JP4254974B2 - Intake duct for vehicle and method for manufacturing the same - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a vehicle intake duct serving as an intake air passage to an engine combustion chamber of an automobile or the like and a method for manufacturing the same.
[0002]
[Prior art]
The need for automobile noise reduction is increasing year by year, and the demand for engine intake noise is also increasing. Conventionally, intake noise has been reduced by adding a resonator 95 to the intake duct 94 (FIG. 9).
However, in recent years, the engine room has been miniaturized, and it is difficult to secure a space for providing the resonator 95. If the ducts 92 and 94 are lengthened, the intake noise is thereby reduced. However, if the ducts 92 and 94 are lengthened, the peak of the air column resonance due to the duct length occurs, and the resonator 95 is required to eliminate this.
In order to solve such a problem, a technique disclosed in Japanese Utility Model Publication No. 62-84525 has been proposed. This technique forms a duct with a non-woven fabric having air permeability and lowers the intake sound.
[0003]
[Problems to be solved by the invention]
However, in the above publication technique, since the nonwoven fabric has insufficient rigidity, it is easy to cause deformation due to negative pressure of intake air.
In order to prevent this deformation, a resin duct having a large number of holes or slits is disposed as a core material, but the manufacturing cost has been increased. Moreover, since the material of the duct core material and the nonwoven fabric are different, there is a problem that it is difficult to recycle. Further, the intake duct of the above-mentioned publication requires a separate mounting flange and has to be assembled, resulting in high costs.
[0004]
SUMMARY OF THE INVENTION The present invention solves the above-described problems, and provides a vehicle air intake duct and a method for manufacturing the same, which has a predetermined rigidity, ensures air permeability, is made of a single material, has a low manufacturing cost, and is easily recycled. The purpose is to provide.
[0005]
[Means for Solving the Problems]
In order to achieve the above object, the gist of the invention described in claim 1 is that partial melts obtained by partially melting granular or massive resin pellets are melt-bonded to each other, and air permeability is provided between the partial melts. The vehicle air intake duct is formed in a cylindrical shape so as to provide a gap. Here, the “partial melt obtained by partially melting granular or massive resin pellets” is used for vehicles by preserving the granular or massive shape of resin pellets even when the entire resin pellets are molten. This is included if a breathable gap can be formed in the intake duct.
The gist of the invention described in claim 2 is that, after heating the convex or concave mold surface forming the semi-cylindrical portion, the resin pellets are partially melted by arranging granular or massive resin pellets on the mold surface. The molding is completed in a semi-molten state where the resin pellets are fused and bonded, and a gas-permeable gap is left between the melted parts of the resin pellets. The present invention resides in a method for manufacturing a vehicle air intake duct, wherein the product is removed from the mold, and the half product is combined and integrated into a cylindrical shape.
A vehicle air intake duct according to a third aspect of the present invention is the vehicle air intake duct according to the first aspect, wherein the partial melts are melt-bonded to each other and a breathable gap is provided between the partial melts. It has a semi-cylindrical portion that becomes the duct body and a flange portion that projects to the outer edge of the semi-cylindrical portion, and both halved products are overlapped and joined to form a cylindrical shape, and through holes from the flange portion The mounting portion provided with is extended horizontally, and the mounting portion is solid and solid.
[0006]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, embodiments of a vehicle intake duct and a method for manufacturing the same according to the present invention will be described in detail.
(1) Embodiment 1
1 to 3 show a vehicle air intake duct and a manufacturing method thereof according to the present invention, FIG. 1 is a perspective view of the vehicle air intake duct, and FIG. 2 is a perspective view of a powder slush molding device as a vehicle air intake duct manufacturing apparatus. FIG. 3 is an explanatory diagram of a manufacturing process using the apparatus of FIG.
[0007]
(1) Vehicle intake duct The vehicle intake duct (hereinafter referred to as “intake duct”) is formed in a cylindrical shape using granular or lump-shaped resin pellets 2 and serving as an intake passage to the engine combustion chamber. It is.
