Resonator integrated pipe and method of manufacturing the same

Abstract

A resonator-integrated pipe (14) includes a pipe portion (24) through which an intake flow passes, and a resonator chamber (30) which is integrated with the pipe portion (24) and is in contact with the pipe portion (24) so that an outer wall of the pipe portion (24) serves as a partition (25). The resonator chamber (30) includes a plurality of opening portions (32, 34) each having an opening (32a) and an opening (34a) which penetrate an outer wall (31) of the resonator chamber (30), a communication hole (36) which is formed in the partition (25) at a position facing the opening (34a) of one opening portion (34) and which communicates with the pipe portion (24), and a plurality of cover members (38) for closing the openings (32a, 34a) of the plurality of opening portions (32, 34).

Description

Technical Field

[0001] This disclosure relates to an integrated resonator conduit and a method for manufacturing the same. Background Technology

[0002] Utility model application with publication number H3-83364 discloses a structure in which an air intake pipe and a resonator chamber are integrally formed, wherein a connecting hole is formed on a partition between the pipe section and the resonator chamber. A cover is attached to the resonator chamber to close an opening used to remove the core (sand mold inserted into the mold) during the casting process. Summary of the Invention

[0003] The technical problem to be solved by the present invention Typically, a support is provided on the core inserted through the opening, and molten metal is poured into the mold while supporting the support. However, in the above structure, since there is only one opening, only a single support can be provided, resulting in unstable support of the core by the support. In this case, the displacement of the core within the mold may lead to a decrease in the quality of the casting (i.e., the resonator integrated pipe).

[0004] Based on the aforementioned problems, this disclosure aims to provide a structure that can suppress quality deterioration during the molding process of resonator integrated pipes.

[0005] Problem-solving methods A first aspect of this disclosure provides a resonator integrated conduit, comprising: a conduit portion through which an intake airflow passes; and a resonator chamber integrally formed with and in contact with the conduit portion, such that the outer wall of the conduit portion serves as a partition, wherein the resonator chamber includes: a plurality of openings, each opening having an opening penetrating the outer wall of the resonator chamber; a connecting hole formed on the partition at a position facing the opening of one of the plurality of openings and communicating with the conduit portion; and a plurality of cover members for closing the openings of the plurality of openings.

[0006] In addition, the duct section can be bent from the upstream side of the air intake to the downstream side, and the resonator chamber is disposed on the duct section, so that the bent outer wall of the duct section is used as a baffle, and the downstream part of the baffle can be formed with a connecting hole.

[0007] In addition, the openings of the multiple openings can be spaced apart from each other on the outer wall of the resonator chamber.

[0008] Furthermore, the inner circumferential surfaces of the openings of the multiple openings can have the same shape, and the outer circumferential surfaces of the multiple cover members that mate with the openings of the multiple openings can have the same shape.

[0009] Furthermore, the inner circumferential surface can be circular, and the outer circumferential surface can be circular. Additionally, the inner circumferential surfaces of the openings of the multiple openings and the outer circumferential surfaces of the multiple cover members adapted to each corresponding opening can be circular, and the diameters of the inner and outer circumferential surfaces can be smaller than the diameter of the pipe section.

[0010] Furthermore, the diameter of the connecting hole can be smaller than the diameter of one of the openings.

[0011] A second aspect of this disclosure provides a method for manufacturing an integrated conduit for a resonator, the method comprising: a first step of forming a casting in which a conduit portion having a first cavity and a resonator chamber having a second cavity are integrally formed, with a partition between the two; a second step of removing a core filling the second cavity through a plurality of openings through the outer wall of the resonator chamber of the casting; a third step of inserting a tool through an opening of one of the plurality of openings and forming a connecting hole on the partition at a position facing the opening of the opening, the connecting hole connecting the resonator chamber and the conduit portion; and a fourth step of closing the openings of the plurality of openings with a cover member.

[0012] Furthermore, in the third step, the partition can be processed by inserting the tool directly into the opening of the opening to form a connecting hole with a diameter smaller than that of the opening.

[0013] Effects of the present invention According to this disclosure, a structure that facilitates the manufacture of an integrated resonator conduit can be realized. Attached Figure Description

[0014] Figure 1 This is a schematic diagram showing the construction of the air intake device 1 according to an embodiment.

