JP2587389B2 - Method of manufacturing intake manifold - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing an intake manifold used for an internal combustion engine of an automobile or the like.

[0002] In this specification, the term "aluminum" shall include aluminum alloys in addition to pure aluminum. In this specification, the term “extended material” refers to an article formed by plastic working such as extrusion, impact extrusion, forging, and pressing.

[0003]

2. Description of the Related Art Conventionally, as an intake manifold, an intake manifold generally manufactured by casting using a sand mold or a mold has been used.

[0004] However, since the surface of the cast product is rough, it is necessary to finish at least the inner surface of the cast product to reduce the air resistance for improving the air intake efficiency, which is troublesome. There was a problem. Moreover, since it is impossible to finish the entire inner surface of the intake manifold smoothly in view of its shape, it has not been possible to sufficiently reduce the air resistance for improving the intake efficiency. Further, in a cast product, the thickness of the peripheral wall cannot be reduced to a certain limit or more due to the flowability of the molten metal at the time of casting, so that there is a problem that the weight increases.

Therefore, one end is closed and the other end is opened, a plurality of holes are formed in a straight line in the peripheral wall, and a branch pipe connecting cylindrical outward projection is integrally formed around each hole. An intake air having a formed aluminum wrought plenum chamber and a plurality of aluminum wrought branch pipes each connected to the plenum chamber with one end inserted into a branch pipe connecting cylindrical outward projection. Manifold was considered. The plenum chamber in this intake manifold is:
After forming a plurality of bulges by performing bulging on the peripheral wall of the aluminum wrought pipe, a hole is formed in the closed wall at the tip of the bulged portion, and a portion around the hole in the closed wall at the end is formed by burring. Is formed by bending outwardly and expanding its tip to form a tubular outwardly projecting portion for connecting a branch pipe. One end of the branch pipe is fitted into the branch pipe connecting cylindrical outer projection, and both are brazed. However, in this intake manifold, there is a problem that the bulging process for forming the tubular outwardly projecting portion for connecting the branch pipe on the aluminum wrought material pipe is troublesome, and the processing equipment cost is increased.

An object of the present invention is to provide a method of manufacturing an intake manifold which solves the above-mentioned problems.

[0007]

According to a method of manufacturing an intake manifold according to the present invention, one end is closed by a closing body, the other end is opened, and a plurality of holes are formed in a peripheral wall in a straight line. An aluminum wrought plenum chamber in which a cylindrical outer projection for branch pipe connection is integrally formed around the hole, and one end is inserted into the cylindrical outer projection for branch pipe connection to form a plenum chamber. A method of manufacturing an intake manifold having a plurality of connected aluminum wrought branch pipes, the method comprising producing two extruded aluminum materials having a substantially semicircular cross section, and pressing one of the materials. Forming a plurality of tubular bulges whose ends are closed by applying a straight line, and forming a hole in the center of the cylindrical bulge of the one material except the peripheral edge of the distal end closing wall. Opening, The remaining portion around the hole of the closed wall in the cylindrical bulging portion of one material is subjected to burring to form a cylindrical outer projection for connecting a branch pipe, and both materials are brazed to each other. The formation of a tubular body,
It is characterized in that the brazing of the closing body to one end of the tubular body and the brazing of the branch pipe to the outward projection by inserting the branch pipe into the cylindrical outward projection for branch pipe connection are performed simultaneously. Is what you do.

