CN105386837A

CN105386837A - Muffler device and manufacturing method for muffler device

Info

Publication number: CN105386837A
Application number: CN201510514855.0A
Authority: CN
Inventors: 高垣仲矢; 幸光秀之
Original assignee: Toyota Motor Corp
Current assignee: Toyota Motor Corp
Priority date: 2014-08-25
Filing date: 2015-08-20
Publication date: 2016-03-09
Also published as: AU2015215314A1; JP2016044626A; RU2015135498A; EP2990622A1

Abstract

The invention discloses a muffler device and a manufacturing method for a muffler. One shell out of an outer layer shell (21) and an inner layer shell (22) has a processed part (21a) that is processed into a shape protruding towards the other shell. An intermediate sheet (50) includes a receiving part (51) in a region that faces the processed part, and the receiving part (51) is formed into a shape that allows the processed part to enter the receiving part. Since the receiving part is formed in the intermediate sheet in a region that faces the processed part, the receiving part is positioned around the processed part when the processed part enters the receiving part, thereby preventing the receiving part from shifting with respect to the processed part.

Description

Muffler and the manufacture method for muffler

Technical field

The present invention relates to a kind of following muffler and the manufacture method for this muffler: the intermediate plate as damping material or sound-absorbing material is arranged between double shells.

Background technique

In No. 2010-190205th, Japanese Patent Application Publication (JP2010-190205A) and No. 2004-150310th, Japanese Patent Application Publication (JP2004-150310A), for the shell of muffler by two sheet metals is stacked on top of each other and form.In JP2004-150310A, sound-absorbing material is filled between two sheet metals.

In JP2004-150310A, in order to play the sound absorption function of sound-absorbing material, be necessary sound-absorbing material to be arranged on given position.As described in JP2004-150310A, when sound-absorbing material is filled between two sheet metals, due to the vibration etc. of shell while using at muffler, and the position of sound-absorbing material can be moved between two sheet metals.When manufacturing muffler, the position of sound-absorbing material also can be moved.

Summary of the invention

The first scheme of the invention of the application is muffler, and the exhaust of discharging from the internal-combustion engine of vehicle is imported into described muffler.Described muffler comprises outer shell, inner layer case and intermediate plate.Described outer shell is arranged on the outer surface of described muffler, extends, and be formed as tubular along assigned direction.Described inner layer case is arranged in the inner side of the described outer shell in described muffler, extends, and be formed as tubular along described assigned direction.Described intermediate plate to be arranged between described outer shell and described inner layer case and to be used as damping material or sound-absorbing material.

A shell in described outer shell and described inner layer case comprises processing department, and described processing department is processed to the shape protruded towards another shell.Described intermediate plate is included in the receiving portion in the region of described processing department, and described receiving portion is formed as allowing described processing department to enter the shape of described receiving portion.

According to the first scheme of the invention of the application, due to receiving portion be formed in intermediate plate in the face of processing department region in, therefore when processing department enters receiving portion, receiving portion is located around processing department, thus prevents receiving portion from moving relative to processing department.In brief, intermediate plate can be located by using processing department and receiving portion, and can prevent the position of the intermediate plate when using muffler from moving relative to inner layer case and outer shell thus.By preventing the movement of the position of intermediate plate, easily play the function of the intermediate plate as damping material or sound-absorbing material.

A described shell can comprise multiple described processing department.Further, corresponding with described multiple processing department respectively multiple receiving portions can be formed in intermediate plate.Described multiple receiving portion can be formed in the position that the circumference along described assigned direction and described outer shell and described inner layer case does not line up each other.Therefore, it is possible to prevent the position of intermediate plate from moving along assigned direction and circumference.

As processing department, the part by processing a described shell can be used and the curved part obtained.Therefore, it is possible under the condition of thickness not changing shell, construct towards the outstanding processing department of another shell described.In other words, muffler of the present invention is configured to by using the shell with uniform thickness as prior art.

Described muffler can comprise separator.Described separator has the flange that the inner peripheral surface along described inner layer case is formed, and the space of the inner side being formed in described inner layer case is divided into the multiple spaces arranged along described assigned direction.Described receiving portion can have hole, and described hole allows described processing department to pass, and allows described processing department and another shell joint described to touch.Therefore, described flange, described processing department and another shell described can be stacked on top of each other and be welded to one another.Because the receiving portion with hole allows processing department and another shell joint to touch, therefore, it is possible to make flange, processing department and another shell easily weld each other, thus easily guarantee the intensity of welding portion.Receiving portion can have the recess except hole.

