U.S. patent application number 14/406157 was filed with the patent office on 2015-06-04 for exhaust system component.
The applicant listed for this patent is FUTABA INDUSTRIAL CO., LTD. Invention is credited to Yuta Shimizu, Shinnosuke Toichi, Munehiro Tsubosaka.
Application Number | 20150152770 14/406157 |
Document ID | / |
Family ID | 49711957 |
Filed Date | 2015-06-04 |
United States Patent
Application |
20150152770 |
Kind Code |
A1 |
Toichi; Shinnosuke ; et
al. |
June 4, 2015 |
EXHAUST SYSTEM COMPONENT
Abstract
An exhaust system component includes a plurality of branch pipe
parts, a collecting pipe part, a first shell member, a second shell
member, and a supporting part. The supporting part is formed
integrally with one of the first shell member and the second shell
member, such that a region surrounded by peripheries of the
plurality of branch pipe parts and the collecting pipe part, and a
part of a periphery of the supporting part is open to form an
opening portion.
Inventors: |
Toichi; Shinnosuke;
(Okazaki-shi, JP) ; Shimizu; Yuta; (Okazaki-shi,
JP) ; Tsubosaka; Munehiro; (Okazaki-shi, JP) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
FUTABA INDUSTRIAL CO., LTD |
Okazaki-shi, Aichi |
|
JP |
|
|
Family ID: |
49711957 |
Appl. No.: |
14/406157 |
Filed: |
May 31, 2013 |
PCT Filed: |
May 31, 2013 |
PCT NO: |
PCT/JP2013/065239 |
371 Date: |
December 5, 2014 |
Current U.S.
Class: |
60/323 |
Current CPC
Class: |
F01N 13/1877 20130101;
F01N 13/1888 20130101; F01N 2260/10 20130101; F01N 13/1805
20130101; F01N 13/10 20130101 |
International
Class: |
F01N 13/10 20060101
F01N013/10 |
Foreign Application Data
Date |
Code |
Application Number |
Jun 6, 2012 |
JP |
2012-128945 |
Claims
1. An exhaust system component that as a whole constitutes a flow
path for guiding exhaust gas from an internal combustion engine
having a plurality of cylinders, the exhaust system component
comprising: a plurality of branch pipe parts that constitute
respectively a plurality of flow paths for guiding the exhaust gas
from the internal combustion engine; a collecting pipe part that
collects the plurality of branch pipe parts to guide exhaust gas
from the plurality of branch pipe parts, to the air or to a
different exhaust system component that is different from the
exhaust system component and that is located at a downstream side;
a first shell member that integrally constitutes a part of an outer
shell forming, in each of the plurality of branch pipe parts, a
flow path from the internal combustion engine to the collecting
pipe part, and a part of an outer shell forming, in the collecting
pipe part, a flow path from each of the plurality of branch pipe
parts to the air or to the different exhaust system component that
is different from the exhaust system component and that is located
at the downstream side; a second shell member that constitutes a
part of the outer shell forming, in each of the plurality of branch
pipe parts, the flow path from the internal combustion engine to
the collecting pipe part, and a part of the outer shell forming, in
the collecting pipe part, the flow path from each of the plurality
of branch pipe parts to the air or to the different exhaust system
component that is different from the exhaust system component and
that is located at the downstream side, the second shell member
being formed separately from the first shell member, and the second
shell member having a concave portion that forms flow paths in the
plurality of branch pipe parts and a flow path in the collecting
pipe part when the second shell member is joined to the first shell
member; and a supporting part that connects two branch pipe parts
adjacent to each other among the plurality of branch pipe parts,
wherein the supporting part is integrally formed with one of the
first shell member and the second shell member, such that a region
surrounded by peripheries of the two branch pipe parts and the
collecting pipe part and by a part of a periphery of the supporting
part is open to form an opening portion.
2. The exhaust system component according to claim 1, further
comprising at least one of: a plurality of the first shell members;
and a plurality of the second shell members.
3. The exhaust system component according to claim 1. wherein each
of the plurality of branch pipe parts is bent in a same direction
and formed in a tubular shape, wherein the exhaust system component
includes a flange part in a plate-like shape to be connected to the
internal combustion engine, the flange part having: a plurality of
connection holes that respectively connects the plurality of branch
pipe parts respectively to a plurality of exhaust ports of the
internal combustion engine; and at least one insertion hole, into
which a fastening component is inserted to a position away from the
connection holes along a direction of the bending of each of the
plurality of branch pipe parts, wherein the supporting part is
formed such that the opening of the opening portion is formed along
the direction of the bending of the plurality of branch pipe parts
connected to the flange part, and the supporting part is formed at
a position where the opening of the opening portion encloses a
region around an axis as a center, the axis orthogonal to an outer
surface of the flange part and extending from a center of the
insertion hole.
4. The exhaust system component according to claim 1, wherein the
exhaust system component is an exhaust manifold.
5. The exhaust system component according to claim 1, wherein the
exhaust system component is a merging member that merges a
plurality of exhaust pipes into one exhaust pipe.
6. The exhaust system component according to claim 1, wherein the
opening portion is formed such that the opening of the opening
portion includes a region enabling a tool for fastening a fastening
component to pass therethrough.
7. The exhaust system component according to claim 1, wherein the
supporting part is a section formed in a plate-like shape.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This international application claims the benefit of
Japanese Patent Application No. 2012-128945 filed Jun. 6, 2012 in
the Japan Patent Office, the entire disclosure of Japanese Patent
Application No. 2012-128945 is incorporated herein by
reference.
TECHNICAL FIELD
[0002] The present invention relates to an exhaust system component
that constitutes a flow path for exhaust gas from an internal
combustion engine.
BACKGROUND ART
[0003] Conventionally, an exhaust manifold, various pipes, a
catalytic converter, a muffler, etc. have been known as a component
(hereinafter, referred to as exhaust system component) that
constitutes an exhaust system forming a flow path for an exhaust
gas from an internal combustion engine of a vehicle.
