JP3990650B2 - Resin intake manifold - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a resin intake manifold made of a synthetic resin used for an internal combustion engine for automobiles.
[0002]
[Prior art]
Air taken into the internal combustion engine is filtered by an air cleaner, passes through a throttle valve, is introduced into a surge tank, passes through an independent intake passage connected to the downstream side of the surge tank, and is distributed and supplied to each cylinder. Is done. As an intake system component for supplying such intake air to each cylinder, there is an intake manifold. Conventionally, as this type of intake manifold, a resin intake manifold formed of a synthetic resin material has been developed (for example, the following patents). Reference 1 etc.).
[0003]
[Patent Document 1]
JP-A-8-252864 Publication
This type of resin intake manifold is molded by synthetic resin injection molding using a molding die at the time of manufacture, so it is divided into multiple pieces for molding, especially from the surge tank through the funnel part. The part that reaches the intake passage is formed in separate pieces.
[0005]
[Problems to be solved by the invention]
When such a resin intake manifold is molded into a plurality of pieces, those pieces are welded by vibration welding or the like after the molding, and the entire resin intake is welded. Manifold is manufactured. However, in this type of resin intake manifold, when the welding line is formed so as to cross at the part from the surge tank to the independent intake passage through the funnel part, a stepped part is likely to occur at the welding part. When the portion is formed so as to cross the flow path of the funnel portion at a right angle, the flow of the intake air is disturbed at that portion, and there is a problem that the ventilation resistance of the intake air increases.
[0006]
In addition, when separate pieces are welded at the welding line and the intake manifold is integrally formed, if the welding line is formed flat and flat, the welding line is formed so as to be positioned in one plane. When a vibration pressure is applied due to vibration from the engine or intake pulsation during use mounted on the engine, there is a problem that the pressure resistance strength and vibration resistance strength in the welding line are liable to decrease.
[0007]
The present invention solves the above-mentioned problems, and provides a resin intake manifold that can improve pressure resistance and vibration resistance and can suppress intake airflow resistance caused by a welding line. With the goal.
[0008]
[Means for Solving the Problems]
In order to achieve the above object, a resin intake manifold of the present invention is formed by welding a plurality of pieces molded into a predetermined shape along a welding line, and is made of a resin having a surge tank and an independent intake passage following the surge tank. In the intake manifold, a funnel portion is formed at a location continuing from the surge tank to the independent intake passage, a welding line is formed so as to cross the vicinity of the funnel portion, and a funnel partition wall separating a plurality of independent intake passages is provided on one side of the funnel portion. The other piece is formed so as to protrude from the other piece, and the other piece is formed with a funnel wall receiving portion for receiving the funnel partition wall, and the joining surface of the funnel partition wall and the funnel wall receiving portion is welded as the welding line. and characterized in that it is formed in a direction substantially along the airflow direction of the funnel portion That.
[0009]
Here, as in claim 2, the funnel partition of the funnel part can be formed in a substantially triangular shape so that the corner part protrudes to the other piece side.
[0010]
According to a third aspect of the present invention, it is possible to form a welding line bent in a substantially square shape at the edge of the funnel partition wall of the funnel portion.
[0011]
[Action]
The resin intake manifold having the above-described configuration is manufactured by molding a plurality of pieces into a predetermined shape with a synthetic resin, and welding these pieces along a welding line by vibration welding or the like. Inside the resin intake manifold, a surge tank and a plurality of subsequent independent intake passages are formed, and a funnel portion is formed at a location continuing from the surge tank to the independent intake passage, and a funnel partition wall is formed in the funnel portion. It is formed so as to protrude from one piece to the other piece, and a welding line is formed and welded to the joint surface of the funnel partition.
[0012]
Therefore, the welding line formed so as to cross the funnel portion is not a flat line on the plane, but is formed in a three-dimensional shape. For this reason, when this intake manifold is mounted on an engine and used, and vibration caused by engine vibration or intake air pulsation is applied to the funnel part, the three-dimensional deformation of that part is effectively suppressed. The pressure resistance strength and vibration resistance strength of the part and the whole manifold can be improved. Further, the step that is likely to occur on the inner wall of the intake passage in the funnel portion is a direction substantially along the ventilation direction that is different from the transverse direction of the intake passage, so that the ventilation resistance of the intake air can be reduced.
[0013]
Further, as in claim 2, if the funnel partition of the funnel part is formed in a substantially triangular shape so that the corner part protrudes to the other piece side, or the funnel part of the funnel part as in claim 3. If a welding line bent in a substantially U shape is formed at the edge of the partition wall, the pressure resistance strength and vibration resistance strength can be further improved, and the airflow resistance of the intake air can be reduced.
