JP3610367B2 - Surge tank with built-in resonator - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a surge tank provided in an intake passage of an engine, and more particularly to a surge tank having a built-in resonator for the purpose of improving volumetric efficiency and reducing intake noise.
[0002]
[Related background]
As is well known, a resonator has been put into practical use in order to improve the volume efficiency in a specific rotation region and reduce the intake noise by actively using the pressure wave generated when the intake valve is opened and closed. . This resonator is provided with a box-like resonator chamber independent of the intake passage of the engine. The resonator chamber is a portion in which the passage cross-sectional area immediately upstream of the throttle, for example, is expanded (hereinafter, this portion is referred to as the downstream of the throttle). In order to distinguish it from the surge tank that distributes the intake air on the side to each cylinder, it is connected to the upstream surge tank) by a hose or the like. The resonator chamber volume, the hose inner diameter, and the hose length are set according to the intake system of the engine so that the above-described effect due to the pressure wave is maximized.
[0003]
[Problems to be solved by the invention]
However, the conventional resonator needs to produce an independent resonator chamber as described above, and also requires parts such as a hose and a hose clip for hose retaining. There was a problem that soared.
[0004]
In addition, since the handling of the intake system of the engine is changed if the mounted vehicle type is different, it is inevitably necessary to reset the specifications of the resonator. However, for example, changing the volume of the resonator chamber means remanufacturing the resonator chamber itself, which has been a factor that further increases the manufacturing cost.
An object of the present invention is to provide a surge tank with a built-in resonator that can reduce the manufacturing cost by reducing the number of assembling steps with a simple configuration.
[0005]
[Means for Solving the Problems]
In order to achieve the above object, according to the first aspect of the present invention, a surge tank is formed by a plurality of housings that are divided along the direction from the upstream connection portion toward the downstream connection portion, and the division plate is disposed in the surge tank. Then, the resonator chamber was partitioned and joined with the peripheral edge of the dividing plate abutting against the housing wall, and a communicating portion was provided on the dividing plate to connect the inside of the surge tank and the resonator chamber. Therefore, the simple structure of partitioning the inside of the surge tank with the dividing plate provided with the communication portion is extremely small in number of parts, and can be completed in advance as a single surge tank, and the peripheral portion of the dividing plate The position of the split plate can be changed due to the structure in which the end face is in contact with the housing wall. As a result, the position of the split plate can be changed to adjust the volume of the resonator chamber, or the communication part provided on the split plate It is possible to obtain desired performance simply by changing the specifications.
In the invention of claim 2, the upstream connection portion communicating with the air intake port and the downstream connection portion communicating with the engine side are both disposed on one side of the dividing plate, and the resonator chamber is formed on the other side of the dividing plate. Accordingly, one side of the dividing plate functions as a surge tank to circulate intake air from the upstream connecting portion to the downstream connecting portion, while the other side of the dividing plate functions as a resonator chamber.
In the invention of claim 3, the communicating portion is a communicating hole provided on the upper surface of the dividing plate, and a tubular shape that extends in the direction along the upper surface of the dividing plate so as to conceal the communicating hole and is integrally formed on the dividing plate. An upper mold that forms the upper surface of the divided plate and the outer surface of the tubular member, a lower mold that forms the lower surface and the communication hole of the divided plate, and a core that forms the inner surface of the tubular member According to the injection molding.
Accordingly, the molten resin is injected into a cavity formed by the upper mold, the lower side, and the core to form a divided plate. And while the lower mold is opened downward, the tubular member is extended in the direction along the upper surface of the dividing plate, so that the upper mold can be opened upward and the core can be opened laterally without any trouble. A tubular member is formed at the same time as the dividing plate by the injection molding.
[0006]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, an embodiment of a surge tank with built-in resonator (upstream surge tank) embodying the present invention will be described.