[0004] Among exhaust manifolds, a known exhaust manifold is
provided with: a flange part including a plurality of passage
holes, through which exhaust gases respectively from a plurality of
exhaust ports of an internal combustion engine with multiple
cylinders pass; and a main body, through which the exhaust gases
that have flown via each of the passage holes of the flange part
from each of the exhaust ports of the internal combustion engine
pass (see, Patent Document 1). The main body described in Patent
Document 1 includes a plurality of branch pipe parts, each of which
is bent in the same direction to be formed in a tubular shape and
which are to be respectively connected to the exhaust ports, and
includes a collecting pipe part having a shape that is configured
to collect the branch pipe parts to form one flow path; the main
body as a whole is formed to be a manifold.
[0005] Specifically, the main body described in Patent Document 1
is configured with plate-like members forming an outer shell of the
main body, and includes recesses (concave portions). In the main
body, the branch pipe parts and the collecting pipe part are formed
by joining peripheries of the multiple outer shell members, and a
space surrounded by the concave portions serves as a flow path for
exhaust gas.
[0006] Here, respective ends of the branch pipe parts are joined
(for example, welded) to peripheries of the passage holes of the
flange part so as to secure the exhaust manifold to the internal
combustion engine. Generally, the securing to the internal
combustion engine is performed by inserting fastening components,
such as bolts, into the insertion holes provided in the flange part
and fastening the fastening components. For this reason, it is
desired that the work through the exhaust manifold can be easily
done.
[0007] Due to high-temperature exhaust gas from each of the exhaust
ports of the internal combustion engine, passing of the exhaust gas
through the branch pipe parts and the collecting pipe part causes
an increase in a temperature of the outer shell members
constituting the main body.
[0008] Consequently, thermal stress is generated in the exhaust
manifold, particularly, in a section where the plurality of branch
pipe parts are merged in the collecting pipe part of the main body
(hereinafter, referred to as merging part), requiring inhibition of
generation of deformation due to the aforementioned thermal stress
in the merging part.
[0009] As an exhaust manifold that achieves the aforementioned
inhibition of deformation, there is an exhaust manifold that is
provided with a plurality of branch pipe parts, one collecting pipe
part, and a portion (hereinafter, referred to as skirt portion)
formed in a plate-like shape and connecting adjacent ones of the
branch pipe parts to each other, and that is formed to be a
manifold as a whole (see, Patent Document 2). Moreover, in order to
attain workability in securing the exhaust manifold to an internal
combustion engine, the skirt portion of the main body described in
Patent Document 2 is provided with light-weight holes, which are
coaxial with insertion holes.
[0010] Here, the main body described in Patent Document 2 is formed
in the following manner: one piece of a plate member is pressed to
form two portions on the one piece of the plate member, the one
portion (hereinafter, referred to as half-split portion)
corresponding to a plurality of branch pipe parts, one collecting
part, and one outer shell member having at least a skirt portion;
and thereafter, the half-split portions are bent so as to face and
abut each other.
PRIOR ART DOCUMENTS
Patent Documents
[0011] Patent Document 1: Japanese Unexamined Patent Application
Publication No. 2009-257247
[0012] Patent Document 2: Japanese Unexamined Patent Application
Publication No. 6-221148
SUMMARY OF THE INVENTION
Problems to be Solved by the Invention
[0013] In the main body described in Patent Document 2, a joining
process, such as welding, is performed after the bending.
[0014] The joining process to the main body described in Patent
Document 2 involves the following problem: since it is necessary to
join peripheries of the light-weight holes in the skirt portion to
each other, in addition to join peripheries of members of the
branch pipe parts to each other and peripheries of members of the
collecting pipe part, requiring many operations in the joining
process.
[0015] That is to say, in a conventional art, an exhaust system
component that includes a plurality of branch pipe parts and one
collecting pipe part and that is configured by joining at least two
outer shell members to each other to thereby form at least the
branch pipe parts and the collecting pipe part involves the
following problem: it is not possible to reduce the operations in
the joining process while ensuring ease of operation performed via
the exhaust system component and inhibiting concentration of stress
at a section where the plurality of branch pipe parts are
merged.
[0016] In view of the above, in one aspect of the present
invention, it is desired, in an exhaust system component, to reduce
operations for the joining process, and also to ensure ease of
operation performed via the exhaust system component and to inhibit
concentration of stress at the section where the plurality of
branch pipe parts are merged.
Means for Solving the Problems
[0017] One aspect of the present invention relates to an exhaust
system component that as a whole constitutes a flow path for
guiding exhaust gas from an internal combustion engine having a
plurality of cylinders.
[0018] The exhaust system component in one aspect of the present
invention comprises a plurality of branch pipe parts, a collecting
pipe part, a first shell member, a second shell member, and a
supporting part.
[0019] The plurality of branch pipe parts constitute respectively a
plurality of flow paths for guiding the exhaust gas from the
internal combustion engine. The collecting pipe part collects the
plurality of branch pipe parts to guide exhaust gas from the
plurality of branch pipe parts, to the air or to a different
exhaust system component that is different from the exhaust system
component and that is located at a downstream side.
[0020] The first shell member integrally constitutes a part of an
outer shell forming, in each of the plurality of branch pipe parts,
a flow path from the internal combustion engine to the collecting
pipe part, and a part of an outer shell forming, in the collecting
pipe part, a flow path from each of the plurality of branch pipe
parts to a downstream side.
[0021] The second shell member constitutes a part of the outer
shell forming, in each of the plurality of branch pipe parts, the
flow path from the internal combustion engine to the collecting
pipe part, and a part of the outer shell forming, in the collecting
pipe part, the flow path from each of the plurality of branch pipe
parts to the downstream side; the second shell member is formed
separately from the first shell member. Moreover, the second shell
member has a concave portion that forms flow paths in the plurality
of branch pipe parts and a flow path in the collecting pipe part
when the second shell member is joined to the first shell
member.
