JPH07166875A - Intake control device for multi-cylinder internal combustion engine - Google Patents

Abstract

(57) [Summary] [Structure] The valve body (II), the cover (III) and the port shell 40 are all made of a resin material, and the valve body has end faces 53a and 54 facing the port shell at the opening end thereof. When the valve shell and the cover are abutted and coupled to the port shell, the end surface 53a,
Biasing projections 46, 47 that abut against 54 and urge them toward the inner wall surface of the cover are formed. The projecting length of the biasing projection is determined by the connecting projection 60 of the cover for connecting the valve body. The urging projection is in a non-contact state with the end face in the unwelded state just brought into contact with the receiving surface portion 50, and has a protruding length which comes into contact with the end face in the welded state. [Effect] In the state where the valve body and the cover are abuttingly coupled, the urging projections abut the end face without melting and constantly urge the port shell to adhere closely to the inner wall surface of the cover. It is possible to surely form the intake passage with a structure.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an intake control device for a multi-cylinder internal combustion engine mounted on an automobile or the like, and is particularly characterized by a structure having two types of intake passages, long and short, and forming one of the intake passages. The present invention relates to an intake control device for a multi-cylinder internal combustion engine having a.

[0002]

2. Description of the Related Art Conventionally, the length of an intake pipe is switched between two stages according to the engine speed, load, etc., and the inertial supercharging effect or resonance supercharging effect is given to the intake air to improve the engine output. An intake control device for an engine that employs a so-called variable intake system is known.

FIG. 1 is a sectional view of an intake control device which employs such a variable intake system in a 6-cylinder internal combustion engine. In this drawing, a cross section of one intake passage corresponding to one cylinder of the engine is shown, but the intake passages are integrally formed in parallel in the direction perpendicular to the paper surface by an amount corresponding to six cylinders. In such an intake control device, the intake air introduced from the side surface of the main body into the surge tank 1 via the throttle valve (not shown) is operated by the switching valve 2 which is a butterfly valve in the low and medium speed range. ) Operation (state indicated by the solid line) to pass through the bypass intake passage 3 as indicated by the arrow A, while the switching valve 2 is opened in the high speed range (state indicated by the chain double-dashed line). ), And is introduced directly into the engine cylinder as indicated by arrow B without passing through the bypass intake passage 3.

That is, by opening / closing the switching valve 2, the pressure reversal wave due to the long intake pipe at low and medium speeds and the pressure reversal wave due to the short intake pipe at low speeds are synchronized, thereby improving the filling efficiency of the entire region. It is to improve both low and medium speed torque and maximum output. Further, in the intake control device adopting such a variable intake system, the main body portion forming the intake passage, the surge tank, etc. is cast using aluminum material, and the switching valve 2 and its rotating shaft 2a etc. are made of steel material. And the like.

Due to such restrictions on the casting technique, the intake control device has three regions, namely, the branch portion (I) forming only the intake passage and the switching valve 2 as a multiple butterfly valve, and the intake passage. And a cover body (III) that forms the surge tank 1 and a port shell 4 that forms a part of the bypass intake passage 3 and that is formed separately.
After that, using fastening means (not shown) such as bolts and nuts, the respective mounting flange surfaces are butted and integrally joined.

Now, the mounting structure of the port shell 4 forming the bypass intake passage 3 (the longer intake passage) will be described. 2 is a view showing a port shell 4 used in the conventional intake air control device shown in FIG.
FIG. 2A is a perspective view showing the appearance thereof, and FIG. 2B is FIG.
It is sectional drawing in the MM part in the inside. As shown in the figure, the port shell 4 corresponding to one bypass intake passage is integrally formed of a resin material with the pair of mounting flange portions 4b.

