JP4280926B2 - Intake device and method of manufacturing intake device - Google Patents

Description

  The present invention relates to an intake device for an internal combustion engine (hereinafter, the internal combustion engine is referred to as an “engine”) and a method for manufacturing the intake device.

  A technique for mounting a resin air intake device on an engine of a vehicle such as a ship or an automobile is known (see, for example, Patent Documents 1 and 2). In Patent Document 1, after three inner members are injection-molded, the three inner members thus formed are joined by a connecting line to form an inner resin molded body. And the outer side resin molded object is formed in the outer side by injection molding by making the formed inner resin molded object into a core. Thereby, in the invention currently disclosed by patent document 1, the hollow resin molding is formed. On the other hand, in the invention disclosed in Patent Document 2, similarly to Patent Document 1, an internal molded body having a predetermined shape is formed in advance in the hollow portion of the manifold. Further, the external molded body element forming the external shape of the manifold is divided into a plurality of members. The external molded body element assembled from a plurality of members is integrally formed with the internal molded body by the joining means, and a flange member is attached to the first joint portion of the formed molded body.

JP-A-7-148769 JP-A-7-148864

  However, in the case of the molded body disclosed in Patent Document 1 or Patent Document 2, each is composed of two or more molded bodies having different shapes. Therefore, it is necessary to prepare a mold separately for each molded body. Further, not only a mold for molding each molded body but also a separate mold for assembling a completed body from a plurality of molded bodies is required. Furthermore, since a plurality of molded bodies are assembled, there is a problem that the number of assembling steps is increased.

  Accordingly, an object of the present invention is to provide an intake device and a method of manufacturing the intake device that can be easily assembled with a reduced number of molds.

  The invention according to claim 1 includes two subassemblies. The two subassemblies have the same shape. Therefore, it is not necessary to form a plurality of molded bodies with a mold. Therefore, the number of molds can be reduced. Further, the two subassemblies are integrally connected with the first end portions, which are one end portions in the direction perpendicular to the axis of the valve shaft member, facing each other. The two subassemblies face each other at their first ends by inverting one of the subassemblies. Thus, even if the two subassemblies have the same shape, an integrated intake device is configured by combining the two subassemblies. Therefore, assembly can be facilitated.

In the invention according to claim 1 or 5, the first sub ends of the two subassemblies are fitted together. Therefore, the two subassemblies can be assembled by a simple process of molding and fitting. Therefore, the assembly can be facilitated and the number of assembly steps is not increased.
In the invention according to claim 2 , the first end portion forms the convex portions and the concave portions alternately. The convex part moves away from the valve shaft member, and the concave part approaches the valve shaft member. Accordingly, the first end portion is formed in a substantially wave shape, and when the first end portion of one subassembly and the first end portion of the other subassembly face each other, the first end portion becomes a shape capable of meshing with each other. Therefore, it is possible to easily determine and assemble the positions of the two subassemblies with a simple structure.

In the invention according to claim 3 or 6, the portion where the two subassemblies are in contact forms a welded portion. Therefore, the two subassemblies are firmly connected by welding. Therefore, the strength can be further increased.
According to a fourth aspect of the present invention, the subassembly has a mounting portion at the second end. Thus, even when the attachment portion protrudes from the subassembly, the attachment portion does not hinder assembly when the subassemblies are connected. Therefore, the assembly of the subassembly can be facilitated. Further, the mounting portion projects from the second end portion of the subassembly, so that the assembly to the vehicle is facilitated. Therefore, the mounting property to the vehicle can be improved.

In the invention according to claim 5 , the two first-shaped subassemblies are opposed to each other by 180 ° so that both ends in the axial direction of the valve shaft member are interchanged, so that the first end portions thereof face each other. Since the subassemblies have the same shape, the number of molds is reduced. In addition, sub-assemblies having the same shape can be assembled by a simple process of assembling, inverting and connecting. Therefore, assembly can be facilitated.

