JPH10141087A - Assembly of engine with sound absorbing member - Google Patents

Abstract

PROBLEM TO BE SOLVED: To effectively reduce engine noise by applying farming material, before foamed, to the inner face of a cover or structural parts, covering the structural parts integrally with the cover and foaming the foaming material with heating when the structural parts of an engine is assembled on the engine via a sound absorbing member. SOLUTION: A sound insulating member which has a sound absorbing member 5 covered with a pump cover 4a is arranged to cover all of an injection pump 2a excluding an area when an operating lever and an injection pipe 3 are arranged. In this case, the sound absorbing member 5 is formed of synthetic resin foaming materials 5' such as urethane foam which is foamed at an atmospheric temperature of 40-50 deg.C. The foaming material 5', before foamed, is applied to either or both of the inner face of the cover 4a or/and the surface of the injection pump 2a. Then, the cover 4a is heated to foam the foaming material 5', so that the sound absorbing member 5 is expanded all over a space between the injection pump 2a and the cover 4a.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for assembling an engine of an automobile or the like for reducing engine noise by using a sound absorbing member made of a synthetic resin foam such as urethane foam.

[0002]

2. Description of the Related Art Conventionally, in order to realize a comfortable vehicle, it has been important to reduce engine noise and keep the interior of the vehicle quiet, and various noise prevention measures have been taken. For example, as shown in FIG.
The injection pump 2a is attached to the side of the engine. The noise generated from the injection pump 2a accounts for a large proportion of the noise of the entire engine.
In addition, as shown in FIG. 5, the noise generated from this portion is reduced by covering with a soundproof member 6 including a pump cover 4a and a sound absorbing member 5.

The pump cover 4a is made of a thin metal material such as a steel plate or a damping steel plate, or a heat-resistant rubber. The sound absorbing member 5 is made of glass wool, sponge rubber, or foamed resin such as urethane foam. Is used. When a foamed resin is used for the sound absorbing member 5, the injection molding is performed from both the injection pump 2a and the pump cover 4a, and the foamed urethane is heated to 40 to 50 ° C. and foamed using the mold. Method of forming fitting type sound absorbing member and injection pump 2a
After the liquid foam material is injected after assembling the pump cover 4a and the pump cover 4a, the liquid foam material is foamed to form a filled sound absorbing member.

In the method of forming the fitting type sound absorbing member, the shape of the sound absorbing member completely matches the shape of the mounting portion due to deformation of the sound absorbing member and variation in the shape of the mounting portion on the engine component side. In some cases, there is a problem that it is difficult to attach the sound absorbing member to the mounting site, or a gap is generated after the attachment, and the sound absorbing effect is reduced. In addition, when the sound absorbing member has a complicated shape, the number of molding members increases because the member is divided and molded. Further, a new mold member for forming the sound absorbing member is required in response to the change in the shape of the mounting portion, which causes a problem of increasing the cost.

A method of forming a filled sound absorbing member is to solve the problem of the fitting type sound absorbing member.
For example, in Japanese Unexamined Utility Model Publication No. 5-64443, a foamed silicone sheet mounted on a side surface of a cylinder block of an engine is filled with a liquid foamed silicone resin between a side portion of the cylinder block and a reinforcing plate, and the resin is filled in a predetermined manner. It has been proposed to foam and harden at a temperature to form a side cover.

[0006]

However, components of an engine such as an injection pump often have a complicated shape as shown in FIG. 5, and therefore are formed between this component and the cover body. The space portion has a complicated shape in which a narrow portion and a wide portion intersect, and it is difficult to form an inflow path of the foaming liquid to the back side of the injection pump.

Therefore, it is difficult to fill the entirety of the space with the foaming liquid by the method of forming the filling type sound absorbing member, and the amount of the foaming liquid is adjusted according to the local width and volume of the space. Since it cannot be adjusted and distributed, there is a problem that the sound absorbing member formed after foaming tends to have a gap or uneven density, and the sound absorbing effect of the foam material cannot be maximized.

Further, in order to inject the liquid foaming material after the assembly, it is necessary to provide an injection port at a position where the foaming liquid can be filled in a space for forming the sound absorbing member.
Unnecessary openings are provided in the cover for soundproofing, and the soundproofing effect will be insufficient.In addition, there is a cover in the cover such as the opening for the operating lever so that this foaming liquid does not leak. There is also a problem that it is necessary to close openings other than the injection port to be filled, and a jig and an operation for closing these openings are required.

SUMMARY OF THE INVENTION The present invention has been made to solve the above-mentioned problem, and an object of the present invention is to provide a simple operation, in which a sound absorbing member for preventing engine noise is provided between a cover body and components of an engine. A method of assembling an engine having a sound absorbing member that can be formed substantially evenly and without gaps over the entire area of a space between a noise generating portion of an engine and an engine member and that can effectively reduce engine noise. To provide.

