JPH02229635A - Suction manifold - Google Patents

Abstract

PURPOSE:To manufacture the suction manifold simply and with a large degree of freedom of a design without necessitating a bulge working process and a brazing process, etc., by forming a plenum chamber use tubular bulge part and a suction branch feed-out use tubular bulge part in a metallic clad sheet. CONSTITUTION:By printing a press-contact inhibitor in a necessary pattern on one face of one of two pieces of Al plates 10, and pressing the other Al plate 10 against this face, a clad sheet 2 having plural groups consisting of a non-press-contacting part for forming a plenum chamber use tubular bulge part and a non-press-contact part for forming a suction branch feed-out use tubular bulge part is made. Subsequently, by leading fluid pressure such as air pressure, etc., into the inside of both the bulge part forming use non-press-contact parts of this clad sheet 2 and the tubular bulge part forming use non-press-contact part which becomes a throttle body fitting use flange 5, they are brought to pre-tube expansion, and thereafter, cut to a necessary shape, brought to regular tube expansion, and a plenum chamber use tubular bulge part 3, a suction branch feed-out use tubular bulge part 3 and a throttle body fitting use flange use tubular bulge part 12 are formed. In the end, by widening the tubular bulge part 12 to the outside, and bending a non-press-contact part 11 to the outside, both the flanges 5, 6 are formed, and a suction manifold 1 is manufactured.

Description

DETAILED DESCRIPTION OF THE INVENTION Field of the Invention This invention relates to an intake manifold used, for example, in a motor vehicle.

In this specification, the term "aluminum" refers to
In addition to pure aluminum, aluminum alloys are included.

BACKGROUND ART Conventionally, intake manifolds have generally been manufactured by casting using sand molds or metal molds.

However, the surface of the cast product is rough, so in order to reduce air resistance to improve intake efficiency, it is necessary to finish at least the inner surface to make it smooth, which poses the problem of tedious work. Ta. Furthermore, because it is impossible to finish the entire inner surface of the intake manifold smooth due to its shape, it has not been possible to sufficiently reduce air resistance to improve intake efficiency. Further, in cast products, the thickness of the peripheral wall cannot be reduced beyond a certain limit due to the flowability of the metal during casting, so there is a problem in that the weight becomes large.

Therefore, an intake manifold consisting of an aluminum main pipe serving as a plenum chamber and an aluminum branch pipe was considered. The main pipe and branch pipes in this intake manifold are formed by performing various processing on a wrought aluminum tube formed by plastic working such as extrusion, impact extrusion, forging, and press working.

For example, the main pipe is made by bulging the circumferential wall of a pipe made of wrought aluminum material to form multiple bulges, drilling holes in the closing wall at the tip of the bulge, and then burring holes in the closing wall at the tip. It is made by bending the surrounding part outward and enlarging its tip to form a cylindrical outward protrusion for connecting a branch pipe. The intake manifold is manufactured by fitting one end of the branch pipe into the cylindrical outward protrusion for connecting the branch pipe and brazing the two.

However, in order to manufacture this intake manifold, the peripheral wall of a wrought aluminum pipe is bulged to form multiple bulges, holes are drilled in the closing wall at the end of the bulges, and then burring is performed. By machining, the portion of the tip closing wall around the hole is bent outward and its tip is expanded to form a cylindrical outward protrusion for connecting a branch pipe, and one end of the branch pipe is further bent into a tube for connecting a branch pipe. There is a problem in that manufacturing is troublesome because it needs to be fitted into the outwardly protruding portion and brazed together. In particular, since the cost of bulge processing is high, there is a problem in that it leads to an increase in cost. Furthermore, there is a problem in that there is little freedom in designing the shape of the intake manifold.

An object of the present invention is to provide an intake manifold that solves the above problems.

Means for Solving the Problems An intake manifold according to the present invention includes a metal laminated plate, a plenum chamber tubular bulge having at least one end opened at the periphery of the laminated plate, and a plenum chamber tubular bulge that is separated from the plenum chamber tubular bulge. A tubular bulge for intake branching and delivery is formed which extends toward the periphery of the plate and has a tip opening at the periphery of the mating plate.

Example Embodiments of the present invention will be described below with reference to the drawings.

In the following description, "upper and lower" refers to the upper and lower sides of the drawing.

In Figure 1, the intake manifold (1) is formed into a horizontally long aluminum laminated plate (2), with one end opening at the right edge of the laminated plate (2), this opening serving as an intake inlet, and the other end being closed. A tubular bulge for the plenum chamber (3) extending from side to side, and a tubular bulge for the plenum chamber (3).
A plurality of tubular bulges for inlet air branching and delivery, which branch out and extend toward the lower edge of the laminated plate (2), and whose tips open at the lower edge of the laminated plate (2), and these openings serve as intake outlets.
4) is formed. The intake branch/delivery tubular bulge (4) is thinner than the plenum chamber tubular bulge (3), and gradually tapers toward the tip.

A throttle body mounting flange (5) is integrally formed on the right edge of the mating plate (2) so as to include the right end opening of the plenum chamber tubular bulge (3). A throttle body incorporating a throttle valve (not shown) is attached to this flange (5), and an air supply pipe from an air cleaner is connected to this throttle body. In addition, the lower edge of the mating plate (2) includes the lower end openings of all the intake branch and delivery tubular bulges (4), and the tips of each intake branch and delivery tubular bulges (4) are connected to the cylinders of the engine. A flange (6) for attachment to the head is integrally formed.