[0015] Figure 2 This is a schematic diagram showing the external structure of the resonator integrated pipe 14.

[0016] Figure 3 This is a schematic diagram showing the internal structure of the resonator integrated pipe 14.

[0017] Figure 4 This is a flowchart illustrating the manufacturing of an integrated resonator conduit.

[0018] Figure 5 It is a schematic diagram used to illustrate a cast part that has been manufactured.

[0019] Figure 6 This is a schematic diagram illustrating the machining of the connecting hole 36.

[0020] [Explanation of reference numerals in the attached figures] 14: Resonator Integrated Pipe 24: Piping Department 24a: First cavity 25: Partition 30: Resonator Chamber 30a: Second cavity 31: Outer wall 32: First opening 32a: First opening 34: Second opening 34a: Second opening 36: Connecting hole 38: Cover component Detailed Implementation

[0021] <Overview of the air intake system> Figure 1 This is a schematic diagram illustrating the construction of an intake device 1 according to one embodiment. For example, the intake device 1 is installed in a vehicle to supply intake air to the engine 2. Figure 1 As shown, the air intake device 1 includes an air intake pipe 5, an air filter 6, and an air intake manifold 7.

[0022] Intake pipe 5 is the passage for airflow to the engine 2. Intake pipe 5 is coupled to intake manifold 7. Intake pipe 5 includes upstream duct 12, resonator integrated duct 14, and downstream duct 16. Although not described in... Figure 1 As shown in the diagram, a turbocharger compressor can be installed inside the intake pipe 5.

[0023] The upstream duct 12 is provided with an air inlet 12a for drawing in intake air. The upstream duct 12 is coupled to the upstream end of the resonator integrated duct 14. The intake air drawn in through the air inlet 12a flows through the upstream duct 12 and enters the resonator integrated duct 14.

[0024] The resonator integrated pipe 14 is an intermediate pipe located between the upstream pipe 12 and the downstream pipe 16. The resonator integrated pipe 14 is coupled to both the upstream pipe 12 and the downstream pipe 16, and the intake air flowing through the resonator integrated pipe 14 flows into the downstream pipe 16.

[0025] In this embodiment, the resonator-integrated conduit 14 adopts a structure in which the conduit section and the resonator chamber are integrally formed. The resonator chamber reduces high-frequency noise generated during the air intake process. The acoustic energy entering the resonator chamber is converted into heat energy through friction, thereby achieving noise reduction at a specific frequency. The specific structure of the resonator-integrated conduit 14 will be described in detail later.

[0026] Downstream duct 16 is located downstream of resonator integrated duct 14. Downstream duct 16 is coupled to intake manifold 7, and intake air flowing through downstream duct 16 flows into intake manifold 7.

[0027] An air filter 6 is installed inside the intake pipe 5 to purify the intake air. The air filter 6 removes fine dust (such as debris and other particulate matter) from the intake air. The air filter 6 is installed in the upstream pipe 12 of the intake pipe 5.

[0028] The intake manifold 7 is coupled to the downstream pipe 16 of the intake pipe 5. The intake manifold 7 is a branch pipe that distributes the intake air flowing in from the intake pipe 5 to each of the multiple cylinders of the engine 2.

[0029] <Detailed Construction of Integrated Resonator Pipeline> Figure 2 This is a schematic diagram showing the external structure of the resonator integrated pipe 14. Figure 3 This is a schematic diagram showing the internal structure of the resonator integrated pipe 14. Figure 3 It is the edge of the resonator integrated pipe 14 and Figure 2 A cross-sectional view taken from a plane parallel to the plane.

[0030] like Figure 2 and Figure 3 As shown, the resonator integrated conduit 14 includes an inlet section 22, a conduit section 24, a bypass gas return section 26, an outlet section 28, and a resonator chamber 30. The inlet section 22 has an opening through which the incoming air flows. The inlet section 22 is coupled to the upstream conduit 12. The incoming air flowing through the upstream conduit 12 flows into the conduit section 24 through the inlet section 22.