[0014]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, an embodiment of the present invention will be described with reference to the drawings. 1 shows a front view of a resin intake manifold 1 used in an in-line four-cylinder engine, FIG. 2 shows a rear view thereof, FIG. 3 shows a right side view thereof, and FIG. 4 shows a left side view thereof. .
[0015]
The resin intake manifold 1 includes a first piece 2 located at the center, a second piece 3 serving as a cover for the upper independent intake passage, and a back side of the surge tank 24 located at the back of the first piece. The third piece 4 and the fourth piece 5 which is located on the back surface of the third piece 4 and forms the cover portion of the resonator 25. The members of the first piece 2, the second piece 3, the third piece 4, and the fourth piece 5 are each molded into a predetermined shape by synthetic resin injection molding, and welded along the welding line ML by vibration welding or the like. Thus, the resin intake manifold 1 is formed.
[0016]
The 1st piece 2 which comprises the center part of the resin-made intake manifolds 1 has the cylinder side attachment flange 20 fixed to the cylinder side (cylinder head side) of an engine, as shown in FIGS. The cylinder side mounting flange 20 is provided with the intake outlets 21 for four cylinders arranged in parallel, and fixing mounting holes 20a are formed at a plurality of locations on the edge. Further, a portion forming a half shell portion of the surge tank 24 is formed on the back side of the first piece 2, and the half shell portions of the four independent intake passages 26 communicating with the surge tank 24 are the first piece 2. It is formed on the front side.
[0017]
As shown in FIG. 1, a throttle side mounting flange 22 for fixing the throttle valve device is formed on the left side of the front surface of the first piece 2. The throttle-side mounting flange 22 is formed with an intake inlet 23, and mounting holes 22a are formed at a plurality of locations on the edge thereof. The intake port 23 communicates with the surge tank 24 in the first piece 2.
[0018]
Further, the throttle side mounting flange 22 is located on the side of the cylinder side mounting flange 20, and the throttle side mounting flange 22 and the cylinder side mounting flange 20 are connected to the cylinder side mounting flange 20. In addition, a plate-like and L-shaped connecting portion is integrally formed therebetween.
[0019]
As shown in FIG. 5, on the front side of the first piece 2, a welding line ML for welding the second piece 3 that becomes the cover wall 31 of the upper independent intake passage 26 is formed in the outer portion of the independent intake passage 26. As shown in FIG. 6, a welding line ML for welding the third piece 4 forming the back side of the surge tank 24 is formed on the back side of the first piece 2. It is formed along the part.
[0020]
Further, as shown in FIGS. 6 and 7, a funnel portion 27 serving as an inlet is formed at a location continuing from the surge tank 24 to the independent intake passage 26, and a welding line ML is formed in the vicinity of the funnel portion 27. . A thick-walled funnel wall 28 is formed at the edge of the funnel portion 27, and a funnel partition wall 29 that divides the four independent intake passages 26 in the funnel portion 27 has a substantially triangular shape as shown in FIG. And formed so as to protrude from the first piece 2 to the third piece 4.
[0021]
As shown in FIGS. 8 and 9, the third piece 4 is formed so as to form an outer shell portion on the back side of the surge tank 24 on the back side of the first piece 2. A surge tank portion 43 is formed in a concave shape, and a resonator portion 41 communicating with the surge tank portion 43 through the communication path 45 is formed. Further, as shown in FIG. 9, a funnel wall receiving portion 44 for receiving the funnel partition wall 29 to be inserted is formed in the third piece 4, and a welding line is formed on the joint surface between the funnel partition wall 29 and the funnel wall receiving portion 44. ML has been done.
[0022]
Further, as shown in FIG. 7, the funnel partition wall 29 of the funnel portion 27 is formed in a substantially triangular shape with corners protruding toward the third piece 4, and is further formed in a substantially square shape at the edge of the funnel partition wall 29. A bent welding line ML is formed. Further, as shown in FIG. 9, a welding line ML is also formed at the edge portion of the funnel wall receiving portion 44 of the third piece 4.
[0023]
On the other hand, as shown in FIGS. 10 to 11, the second piece 3 is formed in a shape that forms the cover wall 31 of the independent intake passage 26 on the front side of the first piece 2, and is formed at the upper part of the four independent intake passages 26. Each of the outer edges of the first piece 2 is welded to the welding line ML on the front side of the first piece 2.
[0024]
Further, a fourth piece 5 forming an outer shell portion is formed as a cover member on the back side of the resonator unit 41 of the third piece 4 and is welded to the back side of the third piece 4. An EGR pipe mounting flange 42 for mounting an EGR pipe is provided on the right side of the third piece 4.
[0025]
The members of the 1 piece 2, the second piece 3, the third piece 4 and the fourth piece 5 having such a structure are joined to each other as shown in FIGS. The joined portion along the weld is welded, and the resin intake manifold 1 is manufactured.
