DE19915819B4 - Intake system for an internal combustion engine - Google Patents

Abstract

Intake system for an internal combustion engine with an air distributor (2), which is connectable to an air supply of the internal combustion engine, with a plurality of suction pipes (6) which are each connected at its one pipe end (7) to the air distributor (2) and each of a combustion chamber of Are associated with internal combustion engine, and with at least one flange (9) to which at least one of the suction pipes (6) is connected at its other pipe end (8),
characterized,
the flange (9) is arranged adjacent to the air distributor (2),
the air distributor (2) consists of an upper part (3) and a lower part (4),
the lower part (4) of the air distributor (2) is formed as a separate component which is connected by a connection (14) along its edge to the upper part (3) of the air distributor (2),
in that at least one holding web (12) fixedly connected thereto is formed on the flange (9), which protrudes into the connection (14) of upper part (3) and lower part (4) and is anchored therein.

Description

The invention relates to a suction system with the features of the preamble of claim 1 and a method for producing such a suction system.

An intake system is usually made of plastic and used in an internal combustion engine to distribute the provided for combustion in the internal combustion engine and supplied via an air supply air to individual combustion chambers of the internal combustion engine. For this purpose, a generic suction system, as for example from the US 5 887 560 A is known, an air distributor, which is connected to said air supply of the internal combustion engine and in which collects the supplied air or distributed to individual suction pipes. These intake pipes open at one end into the air distributor and at the other end to the respective associated combustion chamber of the internal combustion engine. For the connection of the suction pipes to the combustion chamber or to an engine block of the internal combustion engine, a flange is provided, which is connected to the respective suction pipes.

Such an intake system is exposed during operation of the internal combustion engine due to high pressures and pressure fluctuations high static and dynamic loads. In particular, in suction systems, the suction pipes are relatively long and in particular achieve a relatively large deflection, this can lead to the entire intake system is exposed to strong vibrations and vibrations that promote fatigue of the plastic used.

Another suction system is from the DE 196 50 806 A1 known.

The present invention is concerned with the problem of designing a suction system of the type mentioned above so that the risk of fatigue is reduced.

This problem is solved by a suction system with the features of claim 1.

The invention is based on the general idea to fix the flange connected to several suction pipes relatively rigidly on the air manifold. In other words, between the flange and the air distributor a connection with a relatively high rigidity is to be formed. By this measure, the vibration and vibration behavior of the entire intake system is considerably reduced, since relative movements between the flange and the air distributor can be prevented by the proposed attachment. The life of the suction system can be increased in this way. The inventive measure to use a flange fixedly mounted retaining web for fastening the flange to the air manifold, that this holding web protrudes into a connection between an upper part and a lower part of the air distributor and anchored in this connection, the desired attachment of the flange on Air distributor can be achieved particularly easy. Because this holding bridge can be particularly easy to integrate in the formation of the connection between the upper part and lower part of the air distributor in this connection. As a result, no additional installation effort arises during the production of the intake system.

It is useful if the retaining web is integrally formed with the flange. The holding web thus already formed during the formation of the flange thus requires no additional manufacturing step.

According to an advantageous embodiment, the connection between the upper part and the lower part of the air distributor can be formed by a vibration or friction welding process, wherein the upper part and the lower part each have an outwardly projecting welding collar, said welding collar by the welding process on adjacent sides melt and merge together , The retaining bar is then embedded in the thus formed fusion area between the welding collar. As a result of this measure, when forming the welding collar fusion or welding collar welding, an intensive positive engagement is formed by the melt surrounding and enclosing the retaining web.

A particularly high-quality connection is achieved when the plastics from which the upper part, the lower part or their welding collar and the retaining web are made, are chosen so that the retaining web also melts through the welding process in the fusion area and merges with the welding collar. By this proposal to select compatible plastics and to weld together, a cohesive integration of the retaining web is achieved in the connection between the upper part and lower part, which allows no relative movement between the holding web and the connection. This is of particular importance because relative movements between the retaining bar and the connection, in particular in fiber-reinforced plastics due to the high-frequency vibrations show a strong abrasive effect and would quickly cause destruction of the attachment between the flange and air distributor.

According to a development, the welding collar of the upper part and lower part, at least in the region of the respective retaining web respectively have an outwardly adjoining extension, such that the connection between the air distributor and flange takes place substantially in the region of this extension. By this measure, it can be ensured that the connection between the upper part and lower part has the required high quality strength and tightness in the region of the retaining web. This extension acts as a reinforcement of the welding collar and allows a relatively deep and therefore effective anchoring of the retaining bar in the connection between the upper part and lower part.

