JP2002364471A - Producing method of vehicular intake manifold and resin structure body - Google Patents

Abstract

PROBLEM TO BE SOLVED: To enhance jointing strength at a slanting line part when producing a vehicular intake manifold by mutually vibration welding a first jointing member integrally equipped with an engine mounting flange, and a second jointing member with a jointing line having the slanting line part near the flange, which is a straight line slanted with respect to a pressing direction at mutually pressing for vibration welding of the jointing members or a curved line of which tangential line is slanted with respect to the pressing direction, and extending in a loop shape. SOLUTION: A welding margin along the pressing direction 39 at the slanting line part 32a is set larger than a welding margin of remaining parts other than the slanting line part 32a in the jointing line 32. A part corresponding to the slanting line part 32a in the jointing line 32 is vibration welded earlier than other parts while applying first clamp force. Next, a whole of the jointing line 32 is vibration welded while applying second clamp force larger than the first clamp force.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing an intake manifold for a vehicle and a resin structure, and more particularly to a method for press-fitting a pair of synthetic resin joint members to each other during vibration welding of the joint members. A vehicle intake manifold and a resin which are welded to each other at a joining line having a straight line crossing at an angle to the pressing direction at an angle or a curved inclined line portion having a tangent inclined to the pressing direction. The present invention relates to an improvement in a method of manufacturing a structure made of a metal.

[0002]

2. Description of the Related Art Conventionally, a manufacturing method for manufacturing a vehicle intake manifold by vibration-welding a pair of joining members made of a synthetic resin to each other is disclosed in, for example, WO 97/1575.
It is already known from Japanese Patent Publication No. 5 and the like.

[0003]

A joining line of a vehicle intake manifold formed by vibration welding of a pair of joining members made of synthetic resin must have sufficient joining strength to withstand internal pressure. In addition, it is necessary to maintain sufficient joining strength and rigidity in the vicinity of the engine mounting flange in the joining line in view of the fact that the fuel rail and the like are arranged near the flange.

[0004] On the other hand, when welding a joining member made of a synthetic resin, it has been widely practiced to set the welding allowance almost uniformly over the entire area of the joining line. It has been found that a device having not only a plane perpendicular to the surface but also an inclined portion or a curved portion can shorten the welding time and improve the efficiency.
It is already known in 177712 and the like.

In addition, Japanese Patent Application Laid-Open Nos. 5-177712 and WO97 / 15755 include an inclined line portion in which a joining line forms an angle with respect to a pressing direction during welding when welding a joining member made of synthetic resin. In such a case, it is disclosed that the welding allowance is set substantially uniformly over the entire area of the joining line. In this case, at the time of welding of the joining members, the joining members come into contact simultaneously over the entire area of the joining line, and welding is started simultaneously over the entire area.

Therefore, a plurality of branch pipes having a shape projected on a vertical plane bent at substantially 90 degrees and having one end commonly connected to the surge tank and arranged in parallel in the horizontal direction, A first joint member made of synthetic resin, which comprises a vehicle intake manifold having an engine mounting flange commonly connected to the other end of the branch pipe, and a part of each branch pipe integrally provided with the engine mounting flange. A second joining member made of a synthetic resin constituting the remaining portion of each branch pipe, and a joining line connected to a loop having an inclined line portion disposed substantially half way around each branch pipe near the engine mounting flange; When the joints were manufactured by vibration welding with each other, the joining strength of the inclined line portion was lower than that of other portions, and required joining strength could not be obtained.

[0007] This is considered to be due to the fact that the inclined line portion of the joining line cannot receive effective reinforcement backup during welding and the volume of the welding margin is insufficient. That is, since the inclined line portion near the engine mounting flange is arranged on substantially half the circumference of the branch pipe so as to be inclined with respect to the pressurizing direction at the time of welding of the pair of joining members, the entire inner circumference of the intake passage is formed. The cylindrical portion provided in one of the joining members in advance and a part of the inclined line portion are arranged so as to overlap in the pressing direction, and the inclined line portion on the one joining member side during welding. It is difficult to receive a portion corresponding to the above with a mold, and an effective reinforcing backup cannot be received. Further, in the inclined line portion, the height of the inclined line portion in a direction perpendicular to the inclined line portion is reduced, so that the volume of the welding margin is insufficient, and there is a possibility that sufficient joining strength may not be obtained. It is.

The present invention has been made in view of such circumstances, and has as its object to provide a method of manufacturing a vehicle intake manifold and a resin structure capable of sufficiently increasing the joining strength of an inclined line portion. I do.

[0009]

In order to achieve the above object, according to the first aspect of the present invention, the projection on a vertical plane is approximately 9%.
A plurality of branch pipes having a shape bent at 0 degrees and having one end commonly connected to the surge tank and arranged in parallel in the horizontal direction, and an engine mounting flange commonly connected to the other end of each branch pipe In manufacturing a vehicle intake manifold comprising: a first portion made of a synthetic resin, which is integrally provided with an engine mounting flange and constitutes a part of each branch pipe;
The joining member and the second joining member made of synthetic resin, which constitute the rest of each branch pipe, are linearly or obliquely inclined with respect to the pressing direction when the joining members are mutually pressurized during vibration welding. The tangent line is inclined with respect to the pressure direction, and has a slant line portion arranged on the other half side of the other end side of each of the branch pipes. A method of manufacturing a vehicle intake manifold, wherein a welding margin in the inclined line portion along the pressing direction is set to be larger than the welding margin of a remaining portion of the joining line excluding the inclined line portion. Then, a portion of the joining line corresponding to the inclined line portion is subjected to vibration welding while applying a first clamping force prior to the other portion, and then applying a second clamping force larger than the first clamping force. Joining lie Characterized by vibration welding the whole.

