JPH08338330A - Manufacture of air intake duct with resonator - Google Patents

Abstract

PURPOSE: To reduce parts in number, eliminate a welding process, enhance productivity, and thereby lower its cost in the manufacture of an intake duct with complex type resonators. CONSTITUTION: Three parts composed of an air intake duct 1, a first insertion tube 2 branched out of the air intake duct 1 and a second resonator 3 with a second insertion tube 3a at its lower part, which is to be communicated with a first resonator, are integrally molded by blow molding in a state that the second resonator 3 is connected to the side part of the first insertion part 2 by a connecting part 5. The first resonator 4 is formed into two parts composed of divided parts 41 and 42 by injection molding, and the divided parts 41 and 42 are butted to each other in a state that the upper peripheral parts of them hold in the first insertion tube 2, the second resonator 3 and the connecting part 5 while a clamp part 6' is inserted into the insertion hole 5a of the connecting part 5. The clamp parts 6 and 6' are inserted into locking parts 7 so as to allow the divided parts to be fixed.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing an air intake duct for a vehicle engine, the air intake duct having a resonator.

[0002]

2. Description of the Related Art As a means for silencing air intake sound in an air intake duct of a vehicle engine, it comprises an air insertion tube branched from the air intake duct and a cavity chamber (resonator) of a predetermined volume into which the air insertion tube is inserted. A muffler has been conventionally used, and an air suction duct and a resonator having an insertion tube are integrally formed by blow molding into a shape in which these are connected in parallel via an integral hinge to form a resonator. By rotating the insertion pipe of the resonator around the integral hinge to the upper part of the air intake duct and inserting and connecting the insertion tube of the resonator into the hole formed on the upper surface of the air intake duct, the air intake duct with the resonator is configured. Those are disclosed in Japanese Utility Model Publication No. 5-75470.

As a means for suppressing the suction sound, a plurality of resonators are provided as disclosed in, for example, Japanese Utility Model Laid-Open No. 5-57351, as compared with the one in which one resonator is provided in the air suction duct as described above. It is conventionally known that a composite resonator provided in series in an air intake duct is much more effective in that it can resonantly attenuate a plurality of frequency ranges.

[0004]

As described above, the composite resonator is effective as a means for silencing the air intake sound, but the conventional composite resonator is shown in the exploded perspective view of FIG. An upper surface c of the first resonator having a first insertion tube b connected to the branch tube a ′ of the air suction duct a, a first resonator d having a second insertion tube e communicating with the second resonator at the bottom surface, and a first resonator d 3 parts of 2 resonators f are formed by injection molding, and the first resonator upper surface part c, the first resonator d, and the second resonator f are overlapped and welded to form a composite resonator, and the composite resonator is formed. Generally, the first insertion tube b of the resonator is directly welded to the branch tube a ′ of the air suction duct a or is connected by a rubber connector g. ,production Is poor, cost, there is a problem that quasi-construction cost is increased.

An object of the present invention is to solve the above-mentioned conventional problems in an air intake duct with a composite resonator.

[0006]

According to the present invention, there is provided a first insertion tube branched from an air intake duct and having a cross-sectional area smaller than that of the air intake duct, and a first insertion tube having a predetermined volume into which the first insertion tube is inserted. 1. An air intake duct comprising a composite resonator comprising one resonator and a second resonator having a volume smaller than that of the first resonator and communicating with the inside of the first resonator. First
Three parts of the insertion tube and the second resonator are integrally formed by blow molding, the first resonator is formed by injection molding into a two-divided structure, and the first resonator of the two-divided structure is formed by the first insertion tube and the first insertion tube. With the second resonator sandwiched,
It is characterized in that an air intake duct with a composite resonator is manufactured by butt-fixing. Also, the second
A sub-resonator having substantially the same shape as the resonator is formed by blow molding as a separate component, and a partially cut second resonator and a partially cut sub-resonator are butt-welded at their cut portions to blow. The volume of the second resonator is expanded or reduced without changing the layout of the air suction duct, the first insertion tube, and the second resonator integrally formed by molding, and a part of the second resonator is included. The volume of the first and second resonators can be adjusted so that the volume of the first resonator can be reduced or expanded, and it is possible to manufacture an air intake duct with a combined resonator that can support various vehicle types and frequency ranges. It is characterized by

