Internal-combustion engines – Intake manifold – For engine having radiating cylinders
Reexamination Certificate
1999-09-15
2001-05-22
Kamen, Noah P. (Department: 3747)
Internal-combustion engines
Intake manifold
For engine having radiating cylinders
C123S184550, C123S184610
Reexamination Certificate
active
06234132
ABSTRACT:
BACKGROUND OF THE INVENTION
The invention relates to an intake system made of thermoplastic synthetic resin material, especially for the air intake of an internal combustion engine.
It can be learned from the press release of Bayer AG of Nov. 3, 1993 that a simple method for the manufacture of air intake connections for passenger cars consists in making half-shells by the injection molding process. Two of these moldings are encased in plastic at the lines of contact in a second injection molding process such that a shape-conforming and air tight junction is produced. This method is said to have the advantage that parts having smooth surfaces are the result. The method has meantime been further developed and can be used in the meantime in a great number of intake tubes and intake systems. The friction welding process has also proven practical in addition to encasing.
In EP 5933 B1 an air intake tube is disclosed which likewise consists of two half shells. These are welded or cemented together. A disadvantage of this half-shell technique is that very complex tube geometries considerably complicate the joining of the half shells. Particularly where tubes cross over one another or intertwine with one another, joining them by encasing or friction welding is no longer possible. In these cases the technique of lost wax casting is used, which involves greater cost.
SUMMARY OF THE INVENTION
It is therefore the object of the invention to provide an air intake device made of thermoplastic synthetic resin material which, despite complicated shapes, can be manufactured by the half-shell technique. This object is achieved by the invention as described and claimed hereinafter.
An important advantage of the invention is that, first a first element is produced which has a substantially closed shape wherein the cavity is formed by the use of core elements. The first element is simultaneously the lower half shell of the air intake tube, so that a second element, which also is made by injection molding from a thermoplastic synthetic resin material, only forms the cover and the upper half shell of the air intake tube. The joining of the two elements is performed in an advantageous embodiment of the invention by friction welding. The cavity in the first element can be used as an air collector or air collecting chamber. But according to another embodiment of the invention it can be so configured that an additional, insertable element can be incorporated which serves to vary the intake tube length or intake tube openings into the air collecting chamber.
An advantageous embodiment of the invention provides for arranging additional switching elements, i.e., for coupling or uncoupling to the air intake tubes by a swinging or turning movement. It is thus possible to adjust the optimum air intake length according to the engine speed and load.
In an additional embodiment of the invention an air filter or additional air guiding devices are provided in the air collecting chamber.
These and additional features of preferred embodiments of the invention will be found not only in the claims but also in the description and the drawings, and the individual features can each be realized individually or together in the form of subcombinations in the embodiment of the invention and in other fields, and can constitute advantageous as well as independently patentable embodiments, for which protection is hereby claimed.
REFERENCES:
patent: 4440120 (1984-04-01), Butler
patent: 5542711 (1996-08-01), Vaudry
patent: 5657727 (1997-08-01), Uchida
patent: 4102453 (1992-07-01), None
patent: 4403219 (1995-08-01), None
patent: 201 180 (1986-11-01), None
patent: 664 390 (1995-07-01), None
Ponticel: “Vibration-Welded intake Manifolds” Manufacturing Solutions Apr. 1997.
Ernst Volker
Kopec Edvard
Leipelt Rudolf
Wachsmann Klaus
Evenson, McKeown, Edwards & Lenahan P.L.L.C.
Filterwerk Mann & Hummel GmbH
Kamen Noah P.
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