Hereinafter, an embodiment of the present invention will be described with reference to the drawings.
An intake device according to a first embodiment of the present invention is shown in FIG. In the present embodiment, an example in which the intake device 10 is applied to a V-type 8-cylinder engine of an automobile will be described. The intake device 10 is installed in an intake system that supplies intake air to an engine.
The intake device 10 includes two subassemblies 20 as shown in FIGS. 1 and 3. Each of the two subassemblies 20 includes a valve body 21, a valve shaft member 22, a valve body 23, a connecting member 24, and the like. The valve body 21 is made of resin and is accommodated in an intake manifold (not shown). The valve body 21 forms four cylindrical intake passages 25. Each intake passage 25 has an upstream end communicating with a surge tank (not shown) and a downstream end communicating with a corresponding high rotation passage (not shown). The valve shaft member 22 is formed from a metal in a round bar shape, and is supported by a metal bearing 26 of the valve body 21 so as to cross the corresponding intake passage 25. The four valve bodies 23 are formed in a disk shape from resin and are arranged in the corresponding intake passages 25 respectively. Each valve body 23 is fixedly supported by a valve shaft member 22 that crosses the corresponding intake passage 25. The four valve shaft members 22 that respectively cross the four intake passages 25 in a row are arranged substantially coaxially in the axial direction, and are connected to each other by a connecting member 24. Thereby, these four valve shaft members 22 and the four valve bodies 23 supported by them can be rotated integrally.

  The two subassemblies 20 have the same configuration. As a result, when the two subassemblies 20 are assembled as shown in FIG. 2, four intake passages 25 are arranged in two rows in the intake device 10, for a total of eight. In the case of this embodiment, these eight intake passages 25 communicate with each cylinder of a V-type 8-cylinder engine. As shown in FIGS. 1 and 3, the subassembly 20 has a first end portion 31 at one end portion in a direction perpendicular to the axis of the valve shaft member 22. The subassemblies 20 each have a second end 32 at the other end perpendicular to the axis of the valve shaft member 22. That is, the first end portion 31 and the second end portion 32 are located at each end portion in a direction perpendicular to the axis of the valve shaft member 22.

  The first end portion 31 of the subassembly 20 includes a convex portion 41 that moves away from the valve shaft member 22 in a direction perpendicular to the axis of the valve shaft member 22, and a concave portion 42 that approaches the valve shaft member 22. Convex portions 41 and concave portions 42 are alternately formed in the first end portion 31 of the subassembly 20 in the axial direction of the valve shaft member 22. Accordingly, the first end portion 31 of the subassembly 20 has a substantially wave shape in which the convex portions 41 and the concave portions 42 of the valve shaft member 22 are alternately formed. The outer peripheral shape of the convex portion 41 corresponds to the inner peripheral shape of the concave portion 42. Therefore, as shown in FIG. 1, when the first end portions 31 of the two subassemblies 20 are opposed to each other, the convex portion 41 of one subassembly 20 is engaged with the concave portion 42 of the other subassembly 20. .

  By assembling the intake device 10 with the first end portions 31 of the subassemblies 20 facing each other, the second end 32 of each subassembly 20 is positioned outside the intake device 10 as shown in FIG. A mounting portion 51 is installed at the second end portion 32 of each subassembly 20. The mounting portion 51 is formed of resin integrally with the valve body 21 of the subassembly 20. A plurality of attachment portions 51 are installed in the axial direction of the valve shaft member 22.

  The two subassemblies 20 are fitted with the first end portions 31 facing each other. Thereby, the intake device 10 having the eight valve bodies 23 in the eight intake passages 25 is configured. As shown in FIG. 4, each subassembly 20 has a claw portion 61 and a groove portion 62 in the valve body 21. The claw portion 61 is an outer wall that forms the convex portion 41 of the valve body 21 and is formed so as to protrude from the inner wall that forms the concave portion 42. On the other hand, the groove portion 62 is an outer wall that forms the convex portion 41 of the valve body 21 and is recessed from the inner wall that forms the concave portion 42. The shape of the claw portion 61 and the groove portion 62 corresponds to each other. As a result, when the two subassemblies 20 are assembled, the claw portion 61 protruding from the valve body 21 fits into the groove portion 62. Thereby, the two subassemblies 20 are firmly connected. At this time, the connecting portions of the two subassemblies 20 may be welded. By welding the two subassemblies 20, the two subassemblies 20 are more firmly connected.

