JP4866387B2 - Manufacturing method of resin intake manifold - Google Patents

Description

  The present invention relates to an intake manifold provided in an intake system of an engine, and more particularly, to a method for manufacturing a resin intake manifold formed of synthetic resin.

  Conventionally, an intake manifold described in Patent Documents 1 and 2 below is known as this type of technology. In particular, Patent Document 1 describes an intake manifold configured by joining synthetic resin halves. An intake passage is formed inside the intake manifold, and both ends of the intake passage are opened at both ends of the intake manifold. The intake passage includes an upstream straight portion and a downstream curved portion. A flange is formed at the engine side end of one half of the intake manifold. The flange is formed with a straight passage portion that leads to the curved portion of the intake passage due to die cutting during resin molding. The engine-side end of the other half body is joined to this flange.

JP 2003-129909 A JP 2003-49724 A

  However, in the intake manifold described in Patent Document 1, since there is a straight passage portion in the flange, when the flange is connected to the engine, the intake resistance becomes a problem at the joint between the intake manifold intake passage and the engine intake port. There was. In other words, when the intake port is composed of a curved passage, when the flange described above is connected to the engine, the straight passage portion of the flange is connected to the curved passage of the intake port, and at the joint between the straight passage portion and the curved passage. There was a risk that the intake resistance would increase and the intake volume would decrease. In the intake manifold described in Patent Document 1, the straight passage portion could not be eliminated because of die cutting during resin molding, and the flange passage portion could not be all curved curved passage portions.

  The present invention has been made in view of the above circumstances, and the object thereof is to make it possible to form a passage portion of a flange provided at an end portion of each branch passage into a curved passage portion curved by a mold. The object is to provide a method of manufacturing a resin intake manifold.

In order to achieve the above object, the invention described in claim 1 includes a first half body and a first half body formed of a synthetic resin, each of which includes a curved passage portion in which each of a plurality of branch passages branched from the surge tank is curved. The two halves are joined together to form a flange, and a flange is formed at the end of the first half, and the passage formed in the flange is a part of the curved passage of each branch passage. In the manufacturing method of the resin intake manifold in which the curved passage portions are opened on both sides in the thickness direction of the flange and the end of the second half body is joined to the flange. A first mold that is die-cut to the outlet side and a second mold that is die-cut to the inlet side of the curved passage portion are used, the first die includes a first convex portion, and the second die is Including the second convex part, both in the thickness direction of the flange From the first protrusion and the second protrusion aligned demolding can typed one another, in cooperation with the first convex portion is die matching the second convex portions and molding a curved passage portion, the flange A joint portion is formed at which the end portion of the second half body is joined, and a fitting hole is formed adjacent to the joint portion, and a projection that fits into the fitting hole is formed at the end portion of the second half body. Is formed, the protrusion is inserted into the insertion hole, and the end of the second halved body is joined to the joint, and the second mold is fitted adjacent to the second convex portion. Including a step portion for forming a hole, the first convex portion and the second convex portion are matched with each other at the side surface, and the tip surface of the first convex portion is matched with the step portion in the mold-matched state. The purpose is that the tip surface of the two convex portions is matched with the end surface of the first mold at the outlet side opening of the curved passage portion .

According to the configuration of the invention, the first convex portion and the second convex portion are matched with each other from both sides in the thickness direction of the flange, and the curved path is formed by the cooperation of the matched first convex portion and second convex portion. Part is molded. Here, since the first convex portion and the second convex portion are provided so that they can be removed in the opposite directions from the mold-matched state, the curved shape of the curved passage portion is the mold of the first convex portion and the second convex portion. Do not get in the way. In addition, the first convex portion becomes shorter than the thickness of the flange, and it is easy to mold and mold the first convex portion with respect to the second convex portion.

In order to achieve the above-mentioned object, the invention described in claim 2 is a resin intake manifold manufactured by the manufacturing method described in claim 1 .

  According to the configuration of the above invention, since the passage portion of the flange becomes a curved passage portion constituting a part of the curved passage portion of each branch passage, when the flange is connected to an engine having a curved intake port, The curved passage portion of the flange can be continuously connected to the curved intake port.

According to the first aspect of the present invention, the passage portion of the flange provided at the end of each branch passage in the resin intake manifold can be formed into a curved passage portion curved by the mold. Further, it is possible to easily form the curved passage portion with a mold.

