Intake manifold

Abstract

An intake manifold includes a plurality of intake pipes that are provided in line to send air to an engine mounted on a vehicle through the intake pipes. Each of the intake pipes includes a main body formed of resin and an end pipe formed of resin, welded to a lower stream end side of the main body, and joined to the engine. Further, one member of the main body and the end pipe is provided with a rib that is formed on a side surface portion of the one member and that extends toward a lateral side of the other member. The other member is provided with a restriction portion that is formed on a side surface portion of the other member and that interferes with the rib to restrict moving of the main body in the crash direction relative to the end pipe when a weld portion of the main body and the end pipe is broken due to a collision load applied to the intake pipe at a vehicle crash.

Claims

1. An intake manifold comprising a plurality of intake pipes that are provided in line to send air to an engine mounted on a vehicle through the intake pipes, each of the intake pipes including: a main body formed of resin; and an end pipe formed of resin, welded to a lower stream end side of the main body, and configured to be joined to the engine, wherein one member of the main body and the end pipe is provided with a rib that is formed on a side surface portion of the one member and that extends toward a lateral side of the other member, and the other member is provided with a restriction portion that is formed on a side surface portion of the other member and that interferes with the rib to restrict moving of the main body in a crash direction relative to the end pipe when a weld portion of the main body and the end pipe is broken due to a collision load applied to each intake pipe at a vehicle crash.

2. The intake manifold according to claim 1, wherein the one member is the main body, and the other member is the end pipe.

3. The intake manifold according to claim 2, wherein the rib contains: a pair of vertical ribs each of which extends from the side surface portion of the lower stream end side of each of the main bodies of a pair of the intake pipes that are adjacent to each other toward the lateral side of the end pipe; and a connection rib that connects the pair of vertical ribs to each other, and least one of the pair of vertical ribs is arranged to be opposite to or in contact with the restriction portion in the crash direction.

4. The intake manifold according to claim 3, wherein the connection rib is welded to a side of the end pipe.

5. The intake manifold according to claim 1, wherein the end pipe includes a control valve configured to control a volume of air flow.

6. The intake manifold according to claim 1, wherein an alignment direction of the intake pipes corresponds to a longitudinal direction of the vehicle.

7. The intake manifold according to claim 1, wherein flanges are provided on an axial end side of the main body and an axial end side of the end pipe so as to be welded to each other, the rib is integrally formed on a side surface portion of the flange of the one member, and the restriction portion is integrally formed on a side surface portion of the flange of the other member.

Description

BRIEF DESCRIPTION OF DRAWINGS

(1) The present invention is further described in the detailed description which follows, in reference to the noted plurality of drawings by way of non-limiting examples of exemplary embodiments of the present invention, in which like reference numerals represent similar parts throughout the several views of the drawings, and wherein:

(2) FIG. 1 is a perspective view showing an intake manifold in accordance with an example.

(3) FIG. 2 is an enlarged view of a principal part of FIG. 1 and shows a weld state of a main body and an end pipe.

(4) FIG. 3 is an enlarged view of the principal part of FIG. 1 and shows an exploded state of the main body and the end pipe.

(5) FIG. 4 is an enlarged sectional view taken along line IV-IV in FIG. 1.

(6) FIG. 5A is a front view showing an assembled state of the intake manifold.

(7) FIG. 5B is a front view showing an exploded state of the intake manifold.

(8) FIG. 6 is a plan view of a principal part of a vehicle on which an engine including the intake manifold is mounted.

(9) FIG. 7A is a diagram to explain operation of the intake manifold in a state of a vehicle crash.

(10) FIG. 7B is a diagram to explain the operation of the intake manifold in a state just after the vehicle crash.

(11) FIG. 8A is a diagram to explain an intake manifold of another embodiment in the state of the vehicle crash.

(12) FIG. 8B is a diagram to explain the intake manifold of another embodiment in the state just after the vehicle crash.

(13) FIG. 9A is a diagram to explain an intake manifold of still another embodiment in the state of the vehicle crash.

(14) FIG. 9B is a diagram to explain the intake manifold of still another embodiment in the state just after the vehicle crash.

