The present invention relates to an intake apparatus for an internal combustion engine for a vehicle such as an automobile, and particularly, to an intake apparatus adapted to carry out changeover of an effective cross-sectional area of a passage on the side of an intake inlet of an air cleaner depending upon an intake air flow rate.
It is generally known that in an internal combustion engine for a vehicle such as an automobile, in a case where a cross-sectional area of a passage of an intake duct as an intake inlet of an intake system which is opened to an outside is large, noise leaking from the intake inlet becomes large. In contrast, in a case where the cross-sectional area of the passage is too small, when an intake air flow rate is large, an air flow resistance is increased so that air intake efficiency is deteriorated.
From the above viewpoint, there have been proposed various kinds of technologies of varying an effective cross-sectional area of a passage on the side of an intake inlet of an air cleaner depending upon an intake air flow rate. For instance, Japanese Patent Application Unexamined Publication No. 2000-54924 discloses an intake duct including first and second intake passages (as an intake duct) arranged parallel to each other, and a flap valve disposed in the second intake passage. The flap valve is biased toward a closing direction thereof by a biasing member such as a spring, a weight or the like. The flap valve is moved to an opening state and a closing state by a balance between a biasing force of the biasing member in the closing direction and a force acting on the flap valve in an opening direction due to a pressure difference between an upstream side of the flap valve and a downstream side of the flap valve. The flap valve is held in the closing state in a low speed range of the internal combustion engine in which an intake air flow rate is small. The flap valve is moved to the opening state in a high speed range of the internal combustion engine in which an intake air flow rate is large. Owing to the movement of the flap valve, an effective cross-sectional area of the passage is varied in two stages. That is, the intake duct of the conventional art is constructed such that the flap valve is automatically moved to the opening state and the closing state in response to an intake air flow without using a control device or an actuator.
In the intake duct of the above-described conventional art in which the flap valve is opened by the force due to the intake air flow, the flap valve is held in the fully closing state by the biasing member such as a spring in the low speed range of the internal combustion engine. Due to such a construction, there is a problem that the flap valve held in the fully closing state is caused to vibrate due to pulsation of the intake air, vibration of a vehicle during running, and the like. Particularly, when the engine rotation speed is in the vicinity of a set rotation speed at which the flap valve begins to move toward the opening position, slight or fine movement of the flap valve in the opening direction and the closing direction is repeated in response to the pulsation of the intake air, so that noise occurs due to impingement of a tip end of the flap valve against an inner wall surface of the intake passage.
Further, the above-described conventional art also discloses that the flap valve is held in the fully closing state by a magnetic force of a permanent magnet. However, in such a construction using a magnetic force of the permanent magnet in addition to the biasing force of the spring, an opening movement of the flap valve is excessively disturbed to thereby make it difficult to obtain a smoothly opening movement of the flap valve at a desired set rotation speed.
In a first aspect of the present invention, there is provided an intake apparatus for an internal combustion engine equipped with an air cleaner, including:
two intake ducts connected to an intake inlet of the air cleaner; and
a flap mechanism disposed in one of the two intake ducts, the flap mechanism serving for opening and closing the one of the two intake ducts in response to intake air flow entering into the one of the two intake ducts,
the flap mechanism including:
a plate-shaped main flap supported at one end portion thereof so as to be rotatable about a rotation axis between a fully opening position and a fully closing position, the rotation axis being located at the one end portion of the main flap,
a plate-shaped damper flap disposed to make a predetermined angle between the main flap and the damper flap with respect to the rotation axis, the damper flap making a unitary rotation with the main flap,
a damper chamber formed in a portion of an outer wall of the one of the two intake ducts so as to be recessed along a trace of rotational movement of the damper flap, the damper chamber cooperating with the damper flap to form a damper space therebetween, and
a biasing member that biases the main flap in a closing direction;
wherein when the main flap is located in an angular range between the fully closing position and a predetermined opening angle, a peripheral edge of the damper flap is opposed to an inner wall surface of the damper chamber with a fine clearance so that the damper space is rendered substantially closed, and
when the main flap is located with an opening angle larger than the predetermined opening angle, a communication passage that serves to open the damper space is formed between the inner wall surface of the damper chamber and the peripheral edge of the damper flap.