FIG. 1 is a plan view of a surge tank with a built-in resonator in which the upper housing is partially broken, FIG. 2 is a sectional view taken along line II-II in FIG. 1, and FIG. 3 is a sectional view taken along line III-III in FIG. . As shown in these drawings, the upstream surge tank is configured by superposing the upper housing 1 and the lower housing 2 in a monaca shape, and the lower housing 2 has a pair of brackets 3 for attachment to a vehicle. Is provided. Both housings 1 and 2 are injection-molded with a synthetic resin material, and the entire periphery thereof is fixed to each other by ultrasonic welding or the like. A cylindrical upstream connecting portion 4 and a downstream connecting portion 5 are integrally formed in two positions of the upstream surge tank 1 facing each other at approximately 180 degrees in the horizontal direction. The upper half of these connecting portions 4 and 5 is integrally formed with respect to the upper housing 1, and the lower half is integrally formed with respect to the lower housing 2.
[0007]
As shown by a two-dot chain line in FIG. 1, when mounted on a vehicle, an air duct 6 is connected to the upstream connection portion 4, and a throttle body 7 incorporating a throttle valve is connected to the downstream connection portion 5. As indicated by a two-dot chain line arrow, the intake air flows in the upstream surge tank from the upstream connection portion 4 to the downstream connection portion 5 in a substantially horizontal direction, and this flow portion is hereinafter referred to as an intake flow passage 8.
[0008]
In the upstream surge tank, a partition wall 9 is formed in the vertical direction near the upstream connection portion 4, and the partition wall 9 divides the first resonator chamber 10 with respect to the intake flow passage 8. A curved first communication pipe 11 is provided on the bottom surface of the first resonator section chamber 10, one end of the first communication pipe 11 is in the first resonator chamber 10, and the other end is in the intake flow passage 8. As a result, the inside of the first resonator chamber 10 communicates with the inside of the intake flow passage 8 via the first communication pipe 11.
[0009]
The upper half of the partition wall 9 is integrally formed with the upper housing 1 and the lower half is integrally formed with the lower housing 2. The lower half of the first communication pipe 11 is integrally formed with the lower housing 2, and the upper half is manufactured as a separate piece 11a.
On the side of the upper housing 1 in the intake flow passage 8, a dividing plate 12 is disposed substantially horizontally from the upstream connection portion 4 toward the downstream connection portion 5. The dividing plate 12 cooperates with the vertical wall 13 extending downward from the ceiling surface in the upper housing 1, thereby dividing the second resonator chamber 14 on the upper side of the intake flow passage 8. The outer periphery is fixed to the upper housing 1 at predetermined intervals by ultrasonic welding or the like. The dividing plate 12 is injection-molded with a synthetic resin material, and a large number of ribs 12a for securing strength are formed at predetermined intervals on the upper and lower surfaces thereof. The vertical wall 13 may be formed on the divided plate 12 side. In this case, in addition to changing the volume of the housings 1 and 2 in the vertical direction, the volume of the resonator chamber 14 can be changed in the direction of intake air flow only by changing the dividing plate 12.
[0010]
A circular communication hole 15 is formed at a position close to the downstream connection portion 5 of the dividing plate 12, that is, at a position closest to the engine when mounted on the vehicle, and is formed on the upper surface of the dividing plate 12 (on the second resonator chamber 14 side). The second communication pipe 16 having a linear shape is integrally formed so as to conceal the communication hole 15. One end of the second communication pipe 16 opens into the intake flow passage 8 through the communication hole 15, and the other end opens into the second resonator chamber 14. As a result, the second resonator chamber 14 communicates with the second communication chamber 16. It communicates with the inside of the intake flow passage 8 through the hole 15 and the second communication pipe 16. In the present embodiment, the communication hole 15 and the second communication pipe 16 constitute a communication portion, and the inner diameters of the communication hole 15 and the second communication pipe 16 are set to be approximately equal.
[0011]
The configuration of the upstream surge tank is as described above, but the second communication pipe 16 can be injection-molded simultaneously with the divided plate 12 by devising its shape. More specifically, FIG. 4 shows the mutual relationship of the molds during injection molding. The upper mold 21 that forms the upper surface of the divided plate 12 and the outer surface of the second communication pipe 16, the lower surface of the divided plate 12, and Injection molding is performed using the lower mold 22 that forms the communication hole 15 and the core 23 that forms the inner surface of the second communication pipe 16.