According to the second aspect of the present invention, when the flange is connected to an engine having a curved intake port, intake air can flow smoothly. As a result, it is possible to prevent the intake air amount from decreasing due to an increase in the intake resistance at the joint between the flange and the engine.

  Hereinafter, an embodiment embodying a resin intake manifold and a manufacturing method thereof according to the present invention will be described in detail with reference to the drawings.

  FIG. 1 is a front view of a resin intake manifold 1. FIG. 2 is a plan view of the resin intake manifold 1 shown in FIG. FIG. 3 is a bottom view of the resin intake manifold 1 shown in FIG. FIG. 4 is an exploded front view of the resin intake manifold 1.

  As shown in FIGS. 1 to 3, the resin intake manifold 1 of this embodiment schematically includes a surge tank 2 and a plurality of (three in this embodiment) branch passages branched from the surge tank 2. 3 and a flange 4 formed corresponding to the engine side end of each branch passage 3. Each branch passage 3 includes a passage portion 3 a that is curved near the flange 4. A mounting flange 5 for mounting the throttle device is formed outside the surge tank 2. An intake inlet 6 is formed in the mounting flange 5. A bracket 7 is formed outside the surge tank 2 for fixing the resin intake manifold 1 to a predetermined frame.

  As shown in FIG. 4, the resin-made intake manifold 1 is constructed by joining and integrating a synthetic resin lower piece 11 and a synthetic resin upper piece 12 together. The lower piece 11 corresponds to the first half body of the present invention, and the upper piece 12 corresponds to the second half body of the present invention. The lower piece 11 includes a lower tank half shell portion 2 </ b> A constituting the surge tank 2, a lower passage half shell portion 3 </ b> A constituting each branch passage 3, and a flange 4. The upper piece 12 is disposed on the upper side of the lower piece, and includes an upper tank half shell portion 2B constituting the surge tank 2 and an upper passage half shell portion 3B constituting each branch passage 3. The upper piece 11 and the lower piece 12 are each molded into a predetermined shape by injection molding using a synthetic resin as a material. Then, as shown in FIG. 4, the upper piece 11 and the lower piece 12 are combined with each other and joined together by vibration welding to be integrated, whereby one resin intake manifold 1 is manufactured.

  FIG. 5 is a plan view of the lower piece 11. FIG. 6 is a bottom view of the lower piece 11. As shown in FIGS. 5 and 6, a flange 4 that is fixed to a cylinder head 32 (see FIG. 13) of the engine is formed at one end portion (left side of the drawing) of the lower piece 11. In the flange 4, three curved passage portions 13 corresponding to a three-cylinder engine are formed side by side. The curved passage portion 13 constitutes a part of the curved passage portion 3 a of each branch passage 3. A plurality of mounting holes 4 a for fixing to the cylinder head 32 are formed at the edge of the flange 4. The upper surface side of the lower piece 11 is a concave portion 14 of the lower tank half shell portion 2A and a lower passage groove 15 of a plurality of lower passage half shell portions 3A. Further, as shown in FIG. 5, a welding line 16 is formed on the upper surface side of the lower piece 11 along the outer shape of the recess 14 and the lower passage groove 15. The welding line 16 is welded in contact with the upper piece 12 combined on the upper side. On the other hand, as shown in FIG. 6, the mounting flange 5 and the bracket 7 described above are formed on the outer wall of the lower tank half shell portion 2 </ b> A on the lower surface side of the lower piece 11.

  FIG. 7 is a plan view showing the upper piece 12. FIG. 8 is a bottom view of the upper piece 12. As shown in FIG. 8, the lower surface side of the upper piece 12 is a concave portion 17 of the upper tank half shell portion 2B and an upper passage groove 18 of the plurality of upper passage half shell portions 3B. Further, a welding line 19 is formed on the lower surface side of the upper piece 12 along the outer shape of the recess 17 and the upper passage groove 18. The welding line 19 is welded in contact with the welding line 16 formed on the lower piece 11 described above.