[0022] That is, in the exhaust system component, the branch pipe
parts forming respectively the plurality of flow paths, and the
collecting pipe part forming the flow path into which these branch
pipe parts are collected are configured by joining the second shell
member to the first shell member.
[0023] The supporting part in the exhaust system component connects
two branch pipe parts adjacent to each other among the plurality of
branch pipe parts. The supporting part is integrally formed with
one of the first shell member and the second shell member, such
that a region surrounded by peripheries of the branch pipe parts
and the collecting pipe part and by a part of a periphery of the
supporting part is open to form an opening portion.
[0024] That is, in the exhaust system component, the region
surrounded by peripheries of two branch pipe parts adjacent to each
other and the collecting pipe part and by the part of the periphery
of the supporting part is open to form the opening portion. Into
the opening of the opening portion, a tool for fastening a
fastening component can be easily inserted. "Fastening component"
used herein refers to a component for securing the exhaust system
component to a separate device (internal combustion engine) and the
like, and is, for example, bolts and screws, etc. In addition,
through the opening of the opening portion, a component that is
different from the exhaust system component, and a fastening
component, which are to be attached to the separate device, can be
manipulated.
[0025] As a result of these configurations, the exhaust system
component as above can improve operability.
[0026] In addition, according to the aforementioned exhaust system
component, the supporting part that connects the adjacent branch
pipe parts is provided, thereby enhancing stiffness of a section
where the plurality of the branch pipe parts are merged in the
exhaust system component. Consequently, according to the exhaust
system component configured as above, it is possible to inhibit
thermal stress that is generated in the shell members due to
temperature changes of the shell members caused by exhaust gases
passing therethrough; and it is possible to inhibit breakage in the
section where the plurality of branch pipe parts are merged.
[0027] Moreover, according to the aforementioned exhaust system
component, the exhaust system component can be structured by
joining a section where the periphery of the first shell member and
the periphery of the second shell member abut each other. That is
to say, unlike a conventional exhaust system component, according
to the exhaust system component, welding of the periphery of the
supporting part is not necessary to form the opening of the opening
portion, resulting in reduction of a joining (welding) process for
forming the exhaust system component.
[0028] In other words, according to the above-described exhaust
system component, in the exhaust system component comprising the
plurality of branch pipe parts and one piece of the collecting pipe
part, the branch pipe parts and the collecting pipe part being
configured by joining at least two shell members, concentration of
stress at the section where the plurality of branch pipe parts are
merged can be inhibited, and work for the joining process can be
reduced while ensuring ease of operation performed via the exhaust
system component.
[0029] The exhaust system component configured as above can be
applied to an exhaust system component provided with two or more
shell members.
[0030] The exhaust system component may comprise at least one of: a
plurality of the first shell members; and a plurality of the second
shell members.
[0031] That is, the exhaust system component may be configured by:
a combination of one piece of the first shell member and a
plurality of the second shell members; a combination of a plurality
of the first shell members and one piece of the second shell
member; a combination of a plurality of the first shell members and
a plurality of the second shell members; or the like.
[0032] In the exhaust system component comprising at least one of:
a plurality of the first shell members; and a plurality of the
second shell members, if each of the branch pipe parts is
configured with two shell members, shell members that do not
constitute the branch pipe parts do not need to have a section
constituting the branch pipe parts. According to the exhaust system
component comprising at least one of: a plurality of the first
shell members; and a plurality of the second shell members,
variations of the shell members constituting the branch pipe parts
are possible, and improved flexibility in designing the exhaust
system component can be obtained.
[0033] Moreover, each of the plurality of branch pipe parts may be
bent in the same direction and formed in a tubular shape.
[0034] In this case, the exhaust system component may include a
flange part in a plate-like shape to be connected to the internal
combustion engine. The flange part may have: connection holes that
respectively connects the plurality of branch pipe parts
respectively to exhaust ports of the internal combustion engine;
and at least one insertion hole, into which a fastening component
is inserted to a position away from the connection holes along a
direction of the bending of each of the plurality of branch pipe
parts.
[0035] In the exhaust system component, the supporting part may be
formed such that the opening of the opening portion is formed along
the direction of the bending of the branch pipe parts connected to
the flange part; the supporting part is formed at a position where
the opening of the opening portion encloses a region around an axis
as a center, the axis orthogonal to an outer surface of the flange
part and extending from a center of the insertion hole.
[0036] That is, in the exhaust system component, the supporting
part may be formed such that, the position of the opening of the
opening portion relative to the insertion hole of the flange part
can secure a path (tool trajectory) along which a fastening tool
for fastening the fastening component can pass.
[0037] According to the above-described exhaust system component,
when the exhaust system component is secured to the internal
combustion engine, the fastening tool can be easily inserted into
the opening of the opening portion. Consequently, the exhaust
system component enables an ensured operability in securing the
exhaust system component to the internal combustion engine.
[0038] Moreover, the exhaust system component includes an exhaust
manifold, and a merging member that merges a plurality of exhaust
pipes into one exhaust pipe.
BRIEF DESCRIPTION OF THE DRAWINGS
[0039] FIG. 1 is one example of a view showing a configuration of a
part of an exhaust system provided with an exhaust manifold as an
exhaust system component to which the present invention is
applied.
[0040] FIG. 2A is a top view of the exhaust manifold, and FIG. 2B
is a front view of the exhaust manifold.
[0041] FIG. 3A is a side view of the exhaust manifold; FIG. 3B is a
cross sectional view taken along a line IIIB-IIIB in FIG. 2A; and
FIG. 3C is a cross sectional view taken along a line IIIC-IIIC in
FIG. 2B.
[0042] FIG. 4 is one example of a view showing a lower shell member
that constitutes the exhaust system component.
[0043] FIG. 5 is one example of a view showing an intermediate
shell member that constitutes the exhaust system component.
[0044] FIG. 6 is one example of a view showing an upper shell
member that constitutes the exhaust system component.
