JP5828705B2 - 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 resin-made intake manifold made of resin.

  Patent Document 1 discloses a resin intake manifold that is configured by combining a plurality of pieces as a whole. The intake manifold includes a surge tank, a branch passage branched from the surge tank, and a closed space arranged on the curved inner side of the branch passage, and each welding portion of the plurality of pieces is subjected to welding. It is disclosed that they are arranged in a line along the pressing direction.

JP 2009-209762 A

  However, in the resin intake manifold of Patent Document 1, a plurality of pieces are welded to form a lower piece, and further, the lower piece, the upper piece, and the middle piece are welded to form a surge tank and a branch passage. Therefore, the cost increases due to an increase in the number of welding steps.

  In order to secure the strength of the welded part, it is conceivable to prevent the deformation with respect to the applied load during vibration welding by making the welded part thick. However, since an extra amount of resin is required, a resin intake is required. The weight of the manifold will increase. In particular, in the resin intake manifold of Patent Document 1, a wall portion is further formed below the welding line at the edge of the partition wall, which further increases the weight of the resin intake manifold. Furthermore, it is necessary to ensure the strength of the peripheral wall of the surge tank so as not to be deformed by the gas pressure inside the surge tank.

  Therefore, the present invention has been made to solve the above-described problems, and an object of the present invention is to provide a resin intake manifold that can achieve weight reduction while ensuring strength.

One aspect of the present invention made to solve the above problems is a surge tank that introduces air from an intake inlet, and a plurality of curved branches that communicate with the surge tank and distribute the air to a plurality of cylinders of an engine. A resin intake manifold formed on the inner side of the inner peripheral portion of the branch passage, and a portion outside the curved intake pipe portion constituting a part of the branch passage. A first piece that forms a first piece, a second piece that is welded to the first piece to form an inner portion of the intake pipe portion, and a third piece that is welded to the second piece, and the surge The tank is formed by welding a first surge tank forming part provided in the second piece and a second surge tank forming part provided in the third piece, and a plurality of tanks are provided inside the inner peripheral part of the branch passage. of A first rib formed so as to connect between the peripheral wall of the surge tank and the peripheral wall of the branch passage along the arrangement direction of the branch passage, the first rib, the peripheral wall of the surge tank, and the branch passage A hollow portion formed so as to be surrounded by a peripheral wall of the first rib, and a second rib formed so as to be orthogonal to the first rib and to connect between the peripheral wall of the surge tank and the peripheral wall of the branch passage, The first rib is formed substantially parallel to the opening surface of the first surge tank forming portion .

  According to this aspect, since the hollow portion is formed so as to be surrounded by the first rib, the peripheral wall of the surge tank, and the peripheral wall of the branch passage along the arrangement direction of the plurality of branch passages, the resin intake manifold Weight reduction can be achieved.

  Further, a first rib formed so as to connect between the peripheral wall of the surge tank and the peripheral wall of the branch passage inside the branch passage, and formed orthogonal to the first rib, along the arrangement direction of the plurality of branch passages And a second rib formed to connect between the peripheral wall of the surge tank and the peripheral wall of the branch passage. As described above, since the first rib and the second rib orthogonal to each other are provided between the peripheral wall of the surge tank and the peripheral wall of the branch passage, the peripheral wall of the surge tank is deformed by the pressure of the gas inside the surge tank. Can be suppressed. Therefore, durability against the gas inside the surge tank is improved, and the strength of the resin intake manifold can be secured.

In the above configuration, before Symbol second piece comprises a second rib and said cavity and said first rib, said first rib the hollow portion at the center portion in the arrangement direction of the plurality of branch passages It is preferable to provide an opening that communicates with.

  According to this aspect, the first piece that forms the outer portion of the curved intake pipe portion that constitutes a part of the branch passage, and the inner portion of the intake pipe portion that is welded to the first piece are formed. And a second piece. The second piece includes a first rib, a cavity, and a second rib. And a 1st rib is provided with the opening part connected to a cavity part in the center part of the sequence direction of a some branch passage. Thereby, the welding jig | tool for welding a 1st piece and a 2nd piece can be inserted from the opening part of a 1st rib, and can be closely_contact | adhered to a 2nd piece via a cavity part. Therefore, at the time of welding the first piece and the second piece, the welding jig can be reliably held, and the first piece and the second piece can be reliably welded. Therefore, the strength of the welded portion of the resin intake manifold is improved.