  This embodiment is characterized by the configuration related to the flange 4 formed at the engine side end of each branch passage 3. FIG. 9 is an enlarged cross-sectional view of the vicinity of the flange 4 along the line AA in FIG. FIG. 10 is an enlarged cross-sectional view showing the vicinity of the flange 4 in FIG. 9 by disassembling the lower passage half-shell portion 3A and the upper passage half-shell portion 3B. That is, in this embodiment, the passage portion formed in the flange 4 is a curved passage portion 13 that constitutes a part of the curved passage portion 3 a of each branch passage 3. The curved passage portion 13 opens on both sides of the flange 4 in the thickness direction (the vertical direction in the drawing). One end (lower side in the drawing) of the curved passage portion 13 is an outlet, and the other end (upper side in the drawing) is an inlet. As shown in FIGS. 9 and 10, in this embodiment, the lower passage half shell 3 </ b> A and the upper passage half shell 3 </ b> B are joined together, and the end of the upper passage half shell 3 </ b> B is joined to the flange 4. Specifically, the flange 4 is formed with a welding line 16 as a joining portion to which the end of the upper passage half-shell 3B is joined, and an insertion hole 20 is formed adjacent to the welding line 16. . Further, a projection 21 that fits into the fitting hole 20 is formed at the end of the upper passage half-shell 3B. The protrusion 21 is inserted into the insertion hole 20, and the welding line 19 at the end of the upper passage half-shell 3 </ b> B is joined to the welding line 16 of the flange 4.

  Here, molding of the curved passage portion 13 of the flange 4 will be described. FIG. 11 is a cross-sectional view showing a clamping state related to the molding of the curved passage portion 13. FIG. 12 is a cross-sectional view showing the mold opening state relating to the molding of the curved passage portion 13. As shown in FIGS. 11 and 12, in this embodiment, the first mold 22 that is die-cut to the outlet side (lower side in the drawing) of the curved passage portion 13 formed in the flange 4, and the inlet of the curved passage portion 13. A second mold 23 that is die-cut to the side (upper side in the drawing) is used. The first mold 22 includes a first protrusion 24, and the second mold 23 includes a second protrusion 25. Then, when the lower piece 11 including the flange 4 is molded, as shown in FIG. 11, the first convex portion 24 and the second convex portion 25 are engaged with each other so as to be mold-released from both sides in the thickness direction of the flange 4. The curved passage portion 13 is formed by the cooperation of the first convex portion 24 and the second convex portion 25 that have been matched to each other. As shown by being surrounded by a chain line ellipse S1 in FIG. 11, the one side surface 24a of the first convex portion 24 and the one side surface 25a of the second convex portion 25 are each formed in a tapered shape with an angle of about 5 °, The molds are made to be moldable with each other. The taper angle may be an angle of 5 ° or more.

  More specifically, as shown in FIG. 11, the second mold 23 includes a step portion 26 for forming the insertion hole 20 adjacent to the second convex portion 25. In a state where the first convex portion 24 and the second convex portion 25 are mold-matched with each other at the side surfaces 24a and 25a, the tip surface 24b of the first convex portion 24 is matched with the tip surface 26a of the step portion 26, and the second The front end surface 25 b of the convex portion 25 is matched with the end surface 22 a of the first mold 22 at the opening on the outlet side of the curved portion 13.

  According to the resin intake manifold 1 of this embodiment described above, the entire structure is formed by joining and integrating the lower piece 11 and the upper piece 12 made of synthetic resin, and corresponds to the end of each branch passage 3. A flange 4 is formed. A passage portion formed in the flange 4 serves as a curved passage portion 13 constituting a part of the curved passage portion 3 a of each branch passage 3. Therefore, as shown in FIG. 13, when the flange 4 is connected to the cylinder head 32 of the engine having the curved intake port 31, the curved passage portion 13 of the flange 4 can be continuously connected to the curved intake port 31. It becomes. FIG. 13 is a sectional view showing a state where the flange 4 of the resin intake manifold 1 is connected to the cylinder head 32 of the engine. For this reason, as indicated by arrows in FIG. 13, the intake air can smoothly flow from the curved passage portion 3 a of each branch passage 3 to the curved intake port 31 of the cylinder head 32. As a result, it is possible to prevent the intake air amount from decreasing due to an increase in the intake resistance at the joint between the flange 4 and the cylinder head 32.

  In this embodiment, the protrusion 21 at the end of the upper passage half-shell 3B is fitted into the fitting hole 20 of the flange 4, and the welding line 19 at the end of the upper passage half-shell 3B is connected to the welding line 16 of the flange 4. Be joined. Therefore, the end portion of the upper passage half shell portion 3B is securely joined to the flange 4. For this reason, the joining reliability of the flange 4 and the edge part of the upper channel | path half-shell part 3B can be improved.

  Further, in this embodiment, there is no straight portion in the passage portion of the flange 4, and the thickness of the flange 4 can be reduced to the minimum necessary amount accordingly. For this reason, the mechanical strength of the flange 4 can be secured and the weight of the resin intake manifold 1 can be reduced.

