Resonator structure
The resonator structure seals the gap between the intake duct and flange using oil-collecting surface textures, addressing the need for precise tolerance management and lowering manufacturing costs while maintaining noise reduction performance.
Patent Information
- Authority / Receiving Office
- JP · JP
- Patent Type
- Patents
- Current Assignee / Owner
- SUBARU CORP
- Filing Date
- 2022-08-29
- Publication Date
- 2026-05-18
AI Technical Summary
Existing resonator structures in intake ducts require strict tolerance management to maintain a predetermined gap for noise reduction, leading to increased manufacturing costs.
A resonator structure with a flange protruding into the intake duct, featuring surface textures on the inner surface and flange to collect oil mist, allowing the gap to be sealed by collected oil, thereby achieving noise reduction without precise tolerance control.
The structure achieves intended noise reduction performance by sealing the gap with collected oil, eliminating the need for strict tolerance management and reducing manufacturing costs.
Smart Images
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Abstract
Description
Technical Field
[0001] The present invention relates to a resonator structure.
Background Art
[0002] An intake duct connected to an engine includes a resonator in order to reduce noise associated with the suction of air. For example, Patent Document 1 discloses an intake passage and a resonator disposed inside the intake passage. This resonator includes a tubular member and a flange-shaped wall portion that protrudes from the tubular member toward the inner wall surface of the intake passage. A seal member is disposed between the flange-shaped wall portion and the inner wall surface of the intake passage. Alternatively, when the flange-shaped wall portion and the inner wall surface of the intake passage are well sealed without a seal member, the seal member is not disposed.
Prior Art Documents
Patent Documents
[0003]
Patent Document 1
Summary of the Invention
Problems to be Solved by the Invention
[0004] In order to reduce noise as intended, it is necessary to keep the gap between the intake duct and the resonator within a predetermined range from the design value. However, this requires strict tolerance management and can lead to an increase in manufacturing costs.
[0005] An object of the present invention is to provide a resonator structure capable of obtaining intended noise reduction performance without strict tolerance management.
Means for Solving the Problems
[0006] A resonator structure according to an aspect of the present invention is an intake duct, a resonator housed inside the intake duct and extending upward. Equipped with, The resonator includes a flange that protrudes toward the inner surface of the intake duct. At least one of the inner surface and the flange includes a surface texture for collecting oil in the gap between the inner surface and the flange. [Effects of the Invention]
[0007] According to the present invention, the intended noise reduction performance can be obtained without strict tolerance control. [Brief explanation of the drawing]
[0008] [Figure 1] Figure 1 is a perspective view showing a resonator structure according to an embodiment. [Figure 2] Figure 2 is an exploded perspective view showing the resonator structure of Figure 1. [Figure 3] Figure 3 is a perspective view showing the resonator structure of Figure 1 with the upper duct removed. [Figure 4] Figure 4 is a cross-sectional view of the resonator structure of Figure 1 obtained along the central axis. [Figure 5] Figure 5 is a cross-sectional view of a resonator structure according to another embodiment obtained along the central axis. [Figure 6] Figure 6 is a cross-sectional view of the resonator structure of Figure 5, perpendicular to the central axis. [Modes for carrying out the invention]
[0009] Embodiments of the present invention will be described in detail below with reference to the attached drawings. The specific dimensions, materials, and numerical values shown in these embodiments are merely illustrative for ease of understanding and do not limit the present invention unless otherwise specified. In the specification and drawings, elements having substantially the same function and configuration are denoted by the same reference numerals to avoid redundant explanations. Elements not directly related to the present invention are omitted from the illustrations.
[0010] Figure 1 is a perspective view showing a resonator structure 100 according to an embodiment. Figure 2 is an exploded perspective view showing the resonator structure 100 of Figure 1.
[0011] Referring to Figure 1, the resonator structure 100 is applied to the intake duct 1. The intake duct 1 is connected to the intake port of an engine (not shown). In the section where the resonator structure 100 is applied, the intake duct 1 extends upward, specifically parallel to the vertical direction. The intake duct 1 is divided into two parts along the flow path, including a lower duct 11 and an upper duct 12. The lower duct 11 and the upper duct 12 are assembled together.