The alternative plan of the invention of the application is the manufacture method for the muffler according to first scheme of the present invention.In this manufacture method, processing department is formed in the coverboard forming outer shell and inner layer case, and by allowing described processing department to enter receiving portion, intermediate plate is stacked on described coverboard.Then, form by the described coverboard being stacked with described intermediate plate is formed tubular described outer shell and described inner layer case that described intermediate plate is clipped in the middle.

According to the alternative plan of the invention of the application, intermediate plate can be located relative to coverboard by allowing processing department to enter receiving portion.Therefore, it is possible to form outer shell and inner layer case while the intermediate plate of location, thus prevent the position of the intermediate plate when manufacturing muffler from moving.When manufacturing muffler, intermediate plate can be positioned at given position.Therefore, the function of the intermediate plate as damping material or sound-absorbing material is easily played.

When forming described outer shell and described inner layer case, can, by making described coverboard reel around described separator while giving described coverboard pulling force, described coverboard be made to form tubular.By giving coverboard pulling force, intermediate plate and outer shell and inner layer case close contact can be made when forming outer shell and inner layer case.Therefore, the function of the intermediate plate as damping material or sound-absorbing material is easily played.

The third program of the invention of the application is the manufacture method of the muffler of the first scheme for the invention according to the application.In described manufacture method, processing department is formed in the first coverboard of the shell formed in shell, and allows described processing department to enter receiving portion, and intermediate plate be clipped in form another shell between the second coverboard and described first coverboard.Then, described first coverboard be clipped in the middle by described intermediate plate and described second coverboard are formed as tubular, thus form outer shell and inner layer case respectively.

According to the third program of the invention of the application, intermediate plate can be located relative to the first coverboard by allowing processing department to enter receiving portion.Outer shell and inner layer case can be formed while the intermediate plate of location thus, thus can prevent the position of the intermediate plate when manufacturing muffler from moving.When manufacturing muffler, intermediate plate can be positioned at given position, thus play the function of the intermediate plate as damping material or sound-absorbing material.

When forming described outer shell and described inner layer case, while giving described first coverboard and described second coverboard pulling force, described first coverboard and described second coverboard are reeled around described separator.This enables outer shell described in intermediate plate close contact and described inner layer case.Therefore, the function of the intermediate plate as damping material or sound-absorbing material is easily played.

In the alternative plan and third program of the invention of the application, described intermediate plate can comprise multiple receiving portion, and described multiple receiving portion is formed in the position that the circumference along described assigned direction and described outer shell and described inner layer case does not line up each other.Further, a described shell can comprise the multiple described processing department corresponding respectively with described multiple receiving portion.When manufacturing muffler, each can passing through in permission processing department enters each in receiving portion, comes to locate intermediate plate along assigned direction and circumference.

In the alternative plan and third program of the invention of the application, described receiving portion can have hole, and described hole allows described processing department to pass, and described processing department and another shell joint described are touched.Therefore, it is possible to by stacked on top of each other to described flange, described processing department and another shell described and be welded to one another.Because the receiving portion with hole allows processing department and another shell joint to touch, therefore, it is possible to make processing department and another shell easily weld each other, thus easily guarantee the intensity of welding portion.

Accompanying drawing explanation

With reference to accompanying drawing, will be described below the feature of one exemplary embodiment of the present invention, advantage and technology and industry meaning, wherein same reference character represents same element, and wherein:

Fig. 1 is the external view of the muffler according to the first example;

Fig. 2 is the sectional view of the muffler according to the first example;

Fig. 3 is the sectional view of the muffler according to the first example;

Fig. 4 is the external view of the muffler according to the first example, wherein omits outer shell;

Fig. 5 is the sectional view of a part for the structure of the muffler illustrated according to the first example;

Fig. 6 is the view of the manufacture method illustrated for the muffler according to the first example;

Fig. 7 is the plan view of the coverboard according to the first example, and wherein intermediate plate is stacked on described coverboard;

Fig. 8 is the external view of the muffler of variation according to the first example, wherein omits outer shell;

Fig. 9 is the sectional view of a part for the structure of the muffler illustrated according to the second example;

Figure 10 is the sectional view of a part for the structure of the muffler illustrated according to the 3rd example;

Figure 11 is the view of the profile of the separator illustrated according to the 3rd example;

Figure 12 is the view of the manufacture method illustrated for the muffler according to the 3rd example;

Figure 13 is the sectional view of a part for the structure of the muffler of the variation illustrated according to the 3rd example;

Figure 14 is the view of the manufacture method illustrated for the muffler according to the 4th example;

Figure 15 is the sectional view of the structure of the shell illustrated according to the 4th example; And

Figure 16 is to the sectional view of the intermediate plate of the variation of the 4th example according to the first example.

