WO2021013755A1

WO2021013755A1 - Intake distributor made from plastic material with an at least partial inner lining

Info

Publication number: WO2021013755A1
Application number: PCT/EP2020/070363
Authority: WO
Inventors: Benoît Ancel; Julien BORR; Jimmy DONETTI
Original assignee: Sogefi Air & Cooling
Priority date: 2019-07-19
Filing date: 2020-07-17
Publication date: 2021-01-28
Also published as: EP3999732B1; FR3098863B1; EP3999732A1; FR3098863A1

Abstract

The present invention concerns an intake distributor or manifold (1) made from thermoplastic material constituted by two shells (2, 2') assembled together rigidly at respective circumferential peripheral edges (3, 3') and together constituting a distributor body defining a hollow internal space, at least one of the shells (2, 2') comprising a fitted sheet or plate (4, 4') made from metal material, at least partially covering the inner face of the wall of the or each shell (2, 2') in question and preformed so as to substantially conform to the shape of the wall of this shell at least locally, in the manner of a skin, the or each metal sheet (4, 4') being mechanically and rigidly secured to the shell (2, 2') in question. The distributor (1) is characterised in that the or each shell (2, 2') comprises anchoring sites (6) for anchoring attachment means (7) for attaching the or each metal sheet (4, 4') with this shell (2, 2'), these anchoring sites (6) being located in formations (8) made from thermoplastic material situated at the circumferential edge (3, 3') and extending outwards from the wall.

Description

Title of the invention: Plastic intake manifold with at least partial internal liner

The present invention relates to the field of technical equipment of motor vehicles, more particularly the components under the hood linked to the air intake, and relates to a distributor or intake manifold made of plastic for such a vehicle, in particular equipped with an EGR circuit, with at least partial heat-resistant internal lining, preferably metallic.

[0002] Currently, in internal combustion engine vehicles, the exhaust gases are generally reintroduced at the engine air intake in order to reduce the impact in terms of pollution. Before being reinjected (exhaust gas recirculation: “Exhaust Gas Recirculation”, EGR in English), they are reintroduced into the air intake distributor where they are mixed with “new” air ( fresh air sucked in) before entering the engine combustion chamber.

[0003] The temperature of the EGR gases can locally rise up to 400 ° and with the presence of soot and tar in the distributor, can locally cause the walls of the distributor to melt, when the latter is made of plastic.

[0004] This problem is known in the automotive field and to alleviate it, it has already been proposed to replace plastic distributors with cast aluminum distributors. This solution is not satisfactory, particularly in terms of production cost and weight impact on the vehicle.

Another known solution to overcome this problem is to coat the inner wall of the plastic distributor with a layer of aluminum which has good thermal resistance and good thermal conductivity to distribute the heat over the entire surface of the coating .

[0006] Solutions of this type are known in particular from document FR 2 927 127 in the name of PSA. This document discloses the addition of a coating of metallic material on the internal surface of the plastic distributor. Only one embodiment is exemplified in this document. Metallic coating is thus an adherent coating formed by depositing a metal alloy (Fe / Ni), advantageously applied by electrodeposition. However, this solution is not satisfactory either in terms of cost or in terms of assembly.

[0007] Another solution has been proposed in document FR 2 931 900. In this document, the internal metal coating is a metal sheet fixed by single-piece studs with the plastic distributor. The fixing is advantageously carried out by snap-fastening. This solution is not satisfactory either because the fixing points represent areas with little resistance to high temperatures, which can cause the internal coating to detach.

The aim of the invention is to provide a distributor with an improved method of fixing an internal protective metal coating, which is compatible with the cost and assembly constraints associated with mass-produced products and which also has better thermal resistance (in particular elimination of the solution fixing pads as mentioned above), as well as better mechanical resistance.

To this end, the invention relates to an intake distributor or manifold made of thermoplastic material consisting of at least two parts in one piece each and in the form of shells or shells, these shells being assembled rigidly between they at the level of respective circumferential peripheral edges and together constituting a distributor body delimiting an internal hollow volume, at least one of said shells or shells comprising an attached sheet or sheet made of a metallic material, at least partially covering the internal face of the wall of the or each shell concerned and preformed to substantially match at least locally the shape of the wall of this shell in the manner of a skin, said or each metal sheet being mechanically and rigidly attached to the shell concerned,

distributor characterized in that the or each shell comprises anchoring sites for attached fixing means, intended to directly or indirectly secure the or each metal sheet with this shell, these anchoring sites being located in formations of thermoplastic material made in one piece with the wall of said shell, located at the level of the circumferential edge and extending outwardly from said wall, opposite its internal face participating in the delimitation of the internal volume.

