Valve mounting structure

Abstract

To provide a mounting structure for a valve capable of suppressing the occurrence of rattling in a mounting member for mounting the valve to an internal combustion engine.SOLUTION: The mounting structure includes a mounting member 25 separate from a valve, the mounting member 25 fixed to a separator 12 while covering the valve mounted to the separator 12 of the internal combustion engine, to prevent the removal of the valve from the separator 12, the mounting member 25 having a fixed hole 29 through which a resin protrusion 30 protruded from the separator 12 is inserted when covering the valve, the mounting member 25 fixed to the separator 12 by applying resin caulking to the protrusion 30 inserted through the fixed hole 29. On the inner face of the fixed hole 29, a first face 31 located corresponding to the outer face of the protrusion 30, and a second face 32 linked with the first face 31 and located to be farther away from the center of the fixed hole 29 than the first face 31 are formed.SELECTED DRAWING: Figure 9

Description

Technical Field

[0001] The present invention relates to a valve mounting structure.

Background Art

[0002] An internal combustion engine mounted on a vehicle or the like is provided with a valve that adjusts the gas flow area of a passage for flowing gas flowing out of the combustion chamber of the engine into the intake system. Such a valve is attached to the internal combustion engine. Further, as shown in Patent Document 1 for example, the valve is made non-removable from the internal combustion engine by fixing a mounting member that covers the valve to the internal combustion engine. Fixing of the mounting member to the internal combustion engine is performed as follows. That is, a hole is formed in the mounting member through which a protrusion protruding from the internal combustion engine is inserted, and the mounting member is fixed to the internal combustion engine by applying thermal caulking to the protrusion inserted through the hole.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] In the above valve mounting structure for an internal combustion engine, play in the rotational direction around the protrusion occurs in the mounting member due to the clearance between the hole of the mounting member and the protrusion of the internal combustion engine.

Means for Solving the Problems

[0005] Hereinafter, means for solving the above problems and their operational effects will be described. The valve mounting structure that solves the above problem is applied to a valve that adjusts the gas flow area of ​​a passage for flowing gas flowing out of the combustion chamber of an internal combustion engine into the intake system of the same engine. This mounting structure includes a mounting member separate from the valve. The mounting member covers the valve attached to the internal combustion engine and is fixed to the internal combustion engine, thereby making the valve irremovable from the internal combustion engine. The mounting member has a hole through which a resin projection that protrudes from the internal combustion engine when the valve attached to the internal combustion engine is covered is inserted. The mounting member can be fixed to the internal combustion engine by applying resin crimping to the projection inserted through the hole. The inner surface of the hole has a first surface located corresponding to the outer surface of the projection, and a second surface connected to the first surface and located further away from the center of the hole than the first surface.

[0006] According to the above configuration, when the projection inserted into the hole of the mounting member melts due to resin crimping, the molten portion penetrates inward into the second surface of the hole, and in this state the mounting member is fixed to the internal combustion engine. Therefore, rotational rattle around the projection of the mounting member is suppressed by the portion of the projection that melts due to resin crimping and penetrates inward into the second surface, and by the second surface itself.

[0007] The valve mounting structure that solves the above problem is applied to a valve that adjusts the gas flow area of ​​a passage for flowing gas flowing out of the combustion chamber of an internal combustion engine into the intake system of the same engine. This mounting structure includes a mounting member separate from the valve. The mounting member covers the valve attached to the internal combustion engine and is fixed to the internal combustion engine, thereby making the valve irremovable from the internal combustion engine. The mounting member has a hole through which a projection that protrudes from the internal combustion engine when the valve attached to the internal combustion engine is covered is inserted. The mounting member can be fixed to the internal combustion engine by applying resin crimping to the projection inserted through the hole. A projection is formed around the hole in the mounting member that protrudes away from the internal combustion engine.