DETAILED DESCRIPTION

(15) The particulars shown herein are by way of example and for purposes of illustrative discussion of the embodiments of the present invention only and are presented in the cause of providing what is believed to be the most useful and readily understood description of the principles and conceptual aspects of the present invention. In this regard, no attempt is made to show structural details of the present invention in more detail than is necessary for the fundamental understanding of the present invention, the description is taken with the drawings making apparent to those skilled in the art how the forms of the present invention may be embodied in practice.

(16) In accordance with the present embodiment, an intake manifold (1) includes a plurality of intake pipes (3) which are provided in line so as to send air to an engine (2) mounted on a vehicle (6) through the intake pipes. Each of the intake pipes is provided with a main body (8) formed of resin and an end pipe (9) formed of resin, welded to a lower stream end side of the main body, and joined to the engine (refer to, for example, FIGS. 1 to 4). One member of the main body (8) and the end pipe (9) is provided with a rib (27, 31, 32, 33) which is formed on a side surface portion of the one member and which extends toward a lateral side of the other member. The other member is provided with a restriction portion (10) which is formed on a side surface portion of the other member and which interferes with the rib (27, 31, 32, 33) to restrict moving of the main body in a crash direction relative to the end pipe when a weld portion (wp) of the main body (8) and the end pipe (9) is broken due to a collision load (P) applied to each of the intake pipes (3) at a vehicle crash (refer to, for example, FIGS. 4 and 7A to 9B).

(17) Incidentally, the shapes, numbers, arrangement locations, and the like of the rib and the restriction portion are not particularly limited, and are appropriately selected in accordance with the shapes of the engine and the intake pipe. Further, the crash direction is not particularly limited and is set arbitrarily. As the crash direction, for example, a longitudinal direction of the vehicle or a cross direction to the longitudinal direction of the vehicle (for example, a lateral direction of the vehicle) is suggested.

(18) As the intake manifold of this embodiment, for example, it is suggested that the one member is the main body (8) and the other member is the end pipe (9) (refer to, for example, FIGS. 7A, 7B, 9A, and 9B).

(19) According to the embodiment described above, it is suggested that each of the ribs (27) contains a pair of vertical ribs (27a) each of which extends from a side surface portion of a lower stream end side of each of the main bodies (8) of a pair of the intake pipes (3) which are adjacent to each other toward a lateral side of the end pipe (9) and a connection rib (27b) which connects the pair of vertical ribs. The vertical rib (27a) is arranged to be opposite to or in contact with the restriction portion (10) in the crash direction (refer to, for example, FIG. 4).

(20) According to the embodiment described above, for example, the connection rib (27b) is welded to a side of the end pipe (9) (refer to, for example, FIG. 4). In this case, it is preferable that the connection rib (27b) is welded on a reinforcement rib (17a) which is formed along a side surface portion of a pair of the end pipes (9) which are adjacent to each other from a point of view of strength of the intake pipe.

(21) As the intake manifold of this embodiment, for example, it is suggested that each of the end pipes (9) includes a control valve (20) for controlling a volume of air flow (refer to, for example, FIG. 4).

(22) As the intake manifold of this embodiment, for example, it is suggested that an alignment direction (A) of the intake pipes corresponds to the longitudinal direction (B) of the vehicle (refer to, for example, FIG. 6).

(23) Reference signs in parentheses of components described in the above embodiment each indicate a correspondence with a concrete composition mentioned in examples which will be described later.

EXAMPLES

(24) With reference to the drawings, a concrete description of the present invention will be made hereinafter by way of examples. Incidentally, in these examples, as an intake manifold of the present invention, the intake manifold 1 which is used for a horizontally opposed engine (concretely a horizontally opposed four-cylinder engine) 2 will be exemplified (refer to FIG. 6).

(25) (1) Structure of Intake Manifold

(26) As shown in FIG. 1, the intake manifold 1 according to this example includes the plurality of intake pipes 3 which are provided in line to send air to the engine 2 mounted on the vehicle 6 through the intake pipes 3 (refer to FIG. 6). A surge tank 5 on which an air inlet 5a is formed is provided on a central side of the intake manifold 1.