The invention will be better understood, thanks to the description below, which relates to a preferred embodiment, given by way of non-limiting example, and explained with reference to the accompanying schematic drawings, in which:

[0011] [Fig. 1 A] is a perspective view of a distributor according to one embodiment of the invention;

[0012] [Fig. 1 B] is an exploded view of the distributor shown in FIG. 1 A;

[0013] [Fig. 2A] and

[0014] [Fig. 2B] are perspective views of the two constituent parts of the distributor of FIG. 1, before their assembly;

[0015] [Fig. 3] is a sectional view of the distributor of Figure 1 along a plane passing through anchoring sites and superimposed fixing means of its two constituent parts;

[0016] [Fig. 4A] and

[0017] [Fig. 4B] are sectional views of Figures 2A and 2B respectively, along the same sectional plane as that of Figure 3;

[0018] [Fig. 5] is a view on a different scale from detail A of FIG. 2B;

[0019] [Fig. 6] is a view on a different scale from detail B of FIG. 2A;

[0020] [Fig. 7] is a view on a different scale from detail C of FIG. 2B;

[0021] [Fig. 8A] and

[0022] [Fig. 8B] are perspective views of the two cut and formed metal sheets, constituting the two parts of shells composing together (and with partial overlap) the skin or the internal insert (e) of the part of the distributor shown in figure 2A, and,

[0023] [Fig. 9A] and

[0024] [Fig. 9B] are perspective views of the two cut and formed metal sheets constituting the two shell parts making up together (and with partial overlap) the skin or insert screen (e) inside (e) of the distributor part shown in Figure 2B.

Figures 1 to 4 show, for some only partially, a distributor or intake manifold 1 made of thermoplastic material consisting of at least two parts in one piece each and in the form of shells or shells 2, 2 ', these shells 2, 2' being rigidly assembled together at the level of respective circumferential peripheral edges 3, 3 'and together constituting a distributor body 1' delimiting an interior hollow volume 1 ”, at least one of said shells or shells 2, 2 'comprising a sheet or sheet 4, 4' added in a metallic material, at least partially covering the internal face 5 'of the wall 5 of the or each shell 2, 2' concerned and preformed to substantially at least locally match the shape of the wall 5 of this shell in the manner of a skin, said or each metal sheet 4, 4 'being mechanically and rigidly secured to the shell 2, 2' concerned.

According to the invention, the or each shell 2, 2 'comprises anchoring sites 6 for attachment means 7 reported, intended to directly or indirectly secure the or each metal sheet 4, 4' with this shell 2, 2 ', these anchoring sites 6 being located in formations 8 of thermoplastic material made in one piece with the wall 5 of said shell 2, 2', located at the level of the circumferential edge 3, 3 'and s 'extending outwards from said wall 5, opposite its internal face 5' participating in the delimitation of the internal volume 1 ”.

Thus, the invention proposes to achieve the attachment of the attached metal skin 4, 4 'with the body 1' of the distributor outside the interior volume 1 ”for receiving the gas mixture, namely in areas cut off at the 'deviation from this volume, at the level of additional peripheral formations 8 specifically provided for this purpose and formed with the body 1'. The fixing means 7 are therefore, at least for the most part, not directly exposed to the thermal effects of the hot gas flow circulating in the distributor 1.

In addition, as shown in Figures 3 and 4 in particular, these formations 8 are in the form of additional external material thicknesses with respect to the current material thickness of the wall 5. They thus provide locations for locating anchoring sites 6 which do not interfere with the continuity of the wall 5 of the body 1 '(they are not integrated in the thickness of said wall) and which make it possible to keep at these places also, at least the same wall thickness 5 ("e") as for the rest of the body 1 'or of the shell or shell 2, 2' concerned (between the internal face 5 'and said sites 6). Advantageously, a wall thickness (denoted "E" in Figures 4A and 4B) locally greater than the current thickness is provided by these formations 8, for example at least double compared to said current thickness (noted "e" on the figure. figure 4B).

In addition, when the securing means 7, and therefore the sites 6, have elongated shapes, the longitudinal axes of said sites 6 have an arrangement and a tangential extension with respect to the local wall portions 5 concerned, therefore not secant relative to the local plane of said wall 5.

These formations 8 may of course, at least for some be integrated, in structures or parts of the body 1 'fulfilling other functions such as sites for fixing the distributor 1 to other components or reinforcing ribs structural (see Figures 3 and 4A).