The problem underlying the invention is also solved by a method having the features of claim 7. Due to the simultaneous formation of the attachment of the flange on the air distributor and the connection between the upper part and lower part of the air distributor of the production cost of the invention, the suction system is substantially the same size as for a suction system without attachment of the flange on the air manifold. In the intake system according to the invention, it is also possible to align the flange relative to the air distributor prior to the formation of the flange mounting, so as to compensate for any tolerances caused by shrinkage or positional deviation.

Further important features and advantages of the intake system according to the invention will become apparent from the subclaims, from the drawings and from the associated description of the figures with reference to the drawings.

It is understood that the features mentioned above and those yet to be explained not only in the particular combination given, but also in other combinations or alone, without departing from the scope of the present invention.

A preferred embodiment of the invention is illustrated in the drawing and will be explained in more detail in the following description.

The only 1 shows a schematic cross section through an intake system according to the invention.

Corresponding 1 has a modular suction system 1 in an internal combustion engine, not shown, supplied from an air supply, provided for combustion in the internal combustion engine air distributed to individual combustion chambers of the internal combustion engine, an air distribution module 2 on, which is itself modular and consists of a one-piece shell module 3 and a one-piece base module 4 consists. The air distribution modules 3 and 4 are made of plastic and each have an outwardly projecting, fully circumferential welding collar or weld collar 5 on, on which the two modules 3 and 4 , in particular by a vibration or friction welding, are interconnected.

At the top of the shell module 3 are several one-piece intake manifold modules 6 connected or connected, of which in 1 However, only one is shown, as arranged in the direction behind the cutting plane components of the intake 1 have been omitted for simplicity of illustration. The intake manifold module 6 is one end at a first pipe end 7 with the air distribution module 2 and at the other end on a second pipe end 8th with a flange module 9 connected, which is attachable to the internal combustion engine. Through the intake manifold module 6 can thus enter the air distribution module 2 introduced air into the respective associated combustion chamber of the internal combustion engine.

In the flange module 9 is a recording 10 recessed in which an injection valve 11 mountable is what is in 1 is indicated. The flange module 9 extends like the air distribution module 2 approximately perpendicular to the plane of the drawing, so that the air distribution module 2 and the flange module 9 on the one hand run approximately parallel to each other. On the other hand, the flange module extends 9 laterally next to the air distribution module 2 , By this arrangement, the intake manifold modules 6 a relatively large length and a relatively large deflection angle of about 180 °.

At the flange module 9 is at least a jetty 12 formed by the flange module 9 towards the air distribution module 2 projects. The jetty 12 is here in one piece with the flange module 9 educated. At least in the area of this retaining bar 12 are the welding collar 5 from top 3 and lower part 4 each with an adjoining extension 13 Mistake. Also these extensions 13 are like the welding collar 5 preferably in one piece with the upper part 3 or with the lower part 4 educated.

As mentioned above, the top are 3 and the lower part 4 in the area of her sweat collar 5 in particular by a friction welding process connected to each other, wherein a compound 14 is trained. The jetty 12 stands so far from the flange module 9 that he is in this connection 14 , at least in one through the extensions 13 formed area protrudes.

The production of the suction system 1 takes place as follows:
First, the intake manifold modules 6 made of plastic, which is preferably carried out by means of a blow molding process, whereby the shape of the suction modules 6 can be varied relatively easily. Each one flange module 9 associated intake manifold modules 6 then at least with their pipe ends 8th inserted in an injection mold. Thereafter, an injection molding process can take place in which the flange module 9 is made of plastic. This is the flange module 9 assigned pipe end 8th designed so that it is in the injection process on both sides, that is with respect to the intake manifold 6 inside and outside of the plastic of the flange module 9 is bordered. In addition, the wall thickness of the intake manifold module expands 6 in this pipe end 8th , so that overall a highly effective anchoring of the intake manifold 6 in the flange module 9 formed. The pipe end 8th is thus form-fitting with the flange module 9 connected. To between the intake manifold module 6 and the flange module 9 In addition, to form a high-quality solid and tight cohesive connection, special connection methods are used.

After that, the flange module 9 remote pipe ends 7 the intake manifold modules 6 with the shell 3 of the air distribution module 2 connected, including here the connection of the intake manifold 6 to the shell module 3 is designed as a plug connection. The pipe end 7 forms to it an outer neck, while the shell module 3 an inner nozzle 15 having. The connection of the nested nozzles 7 and 15 can then in a conventional manner z. B. be performed by a welded joint, shrink joint, adhesive bond or by a combination of different attachment methods.