[0008] According to the above configuration, when the projection that passes through the hole in the mounting member melts due to resin crimping, the melted portion covers the protrusion of the mounting member, and in this state the mounting member is fixed to the internal combustion engine. Therefore, rotational rattle around the projection of the mounting member is suppressed by the portion that melts due to resin crimping on the projection and covers the projection, as well as the projection itself. [Brief explanation of the drawing]

[0009] [Figure 1] This is a perspective view showing a valve attached to the separator of an internal combustion engine. [Figure 2] This is a perspective view showing the valve in Figure 1 from a different direction. [Figure 3] Figure 2 is a cross-sectional view showing the valve and its surroundings as seen from the direction of arrow 3-3. [Figure 4] This is a plan view showing the mounting members for attaching the valve in Figure 1 to the separator. [Figure 5] Figure 4 is an enlarged view showing the area around the fixing hole in the mounting member. [Figure 6] Figure 5 is a cross-sectional view showing the mounting member and the projection of the separator as seen from the direction of arrow 6-6. [Figure 7] Figure 5 is a cross-sectional view showing the mounting member and the separator's protrusions as seen from the direction of arrow 7-7. [Figure 8] These are cross-sectional views showing the process of applying resin crimping to the protrusions in Figures 6 and 7. [Figure 9] Figure 8 is a cross-sectional view showing the protrusion and its surrounding area as seen from the direction of arrow 9-9. [Figure 10] Figures 8 and 9 show cross-sectional views of the protrusions after they have been crimped with resin. [Figure 11] This is a plan view showing the protrusions in Figure 10. [Figure 12] This is a plan view showing another example of a fixing hole in a mounting member. [Figure 13] This is a plan view showing another example of a fixing hole in a mounting member. [Figure 14]It is a plan view showing another example of a fixing hole in an attachment member. [Figure 15] It is a cross-sectional view showing another example of a second surface in the fixing hole. [Figure 16] It is a cross-sectional view showing another example of a second surface in the fixing hole. [Figure 17] It is a plan view showing another example of a peripheral structure of a fixing hole in an attachment member. [Figure 18] It is a cross-sectional view showing another example of a peripheral structure of a fixing hole in an attachment member.

Mode for Carrying Out the Invention

[0010] Hereinafter, an embodiment of a valve attachment structure will be described with reference to FIGS. 1 to 11. The valve 11 shown in FIGS. 1 and 2 is for adjusting the gas flow area of a passage that returns the gas flowing out from the combustion chamber of an internal combustion engine to the intake system. Examples of such a valve 11 include a PCV valve. The valve 11 is attached to a separator 12 of an internal combustion engine. The separator 12 is formed of resin and is attached to the cylinder head of the internal combustion engine. Further, the valve 11 is connected to the inside of the separator 12 and is connected to the intake passage of the internal combustion engine via a hose.

[0011] In an internal combustion engine, blow-by gas flowing out from the combustion chamber into the crankcase flows into the intake passage through a blow-by gas passage that passes through the cylinder block, cylinder head, separator 12, valve 11, and the inside of the hose. The separator 12 separates liquids such as oil in the blow-by gas passing through the blow-by gas passage from the blow-by gas. The valve 11 adjusts the flow rate of the blow-by gas flowing from the blow-by gas passage to the intake passage of the internal combustion engine by changing the gas flow area of the blow-by gas passage.

[0012] <Valve 11 and its peripheral structure> As shown in FIG. 3, the valve 11 is attached to the separator 12 in an inclined state. The valve 11 includes a flow rate adjustment part 13 and a piping connection part 14. The flow rate adjustment part 13 adjusts the gas flow area of a blow-by gas passage 15 for flowing blow-by gas. The piping connection part 14 is for connecting the flow rate adjustment part 13 to a hose 16. The hose 16 is connected to the intake passage of the internal combustion engine. The blow-by gas of the internal combustion engine is separated from liquids such as oil in the separator 12 and then flows into the hose 16 through the flow rate adjustment part 13 and the piping connection part 14 of the valve 11.