The resin pellet 2 is a plastic material preformed as a feed material in the molding operation, and is in the form of granules or lumps having relatively uniform dimensions. Examples of the resin material include polyethylene resin and polypropylene resin. The size of the resin pellet 2 is preferably in the range of 0.5 mmφ to 5 mmφ from the test results. The shape of the resin pellet 2 includes a columnar product by a cold cut method, a hot cut method, a meteorite-like product or a spherical product by an underwater cut method, but the shape of the resin pellet 2 used in the present invention is particularly limited. None of them may be used.
[0008]
The intake duct 1 is formed by molding a pair of halved products 1a and 1b having a semi-cylindrical portion 11 with a molding device, and combining the halved products 1a and 1b together (FIG. 1). The half-cut products 1a and 1b are provided with a semi-cylindrical portion 11 that becomes a duct body and a flange portion 12 that projects to the outer edge of the semi-cylindrical portion 11. The flange portions 12 related to the pair of halved products 1a and 1b are overlapped with each other and bonded and integrated with an adhesive to form the intake duct 1 in which the hollow portion O serving as an intake passage is formed. In addition to the adhesive, the pair of halved products 1a and 1b can be joined and integrated by welding or a mechanical joining method using a tucker or the like.
[0009]
In the halved products 1a and 1b, the partial melts 2a in which the resin pellets 2 are partially melted are melt-bonded to each other to form a joint portion 21, and an air-permeable gap ε is provided between the partial melts 2a. Thus formed. The partial melt 2a is one in which the resin pellet 2 is melt-bonded and solidified while securing the air-permeable gap ε. The air-permeable gap ε is provided at least in the semi-cylindrical portion 11 that becomes the duct body. In the present embodiment, the half-finished products 1a and 1b are processed in the same manner, and a similar air-permeable gap ε is provided over the entire intake duct.
As shown in the enlarged view in the lower right of FIG. 1, the vicinity of the outer peripheral surface of the resin pellet 2 is partially melted by the heat treatment of the resin pellet 2. Then, the adjacent partial melts 2 a are melt-bonded to each other to form a joint portion 21. Since the partial melt 2a is completely melted only in the vicinity of the outer peripheral surface, the original shape of the resin pellet 2 is preserved. Therefore, even if the adjacent partial melts 2a are melt-bonded to each other, there are restrictions on the remaining shape of the resin pellets 2, where the partial melts 2a collide with each other but are weld-bonded but do not collide with each other. A breathable gap ε is secured.
[0010]
The image for ensuring the air-permeable gap ε is as follows. If rice balls are made by gently grasping the cooked rice, the shape of the rice balls is maintained due to the adhesive effect of the rice grains, while a gap is created between the rice grains. However, even if it is made of rice grains, if it is crushed, it will look like a spear.
Conventionally, even if the resin pellet 2 is in a pre-molded lump of molding material, it has completely lost its shape at the stage of manufacturing the molded product, and has become a solid molded product like a cocoon. On the other hand, the vehicle air intake duct 1 according to the present invention forms a breathable gap ε corresponding to the gap between rice grains, like a rice ball gently grasped, and the partial melts 2a are connected to each other. They are melt-bonded together to create a product shape.
[0011]
Here, the ratio of the air-permeable gap ε in the intake duct 1 can be appropriately selected depending on the heat treatment at the time of molding and the adjustment of the molding pressure in addition to the property and shape of the resin pellet 2.
In the present embodiment, as described above, the intake duct 1 is provided with the same air-permeable gap ε throughout, but may be as follows. By adjusting the opening ratio of the duct body created by the air-permeable gap ε, the intake duct 1 is highly effective for reducing a specific sound range. For example, the air intake duct 1 is formed by forming innumerable holes of the air-permeable gap ε in the duct main body, and increasing the opening ratio only at the front end of the duct on the air opening side. If it does in this way, the pressure fluctuation of the sound radiated | emitted at the duct front-end | tip will be relieve | moderated, and the radiated sound from a duct (noise generated from an engine) can be made small.