[0045] FIG. 7A is a top view of an exhaust manifold, and FIG. 7B is
a front view of the exhaust manifold.
[0046] FIG. 8A is a side view of the exhaust manifold; FIG. 8B is a
cross sectional view taken along a line VIIIB-VIIIB in FIG. 7A; and
FIG. 8C is a cross sectional view taken along a line VIIIC-VIIIC in
FIG. 7B.
[0047] FIG. 9 is a view showing a schematic configuration of an
exhaust system having a merging member.
[0048] FIG. 10A is an enlarged view of the merging member in FIG.
9; FIG. 10B is a cross sectional view taken along a line XB-XB in
FIG. 10A; and FIG. 10C is a cross sectional view taken along a line
XC-XC in FIG. 10A.
EXPLANATION OF REFERENCE NUMERALS
[0049] 1,160 . . . exhaust system, 10,70 . . . exhaust manifold,
12,72 . . . flange part, 16,74 . . . connection hole, 18,76 . . .
insertion hole, 20,78 . . . main body, 22,81 . . . branch pipe
part, 24 . . . collecting pipe part, 28,88,89 . . . supporting
part, 35,40,45,83,90 . . . shell member, 39,49,85,87,93,95 . . .
concave portion, 51,101,102 . . . opening portion, 60 . . .
catalytic converter, 65 . . . exhaust pipe, 120 . . . internal
combustion engine
MODE FOR CARRYING OUT THE INVENTION
[0050] Hereinafter, embodiments of the present invention will be
described with reference to the drawings.
First Embodiment
[0051] <Configuration of Exhaust System>
[0052] As shown in FIG. 1, an exhaust system 1 is a system that
guides exhaust gas from an internal combustion engine 120 having a
plurality of cylinders, into the air.
[0053] The internal combustion engine 120 is an in-line 4-cylinder
internal combustion engine having four cylinders of first to fourth
cylinders #1 to #4 arranged in a straight line, or a V-type
internal combustion engine having four cylinders of first to fourth
cylinders #1 to #4 arranged in a V shape.
[0054] The exhaust system 1 is at least provided with an exhaust
manifold 10, a catalytic converter 60, an exhaust pipe 65. The
exhaust system 1 includes one or more known mufflers and end pipes,
which are not shown.
[0055] Among these components, the catalytic converter 60 is a
mechanism that contains a known catalyst, which purifies exhaust
gas from the exhaust manifold 10; the catalytic converter 60 guides
the exhaust gas purified by the catalyst to the exhaust pipe
65.
[0056] The exhaust pipe 65 is a known pipe constituting a flow path
for the exhaust gas, and constitutes a flow path to guide the
exhaust gas purified by the catalytic converter 60 into the
air.
[0057] <Overall Configuration of Exhaust Manifold>
[0058] As shown in FIG. 2A, FIG. 2B, FIG. 3A, FIG. 3B, and FIG. 3C,
the exhaust manifold 10 includes a flange part 12 and an exhaust
manifold main body (hereinafter, referred to as main body) 20.
[0059] Among these components, the flange part 12 is a plate-like
member, which is to be connected to the internal combustion engine
120. The flange part 12 is provided with connection holes 16-n,
which are to be connected respectively to exhaust ports P1 to P4 of
the internal combustion engine 120; the flange part 12 is also
provided with a plurality of holes (hereinafter, referred to as
insertion holes) 18-m, through which fastening components are
inserted. "Fastening component" used herein refers to known parts
for securing the flange part 12 to the internal combustion engine
120, and are, for example, bolts and screws. In the present
embodiment, the suffix letter "n" indicates a number of cylinders
arranged in straight in the internal combustion engine 120 (in the
embodiment, n=4), and the suffix letter "m" indicates a number of
the insertion holes 18 (in the embodiment, m=5).
[0060] Next, the main body 20 includes an upper shell member 35, an
intermediate shell member 40, and a lower shell member 45. In the
main body 20, these members 35, 40, and 45 are joined to constitute
a flow path that guides exhaust gas from the internal combustion
engine 120 to the catalytic converter 60.
[0061] The main body 20 includes branch pipe parts 22-n and a
collecting pipe part 24.
[0062] The branch pipe parts 22 form respective flow paths for
guiding exhaust gases respectively from the exhaust ports P1 to P4
of the internal combustion engine 120. Each of the branch pipe
parts 22 is formed in a bent tubular shape; one ends of the branch
pipe parts 22 are connected respectively to peripheries of the
connection holes 16 of the flange part 12. The connection of the
branch pipe parts 22 to the flange part 12 is made such that
bending directions of the branch pipe parts 22, which project from
the flange part 12, are in the same direction.
[0063] The collecting pipe part 24 collects ends of the branch pipe
parts 22, which are not connected to the flange part 12, to form a
flow path for guiding exhaust gases from the branch pipe parts 22
to at least one exhaust pipe 65. In the present embodiment, the
collecting pipe part 24 is connected to the exhaust pipe 65 via the
catalytic converter 60.
[0064] Here, in the present embodiment, the insertion holes 18 of
the flange part 12 are provided at a total of five positions: two
positions along an upper side of the flange part 12 (upper side in
FIG. 2B); and three positions along a lower side of the flange part
12 (lower side in FIG. 2B). One of the five insertion holes 18,
i.e., the insertion hole 18-3, is provided at a position where an
axis passing through a center of the insertion hole 18-3 and
orthogonal to an outer surface of the flange part 12 is interposed
between the branch pipe part 22-2 and the branch pipe part
22-3.
[0065] The main body 20 is provided with a supporting part 28. The
supporting part 28 is a member that connects adjacent two of the
branch pipe parts 22 to each other. The supporting part 28 in the
present embodiment is provided as a member that connects the branch
pipe part 22-2 and the branch pipe part 22-3 to each other.