[0012] Referring to Figure 2, the resonator structure 100 comprises an intake duct 1, specifically a section of the intake duct 1, and a resonator 2.
[0013] The resonator 2 is housed inside the intake duct 1. Specifically, the resonator 2 is positioned in the space between the lower duct 11 and the upper duct 12. The resonator 2 reduces noise generated when air is drawn into the intake duct 1 from the outside. The resonator 2 includes a body 21 and one or more flanges 22. In this embodiment, the resonator 2 includes six flanges 22.
[0014] The main body 21 has a generally cylindrical shape. The main body 21 is positioned such that its central axis X extends upward, specifically parallel to the vertical direction. In this disclosure, the radial and circumferential directions with respect to the central axis X of the main body 21 (resonator 2) may simply be referred to as "radial direction" and "circumferential direction." The main body 21 includes a plurality of holes 23. The holes 23 penetrate the main body 21 radially.
[0015] Multiple flanges 22 are arranged along the central axis X. The flanges 22 have a generally annular shape. The flanges 22 project radially outward from the outer surface of the main body 21 toward the inner surface 13 of the intake duct 1. In this embodiment, the flanges 22 project parallel to the horizontal direction.
[0016] FIG. 3 is a perspective view showing the resonator structure 100 of FIG. 1 with the upper duct 12 removed. Each flange 22 includes one or more protrusions 22a. The intake duct 1 includes a notch 11a at a position corresponding to the protrusion 22a. The protrusion 22a is inserted into the notch 11a. The resonator 2 is positioned inside the intake duct 1 by the notch 22a. The flange 22 is spaced apart from the inner surface 13 of the intake duct 1 at positions other than the protrusion 22a.
[0017] FIG. 4 is a cross-sectional view of the resonator structure 100 of FIG. 1 taken along the central axis X. In FIG. 4, for better understanding, only one side of the resonator structure 100 with respect to the central axis X is shown, and only the range including the two flanges 22 is shown. As described above, the flange 22 is spaced apart from the inner surface 13 of the intake duct 1 at positions other than the protrusion 22a (not shown in FIG. 4). Therefore, a gap g is formed between the flange 22 and the inner surface 13.
[0018] An oil mist containing volatilized engine oil and fuel may flow backward from the engine into the intake duct 1. In the resonator structure 100, at least one of the inner surface 13 of the intake duct 1 and the flange 22 includes a surface property Tx for collecting the oil mist in the gap g.
[0019] In the present embodiment, the surface property Tx includes a first region Ar1, a second region Ar2, and a third region Ar3. In FIG. 4, for better understanding, the first region Ar1, the second region Ar2, and the third region Ar3 are exaggerated and may be thinner than those depicted in FIG. 4. Also, in FIG. 4, for better understanding, the first region Ar1 and the third region Ar3 are shown by cross-hatching.
[0020] The first region Ar1 is formed on the inner surface 13 at a position radially opposed to the flange 22. For example, the first region Ar1 may have an annular shape and may be continuous in the circumferential direction. Alternatively, the first region Ar1 may be intermittent in the circumferential direction as long as oil can be sufficiently collected in the gap g as described later.
[0021] In this embodiment, the width d1 of the first region Ar1 in the direction of extension of the resonator 2, i.e., in the direction parallel to the central axis X, is equal to the thickness d2 of the flange 22. In other embodiments, the width d1 may be smaller than the thickness d2, or it may be larger than the thickness d2.
[0022] The second region Ar2 is formed on the inner surface 13 in the upper and lower regions of the first region Ar1. In another view, the second region Ar2 may be provided between the flanges 22 in a direction parallel to the central axis X. For example, the second region Ar2 may or may not be provided in the region above the uppermost flange 22. Similarly, for example, the second region Ar2 may or may not be provided in the region below the lowermost flange 22. For example, the second region Ar2 may have a cylindrical shape and may be continuous in the circumferential direction. Alternatively, the second region Ar2 may be intermittent in the circumferential direction, insofar as enough oil is collected in the gap g.
