burr generated from the contact portion extends toward the first joint flange side, contacts the guide portion, and preferably guides it to the stopper wall side, thereby restricting further movement.

  As a result, the tip of the burr generated by the vibration welding is locked to the stopper wall of the first joint flange, so that the gap opened between the first joint flange and the second joint flange during the joining operation As a result, it is possible to reliably prevent the protrusion of the burrs to the outside and the exposure, so that it is possible to avoid a decrease in quality and at the same time to prevent burrs from entering the passage.

1 is an overall front view of an intake manifold according to an embodiment of the present invention. FIG. 2 is a cross-sectional view of the vicinity of first and second flange portions along line II-II in FIG. 1. 3A to 3D are explanatory views of the operation when the first flange portion and the second flange portion of FIG. 2 are joined by vibration welding. It is an expanded sectional view showing the neighborhood of the 1st and 2nd flange parts of an intake manifold concerning a modification.

  A preferred embodiment of an intake manifold according to the present invention will be described in detail with reference to the accompanying drawings. In FIG. 1, reference numeral 10 indicates an intake manifold according to an embodiment of the present invention.

  This intake manifold 10 is used in, for example, a four-cylinder internal combustion engine having four cylinder chambers mounted on a vehicle or the like, and as shown in FIGS. 1 and 2, first and second casings 12 and 14. Are joined in the vertical direction (directions of arrows A and B).

  The first and second casings 12 and 14 are formed of, for example, a resin material such as a thermoplastic resin, and have a branch pipe 16 having a plurality of branch passages, and one end of the branch pipe 16 is connected to each other to allow air to flow. A surge tank 18 that is temporarily stored, a first connection portion 20 provided at one end along the extension direction of the surge tank 18 and connected to a throttle valve (not shown), and a surge tank 18 at the other end of the branch pipe 16. And a second connection portion 22 formed and connected to each cylinder chamber of the internal combustion engine (not shown).

  The first casing (second divided body) 12 is provided on the lower side (in the direction of arrow A) of the intake manifold 10 and forms a part of the surge tank 18 and the branch pipe 16, and extends along the outer edge of the first casing wall 24. Thus, a first flange portion (second joining flange) 26 is formed.

  As shown in FIGS. 2 to 3D, the first flange portion 26 protrudes outward (in the direction of arrow C <b> 1) in the width direction substantially orthogonal to the extending direction of the first casing 12 with respect to the first casing wall 24. A first base portion 28 connected to the first casing wall 24 and extending substantially in the horizontal direction, and a pair of cover walls 30a and 30b formed on the outer edge in the width direction and the inner edge in the width direction of the first base portion 28. Prepare. That is, the first flange portion 26 forms a U-shaped cross-sectional groove portion 32 that opens toward the second flange portion 36 (in the direction of arrow B) from the pair of cover walls 30a, 30b and the first base portion 28. ing.

  The pair of cover walls 30a and 30b are respectively connected to the first base portion 28 so as to be substantially orthogonal to each other, and protrude toward the second casing 14 (in the direction of arrow B) at the same height. In addition, the one cover wall 30a is provided so as to be outside in the width direction, and the other cover wall 30b is provided so as to be inside in the width direction.

  The second casing (first divided body) 14 is provided on the upper side (in the direction of arrow B) of the intake manifold 10 so as to face the first casing 12 and constitutes a part of the branch pipe 16. A second flange portion (first joining flange) 36 is formed along the outer edge of the groove 34.

  The second flange portion 36 projects outward (in the direction of arrow C1) in the width direction substantially perpendicular to the extending direction of the second casing 14 with respect to the second casing wall 34, and is connected to the second casing wall 34 to be substantially horizontal. A second base portion 38 extending in the direction, a welding wall 40 formed at the center in the width direction of the second base portion 38 and projecting toward the first casing 12 (in the direction of arrow A); It has a pair of stopper walls 42a and 42b formed on the outer edge in the width direction and the inner edge in the width direction.

  The welding wall 40 is formed in a plate shape having a predetermined width in the width direction (the directions of the arrows C1 and C2), and is substantially orthogonal to the end surface of the second base portion 38, and both side surfaces in the width direction are formed on the end surface. On the other hand, they are connected to each other by a guide section 44 having a circular arc cross section. The guide portion 44 is formed with a relatively large radius so as to form a gentle arc.

  The welding wall 40 extends at a predetermined height and a constant width toward the first casing 12 side (in the direction of the arrow A), and is joined to the first flange portion 26 by vibration welding.

