JP2880411B2 - Air cleaner hose with resonator, method of manufacturing the same, and mold structure for manufacturing the same - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an air cleaner hose with a resonator, in which a resonator as a silencer is integrated, a method of manufacturing the same, and a mold structure for manufacturing the same.

[0002]

2. Description of the Related Art In a secondary hose for engine intake,
In some cases, a muffling device such as a resonator that applies the Helmholtz resonance principle is installed to muffle the intake sound. In such a case, conventionally, a mounting structure in which the resin resonator 2 is fitted to the rubber or resin air cleaner hose 3 has been generally used (FIG. 11).

[0003]

However, since the air cleaner hose 3 and the resonator 2 are separate bodies, the fitting portion requires a hose clamp 91, a reinforcing collar 92 for preventing creep deformation, and the like. Required these assembling operations. For this reason, there has been an attempt to blow-mold the resonator 2 and the air cleaner hose 3 integrally. However, a large-diameter parison was extruded, and burrs appeared on the bellows portion 34 in the conventional all-burr method. as a result,
There was a defect that the thickness of the parting portion of the bellows portion 34 was increased and the bending in the parting direction was poor.

SUMMARY OF THE INVENTION The present invention solves the above-mentioned problems, and maintains the flexibility of the bellows portion by preventing burrs from appearing on the bellows portion, and furthermore, obtains an integrally molded product of the air cleaner hose and the resonator, thereby reducing costs. It is characterized by providing an air cleaner hose with a resonator for reducing the amount, a method for manufacturing the same, and a mold structure for manufacturing the same.

[0005]

The air cleaner hose with a resonator according to the first aspect of the present invention is manufactured by blow molding, and the bellows portion provided at least at both ends of the air cleaner hose and at a part thereof has a small swell ratio. While being formed of a resin material, a straight pipe portion of an air cleaner hose extending to the bellows portion and a hollow resonator connected to and integrally formed with the straight pipe portion are formed of a resin material having a large swell ratio. It is characterized by being formed by. here,
"Swell ratio" refers to the ratio of the diameter D [mmφ] of the actually extruded parison to the diameter d [mmφ] of the die for extruding the parison (FIG. 3). “The resin material having a small swell ratio” refers to a resin material having a swell ratio of 1.0 to
1.5 refers to a resin material, for example, a material such as polyolefin-based thermoplastic elastomer (TPO) and low-density polyethylene (LDPE). The “resin material having a large swell ratio” refers to a resin material having a swell ratio exceeding 1.5, for example, a material such as polypropylene (PP) or high-density polyethylene (HDPE).

A mold structure for an air cleaner hose with a resonator according to the second aspect of the present invention is a blow molding mold for the air cleaner hose with a resonator according to the first aspect of the present invention, wherein the resonator and a straight pipe connected to the resonator are integrated. The mold part to be blow-molded is divided from the other mold parts and constitutes a mold slide part which can be slid in the mold dividing direction by the driving means.

A method of manufacturing an air cleaner hose with a resonator according to the third aspect of the present invention uses the mold of the second aspect of the present invention, wherein the mold slide portion is slid back from another mold portion, and then the die is moved from the die. A parison of a resin material having a small swell ratio is extruded, and while moving the mold, this parison is inserted into the cavity relating to the bellows portion from the fitting portion of one end, and after the parison passes through the bellows portion, the swell ratio is large. Switching to the resin material parison, extruding the parison onto the cavity of the mold slide part, and then switching to the resin material with a small swell ratio again just before entering the other end fitting part, and then to the other end fitting part After extruding the parison into the cavity, the other mold portion is closed, and then the mold slide portion is advanced and closed simultaneously with or subsequent to air blowing. Characterized in that it. "Moving the mold" means that the mold can be moved relative to the parison, and includes the case where the parison moves.

[0008]

According to the air cleaner hose with a resonator according to the present invention, the method for manufacturing the same, and the mold structure for manufacturing the same, the resonator and the straight pipe to which the resonator is connected are made of a parison made of a resin material having a large swell ratio. On the other hand, since both ends are fitted with a parison made of a resin material having a small swell ratio, the resonator part secures a large-diameter parison while using the same die, and is formed in the bellows part. Can be installed small parison without burr. Also, when a mold part for integrally blow-molding the resonator part and the straight pipe part to which the resonator part is connected is separated from other mold parts as a mold slide part and slidable in the mold split direction, first, the resonator At the time of disposing the parison in the portion, the mold slide portion is retracted to allow the parison to float in the air, so that the parison can be prevented from hitting the mold and flattening. Then, after closing the other mold portion, the mold slide portion is closed at the same time as or subsequent to the air blowing, whereby the parison is shaped into a desired shape, and the air cleaner hose with the resonator is formed. Be able to build.