[0066] In addition, the supporting part 28 in the present
embodiment is provided such that a region surrounded by peripheries
of the branch pipe parts 22 and the collecting pipe part 24, and a
part of a periphery of the supporting part 28 is open to form an
opening portion 51. The supporting part 28 in the present
embodiment is provided such that the opening of the opening portion
51 encloses a specified region (hereinafter, referred to as tool
trajectory) around the axis, as a center, which is orthogonal to
the outer surface of the flange part 12 and which extends from the
center of the insertion hole 18-3. Here, the specified region is a
region through which a tool for fastening the fastening components,
for example, bolts and screws, can pass.
[0067] For example, the opening of the opening portion 51 in the
present embodiment is arranged coaxially with the insertion hole
18-3; the specified region is a region located coaxially with the
opening of the opening portion 51 and with the insertion hole 18-3.
"Coaxially" used herein includes a state of being coaxial as well
as a state where respective centers are deviated from each other
within a predefined error range.
[0068] <Detailed Configuration of Main Body>
[0069] Next, explanations are given with respect to detailed
configurations of the main body 20.
[0070] The main body 20, i.e., each of the upper shell member 35,
the intermediate shell member 40, and the lower shell member 45,
all of which forming the branch pipe parts 22 and the collecting
pipe part 24, is a plate-like member having a recess (concave
portion).
[0071] The concave portions formed in the upper shell member 35,
the intermediate shell member 40, and the lower shell member 45 are
formed by, for example, press-molding the plate-like members.
[0072] As shown in FIG. 4, the lower shell member 45 is provided
with lower branch parts 46-1 to 46-4, a lower collecting part 48,
and a supporting section 53; the lower branch parts 46-1 to 46-4,
the lower collecting part 48, and the supporting section 53 are
integrally formed.
[0073] The lower branch parts 46-1 to 46-4 are portions that
respectively constitute a part of respective outer shells forming
the branch pipe parts 22-1 to 22-4. The lower branch parts 46-1 to
46-4 respectively have concave portions 47-1 to 47-4, each of which
is a semicircular recess.
[0074] The lower collecting part 48 is a portion that constitutes a
part of an outer shell of the collecting pipe part 24. The lower
collecting part 48 has a concave portion 49, which is a
semicircular recess.
[0075] In the present embodiment, the concave portion 47-1, the
concave portion 47-4, and the concave portion 49 in the lower shell
member 45 are formed to be a contiguous recess extending from each
of the concave portion 47-1 and the concave portion 47-4 to the
concave portion 49.
[0076] The supporting section 53 is a portion that connects the
lower branch part 46-2 and the lower branch part 46-3 and that
serves as the supporting part 28. The supporting section 53 is
provided such that a region surrounded by a periphery of the lower
branch part 46-2, a periphery of the lower collecting part 48, a
periphery of the lower branch part 46-3, and a periphery of the
supporting section 53 is open to form the opening portion 51.
[0077] Here, the supporting section 53 in the present embodiment is
provided such that the opening of the opening portion 51 is located
coaxially with the insertion hole 18-3 of the flange part 12 along
the tool trajectory.
[0078] A manufacturing method of the supporting section 53 of the
lower shell member 45 will be explained. Specifically, in
manufacturing the lower shell member 45, when a plate-like member
is pressed to form the lower branch parts 46-1 to 46-4 and the
lower collecting part 48, a skirt portion is left, which is a
portion having a plate-like shape between the lower branch part
46-2 and the lower branch part 46-3. The opening of the opening
portion 51 is formed in the skirt portion by drilling such that a
part of the skirt portion is left as the supporting section 53.
[0079] As shown in FIG. 5, the intermediate shell member 40
includes intermediate branch parts 41-1 and 41-4, and an
intermediate collecting part 44; these intermediate branch parts
41-1 and 41-4, and the intermediate collecting part 44 are formed
integrally.
[0080] The intermediate branch parts 41-1 and 41-4 are portions
that respectively constitute a part of respective outer shells
forming the branch pipe parts 22-1 and 22-4. The intermediate
branch parts 41-1 and 41-4 respectively have concave portions 42-1
and 42-4, each of which is a semicircular recess.
[0081] The intermediate collecting part 44 is a plate-like portion
that constitutes a part of a portion where the branch pipe part
22-1 and the branch pipe part 22-2 are collected in the collecting
pipe part 24.
[0082] That is, in the main body 20 of the present embodiment, a
periphery of the intermediate shell member 40 is joined to
peripheries of the lower branch parts 46-1, 46-4 and the lower
collecting part 48 in the lower shell member 45, thereby to form a
tubular region surrounded by the intermediate branch part 41-1 and
the lower branch part 46-1, i.e., the branch pipe part 22-1 is
formed by the concave portion 42-1 and the concave portion 47-1.
Also, a tubular region surrounded by the intermediate branch part
41-4 and the lower branch part 46-4 is formed, i.e., the branch
pipe part 22-4 is formed by the concave portion 42-4 and the
concave portion 47-4.
[0083] In addition, a region surrounded by the intermediate
collecting part 44 and the lower collecting part 48 is formed,
i.e., a region where the branch pipe part 22-1 and the branch pipe
part 22-4 of the collecting pipe part 24 are collected is formed by
a flat surface constituting the intermediate collecting part 44 and
the concave portion 49.
[0084] As shown in FIG. 6, the upper shell member 35 includes upper
branch parts 36-2 and 36-3 and an upper collecting part 38.
[0085] Among these components, the upper branch part 36-2 and the
upper branch part 36-3 are portions that respectively constitute
part of respective outer shells forming the branch pipe part 22-2
and the branch pipe part 22-3. The upper branch part 36-2 and the
upper branch part 36-3 respectively have a concave portion 37-2 and
a concave portion 37-3, each of which is a semicircular recess.
[0086] The upper collecting part 38 is a portion that constitutes a
part of an outer shell forming the collecting pipe part 24. The
upper collecting part 38 has a concave portion 39, which is a
semicircular recess.