In the above configuration, before Symbol branch passage includes a curved line portion is welded communicating with the said intake channel section of the passage opening and equipped with the third piece and the second surge tank forming part provided in the second piece The first welded portion formed by welding the passage opening of the intake conduit portion and the curved conduit portion is the second welded portion of the first surge tank forming portion and the second surge tank forming portion. It is preferable that the second rib is disposed at a position closer to the third piece than the welded portion, and is formed so as to connect the first welded portion and the second welded portion.

  According to this aspect, the third piece is welded to the second piece. The surge tank is formed by welding the first surge tank forming part provided in the second piece and the second surge tank forming part provided in the third piece. The branch passage is formed by welding the passage opening of the intake pipe portion provided in the second piece and the curved pipe portion provided in the third piece and communicating with the second surge tank forming portion. In addition, the first welded portion where the passage opening of the intake pipe portion and the curved conduit portion are welded is a third piece than the second welded portion where the first surge tank forming portion and the second surge tank forming portion are welded. It is arranged at the side position. And the 2nd rib is formed so that between the 1st welding part and the 2nd welding part may be connected. Thereby, the durability with respect to the load applied to a 1st welding part improves at the time of welding of a 2nd piece and a 3rd piece. Therefore, the strength of the welded portion of the resin intake manifold is further improved.

  In said aspect, it is preferable that the said 2nd piece is equipped with the recessed part which can be fitted with the convex part of the front-end | tip of the welding jig inserted from the said opening part.

  According to this aspect, since the second piece has the concave portion that can be fitted to the convex portion at the tip of the welding jig to be inserted from the opening, the first piece and the second piece are more reliably welded. can do.

  According to the resin intake manifold according to the present invention, weight reduction can be achieved while ensuring strength.

It is a front view of a resin-made intake manifold. It is the figure which looked at the resin-made intake manifolds shown in FIG. 1 from the drawing right side. It is the figure which looked at the resin-made intake manifolds shown in FIG. 1 from the drawing left side. It is the figure which looked at the resin-made intake manifolds shown in FIG. 1 from the drawing upper side. It is AA sectional drawing of FIG. It is an exploded view of a resin intake manifold. It is the figure of the state which removed the lower piece from the resin-made intake manifolds, Comprising: It is the figure seen from the joining surface side with the lower piece in a middle piece. It is a figure when an upper piece and a middle piece are seen from the left side of FIG. It is BB sectional drawing of FIG. It is CC sectional drawing of FIG. It is a figure which shows arrangement | positioning of the shaping | molding die when forming a middle piece. It is a figure which shows arrangement | positioning of the welding jig | tool when welding an upper piece and a middle piece.

  DESCRIPTION OF EXEMPLARY EMBODIMENTS Hereinafter, embodiments of the invention will be described in detail with reference to the accompanying drawings.

[Description of resin intake manifold]
First, an overall outline of the resin intake manifold 1 will be described. Here, FIG. 1 is a front view of the resin intake manifold 1. 2 is a view of the resin intake manifold 1 shown in FIG. 1 as seen from the right side of the drawing, FIG. 3 is a view of the resin intake manifold 1 shown in FIG. 1 as seen from the left side of the drawing, and FIG. FIG. 1 is a view of a resin intake manifold 1 shown in FIG. 5 is a cross-sectional view taken along the line AA of FIG. 1, and FIG. 6 is an exploded view of the resin intake manifold 1.

  As shown in FIGS. 1-6, the resin-made intake manifold 1 is comprised from the upper piece 10, the middle piece 12, the lower piece 14, etc. As shown in FIG. Further, as shown in FIG. 5, the upper piece 10 is arranged on the upper side of the middle piece 12 and constitutes an upper half shell portion of each branch passage 16 positioned on the upper side of the drawing. That is, the upper piece 10 forms a portion outside the curved intake pipe portion 18 that constitutes a part of the branch passage 16. The upper piece 10 is an example of the “first piece” in the present invention, the middle piece 12 is an example of the “second piece” in the present invention, and the lower piece 14 is an example of the “third piece” in the present invention. .