[0009]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described below in detail based on embodiments.
1 to 10 show an air cleaner hose with a resonator according to the present invention, a method for manufacturing the same, and a mold structure for manufacturing the same. FIG. 1 shows a split mold 1 for blow molding having a cavity in the shape of an air cleaner hose with a resonator, which is a molded product. Here, only a lower mold 1a is shown.
The mold structure is composed of a resonator 2 and a straight pipe section 3 to which the resonator 2 is connected.
1 is divided into a mold part 11 for integrally blow-molding and another mold part 12, and the mold part 11 can be slid in the mold-separating direction by using a known air drive means (not shown). The mold slide portion 11a is provided. Incidentally, a hydraulic pressure or the like can be used as the driving means. Only the mold parts 12, 12 are fixed to the base 1c.

The mold slide portion 11a is formed by forming a large-diameter parison 6 in the cavity 5a corresponding to the resonator 2 and the cavity 5b of the straight pipe portion 31 to which the cavity 5a is connected.
This is to prevent the parison 6a from being flattened and thinned due to contact with the mold 1 when the parison is arranged. When the mold is closed, the mold slide portion 11
a closes behind the mold part 12 so that the parison 6a
And the resonator 2 and the straight pipe portion 31 are integrally formed.

Reference numerals 5c and 5d denote fitting portions 32 and 3 at both ends.
A cavity corresponding to 3 and a reference numeral 5e are cavities corresponding to the bellows portion 34. It is desirable that the outer diameter of the parison 6 including the tube following the cavity is small, and is provided in the mold portion 12. In the peripheral edges of the cavities 5a and 5b, biting projections 112 are formed. This is for cutting off unnecessary portions of the parison 6 that become burrs f when the mold is closed, and fusing necessary edges. Reference numeral 13 denotes the upper mold 1b when the mold is closed.
3 shows an engagement pin with the above. The lower die 1a is provided with a moving mechanism (not shown) that can freely move in a two-dimensional horizontal direction at a predetermined distance downward from the die 7.

Next, a method for manufacturing an air cleaner hose with a resonator using the mold 1 will be described. First,
The mold slide portion 11a slides back from the position of the other mold portions 12 and moves closer to the base 1c (FIG. 1). Next, a soft resin material having a small swell ratio, such as a polyolefin-based thermoplastic elastomer (TPO) (AES (Advanced Elastomer Syst
ems), Product name: "Santoprene" Product model number: 1
01-80, 101-87, 101-75) are extruded in a molten state. Then, the lower die 1a is moved by the moving mechanism, and the parison 6b is connected to the fitting portion 3 of one terminal.
2 from the cavity 5c of the bellows portion 34 into the cavity 5e of the bellows portion 34 (FIG. 2). The soft material was
This is for giving the bellows part 34 flexibility. Parison 6
When arranging b, care must be taken not to protrude outside the cavities 5c and 5e. Here, when the molten resin is extruded from the die 7, the outer diameter D of the parison 6b extruded by the ballast effect is generally larger than the diameter d of the die 7 (FIG. 3). However, the swell ratio of the used polyolefin-based thermoplastic elastomer (TPO) was about 1.
Because it is 1, it is not so noticeable.

When the parison 6b has been arranged in the cavity 5e of the bellows 34, the parison 6 is then switched to a resin material having a large swell ratio. Along with this, a parison 6a having a large diameter corresponding to the resonator 2 and the straight pipe portion 31 is extruded from the die 7 (FIG. 4). Since the resonator 2 requires rigidity, a block copolymer polypropylene (PP) (manufactured by Idemitsu Petrochemical Co., product model number: E-250G, or Showa Denko Co., product model number: S) is used as the resin material.
K711). The switching of the resin material was performed using a known two-layer blow molding head 8 (FIG. 5). The inner layer extruder 81 that has supplied the polyolefin-based thermoplastic elastomer (TPO) is stopped, and the outer layer extruder 82 is operated to pour the block copolymer polypropylene (PP). Then, the lower mold 1a is moved to the parison 6
a is arranged on the cavities 5a and 5b (FIG. 4). Since the mold slide portion 11a is retracted, the parison 6a floats on the cavities 5a and 5b. Such a parison 6a is larger than the cavity shape,
When the mold slide portion 11a is closed, the parison (burr f) that protrudes outside the cavities 5a and 5b into the bite protrusion 112 is formed.
).

