JPH07195421A - Production of box body having bent passage - Google Patents

Abstract

PURPOSE:To produce a box body having a bent passage capable of compactly housing complicated and manifold passage piping. CONSTITUTION:Partition walls W1, W2 forming a bent passage P1 are molded on the inner surfaces of a pair of split members A, B from a primary resin in a first process so as to be continued to the partition walls 3 forming the outer peripheral parts of the split bodies (A) and subsequently, continuous connection spaces C1-C4 having a secondary resin injection ports I opened to the outer peripheral boded parts of a pair of the split bodies to which a pair of recessed grooves are abutted are formed in a second abutting process (B) and, finally, a secondary resin M is injected into the connection spaces from the injection ports I simultaneously with outer peripheral connection parts C5, C6 in an integration process to integrate the split bodies A, B, (C). By this constitution, the bonded part has a sufficient adhesion area by the secondary resin and a box body having a complicated piping system having the bend passage excellent in bonding strength can be mass-produced by a two-stage molding method.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of manufacturing a box used in a piping system having variously bent flow path piping.

[0002]

2. Description of the Related Art Generally, in a complicated piping system, it is necessary to bend the pipes in various ways to form a flow pipe.
Not only is assembly complicated and prone to failure,
The volume of piping becomes large, and it is not possible to meet the demand for compact piping system. For example, as a request for improving the efficiency of an engine of an automobile, an engine equipped with a so-called sequential twin turbo system is usually provided with a map in which an operating range for operating a secondary turbo is represented with respect to a throttle opening and an engine speed. The supercharging is switched according to the map, but the flow path piping such as solenoid valves for performing various controls is complicated and diversified, and assembly in a narrow engine room is complicated, resulting in increased weight and cost. It is the cause.

Therefore, when a complicated and diverse piping system such as a control assembly needs to be installed in a limited space such as an engine room, the entire piping system can be made lightweight and compact.
It is possible to meet various demands such as facilitating the assembling work and improving the reliability of the piping system.

[0004]

In order to meet such a demand, it is indispensable to manufacture a box body whose interior is divided into a curved passage so that a complicated and diversified flow path pipe can be compactly accommodated. Become. As such a method, a box body having a bent passage is manufactured by forming a plurality of partition walls facing each other on the inner surfaces of a pair of half-divided bodies and joining them to form a bent passage, and joining them. Although proposed, it may be insufficient to weld or bond the joint ends in order to obtain a joint strength higher than a certain level.

At present, as a method for forming a hollow body by joining a pair of half-split bodies, JP-A-63-237917, JP-A-63-23918, JP-B-2-20410, and JP-B-2-38377. However, such a method is a method of joining only the outer peripheral portions of a pair of half-split bodies to form a hollow body, and is formed inside the half-split bodies such as a box having a bent passage. The problem is how to firmly join the partition walls for forming the curved passage. Therefore, it is an object of the present invention to provide a method of manufacturing a box body having a bent passage, which can accommodate complicated and diversified flow passage pipes in a compact manner.

[0006]

According to the present invention, a recess is formed on a joint end face of a partition wall provided on an inner surface of a half-divided body, the recess extending continuously along the joint end face, and the joint resin is jointly injected through the concavity. This is done by paying attention to the fact that a jointly bent passage can be achieved at the same time as joining the boxes, and it is a method of manufacturing a box having a bent passage and a connection port for external connection. A plurality of continuously extending facing each other on the inner surface and joining to define a curved passage inside the box,
A step of molding a pair of half-divided bodies with a primary resin, which has a partition wall having a concave groove along the end face; and a step of forming the pair of half-divided bodies with the concave grooves facing each other along the joint portion of the partition wall. A step of butting so as to form an extended joining space, and a partition wall are joined by injecting a secondary resin into the joining space of the pair of half-divided bodies abutted in the previous step to form a pair of half-divided bodies. It is a method of manufacturing a box having a bent passage that includes a step of integrating.

