JP4473717B2 - Intake manifold and manufacturing method thereof - Google Patents

Description

The present invention relates to Lee emissions take manifold and a method of manufacturing an internal combustion engine.

An intake manifold that supplies intake air to the combustion chamber of each cylinder of an internal combustion engine (engine) is a large component among the components of the intake system. Therefore, if the intake manifold can be reduced in weight, the entire engine can be reduced in weight. In addition, the heat resistance required for the intake manifold is low compared to the engine body system and the exhaust system. Therefore, in recent years, it has become the mainstream to form the intake manifold with a synthetic resin material instead of a conventional light alloy such as an aluminum alloy. Various methods for manufacturing such a resin intake manifold have been proposed. For example, Patent Document 1 proposes a manufacturing method in which an adhesive is applied to the first to third divided parts, and ultrasonic welding is performed on a prescribed portion of each divided part.
JP 2003-193920 A

  However, such an ultrasonic welding method is expensive to manufacture. Further, the manufacturing cost can be reduced by reducing the number of divided parts as much as possible.

  Recently, it has been desired to improve the merchantability by reducing the turbidity of the intake sound and improving the tone. The inventors of the present invention have conducted extensive research and found that by improving the shape of the intake manifold, the turbidity of the intake sound can be reduced and the timbre can be improved.

The present invention has been made in view of such conventional problems, lightweight and the production cost is a low cost, reduced turbidity of the intake sound can be improved tone Louis emissions take manifold And an object of the present invention is to provide a manufacturing method thereof.

  The present invention solves the above problems by the following means. In addition, in order to make an understanding easy, although the code | symbol corresponding to embodiment of this invention is attached | subjected, it is not limited to this.

The present invention includes a surge tank (11) having an inlet opening (115) for introducing outside air, and a plurality of holes formed in the surge tank (11) for discharging outside air introduced into the surge tank (11). Intake manifold (10) comprising a portion (111-114) and a plurality of branch pipes (121-124) connected to each hole (111-114) and supplying the outside air to each cylinder of the engine The intake manifold (10) includes a first shell (13) in which a part of the surge tank (11) and a part of the branch pipes (121 to 124) are integrally formed; A second shell (14) in which the other part of the surge tank (11) and the other part of the branch pipes (121 to 124) are integrally formed, and the holes (111 to 114) are mutually connected. Two opposing semicircles and each other The first shell (13) and the second shell are arranged so as to be farther from the intake ports of the cylinders of the engine as they are closer to the inlet opening (115). The joint surface with the shell (14) is formed so as to intersect each straight line portion of the plurality of hole portions (111 to 114) on a straight line.

  According to the present invention, the plurality of holes that are formed in the surge tank and supply the introduced outside air to each cylinder of the engine have straight portions parallel to each other, and all the adjacent straight portions are one reference. It arrange | positioned so that it might be orthogonal or substantially orthogonal to a straight line. Therefore, the first shell to which a part of the surge tank and a part of the branch pipe are joined and the second shell to which the other part of the surge tank and the other part of the branch pipe are joined are welded by a vibration welding method. Manifolds can now be manufactured. Therefore, it is possible to provide an intake manifold that is lightweight and inexpensive to manufacture.

  Furthermore, since the straight line connecting the approximate centers of the holes is inclined with respect to the reference straight line, the turbidity of the intake sound can be reduced and the timbre can be improved.

  Hereinafter, embodiments of the present invention will be described in more detail with reference to the drawings.

  FIG. 1 is a view showing an embodiment of an intake manifold according to the present invention, FIG. 1 (A) is a side view, and FIG. 1 (B) is a front view. 2 is a cross-sectional view taken along the line II-II in FIG.

  The intake manifold 10 of the present embodiment includes a surge tank 11 and branch pipes 121 to 124. The intake manifold 10 is for an in-line four-cylinder engine and is of a type disposed above the cylinder block of the engine. The intake manifold 10 is made of resin.