After that, the parison 6a is arranged on the mold slide portion 11a, and immediately before entering the cavity 5d of the fitting portion 33 at the other end, the resin material of the parison 6 is returned to the original polyolefin-based material having a small swell ratio. Switch to thermoplastic elastomer (TPO). With this switching, the parison 6b is changed to a parison 6b having a small diameter, and the parison 6b is connected to the cavity 5d corresponding to the fitting portion 33 at the other end.
(Fig. 6). The parison 6b is housed in the cavity 5d so as not to protrude from the cavity 5d.

By the way, the parison 6 accompanying the above-mentioned two switchings forms a shape in which a corresponding portion of the resonator 2 and the straight pipe portion 31 swells, but a material having a small swell ratio, here a polyolefin-based thermoplastic elastomer (TPO). )When,
Regarding the cross-sectional structure of a material having a large swell ratio, here, a block copolymer polypropylene (PP), any of (a) and (b) in FIG. 7 may be used. FIG. 7A shows a completely switching structure, and FIG. 7B shows a two-layer structure of the entire parison 6, and the swell ratio is changed by changing each thickness.

At the stage when the parison 6 has been arranged on the lower mold 1a, the mold portion 12 is closed. Then, simultaneously with the air blowing from the air blowing nozzle 19 attached to the mold,
Alternatively, at a point in time after a short delay, the mold slide portion 11a slides out to close the mold, and blow molding is performed (FIG. 8). The parison 6 is placed in the cavity 5 by closing the mold part 12.
b is included, and the mold slide portion 11
With the closing of a, a cavity-shaped body corresponding to the resonator 2 and the straight pipe portion 31 is formed in the mold, and
A burr f is formed on the outer side of the body 2. By blowing air into the parison 6, the parison 6 bulges outward and is shaped into an air cleaner hose A with a resonator. In addition, air blowing is performed by the mold mounting blowing nozzle 19. Reference numeral 14 denotes a parison holding clamp.

When the molded body is cooled, removed from the mold, and taken out, a blow-molded product is obtained in which the resonator 2 and the straight pipe portion 31 are integrated and a burr f is formed around them (FIG. 9). ), By removing the burrs f and the discarded bags g, a desired air cleaner hose A with a resonator is formed.

In the air cleaner hose A with the resonator thus completed, not only the fitting portions 32 and 33 at both ends of the air cleaner hose 3 but also the bellows portion 34 are made of a polyolefin thermoplastic elastomer (T) having a small swell ratio.
PO) and parison 6b in cavities 5c, 5d and 5e.
Burrs are not generated in such a portion even by blow molding (FIGS. 9 and 1).
0). In addition, since the polyolefin-based thermoplastic elastomer (TPO) is a soft resin, the bellows portion 34 has flexibility and flexibility. On the other hand, the straight pipe portion 31 of the air cleaner hose 3 extending to the bellows portion 34 and the portion of the resonator 2 connected to and integrally formed with the straight portion 31 are made of a block copolymer polypropylene (PP) having a large swell ratio. The parison 6a is crushed and expanded by closing the mold slide portion 11a, and the resonator 2, the air cleaner hose through which the hollow resonator 2 communicates with the straight pipe portion 31 in the subsequent blow molding. 3 of the desired product. Since the resonator 2 is made of a hard resin, it has a predetermined rigidity.

The air cleaner hose A with the resonator constructed as described above is an integrally molded product of the air cleaner hose 3 and the resonator 2, and not only does not require a hose clamp and a creep deformation reinforcing ring, which are conventionally required.
The installation work has also been released, and low cost and labor saving have been advanced. Further, by combining materials having different swell ratios and forming a mold structure in which the bellows portion 34 and the fitting portions 32 and 33 do not have burrs f, the flexibility of the bellows portion 34 and the fitting portion 3 are improved.
The sealing function of 2,33 is no longer impaired.
In addition, by selecting a hard material having a large swell ratio for the resonator 2 portion, and selecting a soft material having a small swell ratio for the bellows 34,
While the required rigidity was ensured, the bellows portion 34 was able to have flexibility.