[0087] Here, these concave portion 37-2, the concave portion 37-3,
and the concave portion 39 are formed to be a contiguous recess
extending from each of the concave portion 37-2 and the concave
portion 37-3 to the concave portion 39.
[0088] Here, the upper shell member 35 has an open space between
the upper branch parts 36-2 and 36-3.
[0089] That is, in the main body 20 of the present embodiment,
peripheries of the upper branch part 36-2 and the upper branch part
36-3 in the upper shell member 35 are respectively joined to the
lower branch parts 46-2 and 46-3 in the lower shell member 45, to
form a tubular region surrounded by the upper branch part 36-2 and
the lower branch part 46-2, i.e., the branch pipe part 22-2 is
formed by the concave portion 37-2 and the concave portion 47-2.
Also, a tubular region surrounded by the upper branch part 36-3 and
the lower branch part 46-3 is formed, i.e., the branch pipe part
22-3 is formed by the concave portion 37-3 and the concave portion
47-3.
[0090] Moreover, in the main body 20 in the present embodiment, a
periphery of the upper collecting part 38 in the upper shell member
35 is joined to a periphery of the intermediate collecting part 44
in the intermediate shell member 40, to form a portion surrounded
by the intermediate collecting part 44 and the upper collecting
part 38, i.e., a region where the branch pipe part 22-2 and the
branch pipe part 22-3 of the collecting pipe part 24 are collected
is formed by a flat surface constituting the intermediate
collecting part 44 and the concave portion 39. Moreover, in the
present embodiment, peripheries of the upper branch part 36-2 and
the upper branch part 36-3 in the upper shell member 35 are
respectively joined to the lower branch parts 46-1 and 46-4 in the
lower shell member 45, thereby enabling the supporting section 53
in the lower shell member 45 to function as the supporting part
28.
[0091] Here, "join" used in the embodiment refers to a known method
for achieving connection and fixation between members and includes,
for example, welding.
Effect of First Embodiment
[0092] As described above, in the exhaust manifold 10 of the
present embodiment, the region surrounded by the peripheries of the
branch pipe part 22-2 and the branch pipe part 22-3, the periphery
of the collecting pipe part 24, and the part of the periphery of
the supporting section 53 (supporting part 28) is open to form the
opening portion 51. Moreover, the supporting section 53 (supporting
part 28) is provided such that the opening of the opening portion
51 is located on an extension of the tool trajectory, relative to
the insertion hole 18-3 provided in the flange part 12.
[0093] Thus, according to the exhaust manifold 10, when the exhaust
manifold 10 is fixed to the internal combustion engine 120, a
fastening tool, which fastens fastening components, such as bolts,
can be easily inserted via the opening of the opening portion 51,
and an improved operability in the fastening of the fastening
components can be achieved.
[0094] In addition, according to the exhaust manifold 10, since the
supporting part 28 that connects the branch pipe parts 22-2 and
22-3, which are adjacent to each other, is provided, stiffness of
the portion where the plurality of the branch pipe parts 22 are
merged in the exhaust manifold 10 can be enhanced. Consequently,
according to the exhaust manifold 10, it is possible to inhibit
thermal stress that is generated in the lower shell member 45 and
the upper shell member 35 due to temperature changes of the lower
shell member 45 and the upper shell member 35 caused by exhaust
gases passing therethrough; it is possible to inhibit breakage in
the region where the branch pipe parts 22 are merged.
[0095] Moreover, according to the exhaust manifold 10, the
supporting part 28 can be formed by joining the periphery of the
upper shell member 35 to the lower branch parts 46-2 and 46-3 in
the lower shell member 45. That is to say, unlike a conventional
exhaust manifold, according to the exhaust manifold 10, forming of
the opening of the opening portion 51 does not require welding of
peripheries of openings to each other. Thus, according to the
exhaust manifold 10, joining (welding) process for structuring the
supporting part 28 of the exhaust manifold 10 can be reduced.
[0096] In other words, according to the exhaust manifold 10 that is
provided with a plurality of the branch pipe parts 22-n and one
piece of the collecting pipe part 24, the branch pipe parts 22 and
the collecting pipe part 24 being configured by joining the shell
members 35, 40, and 45, ease of operation performed via the exhaust
manifold 10 can be ensured; concentration of stress at the region
where the plurality of branch pipe parts 22 are merged can be
inhibited; and work for the joining process can be reduced.
Second Embodiment
[0097] Next, the second embodiment of the present invention will be
explained.
[0098] The second embodiment of the present invention is mainly
different from the first embodiment with respect to configurations
of an exhaust manifold to which the present invention is applied.
Accordingly, in the present embodiment, the same configurations as
those in the first embodiment are given with the same reference
numerals, and will not be explained here. Different configurations
of the exhaust manifold from the first embodiment will be mainly
explained.
[0099] <Overall Configuration of Exhaust Manifold>
[0100] As shown in FIG. 7A, FIG. 7B, FIG. 8A, FIG. 8B, and FIG. 8C,
an exhaust manifold 70 includes a flange part 72 and a main body
78.
[0101] The flange part 72 is a plate-like member, which is to be
connected to the internal combustion engine 120. The flange part 72
is provided with connection holes 74-n and insertion holes 76-m.
The connection holes 74-n in the present embodiment are connected
respectively to the exhaust ports P1 to P4 of the internal
combustion engine 120 in the same manner as in the connection holes
16-n in the first embodiment.
[0102] Next, the main body 78 includes an upper shell member 83 and
a lower shell member 90; the shell members 83 and 90 are joined to
constitute a flow path inside the manifold, which guides exhaust
gas from the internal combustion engine 120 to the catalytic
converter 60.
[0103] The main body 78 includes branch pipe parts 81n and a
collecting pipe part 82.
[0104] Among these components, the branch pipe parts 81 form
respective flow paths for respective exhaust gases guided from the
internal combustion engine 120. Each of the branch pipe parts 81 is
formed in a bent tubular shape, and one ends of the branch pipe
parts 81 are connected respectively to peripheries of the
connection holes 74 of the flange part 72. The connection of the
branch pipe parts 81 to the flange part 72 is made such that
bending directions of the branch pipe parts 81, which project from
the flange part 72, are in the same direction.