[0012]
Further, the intake duct 1 can be formed by changing the opening ratio of the duct body formed by the air-permeable gap ε between the pair of halves 1a and 1b. If a similar air-permeable gap ε is provided around the entire circumference of the duct, the intake duct 1 inhales the air warmed in the engine room, the intake air temperature rises, and the oxygen density decreases, so that the engine output may decrease. There is. In order to cope with this, half-finished products 1a and 1b having different hole ratios were prepared, and in order to integrate them, a half-finished product with a small or zero hole ratio was arranged on the heat source side in the engine room. The intake duct 1 is used.
[0013]
{Circle around (2)} Manufacturing Method of Vehicular Air Intake Duct The air intake duct 1 can be made by using, for example, a powder slush molding device 3. The powder slush molding device 3 includes a molding die 3a and a bucket 3b (FIG. 2).
The molding die 3a is composed of a nickel electroformed shell having excellent heat conductivity, and a mold surface 31 for producing a product is formed on the inner surface thereof. The mold surface 31 is a product molding part, and enables the concave part and the flange part 12 to be the semi-cylindrical part 11 to be molded. On the back side of the shell plate forming the mold surface 31, a heating means 32 composed of a heating medium circulation pipe is fixed by welding (FIG. 3). The heating means 32 can set the heating of the mold surface 31 to a predetermined temperature (for example, about 300 ° C.).
[0014]
The bucket 3b has a box shape having an accommodating portion in which the resin pellet 2 is accommodated in the container frame as shown in FIG. The accommodating portion forms a container by standing a side wall on the bottom surface of the bucket. The powder slush molding apparatus 3 normally uses powder raw materials, but in the present invention, resin pellets 2 are used.
[0015]
The manufacturing method of the intake duct 1 is as follows. First, granular or lump-shaped resin pellets 2 as raw materials are put into the bucket 3b. On the other hand, the mold surface 31 of the mold 3a is raised to a predetermined temperature by the heating means 32 (a in FIG. 3). When the mold surface 31 reaches a predetermined temperature, the mold 3a is placed on the bucket 3b and is closed by a clamp (not shown) (FIG. 3B). By this closing, the mold 3a and the bucket 3b are pressed and sealed.
[0016]
Subsequently, the mold surface 31 of the mold 3a is heated to a set temperature (usually 230 to 250 ° C.) by the heating means 32.
After reaching the set temperature, the powder slush molding device 3 is inverted and the resin pellet 2 is moved into the molding die 3a. After a predetermined time has elapsed, the powder slush molding device 3 is returned to its original state, and the resin pellets 2 that have not adhered to the mold surface 31 are collected. Next, the clamp is removed, the mold 3a is cut off from the bucket 3b, and the mold surface 31 faces upward (c in FIG. 3).
[0017]
The resin pellets 2 that have moved into the mold 3a due to the inversion are attached (arranged) to the mold surface 31. It is heated appropriately by the heating means 32 and receives the heat of the 31-type surface to be in a semi-molten state where the surface layer is partially melted. As the resin pellets 2 are partially melted, adjacent resin pellets are melt-bonded (grain boundary welding) and shaped into a mold surface shape. However, since only the surface layer of the resin pellet 2 remains in a partially melted state, or even when the entire resin pellet 2 is in a softened state, the granular or lump shape of the resin pellet 2 is still preserved, the adjacent resin A breathable gap ε is left between the partial melts 2 a of the pellets 2.
The present invention finishes molding in this state. That is, the present invention uses the granular or lump-shaped resin pellets 2, shortens the molding time, and completes the molding while leaving the air-permeable gap ε. As in the past, the resin pellet 2 is not completely softened and integrated into a solid (solid) molded product, but for a somewhat shorter molding time, a molded product with innumerable breathable gaps ε (through holes) To do. Where the partial melts 2a collide with each other, they are melt-bonded to form a molded shape, whereas where the partial melts do not collide with each other, the melting (gelation) is not completed and the air-permeable gap ε is left. Leave. Thereafter, the mold is cooled, and the molded product is cured and fixed in shape.
In addition, as a manufacturing method in which the resin pellets are fused and bonded and the air-permeable gap ε is left between the partial melts 2a of the resin pellets 2, in addition to the molding time, temperature control of the mold surface is combined. You can also.