Then, the contact portion 4a of the port shell is abutted against the inner wall surface of the cover portion (III) formed of aluminum material (see FIG. 2 (b)), and the cover portion II is formed.
The caulking projection 5a located at the tip of the protruding portion 5 formed on the inner wall of I is fitted into the through hole 4c, and then the washer 6 is sandwiched and the projection 5a is hit to make the caulking state. Since only one bypass intake passage is formed in such a port shell 4, in the case of a 6-cylinder internal combustion engine, it is necessary to use six port shells 4 to perform mounting (caulking) work for each.

After the port shell is attached, the cover portion III and the valve body portion (II) are brought into contact with the end surface 4d against the end surface of the valve body portion (II).
By fastening and fixing and with fastening means such as bolts,
The port shell will be firmly fixed inside the device. Even with such a fixing method mainly using caulking, since the valve body portion (II) and the cover portion (III) that form the main body of the device are made of aluminum material,
There is no warp or bending of the main body portion, and the structure is such that it is firmly and firmly fixed.

On the other hand, as one of the policies for automobile development today, development of a fuel-efficient vehicle by reducing the weight of the vehicle, or development of a low-cost vehicle by changing the material and simplifying the manufacturing process is being considered. Therefore, the use of a resin material as a part of the intake control device, which has been conventionally formed of a metal material such as an aluminum material or a steel material, is being studied.

However, if the components of the conventional intake control device are simply made into resin, the mechanical strength of the resin material is smaller than that of the metal material, and the influence of the low heat transfer characteristics or the influence of each component is low. A new problem such as a decrease in assembly accuracy due to a decrease in molding accuracy occurs.

[0011]

In view of the above-mentioned problems of the prior art, the object of the present invention is to reduce the weight of the product and to easily form two kinds of intake passages. An object of the present invention is to provide an intake control device for a multi-cylinder internal combustion engine that can reliably perform the function of (1).

[0012]

SUMMARY OF THE INVENTION An intake control device for a multi-cylinder internal combustion engine according to the present invention includes a shell body which forms a part of two types of intake passages of long and short types which communicate with each cylinder of the multi-cylinder internal combustion engine, and the shell. A cover body abuttingly coupled to the opening end of the body to cover the opening end, and a part of one of the two types of intake passages abuttingly arranged on the inner wall surface of the cover body. An intake control device for a multi-cylinder internal combustion engine, comprising: the shell body, the cover body, and the intake passage formation member made of a resin material; and the shell body and the opening end portion of the cover body. , One has a coupling projection that is coupled to the other by welding, and the other has a coupling receiving surface portion that receives the coupling projection, and the shell body is near the opening end thereof. The suction passage forming member has an end surface facing the suction passage forming member, The passage forming member has an urging protrusion that abuts against the end face and urges the end face toward the inner wall surface of the cover body in a state where the shell body and the cover body are welded and coupled together, The biasing protrusion is in a non-contact state with the end face when the coupling projection is in contact with the coupling receiving surface portion and is in a non-welded state in a non-deformed state of the passage forming member and the cover body. And has a protrusion length that abuts against the end face in a state in which the coupling projection and the coupling receiving surface are welded and coupled.

[0013]

According to the intake control device of the present invention, when the shell body and the cover body are brought into contact with each other and weld-bonded to each other, first, both flange surfaces are arranged so as to face each other, and the connecting projection is projected to one flange surface. Is brought into contact with the receiving surface portion for coupling formed on the other flange surface. In this state, the biasing protrusions of the passage forming member arranged along the inner wall of the cover body are not in contact with the end surface of the shell body.

Here, in order to join the shell body and the cover body, relative vibration is applied between the shell body and the cover body to weld and join the joining projection and the joining receiving surface portion. At this time, the ends of the coupling projections are melted and the two relatively approach each other. At the same time, the end portion of the biasing projection formed on the passage forming member and the end surface of the shell body also approach and come into contact with each other. Further, the fusion of the coupling protrusion progresses, the biasing protrusion comes into strong contact with the end face, and the abutment force biases the passage forming member toward the inner wall of the cover body, thereby closely joining them.

After that, if the molten portion is cooled to room temperature,
The shell body and the cover body are completely connected to each other, while the end portions of the biasing protrusions are not melted and are in contact with the end surface of the shell body while maintaining the initial protruding length.