[0105] The collecting pipe part 82 collects ends of the branch pipe
parts 81-n, which are not connected to the flange part 72, to form
a flow path for guiding exhaust gases from the branch pipe parts 81
to at least one exhaust pipe 65.
[0106] Here, in the present embodiment, the insertion holes 76 of
the flange part 72 are provided at a total of five positions: three
positions along an upper side of the flange part 72 (upper side in
FIG. 7B); and two positions along a lower side of the flange part
72 (lower side in FIG. 7B). Among the five insertion holes 76, the
insertion hole 76-2 and the insertion hole 76-4 are provided in the
following positions: the insertion hole 76-2 is at the position
where an axis that passes through a center of the insertion hole
76-2 and that are orthogonal to an outer surface of the flange part
72 is interposed between the branch pipe part 81-1 and the branch
pipe part 81-2; and the insertion hole 76-4 is at the position
where an axis that passes through a center of the insertion hole
76-4 and that are orthogonal to the outer surface of the flange
part 72 is interposed between the branch pipe part 81-3 and the
branch pipe part 81-4 (see FIG. 8C).
[0107] The main body 78 is provided with two supporting parts 88
and 89.
[0108] The supporting part 88 connects between the branch pipe part
81-1 and the branch pipe part 81-2. The supporting part 88 is
provided such that a region surrounded by a periphery of the branch
pipe part 81-1, a periphery of the collecting pipe part 82, a
periphery of the branch pipe part 81-2, and a part of a periphery
of the supporting part 88 is open to form an opening portion
101.
[0109] The supporting part 89 connects between the branch pipe part
81-3 and the branch pipe part 81-4. The supporting part 89 is
provided such that a region surrounded by a periphery of the branch
pipe part 81-3, a periphery of the collecting pipe part 82, a
periphery of the branch pipe part 81-4, and a part of a periphery
of the supporting part 89 is open to form an opening portion
102.
[0110] Moreover, the supporting part 88 is provided such that the
opening of the opening portion 101 encloses a tool trajectory
around the axis, as a center, which is orthogonal to the outer
surface of the flange part 72 and which extends from the center of
the insertion hole 76-1; the supporting part 89 is provided such
that the opening of the opening portion 102 encloses a tool
trajectory around the axis, as a center, which is orthogonal to the
outer surface of the flange part 72 and which extends from the
center of the insertion hole 76-4. More specifically, in the
present embodiment, the supporting part 88 may be provided such
that the insertion hole 76-1 is located coaxially with the opening
of the opening portion 101; the supporting part 89 may be provided
such that the insertion hole 76-4 is located coaxially with the
opening of the opening portion 102.
[0111] <Detailed Configuration of Main Body>
[0112] Next, explanations are given with respect to detailed
configurations of the main body 78.
[0113] Each of the upper shell member 83 and the lower shell member
90, both of which constitute the main body 78, is plate-like member
having a recess (concave portion). The concave portions formed in
the upper shell member 83 and the lower shell member 90 are formed
by, for example, press-molding the plate-like members.
[0114] The lower shell member 90 is provided with lower branch
parts 91-1 to 91-4, a lower collecting part 94, and supporting
sections 96 and 97; the lower branch parts 91-1 to 91-4, the lower
collecting part 94, and the supporting sections 96 and 97 are
integrally formed.
[0115] The lower branch parts 91-1 to 91-4 are portions that
respectively constitute a part of respective outer shells forming
the branch pipe parts 81 -1 to 81-4. The lower branch parts 91-1 to
91-4 respectively have concave portions 93-1 to 93-4, each of which
is a semicircular recess.
[0116] The lower collecting part 94 is a portion that constitutes a
part of an outer shell of the collecting pipe part 82. The lower
collecting part 94 has a concave portion 95, which is a
semicircular recess.
[0117] In the present embodiment, the concave portions 93-1 to 93-4
and the concave portion 95 are formed to be a contiguous recess
extending from each of the concave portions 93-1 to 93-4 to the
concave portion 95.
[0118] The supporting section 96 is a portion that connects the
lower branch part 91-1 and the lower branch part 91-2. In the
supporting section 96, a region surrounded by a periphery of the
lower branch part 91-1, a periphery of the lower collecting part
94, a periphery of the lower branch part 91-2, and the supporting
section 96 is open to form the opening portion 101.
[0119] The supporting section 97 is a portion that connects the
lower branch part 91-3 and the lower branch part 91-4. In the
supporting section 97, a region surrounded by a periphery of the
lower branch part 91-3, a periphery of the lower collecting part
94, a periphery of the lower branch part 91-4, and the supporting
section 97 is open to form the opening portion 102.
[0120] Here, in the present embodiment, the supporting section 96
is provided such that the opening of the opening portion 101 is
located coaxially with the insertion hole 78-2 of the flange part
72 along the tool trajectory; the supporting section 97 is provided
such that the opening of the opening portion 102 is located
coaxially with the insertion hole 78-4 of the flange part 72 along
the tool trajectory.
[0121] The upper shell member 83 includes upper branch parts 84-1
to 84-4 and an upper collecting part 86.
[0122] Among these components, the upper branch parts 84-1 to 84-4
are portions that respectively constitute a part of respective
outer shells forming the branch pipe parts 81-1 to the branch pipe
part 81-3 in the upper shell member 83. The upper branch parts 84-1
to 84-4 respectively have concave portions 85-1 to 85-4, each of
which is a semicircular recess.
[0123] The upper collecting part 86 is a portion that constitutes a
part of an outer shell forming the collecting pipe part 82. The
upper collecting part 86 has a concave portion 87, which is a
semicircular recess.