In the above construction of the intake apparatus of the present invention, the main flap and the damper flap make a unitary rotation in response to an intake air flow. In a low speed range of the engine in which an intake air flow rate is small, the main flap is held in the fully closing position in which one of the intake air passages is blocked by a biasing force of the biasing member such as a spring or a weight. At this time, when vibration of the main flap is caused due to pulsation of the intake air, vibration of the vehicle during running, and the like, the damper flap formed integrally with the main flap is vibrated within the damper chamber. In the vicinity of the fully closing position of the main flap, a peripheral edge of the damper flap is located close to an inner wall surface of the damper chamber with a fine clearance, so that the damper space is rendered substantially closed. As a result, vibration of the damper flap and vibration of the main flap can be suppressed. That is, the damper flap and the damper chamber constitute a kind of air damper to thereby suppress vibration of the main flap in the vicinity of the fully closing position of the main flap and generation of noise.
On the other hand, when the intake air flow rate is increased to a predetermined level, the main flap is started to move toward the opening position against a biasing force of the biasing members such as a spring. At this time, the damper constituted of the damper flap and the damper chamber provides a slight resistance as a damper until the opening angle reaches a predetermined opening angle. When the main flap is rotated to exceed the predetermined opening angle so that the damper flap is moved into the damper chamber, the damper space is opened through the communication passage to thereby lose the resistance as the damper. Accordingly, the main flap is immediately rotationally moved to the fully opening position together with the damper flap.
In a second aspect of the present invention, there is provided the intake apparatus according to the first aspect, wherein the inner wall surface of the damper chamber includes a peripheral inner-wall surface that is configured to be opposed to a tip end edge of the damper flap with a fine clearance in the angular range between the fully closing position of the main flap and the predetermined opening angle, and be retreated toward an outer peripheral side of the damper chamber to be spaced apart from the tip end edge of the damper flap in an angular range larger than the predetermined opening angle to thereby form the communication passage.
That is, in the vicinity of the fully closing position of the main flap, the tip end edge of the damper flap is located close to the peripheral inner wall surface of the damper chamber with a fine clearance, so that the damper space is retained as a substantially closed space. When the main flap is rotated to exceed the predetermined opening angle, there is generated a large clearance between the tip end edge of the damper flap and the peripheral inner wall surface of the damper chamber is generated so that the damper space is opened.
In a third aspect of the present invention, there is provided the intake apparatus according to the first aspect, wherein the damper chamber has an opening through which the damper chamber is communicated with the intake passage in the one of the two intake ducts, and when the main flap is located in the fully opening position, the main flap closes the opening of the damper chamber.
The intake apparatus for an internal combustion engine according to the present invention can attain the effects as follows. It is possible to vary an effective cross-sectional area of a passage on the side of an intake inlet of an air cleaner, thereby serving to reduce intake noise in a low speed range of the engine and ensure air intake efficiency. Further, when the main flap is located in the vicinity of the fully closing position, vibration of the main flap due to intake pulsation, etc. can be effectively suppressed by a damping function. When the main flap is moved toward the opening position as the intake air flow rate is increased, the damping function is lost when reaching a predetermined opening angle so that the main flap is allowed to immediately open. Accordingly, it is possible to prevent occurrence of noise due to vibration of the main flap, and avoid deterioration in acceleration performance owing to delay in opening movement of a flap mechanism.