[0023] The third region Ar3 is formed on the flange 22 at a position radially opposite to the first region Ar1, i.e., on the outer circumferential surface of the flange 22. A gap g is formed between the first region Ar1 and the third region Ar3. For example, the third region Ar3 may have an annular shape or be continuous in the circumferential direction. Alternatively, the third region Ar3 may be intermittent in the circumferential direction, insofar as sufficient oil is collected in the gap g. In this embodiment, in the vertical direction, the width d3 of the third region Ar3 is equal to the thickness d2 of the flange 22. In other embodiments, the width d3 may be less than the thickness d2.
[0024] Note that the surface properties Tx do not necessarily have to include the third region Ar3.
[0025] The first region Ar1 and the second region Ar2 are formed such that at least one of their "contact angle" and "falling angle" with respect to the oil droplet is different from that of the other.
[0026] For example, in this embodiment, the first region Ar1 and the second region Ar2 are formed such that their "fall angles" relative to the oil droplets are different. Specifically, the fall angle in the first region Ar1 is greater than the fall angle in the second region Ar2.
[0027] The "roll angle," also known as the "slide angle," is an indicator of the droplet removal ability of a target surface. For example, the "roll angle" can be measured using the following procedure: First, a certain amount of oil droplets are formed on a horizontally positioned target surface. Next, the target surface is gradually tilted. Then, the angle between the horizontal direction and the target surface is measured when the oil droplets begin to slide across the surface. In this way, the roll angle is measured. That is, a surface with a larger roll angle can retain oil better.
[0028] In this embodiment, as described above, the falling angle in the first region Ar1 is greater than the falling angle in the second region Ar2. Therefore, the first region Ar1 can hold oil better than the second region Ar2. In other words, the second region Ar2 cannot hold oil as well as the first region Ar1. With this configuration, oil mist adhering to the second region Ar2 falls downward toward the first region below. Since the first region Ar1 can hold oil well, the oil that falls from the second region Ar2 is held in the first region Ar1. Since the first region Ar1 faces the flange 22, the oil is collected in the gap g between the flange 22 and the inner surface 13. Therefore, the gap g is blocked by the collected oil. With this configuration, the resonator structure 100 can be designed so that the intended noise reduction performance is obtained when the gap g is blocked, regardless of the size of the gap g. Therefore, the intended noise reduction performance can be obtained without strictly controlling the tolerance of the gap g.
[0029] Furthermore, in this embodiment, the third region Ar3 is formed such that its angle of contact with the oil droplet is the same as that of the first region Ar1. Therefore, the third region Ar3 can hold oil well, just like the first region Ar1. In this way, since the opposing first region Ar1 and third region Ar3 can hold oil well, more oil can be collected in the gap g.
[0030] For example, the first region Ar1 and the third region Ar3, which have a larger falling angle relative to the oil droplet, may be surfaces containing irregularities of several micrometers, tens of micrometers, or tens of micrometers. Such surfaces may be formed by surface treatment such as blasting or by coating. Alternatively, for example, the surface patterns of the first region Ar1 and the third region Ar3 may be applied to the mold used for press forming of the intake duct 1 and the resonator 2. For example, the falling angles in the first region Ar1 and the third region Ar3 may be between 90 and 180 degrees.
[0031] For example, a second region Ar2 having a smaller falling angle relative to the oil droplet may be a surface containing smaller irregularities than the first region Ar1 and the third region Ar3. For example, the second region Ar2 may be an unprocessed surface for forming the first region Ar1 and the third region Ar3. For example, the second region Ar2 may be a surface after machining or press working. For example, the falling angle in the second region Ar2 may be between 0 and 90 degrees.
[0032] The resonator structure 100 described above comprises an intake duct 1 and a resonator 2 housed inside the intake duct 1 and extending upward. The resonator 2 includes a flange 22 that protrudes toward the inner surface 13 of the intake duct 1. At least one of the inner surface 13 and the flange 22 includes a surface treatment Tx for collecting oil in the gap g between the inner surface 13 and the flange 22. With this configuration, the gap g is sealed by the oil collected by the surface treatment Tx. Therefore, the resonator structure 100 can be designed so that the intended noise reduction performance is obtained when the gap g is sealed, regardless of the size of the gap g. Thus, the intended noise reduction performance can be obtained without strict tolerance control of the gap g.
