JPH06257525A - Manufacture of synthetic resin manifold - Google Patents

Abstract

(57) [Summary] [Object] To provide a method for producing a synthetic resin manifold which has no obstacles on the inner surface of the hollow portion of the manifold and can be easily produced. An internal molded body 1 having a predetermined shape of a hollow portion of a manifold is integrally molded by blow molding or the like to form a plurality of external molded body elements 3 and 5 having a predetermined shape outside the manifold. The external molding elements 3, 5 are integrated with the molding 1 by gluing or welding. This allows
It is possible to manufacture the manifold 9 having no obstacle on the inner surface of the hollow portion, and in the work of integrating the two, it is lightweight and easy to handle, and since injection molding is not necessary, it is possible to easily manufacture without requiring reinforcement.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of manufacturing a synthetic resin manifold used for an intake manifold for an automobile, and more particularly, to easily manufacture a manifold having no obstacle on the inner surface of the hollow portion. Regarding things.

[0002]

2. Description of the Related Art A synthetic resin manifold used for an automobile intake manifold or the like has a complicated shape in which a gas suction portion, a cylinder head joint portion, and a branch pipe connecting both portions are integrated. is there. Various methods have been proposed as the manufacturing method. First,
In the first method, as shown in FIG. 15, a core 101 having the shape of a hollow portion of a manifold is formed of a low melting point alloy,
A synthetic resin manifold 103 is formed on this outer periphery by injection molding, and then the low melting point alloy core 1 is formed.
01 is melted out to obtain a manifold having a desired shape.

The second method is as shown in FIG.
Internal molded body 105 having a predetermined shape of the hollow portion of the manifold
Is integrally molded by blow molding, and sand, water, etc. 1
07 is filled and reinforced, and thereafter, the outer molded body 109 is integrated with the outer periphery by injection molding to obtain a manifold having a desired shape. In the third method, as shown in FIG. 17, an internal molded body 111 having a predetermined shape in the hollow portion of the manifold is integrally molded by blow molding, and then an outer molded body 113 is integrally molded on the outer periphery thereof by reaction injection molding. To obtain a manifold having a desired shape.

The fourth method is as shown in FIG.
The molded element 115, 117 having a predetermined shape of the manifold and divided into a plurality of parts is joined by adhesion or welding to obtain a manifold having a desired shape. The fifth method, as shown in FIGS. 19 and 20, is to form an internal molded body element 119 obtained by dividing an internal molded body having a predetermined shape of the manifold hollow portion into a plurality of parts, and combining these to form an internal structure. The outer molded body 123 is integrated with the outer peripheral body 121 by injection molding to obtain a manifold having a desired shape.

[0005]

The above-mentioned conventional structure has the following problems. First, in the case of the first method, there is a problem that the low melting point alloy core 101 is heavy and difficult to handle, and the work of melting the low melting point alloy core 101 is troublesome. Further, in the case of the second to third methods, pressure is applied during injection molding and the internal molded body is deformed, so that there is a problem that special measures such as reinforcement are required. In addition, in the case of the fourth to fifth methods, there is no problem of the injection molding as described above, but there is a problem that the joint surface such as adhesion has irregularities and the hollow inner surface of the manifold has an obstacle. .

The present invention has been made on the basis of the above points, and an object thereof is to provide a method for manufacturing a synthetic resin manifold which has no obstacles on the inner surface of the hollow portion of the manifold and can be easily manufactured. To do.

[0007]

In order to achieve the above object, a method of manufacturing a synthetic resin manifold according to the present invention comprises:
An internal molded body having a predetermined shape of the manifold hollow portion is integrally molded by blow molding or the like, and a plurality of external molded body elements having a predetermined shape outside the manifold are formed,
It is characterized in that the outer molded body element is integrated with the inner molded body by adhesion or welding.

[0008]

First, an internal molded body having a predetermined shape of the hollow portion of the manifold is integrally molded by blow molding or the like. Further, an external molded body element having a predetermined shape outside the manifold and divided into a plurality of parts is molded. These are all made of synthetic resin and are manufactured by blow molding or injection molding. Then, the outer molded body element is integrated with the inner molded body by adhesion or welding. This makes it possible to manufacture a manifold with no obstacles on the inner surface of the hollow part,
In the work of integrating the two, it is lightweight and easy to handle, and injection molding is not necessary, so that it can be easily manufactured without the need for reinforcement or the like.