  The middle piece 12 includes a surge tank forming portion 22 which is disposed on the lower side of the drawing of FIG. 5 with respect to the upper piece 10 and constitutes the upper half shell portion of the surge tank 20. Further, the middle piece 12 constitutes a lower half shell portion of each branch passage 16 located on the upper side of the surge tank 20 in FIG. That is, the middle piece 12 forms a portion inside the curved intake pipe portion 18 that constitutes a part of the branch passage 16. The surge tank forming part 22 is an example of the “first surge tank forming part” in the present invention.

  Further, the middle piece 12 includes a welding portion 26 that is welded to the surge tank forming portion 24 of the lower piece 14 at the surge tank forming portion 22. Further, the middle piece 12 includes a welded portion 32 that is welded to the curved conduit portion 30 of the lower piece 14 at the passage port 28 of the intake conduit portion 18. The weld portion 32 is disposed at a position closer to the lower piece 14 than the weld portion 26. The weld portion 32 is an example of the “first weld portion” in the present invention, and the weld portion 26 is an example of the “second weld portion” in the present invention.

  The lower piece 14 is disposed on the lower side of the drawing in FIG. 5 with respect to the middle piece 12, and includes a surge tank forming portion 24 that constitutes the lower half shell portion of the surge tank 20. Further, the lower piece 14 constitutes a part of each branch passage 16 located on the lower side of the surge tank 20 in FIG. 5, and includes a curved pipe section 30 that communicates between the surge tank and the intake pipe section 18. I have. The surge tank forming part 24 is an example of the “second surge tank forming part” in the present invention.

  The upper piece 10, the middle piece 12 and the lower piece 14 as described above are formed in a predetermined shape by injection molding using a synthetic resin as a material.

  The branch passage 16 communicates with the surge tank 20, branches from the surge tank 20, is formed in a curved shape, and a plurality of branch passages 16 are formed. Here, as an example, four branch passages 16 are formed. A portion of the branch passage 16 located on the lower side of the drawing in FIG. 5 with respect to the surge tank 20 is formed by a curved conduit portion 30 provided in the lower piece 14. Further, in the branch passage 16, the intake pipe portion 18 located on the upper side in FIG. 5 with respect to the surge tank 20 is formed by the upper piece 10 and the middle piece 12.

  As shown in FIG. 5, the surge tank 20 is formed between the middle piece 12 and the lower piece 14, and is formed so as to be contained inside the inner peripheral portion 34 of the branch passage 16. Further, as shown in FIG. 7 to be described later, the surge tank 20 communicates with the intake introduction port 38 and communicates with the introduction flow path portion 35 in which the flow path axis L1 is formed in a curved shape. And a main flow path portion 37 having a flow path axis L2 formed in a linear shape. Here, the flow path axis L 1 is the central axis of the introduction flow path part 35, and the flow path axis L 1 is the central axis of the main flow path part 37.

  Further, as shown in FIG. 1 and the like, a flange 36 for fixing a throttle device (not shown) is formed in the resin intake manifold 1. The flange 36 is formed with an intake inlet 38 leading to the internal surge tank 20. Further, as shown in FIG. 2, the resin intake manifold 1 is formed with a flange 40 for attaching an EGR pipe (not shown). The flange 40 is formed with an EGR gas inlet 42 communicating with the internal surge tank 20.

  Further, as shown in FIG. 1 and the like, the resin intake manifold 1 has a blow-by gas reduction pipe (not shown) used to recirculate blow-by gas from a crankcase (not shown) of an engine (not shown). A PCV (Positive Crankcase Ventilation) pipe 44 (pipe joint) for attachment is formed. The PCV pipe 44 is formed integrally with the upper piece 10. The PCV pipe 44 communicates with the internal surge tank 20 via a PCV passage 46 (see FIG. 7) described later. The blowby gas introduced from the blowby gas reduction pipe into the PCV pipe 44 is introduced into the surge tank 20 through the PCV passage 46 communicating with the PCV pipe 44.

  Further, as shown in FIG. 1 and the like, the resin intake manifold 1 is formed with a pipe joint 48 for attaching a negative pressure pipe (not shown) for introducing a negative pressure to a brake booster (not shown). This pipe joint 48 leads to the internal surge tank 20.