[0007]

As described above, the number of parts is reduced by integrally molding the three parts of the air suction duct, the first insertion tube and the second resonator having the second insertion tube by blow molding. The work of the welding process for connecting and fixing each of the three parts is not necessary, and the cost can be reduced.
When the first resonator is injection-molded into a two-divided structure, one of the first resonators of the two-divided structure is integrally formed with a clamp part, and the other is provided with a locking part into which the clamp part is inserted and locked. By forming
An air intake duct with a composite resonator can be obtained by simply sandwiching and abutting the integrated first insertion tube and the second resonator, inserting the clamp part into the locking part and locking and fixing it. The cost can be reduced. Furthermore, since the volume of the second resonator contained in the first resonator can be adjusted by welding the sub-resonator, it is easy to change the volume of the first resonator, which makes it possible to accommodate various vehicle types and frequencies. The external shape of the first resonator does not change even if the volume of the two resonators is changed, so that it is not necessary to review the layout with surrounding parts.

[0008]

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

In FIG. 1, 1 is a cylindrical air intake duct, 2 is a first insertion pipe branched from the air intake duct 1, 3
Is a second resonator, 3a is a second insertion pipe, and the air suction duct 1, the first insertion pipe 2 branched from the air suction duct 1 and the second resonator 3 having the second insertion pipe 3a are The second resonator 3 is integrally formed by blow molding while being integrally connected to the side of the first insertion tube 2 at the connecting portion 5. Incidentally, in the blow molding, as is well known in the related art, all the portions which should be originally opened, such as the both end portions of the air suction duct 1, the lower end portion of the first insertion pipe 2 and the lower end portion of the second insertion pipe 3a, are all bags. Since it is formed into a closed state, the desired integrally molded product is obtained by cutting after blow molding at the area indicated by the alternate long and short dash line in FIG. 2 to form an opening.

Reference numeral 4 is a first resonator, and the first resonator 4 is injection-molded into a two-part structure of one divided member 41 and the other divided member 42, as shown in FIGS. 1 (B) and 3. The first resonator 4 having a larger volume than that of the second resonator 3 is formed by abutting the dividing members 41 and 42. At the upper edges of the respective dividing members 41 and 42, a first insertion tube holding portion 41b which fits a half circumference of the outer circumference of the first insertion tube 2, a half circumference of the outer circumference of the second resonator 3 and half the thickness of the connecting portion 5, respectively. , 42b, the second resonator sandwiching portions 41c, 42c, and the connecting portion sandwiching portions 41d, 42d are respectively recessed, and are joined to the entire circumference of the edge of each of the split members 41, 42 including the sandwiching portions. Flange portion 41a for
42a is formed.

Then, the first insertion tube 2, the second resonator 3 and the connecting portion 5 which are integrally formed by blow molding are connected to each other, and the first insertion tube holding portions 41b and 42b and the second resonator holding portion 41 are formed.
c and 42c and the connecting portion sandwiching portions 41d and 42d, respectively, the split members 41 and 42 are butted and joined at the flange portions 41a and 42a, respectively, and the joined portions are fixed, 1 Insertion tube 2 is first resonator 4
The second resonator 3 and the first resonator 4 are communicated with each other by being inserted into the second resonator 3 and most of the lower part except the upper end portion of the second resonator 3 is contained in the first resonator 4. An air intake duct including a composite resonator in a state is configured.

As described above, the air suction duct 1 and the first insertion pipe 2 and the second insertion pipe 3a branched from the air suction duct.
The three parts with the second resonator 3 having the above are integrally formed by blow molding, and the first resonator formed in the two-divided structure by injection molding is combined and fixed,
By configuring the air suction duct with the composite resonator, the number of parts can be reduced, the productivity can be improved, and the manufacturing cost can be reduced.