[0007]

According to the present invention, as shown in FIG. 1, the curved passages P1 and P are formed on the inner surfaces of the pair of halves A and B.
Since the partition walls W1 and W2 forming 2, P3, P4 and P5 are formed so as to be continuous with the partition wall W3 forming the outer peripheral portion of the half body, the groove D formed by the partition walls W1 and W2 is poured. It communicates with the outside through the inlet I to facilitate the injection of the secondary resin. In addition, H is an external connection port. That is, according to the present invention, as shown in FIG.
In the molding process, a pair of halves A and B are molded (see FIG. 2).
(A)), and then, in the second butting step, the outer peripheral joints C5 and C6 of the pair of half halves in which the pair of concave grooves are butted.
Continuous joining cavities C1 to C4 having the above-mentioned secondary resin injection port I opened to the inside are formed (FIG. 2 (B)), and finally 2
The secondary resin supplied from the runner at the same time as the outer peripheral joints C5 and C6 in the integration process with the next resin M2 is injected from the gate communicating with the injection port P into the joining cavities C1 to C4 to form a half-split body. 10A and 10B can be integrated. Therefore, the joint has a sufficient adhesive area with the secondary resin,
It is possible to mass-produce a box having a complicated piping system having a bent passage having excellent bonding strength by a two-step molding method. The runner portion is cut after being taken out. Further, according to the box body having the bent passage of the present invention, it is possible to finish a complicated and diversified piping system into a compact structure by simplifying the structure, facilitating assembly in a narrow space and eliminating an error or malfunction in the installation, The reliability can be improved. Further, there is an advantage that the manufacturing cost can be reduced as a whole by the simplification of the structure and at the same time the weight can be reduced. In the above joining, the outer peripheral joint portion C5 of the half-divided body has a U-shaped cross-section, but as shown in FIG. The contact area with and increases the joint strength. Further, the cooling of the secondary resin M2 that flows in at the time of pouring into the joining space becomes slow, and inconvenience such as insufficient filling does not occur.

[0008]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described in detail below with reference to specific examples shown in the accompanying drawings. FIG. 32 is a perspective view showing an assembled state when a box body having a bent passage manufactured by the method of the present invention is applied to an engine control assembly.
Shows the configuration diagram of the piping system.

In FIG. 32, 10 is an upper piping box, 2
0 is a lower piping box, 30 and 40 are left and right side piping boxes,
Eight three-way solenoid valves SV1 to SV1 and two one-way solenoid valves V1 and V2 are incorporated in an internal space surrounded by four piping boxes.

FIG. 4 shows connecting pipes 1-1 to 8- projecting above the valves SV1 to SV8 and the one-way valves V1 and V2 shown in FIG.
1, V1-1, V2-1 are plan views showing the flow path configuration of the piping box body 10, and FIG.
8, V1, V2 lower connecting pipe 1-2 to 8-2, V1-
2 is a plan view showing the flow path structure of the piping box body 20 for connecting V2-2, and FIG. 6 is a flow path structure of the left side piping box body 30 for connecting the side connecting pipes of the valves SV1 to SV4 of FIG. 7 is a plan view showing the flow path configuration of the right side piping box body 40 connecting the side connection pipes of the valves SV5 to SV8 of FIG. 32.

Each of the above piping boxes is composed of an outer plate A and an inner plate B, and as described above, the outer plate A and the inner plate B are made of the primary resin M1 in the first step by the two-step molding method shown in FIG. Are molded (A), and the two are superposed on each other in the second stage (B), and the partition wall W defining the bent passage is joined with the secondary resin M2 (C).

