JP2709701B2 - Intake manifold and method of manufacturing the same - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an intake manifold used for an automobile engine.

[0002] In this specification, the term "aluminum" shall include aluminum alloys in addition to pure aluminum.

[0003]

2. Description of the Related Art FIG. 3 shows a conventional intake manifold. In FIG. 3, the conventional intake manifold has one intake inlet (21) and a plurality of intake outlets (2
2) an aluminum plenum chamber (20) having a plenum chamber (20); a substantially U-shaped aluminum wrought material branch pipe (23) having one end connected to each intake outlet (22) of the plenum chamber (20); Passage (25) and these intake passages (2
5) is provided with a flange (26) for mounting to a cylinder head made of aluminum casting to which the other end of the branch pipe (23) is connected, and the other end of each branch pipe (23) has a mounting flange ( 26)
Through a cylinder head of an engine (not shown).

[0004] The plenum chamber (20) is joined to a chamber body (27) made of a wrought aluminum wrought material having one end closed and the other end opened by brazing to the open end of the chamber body (27). And a throttle body mounting tubular member (28) made of aluminum casting. Chamber body
A plurality of intake outlets (22) are formed on the peripheral wall of (27), and a cylindrical outwardly projecting portion (2
9) are integrally formed, and one end of each branch pipe (23) is fitted into the cylindrical outer protrusion (29), and is joined to the cylindrical outer protrusion (29) by brazing. Thus, it is connected to the intake outlet (22). A flange (30) is integrally formed at one end of the throttle body mounting tubular member (28), and an end of the flange (30) is attached to a cylinder head mounting flange (26).
Are joined by brazing. A throttle body including a throttle valve (not shown) is mounted on a flange (30) of the throttle body mounting tubular member (28), and an air supply pipe from an air cleaner is connected to the throttle body.

[0005] A branch pipe connecting tubular protruding portion (31) is integrally formed around the intake passage (25) of the mounting flange (26) to the cylinder head. The end is fitted into the cylindrical protrusion (31) and brazed to form the cylindrical protrusion (31).
Connected to the intake passage (25). The mounting flange (26) to the cylinder head and the chamber body (27) of the plenum chamber (20) are connected by an aluminum stay (32). The stay (32) has one end joined to the mounting flange (26) to the cylinder head and the other end joined to the chamber body (27) by brazing.
Then, the end of the flange (30) of the throttle body mounting tubular member (28) is attached to the cylinder head mounting flange (26).
And brazed to the end of the stay (32)
Is joined to the flange (26) for attachment to the cylinder head by brazing, and the other end is joined to the chamber body (27) by brazing, thereby improving the rigidity of the entire intake manifold.

A conventional intake manifold has been manufactured as follows. That is, first, the branch pipe (23), the chamber main body (27), the tubular member (28) for attaching the throttle body, the flange (26) for attaching to the cylinder head, and the stay (32) are separately formed. Thereafter, as shown in FIG. 4, these parts, namely, a branch pipe (23), a chamber body (27), a tubular member (28) for attaching a throttle body, a flange (26) for attaching to a cylinder head, and a stay ( Combine 32) with a predetermined form, fix and hold with a jig, and braze all parts at once. Thus, an intake manifold was manufactured.

[0007]

However, the conventional intake manifold has a large number of parts, and all the parts, namely, the branch pipe (23), the chamber body (27), the throttle body mounting tubular member (28), Since the mounting flange (26) and the stay (32) for mounting to the cylinder head must be formed separately, dedicated molds, tools, etc. necessary to form these parts must be prepared separately. The man-hours for forming the parts are increased as a whole. In addition, branch pipe
(23), the chamber body (27), the cylindrical body (28) for mounting the throttle body, the flange (26) for mounting to the cylinder head, and the stay (32) need to be fixed in a predetermined form and fixed with a jig. Therefore, it is troublesome to assemble these parts into a predetermined form, and the number of jigs for fixing and holding these parts in a predetermined form increases. Therefore, there is a problem that the manufacturing operation of the entire intake manifold is troublesome and the manufacturing cost is increased.

An object of the present invention is to provide an intake manifold which solves the above problems and a method of manufacturing the same.