  The pair of stopper walls 42a and 42b are respectively connected so as to be substantially orthogonal to the second base portion 38, protrude toward the first casing 12 side (in the direction of arrow A) at the same height, and have a welding wall. Each of them is spaced apart from each other in the width direction outside (in the direction of arrow C1) and in the width direction (in the direction of arrow C2) by a predetermined distance. Note that one stopper wall 42a is provided on the outside in the width direction, and the other stopper wall 42b is provided on the inside in the width direction.

  When joining the second casing 14 to the first casing 12, the lower ends of the stopper walls 42a, 42b are formed so as to face the upper ends of the cover walls 30a, 30b.

  In addition, the stopper walls 42a and 42b have corner portions 46 formed substantially at right angles to the connection portion with the end surface of the second base portion 38, respectively.

  Further, in the second flange portion 36, the height of the welding wall 40 with respect to the second base portion 38 is formed to be higher than the height of the stopper walls 42a, 42b, and the welding to the lower ends of the stopper walls 42a, 42b. The height H1 (projection length) of the wall 40 is formed higher than the height H2 of the cover walls 30a, 30b from the first base portion 28 in the first flange portion 26 (H1> H2), and is shown in FIG. 3B. The tip of the welding wall 40 is formed so as to be able to contact the first base portion 28 of the first flange portion 26 so that the welding wall 40 can contact the first base portion 28.

  The intake manifold 10 according to the embodiment of the present invention is basically configured as described above. Next, the first casing 12 and the second casing 14 constituting the intake manifold 10 are welded by vibration. Will be described with reference to FIGS. 2 to 3D.

  First, as shown in FIG. 3A, the first flange portion 26 of the first casing 12 is fixed using a jig or the like (not shown) in a state where the first flange portion 26 faces upward, while the second flange portion 36 is fixed. The second casing 14 is positioned and fixed to the vibrating device so as to face downward, and the first flange portion 26 of the first casing 12 and the second flange portion 36 of the second casing 14 are vertically aligned ( (Directions of arrows A and B).

  More specifically, the stopper walls 42a and 42b of the second flange portion 36 and the cover walls 30a and 30b of the first flange portion 26 are arranged so as to face each other in the vertical direction (the directions of arrows A and B).

  Then, as shown in FIG. 3B, by lowering the second casing 14 toward the first casing 12 together with a vibration device (not shown), the welding wall 40 of the second flange 36 is formed in the groove of the first flange 26. 32, the lower end of the welding wall 40 is brought into contact with the first base portion 28 of the first flange portion 26, and is pressed downward (in the direction of arrow A). At this time, the lower end of the welding wall 40 is in surface contact with the first base portion 28.

  In a state where pressure is applied downward from the second casing 14 to the first casing 12, the vibration device is driven under the control of a controller (not shown) to vibrate the second casing 14 at a predetermined amplitude and a predetermined frequency. Let it. As a result, a vibration force is applied to the welding wall 40 of the second casing 14, and frictional heat is generated on the contact surface between the lower end thereof and the first base portion 28 of the first casing 12 to start melting, thereby causing vibration welding. Done.

  In the process of the vibration welding, as shown in FIG. 3C, the lower end of the welding wall 40 is gradually melted by frictional heat generated between the welding wall 40 and the first base portion 28, and the length thereof is shortened. The second casing 14 descends gradually and approaches the first casing 12 side. At the contact portion between the lower end of the welding wall 40 melted by the frictional heat and the first base portion 28, the resin material melted from between the both side surfaces of the welding wall 40 and the first base portion 28 becomes burrs D. And is extended toward the second flange portion 36 side (the direction of arrow B).

  As shown in FIGS. 3C and 3D, the burrs D extend upward (in the direction of arrow B), for example, so as to be separated from the contact portions, and the tips thereof are provided at the guide portions 44 of the second flange portion 36. After being guided to the stopper walls 42a and 42b on the outer side and the inner side in the width direction along the end face of the second base portion 38 by being in contact with the second base portion 38, the second base portion 38 is locked by being hooked on the corner portion 46 (FIG. 2).

  Therefore, the tips of the burrs D generated by the vibration welding are locked to the stopper walls 42a, 42b (the corner portions 46) of the second flange portion 36, so that the stopper walls 42a, 42b are in the middle of the vibration welding. The burrs D are prevented from protruding outside and inside the first and second flange portions 26 and 36 through a gap 48 opened between the first flange portion 26 and the cover walls 30a and 30b of the first flange portion 26. You.