[0018]
Thereafter, the pair of halved products 1a and 1b formed on the mold surface 31 are removed (see FIG. 3D). Then, by combining both halves 1a and 1b and integrating the flange portions 12 with an adhesive or the like, a desired cylindrical intake duct 1 having a hollow portion O as shown in FIG. 1 is obtained.
[0019]
According to the vehicle intake duct and the manufacturing method thereof configured as described above, the duct body is a resin product, and therefore has a predetermined rigidity required as a product, unlike a nonwoven fabric. No deformation due to negative pressure of intake air. Then, (1) granular or lump resin pellets 2 are used as the molding material, and (2) the molding is completed in a state where the molding time is shortened and the air-permeable gap ε is left, so that an air column resonance peak occurs. The noise level is reduced. The duct body can be easily breathed to reduce the intake noise. The resonator can be abolished or its capacity can be reduced, leading to cost reduction. In addition, it is possible to freely change the aperture ratio of the air-permeable gap ε, and adjustment corresponding to various frequency ranges can be performed.
In addition, since the intake duct 1 of the present invention can be formed only by a resin molded product, the manufacturing cost can be reduced. Since all can be molded with the same material and the same mold, the product cost is reduced. Furthermore, since it is not a composite product, it can be easily recycled.
[0020]
(2) Embodiment 2
(1) Intake duct for vehicle The intake duct of the present embodiment is obtained by adding a mounting portion 13 as shown in FIG. 4 to the intake duct 1 having the shape shown in FIG. The attachment portion 13 is a tongue piece extending horizontally from the flange portion 12 and is integrally formed in the forming process of the half-cut products 1a and 1b. The attachment portion 13 is provided with a through hole 15 for attachment to another member. Unlike the other main parts, the attachment part 13 is solid and solid. Other configurations are the same as those of the first embodiment, and the description thereof is omitted. The same reference numerals as those in the first embodiment denote the same or corresponding parts.
[0021]
(2) Manufacturing method of vehicle air intake duct The slush molding device is the same as that of the first embodiment, except that the mold surface 43 and the heating means 42 are additionally provided so that the mounting portion 13 can be added ( FIG. 5). Reference numeral 4 a is a molding die of the slash molding device 4. Further, a pressing member 41 made of a reflecting plate 4b and a plate piece hanging from the reflecting plate 4b is prepared. The press member 41 is set so that it can be disposed opposite to the part where the mounting portion 13 is formed on the mold 4a. The press member 41 is disposed horizontally, and when the reflecting plate 4b is lowered, the semi-molten resin pellet 2 adhering to the mold surface 43 is pressure-bonded to form a solid (solid) portion having no air-permeable gap ε. Can be finished.
[0022]
The method for manufacturing the intake duct proceeds to the process corresponding to FIG. At this stage, the resin pellet 2 adheres to the portions of the semi-cylindrical portion 11, the flange portion 12, and the attachment portion 13 of the mold surface 43, and the surface layer is partially melted by receiving heat from the mold surface 43. It has become.
Thereafter, the reflecting plate 4b is made to face the mold surface 43 (a in FIG. 5), the reflecting plate 4b is further lowered, and the resin pellet 2 in a semi-molten state at a portion corresponding to the mounting portion 13 is pressed by the press member 41. Crimp it (B in Fig. 5). By the pressure bonding, the resin pellet 2 adhered on the mold surface 43 leaving the air-permeable gap ε is crushed and disappears. While the other main parts complete the molding while leaving the air-permeable gap ε, the mounting portion 13 becomes a solid solid and finishes the molding. In FIG. 4, the thickness of the attachment portion 13 is solid with a thickness equivalent to that of the other semi-cylindrical portion 11 and the flange portion 12. Since the temperature of the heating means 42 at the attachment portion 13 is raised and a large amount of the resin pellet 2 is adhered to the attachment portion 13, only the attachment portion can be made solid even if the entire thickness is substantially the same by pressure bonding. Of course, the heating temperature of the heating means 42 can be made substantially the same throughout, and only the attachment portion 13 can be thinned by pressure bonding to achieve solidification.