[0013] The flow rate adjustment part 13 of the valve 11 includes a cylindrical housing 13a. The housing 13a is screwed into a mounting hole 17 formed in the separator 12. A communication hole 18 is formed at an end of the housing 13a opposite to the end on the piping connection part 14 side. The communication hole 18 is connected to the inside of the separator 12. A flange 19 is formed on the outer peripheral surface of the housing 13a. The flange 19 is formed to have a larger diameter than the mounting hole 17 of the separator 12. The flange 19 is in contact with a portion around the opening of the mounting hole 17 on the outer surface of the separator 12. A seal ring 20 is provided on the outer peripheral surface of the housing 13a at a portion corresponding to the inner peripheral surface of the mounting hole 17. The seal ring 20 seals between the outer peripheral surface of the housing 13a and the inner peripheral surface of the mounting hole 17 by abutting against the inner peripheral surface of the mounting hole 17.

[0014] Inside the housing 13a are a movable member 21, a spring 22, and a ring 23. The movable member 21 is formed in a cylindrical shape and extends along the same axis as the housing 13a. The spring 22 biases the movable member 21 toward the communication hole 18. The ring 23 is fitted onto the inner circumferential surface of the opening on the pipe connection portion 14 side of the housing 13a. The pipe connection portion 14 comprises a cylindrical housing 14a. The housing 14a is fitted into the opening on the pipe connection portion 14 side of the housing 13a of the flow rate adjustment portion 13. As a result, the ring 23 is sandwiched between the housing 14a and the housing 13a. The inside of the housing 14a of the pipe connection portion 14 communicates with the inside of the housing 13a of the flow rate adjustment portion 13 via the ring 23. Furthermore, a flange portion 14c is formed at the end of the housing 14a of the pipe connection portion 14 that is on the flow rate adjustment portion 13 side. A projection 14b is formed on the outer circumferential surface of the end of the housing 14a opposite to the flange 14c. The hose 16 is fitted into the projection 14b.

[0015] In the flow rate adjustment section 13, the movable member 21 inside the housing 13a is biased by the biasing force of the spring 22 toward a position that closes the communication hole 18 of the housing 13a. The end of the movable member 21 on the side of the pipe connection section 14 is inserted inside the ring 23. The outer circumferential surface of the movable member 21 has a smaller diameter than the inner circumferential surface of the ring 23, and the diameter is larger in the part closer to the communication hole 18. Since intake negative pressure from the internal combustion engine acts inside the hose 16 and inside the housing 14a of the pipe connection section 14, the movable member 21 moves toward the pipe connection section 14 side against the biasing force of the spring 22 based on this intake negative pressure. When the movable member 21 moves toward the pipe connection section 14 side, the communication hole 18 of the housing 14a, which was closed by the movable member 21, is opened. When the communication hole 18 is opened, the blow-by gas in the separator 12 of the internal combustion engine flows into the hose 16 via the flow rate adjustment section 13 and the piping connection section 14 of the valve 11.

[0016] The flow rate of blow-by gas at this time varies depending on the relative position of the movable member 21 and the ring 23. That is, during low-load operation of the internal combustion engine, the movable member 21 moves the most towards the pipe connection 14. At this time, the larger diameter portion of the outer surface of the movable member 21 faces the inner surface of the ring 23, so the gas flow area between these outer and inner surfaces becomes smaller. As a result, the flow rate of blow-by gas passing through the valve 11 decreases. As the engine operation transitions to a higher engine load state, the amount of movement of the movable member 21 towards the pipe connection 14 against the biasing force of the spring 22 decreases. As a result, the gas flow area between the outer and inner surfaces increases as the engine load increases. As a result, the flow rate of blow-by gas passing through the valve 11 increases. A spring 24 is provided inside the housing 14a of the pipe connection 14. The spring 24 is intended to suppress excessive movement of the movable member 21 towards the pipe connection 14.