According to the method of the first aspect of the present invention, when the first and second joining members are vibration-welded to each other, a portion corresponding to the inclined line portion comes into contact with another portion first. That is, even if the inclined line portion is bent due to no reinforcing backup of the inclined line portion at a portion overlapping in the pressurizing direction with the cylinder portion provided in one of the joining members, the joint with the other portion is added. The inclined line part will be welded earlier or more by the difference of the welding margin along the pressure direction,
When the welding at the other portion is completed, the amount of welding at the inclined line portion is equal to or greater than the amount of welding at the other portion. Further, at the time of welding the inclined line portion, the first and second joining members are clamped with a relatively small first clamping force according to a relatively small welding area in a direction perpendicular to the pressing direction, and the entire joining line is formed. When welding is performed, that is, when the welding area in the direction perpendicular to the pressing direction is relatively large, the first and second joining members are clamped by the second clamping force larger than the first clamping force. The surface pressure can be appropriately maintained throughout the joining line. As a result, while preventing deformation due to excessive surface pressure, the bonding strength is made substantially uniform over the entire circumference of the bonding line, or the bonding strength of the inclined line portion is made higher than other portions. It is possible to prevent the joint strength from decreasing near the engine mounting flange.

According to a second aspect of the present invention, a plurality of projections having a shape projected on a vertical plane bent at substantially 90 degrees, one end of which is commonly connected to the surge tank, and which are arranged in parallel in the horizontal direction. In manufacturing a vehicle intake manifold including a branch pipe and an engine mounting flange commonly connected to the other end of each branch pipe, a part of each branch pipe is integrally provided with an engine mounting flange. The first joining member made of synthetic resin, and the second joining member made of synthetic resin, which constitutes the rest of each branch pipe, are inclined with respect to the pressing direction when mutually pressurizing at the time of welding these joining members. A vehicle intake device having at least two linear or curved inclined lines having tangent lines inclined with respect to the pressurizing direction, and vibration welding to each other at a joining line connected in a loop shape. A method of manufacturing a hold, wherein a welding margin in the inclined line portion along the pressing direction is set to be larger than the welding margin of a remaining portion of the joining line excluding the inclined line portion, A portion of the line corresponding to the inclined line portion is vibration-welded while applying a first clamping force prior to the other portion, and then a joining line is applied while applying a second clamping force larger than the first clamping force. It is characterized by vibration welding of the whole.

According to a third aspect of the present invention, a projection on a vertical plane is bent at an angle larger than 90 degrees and smaller than 270 degrees and is inverted, and one end is commonly connected to the surge tank. In manufacturing a vehicle intake manifold including a plurality of branch pipes arranged in parallel in the horizontal direction and an engine mounting flange commonly connected to the other end of each branch pipe, a part of each of the branch pipes is manufactured. The first joining member made of synthetic resin and the second joining member made of synthetic resin which integrally form the engine mounting flange and constitute the rest of each of the branch pipes are formed by vibration of the joining members. A pair of inclined line portions that are linear inclining with respect to the pressing direction when mutually pressurizing at the time of welding or curved in which the tangent line is inclined with respect to the pressing direction and in which the tilting directions are opposite to each other. A manufacturing method of an intake manifold for a vehicle, comprising a straight line portion that connects the two inclined line portions substantially orthogonal to the pressing direction, and is vibration-welded to each other at a joining line connected in a loop. The welding margin along the pressing direction at the two inclined line portions is set to be larger than the welding margin of the remaining portion of the joining line except for the two inclined line portions, and the inclination of the joining line is The part corresponding to the line part is first
The vibration welding is performed while applying the above clamping force, and then the entire welding line is subjected to vibration welding while applying the second clamping force larger than the first clamping force.

According to the method of the second or third aspect of the present invention, when the first and second joining members are mutually pressurized and welded at the joining line having at least two inclined line portions, A portion corresponding to each of the inclined line portions of the first and second joining members comes into contact with another portion prior to the other portion, and each of the inclined portions corresponds to a difference in a welding margin between the other portion and the pressurizing direction. The line portion will be welded earlier or more frequently, and when the predetermined amount of welding at the other portion is completed, the amount of welding of each inclined line portion is equal to or greater than the amount of welding of the other portion. Become. Further, since the first and second joining members come into contact with each other at at least two places at the start of the contact, it is possible to avoid a decrease in joining accuracy due to contact variation due to bending or distortion of the first and second joining members. is there. Further, at the time of welding the inclined line portion, the first and second joining members are clamped with a relatively small first clamping force according to a relatively small welding area in a direction perpendicular to the pressing direction, and When the whole is welded, that is, when the welding area in the direction perpendicular to the pressing direction becomes relatively large, the first and second joining members are clamped with the second clamping force larger than the first clamping force. Surface pressure can be appropriately maintained throughout the joining line. As a result, while preventing deformation due to excessive surface pressure, the bonding strength is made substantially uniform over the entire area of the bonding line, or the bonding strength of the inclined line portion is larger than that of other portions. It can be.

Further, according to a fourth aspect of the present invention, the first and second joining members made of synthetic resin constituting the resin structure are
The joining members having a straight line inclined with respect to the pressing direction when the members are mutually pressurized at the time of vibration welding or a curved line with a tangent line inclined with respect to the pressing direction are joined together. In the method for manufacturing a resin structure, vibration welding is performed on the inclined line portion in the pressing direction along the pressing direction by changing the welding margin of the remaining portion of the joining line except for the inclined line portion. And welding the portion of the joining line corresponding to the inclined line portion while applying a first clamping force prior to the other portion, and then applying a second clamping force larger than the first clamping force. It is characterized in that the entire joining line is subjected to vibration welding while applying a clamping force.

According to the method of the fourth aspect of the present invention, when the first and second joining members are mutually pressed and welded by the joining line having the inclined line portion, the first and second joining members are joined. The portion corresponding to each of the inclined line portions of the member comes into contact with the other portion prior to the other portion, and the inclined line portion is welded earlier or more by the difference of the welding margin along the pressing direction with the other portion. That is, when the predetermined amount of welding at the other portion is completed, the amount of welding of the inclined line portion becomes equal to or greater than the amount of welding of the other portion. Further, at the time of welding the inclined line portion, the first and second joining members are clamped with a relatively small first clamping force according to a relatively small welding area in a direction perpendicular to the pressing direction, and the entire joining line is formed. When welding is performed, that is, when the welding area in the direction perpendicular to the pressing direction is relatively large, the first and second joining members are clamped by the second clamping force larger than the first clamping force. The surface pressure can be appropriately maintained throughout the joining line. As a result, while preventing deformation due to excessive surface pressure, the bonding strength is made substantially uniform over the entire area of the bonding line, or the bonding strength of the inclined line portion is larger than that of other portions. It can be.