  Then, as shown in FIG. 2, the tip of the welding wall 40 is further melted, and the second casing 14 is lowered accordingly, so that the stopper walls 42 a and 42 b become the upper ends of the cover walls 30 a and 30 b in the first flange portion 26. , The first casing 12 and the second casing 14 are integrally joined by vibration welding. At this time, the generated burrs D are housed in a space formed between the first flange portion 26 and the second flange portion 36, and do not protrude outside and inside the intake manifold 10 and are not exposed.

  As described above, in the present embodiment, in the intake manifold 10 formed by joining the first and second casings 12 and 14 made of a resin material to each other by vibration welding, the width direction of the second casing 14 The second flange portion 36 protruding outward (in the direction of arrow C1) has a second base portion 38 and projects toward the first flange portion 26 (in the direction of arrow A) with respect to the second base portion 38. A welding wall 40 to which a lower end is welded is provided on the outer side in the width direction (arrow C1 direction) and on the inner side in the width direction (arrow C2 direction) of the welding wall 40 in the second base portion 38, and the first flange portion 26 side ( A pair of stopper walls 42a and 42b projecting in the direction of arrow A) is formed, and a guide portion 44 having an arc-shaped cross section is formed so as to connect the welding wall 40 and the second base portion 38.

  Accordingly, when the first flange portion 26 of the first casing 12 and the second flange portion 36 of the second casing 14 are vibration-welded, the welding wall 40 comes into contact with the first flange portion 26 while vibrating. The lower end of the welding wall 40 is gradually melted by the frictional heat, and a burr D made of a molten resin material is generated at a contact portion between the lower end of the welding wall 40 and the first base portion 28 of the first flange portion 26, and 2 It extends toward the flange portion 36 side (in the direction of arrow B), and when its tip contacts the guide portion 44 having an arc-shaped cross section, it is suitably guided to the stopper walls 42a and 42b and is caught by the corner portion 46. It is locked by.

  As a result, the tips of the burrs D generated by the vibration welding are locked by the stopper walls 42a, 42b (the corner portions 46) of the second flange portion 36, so that the stopper walls 42a, 42b are in the middle of the vibration welding. From the gap 48 opened between the first flange portion 26 and the cover walls 30a, 30b, the burrs D are outside the first and second flange portions 26, 36 in the width direction (direction of arrow C1) and in the width direction (in the direction of arrow C1). The projection is prevented from protruding in the direction of arrow C2).

  Therefore, a decrease in quality due to the exposure of the burrs D to the outside of the intake manifold 10 is avoided, and further, the burrs D are prevented from entering the passage side inside the intake manifold 10, so that the burrs D are formed in the passages. Is prevented from becoming an intake resistance when air flows into the internal combustion engine.

  Further, in the second flange portion 36, the second base portion 38 and the upper end of the welding wall 40 are connected by a guide portion 44 having an arc-shaped cross section, so that they are connected at right angles to each other without providing the guide portion 44. The connection strength can be increased in comparison. Therefore, sufficient strength can be ensured when the welding wall 40 is vibration-welded to the second flange portion 36. Accordingly, when the second casing 14 is vibrated by the vibration device, the welding wall 40 is welded. By ensuring sufficient strength, it is possible to reliably perform welding by vibration welding.

  Further, the second flange portion 36 is provided with a corner portion 46 formed at a substantially right angle at a connection portion between the second base portion 38 and the stopper walls 42a and 42b. The tip of the burr D generated so as to extend toward the side can be securely hooked and locked by the corner portion 46. Therefore, the burrs D generated inside the first and second flange portions 26 and 36 enter the gap 48 opened between the first flange portion 26 and the second flange portion 36 during the vibration welding operation. And can be more reliably prevented from being exposed to the outside.

  Further, in the first flange portion 26, a connecting portion between the pair of cover walls 30a, 30b and the first base portion 28 is also provided with a guide portion 44a (see a two-dot chain line shape in FIG. 2), similarly to the second flange portion 36. ) May be provided. That is, by providing the guide portion 44a also on the first flange portion 26, when the burrs D generated at the time of vibration welding proceed toward the first flange portion 26, they separate from the cover walls 30a, 30b. The burr D can be guided in a direction (a direction away from the gap 48, the center side in the width direction), and the burr D can be prevented from being exposed to the outside.

  On the other hand, the first and second flange portions 26 and 36 in the first and second casings 12 and 14 are not limited to the case where the first and second flange portions 26 and 36 are formed in the above-described shape. For example, the intake manifold 70 shown in FIG. As shown in the figure, the first flange portion 74 of the first casing 72 has a projection 82 projecting from the center in the width direction of the first base portion 76 toward the second flange portion 80 of the second casing 78 (in the direction of arrow B). May be provided, and the second flange portion 80 may be provided with a tapered guide portion 84 that connects both side surfaces of the welding wall 40 and the end surface of the second base portion 38.