In accordance with a preferred embodiment of the invention, substantially optimized in terms of manufacture in particular, and more particularly apparent from Figures 2 to 4, each fixing means 7 consists of a screw, preferably a self-forming or self-forming screw -driller, and each anchoring site 6 consists of a blind hole or well formed in a material formation 8 of the type extra thickness or localized protuberance of the wall 5 of the shell 2, 2 'concerned, substantially level with the circumferential edge 3, 3 'corresponding and extending laterally outwardly therefrom.

Preferably, the or each sheet 4, 4 "is attached directly to the corresponding shell 2, 2" and this without the implementation of an additional intermediate connecting piece (with the exception of a fastening means 7).

Advantageously, as also shown in the aforementioned figures as well as in Figures 8 and 9, it can be provided that the or each preformed metal sheet 4, 4 'comprises side legs 9, advantageously of a single holding with said sheet, extending outwardly and arranged and configured for a positioning coinciding with the formations 8 of the shell 2, 2 'receiving it, each tab 9 having an eyelet 9' for the passage of a means of attachment 7, which coincides with the anchoring site in the form of a blind hole 6 of the corresponding formation 8.

Although of simple manufacture, the aforementioned constitution of the metal sheets 4, 4 'forming the internal thermal protection skin, makes it possible to limit the transmission of heat to the fixing means 7 and the associated anchoring sites 6 (tabs 9 elongated and narrow).

In accordance with an advantageous practical embodiment emerging from Figures 3 and 4 also, the fixing means 7 consist of flat-head screws whose exposure to the interior environment is extremely limited (only their visible surface at the level of the eyelets 9 'is exposed).

In order to guarantee the airtightness of the distributor 1 at the level of the assembly plane of the two shells 2 and 2 '(or at the level of the different assembly planes when there are more than two shells) , more particularly when they are assembled at their coincident facing edges 3, 3 'by vibration or laser welding, the invention preferably provides that the circumferential edge 3, 3' of each shell 2, 2 'comprises a Continuous weld bead 10 which, at the level of formations 8 housing the anchoring sites 6, extends around said sites 6, bypassing them on the outside and forming enveloping bead portions 10 '.

Therefore, despite the projection of the tabs 9 outwardly of the interior volume 1 ”and the situation of the fixing means 7 and their housings 6 outside the latter, the local offset towards the outside of the cord 10 preserves the overall tightness of the distributor 1 (and in particular at the level of the assembly plane).

In order to ensure good wedging of the inner metal skin in the shells 2, 2 ', to allow a certain thermal expansion of this skin and to limit the transmission of heat between the skin and the wall 5 of the shells 2 , 2 ', the or each preformed metal sheet 4, 4' may include reliefs (not shown), for example local deformations of said sheet, prominent on the face of the sheet concerned coming into contact with the internal face 5 'of the wall 5 of the shell 2, 2' concerned, these reliefs constituting support points, said internal face 5 'of the wall 5 of the shell 2, 2 'optionally comprising counter-reliefs (not shown) integrally formed, a discontinuous interstitial space 1 1 thus being formed between the metal skin 4, 4' and the corresponding shell 2, 2 '.

In order to additionally stiffen the structure of the distributor 1, the latter may comprise, at least at the level of one of the shells 2, 2 ', at least one spacer element 12 extending between two formations 8 located on opposite edge portions 3, 3 'by connecting them together and secured at the level of the latter by the fixing means 7 of the preformed metal sheet attached 4, 4', said spacer element 12 being optionally pre- integral with the preformed metal sheet 4, 4 'concerned (see Figures 3, 4B, 5 and 9). This or each spacer element 12 is advantageously in the form of a metal rod or strip having a limited apparent surface exposed to the gaseous fluid circulating inside the body 1 '.

Depending on the constitution of the distributor 1 and the nature, shape and function of its constituent parts, at least one of the shells 2, 2 '(and possibly both) may include one or more openings 13 in its wall 5, where appropriate extended by end pieces, such as pipes, the or each preformed metal sheet attached 4, 4 'in this shell 2, 2' comprising openings 14 coincident with those of said wall 5, advantageously with deformations local of said sheet 4, 4 'partially inserting into said openings 13 of the wall 5 of said shell 2, 2 (the edges of the openings 14 may be curved like the edges of the corresponding openings 13). The local deformations of the sheet 4, 4 ’can thus constitute thermal protective linings of the openings 13 of the wall 5 and of the inner surface of the primers at least of the end pieces which extend them outwards.