[0031] The pipe section 24 forms a flow channel through which the intake airflow entering from the inlet section 22 passes. The pipe section 24 is a tubular component with an internal cavity (hereinafter referred to as the first cavity 24a) through which the intake airflow passes. The pipe section 24 is made of metal. The intake airflow within the pipe section 24 flows towards the outlet section 28. Figure 3 As shown, the pipe section 24 does not form a straight flow channel, but rather a curved flow channel. The pipe section 24 bends from the upstream side where the air enters to the downstream side.

[0032] The outlet 28 has an opening through which the intake air flows out. The outlet 28 is coupled to the downstream pipe 16. The intake air flowing through the pipe section 24 flows out from the outlet 28 into the downstream pipe 16.

[0033] The return section 26 has an opening through which blow-by gas from engine 2 is recirculated back into pipe section 24. The recirculated blow-by gas flows together with the intake air flowing through upstream pipe 12 from outlet section 28 into downstream pipe 16. Blow-by gas refers to combustion gases that leak into the crankcase through gaps in, for example, the piston rings or turbocharger of engine 2.

[0034] The resonator chamber 30 eliminates intake noise through resonance effect based on Helmholtz theory. Here, intake noise refers to high-frequency noise generated during the intake process. According to Helmholtz theory, when air enters through the vent provided in the resonator chamber, the air in the resonator chamber will resonate at a specific frequency (resonant frequency). The resonator designed using this phenomenon can cancel the noise at the corresponding resonant frequency through resonance effect. Here, the resonant frequency generated in the resonator chamber is determined by the length (i.e., depth), cross-sectional area, and volume of the vent. Specifically, the resonant frequency increases when the cross-sectional area of ​​the vent increases, and decreases when the length of the vent and the volume of the resonator chamber increase. In this embodiment, the resonator chamber 30 is used as the resonator chamber, and the connecting hole 36 is used as the vent. A cavity (hereinafter referred to as the second cavity 30a) is formed inside the resonator chamber 30. The resonator chamber 30 is connected to the pipe section 24 through the connecting hole 36 (see...). Figure 3 Specifically, the second cavity 30a is connected to the first cavity 24a through the connecting hole 36. According to Helmholtz theory, the resonant frequency increases when the cross-sectional area of ​​the connecting hole 36 increases, and the resonant frequency decreases when the length and volume of the connecting hole 36 increase.

[0035] The resonator chamber 30 is made of metal and is integrally formed with the conduit section 24. Specifically, the metal resonator chamber 30 and the conduit section 24 are integrally formed by a casting process. When the resonator chamber 30 and the conduit section 24 are integrated in this way, it is not necessary to use components such as coupling members to couple the resonator chamber 30 to the conduit section 24.

[0036] like Figure 3 As shown, the resonator chamber 30 is disposed within the conduit portion 24, such that the outer wall of the conduit portion 24 serves as a partition 25. The partition 25 is a wall-like member that separates the resonator chamber 30 from the conduit portion 24. In this embodiment, the conduit portion 24 is bent from the upstream side to the downstream side. The resonator chamber 30 is disposed on the conduit portion 24, such that the outer wall of the conduit portion 24, which is bent at a predetermined curvature, serves as the partition 25. Therefore, the partition 25 that separates the resonator chamber 30 from the conduit portion 24 also serves as part of the outer wall of the resonator chamber 30. As a result, no gap is formed between the resonator chamber 30 and the conduit portion 24. This allows for an increase in the volume of the resonator chamber 30.

[0037] like Figure 3 As shown, the resonator chamber 30 includes an outer wall 31, a connecting hole 36, and a cover member 38. The outer wall 31 of the resonator chamber 30 has a first opening 32. The outer wall 31 is the wall facing the partition 25. The outer wall 31 is connected to the conduit section 24 via a side wall (see...). Figure 2Therefore, the partition 25, outer wall 31, and sidewalls together form the resonator chamber 30. The first opening 32 has a first opening 32a penetrating the outer wall 31. In this embodiment, the first opening 32a is a circular through hole. More specifically, the first opening 32a is a through hole with a circular inner circumferential surface. The first opening 32a serves as an outlet for removing the core (specifically, the sand material constituting the core) filling the second cavity 30a during the resonator manufacturing process.

