Intake manifold and process for making it

Details Intake manifold and process for making it Intake manifold and process for making it

1994-11-15

1996-10-01

McMahon, Marguerite

Internal-combustion engines

Intake manifold

Manifold tuning, balancing or pressure regulating means

F02M 3510, F02M 3512, F02M 3514

Patent

active

055603300

DESCRIPTION:

BRIEF SUMMARY
The invention relates to an intake manifold and a process for making it.
A thermoplastic intake manifold is known from Published German Patent Application DE-OS 38 38 921. This intake manifold is produced according to the so-called core melt-out process; i.e., a core is produced first from a tin bismuth alloy having a low melting point. This core is placed in a mold. A remaining space between the mold and the core is filled with a thermoplastic material by means of injection molding. Then, the core is melted out in a melt-out bath.
Furthermore, from Laid-open Japanese Patent Application 1-216067, a process is known for manufacturing an intake pipe from plastic material, in which case first two flange pieces are injection-molded from a thermoplastic material; then a branch pipe part is formed from a thermoplastic material by means of blowing; and the flange pieces and the pipe part are connected with one another.
A disadvantage of the known processes is the fact that several operating steps are required for producing the engine intake manifold. While, in the case of the melt-out technique, the producing and melting-out of the core requires considerable investments with respect to equipment; in the case of the manufacturing process according to Japanese Patent Document 1-216067, the separate manufacturing of the individual elements and the joining of the individual elements is not completely without problems with respect to inaccuracies of the fit.
It is an object of the invention to provide an intake manifold and a process for making it which can be carried out in a simple manner and without high tooling costs.
Based on the preambles of the successive main claims, this object is achieved by means of the characteristics of their characterizing parts.
The process according to the invention is distinguished by the fact that the individual intake pipes and the manifold connecting the intake pipes on the intake side are formed in one piece. A substantial advantage of the invention is the fact that the intake manifold may be produced in a single process step and transition points or seams between the intake pipes and the manifold do not exist. Thus, a shaped intake manifold is produced which has very advantageous flow characteristics.
In accordance with a further development of the invention, it is envisioned to simultaneously mold a shunt resonator onto the intake manifold. Such a shunt resonator serves to reduce the sound radiation and comprises a hollow space which is connected by means of a small opening with the manifold. Such a shunt resonator may advantageously be integrated in the space between two intake pipes. Thus, this space can be utilized in an advantageous manner, while the outer dimensions of the intake manifold remain unchanged.
In accordance with a further development of the invention, the intake manifold is fastened directly to an air filter housing. A simple fastening method is to provide plug-type connections, for example, in the form of flange pieces which are arranged on the intake manifold and engage in recesses in the filter housing.
It is also possible to provide a shunt resonator in the air filter housing. By way of an opening, this shunt resonator may be connected with the manifold or with the clean-air space of the air filter housing. The important thing for a shunt resonator is that it is arranged close to the noise source. This is assured by connecting the shunt resonator on the clean-air side.
In accordance with a further embodiment of the invention, a so-called resonator can be arranged in the manifold. This is a short pipe piece which causes a cancellation of sound waves of a defined frequency. The length of the pipe piece is determined by the sound waves and amounts to lambda/4.
In order to connect the intake pipes to the engine block, connecting flanges may advantageously be provided which are connected with the intake pipes by way of a plug-type or a welded connection. The connection between the clean-air outlet of the air filter and the intake of the manifold is suitable for

REFERENCES:
patent: 3990414 (1976-11-01), Malphettes
patent: 3990415 (1976-11-01), Malphettes
patent: 4538556 (1985-09-01), Takeda
patent: 4543918 (1985-10-01), Ma
patent: 4546733 (1985-10-01), Fukami et al.
patent: 5243933 (1993-09-01), Mukawa
patent: 5377629 (1995-01-01), Brackett et al.

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