[0016]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Embodiments of the intake control device of the present invention will be described below with reference to the drawings. FIG. 3 is a plan view showing the appearance of the intake control device. As shown in FIG.
It consists of a combination of resin injection molded parts forming two regions I, II and III. That is, a branch part (I) connected to a head intake port of an engine, a multiple butterfly valve as an intake switching valve, and a valve body part as a shell forming a part of two types of intake passages, long and short (II), the cover portion (III) as a cover body that covers the opening end of the valve body portion and forms the surge tank and the bypass intake passage (long intake passage) is formed by injection molding or the like, and then joined. The respective flange surfaces are integrally joined by vibration welding or the like.

FIG. 4 is a perspective view of the intake control system shown in FIG.
FIG. 3 is a side view showing the outer appearance of the engine. As shown in the drawing, a flange portion 10 (10a, 10b) for attaching a throttle body for adjusting the output of the engine is formed. FIG. 5 is a side view of the intake control device shown in FIG. 3 as seen from the direction of the arrow L. As shown in FIG.
An actuator 30 in which a gear mechanism for driving the multiple butterfly valves installed therein is installed is attached to the side surface.

Reference numeral 2 shown in FIGS. 3 and 4
Reference numeral 0 indicates the outer appearance of the end bearing that supports one end of the valve rotation shaft in the radial direction, and the rotation shaft of the multiple butterfly valve is arranged at this position. FIG. 6 is a sectional view taken along the line CC in FIG. As shown in this figure, inside the valve body (II),
A multi-integrated butterfly valve in which the butterfly valve 21 and the rotary shaft 21a are integrally molded of a resin material is rotatably supported by an intermediate bearing 22 and is arranged in the intake passage. Also, inside the cover part (III),
A port shell 40 as an intake passage forming member for forming a bypass intake passage is arranged in contact with and fixed to the inner wall of the cover portion (III).

The mounting structure of the port shell 40 will be described below with reference to FIGS. 7 to 13. FIG. 7 is a view of the valve body (II) as seen from the end face direction on the cover (III) mounting side.
Inside the valve body (II), a passage 51 forming a part of a short intake passage and a passage 52 forming a part of a long intake passage (a bypass intake passage) are formed. Further, four convex portions 53 protruding inward from the outer wall of the valve body are formed above the passage 51, and an end surface 55 is formed at the peripheral edge of the passage 52 in the vicinity of the passage 52. A plurality of end faces 54 recessed between the passages 52, 52 of 55
(Four in this embodiment) are formed.

FIG. 8 is a sectional view of the valve body taken along the line D--D in FIG. 7, and as shown in the drawing, the cover (II
I) A concave flange portion 50 having a coupling receiving surface portion for abutting and embedding a part of the cover (3) when vibrating and welding the cover (III) is formed on the end surface (opening end) on the mounting side, and The end surface 53a and the end surface 54 of the convex portion 53 are
It is formed at a position slightly recessed from the end of the valve body.

In FIG. 9, the cover (III) is attached to the valve body (I
I) It is a view seen from the end face direction on the mounting side, and as shown in the figure, inside the cover (III), an outer passage wall 61 forming a part of a passage wall forming a bypass intake passage is formed into a substantially semicircular section. Six pieces are formed so as to project outward in a shape. Further, between the outer passage walls 61, a total of four protrusions 63 for thermally crimping a port shell described later, except for the central portion, are formed. Further, grooves 62 extending in the vertical direction are formed on both sides of each outer passage wall 61,
A fitting rib 44 of a port shell described later is fitted and fitted into this groove. Further, on the outer periphery of the outer passage wall 61, there is formed a contact surface 64 for contacting and closely contacting the contact portion 48 of the port shell, which will be described later (a portion indicated by a dot).