Thereafter, the mold 4 is cooled, and the molded product is cured and fixed in shape. Then, the pair of halves 1a and 1b formed on the mold surface 43 are removed from the mold (see D in FIG. 3), the halves 1a and 1b are combined, and the flange portions 12 are integrated with an adhesive or the like. If it makes it, it will obtain the intake duct 1.
[0023]
In the vehicle intake duct and the manufacturing method thereof configured as described above, in addition to the functions and effects of the first embodiment, the mounting portion can be integrally formed. Since the attachment portion is solid, the mechanical strength is large and the attachment portion is effective. Compared to conventional products that had to be molded separately and assembled, the cost can be reduced.
[0024]
(3) Embodiment 3
In the present embodiment, the intake duct 1 is formed using a mold 5 as shown in FIG. In the present invention, the resin pellets 2 are adhered to the heated mold surface 53 in a single layer or multiple layers, a part of the resin pellets 2 is melted, and the adjacent resin pellets are melt-bonded to each other to leave a breathable gap ε. A breathable intake duct 1 is formed. In the first and second embodiments, since the mold surfaces 31 and 43 are concave, the molded intake duct 1 is a product whose outer shape is regulated. The outer shape in contact with the mold surfaces 31 and 43 is relatively smooth, whereas the inner shape is in a rugged state compared to the outer shape because the resin pellet 2 remains in the partial melt 2a.
In the present embodiment, the air intake duct 1 is formed on the base 52 of the mold 5 so that the mold surface 53 is convex and the internal shape of the product is regulated. A heating means 51 made of a heating plate with a predetermined thickness is assembled to the mold surface 53 so that the semi-cylindrical portion 11 and the flange portion 12 can be formed.
[0025]
The method for manufacturing the intake duct is basically the same as that of the first embodiment. After heating the heating means 51 to a predetermined temperature, the resin pellets 2 are adhered (arranged) to the mold surface 53, and this is partially melted into a semi-molten state. Then, the molding is completed in a state in which the resin pellets 2 are fusion-bonded and the air-permeable gap ε is left between the partial melts 2 a of the resin pellets 2. Thereafter, the half-cut products 1a and 1b formed on the mold surface 53 are removed from the mold, and the half-cut products 1a and 1b are combined and integrated into the vehicle intake duct 1. The intake duct 1 thus completed has the same shape as that shown in FIG. However, the air intake duct 1 has a smooth inner shape. Therefore, in addition to the operation and effect of the first embodiment, the intake duct 1 with a low intake resistance is obtained, which is more excellent.
[0026]
(4) Embodiment 4
In the present embodiment, as shown in FIG. 7, the intake duct 1 is formed by using a convex (pipe-shaped) mold 7 corresponding to the inner shape of the intake duct 1. A heat medium G passes through the pipe-shaped mold 7.
In the method of manufacturing the intake duct, the heating medium G is poured to bring the surface of the mold 7 to a predetermined temperature. Thereafter, the resin pellet 2 is adhered to the mold surface 71 on the mold surface, and this is in a partially molten state. Then, the resin pellets are fusion-bonded to each other with the air-permeable gap ε left between the partial melts 2a of the resin pellets 2 to complete the molding. After passing through the cooling step, it is divided into two parts by a cutter 8 or the like, and divided into half-finished products 1a and 1b and removed from the mold. Thereafter, the half-cut products 1a and 1b are joined to form the intake duct 1. The air intake duct 1 thus formed is the air intake duct 1 shown in FIG. The action and effect of the intake duct 1 are almost the same as those of the third embodiment.
[0027]
(5) Embodiment 5
In the present embodiment, as shown in FIG. 8, the intake duct 1 is formed using a press mold. The intake duct corresponds to FIG. By closing the upper mold 62 and the lower mold 61, the cavity C of the intake duct 1 is formed. The cavity C has a thickness of W1 at the semi-cylindrical portion 11 and the flange portion 12 so that an air-permeable gap ε is formed between the partial melts 2a by hot press molding. On the other hand, the cavity thickness at the location of the attachment portion 13 is thin with W2, and W1> W2. In FIG. 8, the A zone is a semi-cylindrical portion 11 and a flange portion 12 with a breathable gap, and the B zone is a solid attachment portion 13.