[0033] Furthermore, in the resonator structure 100, the surface properties Tx include a first region Ar1 formed on the inner surface 13 so as to face the flange 22, and a second region Ar2 formed on the inner surface 13 in the regions above and below the first region Ar1, and formed such that the angle of fall for oil droplets is different from that of the first region Ar1. Specifically, the angle of fall in the first region Ar1 is greater than the angle of fall in the second region Ar2. With this configuration, the first region Ar1 and the second region Ar2 formed on the inner surface 13 of the intake duct 1 can collect oil adhering to the inner surface 13 into the gap g.
[0034] Furthermore, in the resonator structure 100, the width d1 of the first region Ar1 in the extending direction of the resonator 2 is equal to the thickness d2 of the flange 22. With this configuration, the first region Ar1 is formed across the gap g, so the gap g can be sufficiently sealed.
[0035] Furthermore, in the resonator structure 100, the surface texture Tx includes a third region Ar3 which is formed to face the first region Ar1 at the flange 22 and whose falling angle is the same as that of the first region Ar1. With this configuration, the third region Ar3 facing the first region Ar1 is formed to have the same falling angle as the first region Ar1. Therefore, more oil can be collected in the gap g between the first region Ar1 and the third region Ar3.
[0036] Next, other embodiments will be described.
[0037] Figure 5 is a cross-sectional view of a resonator structure 100A according to another embodiment obtained along the central axis X. Similar to Figure 4, in Figure 5, for better understanding, only one side of the resonator structure 100A with respect to the central axis X is shown, and only the portion including the two flanges 22 is shown.
[0038] The resonator structure 100A differs from the resonator structure 100 in the shape of the flange 22 and the position of the surface texture Tx. In other respects, the resonator structure 100A may be the same as the resonator structure 100.
[0039] In this embodiment, the flange 22 is tilted downward as it approaches the inner surface 13 of the intake duct 1. Each flange 22 also includes a plurality of ribs 22b arranged radially with respect to the central axis X. In Figure 5, however, only a single rib 22b is shown for each flange 22. The rib 22b protrudes upward from the upper surface 22c of the flange 22. The rib 22b extends radially outward from the connection point between the flange 22 and the body 21. The rib 22b is formed to be spaced apart from the outer edge of the flange 22.
[0040] Figure 6 is a cross-sectional view of the resonator structure 100A of Figure 5, perpendicular to the central axis X, with the flange 22 viewed from above. In this embodiment, the surface texture Tx includes a fourth region Ar4 and a fifth region Ar5. In Figures 5 and 6, for better understanding, the fourth region Ar4 is shown with cross-hatching.
[0041] The fourth region Ar4 is provided on the upper surface 22c of the flange 22 in the region between the multiple ribs 22b. That is, the fourth region Ar4 includes multiple fan-shaped portions. The fourth region Ar4 is formed so as to be spaced apart from the outer edge of the flange 22. Referring to Figure 5, the fourth region Ar4 is also formed on the side surface of the rib 22b.
[0042] Referring to Figure 6, the fifth region Ar5 is formed on the upper surface 22c of the flange 22, in an area other than the fourth region Ar4. Specifically, the fifth region Ar5 is formed on the upper surface of the rib 22b. Furthermore, the fifth region Ar5 is provided in the annular region between the fourth region Ar4 and the outer edge of the flange 22 in the radial direction.
[0043] The fourth region Ar4 and the fifth region Ar5 are formed such that their "contact angles" with respect to oil droplets are different. Specifically, the contact angle in the fourth region Ar4 (the first contact angle) is greater than the contact angle in the fifth region Ar5 (the second contact angle). In other words, the fourth region Ar4 is oleophobic, and the fifth region Ar5 is lipophilic.