[0017] <Mounting structure of valve 11 to separator 12 of internal combustion engine> The valve 11 is attached to the separator 12 of the internal combustion engine by screwing the housing 13a into the mounting hole 17 of the separator 12. The valve 11 attached to the separator 12 is made irremovable from the separator 12 by a metal mounting member 25. The mounting member 25 covers the valve 11 attached to the separator 12. The mounting member 25 is fixed to the separator 12, making the valve 11 irremovable from the separator 12 by the mounting member 25.

[0018] As shown in Figures 1 and 2, the mounting member 25 comprises a fixing portion 26, a front covering portion 27, and a side covering portion 28. The fixing portion 26 is formed in the shape of a plate extending substantially horizontally above the valve 11. The fixing portion 26 is fixed to the separator 12. The front covering portion 27 is formed in the shape of a plate extending downward from one side of the fixing portion 26 on the side of the pipe connection portion 14. The front covering portion 27 covers the flange portion 14c of the housing 14a of the pipe connection portion 14 of the valve 11. The side covering portion 28 is formed in the shape of a plate extending downward from two sides of the fixing portion 26 that are in contact with the front covering portion 27. The side covering portion 28 covers the portion of the separator 12 into which the valve 11 is screwed.

[0019] As shown in Figure 3, a fixing hole 29 is formed in the fixing portion 26 of the mounting member 25. The separator 12 has a resin projection 30 that protrudes upward. When the mounting member 25 covers the valve 11 attached to the separator 12, the projection 30 is inserted into the fixing hole 29 in the fixing portion 26 of the mounting member 25, as shown by the dashed line in Figure 3. By applying resin crimping to the projection 30 inserted into the fixing hole 29 in this way, the projection 30 deforms so that its diameter expands, as shown by the solid line in Figure 3. As a result, the mounting member 25 is fixed to the separator 12 of the internal combustion engine. Consequently, at least the flow rate adjustment portion 13 of the valve 11, more specifically the pipe connection portion 14 and the flow rate adjustment portion 13, become inremovable from the separator 12 of the internal combustion engine by the mounting member 25.

[0020] <Details of the fixing hole 29> As shown in Figure 4, the fixing portion 26 of the mounting member 25 has a plurality of fixing holes 29. The projection 30 of the separator 12 is inserted through each of the plurality of fixing holes 29. On the inner surface of the fixing hole 29, a first surface 31 is formed which corresponds to the outer surface of the projection 30, and a second surface 32 is formed which is connected to the first surface 31 and is positioned further away from the center of the fixing hole 29 than the first surface 31. The second surface 32 is curved in an arc shape so that it is positioned further away from the center of the fixing hole 29 than the first surface 31. On the inner surface of one fixing hole 29, a plurality of second surfaces 32 are formed at intervals around the center line of the fixing hole 29. The second surfaces 32 are formed on both sides of the center of the fixing hole 29. In this example, the position of the second surface 32 around the center line of the fixing hole 29 is the same for each of the plurality of fixing holes 29.

[0021] Next, the operation of the mounting structure for the valve 11 in this embodiment will be described. When fixing the mounting member 25 to the separator 12 of the internal combustion engine, the mounting member 25 is positioned to cover the valve 11 attached to the separator 12. At this time, the projection 30 of the separator 12 is inserted through the fixing hole 29 of the fixing portion 26 of the mounting member 25, as shown in Figures 5 to 7. Then, as shown in Figure 8, the crimping horn 33 is lowered from above the projection 30, causing the tip of the projection 30 to melt as shown by the dashed line in Figures 8 and 9. As a result, the melted portion of the projection 30 enters the inside of the second surface 32 of the fixing hole 29, as shown by the dashed line in Figure 10. In this state, as shown in Figure 11, the mounting member 25 is fixed to the separator 12 of the internal combustion engine by the projection 30.