In the above, the dividing members 41 and 42 are
When the first insertion tube 2, the second resonator 3 and the connecting portion 5 are sandwiched and fixed by abutting with the flange portions 41a and 42a, the fixing means may be welding fixing which is generally used in the past. However, in the illustrated embodiment, the fixing means by the insertion locking of the clamp portion 6 and the locking portion 7 provided on the split members 41 and 42 is adopted.

That is, at the time of injection molding of the first resonator 4 having a two-divided structure, a plurality of clamp portions 6 are integrally formed on the flange portion 41a of one of the divided members 41, and the flange portion 42a of the other divided member 42 is formed. Forms a locking portion 7 into which the above-mentioned clamp portion 6 is inserted and locked, and the connecting portion 5 of the integrally formed component formed by blow molding has a clamp protruding from the connecting portion holding portion 41d of one of the split members 41. The insertion member 5a through which the portion 6'is inserted is formed, and the split member 41 is sandwiched between the first insertion tube 2, the second resonator 3 and the connection portion 5.
And 42 are butted against each other, the clamp portion 6'of the connection portion sandwiching portion 41d is inserted through the insertion port 5a of the connection portion 5 and inserted into the locking portion 7 of the other split member 42 to be locked. By directly inserting and locking the clamp part 6 at the position of the corresponding locking part 7, the first resonator 4 is formed by the butting and fixing of the split members 41 and 42, and the integrally molded product by blow molding and The fixing with the first resonator 4 can be performed at the same time, and by adopting such a configuration, an integrally molded product by blow molding and a first structure divided into two parts by injection molding are formed. No welding process is required to manufacture an air suction duct with a composite resonator formed by fixing it to the resonator 4, further improving productivity and significantly reducing production cost. It can be achieved.

Next, a method of changing the volumes of the first and second resonators to cope with the suction sounds of various frequency bands which differ depending on the vehicle type will be described with reference to FIG.

As shown in FIG. 4 (A), a sub-resonator 8 having a second insertion tube 8a at the lower part of the same shape as the second resonator 3 in the integrally molded product by blow molding is separately molded for blow molding. To form. Then, if necessary, the lower part including the second insertion tube 3a of the second resonator 3 is cut off using the alternate long and short dash line 3b as the cut surface, and the upper portion of the sub-resonator 8 is cut off using the alternate long and short dash line 8b as the cut surface. The cut surfaces 3b and 8b are butted and welded to each other to form a second resonator.
As shown in (B), the volume of the second resonator can be enlarged or reduced, and the volume can be increased or reduced by changing the cutting height of the second resonator 3 and the cutting height of the sub-resonator 8. It can be arbitrarily selected in the range from almost double to nearly 1/2. Also, since most of the lower part of the second resonator is included in the first resonator, as the volume of the second resonator is expanded or contracted, only the volume of the first resonator is changed without changing its outer shape. It is reduced or expanded.

As described above, the second resonator and the first resonator
Since the volume change with the resonator can be easily done, it is possible to accurately respond to the intake sound of various frequency ranges that differ depending on the vehicle type, and even if the volume of the second resonator and the first resonator is changed, The external shape is completely unchanged, so there is no need to review the layout with surrounding parts.

[0018]

As described above, according to the present invention, the three parts of the air suction duct, the first insertion tube and the second resonator are integrally formed by blow molding, and the two parts are formed by injection molding.
The first resonator formed in a divided structure, by sandwiching the first insertion tube and the second resonator, by butting and fixing, to obtain an air suction duct with a composite resonator, the number of parts is small, The welding work process can be simplified or completely omitted, and the productivity can be improved and the production cost can be reduced. Further, the volume of the second resonator can be easily changed, and accordingly, the volume of the first resonator also relatively changes, and the volumes of the first and second resonators are adjusted without changing the outer shape of the entire component. As a result, it is possible to accurately correspond to the suction sound of various frequency ranges that differ depending on the vehicle type, and it is possible to bring about a great effect in practical use.