  In the intake device 10 configured as described above, the intake air whose flow rate is adjusted by the throttle valve flows into the surge tank. At this time, if each intake passage 25 of the intake device 10 is closed by each valve body 23, the intake air flowing into the surge tank is supplied to each cylinder of the engine via a low rotation passage (not shown). On the other hand, when each intake passage 25 of the intake device 10 is opened by each valve body 23, the intake air flowing into the surge tank passes through each intake passage 25 having a smaller flow resistance and a high-speed rotation passage (not shown) in order. Supplied to each cylinder. The passage length passing through the low rotation passage is longer than the passage length passing through the intake passage 25 and the high rotation passage. As a result, the intake air supplied to each cylinder changes according to the opening and closing of each intake passage 25 by each valve body 23.

Next, a method for manufacturing the intake device 10 having the above configuration will be described.
As shown in FIG. 5A, the sub-assembly 20 is first processed in the intake device 10. A metal valve shaft member 22 equipped with a bearing 26 is placed in a molding die (not shown), and molten resin is injected from an injection machine. Thereby, the four valve bodies 23 and the valve body 21 are shape | molded by resin substantially simultaneously. When the molding of the four valve bodies 23 and the valve body 21 is completed, the molten resin is injected from the injection machine into the molding die, and the three connecting members 24 are resin molded substantially simultaneously. When the resin molding of the connecting member 24 is completed, the subassembly 20 as a molded product is released from the molding die. By repeating these steps, a plurality of subassemblies 20 having the same shape are formed as shown in FIGS. 3 and 5A.

  Moreover, you may form the two subassemblies 20 not only in said procedure but in the following procedure. First, the valve shaft member 22 is installed in a molding die (not shown), and a molten resin is injected from an injection machine so that the valve shaft member 22 and the valve body 23 are integrally molded. The integrally formed valve shaft member 22 and valve body 23 are installed in a molding die of the valve body 21 in accordance with the number of intake passages 25 formed by the valve body 21. In the case of this embodiment, four integrally formed valve shaft members 22 and a valve body 23 are installed in a molding die of the valve body 21. By injecting molten resin from the injection machine, the integral valve shaft member 22, the valve body 23, and the valve body 21 are resin-molded. Finally, the molten resin is injected from the injection machine, and the connecting member 24 is resin molded substantially simultaneously. By repeating these steps, a plurality of subassemblies 20 having the same shape as shown in FIGS. 3 and 5A may be formed.

  When the subassembly 20 is formed, the intake device 10 is assembled from the two subassemblies 20. As shown in FIG. 5B, the two subassemblies 20 are inverted 180 degrees up and down, that is, 180 degrees so that both ends in the axial direction of the valve shaft member 22 are interchanged. Thereby, as shown in FIG. 1 and FIG. 5 (B), as for the two subassemblies 20, the 1st end parts 31 each oppose. At this time, the convex portion 41 of one subassembly 20 is opposed to the concave portion 42 of the other subassembly 20.

  The two subassemblies 20 with the first end portions 31 facing each other are brought close to each other, and the convex portion 41 and the concave portion 42 are engaged with each other as shown in FIGS. 2 and 5C. At this time, the claw portion 61 of one subassembly 20 fits into the groove portion 62 of the other subassembly 20. As a result, the intake device 10 is configured by the two subassemblies 20.

  After fitting the convex portions 41 and the concave portions 42 of the two subassemblies 20, a portion where the two subassemblies 20 are in contact may be welded. In the welding, the resin is melted by heating the portion where the two subassemblies 20 are in contact, and the resin is solidified by cooling. Thereby, in addition to the fitting of the convex part 41 and the concave part 42 and the claw part 61 and the groove part 62, the strength of the connecting part of the two subassemblies 20 is further increased by welding.