[0010]

The following is a method for assembling an engine having a sound absorbing material to achieve the above object. First, the first method is to apply an unfoamed foaming material that foams by heating. When the engine components that generate noise are covered with a cover through a sound absorbing member and assembled to the engine, the cover is used. Applying an unfoamed foaming material that foams by heating to the inner surface of the body or one or both of the component parts, further covering the component part with the cover body, and then heating the component part to heat the component part The sound absorbing member is expanded and formed by foaming the foam material, and the integrated components are assembled to the engine body.

Alternatively, when the components of the engine that generate noise are covered with a cover via a sound absorbing member and assembled to the engine, the inner surface of the cover or one or both of the components is foamed by heating. An unfoamed foam material to be applied is applied, the component parts are covered with the cover body, and assembled to the engine body. Further, the component parts are heated to foam the foam material, thereby expanding the sound absorbing member. .

[0012] An unfoamed foaming material foamed by heating is applied to at least a part of a surface forming a space between a noise generating portion of the engine and an engine member facing the noise generating portion. Assemble the engine members,
Further, the noise generating portion is heated to foam the foam material, so that the sound absorbing member is formed between the engine body and the engine member.

Next, a second method is to apply an unfoamed foaming material which foams by heating, and then preliminarily foam by heating for a short time. The components of the engine which generate noise are connected via a sound absorbing member. At the time of covering with a cover body and assembling it to an engine, an unfoamed foaming material that foams by heating is applied to the inner surface of the cover body or one or both of the components, and then pre-foamed by heating for a short time. Then, the component parts are covered with the cover body, and then the component parts are heated to foam the foam material to expand the sound absorbing member, and the integrated component parts are assembled to the engine body.

Alternatively, when the components of the engine that generate noise are covered with a cover through a sound absorbing member and assembled to the engine, the inner surface of the cover or one or both of the components is foamed by heating. After applying the unfoamed foam material, the foamed material is pre-foamed by heating for a short time, and the components are attached to the engine body while being covered with the cover body. Further, the components are heated to foam the foam material. This causes the sound absorbing member to expand.

As described above, after applying the unfoamed foamed material foamed by heating, the foamed material is heated for a short time at the foaming temperature,
By performing prefoaming for foaming about half of complete foaming, the unfoamed gel-like foamed material can be solidified and liquid dripping of the foamed material can be prevented, so that the assembling operation can be simplified. The third method is to attach a foamable sheet formed by molding a non-foamed foam material that is foamed by heating into a sheet shape, and the components of the engine that generates noise are covered with a cover through a sound absorbing member. When covering and assembling with an engine, a foamable sheet formed by molding an unfoamed foam material that foams by heating into a sheet is attached to one or both of the inner surface of the cover body and the component parts, The parts are mounted on the engine body with the parts covered with the cover body, and the constituent parts are heated to foam the foam material to expand the sound absorbing member.

Alternatively, when the components of the engine that generate noise are covered with a cover body through a sound absorbing member and assembled to the engine, foaming is generated by heating one or both of the inner surface of the cover body and the components. A foamable sheet formed by molding an unfoamed foam material into a sheet shape, attaching the component parts to an engine body in a state where the component parts are covered with the cover body, and further heating the component parts to form the foam material. To expand the sound absorbing member.

An unfoamed foamed material foamed by heating is formed in a sheet shape on at least a part of a surface forming a space between a noise generating portion of the engine and an engine member facing the noise generating portion. The engine member is assembled by attaching a foamable sheet, and further, the noise generating portion is heated to foam the foam material, so that the sound absorbing member is expanded between the engine body and the engine member.

As described above, when a foamable sheet formed by molding a non-foamed foam material into a sheet instead of applying the unfoamed foam material is adhered, depending on the thickness of the formed sound absorbing member, By arranging one or more sheets, an appropriate amount of the foam material can be easily distributed. In any of the first to third methods, the heating for foaming performed after assembling to the engine is performed by heating with high-temperature air or steam from the outside of the components, the noise generating portion, or the cover body. However, if the heat generated by the engine itself is generated when the engine is operated in a bench test or the like and the heat generated by the engine itself is used, a heat source for heating and a heating operation can be eliminated.

[0019]

Embodiments of the present invention will be described with reference to the drawings. First, the case where the injection pump 2a is covered with the pump cover 4a will be described as an example. As shown in FIGS. 4 and 5, the injection pump 2 a is attached to the side of the engine body 1, sucks fuel from the lower injection pipe 3, pressurizes the fuel and pressurizes the cylinder through the upper injection pipe 3 and the fuel injection nozzle. It is configured to inject fuel into the inside.