According to another method of manufacturing an intake manifold according to the present invention, one end is closed and the other end is opened, and a plurality of holes are formed in a straight line in a peripheral wall, and a branch pipe is connected around each hole. And a plurality of aluminum extensions connected to the plenum chamber with one end inserted into the branch tube connection cylindrical outward projection and having one end inserted into the branch pipe connecting cylindrical outward projection. A method of manufacturing an intake manifold having a drawn material branch pipe,
Pressing an aluminum plate to form a first material having a substantially semicircular cross section, and pressing the aluminum plate to form a plurality of cylindrical bulges having a substantially semicircular cross section and a closed end. Making a second material having a protruding portion formed in a straight line, making a hole in a central portion of the cylindrical portion of the second material excluding a peripheral portion of a distal end closing wall; By burring the remaining portion of the cylindrical bulging portion of the material around the hole of the closing wall to form a cylindrical outward projection for connecting the branch pipe, and by brazing the two materials to each other Simultaneous formation of the tubular body, closing of one end of the tubular body, and brazing of the branch pipe to the outwardly protruding part by inserting the branch pipe into the cylindrical outwardly protruding part for branch pipe connection. It is a feature.

[0009]

According to the method of manufacturing the intake manifold of the first invention, a plurality of aluminum extruded members each having a substantially semicircular cross section are subjected to press working to one of the two materials, the ends of which are closed. The cylindrical bulge is formed in one straight line,
A hole is made in the center of the cylindrical bulging portion of the one material except the peripheral edge of the tip closing wall, and a burring process is performed on a remaining portion around the hole of the closing wall in the cylindrical bulging portion of the one material. Is performed to form a cylindrical outwardly projecting portion for branch pipe connection, so that it is not necessary to perform bulge processing to form the cylindrically outwardly projecting portion. In addition, the formation of the tubular body by brazing the two materials to each other, the brazing of the closing body to one end of the tubular body, and the insertion of the branch pipe into the cylindrical outer projection for connecting the branch pipe. Since the branch pipe is brazed to the outward projection at the same time,
The brazing operation can be performed at once.

According to the method of manufacturing an intake manifold of the second invention, a plurality of tubular bulges having a substantially semicircular cross section and a closed end are linearly formed by pressing an aluminum plate. The formed second material is made, and a hole is made at a central portion of the cylindrical closed bulging portion of the second material except for a peripheral edge of the distal end closing wall, and a hole is formed in the cylindrical bulging portion of the second material. Since the remaining portion around the hole of the closing wall is subjected to burring to form the cylindrical outer projection for connecting the branch pipe, it is not necessary to perform bulging to form the cylindrical outer projection. Further, to form a tubular body by brazing the two materials to each other, to close one end of the tubular body, and to insert the branch pipe into the cylindrical outer protrusion for connecting the branch pipe to the outer protrusion. And the brazing of the branch pipe are performed at the same time, so that the brazing operation can be performed at once.

[0011]

Embodiments of the present invention will be described below with reference to the drawings.

FIG. 1 shows an intake manifold manufactured by the method of the present invention.

In FIG. 1, an intake manifold (1) has one end closed and the other end open, a plurality of holes (3) formed in a peripheral wall, and a branch pipe around each hole (3). A cylindrical plenum chamber (2) integrally provided with a connecting tubular outer projection (4) and one end thereof are fitted and connected to the branch pipe connecting tubular outer projection (4). And a plurality of branch pipes (5) made of wrought aluminum.

The plenum chamber (2) includes a tubular body (6).
And a closed body (7) made of wrought aluminum material that closes one end of the opening. The tubular body (6) is formed by joining two aluminum wrought component members (8) and (9) each of which is vertically divided into two parts by a vertical plane including an axis. The cylindrical outwardly protruding portion (4) is formed on one of the constituent members (8), and has an expanded portion (4a) formed at the tip thereof. At the open end of the plenum chamber (2), a tubular body (1
1) is fixed. One end of the cylindrical member (11) has a flange
(12) is provided. A throttle body with a built-in throttle valve (not shown) is mounted on the throttle body mounting tubular member (11), and an air supply pipe from an air cleaner is connected to the throttle body. The tip of each branch pipe (5) is collectively connected to one connecting member (13) for mounting to the cylinder head of the engine, and each branch pipe (5) is connected through this connecting member (13). It is connected to a cylinder head of an engine (not shown). The connecting member (13) may be made of any of an aluminum wrought material and an aluminum casting. The connection member (13) has a rectangular shape and four holes (not shown).
And a branch pipe connecting cylindrical protrusion (14) integrally provided around the hole. At the end of the protruding part (14)
(14a) is provided. Further, a fuel injection device insertion port (15) is formed above each protruding portion (14) of the connection member (13). Then, the branch pipe (5) is inserted into the expanded pipe part (14a) at the tip of the protruding part (14) and brazed.