  The surge tank 11 has a substantially rectangular parallelepiped shape that is long in the cylinder row direction, and the air that flows in from a throttle body (not shown) connected to one end 115 of the surge tank 11 is temporarily collected before being supplied to the engine. It is a volume part that absorbs pulsation.

  The branch pipes 121 to 124 include an upper branch part 129 and a lower branch part 130. The upper branch part 129 includes an upper half part 126 and a lower half part 127. The lower branch part 130 includes an upper half part 127 'and a lower half part 126'. As shown by the arrows in FIG. 1B, the two halves are vertically divided at the one-dot chain line portion, and are integrally formed as described later.

  Both branch portions 129 and 130 are connected by a flange portion 128. Reference numeral 131 denotes a mounting flange for mounting the intake manifold to the cylinder head.

  As shown in FIG. 2, four holes 111 to 114 are formed in the cylinder row direction on one end surface of the surge tank 11 in the longitudinal direction. The air in the surge tank 11 flows into the branch pipes 121 to 124 from these holes 111 to 114.

  The holes 111 to 114 are formed in a long hole shape including two semicircles 111a to 114a and 111b to 114b facing each other and linear portions 111c to 114c and 111d to 114d parallel to each other. And all the adjacent linear parts 111c-114c, 111d-114d are arrange | positioned so that it may line up on one reference | standard straight line. In FIG. 2, a reference straight line L parallel to the crankshaft is shown by a one-dot chain line.

  Moreover, the hole parts 111-114 differ in the height position of an up-down direction, respectively. That is, a straight line L1 (shown by a two-dot chain line) connecting the centers 111e to 114e of the holes 111 to 114 is disposed so as to be inclined with respect to the reference straight line L. And the holes 111-114 are formed so that the straight line L1 may straddle all the straight parts 111c-114c, 111d-114d. The communication hole (for example, the hole 111) closer to the inlet opening 115 of the surge tank 11 is positioned higher, and the communication hole (for example, the hole 114) farther from the inlet opening 115 is positioned lower.

  This is because the turbidity of the intake sound can be reduced by making the path length from the inlet opening 115 to each cylinder intake port (the outlet 125 of the branch pipe 12) substantially uniform (equal length). Therefore, the hole 111 close to the inlet opening 115 is formed upward so as to be away from the cylinder intake port, and the hole 114 far from the inlet opening 115 is formed downward so as to be close to the cylinder intake port. The path length from the opening 115 to each cylinder intake port (the outlet 125 of the branch pipe 12) is made substantially uniform (equal length). The reason for this will be described later.

  The branch pipes 121 to 124 are cylindrical objects having a curvature. One end of each of the branch pipes 121 to 124 is coupled to the surge tank 11, and the other end 125 communicates with a cylinder intake port of the engine.

  The intake manifold 10 is configured as described above, and is manufactured by the vibration welding method as follows. The vibration welding method is a method widely known as a method for joining resin parts, but will be briefly described in order to facilitate understanding of the present invention. The vibration welding method is a method in which one resin part is fixed and the other resin part is pressurized and the joint surface is melted and welded by frictional heat generated by reciprocating vibration in the cylinder row direction (longitudinal direction of the surge tank). It is. Since an adhesive (organic solvent) is not used, the manufacturing method is inexpensive and has a feature that it hardly causes adverse effects on the global environment.

  The intake manifold 10 is manufactured by vibration welding the upper shell 13 and the lower shell 14.

  The upper shell 13 is a resin component in which the upper half portion 116 of the surge tank 11 and the upper half portion 126 of the branch pipe 12 are integrally formed.

  The lower shell 14 is a resin component in which the lower half portion 117 of the surge tank 11 and the lower half portion 127 of the branch pipe 12 are integrally formed.

  These two resin parts 13 and 14 are reciprocally vibrated in the direction of arrow A (that is, the longitudinal direction of the surge tank 11) while being pressurized, and are melt-welded by the frictional heat generated at that time.