[0009]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The first embodiment of the present invention will be described below with reference to FIGS.
An example will be described. 1 to 3 show process parts of a manifold, and FIG. 4 shows a cross section of a branch pipe of the manifold. First, the internal molded body 1 having a predetermined shape of the manifold hollow portion shown in FIG. 1 is molded.
This is integrally molded by blow molding. That is, a space having the inner surface of the manifold hollow is formed between the upper mold and the lower mold, and the parison is sandwiched between the upper mold and the lower mold to inject air or the like. As a result, the parison is formed into a thin film along the shape of the space.

Further, as shown in FIG. 2, an external molded body element 3 having a predetermined shape outside the manifold and divided into a plurality of parts,
5 is molded. This is molded separately by injection molding. In this embodiment, the external molded body elements 3 and 5 are divided into two along the flow direction of the manifold. The outer surface is formed into a predetermined shape of the outer surface of the manifold, and the inner surface is formed into the same shape as the outer surface of the inner molded body 1 and serves as a bonding portion with the inner molded body 1.

Next, as shown in FIG.
Adhesive 7 is applied to the outer surface of the outer molded body, and the outer molded body elements 3, 5 are covered and pressed from above and below. As a result, the inner molded body 1 and the outer molded body elements 3 and 5 are integrated, and
A manifold 9 having a predetermined shape as shown in is completed.

According to this embodiment, the following effects can be obtained. First, it is possible to manufacture the manifold 9 having no obstacle on the inner surface of the hollow portion. This is because the inner molded body 1 is integrally molded by blow molding, and it is possible to obtain the one that satisfies the ventilation performance required for the manifold 9. Further, since the inner molded body 1 and the outer molded body elements 3 and 5 are integrated by adhesion, the inner molded body 1
Since it is lightweight and easy to handle, and injection molding is not necessary, the reinforcement 11 as shown by the chain double-dashed line in FIG. 4 is not necessary and can be easily manufactured. Incidentally, the outer surface of the manifold 9 is exposed at the bonding portion by bonding the outer molded body elements 3 and 5, but this does not affect the performance of the manifold 9.

Next, a second embodiment will be described with reference to FIG. In the case of this embodiment, the groove portion 17 is formed on the inner surface of the outer molded body elements 13 and 15. This is an escape space for the adhesive, and grooves or depressions are formed at intervals. Therefore, also in the case of this embodiment, it is possible to manufacture a manifold having no obstacle on the inner surface of the hollow portion, the inner molded body is one lightweight and easy to handle, and injection molding is not necessary, so that it is possible to easily manufacture without requiring reinforcement or the like. . or,
Since the groove portion 17 is formed, the adhesive strength can be increased by allowing excess adhesive to escape into the groove portion 17.

Next, a third embodiment will be described with reference to FIG. In the case of the second embodiment described above, the groove portion is formed on the inner surface of the outer molded body element, but in the case of this embodiment, the groove portion 23 is formed on the joint surface of the outer molded body elements 19 and 21. In the case of this embodiment as well, the same operational effects as those of the above embodiment can be obtained.

Next, a fourth embodiment will be described with reference to FIG. In the case of this embodiment, the outer molded body elements 25 and 27 are molded with a gap left between them with respect to the inner molded body 1, and the pressing molds 29 and 31 are used to form the outer molded body into the inner molded body 1. The elements 25 and 27 are brought into close contact with each other and the adhesive 29 is injected into the gap at an extremely low pressure by an injection device. In the case of this embodiment as well, the same operational effects as those of the above embodiment can be obtained. Further, since the injection pressure of the adhesive 29 can be made extremely low, the internal molded body 1 can be integrated without being deformed.

Next, a fifth embodiment will be described with reference to FIG. In the case of this embodiment, high frequency vibration welding is used instead of adhesion. That is, the outer molded body elements 35 and 37 are brought into close contact with the inner molded body 1 by utilizing the vibrators 31 and 33, and high frequency vibration is applied to weld and join the joint surfaces of the outer molded body elements 35 and 37. Is. In the case of this embodiment as well, the same operational effects as those of the above embodiment can be obtained.