[Brief description of drawings]

1 shows an embodiment of the present invention, (A) is a front view showing an example of an air suction duct with a composite resonator manufactured by the method of the present invention, (B) is an exploded perspective view of (A) FIG. 2C is a cross-sectional view taken along the line CC of FIG.

FIG. 2 is a front view of the integrally molded product immediately after blow molding, in which a part of the integrally molded product is cut away to show the integrally molded product including the air suction duct, the first insertion tube, and the second resonator shown in FIG. It is a figure explaining the state manufactured.

3A and 3B show a first resonator having a two-divided structure shown in FIG. 1, in which FIG. 3A is a side view of a divided member injection-molded into the two-divided structure, and FIG.

FIG. 4 is a diagram showing a method of changing the volume of the second resonator,
(A) is a front view of the second resonator integrally formed with the air suction duct and the first insertion tube by blow molding and a sub-resonator blow-molded to have substantially the same shape as the second resonator before being cut off; (B) is a front view showing a state in which both ends of the second resonator and the sub-resonator are cut off and the cut edges are welded to form second resonators having different volumes.

FIG. 5 is an exploded perspective view showing an example of a method of manufacturing a conventional air suction duct with a composite resonator.

[Explanation of symbols]

 1 Air Intake Duct 2 1st Insertion Pipe 3 2nd Resonator 3a 2nd Insertion Pipe 4 1st Resonator 5 Connection Part 5a Insertion Port 6 Clamping Part 6'Clamping Part 7 Locking Part 8 Sub-Resonator 41 Dividing Member 42 Dividing Member 41a Flange Part 41b 1st insertion tube holding part 41c 2nd resonator holding part 41d Connection part holding part 42a Flange part 42b 1st insertion tube holding part 42c 2nd resonator holding part 42d Connection part holding part

Claims (4)

[Claims] 1. A first insertion tube branched from an air suction duct, a first resonator having a predetermined volume into which the first insertion tube is inserted, and a volume smaller than the first resonator, and the first resonator has a volume smaller than that of the first resonator. In an air suction duct provided with a composite resonator configured with a second resonator having a second insertion tube communicating with each other, three parts of the air suction duct, the first insertion tube and the second resonator are integrally formed by blow molding. And the first resonator is formed into a two-part structure by injection molding, and the first resonator having the two-part structure is sandwiched between the first insertion tube and the second resonator and fixed by butting. And a method for manufacturing an air intake duct with a resonator. 2. The method for manufacturing an air intake duct with a resonator according to claim 1, wherein a clamp part is inserted into one of the first resonators of the two-part structure and the other part is engaged with the clamp part. Part is formed respectively, and
An air suction duct with a resonator characterized in that the first resonator having a split structure is fixed by sandwiching and abutting the first insertion tube and the second resonator, and inserting and locking the clamp portion into the locking portion. Production method. 3. The method for manufacturing an air intake duct with a resonator according to claim 2, wherein the first insertion pipe and the second resonator, which are integrally formed with the air intake duct by blow molding, are integrally connected at a connecting portion. The connecting portion is provided with an insertion port into which a clamp portion formed on one of the first resonators of the two-divided structure is inserted, and the first resonator of the two-divided structure is connected to the first insertion pipe. When the clamp part is inserted and fixed to the other locking part of the first resonator, the clamp part of the part is inserted into the insertion port of the connection part. The air suction device with a resonator characterized in that the first resonator and the integrally molded product by blow molding are coupled and fixed by being inserted into and locked in the other locking portion of the first resonator. Manufacturing method of inlet duct. 4. The method for manufacturing an air intake duct with a resonator according to claim 1, wherein a sub-resonator having substantially the same shape as the second resonator is formed as a separate part by blow molding, and a part thereof is cut off. The volume of the second resonator can be changed by butt-welding the second resonator and the partially cut sub-resonator at the cutting portion, and the volume of the first resonator including a part of the second resonator can be changed. A method of manufacturing an air intake duct with a resonator, which is relatively variable.