(27) The intake pipes 3 extend downward from right and left sides of the surge tank 5 so as to be curved. Concretely, the pair of intake pipes 3 are provided on each of the right and left sides so as to correspond to a pair of combustion chambers (not shown) which are respectively disposed on the right and left sides of the engine 2. The alignment direction A of the pair of intake pipes 3 which are provided on each of the right and left sides corresponds to the longitudinal direction B of the vehicle (refer to FIG. 6). That is, in a state in which the vehicle 6 is equipped with the engine 2 on which the intake manifold 1 is mounted, the alignment direction A of the intake pipes 3 corresponds to the longitudinal direction B of the vehicle. Air introduced into the surge tank 5 is supplied to the combustion chambers of the engine 2 through each of the intake pipes 3.

(28) Each of the intake pipes 3 is provided with the main body 8 and the end pipe 9 which is welded to the lower stream end side of the main body 8 (that is, the lower stream end side of air stream of the main body 8) and which is joined to the engine 2 as shown in FIGS. 2 to 4. Each of the main body 8 and the end pipe 9 is formed of synthetic resin of heat resistance, such as, polyamide resin. Incidentally, the main body 8 of each intake pipe 3 and the surge tank 5 are structured by welding a lower member 11 whose upper surface side is open and an upper member 12 whose lower surface side is open to close an opening of the upper surface side of the lower member 11 to each other by vibration welding (refer to FIGS. 5A and 5B).

(29) A plurality of the end pipes 9 (two end pipes 9 are shown in the drawings) are integrally formed on a base 16 which is joined to the engine 2 with a plurality of bolts 14 so that the end pipes are adjacent to each other (refer to FIGS. 7A and 7B). A reinforcement rib 17 which shows a gridded shape is formed on the side surface portions of the end pipes 9. The connection rib 27b of the rib 27 which will be described later is welded on a reinforcement rib 17a which composes the reinforcement rib 17 and which is formed to extend in a lateral direction across the pair of end pipes 9 which are adjacent each other (refer to FIGS. 3 and 4).

(30) A control valve 20 for controlling a volume of air flow is provided in each of the pair of end pipes 9 as shown in FIGS. 4, 5A, and 5B. The control valves 20 are connected each other with a connection shaft 21a, and a drive shaft 21b provided on one of the control valves 20 is driven by an actuator (not shown) to adjust a space area in the end pipe 9. Concretely, each of the control valves 20 controls the space area in the end pipe 9 in accordance with a load situation of the engine 2 so as to generate tumble flow in a cylinder of the engine 2.

(31) As shown in FIG. 4, a flange 23 on which a projection stripe 23a is formed to serve as a welding margin is provided on one end side (that is, an upper end side) of each of the end pipes 9. Further, a flange 24 on which a projection stripe 24a is formed to be joined to the projection stripe 23a and to serve as a welding margin is provided on a lower end side of each of the main bodies 8. Ribs 24b are formed on the flange 24 so that each of the ribs 24b is positioned at an inner circumference side or an outer circumference side with a gap with respect to the projection stripe 24a. Both the flanges 23, 24 are fixed to each other by receiving relative displacement with vibration between the main body 8 and the end pipe 9 so as to melt the projection stripes 23a, 24a in a state in which the projection stripes 23a, 24a of both the flanges 23, 24 are in contact with each other.

(32) The rib 27 is integrally formed on the side surface portion of the lower stream end side of each of the main bodies 8 so as to extend toward the lateral side of the end pipe 9 as shown in FIGS. 3 and 4. Further, the end pipe 9 is provided with a restriction portion 10 which is integrally formed on the side surface portion of the end pipe 9 and which interferes with the rib 27 to restrict moving of the main body 8 in the crash direction (concretely, the longitudinal direction B of the vehicle) relative to the end pipe 9 when the weld portion wp of the main body 8 and the end pipe 9 is broken due to the collision load P applied to the intake pipe 3 at the vehicle crash. The restriction portion 10 is formed of a part of the flange 23.

(33) Each of the ribs 27 contains the pair of vertical ribs 27a, 27a each of which extends from the side surface portion of each of the main bodies 8 of the pair of intake pipes 3 toward the lateral side of the end pipe 9 and the connection rib 27b which connects lower end sides of the pair of vertical ribs 27a, 27a to each other. The vertical rib 27a is disposed to be opposite to the restriction portion 10 of the end pipe 9 in the longitudinal direction B of the vehicle.