[0016]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, embodiments of the present invention will be described based on embodiments of the present invention shown in the accompanying drawings.

FIGS. 1 to 8 show a first embodiment of the present invention. FIG. 1 is a perspective view of an intake passage structure and a throttle body, FIG. 2 is a side view of the intake passage structure, and FIG. 2, FIG. 4 is a cross-sectional view taken along line 4-4 of FIG. 3, FIG. 5 is a cross-sectional view of the second joining member viewed from a direction along line 5-5 of FIG. 2, and FIG. 7 is an enlarged sectional view taken along line 6-6 in FIG. 2, FIG. 7 is a sectional view corresponding to FIG. 6 in a state after welding, and FIG. 8 is a line 8-8 in FIG. 3 in a state before welding. It is an expanded sectional view which follows.

First, in FIGS. 1 to 3, an intake system in which a throttle body 11 integrally has a surge tank 12 and a resin structure that connects between a four-cylinder engine body and the surge tank 12 (not shown). Attached to the passage structure 14, the intake passage structure 1
Reference numeral 4 indicates that the first, second, and third joining members 15, 16, 17 made of synthetic resin are vibration-welded to each other.

The throttle body 11 has a cylindrical shape extending vertically and is coupled to the center of the upper surface of the first joining member 15. A butterfly type throttle valve (not shown) for controlling the amount of flowing air includes a throttle body 11. The throttle shaft 11 is fixed to a valve shaft 18 rotatably supported on the throttle body 11, and a throttle drum 19 is attached to a protruding end of the valve shaft 18 from the throttle body 11.

Referring to FIGS. 4 and 5, a connecting cylinder 15a for connecting the throttle body 11 is integrally provided at the center of the first joining member 15, and the surge tank 12 is First, second and third joining members 15,
16 and 17, the intake chamber 2 connected to the connection cylinder 15a.
0 is formed.

The intake manifold 13 includes a plurality of, for example, four branch pipes 21A, 21B, 21 connecting between an engine mounting flange 22 for mounting on a cylinder head (not shown) of the engine body and the surge tank 12.
C and 21D are arranged in parallel in the horizontal direction such that, for example, a pair of C and 21D are arranged on both sides of the throttle body 11 and the connection cylinder 15a.

The branch pipe 21A has a first straight pipe portion 23 having one end connected to the surge tank 12 and rising upward, and a first straight pipe portion 2 which is bent within a range of substantially 90 degrees in a vertical plane and has a first straight pipe portion 2.
A curved tube portion 24 having one end connected to the other end of the third tube 3 and a second straight tube portion 25 having one end connected to the other end of the curved tube portion 24 and extending substantially horizontally, and has a vertical plane. Branch pipe 2 to
1A has a shape in which the intermediate portion is bent at approximately 90 degrees. The other branch pipes 21B, 21C and 21D also have the same basic configuration as the above-described branch pipe 21A, and the projection of each of the branch pipes 21B to 21D on a vertical plane also has an intermediate portion of approximately nine.
The shape is bent to 0 degrees.

In each of the branch pipes 21A to 21D, an intake passage 26 is provided.
A, 26B, 26C, and 26D are formed, respectively, and the air introduced into the intake passage structure 14 from the throttle body 11 flows downward in the surge tank 12 as indicated by a broken arrow in FIG. Later, the air is inverted upward and divided into each of the intake passages 26A to 26D. Further, the air introduced into each of the intake passages 26A to 26D flows upward, then changes the flow direction by approximately 90 degrees, and flows substantially horizontally toward the engine body.

On the other hand, passage holes 27A, 27 for connecting the intake passages 26A to 26D to respective intake ports (not shown) of the cylinder head are formed in the engine mounting flange 22.
B, 27C, and 27D are provided individually corresponding to each of the intake passages 26A to 26D. As shown in FIG. 1, fuel injection valves 28 for supplying fuel to the respective intake ports of the cylinder head are mounted on the engine mounting flange 22, and each of the fuel injection valves 28 is provided with a fuel. Rail 2
9 are connected in common, but on the upper part of the engine mounting flange 22, mounting portions 30, 30... For mounting the fuel injection valves 28, 28. 31 ... (see FIG. 2)
Are provided integrally.

Such an intake manifold 13 has a first
And the second joining members 15 and 16 are vibration-welded to each other at a joining line 32 connected in a loop shape. The first joining member 15 is provided with an engine mounting flange 22 integrally with each other. Branch pipe 21A ~
21D and a part of the upper part of the surge tank 12.
21D and a main part of the surge tank 12.

In FIG. 6, a joining flange 33 is formed integrally along the joining line 32 around the entire lower end of the first joining member 15, and the center of the joining flange 33 in the width direction has a tip surface. Are integrally provided so as to protrude toward the second joining member 16 side.

On the other hand, the entire circumference of the upper end of the second joining member 16
Joint flange 35 facing joint flange 33 of first joint member 15
Are formed integrally with each other, and a welding ridge 36 corresponding to the welding surface 34a of the ridge 34 projects at the center of the joining flange 35 in the width direction so as to protrude toward the second joining member 15 side. The width of the welding ridge 36 is set smaller than that of the ridge 34. The joining flange 3 of the second joining member 16
5, regulating walls 37, 3 projecting toward the first joining member 15 so as to sandwich the welding ridge 36 from inside and outside.
8 are provided integrally.