Next, a sixth embodiment will be described with reference to FIG. In the case of this embodiment, the joint surface of the external molded body elements is welded in the fifth embodiment, whereas the inner surface of the external molded body element is used as the welded portion, and the external molded body element 39 is used. , 41 are formed on the inner surface of the inner surface of the outer surface of the inner surface of the outer molded body element 41 to form a plurality of convex portions 43. The joining surfaces of the convex portions 43 and the internal compact 1 are welded and integrated. In the case of this embodiment as well, the same operational effects as those of the above embodiment can be obtained.

Next, a seventh embodiment will be described with reference to FIGS. In the case of this embodiment, a synthetic resin containing conductive whiskers and an ordinary synthetic resin not containing conductive whiskers are used for welding. That is, conductive whiskers are mixed in the inner molded body 45 to mold the inner molded body 45. A synthetic resin material mixed with conductive whiskers has a property of being heated when irradiated with a high frequency. On the other hand, the external molded body element 4
Reference numerals 7 and 49 are made of ordinary synthetic resin, and the outer molded body elements 47 and 49 are brought into close contact with the inner molded body 45 by using a pressing die and a high frequency is irradiated. Then, the internal molded body 45
Are heated, and the outer molded body elements 47 and 49 are welded and integrated at room temperature.

FIG. 11 shows a modification of the above embodiment,
A conductive whisker is mixed into one of the two outer molded body elements 51 divided into two parts, and the other outer molded body element 53 is made of synthetic resin, and is welded at the joint surface of the outer molded body elements 51, 53. , FIG. 12 likewise shows the external molded element 5
The electrically conductive whiskers are mixed in 5, 57 and the inner surface of the electrically conductive whiskers is welded to the inner molded body 1. According to this embodiment, the same operational effect as the above embodiment can be obtained.

Next, an eighth embodiment will be described with reference to FIGS. 13 to 14. In the case of this embodiment, a hot plate welding means is used to heat and weld the joint surface of the external molded body element. First, as shown in FIG. 13, the external molded body element 5
9 and 61 are sandwiched between heating plates 63, and after reaching a predetermined temperature, they are separated. Next, the outer molded body elements 59, 6 are added to the inner molded body 1.
1 is brought into close contact, and the joint surfaces are welded and integrated. In the case of this embodiment as well, the same operational effects as those of the above embodiment can be obtained.

The present invention is not limited to the above embodiments. For example, in this embodiment, the external molded body elements 3 and 5 are divided into two along the flow direction of the manifold, but how many divisions are made is arbitrary, and the division method is also arbitrary. Further, although the inner molded body 1 is molded by blow molding, it may be molded by a method such as vacuum molding. Further, the inner compact 1 does not have to be in the form of a film and may be thick.

[0022]

As described in detail above, according to the method for manufacturing a synthetic resin manifold according to the present invention, a manifold having no obstacles on the inner surface of the hollow portion can be manufactured, and the internal molded body is lightweight and easy to handle. Since molding is not required, it can be easily manufactured without the need for reinforcement.

[Brief description of drawings]

FIG. 1 is a perspective view showing an internal compact according to a first embodiment of the present invention.

FIG. 2 is a view showing the first embodiment of the present invention and is a perspective view showing an arrangement of an inner molded body and an outer molded body element.

FIG. 3 is a perspective view showing a first embodiment of the present invention in which an inner molded body and an outer molded body element are integrated with each other.

FIG. 4 is a sectional view showing a first embodiment of the present invention and showing a state in which an inner molded body and an outer molded body element are integrated.

FIG. 5 is a sectional view showing a second embodiment of the present invention, showing a state in which an inner molded body and an outer molded body element are integrated.

FIG. 6 is a cross-sectional view showing a third embodiment of the present invention in a state in which an inner molded body and an outer molded body element are integrated.

FIG. 7 is a cross-sectional view showing a fourth embodiment of the present invention, showing a state in which an inner molded body and an outer molded body element are integrated.

FIG. 8 is a sectional view showing a fifth embodiment of the present invention and showing a state in which an inner molded body and an outer molded body element are integrated.