Next, a first method of manufacturing such an intake manifold (1) will be described with reference to FIGS.

First, two aluminum extrusion materials 20 and 21 having a substantially semicircular cross section are prepared. Flanges (22) and (23) are integrally provided on both side edges of both materials (20) and (21) (see FIG. 2). Then, a plurality of tubular bulges (24) in which one material (20) is subjected to press working and the tip is closed
Are formed in a straight line (see FIG. 3). Then, the cylindrical bulge
After making a hole in the center of the closed wall at the tip end except for the peripheral edge of (24), the remaining portion around the hole in the closed wall is burred so as to be flush with the peripheral wall of the bulging portion. Bends the bulges to form a tube-shaped outward projection for connecting a branch pipe.
(4) and a hole (3) is formed. Thereafter, the distal end of the cylindrical outwardly protruding portion (4) is expanded to form an expanded portion (4a). Finally, a sizing process is performed on the expanded portion (4a) using a sizing tool to make both the inner and outer contours of the cross section of the expanded portion (14) into perfect circles. Then, the blanks (20) and (21) are brazed with flanges (22) and (23) to form a tubular body (6), and a closure (7) is brazed. Also, at the same time as brazing the two materials (20) and (21) and brazing the closure (7), brazing the branch pipe (5) to the cylindrical outward projection (4),
Brazing the tubular body (11) for mounting the throttle body to the plenum chamber (2) and brazing the connecting member (13) to the branch pipe (5). Thus, the intake manifold (1) is manufactured.

The second method of manufacturing the intake manifold (1) is as follows. That is, the aluminum plate is pressed to produce a material having a semicircular cross section as shown in FIG. 3 and a material having a semicircular cross section and having a plurality of cylindrical bulges. Thereafter, it is manufactured in the same manner as in the first method described above.

In the case of the second method, the following is also possible. That is, by pressing the aluminum plate, as shown in FIG. 4, a first material (25) having a semicircular cross section and a plurality of cylindrical expansion members having a semicircular cross section and having a closed end are provided. A second material (26) in which the protrusion (27) is formed in a straight line is formed. When producing both materials (25) and (26), semicircular closures (28) and (29) are integrally formed at one end of both materials (25) and (26). In addition, each material (2
5) Flanges (30), (31), (32), and (33) are integrally provided on both side edges of (26) and the straight portions of the closing bodies (28) and (29), respectively.
Next, after making a hole in the center of the tubular bulging portion (27) except for the peripheral edge in the tip closing wall, the remaining portion around the hole in the closing wall is subjected to burring and the peripheral wall of the bulging portion. The bulging portion is bent outward so as to be flush with each other to form a tubular outward projecting portion (4) for connecting a branch pipe, and a hole (3) is formed. Thereafter, the distal end of the cylindrical outwardly protruding portion (4) is expanded to form an expanded portion (4a). Finally, a sizing process is performed on the expanded portion (4a) using a sizing tool to make both the inner and outer contours of the cross section of the expanded portion (14) into perfect circles. And
Both materials (25) and (26) are brazed together with flanges (30) and (31) to form a tubular body (6), and the closed bodies (28) and (29) are flanged together (32) and (33). Brazing with In addition, both materials (25)
(26) Brazing and closing body (28) (29) Simultaneously with brazing, braid of branch pipe (5) to cylindrical outward projection (4), brazing to plenum chamber (2) Brazing the throttle body mounting cylinder (11) and connecting members (1
3) Brazing is performed. Thus, the intake manifold (1) is manufactured. However, in this intake manifold (1),
One end of the tubular body (6) is closed by (28) and (29).