When the first and second joining members 15, 16 are welded to each other, the first and second joining members 15, 1
For example, the first joining member 15 is connected to the second
By applying pressure along the pressing direction 39 toward the joining member 16, the tip of the welding ridge 36 is brought into contact with the welding surface 3 of the ridge 34.
4a, the first and second joining members 15,
On the other hand, in this embodiment, the first joining member 15 is vibrated at a high speed. Accordingly, the frictional heat generated between the tip of the welding ridge 36 and the welding surface 34a causes the tip of the welding ridge 36 to be vibration-welded to the ridge 34 as shown in FIG. The entire circumferences of the two joining members 15 and 16 are joined along a joining line 32 that continues in a loop.

The two regulating walls 3 of the second joining member 16
7, 38, the front end of the joining flange 3 of the first joining member 15
While the welding and joining of the two joining members 15 and 16 are advanced to the position close to and opposite to the position 3, the joint serves as a guide for stopping the vibration welding process, and the tip of the welding protrusion 36 is attached to the welding surface 34 a. The flash generated by vibration welding,
It has a function of preventing the inside and outside of the first and second joining members 15 and 16, that is, the inside and outside of the intake manifold 13.

Referring to FIG. 2, the joining line 32 of the first and second joining members 15 and 16 has an angle α1 with a plane perpendicular to the pressing direction 39 near the engine mounting flange 22. And each branch pipe 21A-21
A linear inclined line portion 32a arranged substantially half way around D ...
Are arranged at the ends of the branch pipes 21A, 21D along the arrangement direction of the respective branch pipes 21A, 21D corresponding to the curved pipe portions 24.
9, a curved inclined line portion 32b inclined so as to form an angle α2 with a plane perpendicular to the plane 9;
The pressure is connected to a straight line portion 32c connecting the inclined line portions 32a, 32b in the branch tubes 21A, 21D so as to be substantially orthogonal to the inclined line portion 32b in the branch tubes 21A, 21D. Curved portion 2 of each of the branch pipes 21A to 21D which is substantially orthogonal to the direction 39.
4 and a straight line portion 32d arranged substantially in the half circumference.

Furthermore, since the first mounting member 15 is provided with the engine mounting flange 22 integrally therewith, the inclined line portions 32a are inclined so as to become lower as they go toward the engine mounting flange 22. The inclination direction of the inclined line portions 32b is set to be lower as the distance from the engine mounting flange 22 increases. That is, both inclined line portions 32a and 32b are
They are arranged so as to be closer to each other as they go upward along the pressing direction 39, that is, to be inclined to the opposite sides as they move toward the pressing direction 39.

Incidentally, the joining line 32 of the first and second joining members 15, 15 constituting the intake manifold 13.
Is required to have sufficient bonding strength to withstand the internal pressure, but the first and second bonding members 15, 1
If the welding margin of No. 6 is set substantially evenly over the entire area of the joining line 32, the joining strength of the inclined line portions 32a..., 32b. Can not be.

Moreover, the inclined line portions 32a are inclined with respect to the pressing direction 39 when the first and second joining members 15 and 16 are mutually pressurized during welding, and are branched into branch pipes 21A to 21D.
Of the intake passages 26A-
26D so as to constitute the entire inner periphery of the first joining member 1
5 and a part of the inclined line portions 32a are arranged so as to overlap in the pressing direction at the time of welding, and the first and second joining members 15 and 16 are applied to each other. When pressing, it is difficult to receive a portion corresponding to the inclined line portions 32a on the first joining member 15 side with a mold, and the inclined line portions 32a of the joining lines 32 receive an effective reinforcing backup during welding. I can't.

The welding ridges 36 provided on the second joining member 16 at portions corresponding to the inclined line portions 32a.
The welding margin L 'along the pressing direction 39 among the welding margins set before the welding is set relatively large as shown in FIG. The same applies to the welding ridges 36 at portions corresponding to the inclined line portions 32b of the joining line 32, and the pressing direction 39 of the welding ridges 36 at the inclined line portions 32a, 32b of the joining line 32. Is larger than the welding margin L along the pressing direction 39 of the welding ridge 36 at the remaining portion of the joining line 32 except the inclined line portions 32a, 32b (L '> L). ) Set it.

Thus, the first and second joining members 15,
When the first and second joining members 15 and 16 are welded by pressing each other, the portions corresponding to the inclined line portions 32a... 32b of the first and second joining members 15 and 16 are replaced by other portions such as linear line portions 32c. , And the other portions such as the straight line portions 32c, 32d, etc.
When the first and second joining members 15 and 16 come into contact with the portions corresponding to 2a, 32b, the gaps corresponding to the difference (L'-L) between the welding margins L ', L are first and second. This will occur between the joining members 15 and 16.

The first joining member 15 is connected to the second joining member 1
By vibrating in a direction perpendicular to the pressing direction 39 while pressing the pressing side 6, welding of the welding ridges 36 on the welding surfaces 34 a in the inclined line portions 32 a, 32 b. Welding ridge 36 in a direction along
The gap disappears as the protrusion amount decreases, and the welding protrusions 36 are formed on the welding surface 34a at other portions of the joining line 32 except for the inclined line portions 32a, 32b, that is, the straight line portions 32c, 32d, and the like. They are welded in contact.

The surface pressure of the welding portion, that is, the welding pressure is obtained by dividing the clamping force by the area of the welding portion in a plane perpendicular to the pressing direction 39, and is close to the pressure resistance of the resin material. When the surface pressure of the welding portion is set to the value and the first and second joining members 15 and 16 are clamped with the same clamping force from the start to the end of the vibration welding, the inclined line portions 32a. Since the welding is started in advance, the surface pressure exceeding the pressure resistance acts on the inclined line portions 32a, 32b, and deformation may occur. On the other hand, when the surface pressure and thus the clamping force are set on the basis of the welding area in the inclined line portions 32a, 32b,
When welding the entire joining line 32, the surface pressure becomes insufficient.

Therefore, the first clamping force for clamping the first and second joining members 15 and 16 during the vibration welding of the inclined line portions 32a. Is set to be smaller than the second clamping force for clamping the first and second joining members 15 and 16 during welding.