[0038] The outer wall 31 of the resonator chamber 30 has a second opening 34. The second opening 34 has a second opening 34a penetrating the outer wall 31. The second opening 34a is a circular through-hole. More specifically, the second opening 34a is a through-hole with a circular inner circumferential surface. The second opening 34a on the outer wall 31 is located differently from the first opening 32a. The first opening 32a of the outer wall 31 is located upstream of the partition 25, while the second opening 34a is located downstream of the partition 25. The second opening 34a serves as an outlet for removing the core filling the second cavity 30a during the resonator manufacturing process. In this embodiment, as... Figure 3 As shown, the first opening 32a and the second opening 34a of the outer wall 31 are spaced apart from each other in the airflow direction through the conduit 24. This allows for efficient removal of the core filling the second cavity 30a. Furthermore, in this embodiment, the outer wall 31 of the resonator chamber 30 has two openings. However, the embodiment is not limited to this and may have three or more openings.

[0039] As described above, when the resonator chamber 30 and the conduit portion 24 are manufactured together by casting, a core is required in the corresponding portion of the resonator chamber 30. The core includes a support portion (such as...). Figure 5 The support portion 52 shown is used to support the core when molten metal is poured into the mold to form the resonator integrated conduit 14. When the resonator chamber 30 has multiple openings (first opening 32 and second opening 34) as in this embodiment, the core may include multiple support portions configured to couple with the core through the first opening 32 and the second opening 34. In this case, by using multiple support portions to support the core, core drift or rotation can be suppressed when molten metal is poured into the mold, thereby reducing the probability of core position deviation during the casting process.

[0040] Since the first opening 32 and the second opening 34 are spaced apart from each other on the outer wall 31, the core can be supported more stably. Furthermore, when multiple openings are provided at any position on the outer wall 31, the design freedom of the external shape of the resonator chamber 30 is increased compared to the case of a single opening with a larger opening. This makes it easier to increase the volume of the resonator chamber 30. In this case, the smaller the openings included in the multiple openings, the greater the freedom of the external shape of the resonator chamber 30. In this embodiment, the diameter of the inner circumferential surface of the openings of the multiple openings and the diameter of the outer circumferential surface of the cover member 38 are smaller than the diameter of the pipe portion 24.

[0041] The connecting hole 36 is a through hole penetrating the partition 25 and connecting the pipe section 24 and the resonator chamber 30. In this way, the pipe section 24 and the resonator chamber 30 can be connected to each other without the need for a connecting member. When the through hole in the partition 25 is the connecting hole 36, the length (i.e., depth) of the connecting hole 36 can be determined by adjusting the thickness of the partition 25. In this embodiment, the connecting hole 36 is circular. When the connecting hole 36 is circular, the cross-sectional area can be determined by adjusting the diameter of the connecting hole 36.

[0042] A connecting hole 36 is formed on the partition 25 at the position of the second opening 34a facing the second opening 34. On the other hand, no connecting hole 36 is formed on the partition 25 at the position of the first opening 32a facing the first opening 32. As described above, a connecting hole 36 is formed on the partition 25 at the position of an opening (i.e., the second opening 34a) provided with one of the plurality of openings facing the outer wall 31 of the resonator chamber 30.

[0043] A connecting hole 36 is formed in the downstream portion of the partition 25, which bends from the upstream side to the downstream side. By forming the connecting hole 36 in the downstream portion of the partition 25 that bends from the upstream side to the downstream side, it is possible to prevent the intake air flowing through the duct section 24 from entering the resonator chamber 30 through the connecting hole 36. As a result, the intake air can be properly supplied to the engine 2.

[0044] The diameter of the connecting hole 36 is smaller than the diameter of the second opening 34a of the second opening 34. For example, the diameter of the connecting hole 36 is one-half to two-thirds of the diameter of the second opening 34a. As described later, the connecting hole 36 is formed by machining a tool (such as a drill bit) into the second opening 34a. Therefore, by making the diameter of the connecting hole 36 smaller than the diameter of the second opening 34a, it is easier to insert the tool into the second opening 34a, thereby machining the connecting hole 36 more smoothly.