That is, in the case of the upper piping box 10, the outer plate 10
As shown in FIG. 8, A has a single groove 101 formed on the upper side surface along the center of the partition wall W, with small gas vent holes 108 formed at predetermined intervals, and four protrusions. External connection pipes 102 to 105 and two external connection holes 10
6 and 107 are formed, the two inner protrusions Wa and W are formed along the outer edge of the partition wall W except the outer periphery on the lower side surface thereof.
a is formed. On the other hand, the inner plate 10B shown in FIG. 10 is formed with two stepwise outer protrusions Wb and Wb on the upper side surface as shown in FIG. Connection ports 111 to 119 connected to the input connection pipes 1-1 to 8-1 of the SVs 1 to 8 and communication pipes 120 and 122 to 12 connected to the above four external connection pipes 102 to 105.
A communication pipe 121 for connecting the 5 and the bent passage 11 to the lower piping box body 20 is formed. Note that 126 and 127 are mounting holes, and engaging claws 128 that mesh with the lower piping box body 20 are formed on the diagonal lines around the mounting holes 126 and 127. When the outer plate 10A and the inner plate 10B are overlapped with each other and the inner protrusion Wa is engaged with the outer protrusion Wb, a hollow portion 130 for injecting the bonding resin is formed along the partition wall W. . Note that one of the outer peripheral partition walls is simply abutting of the ridges, while the other bulge is joined in the above-described meshing form.

Therefore, when the bonding resin is injected from the periphery of the outer plate 10A and the inner plate 10B which are superposed on the hollow portion 130, the hollow secondary portion 130 is filled with the bonding secondary resin M2 and the outer peripheral portion is filled with the resin. Rotate, outer plate 10A and inner plate 10
B is joined to form the upper pipe box body 10. 11 to 14 show 11- of the upper piping box body 10.
11th line, 12-12th line, 13-13th line and 14-14
15 and 16 are a side view and a front view, respectively.

On the other hand, the lower piping box body 20 is composed of an outer plate 20A and an inner plate 20B, has the same construction as the upper piping box body 10 and is joined in the same manner. That is, as shown in FIG. 17, a single groove 201 is formed on the lower surface of the outer plate along the center of the partition wall W, and the small gas vent holes 20 are formed at predetermined intervals.
8 is drilled. On the other hand, the inner plate 20 shown in FIG.
In B, the connection ports 211 to 219 connected to the input connection pipes 1-2 to 8-2 of the eight valves SV1 to 8 and the connection pipes 112 to 116 from the upper pipe box body 10 are connected to the lower surface. It has mouths 220-225. 226,
227 is a mounting hole, and an engaging hole 228 that meshes with the engaging claw 128 of the upper piping box body 10 is formed on a diagonal line around the mounting hole 217. 19 to 22 are lines 19-19, 20-20, 21- of the lower piping box 20.
FIG. 21 is a sectional view taken along line 21 and line 22-22, and FIG. 23 is a front view thereof.

The left side piping box 30 includes an outer plate 30A and an inner plate 3.
0B and are joined in the same manner as the upper piping box body 10, but the outer plate 30A is flat, while the inner plate 30B has six outputs upward as shown in FIGS. 324 and 325. The pipes 307 to 312 are projected, and the connection ports 301 to 304 for connecting with the output connection pipes 1-3 to 4-3 of the valves SV1 to 4 are formed inward, and the two output pipes 30 are provided.
5, 306 are protruding. 26, 27 and 28 are lines 26-26, 27-27 and 2 in FIG.
FIG. 8 is a sectional view taken along line 8-28.

On the other hand, the right side piping box body 40 is composed of an outer plate 40A and an inner plate 40B and is joined in the same manner as the left side piping box body 30. That is, the inner plate 40B is shown in FIG.
As shown in FIG. 1, the two output tubes 407 to 40 are directed upward.
8 protrudes, and inwardly, connection ports 401 to 404 are connected to the output connection pipes 5-3 to 8-3 of the valves SV5 to 9 respectively.
Is formed, and two output tubes 405 and 406 are projected.