FIG. 10 is a sectional view of the cover (III) shown in FIG. 9. FIG. 10 (a) is a sectional view taken along the line EE, and FIG. 10 (b) is a sectional view taken along the line FF. It is a figure. As shown in the figure, on the end surface of the valve body (II) on the mounting side, a convex flange portion 60 having a coupling projection portion that is fitted and inserted into the concave flange portion 50 of the valve body is provided in the entire area excluding the opening 10c. It is formed over.

11 and 12 show a port shell 40 in which the portions corresponding to the three bypass intake passages are integrally formed of a resin material. FIG. 11 shows the port shell viewed from the surge tank side. A front view of the shell (FIG. 11 (a)),
FIG. 12 shows a plan view (FIG. 11B) and a cross-sectional view taken along line GG (FIG. 11C), and FIG.
Rear view of the port shell from the I side (Fig. 12)
(A)), the sectional view in the HH part (Drawing 12 (b)), and the side view by arrow S (Drawing 12 (c)) are each shown. As shown in both figures, the integrally formed port shell 40 has an inlet flange portion 42 that forms an inlet portion of the bypass intake passage in an upper portion thereof, and has a cross-section half ring shape downward from the flange portion. A fitting rib 44 having a side wall 43 for forming the passage 41 so as to be formed and having a tip end of the side wall fitted and fitted into the groove 62 of the cover (III).
have. Further, a through hole 45 into which the protrusion 63 is inserted when caulking and fixing it to the cover (III) is provided between the side walls 43 and in the substantially central portion in the vertical direction. Further, an end portion 49 which is fitted to the end surface 55 side of the valve body (II) is formed at the peripheral edge of the passage 41 which cooperates with the outer passage wall 61 of the cover (III) and constitutes a part of the bypass intake passage. ing.

Further, on the upper and lower end surfaces of the port shell facing the surge tank side, the port shell is disposed between the cover (III) and the valve body (II), and the valve shell and the valve shell are connected and fixed to each other. End faces 54, 53 of the body (II)
Energizing protrusions 46 and 47 are formed to abut the a and urge the port shell toward the cover (III). Here, the protrusion length of the biasing protrusions 46 and 47 will be described.
In a state where the port shell 40 is caulked and fixed (temporarily fixed) along the inner wall of the cover (III), the cover (III) and the valve body (II) are opposed to each other and the convex flange portion 60 of the cover (III) is provided. The coupling projection is brought into contact with the coupling receiving surface portion of the concave flange portion 50 of the valve body (II). When the cover (III) and the port shell 40 are in the non-deformed state in the unwelded state just brought into contact with each other, the biasing protrusions 46, 47 are in the non-contact state with the end faces 54, 53a. Here, the non-deformed state means a state in which there is no warpage after molding, a temporary fixing failure, an influence of external force, or the like, and the element is formed according to a design dimension. In this embodiment, the lower end surface of the port shell and the lower end surface of the cover (III) are located on the same plane with the port shell 40 fixed to the cover (III) by caulking. , Cover (II
I) Projection length H of the connecting projection of the convex flange portion 60
₁ (see FIG. 10) and the projecting length H ₂ of the biasing protrusion 46 of the port shell 40 (see FIG. 12 (b)) are formed so that H ₁ > H ₂ (the valve is The end surface 54 of the body (II) and the coupling receiving surface portion of the concave flange portion 50 are formed so as to be located on the same plane.) In this case, the difference in the amount of protrusion is preferably about 0.2 to 0.5 mm. Then, when the joining projection and the joining receiving surface portion are welded and joined, the end portions of the biasing projections 46 and 47 come into contact with the end surfaces 54 and 53a,
Further, the port shell 40 is biased toward the inner wall of the cover (III). That is, the biasing protrusions 46, 4
7 has a length such that it does not melt and strongly abuts the end faces 54, 53a from a non-contact state to urge the port shell 40.