In order to prevent the noise of the injection pump 2a, a soundproof member 6 in which the sound absorbing member 5 is covered with a pump cover 4a is provided with an operating lever 8 and an injection pipe 3 as shown by the hatched portion in FIG. Except for the exclusion part 9 where the
Substantially covers the whole. This pump cover 4a
It is made of a material that has heat resistance and a sound insulation effect, and can maintain the cover shape, such as a thin metal material such as a steel plate or a damping steel plate, or a heat-resistant rubber.

The sound-absorbing member 5 is formed as follows using a synthetic resin foam material 5 'such as urethane foam which foams when the ambient temperature reaches, for example, 40 to 50.degree. First, an appropriate amount of the foamed material 5 ′ before foaming is applied to one or both of the inner surface of the pump cover 4a and the surface of the injection pump 2a while taking into account the volume of the foamed material after foaming. This proper amount application can be made more appropriate by partially applying the foam material 5 'or partially applying the foam material 5' several times in accordance with the local volume of the space portion.

As a first method, a pump cover 4a in which a foaming material 5 'before foaming is applied to an injection pump 2a alone before being assembled to the engine body 1.
The pump cover 4a is heated from the outside with heated air, water vapor, infrared rays, or the like, and the temperature of the pump cover 4a or its surrounding atmosphere is raised to the foaming temperature to foam the foamed material 5 '. The sound absorbing member 5 is formed so as to expand, and the injection pump 2 a covered with the cover body 4 is attached to the engine body 1 via the sound absorbing member 5.

Alternatively, as a second method, in some cases, as shown in FIG. 1A, the injection pump 2a is mounted on the engine body 1 with the pump cover 4a covered, and after this mounting, By heating the part of the injection pump 2a, the ambient temperature of the pump cover 4a or its surroundings is raised to the foaming temperature, and the foamed material 5 'is foamed, so that the sound absorbing member 5 as shown in FIG. , Expand and form.

This heating may be performed by heating with high-temperature air or steam from the outside of the engine, but is preferably performed by the heat generated by the engine itself when the engine is operated in a bench test or the like. By utilizing the heat generated by the engine itself, it is not necessary to prepare a heat source for heating again, the foaming of the sound absorbing member 5 can be performed during the trial operation after the engine is assembled, and the molding operation of the sound absorbing member 5 can be simplified.

Here, the injection pump 2a has been described as an example of the component 2 of the engine. However, the present invention is not limited to this, and can be applied to other components of the engine that generate engine noise. Next, as another embodiment of the present invention, the noise generating portion of the engine will be described.
The sound absorbing member 5 is inserted into the gap between the V banks
Will be described.

In this case, as shown in FIG.
An unfoamed foam material 5 'is previously applied to one or both of the surface of the V-bank portion 10b of the cylinder block constituting a part of the noise generating portion 10 of the engine and the lower surface of the intake manifold 10a as an engine member. After applying an appropriate amount, the intake manifold 10a is
Assemble the engine by assembling it with the bank part 10b.

Such a coating is easy to apply on a surface facing the space, which can be filled in a space formed by a part of the engine or an engine member while foaming.
What is necessary is just to select a surface that does not disturb the assembling work and apply it. Then, the noise generating portion 10 is heated by high-temperature air, water vapor, or heat generated by the engine to foam the foamed material 5 ′, and the sound absorbing material 5 as shown in FIG.
Is formed between the V bank portion 10b and the engine member 10a.

According to the above-described method of assembling the engine, the foamed material 5 'can be easily dispersed and disposed to the depth of the narrow portion of the space 7 where the sound absorbing member 5 is formed. The amount of the foamed material 5 'can be easily adjusted and distributed according to the local volume, and the sound absorbing member 5 formed after foaming can be prevented from having a gap or uneven density. This makes it possible to make the most of the sound absorbing effect that the device has.

Further, it is not necessary to provide an unnecessary opening for injecting the foaming liquid in the cover body for soundproofing, and the opening of the cover body other than the opening for injecting is closed to prevent leakage of the foaming liquid. This eliminates the necessity and simplifies the molding operation of the sound absorbing member 5. In addition, after applying an unfoamed foamed material that foams by heating, by heating at a foaming temperature for a short time and performing prefoaming to foam about half of complete foaming, an unfoamed gel foamed material is produced. Since it is solidified and liquid dripping of the foamed material can be prevented, the assembling work can be simplified.

Further, instead of applying the unfoamed foam material, the unfoamed foam material may be formed into a sheet and the foamable sheet may be adhered to a necessary portion. When this foamable sheet is used, the work of applying the foamable sheet formed in an appropriate shape in advance may be performed instead of the work of applying the foam material, and the work may be performed according to the thickness of the sound absorbing member to be expanded and formed. By arranging a plurality of sheets, it is possible to easily distribute an appropriate amount of the foaming material, thereby improving work efficiency.