[0019]

According to the method of manufacturing the intake manifold of the present invention, it is not necessary to perform bulge processing when forming the cylindrical outwardly projecting portion for connecting the branch pipe. Is also cheaper. Further, since the brazing operation can be performed at one time, the operation is facilitated.

Moreover, since the inner surface can be easily polished before joining the materials constituting the plenum chamber, the smoothness of the inner surface of the plenum chamber is improved,
The intake efficiency is improved. Furthermore, the plenum chamber of the intake manifold manufactured by the method of the present invention can be made thinner than a conventional casting, and the weight can be reduced.

[Brief description of the drawings]

FIG. 1 is a perspective view showing an intake manifold manufactured by a first method of the present invention.

FIG. 2 is a cross-sectional view showing an intermediate stage of the first method of the present invention.

FIG. 3 is a cross-sectional view showing another stage in the middle of the first method of the present invention.

FIG. 4 is a perspective view showing a modification of the second method of the present invention at an intermediate stage.

[Explanation of symbols]

 (1) Intake manifold (2) Plenum chamber (3) Hole (4) Outer cylindrical projection for connecting branch pipe (5) Branch pipe (6) Cylindrical body (20) Material (21) Material (24) Tube (25) Material (26) Material (27) Cylindrical bulge

 ──────────────────────────────────────────────────続 き Continuation of the front page (56) References JP-A-63-268966 (JP, A) JP-A-63-101080 (JP, A) Fully open 1987-36044 (JP, U) Really open Showa 57- 188950 (JP, U)

Claims (2)

(57) [Claims] 1. One end is closed by a closing body and the other end is open, and a plurality of holes are formed in a straight line in a peripheral wall, and a cylindrical outwardly projecting portion for connecting a branch pipe is formed around each hole. Are formed integrally with each other, and a plurality of aluminum wrought branch pipes each connected to the plenum chamber with one end inserted into the branch pipe connection cylindrical outward projection. A method of manufacturing an intake manifold provided with a plurality of tubular extruded materials having two semi-circular cross-sections made of extruded aluminum; Forming the projecting portion in a straight line, making a hole in the center excluding the peripheral edge of the distal end closing wall of the cylindrical bulging portion of the one material, and forming a hole in the cylindrical bulging portion of the one material. Survival around holes in closed walls To form a tubular outward projection for branch pipe connection, and to form a tubular body by brazing the two materials to each other, and to form a closed body at one end of the tubular body. A method for manufacturing an intake manifold, comprising simultaneously performing brazing and brazing a branch pipe to an outwardly protruding portion by inserting the branch pipe into a cylindrical outwardly protruding portion for connecting a branch pipe. 2. One end is closed and the other end is open. A plurality of holes are formed in a straight line in a peripheral wall, and a branch pipe connecting cylindrical outward projection is integrally formed around each hole. An intake air having a formed aluminum wrought plenum chamber and a plurality of aluminum wrought branch pipes each connected to the plenum chamber with one end inserted into a branch pipe connecting cylindrical outward projection. A method of manufacturing a manifold, comprising: forming a first material having a substantially semi-circular cross section by pressing an aluminum plate; and forming a first material having a substantially semi-circular cross section by similarly pressing the aluminum plate. Forming a second material in which a plurality of tubular bulges are closed in a straight line, and a central portion of the tubular bulge of the second material excluding a peripheral edge of a distal end closing wall. Drilling holes in A burring process is performed on a remaining portion of the cylindrical bulging portion of the second material around the hole of the closing wall to form a cylindrical outer projection for connecting a branch pipe, and the two materials are brazed to each other. Simultaneously forming the tubular body, closing one end of the tubular body, and brazing the branch pipe to the outer protrusion by inserting the branch pipe into the tubular outer protrusion for connecting the branch pipe. A method for manufacturing an intake manifold.