The upper piping box 10 and the valves SV1-8
As shown in FIGS. 4 and 33, the upper end 1-1 of the valve SV1 is connected to an assist air supply port (not shown). The upper ends 2-1 and 5- of the valves SV2 and SV5, 6 and 7
1, 6-1 and 7-1 communicate with each other through a bent passage 11 and are open to the atmosphere through a hole 11a and an air filter (not shown). Valves V1 and V2 upper ends V1-1, V2-1
Is connected to the manifold boost P via a bent passage 12. Upper end connecting pipes 3-1 and 8 of valves SV3 and 8
-1 is connected to the vacuum tank S of FIG. 3 via the bent passage 13 and the lower communication pipe 124. The upper end 4-1 of the valve SV4 is connected to the supply passage Sry from a turbocharger (not shown) via the bent passage 14 and the communication pipe 123.

On the other hand, the valves SV1-8 and the lower piping box 2
5 and 33, the lower ends 1-2 and 3-2 of the valves SV1 and 3 are connected to the bent passage 21,
It is connected to the bent passage 11 through the communication port 220 and is also opened to the atmosphere through an air filter. Valve S
The lower ends of V2, V5 and V6 are the bent passage 22 and the communication port 22.
It communicates with the manifold booth P via a one-way valve V1. The valve SV4 is connected to the one-way valve V1 via the bent passage 23, and is connected to the vacuum tank S. The lower end of the valve SV7 has a bent passage 24 and a communication port 22.
It is connected to the pressure tank T of FIG.
The lower end of the valve 8 is connected to the supply passage Sry from the turbocharger through the bent passage 25 and the communication port 223.

As shown in FIGS. 6 and 33, the connection between the valves SV1 to 4 and the left side piping box 30 is such that the output pipe 1-3 of the valve SV1 is connected to the fuel via the bent passage 31 and the communication pipe 305. The valve SV2 is connected to the control valve PRCV, and is connected to the first supply passage of the air control valve ACV via the bent passage 32 and the communication pipe 308.
On the other hand, the output pipe 3-3 of the valve SV3 communicates with the second supply passage of the air control valve ACV via the bent passage 33 and the communication pipe 306. Furthermore, the output pipe 4-3 of the valve SV4 is connected via a bent passage 34 and a communication pipe 311 to an intake cut valve (not shown) arranged in the supply passage of the turbocharger.

Further, the connection between the valves SV5-8 and the left side piping box 40 is as shown in FIGS. 7 and 33, the output pipe 5-3 of the valve SV5 is a bent passage 41 and a communication pipe 407.
Through the intercooler IC to the rotary engine R
It is connected to an on-off valve (not shown) connected to the first supply path leading to E. The output pipe 6-3 of the valve SV6 has a bent passage 4
2. It is connected to an oil control valve (not shown) of the rotary engine RE via a communication pipe 408. On the other hand,
The output pipe 7-3 of the valve SV7 is connected to the on-off valve (not shown) of the exhaust gas supply passage to the second turbocharger T / C via the bent passage 44 and the communication pipe 405. The output pipe 8-3 of the valve SV8 includes a bent passage 43 and a communication pipe 406.
Via a supply path of the second turbocharger T / C, and is connected to a relief valve (not shown) provided in a relief path communicating with the air cleaner AC.

[Brief description of drawings]

FIG. 1 is a plan view showing an internal configuration of a box body according to the present invention.

FIG. 2 is a cross-sectional view showing the steps of the manufacturing method according to the present invention.

FIG. 3 is a cross-sectional view showing another joining mode of the half-split body outer circumferential joining portion.

FIG. 4 is a plan view showing a flow path configuration of a piping box body 10 that connects the connection pipes 1-1 to 8-1 protruding above the valves SV1 to 8 of FIG. 32.

FIG. 5 is a lower connecting pipe 1-of the valves SV1-8 of FIG.
It is a top view which shows the flow path structure of the piping box 20 which connects 2-8-2.

FIG. 6 is a plan view showing a flow path configuration of a left side piping box body 30 that connects the side connecting pipes of the valves SV1 to SV4 of FIG. 32.

FIG. 7 is a plan view showing a flow path configuration of a right side piping box body 40 connecting the side connecting pipes of the valves SV5 to SV8 of FIG. 32.

8 is a top view of the upper piping box body 10 shown in FIG. 4. FIG.

