Plastic and nonmetallic article shaping or treating: processes – Mechanical shaping or molding to form or reform shaped article – To produce composite – plural part or multilayered article
Patent
1998-03-03
2000-09-12
Kamen, Noah P.
Plastic and nonmetallic article shaping or treating: processes
Mechanical shaping or molding to form or reform shaped article
To produce composite, plural part or multilayered article
264255, 264261, 264263, 12318461, B29C 4514, F02M 3510
Patent
active
061173800
DESCRIPTION:
BRIEF SUMMARY
TECHNICAL FIELD
The present invention relates to a method and apparatus for manufacturing a synthetic resin-made tubular member having differently oriented inlet and outlet tube portions, and to a synthetic resin-made intake manifold for an internal combustion engine.
BACKGROUND ART
As is well known, an intake manifold is connected to a cylinder head of an internal combustion engine (engine) for feeding intake air into combustion chambers of individual cylinders. The intake manifold is a considerably large-size component of the air-intake system, so for purposes of reducing the weight of the peripheral arrangement of the engine, the intake manifold is formed of synthetic resin instead of conventional light alloy (e.g., aluminum alloy and the like).
Since the intake manifold is an air-intake system component is exposed to lower temperature conditions than any air other-exhaust system component, it is feasible to form the intake manifold of synthetic resin (in particular, a synthetic resin of the type reinforced with fibers or the like). It is to be understood that the intake manifold is usually constructed in the form of a tubular member having plural outlet tube portions (equal in number to corresponding cylinders) branched from one inlet tube portion.
In the prior art, when manufacturing such an intake manifold from synthetic resin, separate halves in a pair, previously formed from synthetic resin, are brought in abutment against each other, and then joined together by applying an adhesive to their abutting surface or by thermally melting the abutting portions.
However, the intake manifold is subject to some degree of thermal effect and successive vibrations from the engine and the like, though temperature conditions are relatively low as compared with those in the exhaust system. Therefore, in order to stably ensure the reliability of the intake manifold for long-time use, it is necessary to use good care in the process of molding, with respect to various quality aspects, such as strength, rigidity, and sealing performance.
When aforesaid use conditions are considered, such prior art method as mentioned above can hardly be said to be sufficient to stably ensure high strength of bond between the separate halves and the sealing characteristics of the butt-joined portion. Further, for purposes of manufacturing a mass-production item such as intake manifold for mass-production automotive engines, a need exists for a method that can assure higher production efficiency.
As a method for molding a hollow tubular item, such as a synthetic resin-made pipe, it is known to bring synthetic resin-made halves into abutment against each other and fill a melted resin mass into an interior passage formed along peripheral edge of the abutting portions to thereby join the halves together to obtain a hollow molded product. It is also known to carry out such melted resin loading into the interior passage, within a molding die in which separate halves are molded when the separate halves are joined together as mentioned before.
By employing such a method, it is possible to more stably ensure high strength of bond between the so joined halves and good sealing performance of the buttjoined portion as compared to the prior art practice in which such joining is carried out by adhesion or thermal melting.
For example, in Japanese Patent Publication No. 2 -38377, there is disclosed a die construction including one pair of dies one of the dies has a male molding portion and a female molding portion for molding one separate half set and the other die has a female molding portion and a male molding portion provided in opposed relation to the molding portions of the one die. In this conjunction, there is also disclosed a method (called "die slide injection (DSI) method") where after separate halves are simultaneously molded (injection molded) by using such a pair of dies, one of the dies is caused to slide relative to the other die so that separate halves left in respective female molding portions are brought into abutment with each
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Okada Daimon
Shimonishi Akira
Shirai Junichiro
Takashina Ryuji
Daikyo Co., Ltd.
Huynh Hai
Kamen Noah P.
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