[0012]
When the upper mold 21, the lower mold 22, and the core 23 are closed, a cavity corresponding to the entire divided plate 12 including the second communication pipe 16 and the communication hole 15 is formed, and molten resin is injected into the cavity. By doing so, the entire divided plate 12 is formed. In order to take out the divided plate 12 after molding, it is necessary to open the upper mold 21, the lower mold 22, and the core 23, but the lower mold 22 that is not related to the molding of the second communication pipe 16 is naturally. The mold can be opened downward. Further, as is apparent from the drawing, the upper mold 21 and the core 23 are formed so that the second communication pipe 16 is opened laterally along the upper surface of the dividing plate 12. The core 23 can be opened sideways without hindrance. As a result, the second communication pipe 16 is formed simultaneously with the divided plate 12 by one injection molding.
[0013]
On the other hand, the resonator built-in surge tank configured as described above functions as described below when mounted on a vehicle.
Intake air taken in from an air intake port (not shown) passes through an air filter, an air flow meter, and an air duct 6 and flows into the intake flow passage 8 from the upstream connection portion 4 of the upstream surge tank, and then from the downstream connection portion 5 to the throttle body. 7. It is distributed to the intake manifold of each cylinder through the downstream surge tank, and is introduced into the combustion chamber of the engine together with the fuel injected from the injector when the intake valve is opened. At this time, the pressure wave generated with the opening and closing of the intake valve is reflected to the upstream surge tank, reaches the first resonator chamber 10 through the first communication pipe 11, and passes through the second communication pipe 16. After that, it reaches the second resonator chamber 14 and generates resonance in both the resonator chambers 10, 14, thereby improving the volume efficiency in the specific rotation region and reducing the intake noise.
[0014]
Needless to say, the volume of the first and second resonator chambers 10 and 14 and the inner diameter and length of the first and second communication pipes 11 and 16 are set so that the above-mentioned effect by the pressure wave becomes the highest. It is set according to the intake system of the engine.
And since the surge tank with a built-in resonator according to this embodiment is configured as described above, it has the following advantages.
[0015]
First, the upstream surge tank is partitioned by a partition wall 9 and a dividing plate 12 to provide first and second resonator chambers 10 and 14, and the resonator chambers 10 and 14 communicate with the intake flow passage 8. The first and second communication pipes 11 and 16 are formed integrally with the dividing plate 12 and the lower housing 2. As a result, the number of parts is extremely small compared to the conventional resonator that is manufactured by connecting an independent resonator chamber with a hose, and the upstream surge tank alone can be completed in advance. The number of man-hours can be reduced, and as a result, the manufacturing cost can be greatly reduced.
[0016]
As is well known, the dimensions of the resonator (volume of the resonator chambers 10, 14 and inner diameter and length of the communication pipes 11, 16) need to be set according to the handling of the intake system of the mounted vehicle type. The specifications relating to the second resonator chamber 14 can be dealt with simply by changing the dividing plate 12. That is, when the divided plate 12 having the second communication pipe 16 having the optimum inner diameter and length for each vehicle type is manufactured in advance and the divided plate 12 is fixed in the upstream surge tank, it is adapted to the vehicle type. What is necessary is just to determine an up-down position so that the volume 2nd resonator chamber 14 may be formed.
[0017]
As a result, the upper housing 1 and the lower housing 2 can be shared by different vehicle types by preparing only the dividing plate 12 for each vehicle type. Moreover, although the dividing plate 12 needs to be manufactured for each vehicle type, the shape of the second communication pipe 16 is devised as described above, so that it can be easily manufactured by one injection molding, and the above-described cost reduction is further achieved. Can push forward.