The timing for changing the clamping force may be based on the pressure stroke during vibration welding or the time elapsed from the start of vibration welding. When the vibration welding of the entire joining line 32 is started, the load in the direction perpendicular to the pressing direction 39 changes, so that the clamping force may be changed according to the change in the load. Further, the clamping force may be changed abruptly in a step-like manner, or may be changed gradually.

Next, the operation of the first embodiment will be described. In the welding margin set before welding by the first joining member 15 along the joining line 32 having a loop shape, the inclined line portions 32a, 32b,. The welding margin L 'in the direction along the pressing direction 39 of the portion corresponding to the welding line L is the remaining portion of the joining line 32 except for the inclined line portions 32a, 32b, that is, the linear portions 32c, 32d, etc. Since the welding margin L along the pressure direction 39 is set to be larger than the welding margin L, the inclined line portions 32 of the first and second joining members 15 and 16 are set at the time of welding.
The parts corresponding to a ..., 32b ... come into contact with other parts prior to the other parts.

Thus, the inclined line portions 32a,.
, The inclined line portions 32a, 32b are earlier than other portions, such as the linear line portions 32c, 32d, by the welding margin difference (L'-L) along the pressing direction 39. A large amount of welding is performed, and when a predetermined amount of welding at the other portion is completed, each of the inclined line portions 32a
, 32b are equal to or larger than the welding amount of the other parts. Moreover, since the first and second joining members 15 and 16 come into contact with at least two inclined line portions 32a and 32b at the start of the contact, contact variations due to bending and distortion of the first and second joining members 15 and 16 are provided. It is possible to avoid a decrease in bonding accuracy due to the above. As a result, the joining strength is made substantially uniform over the entire area of the joining line 32, or the inclined line portions 32a.
2b can be made stronger than other parts, and the range of angles formed by the inclined line portions 32a, 32b with a plane perpendicular to the pressing direction 39 is greatly increased, so that the intake manifold 13 , 32b... Can be sufficiently increased while increasing the degree of freedom in the design of.

The two inclined line portions 32a, 32b
Are inclined to the opposite sides as they move in the pressing direction 39, so that when the first and second joining members 15, 16 are mutually pressed and welded, the respective inclined line portions 32a, 32
It is possible to offset the sliding component force generated in b, and to perform accurate welding while preventing the displacement of the two joining members 15 and 16.

By the way, the engine mounting flange 22
Are formed on the first joining member 15 on the side of the first joining member 15. A portion of the joining line 32 that overlaps with the tubular portions 15 b along the pressing direction 39 is inclined. Line portion 32a, and the inclined line portion 32
Since the bonding strength at a is sufficiently increased as described above,
A decrease in joining strength in the vicinity of the engine mounting flange 22 can be reliably prevented, and an increase in the time required for welding and an increase in burrs can be avoided.

Since the inclined line portions 32a are inclined so as to be located at a lower position toward the engine mounting flange 22, the second joining members 1 at the time of vibration welding.
The second joining member 16 can be supported over the entire circumference of the joining line 32 by the mold on the sixth side. On the other hand, in the mold on the first joining member 15 side, the engine mounting flange 22
And the fuel rail 2 arranged above the fuel injection valve 28.
9, it is difficult to support a part of the inclined line portions 32a of the joining lines 32 in order to prevent interference with the mounting portions 30 ... 31, but by making a difference in the welding allowance as described above. There is no problem because it compensates for the inability to support some of the inclined line portions 32a.

Moreover, when the inclined line portions 32a, 32b are welded, the first and second joints are made with a relatively small first clamping force in accordance with the relatively small welding area in the direction perpendicular to the pressing direction 39. When the members 15 and 16 are clamped and the entire welding line 32 is welded, that is, when the welding area in the direction perpendicular to the pressing direction 39 becomes relatively large, the second clamping force is larger than the first clamping force. 1
In addition, since the second joining members 15 and 16 are clamped, the surface pressure during welding can be appropriately maintained throughout the joining line 32. As a result, it is possible to prevent deformation from occurring due to excessive surface pressure.

FIGS. 9 to 13 show a second embodiment of the present invention. FIG. 9 is a side view of the intake passage structure, and FIG. 10 is a state before the first and second joining members are welded. 9 is a side view corresponding to FIG. 9, FIG. 11 is a sectional view taken along line 11-11 of FIG. 10, FIG. 12 is a sectional view taken along line 12-12 of FIG. 9, and FIG.
FIG. 13 is a sectional view taken along line 3-13.

First, in FIG. 9, the intake passage structure 44
Has a surge tank 42, an unillustrated four-cylinder engine body, and an intake manifold 43 as a resin structure connecting the surge tank 42 to each other. 3 joining members 4
5, 46 and 47 are formed by vibration welding.

The surge tank 42 is formed by welding and joining the second and third joining members 46 and 47 to each other.
Connected to.

The intake manifold 43 has an engine mounting flange 48 for mounting on a cylinder head (not shown) of the engine body and a plurality of branch pipes 49 connecting between the surge tanks 42 arranged horizontally in parallel. Each of the branch pipes 49 has a first straight pipe portion 50 having one end connected to the surge tank 42 and rising upward, and a first straight pipe portion bent in a range of approximately 180 degrees in a vertical plane. Part 50
A curved tube portion 51 having one end connected to the other end of the curved tube portion;
A second straight pipe part 5 having one end connected to the other end of the first straight pipe 1 and extending downward;
The projection of each of the branch pipes 49 on the vertical plane has a shape that is bent and inverted at an angle larger than 90 degrees and smaller than 270 degrees. Each branch pipe 49 to a vertical plane in the example
.. Have a shape in which an intermediate portion near the engine mounting flange 48 is bent at approximately 180 degrees.