Depending on the gas flow in the distributor 1 and the exposure of its constituent parts to the thermal effects of the latter, only one of the shells 2, 2 'may include a metallic skin for the inner coating. Preferably, however, each shell 2, 2 'comprises at least one attached preformed metal sheet 4, 4', preferably at least two sheets 4 and 4 'overlapping each other in part (Figures 2A and 2B). This latter variant allows better compensation for manufacturing tolerances and thermal expansions, and facilitates manufacturing and assembly.

According to a very favorable constructive variant shown in the appended figures, the distributor 1 comprises two shells 2 and 2 'each of which comprises at least one preformed metal sheet attached 4, 4', these preformed metal sheets 4, 4 'in in the form of shells, or parts of shells 15 ', 15 ", together constituting a hollow body 15 which substantially delimits the volume of the plenum and which is mounted in the hollow body 1' of the distributor 1 by lining it internally.

Advantageously, and as emerges in particular from Figure 1B, each preformed sheet 4, 4 'constitutes part of a shell 15' or 15 ", the assembly of these two shells 15 'and 15" resulting in to the hollow body 15 for the internal lining of the hollow body 1 'of the distributor 1.

This construction offers optimum thermal protection of the wall 5 of the distributor 1.

When the two shells 2 and 2 'each comprise at least one metal shell 4, 4' as mentioned above, the material formations 8 comprising the anchoring sites 6 of the two shells 2 and 2 'forming the body of the distributor 1 are coincident with each other, and the enveloping weld bead portions 10 'at the level of the formations 8 of the two shells 2 and 2' define by mutual cooperation two by two the housing cavities 16 for the visible parts of the fixing means 7, for example screw heads.

These cavities 16 constitute peripheral lateral niches set back relative to the internal volume of the hollow body 1 'and in which also extend the legs 9. These cavities 16 of flat shape have only limited fluid communication with the internal volume of the hollow body 1 ′, through a constricted passage further receiving the tabs 9 of the two shells 15 and 15 ′ and, where appropriate, a spacer end 12 (see Figures 3 and 4 and see below). As shown in Figure 3, the thicknesses of the portions of cord 10 'are determined such that the heads of the screws 7 do not touch after assembly, but also such that the opening of the housing cavities 16 remote has a reduced section, limiting the propagation of hot gases in these cavities. These housings 16 are, where appropriate, dimensioned to also receive the spacers 12 (for example spacing of 1 mm to 3 mm between the heads of screws 7 opposite).

Preferably, each attached preformed metal sheet 4, 4 'consists of a stamped metal sheet, having lateral securing tabs 9 in one piece and, where appropriate, cutouts 14, said sheet 4, 4' consisting of aluminum or stainless steel.

By way of example, each skin or shell of a shell 2, 2 'can consist of a single metal sheet of type 1, 4509 or 1, 4301 stainless steel, for example with a thickness between 0.8 mm and 1.0 mm.

[0051] Alternatively, each shell or skin may consist of two sheets of aluminum or stainless steel overlapping partially and locally to ensure uninterrupted coverage in the event of thermal expansion.

The shells 2, 2 ’for their part are made of thermoplastic material, where appropriate reinforced with fibers. They can advantageously have outer stiffening wings or ribs.

The invention also relates to a motor vehicle with an internal combustion engine, characterized in that it comprises at least one intake distributor 1 as mentioned above.

Of course, the invention is not limited to the embodiment described and shown in the accompanying drawings. Modifications remain possible, in particular from the point of view of the constitution of the various elements or by substitution of technical equivalents, without thereby departing from the scope of protection of the invention.

Claims

[Claim 1] Distributor or intake manifold (1) made of thermoplastic material consisting of at least two parts in one piece each and in the form of shells or shells (2, 2 '), these shells (2, 2' ) being rigidly assembled together at the level of respective circumferential peripheral edges (3, 3 ') and together constituting a distributor body (1') delimiting an interior hollow volume (1 ”), at least one of said shells or shells (2, 2 ') comprising a sheet or sheet (4, 4') made of a metallic material, at least partially covering the internal face (5 ') of the wall (5) of the or each shell (2, 2') concerned and preformed to substantially match at least locally the shape of the wall (5) of this shell in the manner of a skin, said or each metal sheet (4, 4 ') being mechanically and rigidly secured to the shell (2, 2 ') concerned,

distributor (1) characterized in that the or each shell (2, 2 ') comprises anchoring sites (6) for attached fixing means (7), intended to directly or indirectly secure the or each metal sheet (4 , 4 ') with this shell (2, 2'), these anchoring sites (6) being located in formations (8) of thermoplastic material made in one piece with the wall (5) of said shell (2 , 2 '), located at the level of the circumferential edge (3, 3') and extending outwardly from said wall (5), opposite its internal face (5 ') participating in the delimitation of the volume inside (1 ”).