  In the resin intake manifold 1 having such a structure, air (intake air) filtered by an air cleaner (not shown) is introduced into the surge tank 20 from the intake inlet 38 through a throttle device (not shown). . The air introduced into the surge tank 20 is blowby gas introduced into the surge tank 20 through the PCV passage 46 or EGR gas introduced into the surge tank 20 from the EGR gas inlet 42. It is mixed with gas other than air. Thereafter, a mixed gas of air and a gas other than air is distributed to each branch passage 16 and introduced into each cylinder (not shown) of the engine through each branch passage 16.

  In addition, the resin intake manifold 1 having such a structure is manufactured by combining the upper piece 10, the middle piece 12, and the lower piece 14 together and joining them together by vibration welding.

[Explanation of middle piece]
Next, the middle piece 12 among the pieces constituting such a resin intake manifold 1 will be described. Here, FIG. 7 is a view showing a state in which the lower piece 14 is removed from the resin intake manifold 1, and is a view as seen from the joint surface side of the middle piece 12 with the lower piece 14.

  As shown in FIG. 7, a flange 50 that is fixed to a cylinder head (not shown) of an engine (not shown) is formed on the side of the middle piece 12 that joins the lower piece 14. The flange 50 is formed with four intake outlets 52 corresponding to a four-cylinder engine side by side. A plurality of mounting holes 54 for fixing to the cylinder head are formed at the edge of the flange 50. Further, a concave surge tank forming portion 22 constituting the upper half shell portion of the surge tank 20 is formed on the side of the middle piece 12 where the lower piece 14 is joined. Four passage ports 28 corresponding to the respective branch passages 16 are formed side by side on the opposite side of the flange 50 across the surge tank forming portion 22. A gas introduction hole 56 communicating with the surge tank 20 is formed in the middle portion of the middle piece 12 so as to correspond to the pipe joint 48.

  As will be described later, the middle piece 12 includes a first rib 58, a cavity 64, and a second rib 68 (see FIGS. 7 to 10).

[Description of the structure between the peripheral wall of the surge tank and the peripheral wall of the branch passage]
Next, the structure between the peripheral wall of the surge tank 20 and the peripheral wall (passage port 28) of the branch passage 16 in the middle piece 12 will be described with reference to FIGS. 8 is a side view of FIG. 7 as viewed from the left side, FIG. 9 is a sectional view taken along line BB in FIG. 7, and FIG. 10 is a sectional view taken along line CC in FIG.

  As shown in FIGS. 7 and 8, the first rib 58 is located inward of the inner peripheral portion 34 of the branch passage 16 in the short direction of the surge tank 20 (in the direction orthogonal to the flow path axis L2, as shown in FIG. In the vertical direction (left and right direction in FIG. 8), the peripheral wall 60 of the surge tank 20 and the peripheral wall 62 of the branch passage 16 are connected to each other. As shown in FIG. 7, the first rib 58 is formed across the four passage openings 28 along the arrangement direction of the four passage openings 28. Further, as shown in FIG. 8, the first rib 58 is formed in a flat plate shape that is horizontally long in the horizontal direction of the drawing, and between the peripheral wall 60 of the surge tank 20 and the peripheral wall 62 of the passage port 28 in the horizontal direction of the drawing. Are connected.

As shown in FIGS. 8 and 9, the cavity 64 is formed so as to be surrounded by the peripheral wall 60 of the surge tank 20, the peripheral wall 62 of the branch passage 16, and the first rib 58. And this cavity part 64 is formed along the sequence direction (left-right direction of FIG. 9) of the four passage openings 28. Thus, since the cavity part 64 is formed, the middle piece 12 can be reduced in weight, and the cost can be reduced by eliminating excess resin.

  Further, as shown in FIGS. 7 and 9, the first rib 58 includes an opening 66 at the center in the arrangement direction of the four passage openings 28 (the direction of the flow path axis L2 of the surge tank 20). Second ribs 68 are formed at both ends of the portion 66. The second rib 68 is formed to be orthogonal to the first rib 58 as shown in FIG. Further, the second rib 68 is formed so as to connect between the peripheral wall 60 of the surge tank 20 and the peripheral wall 62 of the branch passage 16, and more specifically, to connect between the welded portion 26 and the welded portion 32. Has been. Since the first rib 58 and the second rib 68 are orthogonal to each other in this manner, stress concentration due to gas pressure inside the surge tank 20 can be avoided on the peripheral wall 60 of the surge tank 20, and a resin intake manifold can be avoided. The pressure resistance of 1 is improved.