According to the invention then to the shell module 3 the sub-module 4 set, wherein the holding webs 12 between the welding collar 5 from top 3 and lower part 4 are arranged. Preferably, for the retaining bar 12 and for the welding collar 5 or for the extensions 13 used compatible plastics, so that in a subsequently carried out friction welding, the mutually contacting surfaces of the welding collar 5 , their extensions 13 and the retaining bars 12 heated, melted and fused together. In these fusion zones, a thorough mixing of the plastics, whereby a cohesive connection is formed, through which the holding web 12 quasi one-piece with the connection 14 or with the welding collar 5 and the extensions 13 is trained.

Preferably, the retaining web 12 in the area of its embedding in the compound 14 at least one breakthrough 16 in the course of the welding process of the melt of the welding collar 5 is filled, which in addition an intensive positive engagement is formed. By the thus achieved anchoring of the retaining bar 12 in the connection 14 becomes an effective fixation of the flange module 9 at the air distribution module 2 achieves the relative movements between the flange module caused by vibrations or vibrations 9 and air distribution module 2 reduces and thus reduces the risk of fatigue, especially at high-frequency dynamic loads.

Claims (7)

Intake system for an internal combustion engine with an air distributor ( 2 ), which is connectable to an air supply of the internal combustion engine, with a plurality of suction pipes ( 6 ), each at its one pipe end ( 7 ) with the air distributor ( 2 ) are connected and each associated with a combustion chamber of the internal combustion engine, and with at least one flange ( 9 ), with which at least one of the suction tubes ( 6 ) at its other pipe end ( 8th ), characterized in that the flange ( 9 ) adjacent to the air distributor ( 2 ) is arranged, that the air distributor ( 2 ) from an upper part ( 3 ) and from a lower part ( 4 ), that the lower part ( 4 ) of the air distributor ( 2 ) is formed as a separate component, which by a compound ( 14 ) along its edge with the top ( 3 ) of the air distributor ( 2 ) is connected to the flange ( 9 ) at least one retaining web ( 12 ) formed in the connection ( 14 ) of upper part ( 3 ) and lower part ( 4 ) and anchored therein. Intake system according to claim 1, characterized in that each retaining web ( 12 ) in one piece with the flange ( 9 ) is trained. Intake system according to claim 1 or 2, characterized in that the connection ( 14 ) between upper part ( 3 ) and lower part ( 4 ) is formed by a vibration or friction welding process, wherein upper part ( 3 ) and lower part ( 4 ) each have an outwardly projecting welding collar ( 5 ), which by means of the welding process melt on mutually adjoining sides and fuse together, each retaining web ( 12 ) in the thus formed fusion area between the welding collars ( 5 ) is embedded. Intake system according to one of claims 1 to 3, characterized in that the welding collar ( 5 ) of upper part ( 3 ) and lower part ( 4 ) and each jetty ( 12 ) consist of plastics which are coordinated so that the retaining web ( 12 ) melts through the welding process in the fusion area and with the welding collar ( 5 ) merges. Intake system according to one of claims 1 to 4, characterized in that the welding collar ( 5 ) of upper part ( 3 ) and lower part ( 4 ) at least in the region of the at least one retaining web ( 12 ) an external extension ( 13 ), such that the compound ( 14 ) with the flange ( 9 ) essentially in the area of this enlargement ( 13 ) he follows. Intake system according to one of Claims 1 to 5, characterized in that the intake system ( 1 ) has a modular construction, comprising an air distribution module ( 2 ), which consists of a one-piece shell module ( 3 ) made of plastic and a sub-module ( 4 ) consists of plastic, several, each one-piece intake manifold modules ( 6 ) made of plastic, and at least one one-piece flange module ( 9 ) made of plastic. Method for producing an intake system ( 1 ) according to one of claims 1 to 6, comprising the following steps: A: producing the suction tubes ( 6 ), B: Inserting the suction tubes ( 6 ) in an injection mold, C: molding of the flange ( 9 ), wherein at least one retaining web ( 12 ) is formed, D: placing the lower part ( 4 ) on the top ( 3 ), wherein the at least one retaining web ( 12 ) between welding collar ( 5 ) of upper part 3 and lower part ( 4 F) carrying out a welding process for melting and fusing the plastics of the welding collar ( 5 ) and the at least one retaining web ( 12 ).

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