[0026]
In the resin-made intake manifold 1 having the above-described configuration, its cylinder side mounting flange 20 is fixed to the cylinder head side of an engine (not shown), a throttle valve device (not shown) is fixed to its throttle side mounting flange 22, and an EGR pipe or the like. Used by connecting piping and sensors.
[0027]
When the engine is in operation, the air taken into the engine is filtered by an air cleaner, passes through the throttle valve device, is introduced into the resin intake manifold 1 from the intake inlet 23, and enters the surge tank 24. Then, it passes through an independent intake passage 26 connected to the downstream side of the surge tank 24, passes through the intake outlet 21, and is distributed and supplied to each cylinder of the engine.
[0028]
When such intake air is supplied to each cylinder, vibration is generated by pressure pulsation generated in the resin intake manifold 1 in accordance with the opening / closing operation of the throttle valve, and vibration transmitted from the engine block is also generated by the resin intake manifold. 1 occurs.
[0029]
However, the funnel partition wall 29 of the funnel portion 27 of the first piece 2 located in the vicinity of the center portion of the joint portion of the first piece 2 and the third piece 4 that constitutes the main portion is not particularly inclined toward the third piece 4 side. It is formed in a substantially triangular shape so that the portion protrudes, and a welding line ML formed on the edge of the funnel partition wall 29 is welded in a three-dimensional shape.
[0030]
For this reason, when the intake manifold is used, even if vibration due to engine vibration or intake air pulsation is applied to the funnel part or the entire manifold, the three-dimensional deformation of that part can be effectively suppressed. The pressure resistance strength and vibration resistance strength of the part and the whole manifold can be improved.
[0031]
In addition, air sucked in use passes through an independent intake passage 26 connected to the downstream side of the surge tank 24 and is distributed and supplied to each cylinder of the engine through the intake outlet 21. The step that is likely to occur on the inner wall of the inner intake passage due to the welding line is in a direction substantially along the ventilation direction that is different from the transverse direction of the independent intake passage 26, so that the ventilation resistance of the intake air can be suppressed and reduced.
[0032]
【The invention's effect】
As described above, according to the resin intake manifold of the present invention, the welding line formed so as to cross the funnel portion is not a flat line on the plane, but is formed in a three-dimensional shape. Therefore, when this intake manifold is mounted on an engine and used, and vibration caused by engine vibration or intake air pulsation is applied to the funnel part, the three-dimensional deformation of that part is effectively suppressed. The pressure resistance strength and vibration resistance strength of the part and the whole manifold can be improved. Further, the step that is likely to occur on the inner wall of the intake passage in the funnel portion is a direction substantially along the ventilation direction that is different from the transverse direction of the intake passage, so that the ventilation resistance of the intake air can be reduced.
[Brief description of the drawings]
FIG. 1 is a front view of a resin intake manifold according to an embodiment of the present invention.
FIG. 2 is a rear view of the intake manifold.
FIG. 3 is a right side view of the intake manifold.
FIG. 4 is a left side view of the intake manifold.
FIG. 5 is a plan view of the first piece 2;
6 is a rear view of the first piece 2. FIG.
7 is a perspective view of a funnel portion of the first piece 2. FIG.
8 is a front view of a third piece 4. FIG.
9 is a front view of the third piece 4. FIG.
FIG. 10 is an exploded left side view of the intake manifold.
FIG. 11 is an exploded right side view of the intake manifold.
FIG. 12 is an exploded sectional view of the intake manifold.
[Explanation of symbols]
1-resin intake manifold 2-first piece 3-second piece 4-third piece 5-fourth piece 21-intake outlet 23-intake inlet 24-surge tank 26-independent intake passage 27-funnel portion 28 -Funnel wall 29-Funnel partition wall 44-Funnel wall receiving part

Claims (3)

In a resin intake manifold formed by welding a plurality of pieces molded in a predetermined shape along a welding line, and having a surge tank and an independent intake passage following the surge tank,
A funnel portion is formed at a location continuing from the surge tank to the independent intake passage, a welding line is formed so as to cross the vicinity of the funnel portion, and a funnel partition wall separating a plurality of independent intake passages is one piece Is formed so as to protrude from the other piece, a funnel wall receiving portion for receiving the funnel partition wall is formed on the other piece, and a joining surface of the funnel partition wall and the funnel wall receiving portion is welded as the welding line , The resin intake manifold, wherein the welding line is formed in a direction substantially along a ventilation direction of the funnel portion . 2. The resin intake manifold according to claim 1, wherein the funnel partition wall of the funnel portion is formed in a substantially triangular shape with a corner portion protruding toward the other piece side. The resin intake manifold according to claim 1 or 2, wherein a welding line bent in a substantially U-shape is formed at an edge portion of the funnel partition wall of the funnel portion.

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