Due to the biasing projections 46 and 47, the port shell 40 is in a state of being pressed firmly against the inner wall surface of the cover (III) so that the bypass intake passages are surely separated from each other without communicating with each other. Will be formed. Here, a procedure for attaching and fixing the above-mentioned port shell 40 will be described below. First, the fitting rib 44 formed at the end of the port shell side wall 43 is fitted in the groove 62 formed in the inner surface of the cover (III), and the contact portion 48 is formed in the contact surface of the cover (III). The projection 63 of the cover (III) is fitted into the through hole 45 of the port shell so as to come into contact with 64. And through hole 4
The tip portion of the protrusion 63 protruding from 5 is deformed by applying heat to make it caulked. In addition, this caulking is a cover (II
Even if the opening side of I) faces downward, the port shell 40, which was previously placed in contact with the inner wall surface, is temporarily fixed so that it does not fall off, and the port shell 40 is in close contact with the inner wall surface of the cover (III). It is not a necessary structure for fixing in the state.

After that, the cover (III) to which the port shell 40 is caulked and fixed is opposed from the upper side in the vertical direction so that the convex flange portion 60 is fitted into the concave flange portion 50 of the valve body (II). Deploy. Then, when the cover (III) is placed on the valve body (II), first, the convex flange portion 60 (coupling projection) of the cover (III) is changed to the concave flange portion 50 of the valve body (II).
(Attachment surface for coupling). At this time, cover (II
I) Internal biasing projections 46, 4 of the port shell 40
7 and the valve body (II) end faces 54 and 53a are in a non-contact state. Next, an external force is applied so that the two flange portions 50 and 60 come closer to each other, and high frequency vibration is applied so that the two flange portions relatively move.
Then, due to the frictional heat due to such vibration, the end region of the connecting projection of the convex flange 60 is melted and fixed to the connecting receiving surface of the mating concave flange 50, and the two are firmly connected. It will be. At this time, the biasing protrusions 46, 47 that were in the non-contact state come into contact with the end faces 54, 53a and further come into strong abutment, so that the port shell 40 is pressed and biased so as to be in close contact with the inner wall surface of the cover (III). Then, the port shell 40 is firmly and closely fixed.

Due to such vibration welding, the valve body (I
FIG. 13 shows a state in which I) and the cover (III) are fixed. This figure is a partial cross-sectional view of the device in a fixed state,
As shown, in this state, the port shell 40
The urging protrusions 4 provided at the ends in the vertical direction of the
6 and 47 are end faces 5 formed on the valve body (II)
4, 53a are in contact with each other. As a result, the port shell 40 is strongly pressed toward the inner wall surface of the cover (III), so that the port shell and the inner wall surface of the cover are more surely brought into close contact with each other.

Therefore, even if the valve body, the cover, the port shell, and the like are all made of a resin material, the bypass intake passage can be reliably formed regardless of the rigidity thereof.

[0029]

As described above, according to the intake control device of the present invention, the biasing protrusions (46, 47) for biasing the port shell (intake passage forming member) toward the cover inner wall side are provided. The protrusion length of the biasing protrusion is determined by the connecting protrusion (60).
In a non-welded state in which the end face (54, 53a) is simply in contact with the receiving surface portion (50) for coupling, and the end face (54, 53a) is in a welded state.
Since the urging protrusion does not melt, the urging protrusion maintains the initial protruding length and strongly urges the port shell 40. Therefore, even if the components are made of resin, the bypass intake passage can be formed with high accuracy, and the original function of the intake control device can be reliably ensured.

[Brief description of drawings]

FIG. 1 shows a cross-sectional view of a conventional intake control device.

2A and 2B are diagrams showing a shape and a mounting structure of a port shell in a conventional intake air control device, FIG. 2A is a perspective view thereof, and FIG. 2B is a MM portion in FIG. 2A. FIG.

FIG. 3 is an external plan view of an intake air control device according to the present invention.

FIG. 4 is an external side view of the intake control device taken along the arrow R in FIG.

5 is an external side view of the intake control device taken along the arrow L in FIG.

FIG. 6 is a cross-sectional view of the intake control device at CC section in FIG.

FIG. 7 is a view of the valve body forming the intake control device as seen from the end surface direction on the cover attachment side.