[0044] The "contact angle" is an indicator of the oleophilicity and oleophobicity of a target surface. A larger contact angle indicates higher oleophobicity and lower oleophilicity. For example, the "contact angle" may be measured by a method specified in standards such as JIS. For example, the "contact angle (static contact angle)" can be measured by the following procedure. First, a certain amount of oil droplet is formed on the target surface, which is placed horizontally. Next, the angle formed between the target surface and the tangent at the lowest point of the outer surface of the oil droplet is measured using a measuring device such as a camera or microscope. In this way, the contact angle is measured.
[0045] Referring to Figure 5, the surface properties Tx include a sixth region Ar6. The sixth region Ar6 is provided over the entire lower surface 22d of the flange 22. The sixth region Ar6 has a third contact angle with respect to the oil droplet that is smaller than the first contact angle. In this embodiment, the third contact angle of the sixth region Ar6 is the same as the second contact angle of the fifth region Ar5. That is, the sixth region Ar6 is lipophilic.
[0046] Referring to Figure 6, in the resonator structure 100A, some of the oil adhering to the fifth region Ar5 on the upper surface of the rib 22b flows down towards the fourth region Ar4 between the ribs 22b. The remaining oil adhering to the fifth region Ar5 on the upper surface of the rib 22b flows down towards the annular fifth region Ar5 due to gravity from the inclined flange 22. The oil adhering to the fourth region Ar4 is repelled by the oil-repellent fourth region Ar4 and flows down towards the annular fifth region Ar5 due to gravity from the inclined flange 22. Therefore, the oil adhering to the upper surface 22c of the flange 22 is collected in the annular fifth region Ar5 on the outer edge of the flange 22. The gap g is blocked by the collected oil. With this configuration, the resonator structure 100A can be designed so that the intended noise reduction performance is obtained when the gap g is blocked. Furthermore, the patterns of the fourth region Ar4 and the fifth region Ar5 are not limited to those shown in Figures 5 and 6, and other patterns may be used as long as sufficient oil is collected in the gap g.
[0047] Furthermore, referring to Figure 5, in this embodiment, the sixth region Ar6 on the lower surface 22d of the flange 22 is lipophilic. Therefore, oil adhering to the sixth region Ar6 does not fall off but flows down along the sixth region Ar6 to the outer edge of the flange 22. Thus, more oil can be collected in the gap g.
[0048] The oil-repellent fourth region Ar4 may be formed, for example, by surface treatment such as blasting or by coating. Alternatively, for example, the surface pattern of the fourth region Ar4 may be applied to the mold used for press working of the resonator 2. For example, the first contact angle in the fourth region may be 150 to 180 degrees.
[0049] The lipophilic fifth region Ar5 and sixth region Ar6 can be, for example, unprocessed surfaces to impart oil repellency. For example, the fifth region Ar5 and sixth region Ar6 can be surfaces after machining or press working. For example, the second contact angle in the fifth region Ar5 and the third contact angle in the sixth region Ar6 may be between 0 and 5 degrees.
[0050] In this resonator structure 100A, similar to the resonator structure 100 described above, the gap g is sealed by oil collected by the surface properties Tx. Therefore, the resonator structure 100A can be designed so that the intended noise reduction performance is obtained when the gap g is sealed, regardless of the size of the gap g. Thus, the intended noise reduction performance can be obtained without strict tolerance control of the gap g.
[0051] Furthermore, in the resonator structure 100A, the surface properties Tx include a fourth region Ar4 formed on the upper surface 22c of the flange 22 and having a first contact angle with respect to the oil droplet, and a fifth region Ar5 formed on the upper surface 22c of the flange 22 and having a second contact angle smaller than the first contact angle with respect to the oil droplet. With this configuration, oil adhering to the upper surface 22c of the flange 22 can be collected in the gap g by the fourth region Ar4 and the fifth region Ar5 formed on the upper surface 22c.
[0052] Furthermore, in the resonator structure 100A, the surface properties Tx include a sixth region formed on the lower surface 22d of the flange 22, which has a third contact angle with respect to the oil droplet that is smaller than the first contact angle. With this configuration, oil adhering to the lower surface 22d of the flange 22 can be collected in the gap g by the sixth region Ar6 formed on the lower surface 22d.