  The second rib 68 includes a first portion 70 formed on the side where the cavity 64 is formed, and a second portion 72 on the side where the lower piece 14 is disposed, with the position of the first rib 58 as a boundary. It has. Here, a welded portion 26 and a welded portion 32 are provided as welded portions between the middle piece 12 and the lower piece 14. As shown in FIG. 10, with respect to the arrangement direction of the middle piece 12 and the lower piece 14, the welded portion 32 protrudes toward the lower piece 14 with respect to the welded portion 26, and a step between the welded portion 26 and the welded portion 32. have. Therefore, the second portion 72 of the second rib 68 is formed so as to connect between the welded portion 26 and the welded portion 32 having such a step. As shown in FIG. 8, the second portion 72 is formed in a trapezoidal or triangular shape when viewed from the arrangement direction of the four passage openings 28. By forming the second portion 72 as described above, when the middle piece 12 and the lower piece 14 are welded, durability against a load applied to the welded portion 32 of the middle piece 12 can be provided.

  FIG. 11 shows a layout of the mold when such a middle piece 12 is manufactured. As shown in FIG. 11, a cavity 84 is formed between the first mold 74, the second mold 76, the first slide mold 78, the second slide mold 80, and the third mold 82. Then, the molten resin is injected into the cavity 84, and the resin is cooled to a predetermined temperature. More specifically, as shown in FIG. 11, the first slide mold 78 and the second slide mold 80 are inserted between the first molding die 74 and the second molding die 76 from both sides, and the third The molding die 82 is disposed between the first slide die 78 and the second slide die 80 through the inside of the second molding die 76 and the opening 66.

  Further, FIG. 12 shows a layout of the welding jig when the upper piece 10 and the middle piece 12 are welded. As shown in FIG. 12, the first welding jig 86 is arranged on the upper side of the upper piece 10, and the second welding jig 88 and the third welding jig 90 are inserted into the cavity 64 of the middle piece 12 from both sides. To do. Then, the fourth welding jig 92 is inserted from the opening 66 of the first rib 58 and disposed between the second welding jig 88 and the third welding jig 90 through the cavity 64. At this time, the convex portion 94 at the tip of the fourth welding jig 92 is fitted into the concave portion 96 formed between the two branch passages 16 in the middle of the four branch passages 16 in the middle piece 12. As described above, the welding jigs are arranged and welded to the upper piece 10 at the welding portion 98 of the middle piece 12 by vibration welding.

  By arranging the welding jigs in this way, the welding jigs can be held even when a load is applied when the upper piece 10 and the middle piece 12 are welded by vibration welding. Strength can be secured.

[Effect of this embodiment]
According to this embodiment, the cavity 64 formed so as to be surrounded by the first rib 58, the peripheral wall 60 of the surge tank 20, and the peripheral wall 62 of the branch passage 16 along the arrangement direction of the plurality of branch passages 16. Therefore, the weight of the resin intake manifold 1 can be reduced. In addition, the cost can be reduced by eliminating excess resin.

  Further, it is formed so as to connect between the peripheral wall 60 of the surge tank 20 and the peripheral wall 62 of the branch passage 16 inside the inner peripheral portion 34 of the branch passage 16 and is formed along the arrangement direction of the plurality of branch passages 16. The first rib 58 is provided. The second rib 68 is formed so as to be orthogonal to the first rib 58 and connect between the peripheral wall 60 of the surge tank 20 and the peripheral wall 62 of the branch passage 16. As described above, since the first rib 58 and the second rib 68 that are orthogonal to each other are provided between the peripheral wall 60 of the surge tank 20 and the peripheral wall 62 of the branch passage 16, the surge is caused by the gas pressure inside the surge tank 20. It can suppress that the surrounding wall 60 of the tank 20 deform | transforms. Therefore, durability against the gas inside the surge tank 20 is improved, and the strength of the resin intake manifold 1 can be secured.