[0124] Here, in the present embodiment, the concave portions 85-1
to 85-4, and the concave portion 87 are formed to be a contiguous
recess extending from each of the concave portions 85-1 to 85-4 to
the concave portion 87.
[0125] Here, the upper shell member 83 has an open space among each
of the upper branch parts 84.
[0126] That is, in the main body 78 of the present embodiment, a
periphery of the upper shell member 83 is joined to a periphery of
the lower shell member 90, to form a tubular region surrounded by
the upper branch parts 84-n and the lower branch parts 91-n, i.e.,
the branch pipe parts 81-n are formed by the concave portions 85-n
and the concave portions 93-n. Also, a tubular region surrounded by
the upper collecting part 86 and the lower collecting part 94 is
formed, i.e., the collecting pipe part 82 is formed by the concave
portion 87 and the concave portion 95.
[0127] Moreover, the main body 78 in the present embodiment,
peripheries of the upper branch parts 84-1 and 84-2 in the upper
shell member 83 are respectively joined to the lower branch parts
91-1 and 91-2 in the lower shell member 90, thereby enabling the
supporting section 96 in the lower shell member 90 to function as
the supporting part 88. Peripheries of the upper branch parts 84-3
and 84-4 in the upper shell member 83 are respectively joined to
the lower branch parts 91-3 and 91-4 in the lower shell member 90,
thereby enabling the supporting section 97 in the lower shell
member 90 to function as the supporting part 89.
Effect of Second Embodiment
[0128] As described above, the same effects as those obtained by
the exhaust manifold 10 of the first embodiment can be obtained by
the exhaust manifold 70 of the present embodiment.
Other Embodiments
[0129] Although the embodiments of the present invention have been
described above, the present invention should not be limited to the
aforementioned embodiments, and can be carried out in various
manners without departing from the main idea of the present
invention.
[0130] For example, in the above-described embodiments, a number of
the branch pipe parts 22 in the main body 20 and a number of the
branch pipe parts 81 in the main body 78 are four; however, the
numbers of the branch pipe parts 22 and 81 are not limited to the
numbers in the above-described embodiments. That is, any number of
the branch pipe parts 22 and 81 may be used as long as such a
number is specified depending on a number of cylinders of the
internal combustion engine 120.
[0131] Moreover, in the above-described embodiments, the numbers of
the shell members 35, 40, 45, 83, 90 constituting the main bodies
20 and 78 are two or three; however, the number of the shell
members constituting the main body is not limited to two or three,
and may be any numbers. That is, the main body may be constituted
by a combination of two shell members, or a combination of three or
more shell members.
[0132] Although in the above-described embodiments, the shape of
the branch pipe parts 22 and 81 has a bent shape, shapes of the
branch pipe parts 22 and 81 are not limited to the bent shape and
may be, for example, a straight pipe.
[0133] In the above-described embodiments, an object to which the
present invention is applied is an exhaust manifold; however, an
object to which the present invention is applied is not limited to
an exhaust manifold.
[0134] That is, an object to which the present invention is applied
may be any exhaust system component that is provided with a
plurality of branch pipe parts and one collecting pipe part, the
branch pipe parts and the collecting pipe part being configured by
joining at least two shell members.
[0135] As an object to which the present invention is applied may
be, specifically, as shown in FIG. 9, FIG. 10A, FIG. 10B, and FIG.
10C, a merging member 150 in an exhaust system 160 that is provided
with: exhaust pipes 130 and 131 through which exhaust gas from the
internal combustion engine 120 passes; a merging member 150 that
merges the exhaust pipes 130 and 131; and exhaust pipes 133 and 134
that guide exhaust gas that has passed through the merging member
150.
[0136] More specifically, as shown FIG. 10A, the merging member 150
includes: pipe connection parts 151 and 152, to which the exhaust
pipes 130 and 131 are connected; pipe connection parts 153 and 154,
to which the exhaust pipes 133 and 134 are connected; a
merge-splitting part 155 that merges exhaust gases from the pipe
connection parts 151 and 152 and guides the exhaust gases to the
pipe connection parts 153 and 154; and a supporting part 156 that
connects between the pipe connection part 151 and the pipe
connection part 152.
[0137] Here, as shown in FIG. 10B and FIG. 10C, the merging member
150 includes two shell members 158 and 159, each of which is a
plate-like member having a recess (concave portion); the merging
member 150 is formed by joining the shell members 158 and 159.
[0138] That is, the pipe connection parts 151 and 152, the pipe
connection parts 153 and 154, and the merge-splitting part 155 are
formed by joining the shell members 158 and 159, i.e., these
components are portions configured with the shell members 158 and
159.
[0139] Here, the supporting part 156 is provided in one of the
shell member 158 and the shell member 159. In the example
illustrated in FIG. 10B and FIG. 10C, the supporting part 156 is
provided in the shell member 159.
[0140] Moreover, the supporting part 156 is provided such that a
region surrounded by peripheries of the pipe connection parts 151
and 152 of one member of the shell member 158 and the shell member
159, the one member provided with the supporting part 156, a
periphery of the merge-splitting part 155, and a periphery of the
supporting part 156 is open to form an opening portion 157.
[0141] According to the merging member 150, separate parts that are
not the merging member 150 or fastening components, which are to be
attached to another device, can be operated through the opening of
the opening portion 157. As a result, according to the merging
member 150, improved operability in operation with the separate
parts or the fastening components can be obtained.
Corresponding Relationship Between Embodiments and Claims
[0142] Lastly, the relationship between descriptions in the
above-described embodiments and descriptions in clams will be
explained.
[0143] The upper shell members 35 and 83, the lower shell members
45 and 90, and the intermediate shell member 40 in the
above-described embodiments correspond to one example of a first
shell member and a second shell member in the descriptions of the
claims; the flange parts 12 and 72 correspond to one example of a
flange part in the descriptions of the claims.
[0144] Furthermore, the supporting parts 28, 88, and 89 in the
above-described embodiments correspond to one example of a
supporting part in the descriptions of the claims.
* * * * *