  The protrusion 82 of the first flange portion 74 is formed, for example, in a rectangular shape in cross section, and is formed so as to protrude upward (in the direction of arrow B) at a predetermined height.

  The guide portion 84 of the second flange portion 80 is inclined linearly in a direction away from the first flange portion 74 (direction of arrow B) toward the stopper walls 42a and 42b from both side surfaces in the width direction of the welding wall 40. Both ends in the width direction are connected to the corners 46. In other words, the end of the welding wall 40 connected to the second base portion 38 is formed in a tapered shape inclined in a direction away from the first flange portion 74.

  Next, in a case where the first and second casings 72 and 78 having the first and second flange portions 74 and 80 according to the above-described modification are joined by vibration welding, the second welding is performed in the process of vibration welding. The lower end of the welding wall 40 of the flange portion 80 starts to gradually melt by frictional heat generated between the first flange portion 74 and the projection 82 of the first base portion 76, and the lower end of the welding wall 40 melted by the frictional heat. At the contact portion with the protrusion 82, the burr D, which is a resin material melted from between the both side surfaces of the welding wall 40 and the first base portion 76, toward the second flange portion 80 (in the direction of arrow B). It is generated to extend.

  The tips of the burrs D, for example, extend upward and come into contact with the tapered guide portions 84, respectively, so that the outer ends in the width direction (in the direction of the arrow C1) and the inner sides in the width direction (in the direction of the arrow C2). And is locked by being hooked on a corner 46 formed between the stopper walls 42a and 42b.

  Therefore, the tips of the burrs D generated by the vibration welding are locked to the stopper walls 42a, 42b of the second flange portion 80, so that the stopper walls 42a, 42b and the first flange portion 74 are in the middle of the vibration welding. The burr D is prevented from protruding outside and inside the first and second flange portions 74 and 80 through the gap 48 opened between the cover walls 30a and 30b.

  Then, the distal end of the welding wall 40 is further melted, and the second casing 78 descends accordingly, and the stopper walls 42a, 42b abut against the upper ends of the cover walls 30a, 30b in the first flange portion 74, whereby the first The casing 72 and the second casing 78 are connected by vibration welding.

  As described above, the guide portion 44 having an arc-shaped cross section is provided, or the tapered guide portion is inclined in a direction (arrow B direction) gradually separating from the first flange portion 74 toward the stopper walls 42a and 42b. Providing 84 makes it possible to reliably and suitably guide the tip of the burr D generated during the vibration welding to the stopper walls 42a, 42b side, and to be locked by the stopper walls 42a, 42b.

  In addition, the intake manifold according to the present invention is not limited to the above-described embodiment, but may adopt various configurations without departing from the gist of the present invention.

10, 70 ... intake manifold 12, 72 ... first casing 14, 78 ... second casing 26, 74 ... first flange 28, 76 ... first base 30a, 30b ... cover wall 32 ... groove 34 ... second casing Walls 36, 80: Second flange portion 38: Second base portion 40: Welding walls 42a, 42b: Stopper walls 44, 44a, 84: Guide portion 46: Corner portion 82: Projection D: Burr

Claims (4)

It is composed of first and second divided bodies made of a resin material, and has a passage through which air flows inside, so that the joined end of the first divided body and the joined end of the second divided body vibrate each other. In the intake manifold joined by welding,
At the joint end of the first and second divided bodies, first and second joint flanges extending in a width direction substantially orthogonal to the extending direction of the passage are provided so as to face each other,
A base portion extending in the width direction, the first joining flange;
A welding wall protruding toward the second joint flange side with respect to the base portion, one end of which is welded to the second joint flange;
A set of stopper walls provided on the base portion on the outside in the width direction and on the inside in the width direction of the welding wall, and extending toward the second joint flange side;
A guide portion formed so as to connect the other end portion of the welding wall and the base portion, and extending in a direction away from the second joining flange toward the stopper wall from the welding wall;
An intake manifold comprising: The intake manifold according to claim 1,
An intake manifold, wherein a corner is formed at a connection portion between the base portion and the stopper wall. The intake manifold according to claim 1 or 2,
The intake manifold, wherein the guide portion is formed in an arc-shaped cross section or in a tapered shape gradually inclined toward the stopper wall side in a direction away from the second joint flange. The intake manifold according to any one of claims 1 to 3,
The second joining flange includes a second base portion,
A second stopper wall extending toward the first joint flange side with respect to the second base portion, and connecting an end of the second stopper wall to the second base portion; An intake manifold in which a second guide is formed at a position facing the guide.

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