Embodiment

Example of the present invention is hereafter being described.

Muffler according to this example is described.Fig. 1 is the external view of muffler 1.Fig. 2 is the sectional view intercepted along the line A1-A1 in Fig. 1, and Fig. 3 is the sectional view intercepted along the line A2-A2 in Fig. 1.Fig. 1 is the external view from muffler 1 seen by the arrow B 2 shown in the arrow B 1 shown in Fig. 2 and Fig. 3.

A pair end cap 11,12 and shell 20 form the outer surface of muffler 1.Shell 20 is formed as tubular, and extends along the longitudinal direction (substantially horizontal in Fig. 1, corresponding to assigned direction of the present invention) of muffler 1.Opening portion is formed on the two ends in the longitudinal direction of muffler 1 of shell 20, and opening portion is closed respectively by the end cap 11,12 of metal.Each in end cap 11,12 is all by being welded and fixed to shell 20.

As shown in Figures 2 and 3, shell 20 has double layer construction, and comprises outer shell 21 and inner layer case 22.Outer shell 21 and inner layer case 22 are both formed as tubular, and along the longitudinal extension of muffler 1.Outer shell 21 is arranged on the outer surface of muffler 1, and inner layer case 22 is arranged in the inner side of the outer shell 21 in muffler 1.As described later, outer shell 21 and inner layer case 22 are formed by a metal coverboard.

Inside inner layer case 22, arrange the separator 31 to 34 of four metals.Inner layer case 22 is arranged along the outward edge of separator 31 to 34, and flange is arranged in the outward edge of each in separator 31 to 34, and contacts with the inner peripheral surface of inner layer case 22.The space be formed in inside inner layer case 22 is divided into five space S 1 to S5 by each in separator 31 to 34.Each in space S 1 to S5 is all used as the expansion chamber of exhaust.

Space S 1 is the space surrounded by a part for end cap 11, separator 31 and inner layer case 22, and space S 2 is the spaces surrounded by a part for separator 31,32 and inner layer case 22.Space S 3 is the spaces surrounded by a part for separator 32,33 and inner layer case 22, and space S 4 is the spaces surrounded by a part for separator 33,34 and inner layer case 22.Space S 5 is the spaces surrounded by a part for separator 34, end cap 12 and inner layer case 22.In this example, four separators 31 to 34 are set.But the quantity of separator can suitably set.

The downtake pipe 41 of metal is through each in end cap 11 and separator 31 to 34.An end 41a of downtake pipe 41 is positioned at the outside of muffler 1, and is connected with an end of ingress pipe (not shown).Another end of ingress pipe is connected with the relief opening of the internal-combustion engine of vehicle.Therefore, muffler 1 is imported into from the gas (exhaust) of relief opening discharge.

Because another end 41b of downtake pipe 41 is positioned at space S 5, the exhaust therefore from relief opening is mobile in downtake pipe 41, and is discharged into space S 5 from another end 41b.The exhaust be discharged in space S 5 moves through according to this order of space S 4, space S 3, space S 2 and space S 1.In each in separator 31 to 34, opening portion formed for allow exhaust through.Such as, as shown in Figures 2 and 3, separator 32 have for allow be vented through opening portion 32a.

The second exhaust pipe 42 of metal is through each in end cap 12 and separator 31 to 34.An end 42a of second exhaust pipe 42 is positioned at the outside of muffler 1, and another end 42b of second exhaust pipe 42 is positioned at space S 1.As described above, the exhaust having moved to space S 1 is guided in second exhaust pipe 42 from another end 42b, and discharges from an end 42a.