Referring to
In
As shown in
The arms 19 are located on an outside of the side walls 7a, 7a of the secondary duct 7. A tension coil spring 23 as a biasing member is disposed between each of the pins 20 disposed on the tip end portions of the arms 19 and each of pins 22 disposed on the side walls 7a, 7a. The coil spring 23 is disposed along a longitudinal direction of the secondary duct 7 to expand in its length as an opening angle of the main flap 15 is increased. With this construction, the whole flap valve 13 is urged in a clockwise direction as viewed in
The main flap 15 has a rectangular plate shape corresponding to a rectangular shape of the cross section of the secondary duct 7. As shown in
The flap valve 13 is made of a synthetic resin material, and formed as an integral part as shown in
The damper chamber 11 is defined by the damper casing portion 12 formed to upwardly bulge from the upper surface of the upper wall 7b of the secondary duct 7 as shown in
Further, the arcuate peripheral inner-wall surface 11a of the damper chamber 11 which is opposed to the tip end edge 16a of the damper flap 16 with the fine clearance is formed only in a relatively small angular range extending upwardly from the opening 32. An increased-diameter inner-wall surface 11d is formed on an upper side of the angular range of the peripheral inner-wall surface 11a, and located in a position retreated toward an outer peripheral side of the damper chamber 11 with respect to the arcuate trace of rotational movement of the tip end edge 16a of the damper flap 16. That is, the increased-diameter inner-wall surface 11d is located spaced apart from the arcuate trace of rotational movement of the tip end edge 16a of the damper flap 16 with a sufficiently large gap. In this state, a communication passage 33 that serves to open the damper space 31 and communicate the damper space 31 with the intake passage in the secondary duct 7 is formed over a whole width of the damper flap 16. In this embodiment, the increased-diameter inner-wall surface 11d is also formed into a partially cylindrical shape having a diameter larger than that of the peripheral inner-wall surface 11a. However, since the increased-diameter inner-wall surface 11d is spaced apart from the tip end edge 16a of the damper flap 16, the shape of the increased-diameter inner-wall surface 11d may be optionally determined without being limited to the partially cylindrical shape in this embodiment.
A boundary between the peripheral inner-wall surface 11a coming close to the tip end edge 16a of the damper flap 16 and the increased-diameter inner-wall surface 11d relatively farther spaced from the tip end edge 16a is located within an angular range corresponding to a predetermined opening angle of the main flap 15 which is necessary to suppress vibration or fluttering of the main flap 15. The angular range is set to, for example, about 10 degrees to 20 degrees, but is not limited to this range.
An operation of the thus constructed intake apparatus according to the embodiment will be explained hereinafter. In an engine low speed range in which the intake air flow rate of the internal combustion engine 1 is lower than a predetermined level, the damper flap 16 as a whole is urged in the clockwise direction in
When the intake air flow rate is increased to the predetermined level, the main flap 15 starts to rotationally move in the opening direction against the tensile force of the coil spring 23 by the force of the intake air flow. The damper flap 16 and the damper chamber 11 which constitute a damper provide a slight resistance until the tip end edge 16a of the damper flap 16 passes over the peripheral inner-wall surface 11a of the damper chamber 11, namely, until the damper flap 16 is rotated by a predetermined opening angle.
When the damper flap 16 is further rotated beyond the predetermined opening angle and the tip end edge 16a of the damper flap 16 approaches the increased-diameter inner-wall surface 11d of the damper chamber 11, air is escaped from the damper space 31 through the communication passage 33 between the tip end edge 16a of the damper flap 16 and the increased-diameter inner-wall surface 11d as indicated by arrow S in
Owing to the above-described operation, upon shifting the internal combustion engine 1 from an idling state to an acceleration state, the main flap 15 is allowed to immediately move to the fully opening position in response to increase in the intake air flow rate. As a result, it is possible to surely avoid deterioration in acceleration performance which is caused due to a delay in the opening movement of the main flap 15.
The present invention is not limited to the above-described embodiment, and various modifications thereof may be provided. For example, although in this embodiment, the communication passage 33 is defined by the increased-diameter inner-wall surface 11d so as to extend over the whole width of the damper flap 16, the communication passage can also be formed by a grooved portion on the inner-wall surface of the damper chamber 11 which is opposed only to a part of the tip end edge 16a of the damper flap 16 in the width direction when the main flap 15 is rotationally moved in the opening direction together with the damper flap 16. Further, the communication passage can be formed by a grooved portion on the side inner-wall surfaces 11b of the damper chamber 11 which are opposed to the side edges 16b of the damper flap 16 when the main flap 15 is rotationally moved in the opening direction together with the damper flap 16.
This application is based on a prior Japanese Patent Application No. 2011-275160 filed on Dec. 16, 2012. The entire contents of the Japanese Patent Application No. 2011-275160 are hereby incorporated by reference.
Although the invention has been described above by reference to a certain embodiment of the invention and modifications thereof, the invention is not limited to the embodiment and the modifications as described above. Variations of the embodiment and the modifications as described above will occur to those skilled in the art in light of the above teachings. The scope of the invention is defined with reference to the following claims.
Number | Date | Country | Kind |
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2011-275160 | Dec 2011 | JP | national |