  Furthermore, according to the method for manufacturing the resin intake manifold of this embodiment, the first convex portion 24 and the second convex portion 25 are engaged with each other from both sides in the thickness direction of the flange 4 to perform mold matching. Then, the curved passage portion 13 is formed by the cooperation of the matched first and second convex portions 24 and 25. Here, since the 1st convex part 24 and the 2nd convex part 25 are provided so that mold release is possible in the opposite direction from the state in which the mold was matched, the curved shape of the curved path part 13 is the 1st convex part 24 and 2nd. It does not interfere with the mold removal of the convex portion 25. For this reason, the passage portion of the flange 4 can be formed into the curved passage portion 13 curved by the molds 22 and 23.

  Moreover, in this embodiment, since the 1st convex part 24 becomes short compared with the thickness of the flange 4, the mold alignment and die cutting of the 1st convex part 24 with respect to the 2nd convex part 25 become easy. For this reason, the shaping | molding by the metal mold | die 22 and 23 of the curved channel | path part 13 can be made easy.

  In addition, this invention is not limited to the said embodiment, A part of structure can also be changed suitably and implemented in the range which does not deviate from the meaning of invention.

  For example, in the above-described embodiment, the present invention is embodied in the resin intake manifold 1 for a three-cylinder engine. However, the present invention is not limited to a three-cylinder engine, and may be embodied in a resin intake manifold for any multi-cylinder engine. .

The front view which shows a resin-made intake manifold. The top view which shows a resin-made intake manifold. The bottom view which shows a resin-made intake manifold. The front view which decomposes | disassembles and shows a resin-made intake manifold. The top view which shows a lower piece. The bottom view which shows a lower piece. The top view which shows an upper piece. The bottom view which shows an upper piece. The expanded sectional view along the AA line of FIG. 2 which shows the vicinity of a flange. FIG. 10 is an enlarged cross-sectional view showing the vicinity of the flange of FIG. 9 disassembled into a lower passage half shell and an upper passage half shell. Sectional drawing which shows the clamping state which concerns on shaping | molding of a curved channel | path part. Sectional drawing which shows the mold open state similarly related to shaping | molding of a curved channel | path part. Sectional drawing which shows the state which connected the flange of the resin-made intake manifolds to the cylinder head of an engine.

DESCRIPTION OF SYMBOLS 1 Resin intake manifold 2 Surge tank 3 Branch passage 3a Curved passage 4 Flange 11 Lower piece (first half)
12 Upper piece (second half)
13 Curved passage portion 16 Welding line (joint)
20 Insertion hole 21 Protrusion 22 First mold 22a End surface 23 Second mold 24 First convex portion 24a One side surface 24b Front end surface 25 Second convex portion 25a One side surface 25b Front end surface 26 Step 26a Front end surface

Claims (2)

Each of the plurality of branch passages branched from the surge tank includes a curved passage portion, and is configured by joining and integrating the first half body and the second half body each formed of synthetic resin, A flange is formed at an end of the first half body, and a passage portion formed in the flange is a curved passage portion constituting a part of a curved passage portion of each branch passage, and the thickness direction of the flange In the method of manufacturing a resin intake manifold in which the curved passage portion is open on both sides and an end of the second half is joined to the flange,
A first mold that is die-cut to the outlet side of the curved passage portion and a second mold that is die-cut to the inlet side of the curved passage portion are used, and the first die has a first convex portion. The second mold includes a second convex portion, the first convex portion and the second convex portion are mold-matched from both sides in the thickness direction of the flange so that the molds can be removed from each other. The curved passage portion is formed by cooperation of a convex portion and the second convex portion ,
The flange is formed with a joint where the end of the second half is joined, and an insertion hole is formed adjacent to the joint, and the end of the second half is formed at the end of the second half A protrusion is formed in the insertion hole, the protrusion is inserted into the insertion hole, and the end of the second half is joined to the joint.
The second mold includes a step portion for forming the insertion hole adjacent to the second convex portion, and the first convex portion and the second convex portion are matched with each other on a side surface, and the die In the combined state, the tip surface of the first convex portion is mold-matched with the stepped portion, and the tip surface of the second convex portion is the opening of the curved mold portion at the outlet side opening of the first mold. A method for manufacturing a resin intake manifold, wherein the mold is matched with an end face . A resin intake manifold manufactured by the manufacturing method according to claim 1 .

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