[0045] The cover member 38 closes the first opening 32a of the first opening 32 and the second opening 34a of the second opening 34. Each cover member 38 is installed in each of the first opening 32 and the second opening 34 by a press-fit. The outer peripheral surface of the cover member 38 that is embedded in the first opening 32a has the same shape as the inner peripheral surface of the first opening 32a. Specifically, the outer peripheral surface of the cover member 38 embedded in the first opening 32a is circular and has the same shape as the inner peripheral surface of the first opening 32a. Furthermore, in this example, the cover member 38 that closes the first opening 32a has the same shape as the cover member 38 that closes the second opening 34a. This allows for the use of two small cover members 38, which helps reduce manufacturing costs compared to using a single larger cover member. It should be noted that the shapes of the two cover members 38 are not limited to being identical and can also differ.

[0046] <Manufacturing process of integrated resonator channels> Figure 4 This is a flowchart illustrating the manufacturing process of an integrated resonator conduit.

[0047] First, the operator prepares the mold and the core (step S102). Here, the mold consists of an upper mold and a lower mold. The core includes a first core that fills the first cavity 24a of the pipe section 24, and a second core that fills the second cavity 30a of the resonator chamber 30. For example, the operator places the core in the lower mold and then installs the upper mold.

[0048] Next, the operator pours molten metal (i.e., melted metal) into the mold prepared in step S102 (step S104). As the temperature of the poured molten metal drops, it solidifies and forms a casting. When the molten metal is poured into the mold, the core is formed by… Figure 5 The core 50 shown is supported by two support portions 52. The two support portions 52 are installed in conjunction with the mold. By supporting the core 50 with two support portions 52 in this way, its position within the mold can be stabilized, and drift and rotation of the core within the mold can be suppressed.

[0049] Figure 5 This is a schematic diagram used to illustrate a cast iron part that has already been manufactured. Figure 5 In the image, the casting is shown in its demolded state. The completed casting is an integral structure, in which the pipe portion 24 having a first cavity 24a and the resonator chamber 30 having a second cavity 30a are integrally formed, with a partition 25 between them. Here, it is assumed that the core 54 (first core) is still located within the first cavity 24a, and the core 50 (second core) is still located within the second cavity 30a. The support portion 52 of the core 50 is inserted through the first opening 32a and the second opening 34a, respectively. Figure 5 For ease of explanation, the support part of the core 54 has been omitted.

[0050] Next, the operator removes the core 50 filling the second cavity 30a of the resonator chamber 30 through the first opening 32a and the second opening 34a on the outer wall 31 of the resonator chamber 30 of the casting (step S106). For example, the operator can apply vibration to the sand core 50 to break it and discharge sand particles through the first opening 32a and the second opening 34a. At this time, the operator also removes the core 54 filling the first cavity 24a of the pipe section 24. Specifically, the operator breaks the core 54 filling the first cavity 24a and removes the core 54 through the openings of the inflow section 22, the outflow section 28, and the return section 26.

[0051] Subsequently, the operator forms a communication hole 36 on the partition 25 between the pipe section 24 and the resonator chamber 30 (step S108). Specifically, the operator forms the communication hole 36 at a position on the partition 25 facing the second opening 34a, thereby enabling communication between the resonator chamber 30 and the pipe section 24. In this way, even if the pipe section 24 and the resonator chamber 30 are integrally formed structures, the communication hole 36 can still be formed through the second opening 34a.

[0052] Figure 6 This is a schematic diagram illustrating the formation of the connecting hole 36. The operator inserts a tool (e.g., a drill bit) into the second cavity 30a through the second opening 34a in the direction indicated by the arrow. Subsequently, the operator uses the inserted tool to machine a predetermined position on the partition 25, forming the connecting hole 36 (see [link]). Figure 3 Specifically, the operator inserts a tool along a straight line to machine the partition 25 to form a connecting hole 36, the diameter of which is smaller than the diameter of the second opening 34a. In this way, when the connecting hole 36 is machined using a tool (rather than during the casting process), a connecting hole 36 with the desired diameter can be formed with high precision at the desired location on the partition 25.

[0053] Next, the operator uses the cover member 38 to close the first opening 32a and the second opening 34a (step S110). For example, the operator closes the first opening 32a and the second opening 34a respectively by pressing the cover member 38 (see...). Figure 3 ).

[0054] Therefore, the integrated resonator pipe 14 is now complete. It should be noted that... Figure 4 The steps S104 shown correspond to the first process, S106 to the second process, S108 to the third process, and S110 to the fourth process.