Referring also to FIG. 10, the intake manifold 43 includes first and second joining members 45 and 46,
For example, the first joint member 45 is configured to be welded and joined to each other at a joining line 53 connected in a loop by vibrating while pressing the first joint member 45 toward the second joint member 46 along the pressing direction 39. And the first joining member 4
5 are formed so as to constitute the upper half portion of the curved pipe portions 51 in each of the branch pipes 49. The second joint member 46 integrally includes an engine mounting flange 48 and the remaining part of each of the branch pipes 49. And a part of the surge tank 42.

The joining line 53 of the first and second joining members 45 and 46 has an angle α3 with a plane perpendicular to the pressing direction 39 near the engine mounting flange 48.
A linear inclined line portion 53a arranged at a portion corresponding to the branch pipes 49 at both ends along the arrangement direction of the branch pipes 49, and a plane orthogonal to the pressing direction 39. Is inclined at α4 and each branch pipe 49 is inclined.
Linear inclined lines 53b arranged at portions corresponding to the branch pipes 49 at both ends along the arrangement direction, and inclined lines 53 substantially orthogonal to the pressing direction 39.
a, a linear line portion 53c connecting between the branch pipes 49 and a substantially half circumference of the branch pipes 49 on the engine mounting flange 48 side and substantially orthogonal to the pressing direction 39; , Each of which has a linear line portion 53e which is disposed on a substantially half circumference on the opposite side of the engine mounting flange 48 of each of the branch pipes 49 and is substantially orthogonal to the pressing direction 39, and is connected in a loop. .

In FIG. 11, a joining flange 54 along the joining line 53 is formed integrally with the entire periphery of the lower end of the first joining member 45.
A ridge 55 having a flat welding surface 55 a at the distal end surface is integrally provided so as to protrude toward the second joining member 46. In addition, on the entire periphery of the joining flange portion 54, the regulating wall portion 5 protruding toward the second joining member 46 so as to sandwich the ridge 55 from inside and outside.
6, 57 are provided integrally.

On the other hand, the entire periphery of the upper end of the second joining member 46
A joining flange portion 58 facing the joining flange 54 of the first joining member 45
Are formed integrally, and a welding ridge 59 corresponding to the welding surface 55a of the ridge 55 projects at the center of the joining flange 58 in the width direction so as to project toward the second joining member 45 side. The width of the welding protrusion 59 is set to be narrower than the width of the protrusion 55. In addition, regulating walls 60 and 61 projecting toward the first joining member 45 are integrally provided on the entire periphery of the joining flange 58 so as to sandwich the welding ridge 59 from inside and outside.

At the time of vibration welding of the first and second joining members 45 and 46, the tip of the welding ridge 59 is connected to the welding surface 5 of the ridge 55.
5a, the first and second joining members 45,
On the other hand, in this embodiment, the first joint member 45 is vibrated at a high speed. As a result, the distal end of the welding ridge 59 is vibration-welded to the ridge 55 as shown in FIG. 12 by frictional heat generated between the distal end of the welding ridge 59 and the welding surface 55a. The entire periphery of the two joining members 45 and 46 is joined along a joining line 53 that continues in a loop.

The regulating wall 56 of the first joining member 45,
57 and both regulating wall portions 60, 61 of the second joining member 46.
Serves as a guide for stopping the vibration welding process in a state where the welding and joining of the two joining members 45 and 46 are advanced to positions where the tips of the 56 and 60; The tip of the welding ridge 59 is a welding surface 55a.
Generated by vibration welding to the first and second
It has a function of preventing the inside of the joining members 45 and 46, that is, the inside of the intake manifold 43, from outside.

In FIG. 13, the welding margin L 'along the pressing direction 39 before welding of the welding ridge 59 provided on the second joining member 46 at the inclined line portion 53b of the joining line 53 and the welding line 53 are formed. Inclined line 53a
, The welding margin L ′ along the pressing direction 39 before welding of the welding ridges 59 provided on the second joining member 46 is caused in the remaining portion of the joining line 53 except for the inclined line portions 53a, 53b. The welding margin L of the welding ridge 59 along the pressing direction 39 (see FIG. 11) is set to be larger (L '> L).

Thus, the first and second joining members 45,
When the two are pressurized and welded to each other, the portions of the first and second joining members 45, 46 corresponding to the inclined line portions 53a, 53b, as shown in FIG.
, 53d, 53e, etc., and comes in contact with the other parts in advance, and the straight line portions 53c, 53d,.
In other parts such as 53e ..., inclined line parts 53a ..., 5
The first and second joining members 4 at portions corresponding to 3b.
5, 46, the difference between the welding margins L ', L (L'
-L) corresponds to the first and second joining members 4
It will occur between 5,46.

The first joining member 45 is connected to the second joining member 4
By vibrating in the direction perpendicular to the pressing direction 39 while pressing the pressing side 6, welding of the welding protrusion 59 to the welding surface 55 a in the inclined line portions 53 a, 53 b. Welding ridge 59 in a direction along
The gap disappears with a decrease in the amount of protrusion of the joint line 53, and other portions of the joining line 53 except the inclined line portions 53a, 53b, that is, the straight line portions 53c, 53d,.
The welding protrusions 59 are brought into contact with the welding surface 55a and welded by 3e.

Further, when the inclined line portions 53a, 53b are welded, the first and second joints are made with a relatively small first clamping force in accordance with the relatively small welding area in the direction perpendicular to the pressing direction 39. When the members 45 and 46 are clamped and the entire welding line 53 is welded, that is, when the welding area in the direction perpendicular to the pressing direction 39 becomes relatively large, the second clamping force is larger than the first clamping force. 1
Clamping of the second joining members 45 and 46 is the same as in the first embodiment.

In the second embodiment, as in the first embodiment, the joining strength of the first and second joining members 45 and 46 is made substantially uniform over the entire area of the joining line 53, or the inclined line portions 53a. , 53b... Can be greater than other portions, and the inclined line portion 53a
, 53b... Can greatly increase the degree of freedom of the design of the intake manifold 43 by greatly increasing the limit range of the angle formed by the plane perpendicular to the pressing direction 39.