In the manufacturing method of the intake duct using such a press mold 6, the press mold 6 is heated to a predetermined temperature by a heating means (not shown). Then, the resin pellets 2 are arranged on the mold surface 63, and this is in a partially molten state that is partially melted. Next, the molding is completed in a state in which the resin pellets are fused and bonded by closing the mold and the air-permeable gap ε is left between the partial melts 2 a of the resin pellet 2. At this time, since the cavity thickness of the portion of the attachment portion 63 is W2, the resin pellet 2 in a semi-molten state is crushed to become a solid attachment portion. Thereafter, when the mold is opened and the molded product is taken out, the intake duct 1 similar to that shown in FIG. 4 is formed. The intake duct 1 of the present embodiment can obtain the same effects as those of the second embodiment.
[0028]
In addition, in this invention, it is not restricted to what is shown to the said embodiment, According to the objective and a use, it can change variously in the range of this invention. The shape, material, and the like of the semi-cylindrical portion 11, the flange portion 12, and the attachment portion 13 related to the intake duct 1 can be selected as appropriate. Moreover, the shaping | molding apparatus which produces the intake duct 1 is not limited to embodiment, It can select suitably according to a use.
[0029]
【The invention's effect】
As described above, the vehicle air intake duct and the method for manufacturing the same according to the present invention have a superior effect in that a single material can reduce the manufacturing cost and facilitate recycling, and can secure a desired air permeability while having a predetermined rigidity. Demonstrate.
[Brief description of the drawings]
FIG. 1 is a perspective view of a vehicle intake duct according to a first embodiment.
FIG. 2 is a schematic perspective view of a powder slush molding device that is an apparatus for manufacturing a vehicle intake duct.
3 is an explanatory diagram of a manufacturing process using the apparatus of FIG. 2;
4 is a perspective view of a vehicle intake duct according to Embodiment 2. FIG.
FIG. 5 is a schematic view of a slush molding device that is an apparatus for manufacturing a vehicle intake duct.
6 is a schematic cross-sectional view of a manufacturing die for a vehicle intake duct in Embodiment 3. FIG.
FIG. 7 is a schematic cross-sectional view of a manufacturing mold for a vehicle intake duct in a fourth embodiment.
FIG. 8 is a schematic cross-sectional view of a main part of a press mold for a vehicle intake duct according to a fifth embodiment.
FIG. 9 is an explanatory diagram of a conventional technique.
[Explanation of symbols]
1 Intake duct 1a, 1b Half product 11 Half cylinder
12 Flange
13 Mounting part
15 Through- hole 2 Resin pellet 2a Partial melt 31, 43, 53, 63, 71 Mold surface ε Breathable gap

Claims (3)

  The partial melts in which the granular or lump-shaped resin pellets are partially melted are melt-bonded to each other, and are formed in a cylindrical shape so as to provide a breathable gap between the partial melts. Intake duct for vehicles.   After heating the convex or concave mold surface forming the semi-cylindrical part, a granular or lump-shaped resin pellet is placed on the mold surface to obtain a semi-molten state in which the resin pellet is partially melted. The molding is completed in a state in which a gas-permeable gap is left between the partial melts of the resin pellets, and then the half-divided product having the semi-cylindrical portion formed on the mold surface is removed, and the half-divided product is removed. A method for manufacturing an intake duct for a vehicle, characterized by combining and integrating them into a cylindrical shape. The partial melts are melt-bonded to each other and an air-permeable gap is provided between the partial melts so that a pair of halved products are formed between the semi-cylindrical portion that becomes the duct body and the outer edge of the semi-cylindrical portion. A flange portion that projects, and both halves are overlapped and joined to form a cylindrical shape, and a mounting portion provided with a through hole is horizontally extended from the flange portion, and the mounting portion The air intake duct for a vehicle according to claim 1, which is solid and solid.

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