In the present invention, the present invention is not limited to the above-described embodiment, but can be variously changed within the scope of the present invention depending on the purpose and application. In the embodiment, the parison 6 is disposed in the cavity 5 by moving the lower mold 1a, but the head of the parison 6 may be moved while fixing the lower mold 1a.
The resonator 2 may be used not only for reducing intake noise, but also for reducing exhaust noise and the like.

[0021]

As described above, the air cleaner hose with the resonator, the method of manufacturing the same, and the mold structure for manufacturing the same according to the present invention can obtain an integrally molded product of the resonator and the air cleaner hose while securing the flexibility of the bellows. So that
It has excellent effects, such as reducing the number of parts, eliminating assembly work, and reducing product costs.

[Brief description of the drawings]

FIG. 1 is a perspective view of a lower mold for manufacturing an air cleaner hose with a resonator shown in an embodiment.

FIG. 2 is a perspective view showing a state in which a parison is provided in a cavity relating to a bellows portion.

FIG. 3 is a cross-sectional view showing a relationship between a die and a parison.

FIG. 4 is a perspective view showing a state in which a parison is provided in a cavity related to a resonator.

FIG. 5 is a sectional view of a two-layer head for blow molding.

FIG. 6 is a perspective view showing a state in which a parison has been arranged in a cavity of a lower mold.

FIG. 7 is a sectional structural view of a parison.

FIG. 8 is a perspective view of a closed state.

FIG. 9 is a perspective view of a blow-molded product taken out from the mold.

FIG. 10 is a perspective view of an air cleaner hose with a resonator.

FIG. 11 is an explanatory cross-sectional view showing a state where a conventional resonator and an air cleaner hose are fitted to each other.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Mold 11 Mold part 11a Mold slide part 12 Mold part 2 Resonator 3 Air cleaner hose 31 Straight pipe part 32 Fitting part 33 Fitting part 34 Bellows part 5 Cavity 6 Parison 7 Dice

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁶ Identification code FI F01N 1/02 F01N 1/02 F02M 35/12 F02M 35/12 B // B29K 21:00 101: 00 (58) Fields surveyed (Int.Cl. ⁶ , DB name) B29D 23/00-23/24 B29C 49/00-49/80 F01N 1/02 F02M 35/12

Claims (3)

(57) [Claims] An air cleaner hose is formed by blow molding, and at least a bellows portion provided at at least both ends of the air cleaner hose and a part thereof is formed of a resin material having a small swell ratio, and is extended to the bellows portion. An air cleaner hose with a resonator, wherein a straight pipe portion of the air cleaner hose and a hollow resonator connected to the straight pipe portion and integrally formed are formed of a resin material having a large swell ratio. 2. The air cleaner hose according to claim 1, wherein at least both ends of the air cleaner hose and a bellows part provided at a part thereof are formed of a resin material having a small swell ratio, and a straight pipe part of the air cleaner hose extending at the bellows part. And a blow-molding mold for an air cleaner hose with a resonator in which the hollow body connected to the straight pipe portion and integrally formed with the hollow resonator are formed of a resin material having a large swell ratio. An air cleaner with a resonator, in which a mold portion for integrally blow molding a straight pipe portion connected to the resonator is divided from another mold portion and constitutes a mold slide portion slidable in a mold splitting direction by a driving means. Hose mold structure. 3. A mold slide part which is formed by integrally blowing a resonator and a straight pipe part connected to the resonator with another mold part, and which can be slid in a mold direction by a driving means. Using the mold of an air cleaner hose with a resonator that constitutes the above, the mold slide portion is slid back from the other mold portion, and then a parison of a resin material having a small swell ratio is extruded from the die, and While moving the mold, the parison is inserted from the fitting portion of one end into the cavity relating to the bellows portion, and after the parison has passed through the bellows portion, the parison is switched to a parison made of a resin material having a large swell ratio, and the mold slide portion is formed. The parison is extruded onto the cavity of the above, and then, immediately before entering the fitting portion at the other end, the parison is again switched to a parison made of a resin material having a small swell ratio, and After the parison is extruded into the cavity, the other mold portion is closed, and then the mold slide portion is advanced simultaneously with or subsequent to the air blowing to close the mold. Of manufacturing an air cleaner hose with a resonator.