FIG. 14 shows a third embodiment of the present invention. In the intake duct 63 as a resin structure, for example, an intermediate portion is bent upward to avoid interference with main parts of the engine. The intake duct 63 has a first and a second joining member 66, 67 made of synthetic resin pressed along the pressing direction 39. While being vibration welded to each other.

A first joining member 66 which integrally has flanges 64 and 65 at both ends and constitutes a lower half of the intake duct 63.
And the second joining member 67 constituting the rest of the intake duct 63
Is welded and joined to each other at a joining line 68 connected in a loop shape.
4 and 65, inclined line portions 68a and 68b inclined with respect to the pressing direction 39, and the inclined line portions 6a and 68b.
8a and 68b are connected to the outer ends thereof so that the pressing direction 3
Straight line portions 68c and 68d extending in a direction orthogonal to 9
And an inclined line portion 68 inclined with respect to the pressing direction 39 and connected to the inner ends of the straight line portions 68c and 68d.
e, 68f and a curved line portion 68g which is convexly curved on the side facing the pressing direction 39 and connects the two inclined line portions 68e, 68f, and is connected in a loop.

The welding margin of the inclined line portions 68a, 68b, 68e, 68f of the joining line 68 along the pressing direction 39 is the same as that of the inclined line portion 68 of the joining line 68.
The welding margin along the pressing direction 39 at the remaining portions excluding a, 68b, 68e, and 68f is set to be larger. Thereby, when the first and second joining members 66 and 67 are mutually pressed and welded, the first and second joining members 66 and 6 are welded.
7, the portions corresponding to the inclined line portions 68a, 68b, 68e, 68f come into contact with other portions such as the straight line portions 68c, 68d and the curved portion 68g in advance.
The straight line portion 68 in a direction along the pressing direction 39
After the gaps at other portions such as c and 68d and the curved portion 68g disappear, welding of the entire joining line 68 including the straight line portions 68c and 68d and the curved portion 68g is started.

Further, the inclined line portions 68a, 68b, 68
During welding of e and 68f, the first and second joining members 66 and 67 are clamped with a relatively small first clamping force in accordance with the relatively small welding area in the direction perpendicular to the pressing direction 39, and joined. When the entire line 68 is welded, that is, when the welding area in the direction perpendicular to the pressing direction 39 becomes relatively large, the first and second joining members 66 and 67 are applied with the second clamping force larger than the first clamping force. Is the same as in the first and second embodiments.

According to the third embodiment, as in the first and second embodiments, it is possible to prevent the deformation caused by the excessive surface pressure and to reduce the bonding strength of the bonding line 68. The bonding strength of the inclined line portions 68a, 68b, 68e, and 68f can be made substantially equal over the entire area, or higher than other portions.

Although the embodiments of the present invention have been described above, the present invention is not limited to the above embodiments, and various design changes can be made without departing from the present invention described in the appended claims. It is possible.

[0067]

As described above, according to the first aspect of the present invention, the projection on the vertical plane has a shape bent at substantially 90 degrees, one end is commonly connected to the surge tank, and A vehicle intake manifold having a plurality of branch pipes arranged in parallel to each other and an engine mounting flange commonly connected to the other end of each branch pipe is used for vibration of first and second joining members made of synthetic resin. When manufacturing by welding, while preventing deformation due to excessive surface pressure, the bonding strength is made almost uniform over the entire circumference of the bonding line, or the bonding strength of the inclined line part is It can be larger than the part, and it is possible to prevent a decrease in bonding strength near the engine mounting flange.

According to the second or third aspect of the present invention, the projection on the vertical plane has a shape bent at substantially 90 degrees, one end of which is commonly connected to the surge tank and is arranged in parallel in the horizontal direction. A plurality of branch pipes and an engine mounting flange commonly connected to the other ends of the respective branch pipes, or a vehicle intake manifold projected on a vertical plane is larger than 90 degrees and larger than 270 degrees. A plurality of branch pipes having a shape that is bent at a small angle and inverted and has one end commonly connected to the surge tank and arranged in parallel in the horizontal direction, and an engine commonly connected to the other end of each branch pipe When manufacturing a vehicle intake manifold having a mounting flange by vibration mounting of first and second joining members made of synthetic resin, contact due to bending and distortion of the first and second joining members. Make the joint strength almost uniform over the entire joint line while preventing the joint accuracy from decreasing due to the fluctuation and preventing the deformation from occurring due to the excessive surface pressure. Can be larger than other parts.

According to the fourth aspect of the present invention, when the resin structure is manufactured by vibration welding of the first and second joining members made of synthetic resin, the surface pressure becomes excessively large. While preventing deformation, the joining strength can be made substantially uniform over the entire area of the joining line, or the joining strength of the inclined line portion can be made larger than other portions.

[Brief description of the drawings]

FIG. 1 is a perspective view of an intake passage structure and a throttle body of a first embodiment.

FIG. 2 is a side view of the intake passage structure.

FIG. 3 is a view as viewed in the direction of arrow 3 in FIG. 2;

FIG. 4 is a sectional view taken along line 4-4 of FIG. 3;

FIG. 5 is a cross-sectional view of the second joining member viewed from a direction along line 5-5 in FIG.

FIG. 6 is an enlarged sectional view taken along line 6-6 in FIG. 2 in a state before welding.

FIG. 7 is a cross-sectional view corresponding to FIG. 6 in a state after welding.

FIG. 8 is an enlarged sectional view taken along line 8-8 in FIG. 3 in a state before welding.

FIG. 9 is a side view of an intake passage structure according to a second embodiment.

FIG. 10 is a side view corresponding to FIG. 9 in a state before welding of the first and second joining members.

FIG. 11 is a sectional view taken along line 11-11 of FIG. 10;

FIG. 12 is a sectional view taken along line 12-12 of FIG. 9;

FIG. 13 is a sectional view taken along line 13-13 of FIG. 10;

FIG. 14 is a side view of the intake duct of the third embodiment.