In such a configuration, intake air is sent to the intake inlet via a throttle body (not shown). This intake air passes through the plenum chamber tubular bulge (3), enters each intake branch delivery tubular bulge (4), and passes through the intake branch delivery tubular bulge (4) to the engine. fed into the cylinder head.

The intake manifold (1) is manufactured as follows.

That is, an anti-crimping agent is printed in the desired pattern on one side of one of the two aluminum plates, and the other plate is crimped to this surface to create a laminated plate with a non-crimped part. It is manufactured by the so-called roll bonding method, which introduces fluid pressure such as air pressure into the non-crimped portion of the plate. To explain in more detail the method for manufacturing the intake manifold, an aluminum plate (1
Prepare two sheets of aluminum plate (10) and print an anti-crimping agent in the desired pattern on one side of one aluminum plate (10).
By crimping the other aluminum plate (IO) to this surface, a laminated plate having a plurality of sets consisting of a non-crimped part for forming a tubular bulge for a plenum chamber and a non-crimped part for forming a tubular bulge for intake branch and delivery. Create (2). This mating plate (2) has a non-crimped part for forming a tubular bulge that is thicker than the plenum chamber tubular bulge (3) and will serve as the throttle body mounting flange (5), and a cylinder head bulge. A non-crimping portion (11) for forming a connecting flange (6) is also provided. Next, this laminated board (
2) a non-crimped part for forming a tubular bulge for the plenum chamber;
Fluid pressure such as air pressure is introduced into the non-crimped part for forming the tubular bulge for intake branch and delivery and the non-crimped part to form the tubular bulge that will become the flange (5) for attaching the throttle body. The sections are pre-inflated to form tubular bulges that are each thinner than the final state. At this time, the non-crimping portion (11) for forming the flange (6) for connection to the cylinder head is kept in a non-bulging state. Thereafter, the laminated plate (2) is cut into a desired shape, and the pre-inflated tubular bulging portion is main-inflated into a tubular bulging portion for a plenum chamber (3).
The tubular bulge (12) that will become the intake branch/delivery tubular bulge (4) and the throttle body mounting flange (5) are formed (see Figure 2). At this time, the flange (6) for connection to the cylinder head is formed. 〉Non-crimped portion (11) for forming
In this step, the space between both aluminum plates (IO) is sealed to prevent fluid pressure from escaping between both aluminum plates (10). Finally, the tubular bulging portion (12) is expanded outward, and the non-crimped portion (11) is bent outward to form both flanges (5) and (6). In this way, the intake manifold (1) is manufactured.

FIG. 3 shows another embodiment of the invention. In FIG. 3, the intake manifold (15) has a bent intake branch delivery tubular bulge (16).

Such an intake manifold (15) is produced by making the intake manifold (1) as shown in FIG. Manufactured by

In the above two embodiments, the flange for connection to the cylinder head is formed integrally with the tubular bulge for intake branch and delivery, but this flange is formed separately from the tubular bulge, and It may be joined to the bulge.

Further, in the above two embodiments, the tubular bulging portion for the plenum chamber has one end open to the periphery of the mating plate and the other end closed, but the invention is not limited to this, and both ends may be open. . In this case, the opening at one end is closed with a separate member.

Effects of the Invention The intake manifold of the present invention includes a metal laminated plate, a plenum chamber tubular bulge portion with at least one end opening at the periphery of the laminated plate, and a tubular bulge portion for the plenum chamber that is separated from the plenum chamber tubular bulge portion toward the periphery of the laminated plate. Since the air intake manifold is formed with a tubular bulge for air intake branching and delivery that extends from the side and has its tip opened at the periphery of the laminated plate, it is possible to achieve a reduction in weight compared to a conventional air intake manifold. Further, in the intake manifold according to the present invention, for example, an anti-crimping agent is printed in a desired pattern on one side of one of the two metal plates, and the other plate is crimped to this surface to form a non-crimped part. It can be manufactured using the so-called roll bonding method, which involves creating a laminated plate with a laminate and introducing fluid pressure such as air pressure into the non-crimped part of the laminated plate, so it can be manufactured using the so-called roll bonding method. etc., making it easy to manufacture and reducing manufacturing costs. Moreover, since the degree of freedom in designing the plenum chamber tubular bulge and the intake branch/delivery tubular bulge is increased, it is possible to easily manufacture products that can be applied to various types of engines.

[Brief explanation of the drawing]

FIG. 1 is a perspective view showing an embodiment of the intake manifold according to the present invention, FIG. 2 is a perspective view showing a state in the middle of manufacturing the intake manifold shown in FIG. 1, and FIG. 3 is a perspective view showing an embodiment of the intake manifold according to the present invention. It is a perspective view showing an example of this. (1) (15)...Intake manifold, (2)...Platform plate, (3)...Tubular bulge for plenum chamber, (
4) (18)... Tubular bulge for intake branch delivery. that's all

Claims (1)

[Claims] The metal laminated plate includes a plenum chamber tubular bulge having at least one end opening at the periphery of the laminated plate, and a tubular bulge for the plenum chamber that branches off from the plenum chamber tubular bulge and extends toward the periphery of the laminated plate;
The intake manifold is also formed with a tubular bulge for intake branching and delivery, the tip of which is open at the periphery of the mating plate.