[0053] Furthermore, in the resonator structure 100A, the fifth region Ar5 includes the outer peripheral edge of the upper surface 22c of the flange 22. With this configuration, the lipophilic fifth region Ar5 is formed on the outer peripheral edge of the flange 22 close to the gap g. Therefore, oil can be retained near the gap g.
[0054] Furthermore, in the resonator structure 100A, the flange 22 is tilted downward as it approaches the inner surface 13. Therefore, the gravity caused by the tilt of the flange 22 can easily collect the oil in the gap g.
[0055] Although embodiments have been described above with reference to the attached drawings, the present invention is not limited to these embodiments. It will be obvious to those skilled in the art that various modifications or alterations can be conceived within the scope of the claims, and these will naturally also fall within the technical scope of the present invention.
[0056] For example, referring to Figure 4, in the resonator structure 100, the first region Ar1 and the second region Ar2 are formed such that their "fall angles" to the oil droplet are different from each other. In other embodiments, the first region Ar1 and the second region Ar2 may be formed such that their "contact angles" to the oil droplet are different from each other.
[0057] For example, the contact angle in the first region Ar1 may be greater than the contact angle in the second region Ar2. In other words, the first region Ar1 may be oil-repellent, and the second region Ar2 may be lipophilic.
[0058] In this case, the oil mist adhering to the second region Ar2 flows downward towards the first region below. Since the first region Ar1 is oil-repellent, the oil accumulates in the first region Ar1. As the first region Ar1 faces the flange 22, the gap g is blocked by the accumulated oil.
[0059] In this case, the third region Ar3 may be formed such that its contact angle with respect to the oil droplet is the same as that of the first region Ar1. That is, the third region Ar3 may have oil-repellent properties, similar to the first region Ar1. With such a configuration, oil accumulates in both the opposing first region Ar1 and the third region Ar3, allowing more oil to be collected in the gap g.
[0060] In further embodiments, the contact angle in the first region Ar1 may be smaller than the contact angle in the second region Ar2. In other words, the first region Ar1 may be lipophilic, and the second region Ar2 may be oleophobic.
[0061] In this case, the oil collected in the first region Ar1 is repelled by the lower second region Ar2, which has oil-repellent properties. Therefore, the oil is retained in the first region Ar1. Since the first region Ar1 faces the flange 22, the gap g is sealed by the retained oil.
[0062] In this case, the third region Ar3 may be different from the first region Ar1 and may have oil-repellent properties. With such a configuration, oil accumulates in the oil-repellent third region Ar3, so a sufficient amount of oil can be secured between the inner surface 13 and the flange 22 to seal the gap g. [Explanation of Symbols]
[0063] 1. Intake duct 2 resonators 13. Inner surface of the intake duct 22 Tsuba 22c Top of the guard 22d Lower surface of the guard 100 Resonator Structure 100A resonator structure Ar1 1st area Ar2 2nd area Ar3 3rd area Ar4 4th area Ar5 5th area Ar6 6th area d1 Width of the first region d2 Guard thickness g gap Tx surface texture
Claims
1. Intake duct and, A resonator housed inside the intake duct and extending upward, Equipped with, The resonator includes a flange that protrudes toward the inner surface of the intake duct. At least one of the inner surface and the flange includes a surface texture for collecting oil in the gap between the inner surface and the flange. Resonator structure.
2. The aforementioned surface properties are A first region formed on the inner surface so as to face the flange, A second region is formed in the inner surface in the region above and below the first region, and is formed such that at least one of the contact angle and the falling angle for the oil droplet is different from that of the first region. including, The resonator structure according to claim 1.
3. The resonator structure according to claim 2, wherein the angle of fall of an oil droplet in the first region is greater than the angle of fall of an oil droplet in the second region.
4. The aforementioned surface properties are A third region is formed in the flange so as to face the first region, and such that at least one of the contact angle and the fall angle is the same as that of the first region. including, The resonator structure according to claim 2.
5. The aforementioned surface properties are A fourth region formed on the upper surface of the flange, having a first contact angle with respect to the oil droplet, A fifth region is formed on the upper surface of the flange and has a second contact angle with respect to the oil droplet that is smaller than the first contact angle, The resonator structure according to claim 1, including the above.