[0009]

SUMMARY OF THE INVENTION An intake manifold according to the present invention comprises an aluminum plenum chamber having an intake inlet and a plurality of intake outlets, and a plurality of generally U-shaped aluminum tubes having one end connected to the intake outlet of the plenum chamber. An intake manifold comprising: a wrought material branch pipe; and a flange for mounting to an aluminum cylinder head having a plurality of intake passages and the other end of the branch pipe connected to each of the intake passages. The plenum chamber and the flange for mounting to the cylinder head are formed integrally, and the suction outlet of the plenum chamber and the suction passage of the flange for mounting to the cylinder head face in the same direction.

A method of manufacturing an intake manifold according to the present invention is an aluminum plenum chamber having an intake inlet and a plurality of intake outlets, and an aluminum cylinder head having a plurality of intake passages oriented in the same direction as the intake outlet of the plenum chamber. Casting an aluminum wrought pipe into a substantially U-shape to form a branch pipe, and suctioning the mounting flange to a plenum chamber inlet and a cylinder head. The passage is directed upward, and in this state, one end of the branch pipe is connected to the intake outlet of the plenum chamber, and the other end is connected to the intake passage for attachment to the cylinder head.

[0011]

According to the intake manifold of the present invention, since the plenum chamber and the flange for mounting to the cylinder head are formed integrally, it is easier to form these parts than if they were formed separately. The number of necessary dedicated molds, tools and the like is reduced, and the man-hour for forming is reduced. In particular, if the plenum chamber and the flange for mounting to the cylinder head are integrally cast as in the method of the present invention, only one mold needs to be used to form the integrated body, and the man-hour is also reduced. You only need one. Further, since the intake outlet of the plenum chamber and the intake passage of the flange for attachment to the cylinder head face in the same direction, a plenum for connecting both ends of the substantially U-shaped branch pipe to the intake outlet and the intake passage is provided. The work of assembling the flange for mounting to the chamber and the cylinder head and the branch pipe into a predetermined form is simple, and the number of jigs for fixing and holding these in a predetermined form is small. Especially,
As in the method of the present invention, the intake outlet of the plenum chamber is directed upward and the intake passage of the flange for attachment to the cylinder head is directed upward, and in this state, one end of the branch pipe is connected to the intake outlet of the plenum chamber, If the ends are respectively connected to the intake passages for attachment to the cylinder head, a jig for fixing and holding the plenum chamber and the flange for attachment to the cylinder head and the branch pipe in a predetermined form is not required.

[0012]

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

FIG. 1 shows an intake manifold according to the present invention, and FIG. 2 shows a manufacturing method thereof.

In FIG. 1, an intake manifold according to the present invention comprises an intake inlet (2) and a plurality of intake outlets (3).
A plenum chamber having a plenum chamber;
A substantially U-shaped aluminum wrought branch pipe (4) having one end connected to each intake outlet (3) of (1), and a plurality of intake passages (6)
And a flange (5) for attachment to a cylinder head to which the other end of the branch pipe (4) is connected to each of the intake passages (6), and the other end of each branch pipe (4). Are connected to a cylinder head (not shown) of the engine via a mounting flange (5).

The plenum chamber (1) is a straight tube with one end closed and the other end open, and a throttle body mounting flange (7) is formed at the open end.
The end of the throttle body mounting flange (7) is integrally connected to the end of the mounting flange (5) to the cylinder head. A throttle body having a built-in throttle valve (not shown) is attached to the flange (7), and an air supply pipe from an air cleaner is connected to the throttle body. A plurality of intake outlets (3) are formed on the peripheral wall of the plenum chamber (1), and a cylindrical outer projection (8) for connecting a branch pipe around each intake outlet (3) is the same as the intake outlet (3). One end of each branch pipe (4) is fitted into a cylindrical outward projection (8), and is formed integrally so as to be on the axis.
It is connected to the intake outlet (3) by being joined to the cylindrical outward projection (8) by brazing.

A branch pipe connecting tubular projection (9) is integrated around the intake passage (6) of the flange (5) for attachment to the cylinder head so as to be coaxial with the intake passage (6). The other end of each branch pipe (4) is fitted into a cylindrical projection (9), and is joined to the cylindrical projection (9) by brazing to form an intake passage ( 6) Connected to. Flange (5) for mounting to cylinder head and plenum chamber
(1) is connected integrally with the stay (10). The end of the throttle body mounting flange (7) is integrally connected to the end of the mounting flange (5) to the cylinder head, and the mounting flange to the cylinder head is connected.
Since the (5) and the plenum chamber (1) are integrally connected by the stay (10), the rigidity of the entire intake manifold is improved.