[Claim 2] Distributor according to claim 1, characterized in that each fixing means (7) consists of a screw, preferably a self-forming or self-drilling screw, and in that each anchoring site (6) consists in a blind hole or well formed in a formation of matter

(8) of the type extra thickness or localized protuberance of the wall (5) of the shell (2, 2 ') concerned, substantially level with the corresponding circumferential edge (3, 3') and extending laterally outwards from this last.

[Claim 3] Distributor according to claim 1 or 2, characterized in that the or each preformed metal sheet (4, 4 ’) has tabs

(9) lateral, advantageously integral with said sheet, extending outwardly and arranged and configured for a positioning coinciding with the formations (8) of the shell (2, 2 ') receiving it, each tab (9) having an eyelet (9') for the passage of a means of attachment (7), which coincides with the anchoring site in the form of a blind hole (6) of the corresponding formation (8).

[Claim 4] Distributor according to any one of claims 1 to 3, characterized in that the circumferential edge (3, 3 ') of each shell (2, 2') comprises a continuous weld bead (10) which, at the level of the formations (8) housing the anchoring sites (6), extend around said sites (6) bypassing them on the outside and forming enveloping cord portions (10 ').

[Claim 5] Distributor according to any one of claims 1 to 4, characterized in that the or each preformed metal sheet (4, 4 ') comprises reliefs, for example local deformations of said sheet, prominent on the face of the sheet coming into contact with the internal face (5 ') of the wall (5) of the shell (2, 2') concerned, these reliefs constituting support points, said internal face (5 ') of the wall ( 5) of the shell (2, 2 ') optionally comprising integral counter-reliefs, a discontinuous interstitial space (1 1) thus being formed between the metal skin (4, 4') and the shell (2, 2 ') corresponding.

[Claim 6] Distributor according to any one of claims 1 to 5, characterized in that it comprises at least one spacer element (12) extending between two formations (8) located on edge portions (3 , 3 ') opposite by connecting them to each other and secured at the level of the latter by the fixing means (7) of the attached preformed metal sheet (4, 4'), said spacer element (12) possibly being pre- secured to the preformed metal sheet (4, 4 ') concerned.

[Claim 7] Distributor according to any one of claims 1 to 6, characterized in that at least one of the shells (2, 2 ') comprises one or more openings (13) in its wall (5), where applicable if necessary extended by end pieces, such as tubes, the or each preformed metal sheet attached (4, 4 ') in this shell (2, 2') comprising openings (14) coincident with those of said wall (5), advantageously with some local deformations of said sheet (4, 4 ') partially fitting into said openings (13) of the wall (5) of said shell (2, 2').

[Claim 8] Distributor according to any one of claims 1 to 7, characterized in that each shell (2, 2 ') comprises at least one attached preformed metal sheet (4, 4'), preferably at least two sheets (4 and 4 ') overlapping in part.

[Claim 9] Distributor according to any one of claims 1 to 7, characterized in that it comprises two shells (2 and 2 ') each of which comprises at least one attached preformed metal sheet (4, 4'), these sheets preformed metal (4, 4 '), in the form of shells or parts of shells 15', 15 ", together constituting a hollow body (15) which substantially delimits the volume of the plenum and which is mounted in the hollow body of the distributor ( 1) by lining it internally.

[Claim 10] A distributor according to claim 4 and claim 9, characterized in that the material formations (8) comprising the anchoring sites (6) of the two shells (2 and 2 ') forming the body of the distributor (1 ) are coincident with each other, and in that the enveloping weld bead portions (10 ') at the level of the formations (8) of the two shells (2 and 2') delimit by mutual cooperation two by two of the housing cavities (16 ) for the visible parts of the fixing means (7), for example screw heads.

[Claim 1 1] Distributor according to any one of claims 1 to 10, characterized in that the formations (8) consist of extra thicknesses of external material, additional compared to the current material thickness of the wall (5) .

[Claim 12] Distributor according to any one of claims 1 to 1 1, characterized in that each attached preformed metal sheet (4, 4 ') consists of a stamped metal sheet, having lateral securing tabs (9) of in one piece and, where appropriate, cutouts (14), said sheet (4, 4 ') consisting of aluminum or stainless steel. [Claim 13] Motor vehicle with an internal combustion engine, characterized in that it comprises at least one intake manifold (1) according to any one of claims 1 to 12.