In addition, if the heating is performed by the heat generated by the engine itself during the test operation of the engine, the foaming can be performed in the test operation process after the engine is assembled. Since a heat source for heating can be dispensed with, the molding operation is simplified and the cost can be reduced.

[0032]

According to the assembling method of the present invention, before assembling,
A simple operation of applying an unfoamed foaming material that foams by heating to the surface facing the space where the sound absorbing member is formed, or attaching a foaming sheet, and then assembling and heating the engine. A noise-absorbing member for preventing noise is provided almost uniformly without gaps over the entire space between the cover body and the components of the engine, or over the entire space between the noise-generating portion of the engine and the engine members. Can be formed.

Therefore, according to the assembling method of the present invention, it is possible to manufacture an engine having a sound absorbing member capable of effectively reducing engine noise. Further, since foaming can be performed by utilizing heat generated by the engine during operation of the engine, a heat source for heating for foaming and a heating operation can be eliminated, and the operation of forming the sound absorbing member can be simplified.

[Brief description of the drawings]

FIG. 1 is a structural view of an engine showing an embodiment of the present invention, wherein (a) shows a state before foaming, and (b) shows a state after foaming.

FIG. 2 is a structural view of an engine showing another embodiment of the present invention, wherein (a) shows a state before foaming and (b) shows a state after foaming.

FIG. 3 is a perspective view of an engine showing an injection pump.

FIG. 4 is a partial perspective view of the engine showing a pump cover of the injection pump.

5A and 5B are diagrams showing a structure of a soundproof cover of the injection pump, wherein FIG. 5A is a plan sectional view and FIG. 5B is a side sectional view.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 1 ... Engine 2 ... Engine component 2a ... Injection pump (engine component) 3 ... Injection pipe 4 ... Cover 4a ... Pump cover (cover) 5 ... Sound absorbing member 5 '... Foaming material 6 ... Soundproofing member 7 ... Space part 8 Lever 9 Excluded part 10 Noise generating part 10a Intake manifold (engine member) 10b V bank part (noise generating part)

Claims (7)

[Claims] When a component of an engine that generates noise is covered with a cover through a sound absorbing member and assembled to the engine, heat is generated on one or both of the inner surface of the cover and the component. Applying an unfoamed foam material, further covering the component parts with the cover body, then heating the component parts to foam the foam material to expand and form the sound absorbing member, and the integrated An assembling method of an engine including a sound absorbing member configured to assemble components to an engine body. 2. When a component of the engine that generates noise is covered with a cover through a sound absorbing member and assembled to the engine, foam is generated by heating one or both of the inner surface of the cover and the component. An unfoamed foam material to be applied is applied, the component parts are covered with the cover body, and assembled to the engine body. Further, the component parts are heated to foam the foam material, thereby expanding the sound absorbing member. A method of assembling an engine including the sound absorbing member as described above. 3. An unfoamed foaming material foamed by heating is applied to at least a part of a surface forming a space between a noise generating portion of the engine and an engine member facing the noise generating portion, Assembling an engine member, further assembling an engine including a sound absorbing member configured to heat the noise generating portion to foam the foam material, thereby expanding the sound absorbing member between the engine body and the engine member. Method. 4. When the components of the engine that generate noise are covered with a cover through a sound absorbing member and assembled to the engine, the foam is generated by heating one or both of the inner surface of the cover and the components. After applying the unfoamed foaming material to be pre-foamed by heating for a short time, further cover the component with the cover body, and before or after assembling the component to the engine body, the component A method of assembling an engine including a sound absorbing member configured to expand the sound absorbing member by heating to expand the foam material. 5. When the components of the engine that generate noise are covered with a cover through a sound absorbing member and assembled to the engine, the internal surface of the cover or one or both of the components is foamed by heating. Affix a foamable sheet formed by molding an unfoamed foam material into a sheet shape,
Further, the component parts are covered with the cover body, and before or after assembling the component parts to the engine body,
A method for assembling an engine including a sound absorbing member configured to heat the component parts to expand the foam material to expand the sound absorbing member. 6. An unfoamed foamed material foamed by heating is formed in a sheet shape on at least a part of a surface forming a space between a noise generating portion of the engine and an engine member facing the noise generating portion. Attach a foamable sheet, assemble the engine member, further heat the noise generating portion to foam the foam material, and expand the sound absorbing member between the engine body and the engine member. A method of assembling an engine having a sound absorbing member according to the present invention. 7. The method for assembling an engine with a sound absorbing member according to claim 2, wherein the heating is performed by heat generated by operation of the engine.