9 is a rear view of the upper surface piping box body 10 shown in FIG. 4. FIG.

FIG. 10 is a cross-sectional view of essential parts showing a joined state of the piping box.

FIG. 11: 11-11 of the upper piping box body 10 shown in FIG.
It is a line sectional view.

12-12 of the upper piping box 10 shown in FIG.
It is a line sectional view.

FIG. 13: 13-13 of the upper piping box 10 shown in FIG.
It is a line sectional view.

14 is a top view of the upper piping box 10 shown in FIG.
It is a line sectional view.

15 is a side view of the upper piping box body 10 shown in FIG.

16 is a front view of the upper piping box body 10 shown in FIG.

17 is a rear view of the lower piping box body 20 shown in FIG.

FIG. 18 is a top view of the lower piping box body 20 shown in FIG.

FIG. 19 is a lower piping box body 20 shown in FIG.
It is a line sectional view.

20 is a lower piping box body 20-20 shown in FIG.
It is a line sectional view.

21 to 21 of the lower piping box body 20 shown in FIG.
It is a line sectional view.

22 is a lower piping box 20 22-22 shown in FIG.
It is a line sectional view.

FIG. 23 is a front view of the lower piping box body 20 shown in FIG. 5.

24 is a top view of the left side piping box body 30 shown in FIG.

25 is an inner side view of the left side piping box body 30 shown in FIG.

[Fig. 26] 26-2 of the left side piping box body 30 shown in Fig. 6
It is a 6 line sectional view.

FIG. 27 is a left side piping box 27 shown in FIG.
It is a 7 line sectional view.

28-2 of the left side piping box 30 shown in FIG.
FIG. 8 is a sectional view taken along line 8.

FIG. 29 is an end view showing a joined state of the lateral piping box with the valve SV.

30 is a top view of the right side piping box body 40 shown in FIG. 7. FIG.

31 is an inner side view of the left side piping box body 40 shown in FIG. 7. FIG.

FIG. 32 is a perspective view showing a configuration of an engine control assembly to which the box manufactured according to the present invention is applied.

FIG. 33 is a system configuration diagram of an engine control assembly according to the present invention.

FIG. 34 A of the engine control assembly of FIG.
FIG.

FIG. 35 is B of the engine control assembly of FIG. 32.
It is a -B line sectional view.

[Explanation of symbols]

 SV1-8 ... Solenoid valve 10 ... Upper piping box 20 ... Lower piping box 30 ... Left side piping box 40 ... Right side piping box

 ─────────────────────────────────────────────────── ─── Continuation of the front page (72) Yoshihiro Takemoto, Inventor Yoshihiro Takemoto, Higashihiroshima City, Hiroshima Prefecture, 175, Ojihara, Hachimotomatsucho Daikyo Co., Ltd. No. 175 1 Daikyo Co., Ltd.

Claims (2)

[Claims] 1. A method of manufacturing a box body having a bent passage and a connection port for external connection, comprising a plurality of continuous extensions that face each other on an inner surface and are joined together to define a bent passage inside the box body. A step of molding a pair of half-divided bodies with a primary resin, which has a partition wall having concave grooves along the end faces, and a pair of the half-divided bodies, the concave grooves facing each other along the joint portion of the partition walls. The process of butting so as to form an extended joining space and the joining space of the pair of half halves that were butted in the previous process
A method of manufacturing a box body having a bent passage, comprising the steps of injecting a next resin to join the partition walls and integrating a pair of half-divided bodies. 2. The partition forming the curved passage is formed so as to be continuous with the partition forming the outer peripheral portion of the half-split body,
In the abutting step, a continuous joining cavity having a secondary resin injection port opened to the outer peripheral joint portion of the pair of half halves in which the pair of concave grooves are abutted is formed, and integrated with the secondary resin. The manufacturing method according to claim 1, wherein the secondary resin is injected from the injection port into the bonding space at the same time as the outer peripheral bonding portion in the step.