FIG. 9 is a cross-sectional view showing a sixth embodiment of the present invention, showing a state in which an inner molded body and an outer molded body element are integrated.

FIG. 10 is a cross-sectional view showing a seventh embodiment of the present invention, showing a state in which an inner molded body and an outer molded body element are integrated.

FIG. 11 is a view showing a seventh embodiment of the present invention and is a cross-sectional view showing a state where another internal molded body and an external molded body element are integrated.

FIG. 12 is a cross-sectional view showing a seventh embodiment of the present invention in a state where another internal molded body and an external molded body element are integrated.

FIG. 13 is a sectional view showing the eighth embodiment of the present invention in a state where the external molded body element is sandwiched between heating plates.

FIG. 14 is a view showing an eighth embodiment of the present invention and is a cross-sectional view showing a state where an inner molded body and an outer molded body element are integrated.

FIG. 15 is a cross-sectional view showing a method for forming a manifold in a conventional example.

FIG. 16 is a cross-sectional view showing a method for forming a manifold in a conventional example.

FIG. 17 is a cross-sectional view showing a method for forming a manifold in a conventional example.

FIG. 18 is a cross-sectional view showing a method for forming a manifold in a conventional example.

FIG. 19 is a view showing a conventional example and is an exploded cross-sectional view of an internal molded body.

FIG. 20 is a cross-sectional view showing a state in which an outer molded body is covered around the inner molded body in a view showing a conventional example.

[Explanation of symbols]

 1 Internal molded body 3 External molded body element 5 External molded body element 7 Adhesive 9 Manifold

─────────────────────────────────────────────────── ───

[Procedure amendment]

[Submission date] February 25, 1994

[Procedure Amendment 1]

[Document name to be amended] Statement

[Name of item to be corrected] Claim 1

[Correction method] Change

[Correction content]

[Procedure Amendment 2]

[Document name to be amended] Statement

[Correction target item name] 0007

[Correction method] Change

[Correction content]

[0007]

In order to achieve the above object, a method of manufacturing a synthetic resin manifold according to the present invention comprises:
An internal molded body having a predetermined shape of the manifold hollow portion is integrally molded by blow molding or the like, and a plurality of external molded body elements having a predetermined shape outside the manifold are formed,
It is characterized in that the inner molded body and the outer molded body element are integrated by adhesion or welding.

[Procedure 3]

[Document name to be amended] Statement

[Correction target item name] 0008

[Correction method] Change

[Correction content]

[0008]

First, an internal molded body having a predetermined shape of the hollow portion of the manifold is integrally molded by blow molding or the like. Further, an external molded body element having a predetermined shape outside the manifold and divided into a plurality of parts is molded. These are all made of synthetic resin and are manufactured by blow molding or injection molding. Then, the inner molded body and the outer molded body element are integrated by adhesion or welding. This makes it possible to manufacture a manifold with no obstacles on the inner surface of the hollow part, and in the work of integrating the two, it is lightweight and easy to handle, and injection molding is not required, so reinforcement is not necessary and it can be easily manufactured. is there.

[Procedure amendment 4]

[Document name to be amended] Statement

[Correction target item name] 0013

[Correction method] Change

[Correction content]

Next, a second embodiment will be described with reference to FIG. In the case of this embodiment, the groove portion 17 is formed on the inner surface of the outer molded body elements 13 and 15. This is an escape space for the adhesive, and grooves or depressions are formed at intervals. Therefore, also in the case of this embodiment, it is possible to manufacture a manifold having no obstacles on the inner surface of the hollow portion, the inner molded body 1 is lightweight and easy to handle, and injection molding is not necessary, so that reinforcement is not necessary. . or,
Since the groove portion 17 is formed, the adhesive strength can be increased by allowing excess adhesive to escape into the groove portion 17.

Claims (1)

[Claims] 1. An internal molded body having a predetermined shape in a hollow portion of a manifold is integrally molded by blow molding or the like, and a plurality of external molded body elements having a predetermined shape outside the manifold are molded to form the internal molded body. A method for manufacturing a synthetic resin manifold, characterized in that an external molded body element is integrated with the same by adhesion or welding.