[0022] According to the embodiment described in detail above, the following effects can be obtained. (1) When the projection 30 inserted into the fixing hole 29 of the mounting member 25 melts due to resin crimping, the molten portion enters the inside of the second surface 32 of the fixing hole 29, and in this state the mounting member 25 is fixed to the separator 12 of the internal combustion engine. As a result, rotational rattle around the projection 30 of the mounting member 25 is suppressed by the portion of the projection 30 that melts due to resin crimping and enters the inside of the second surface 32 and the second surface 32.

[0023] (2) The second surface 32 of the fixing hole 29 is curved in an arc shape so that it is positioned further away from the center of the fixing hole 29 than the first surface 31. By making the second surface 32 as described above, when the fixing hole 29 of the mounting member 25 is formed by punching with a punch during the manufacturing of the mounting member 25, wear of the punch associated with the punching can be suppressed. In addition, by making the second surface 32 of the fixing hole 29 arc-shaped, when the projection 30 melts due to resin crimping, the molten portion can easily enter the inside of the second surface 32 of the fixing hole 29.

[0024] (3) Multiple second surfaces 32 are formed in the fixing hole 29 at intervals around the center line of the fixing hole 29. As a result, the rattle in the rotational direction of the mounting member 25 around the projection 30 is suppressed at multiple spaced positions around the center line of the fixing hole 29 by the joints between the projection 30, where it has melted due to resin crimping and entered the inside of the second surface 32, and the second surface 32. Thus, the strength of the mounting member 25 and the projection 30 against the rattle can be increased.

[0025] (4) Multiple fixing holes 29 are formed in the fixing portion 26 of the mounting member 25, and the projections 30 of the separator 12 are inserted through each of these fixing holes 29, so that the mounting member 25 fixed to the separator 12 is less likely to move in the rotational direction around the projections 30.

[0026] The above embodiment can also be modified as follows, for example. The above embodiment and the following modifications can be combined and implemented to the extent that they do not contradict each other technically. The number of fixing holes 29 may be set to one or to three or more.

[0027] The number of second surfaces 32 in a single fixing hole 29 may be one or three or more. As shown in Figure 12, the position of the second surface 32 formed in the fixing hole 29 may differ for each of the multiple fixing holes 29 with respect to the center line of the fixing hole 29. In this case, the rotational rattle of the mounting member 25 around the projection 30 can be more effectively suppressed by the portion of the projection 30 that has melted due to resin crimping and entered the inside of the second surface 32 and the second surface 32.

[0028] As shown in Figure 13, the fixing hole 29 may be formed in a square shape. In this case, the area on the inner surface of the fixing hole 29 that is close to the projection 30 becomes the first surface 31, and the areas on the inner surface of the fixing hole 29 corresponding to the four corners become the second surfaces 32. It is also possible to form the fixing hole 29 in a polygonal shape other than a square.

[0029] As shown in Figure 14, the fixing hole 29 may be formed in the shape of an elongated hole. In this case, the portion of the inner surface of the fixing hole 29 that is parallel and close to the projection 30 becomes the first surface 31, and the portion of the inner surface of the fixing hole 29 that is curved in an arc becomes the second surface 32.

[0030] As shown in Figures 15 and 16, the second surface 32 of the fixing hole 29 may be formed by a step. In this case, the inner portion of the second surface 32 of the fixing hole 29 is not to penetrate the fixing portion 26 of the mounting member 25 in the thickness direction, i.e., in the vertical direction in Figures 15 and 16.

[0031] Instead of forming a second surface 32 in the fixing hole 29, a projection 34 may be formed around the fixing hole 29 of the fixing portion 26 of the mounting member 25, as shown in Figures 17 and 18, in a direction away from the separator 12, i.e., projecting upward in Figure 18. In this case, when the projection 30 that passes through the fixing hole 29 melts due to resin crimping, the melted portion covers the projection 34, and the mounting member 25 is fixed to the separator 12 in this state. Therefore, rotational rattle around the projection 30 of the mounting member 25 is suppressed by the portion of the projection 30 that melts due to resin crimping and covers the projection 34, and by the projection 34 itself. The number of projections 34 can be one per fixing hole 29, or there can be three or more.