  As described above, the holes 111 to 114 formed in the surge tank 11 are formed of two semicircles 111a to 114a and 111b to 114b facing each other and linear portions 111c to 114c and 111d to 114d parallel to each other. All the straight portions 111c to 114c and 111d to 114d which are formed in a hole shape and are adjacent to each other are arranged on one reference straight line (in this embodiment, a straight line L). Here, the reason for making such a shape will be described.

  In order to reduce the turbidity of the intake sound, after changing the vertical position of the holes 111 to 114, the joint surface of the upper shell 13 and the lower shell 14 is made flat so that it can be processed by the vibration welding method. In this case, as shown in FIG. 3, the length L1 of the inlet opening portion is narrower than the maximum width LMAX which is the diameter of the hole. Then, 111f-114f shown by hatching among the holes 111-114 cannot be punched.

  If it is formed so as to be divided at the maximum width portion of the communication hole in consideration of die cutting, the joint surface of the upper shell 13 and the lower shell 14 becomes stepped as shown in FIG. In such a shape, the joint surface cannot be reciprocally vibrated, and therefore cannot be welded by the vibration welding method.

  Therefore, in the present embodiment, the holes 111 to 114 are formed into a long hole shape in which two upper and lower circular arcs are connected to each other by parallel straight portions, and all the straight portions are crossed by the joint surfaces of the upper shell 13 and the lower shell 14. I did it.

  Thus, according to this embodiment, the vertical position of the holes 111 to 114 can be changed to reduce the turbidity of the intake sound, and the upper shell 13 and the lower shell 14 are welded by the vibration welding method. This made it possible to produce an inexpensive resin intake manifold.

  The present invention is not limited to the embodiment described above, and various modifications and changes can be made within the scope of the technical idea, and it is obvious that these are equivalent to the present invention.

  In the present embodiment, an intake manifold for an in-line four-cylinder engine has been described as an example, but it is obvious that the present invention is not limited to such an engine.

It is a figure which shows one Embodiment of the intake manifold by this invention. It is II-II sectional drawing of FIG. 1 (B). It is a figure explaining the arrangement position of the holes 111-114. It is a figure explaining the arrangement position of the holes 111-114.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 Intake manifold 11 Surge tank 111-114 Hole part 115 Inlet opening part 116 Upper half part of a surge tank (a part of surge tank)
117 Lower half of surge tank (other part of surge tank)
121-124 Branch pipe 126 Upper half of branch pipe (part of branch pipe)
127 Lower half of branch pipe (other part of branch pipe)
13 Upper shell (first shell)
14 Lower shell (second shell)

Claims (3)

A surge tank with an inlet opening for introducing outside air;
A plurality of holes that are formed in the surge tank and discharge outside air introduced into the surge tank,
A plurality of branch pipes connected to each hole and supplying the outside air to each cylinder of the engine;
An intake manifold comprising:
The intake manifold has a first shell in which a part of the surge tank and a part of the branch pipe are integrally formed, and another part of the surge tank and another part of the branch pipe are integrally formed. A second shell formed,
The hole is formed in a long hole shape composed of two semicircles facing each other and linear portions parallel to each other, and is arranged so as to be away from the intake port of each cylinder of the engine as it is closer to the inlet opening. And
The joint surface between the first shell and the second shell is formed so that the straight portions of the plurality of holes intersect each other in a straight line.
Intake manifold characterized by that. Intake manifold according to claim 1 ,
The surge tank and the branch pipe are made of resin.
Intake manifold characterized by that. An intake manifold manufacturing method for manufacturing the intake manifold according to claim 2 ,
The first shell and the second shell are reciprocally oscillated while pressurizing the joint surfaces together to melt and weld the joint surfaces of the first shell and the second shell,
An intake manifold manufacturing method characterized by the above.

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