[Explanation of symbols]

12, 42 ... surge tank 13, 43 ... intake manifold for vehicle as a resin structure 15, 45, 66 ... first joining member 16, 46, 67 ... second joining member 21A ~ 21D, 49 ... Branch pipe 22, 48 ... Engine mounting flange 32, 53, 68 ... Joining line 32a, 32b, 53a, 53b, 68a, 68b, 6
8e, 68f: inclined line section 39: pressurizing direction 63: intake duct as resin structure

Claims (4)

[Claims] 1. A plurality of branch pipes (21A) having a shape projected on a vertical plane bent at substantially 90 degrees and having one end commonly connected to a surge tank (12) and arranged in parallel in a horizontal direction. , 21B, 21C, 21D) and an engine mounting manifold (13) including an engine mounting flange (22) commonly connected to the other ends of the branch pipes (21A to 21D). For each branch pipe (21A)
21D) and a synthetic resin second joining member (16) constituting the rest of each of the branch pipes (21A to 21D). A straight line inclined with respect to the pressing direction (39) or a curved line having a tangent line inclined with respect to the pressing direction (39) when the joint members (15, 16) are mutually pressurized during vibration welding. A vehicle having an inclined line portion (32a) arranged substantially at the other end side of each of the branch pipes (21A to 21D) and being vibration-welded to each other at a joining line (32) connected in a loop. A method for manufacturing an intake manifold for
The pressing direction (39) in the inclined line portion (32a)
Is set to be larger than the welding allowance of the remaining portion of the joining line (32) except the inclined line portion (32a), and the inclined line portion (32a) of the joining line (32) is set. ) Is vibration-welded while applying a first clamping force prior to the other portions, and then the entire joining line (32) is vibrated while applying a second clamping force greater than the first clamping force. A method for manufacturing an intake manifold for a vehicle, comprising welding. 2. A plurality of branch pipes having a shape projected on a vertical plane bent at substantially 90 degrees, one end of which is commonly connected to a surge tank (12, 42) and arranged in parallel in a horizontal direction. In manufacturing a vehicle intake manifold (13) including (21A, 21B, 21C, 21D) and an engine mounting flange (22) commonly connected to the other end of each branch pipe (21A to 21D), Each branch pipe (2) is integrally provided with an engine mounting flange (22).
1A to 21D), a first joining member (15) made of synthetic resin, and a second joining member (16) made of synthetic resin, which constitutes the rest of each branch pipe (21A to 21D).
When the joining members (15, 16; 45, 46) are welded to each other at the time of welding, a straight line inclined with respect to the pressing direction (39) or a tangent line inclined with respect to the pressing direction (39) is formed. A method of manufacturing an intake manifold for a vehicle, comprising at least two curved inclined line portions (32a, 32b) at two locations and vibration welding to each other at a joining line (32) connected in a loop, The welding margin along the pressing direction (39) at the inclined line portions (32a, 32b) is changed to the welding margin at the remaining portion of the joining line (32) except for the inclined line portions (32a, 32b). The portions corresponding to the inclined line portions (32a, 32b) of the joining line (32) are subjected to vibration welding while applying a first clamping force prior to the other portions, and then the first portion. Kula Method for producing a vehicle intake manifold, characterized by vibration welding the entire joint line while applying a large second clamping force than flop force (32). 3. A projection on a vertical plane is bent at an angle larger than 90 degrees and smaller than 270 degrees and has an inverted shape, one end of which is commonly connected to a surge tank (42) and is horizontally connected. A vehicle intake manifold (43) including a plurality of branch pipes (49) arranged in parallel in the direction and an engine mounting flange (48) commonly connected to the other end of each branch pipe (49) is manufactured. In this case, a first joining member (45) made of synthetic resin, which constitutes a part of each branch pipe (49), and the engine mounting flange (4)
8) and a second joining member (46) made of synthetic resin, which constitutes the rest of each of the branch pipes (49), are added to each other at the time of vibration welding of the joining members (45, 46). A pair of inclined line portions having a linear shape inclined with respect to the pressing direction (39) at the time of pressing, or a curved shape having a tangent line inclined with respect to the pressing direction (39), and having the inclination directions opposite to each other. (53a, 53b) and the pressing direction (3
9), the two inclined line portions (53a, 53)
b) A method of manufacturing an intake manifold for a vehicle having a straight line portion (53c) connecting between them and being vibration-welded to each other at a joining line (53) connected in a loop, wherein the two inclined line portions ( The welding margin along the pressing direction (39) at 53a, 53b) is set to be larger than the welding margin at the remaining portion of the joining line (53) except for the two inclined line portions (53a, 53b). Then, portions of the joining line (53) corresponding to the inclined line portions (53a, 53b) are subjected to vibration welding while applying a first clamping force prior to the other portions, and then to a first clamping force. A method for manufacturing an intake manifold for a vehicle, wherein the entire welding line (53) is subjected to vibration welding while applying a large second clamping force. 4. A first and second joining member (15, 1) made of synthetic resin constituting a resin structure (13, 43, 63).
6; 45, 46; 66, 67) are inclined with respect to the pressing direction (39) when they are pressed together during vibration welding of the joining members (15, 16; 45, 46; 66, 67). An inclined line portion (32a, 32) having a linear shape or a curved shape in which a tangent is inclined with respect to the pressing direction (39).
b; 53a, 53b; 68a, 68b, 68e, 68
f), wherein the inclined line portions (32a, 32b; 53a, 53) are vibration-welded to each other at the joining lines (32, 53, 68) having the f).
b; 68a, 68b, 68e, 68f) along the pressing direction (39) with the welding margin (32, 5).
3, 68) of the inclined line portions (32a, 32b;
53a, 53b; 68a, 68b, 68e, 68f) are set to be larger than the welding margins of the remaining portions, and the inclined line portions (32a, 32b; 53a, 53a, 53b, 68b) of the joining lines (32, 53, 68) are set. 53b; 68a, 68
b, 68e, 68f) is vibratory-welded while applying a first clamping force prior to the other portions, and then applying a second clamping force greater than the first clamping force to the joining line (32). , 53, 68) by vibration welding.