The plenum chamber (1), the flange (7) for attaching the throttle body, the flange (5) for attaching to the cylinder head, and the stay (10) are integrally formed of an aluminum casting as a whole. This integrated object is indicated by (11).

The intake manifold is manufactured as follows. That is, first, an integrated body (11) including a plenum chamber (1), a throttle body mounting flange (7), a mounting flange (5) to a cylinder head, and a stay (10).
Are integrally cast using aluminum. This casting is performed by general casting or die casting.
A substantially U-shaped branch pipe (4) is formed by bending an extruded aluminum pipe. Then, FIG.
As shown in the figure, the unit (11) is connected to the intake port (3) of the plenum chamber (1) and the mounting flange to the cylinder head.
Arrange so that the air inlet (6) of (5) faces upward. Then, one end of the branch pipe (4) is inserted into the cylindrical outward projection (8) of the plenum chamber (1), and the other end is inserted into the cylindrical projection (9) of the flange (5) for mounting to the cylinder head. Inside. In this way, the integrated body (11) and the branch pipe (4) are combined in a predetermined form. In this state, there is no need for a jig for fixing and holding the integrated object (11) and the branch pipe (4) in a predetermined form. Thereafter, the branch pipe (4), the cylindrical outer protrusion (8) and the cylindrical protrusion (9) are collectively brazed, and one end of the branch pipe (4) is connected to the inlet of the plenum chamber (1). 3) Connect the other end to the intake port (6) of the flange (5) for mounting to the cylinder head. Thus, an intake manifold is manufactured.

[0019]

According to the intake manifold and the method of manufacturing the intake manifold of the present invention, as described above, the number of dedicated molds, tools, and the like necessary for forming each component constituting the intake manifold is reduced. In addition, the number of steps required for forming is reduced. In particular, if the plenum chamber and the flange for mounting to the cylinder head are integrally cast as in the method of the present invention, only one mold needs to be used to form the integrated body, and the man-hour is also reduced. You only need one. In addition, the plunger chamber for connecting the both ends of the substantially U-shaped branch pipe to the intake outlet and the intake passage and the flange for mounting to the cylinder head and the branch pipe are easily combined with each other in a predetermined form. The number of jigs for holding the pieces in a predetermined form can be reduced. In particular, as in the method of the present invention, the intake outlet of the plenum chamber is directed upward and the intake passage of the flange for attachment to the cylinder head is directed upward, and in this state, one end of the branch pipe is connected to the intake outlet of the plenum chamber. If the other end is connected to the intake passage for attachment to the cylinder head, no jig is required. Therefore, the manufacturing operation of the entire intake manifold is simplified, and the manufacturing cost is reduced.

[Brief description of the drawings]

FIG. 1 is a perspective view showing an intake manifold according to the present invention.

FIG. 2 is a perspective view showing a method of manufacturing an intake manifold according to the present invention.

FIG. 3 is a perspective view showing a conventional intake manifold.

FIG. 4 is a perspective view showing a conventional method of manufacturing an intake manifold.

[Explanation of symbols]

 (1) Plenum chamber (2) Suction inlet (3) Suction outlet (4) Branch pipe (5) Flange for mounting to cylinder head (6) Suction passage

Claims (2)

(57) [Claims] 1. An aluminum plenum chamber having an intake inlet and a plurality of intake outlets, a plurality of substantially U-shaped aluminum wrought branch pipes each having one end connected to the intake outlet of the plenum chamber, and a plurality of intakes. An intake manifold having a passage opening and a flange for attachment to an aluminum cylinder head in which the other end of the branch pipe is connected to each of these intake passages, for mounting to a plenum chamber and a cylinder head. An intake manifold in which a flange is integrally formed, and an intake outlet of a plenum chamber and an intake passage of a flange for attachment to a cylinder head face in the same direction. 2. An aluminum plenum chamber having an intake inlet and a plurality of intake outlets, and a flange for mounting to an aluminum cylinder head having a plurality of intake passages oriented in the same direction as the intake outlet of the plenum chamber. To form a branch pipe by bending a wrought aluminum pipe into a substantially U-shape, and directing an intake outlet of a plenum chamber and an intake passage of a flange for mounting to a cylinder head upward. A method of manufacturing an intake manifold, comprising connecting one end of a branch pipe to an intake outlet of a plenum chamber and the other end to an intake passage for attachment to a cylinder head.