  Further, the upper piece 10 that forms the outer portion of the curved intake pipe portion 18 that constitutes a part of the branch passage 16, and the middle piece 12 that welds the upper piece 10 and forms the inner portion of the intake pipe portion 18. And having. The middle piece 12 includes a first rib 58, a cavity 64, and a second rib 68. The first rib 58 includes an opening 66 that communicates with the cavity 64 at the center in the arrangement direction of the plurality of branch passages 16. Accordingly, the fourth welding jig 92 for welding the upper piece 10 and the middle piece 12 can be inserted from the opening 66 of the first rib 58 and brought into close contact with the middle piece 12 through the cavity 64. . Therefore, when the upper piece 10 and the middle piece 12 are welded, the first welding jig 86, the second welding jig 88, the third welding jig 90, and the fourth welding jig 92 can be reliably held. The upper piece 10 and the middle piece 12 can be reliably welded. Therefore, the strength of the welded portion of the resin intake manifold 1 is improved.

  The second rib 68 is formed so as to connect between the welded portion 26 and the welded portion 32. Thereby, the durability with respect to the load applied to the welding part 32 improves at the time of welding of the middle piece 12 and the lower piece 14. Therefore, the strength of the welded portion of the resin intake manifold 1 is further improved.

  Moreover, since the middle piece 12 is provided with the recessed part 96 which can be fitted with the convex part 94 of the front-end | tip of the 4th welding jig | tool 92 inserted from the opening part 66, the upper piece 10 and the middle piece 12 are connected more reliably. Can be welded.

  It should be noted that the above-described embodiment is merely an example and does not limit the present invention in any way, and various improvements and modifications can be made without departing from the scope of the invention.

DESCRIPTION OF SYMBOLS 1 Resin intake manifold 10 Upper piece 12 Middle piece 14 Lower piece 16 Branch passage 20 Surge tank 28 Passage port 30 Curved pipe part 34 Inner peripheral part 58 1st rib 60 Peripheral wall 62 Peripheral wall 64 Cavity part 66 Opening part 68 2nd rib 74 1st 1 molding die 76 second molding die 78 first slide die 80 second slide die 82 third molding die 86 first welding jig 88 second welding jig 90 third welding jig 92 fourth welding jig 94 convex portion 96 Concave portion 98 Welded portion

Claims (4)

A surge tank for introducing air from an intake air inlet; and a plurality of curved branch passages communicating with the surge tank and distributing the air to a plurality of cylinders of the engine, the surge tank having an inner periphery of the branch passage In the resin intake manifold formed on the inner side than the part,
A first piece forming an outer portion of a curved intake pipe portion constituting a part of the branch passage;
A second piece welded to the first piece to form an inner portion of the intake pipe section;
A third piece welded to the second piece,
The surge tank is formed by welding a first surge tank forming part provided in the second piece and a second surge tank forming part provided in the third piece,
Inside the inner periphery of the branch passage,
A first rib formed so as to connect between a peripheral wall of the surge tank and a peripheral wall of the branch passage along an arrangement direction of the plurality of branch passages;
A cavity formed so as to be surrounded by the first rib, the peripheral wall of the surge tank, and the peripheral wall of the branch passage;
A second rib formed so as to be orthogonal to the first rib and connect between the peripheral wall of the surge tank and the peripheral wall of the branch passage ;
The first rib is formed substantially parallel to the opening surface of the first surge tank forming portion;
Resin intake manifold according to claim. The resin intake manifold according to claim 1,
Before Stories second piece comprises a second rib and said cavity and said first rib,
The first rib includes an opening communicating with the cavity at a central portion in the arrangement direction of the plurality of branch passages;
Resin intake manifold featuring The resin intake manifold according to claim 2,
Before SL branch passage includes a curved conduit portion communicating with the said intake channel section of the passage opening and equipped with the third piece and the second surge tank forming part provided in the second piece is formed by welding,
The first welded portion where the passage opening of the intake duct portion and the curved conduit portion are welded is more than the second welded portion where the first surge tank forming portion and the second surge tank forming portion are welded. Arranged at the position of the third piece side,
The second rib is formed so as to connect the first welded portion and the second welded portion;
Resin intake manifold featuring The resin intake manifold according to claim 2 or 3,
The second piece has a recess that can be fitted with a protrusion at the tip of a welding jig to be inserted from the opening,
Resin intake manifold featuring

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