[0032] The mounting location of the valve 11 and the fixing location of the mounting member 25 may be any location other than the separator 12 in the internal combustion engine. • Although a PCV valve is given as an example for valve 11, valve 11 may be a valve other than a PCV valve, such as an EGR valve.

[0033] Next, we will describe the technical concept that can be understood from the above embodiment. (A) In a valve mounting structure applied to a valve that adjusts the gas flow area of ​​a passage for flowing gas flowing out of the combustion chamber of an internal combustion engine into the intake system of the same engine, the mounting member is separate from the valve and covers the valve attached to the internal combustion engine and is fixed to the internal combustion engine, thereby making the valve irremovable from the internal combustion engine, The mounting member has a hole formed in it for inserting a resin projection that protrudes from the internal combustion engine when it is covered by a valve attached to the internal combustion engine. The mounting member can be fixed to the internal combustion engine by applying resin crimping to the projection inserted through the hole. A valve mounting structure comprising a first surface located on the inner surface of the hole, corresponding to the outer surface of the projection, and a second surface connected to the first surface and located further away from the center of the hole than the first surface.

[0034] (B) The valve mounting structure according to (A), wherein the second surface is curved in an arc shape so that it is positioned further away from the center of the hole than the first surface.

[0035] (C) The valve mounting structure according to (A) or (B), wherein a plurality of the second surfaces are formed in the hole at intervals around the center line of the hole.

[0036] (D) The mounting member has a plurality of holes formed therein, The mounting structure for a valve according to any one of (A) to (C), wherein the second surface formed in the hole is positioned differently for each of the multiple holes with respect to the center line of the hole. [Explanation of Symbols]

[0037] 11… Valve 12... Separator 15…Blow-by gas passage 16...Hose 17…Mounting holes 25…Mounting parts 26…Fixed part 27…Front covering part 28... Side covering 29…Fixing hole 30…Protrusion 31...Side 1 32…Second side 33... Crimping horn 34… protrusion

Claims

1. In a valve mounting structure applied to a valve that adjusts the gas flow area of ​​a passage for flowing gas flowing out of the combustion chamber of an internal combustion engine into the intake system of the same engine, the mounting member is separate from the valve and covers the valve attached to the internal combustion engine and is fixed to the internal combustion engine, thereby making the valve irremovable from the internal combustion engine, The mounting member has a hole formed in it for inserting a resin projection that protrudes from the internal combustion engine when it is covered by a valve attached to the internal combustion engine. The mounting member can be fixed to the internal combustion engine by applying resin crimping to the projection inserted through the hole. The inner surface of the hole has a first surface located corresponding to the outer surface of the projection, and a second surface connected to the first surface and located further away from the center of the hole than the first surface. The mounting member has a plurality of holes formed therein, A valve mounting structure in which the second surface formed in the hole is positioned differently for each of the multiple holes with respect to the center line of the hole.

2. The valve mounting structure according to claim 1, wherein the second surface is curved in an arc shape so that it is positioned further away from the center of the hole than the first surface.

3. The valve mounting structure according to claim 1, wherein a plurality of the second surfaces are formed in the hole at intervals around the center line of the hole.

4. In a valve mounting structure applied to a valve that adjusts the gas flow area of ​​a passage for flowing gas flowing out of the combustion chamber of an internal combustion engine into the intake system of the same engine, the mounting member is separate from the valve and covers the valve attached to the internal combustion engine and is fixed to the internal combustion engine, thereby making the valve irremovable from the internal combustion engine, The mounting member has a hole formed in it for inserting a resin projection that protrudes from the internal combustion engine when it is covered by a valve attached to the internal combustion engine. The mounting member can be fixed to the internal combustion engine by applying resin crimping to the projection inserted through the hole. A valve mounting structure comprising: a flat surface located on the circumference of the hole in the mounting member, and a projection that protrudes away from the internal combustion engine at a position adjacent to the flat surface on the circumference.

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