[0055] <Effects of the Example> The resonator-integrated conduit 14 in the above embodiment includes a resonator chamber 30 in contact with the conduit portion 24, such that the outer wall of the conduit portion 24 serves as a partition 25. The resonator chamber 30 includes: a plurality of openings (a first opening 32 and a second opening 34), each having an opening penetrating the outer wall 31; a connecting hole 36 formed on the partition 25 at a position facing the second opening 34a of the second opening 34, and communicating with the conduit portion 24; and a plurality of cover members 38 for closing the first opening 32a and the second opening 34a. In the above configuration, two support portions 52 of the core 50 can be provided so that they can be inserted into the first opening 32 and the second opening 34 during the manufacture of the resonator-integrated conduit 14. In this way, since the two support portions 52 support the core 50, drift or rotation of the core 50 can be suppressed when molten metal is poured into the mold, thereby reducing positional fluctuations of the core 50. Furthermore, since the connecting hole 36 is formed on the partition 25 at a position corresponding to the second opening 34a, the connecting hole 36 can be easily processed through the second opening 34a, and the connecting hole 36 can be formed with high precision. Thus, a structure of the resonator integrated conduit 14 that is easy to manufacture and has high precision can be achieved.

[0056] This disclosure has been described based on exemplary embodiments. The technical scope of this disclosure is not limited to the scope described in the above embodiments, and various changes and modifications can be made within the scope of this disclosure. For example, all or part of the apparatus may be configured with any functionally or physically distributed or integrated units. Furthermore, new exemplary embodiments resulting from any combination are included in the exemplary embodiments. Moreover, the effects of the new exemplary embodiments resulting from the combination also have the effects of the original exemplary embodiments.

Claims

1. A resonator-integrated conduit, comprising: The intake airflow passes through the pipeline section; as well as A resonator chamber is integrally formed with and in contact with the pipe section (24), such that the outer wall of the pipe section serves as a partition, wherein the resonator chamber comprises: Multiple openings, each having an opening that penetrates the outer wall of the resonator chamber; A connecting hole is formed on the partition at an opening facing one of the plurality of openings and communicates with the pipe portion; and Multiple cover components are used to close the openings of the multiple openings.

2. The resonator integrated conduit according to claim 1, wherein, The pipe section bends from the upstream side where the air enters to the downstream side. The resonator chamber is disposed on the conduit section, such that the curved outer wall of the conduit section serves as the partition; and The connecting hole is formed in the downstream portion of the partition.

3. The resonator integrated conduit according to claim 1, wherein, The openings of the plurality of openings are spaced apart from each other on the outer wall of the resonator chamber.

4. The resonator integrated conduit according to claim 1, wherein, The inner circumferential surfaces of the openings of the plurality of openings have the same shape; and The outer peripheral surfaces of the multiple cover members that are adapted to the openings of the multiple openings have the same shape.

5. The resonator integrated conduit according to claim 4, wherein, The inner circumferential surface is circular, and The outer peripheral surface is circular.

6. The resonator integrated conduit according to claim 1, wherein, The inner peripheral surfaces of the multiple openings and the outer peripheral surfaces of the multiple cover members adapted to each corresponding opening are circular, and The diameters of the inner and outer circumferential surfaces are smaller than the diameter of the pipe section.

7. The resonator integrated conduit according to claim 1, wherein, The diameter of the connecting hole is smaller than the diameter of one of the openings.

8. A method for manufacturing an integrated resonator conduit, the method comprising: The first step is to form a casting, wherein the pipe section with a first cavity and the resonator chamber with a second cavity are integrally formed, and a partition is provided between the two. The second step is to remove the core filling the second cavity through the openings of multiple openings through the outer wall of the resonator chamber of the casting; The third step involves inserting a tool into one of the multiple openings and forming a connecting hole on the partition plate at the position facing the opening of that one opening. This connecting hole connects the resonator chamber to the conduit section. The fourth step is to seal the openings of the plurality of openings with a cover member.

9. The method for manufacturing an integrated resonator conduit according to claim 8, wherein, In the third step, the partition is processed by inserting a tool straight into the opening of one of the openings to form a connecting hole with a diameter smaller than that of the opening.

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