[0018]
On the other hand, in this embodiment, the position of the second communication pipe 16 on the dividing plate 12 is set closest to the engine. This is a consideration for causing the pressure wave from the engine to act effectively in the second resonator chamber 14, but if the shape of the dividing plate 12 is determined, the position of the second communication pipe 16 is uniquely determined. Therefore, there is no need to change the position. On the other hand, in consideration of the period of the pressure wave in the intake system, the second communication pipe 16 may be provided at the antinode portion of the period where the pressure wave becomes maximum. In this case, it is necessary to change the position of the second communication pipe 16 in accordance with the intake system of the engine, but the second communication pipe 16 is optimally adapted to each vehicle type, as with the above-described inner diameter and length. If the dividing plate 12 provided at the position is manufactured, the housings 1 and 2 can be shared as described above.
[0019]
This is the end of the description of the embodiment. However, the embodiment of the present invention is not limited to this embodiment. For example, in the above embodiment, the first resonator chamber 10 and the first communication pipe 11 are provided in the upstream surge tank in addition to the second resonator chamber 14 and the second communication pipe 16. The first resonator chamber 10 and the first communication pipe 11 may be omitted as long as the resonance characteristics required for the above can be realized.
[0020]
In the above embodiment, the division plate 12 is arranged in the upper housing 1 to partition the second resonator chamber 14, but the arrangement state of the division plate 12 is not limited to this, for example, A similar dividing plate may be disposed in the lower housing 2 to add a new resonator chamber.
On the other hand, in the above-described embodiment, the second communication pipe 16 is formed to open sideways along the upper surface of the division plate 12 so as to be integrally formed with the division plate 12, but the shape of the second communication pipe 16 is this. For example, it may be formed in a general upright pipe shape.
[0021]
【The invention's effect】
According to the resonator internal surge tank of the invention of claim 1 as described above, because of the simple structure that only divides the surge tank by a dividing plate having a communication unit, on a very small number of parts In addition, the surge tank can be completed in advance to reduce the number of man-hours in the assembly line, and the desired performance can be obtained simply by changing the position of the split plate and the specifications of its communication part. Can be greatly reduced.
According to the surge tank with a built-in resonator according to the third aspect of the present invention, the tubular member can be formed at the same time as the divided plate by one injection molding, so that the manufacturing cost can be further reduced.
[Brief description of the drawings]
FIG. 1 is a partially broken plan view showing a surge tank with a built-in resonator according to an embodiment.
FIG. 2 is a cross-sectional view taken along the line II-II in FIG.
3 is a cross-sectional view taken along line III-III in FIG.
FIG. 4 is an explanatory diagram showing the interrelationship of molds during injection molding.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 Upper housing 2 Lower housing 4 Upstream connection part 5 Downstream connection part 12 Split plate 14 2nd resonator chamber 15 Communication hole (communication part)
16 Second communication pipe (communication portion , tubular member )

Claims (3)

A plurality of housings that are divided along the direction from the upstream connection portion that communicates with the air intake port to the downstream connection portion that communicates with the engine side, and that form a surge tank in which intake air flows;
Is formed along the said direction, dividing plate periphery end face c c Managing walls forming the housing is joined in a state that is not abutting, and are arranged in the surge tank in order to divide the resonator chamber When,
A surge tank with a built-in resonator, comprising a communication portion provided on the dividing plate and communicating with the inside of the surge tank and the resonator chamber. The upstream connection portion communicating with the air intake port and the downstream connection portion communicating with the engine side are both disposed on one side of the division plate, and the resonator chamber is formed on the other side of the division plate. Characteristic claims 1 Surge tank with built-in resonator. The communication part is
  A communication hole provided on the upper surface of the divided plate;
  A tubular member extending in a direction along the upper surface of the divided plate so as to conceal the communication hole, and formed integrally with the divided plate;
  The divided plate includes an upper mold that forms the upper surface of the divided plate and the outer surface of the tubular member, a lower mold that forms the lower surface of the divided plate and the communication hole, and a core that forms the inner surface of the tubular member; It is injection-molded by 1 Surge tank with built-in resonator.

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