8 is a cross-sectional view of the valve body taken along the line DD in FIG.

FIG. 9 is a view of a cover forming the intake control device as seen from the end surface direction on the valve body mounting side.

10 is a cross-sectional view of the cover shown in FIG. 9, and FIG. 10A is a cross-sectional view taken along the line EE in FIG.
(B) is sectional drawing in the FF section.

FIG. 11 shows a port shell incorporated in the intake control device according to the present invention, FIG. 11 (a) is a front view thereof, FIG. 11 (b) is a plan view thereof, and FIG. 11 (c) is a view thereof. 11
It is sectional drawing in the GG part in (a).

FIG. 12 is a view showing a port shell incorporated in the intake control device according to the present invention, FIG. 12 (a) is a rear view thereof, and FIG. 12 (b) is a H-H part in FIG. 12 (a). 12C is a cross-sectional view of FIG. 12C, and FIG.

FIG. 13 shows a partial cross-sectional view of an intake control device having a port shell built therein.

[Explanation of symbols for main parts]

 40 Port shell (intake passage forming member) 44 Fitting rib 45 Through hole 46, 47 Energizing protrusion 50 Concave flange portion (combining receiving surface portion) 51, 52 Passage 53 Convex portion 53a, 54, 55 End surface 60 Convex flange portion ( Coupling protrusion) 61 Outer passage wall 62 Groove 63 Protrusion 70 Surge tank

Continuation of front page (51) Int.Cl. ⁶ Identification number Reference number within the agency FI Technical indication location F02M 35/10 102 Y (72) Inventor Akira Takahashi 5-3-8 Shiba, Minato-ku, Tokyo Mitsubishi Motors Corporation Incorporated (72) Inventor Toru Hashimoto 5-3-8 Shiba, Minato-ku, Tokyo Mitsubishi Motors Corporation (72) Inventor Mitsuhiro Miyake 5-33-8 Shiba, Minato-ku, Tokyo Mitsubishi Motors Corporation (72) Inventor Akiyuki Shinjo 2480 Kuno, Odawara-shi, Kanagawa Mikuni Odawara factory (72) Inventor Shigeo Tsukakoshi 2-14-14 Shin-Yokohama, Kohoku-ku, Yokohama, Kanagawa 10 Tokyo Roki Co., Ltd. (72) Inventor Miyawa 2-14-14 Shin-Yokohama, Kohoku-ku, Yokohama-shi, Kanagawa, Tokyo Filter Co., Ltd. (72) Naoto Nishimoto 2-14-14 Shin-Yokohama, Kohoku-ku, Yokohama, Kanagawa Prefecture, Tokyo Filter Co., Ltd.

Claims (1)

[Claims] 1. A shell body that forms a part of two types of intake passages, long and short, communicating with each cylinder of a multi-cylinder internal combustion engine, and abuttingly coupled to an open end portion of the shell body to cover the open end portion. The cover body is disposed in contact with the inner wall surface of the cover body, and
An intake control device for a multi-cylinder internal combustion engine, comprising: an intake passage forming member that forms a part of one of the three kinds of intake passages, wherein the shell body, the cover body, and the intake passage forming member are made of resin. Made of a material, at the open end of the shell body and the cover body, one has a coupling projection that is coupled to the other by welding, and the other receives the coupling projection. The shell has an end surface facing the intake passage forming member in the vicinity of an opening end thereof, and the intake passage forming member is in a state in which the shell and the cover body are weld-bonded to each other. And has an urging protrusion that abuts against the end face and urges it toward the inner wall surface of the cover body, wherein the urging protrusion is in a non-deformed state of the passage forming member and the cover body, The coupling projection contacts the coupling receiving surface portion. In the unwelded state, the protrusion is in a non-contact state with the end face, and has a protrusion length that abuts against the end face in the welded state of the joint protrusion and the joint receiving surface portion. An intake control device for a multi-cylinder internal combustion engine characterized by the above.