(34) An upper end side of each of the vertical ribs 27a is connected to the flange 24 of the main body 8. Further, the connection rib 27b is welded on the reinforcement rib 17a which is provided on the end pipes 9. A protrusion 28a which serves as a welding margin is formed on an upper surface side of the reinforcement rib 17a. A protrusion 29a which serves as a welding margin to be joined to the protrusion 28a is formed on a lower surface side of the connection rib 27b. Furthermore, a rib 29b is formed on the lower surface side of the connection rib 27b so that the rib 29b is positioned at an outer peripheral side with a gap with respect to the protrusion 29a. The connection rib 27b and the reinforcement rib 17a are fixed to each other by receiving relative displacement with vibration between the main body 8 and the end pipe 9 so as to melt the protrusions 28a, 29a in a state in which the protrusions 28a, 29a of the connection rib 27b and the reinforcement rib 17a are in contact with each other.

(35) (2) Operation of Intake Manifold

(36) An operation of the intake manifold 1 of the above structure will be described hereinafter. The weld portion wp of the main body 8 and the end pipe 9 is sometimes broken and separated (refer to FIG. 7B) due to the collision load P applied to the intake pipe 3 at the vehicle crash from the front side (refer to FIG. 7A). At this moment, the vertical rib 27a and the restriction portion 10 interfere with each other (that is, the restriction portion 10 catches the vertical rib 27a) to restrict moving of the main body 8 in the crash direction (concretely, the longitudinal direction B of the vehicle) relative to the end pipe 9 which is joined to the engine 2. Therefore, the weld fracture surface of the main body 8 and the end pipe 9 is hard to be exposed to restrain harm which the weld fracture surface applies to peripheral parts (for example, a fuel hose).

(37) (3) Effects in this Example

(38) According to the intake manifold 1 of this example, each of the intake pipes 3 includes the main body 8 formed of resin and the end pipe 9 formed of resin, welded to the lower stream end side of the main body 8, and joined to the engine 2. The main body 8 is provided with the rib 27 which is formed on the side surface portion of the lower stream end side of the main body 8 and which extends toward the lateral side of the end pipe 9. The end pipe 9 is provided with the restriction portion 10 which is formed on the side surface portion of the end pipe 9 and which interferes with the rib 27 to restrict moving of the main body 8 in the crash direction relative to the end pipe 9 when the weld portion wp of the main body 8 and the end pipe 9 is broken due to the collision load P applied to the intake pipe 3 at the vehicle crash. Therefore, since the rib 27 and the restriction portion 10 interfere with each other at the vehicle crash, the main body 8 is restricted from moving in the crash direction relative to the end pipe 9 which is joined to the engine 2. Hence, the weld fracture surface of the main body 8 is hard to be exposed to restrain harm which the weld fracture surface applies to the peripheral parts. Further, the intake manifold has a structure which is more lightweight and inexpensive than that of the conventional intake manifold including a metal holder.

(39) According to this example, each of the ribs 27 contains the pair of vertical ribs 27a and the connection rib 27b. The vertical rib 27a is arranged to be opposite to the restriction portion 10 in the crash direction. Hence, since the vertical rib 27a and the restriction portion 10 interfere with each other, the main body 8 is restricted from moving in the crash direction relative to the end pipe 9. Because the rib 27 is provided to be put across each of the main bodies 8 of the pair of intake pipes 3 which are adjacent to each other, the strength of the pair of intake pipes 3 is increased.

(40) According to this example, the connection rib 27b is welded to the side of the end pipe 9. Therefore, weld strength of the main body 8 and the end pipe 9 is increased. According to this example, particularly, the connection rib 27b is welded on the reinforcement rib 17a which is formed across the side surface portion of the pair of end pipes 9 which are adjacent each other. Hence, the strength of the pair of intake pipes 3 is further increased.

(41) According to this example, each of the end pipes 9 includes the control valve 20 for controlling the volume of air flow. Therefore, installation accuracy of the control valve 20 is increased.

(42) According to this example, the alignment direction A of the intake pipes 3 corresponds to the longitudinal direction B of the vehicle. Therefore, the main body 8 is restricted from moving in the crash direction (that is, the longitudinal direction B of the vehicle) relative to the end pipe 9 at the vehicle crash from the front side.