  As described above, in one embodiment of the present invention, one of the two subassemblies 20 is inverted and assembled. Thereby, the two subassemblies 20 can be formed in the same shape. Therefore, only the mold corresponding to the single subassembly 20 is prepared. Therefore, the number of molds can be reduced.

  In the first embodiment, the intake device 10 is manufactured by a simple process of forming the sub-assembly 20 having the same shape, inverting one of the sub-assemblies 20 and connecting the two sub-assemblies 20. Therefore, there is no need to prepare a plurality of molded bodies or assemble a plurality of molded bodies. Therefore, assembly becomes easy and the number of assembly steps can be reduced.

  In the above-described embodiment of the present invention, the example in which the four intake passages 25 are arranged in two rows in the valve body 21 of the intake device 10 and the intake device 10 is applied to a V-type 8-cylinder engine has been described. However, not only the V-type 8-cylinder engine but the engine of the present invention can be applied to any engine in which two or more cylinders are arranged in two or more rows. Moreover, the shape of the convex part 41 and the recessed part 42 in the 1st end part 31 of the subassembly 20 is an illustration. That is, the shape is not limited to the shape described in the above embodiment as long as the two subassemblies 20 can be engaged with each other between the first end portions 31. Furthermore, the shape and connecting method of the connecting member 24 that connects the valve shaft member 22 are examples, and are not limited to those disclosed in the above embodiment.

It is the schematic which shows the subassembly of the intake device by one Embodiment of this invention, Comprising: It is a figure which shows the form which made the 1st end parts of two subassemblies face each other. It is the schematic which shows the intake device by one Embodiment of this invention. It is the schematic which shows the subassembly of the intake device by one Embodiment of this invention, Comprising: It is a figure which shows the form which arranged two subassemblies in parallel. It is the schematic which expanded a part of subassembly shown in FIG. It is the schematic which shows the assembly | attachment procedure of the intake device by one Embodiment of this invention.

Explanation of symbols

  DESCRIPTION OF SYMBOLS 10 Intake device, 20 Subassembly, 21 Valve body, 22 Valve shaft member, 23 Valve body, 25 Intake passage, 31 1st end part, 32 2nd end part, 41 Convex part, 42 Concave part, 51 Attachment part

Claims (6)

A valve body that forms a plurality of intake passages, a plurality of valve bodies that are respectively disposed in the plurality of intake passages, and a valve that supports both of the plurality of valve bodies by supporting both end portions in the axial direction on the valve body Comprising two subassemblies having a shaft member;
Each of the two subassemblies has the same shape, each having a first end at one end in a direction perpendicular to the axis of the valve shaft member and a second end at the other end. ,
The first end of one of the subassemblies is connected to and integrally connected to the first end of the other subassembly, and the two subassemblies are fitted to each other. an intake device characterized in that is. The first end portion intersects a convex portion moving away from the valve shaft member and a concave portion approaching the valve shaft member.
The intake device according to claim 1, wherein the intake devices are formed mutually . The intake device according to claim 1 or 2, wherein a portion where the two subassemblies are in contact forms a welded portion . Each of the subassemblies has an attachment portion for fixing to the vehicle at the second end portion.
Intake device according to any one claim from claim 1, wherein 3 of the that. A valve body forming an intake passage of the multiple, plurality of valve bodies being respectively disposed in said plurality of intake passages, and both end portions in the axial direction is supported by the valve body for supporting the plurality of valve bodies, respectively Comprising two subassemblies having a valve stem member;
The two assemblies have the same shape, and each has an air intake device having a first end at one end in a direction perpendicular to the axis of the valve shaft member and a second end at the other end. A manufacturing method of
Assembling the two sub-assemblies of the same shape;
Reversing one of the two subassemblies by 180 ° so that both axial ends of the valve shaft member are interchanged, and making the first ends of the two subassemblies face each other;
Connecting the two subassemblies with the first ends facing each other;
And in the step of connecting the two subassemblies, the two subassemblies are fitted together. The method of manufacturing an intake device according to claim 6 , further comprising welding a portion where the two connected subassemblies are in contact with each other .

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