(43) As many apparently widely different examples of this invention may be made without departing from the spirit and scope thereof, it is to be understood that the invention is not limited to the specific examples thereof except as defined in the appended claims. That is, according to this example, each of the ribs 27 is provided to be put across the pair of main bodies 8 which are adjacent to each other. However, it is to be understood that the present invention is not intended to be limited to this example. For example, a rib 31 may be provided to be put across the pair of end pipes 9 which are adjacent to each other as shown in FIGS. 8A and 8B. Further, for example, a rib 32 or a rib 33 may be provided to be integrally formed on the single main body 8 or the single end pipe 9 as shown in FIGS. 9A and 9B.

(44) According to the example described above, the rib 27 is opposite to the restriction portion 10 in the state in which the main body 8 and the end pipe 9 are welded to each other. However, it is to be understood that the present invention is not intended to be limited to this example. For example, the rib 27 may be in contact with the restriction portion 10 in a state in which the main body 8 and the end pipe 9 are welded to each other.

(45) According to the example described above, the rib 27 is welded to the end pipes 9. However, it is to be understood that the present invention is not intended to be limited to this example. For example, the rib 27 may not be welded to the end pipe 9.

(46) According to the example described above, the restriction portion 10 is formed with a part of the flange 23 of the end pipe 9. However, it is to be understood that the present invention is not intended to be limited to this example. For example, the restriction portion 10 may be provided on a portion of the end pipe 9 except the flange 23.

(47) According to the example described above, each of the end pipes 9 includes the control valve 20. However, it is to be understood that the present invention is not intended to be limited to this example. For example, the end pipe 9 may not include the control valve 20. Further, each of the end pipes 9 may include another functional component instead of or in addition to the control valve 20.

(48) According to the example described above, the main body 8 and the end pipe 9 are fixed to each other by vibration welding. However, it is to be understood that the present invention is not intended to be limited to this example. For example, the main body 8 and the end pipe 9 may be fixed to each other by, for example, laser welding, ultrasonic welding, thermal welding, or induced welding.

(49) According to the example described above, the structure including the horizontally opposed engine 2 as the engine is described. However, it is to be understood that the present invention is not intended to be limited to this example. For example, an inline engine or a V-type engine may be applied to the example. Further, according to the example described above, the structure including the front engine is described. However, it is to be understood that the present invention is not intended to be limited to this example. For example, a rear engine or a mid-ship engine may be applied to the example.

(50) According to the example described above, the intake manifold 1 includes the pair of intake pipes 3 which are provided in line. However, it is to be understood that the present invention is not intended to be limited to this example. For example, the intake manifold 1 may include three or more intake pipes 3 which are provided in line. Incidentally, the shape, the number, and the like of the intake pipe are appropriately selected in accordance with the form of the engine.

(51) According to the example described above, the rib 27 and the restriction portion 10 restrict moving of the main body 8 in the crash direction (the longitudinal direction B of the vehicle) relative to the end pipe 9 at the vehicle crash from the front side. However, it is to be understood that the present invention is not intended to be limited to this example. For example, the rib and the restriction portion may restrict moving of the main body 8 in the crash direction (a direction crossing the longitudinal direction B of the vehicle) relative to the end pipe 9 at the vehicle crash from the lateral side instead of or in addition to at the vehicle crash from the front side.

(52) According to the example described above, the intake manifold 1 includes the intake pipes whose alignment direction A corresponds the longitudinal direction B of the vehicle. However, it is to be understood that the present invention is not intended to be limited to this example. For example, the intake manifold may include the intake pipes whose alignment direction A corresponds a direction crossing the longitudinal direction B of the vehicle (for example, a lateral direction of the vehicle).

(53) It is noted that the foregoing examples have been provided merely for the purpose of explanation and are in no way to be construed as limiting of the present invention. While the present invention has been described with reference to exemplary embodiments, it is understood that the words which have been used herein are words of description and illustration, rather than words of limitation. Changes may be made, within the purview of the appended claims, as presently stated and as amended, without departing from the scope and spirit of the present invention in its aspects. Although the present invention has been described herein with reference to particular structures, materials and embodiments, the present invention is not intended to be limited to the particulars disclosed herein; rather, the present invention extends to all functionally equivalent structures, methods and uses, such as are within the scope of the appended claims.

(54) The present invention is not limited to the above-described embodiments, and various variations and modifications may be possible without departing from the scope of the present invention.

(55) The present invention is widely used as a technology relating to an intake manifold sending air to an engine which is used in a vehicle such as a passenger car, a bus, or a truck.