As shown in figures 1 and 3, multiple curved part (corresponding to processing department of the present invention) 21a is arranged in outer shell 21, and curved part 21a by by the bend portions of outer shell 21 in case towards shell 20 inner side protrude and formed.The thickness of curved part 21a equals the thickness of the outer shell 21 not comprising curved part 21a.As shown in Figure 1, multiple curved part 21a arranges along the outward edge of each separator in separator 31 to 34, and the part that each separator in welding curved part 21a, inner layer case 22 and separator 31 to 34 is stacked on top of each other.

As shown in Figure 2, two intermediate plates 50 are arranged between outer shell 21 and inner layer case 22.In brief, intermediate plate 50 is clipped between outer shell 21 and inner layer case 22.Because the temperature of muffler 1 becomes high because of the heat of exhaust, therefore intermediate plate 50 is formed by the material with heat resistance.

Intermediate plate 50 can have damped vibration function (vibration-damping function).For the intermediate plate 50 with vibration-damping function, the plate formed by carbon (expanded graphite etc.) can be used.When exhaust is guided in muffler 1, outer shell 21 and inner layer case 22 are vibrated.By being arranged between outer shell 21 and inner layer case 22 by the intermediate plate 50 with vibration-damping function, intermediate plate 50 can the vibration of damping outer shell 21 and inner layer case 22.Because the vibration of outer shell 21 and inner layer case 22 is damped, the sound produced with vibration can be reduced.

Meanwhile, intermediate plate 50 also can have sound absorption function (acoustic absorption function).For the intermediate plate 50 with sound absorption function, the plate formed by such as glass wool can be used.The sound produced because intermediate plate 50 absorbs the vibration because of outer shell 21 and inner layer case 22, therefore, it is possible to reduce the sound transmitted outside muffler 1.

Intermediate plate 50 is arranged in the position that being easy in muffler 1 produces vibration and sound.In the sectional view of the muffler 1 shown in Fig. 2, the length in the horizontal direction of muffler 1 is less than the length on the vertical direction shown in Fig. 2 of muffler 1.Therefore, vibration and sound are easy to produce in the substantially horizontal shown in Fig. 2 two side surfaces of shell 20.Thus, in this example, as shown in Figure 2, in the substantially horizontal shown in Fig. 2 two side surfaces of shell 20, intermediate plate 50 is arranged between outer shell 21 and inner layer case 22.

Arrange that the position of intermediate plate 50 is not restricted to the position shown in Fig. 2.Consider shell 20 vibrational state and from the sonorific state of this shell 20, for arranging that the position of intermediate plate 50 can preset.In order to play vibration-damping function and sound absorption function, be necessary intermediate plate 50 to be arranged to do not allow intermediate plate 50 to move from the given location preset.Meanwhile, in this example, two intermediate plates 50 are provided with.But, the quantity of intermediate plate 50 can be one, three or more.

Fig. 4 is the view of the muffler 1 shown in Fig. 1 omitting outer shell 21.Fig. 4 illustrates the external view of an intermediate plate 50 in two intermediate plates 50.Two intermediate plates 50 have identical structure.

As shown in Figure 4, intermediate plate 50 has multiple (particularly, 16) hole (corresponding to receiving portion of the present invention) 51, and each hole 51 is through intermediate plate 50.Each being formed in the curved part 21a in outer shell 21 enters the inner side in each hole 51.Particularly, as shown in Figure 5, the curved part 21a of outer shell 21 gives prominence to and the inner side of access aperture 51 towards inner layer case 22.Fig. 5 illustrates the structure of a part for the muffler 1 along the longitudinally cutting of muffler 1.

In intermediate plate 50, hole 51 is formed in the region of curved part 21a, and is also formed along the profile of curved part 21a.The curved part 21a of the inner side of access aperture 51 contacts with the outer surface of inner layer case 22.Curved part 21 gives prominence to the thickness of intermediate plate 50 towards inner layer case 22.

As shown in Figure 5, flange 32b is arranged on the outward edge of separator 32.Flange 32b is formed along the inner peripheral surface of inner layer case 22, and also contacts with the inner peripheral surface of inner layer case 22.The flange being similar to flange 32b is also arranged in each in separator 31,33,34.

In Figure 5, curved part 21a, inner layer case 22 and flange 32b part stacked on top of each other is welded.Therefore, outer shell 21 and inner layer case 22 are fixed to separator 32.Similarly, the flange of each separator in separator 31,33,34 is stacked on inner layer case 22 and curved part 21a, and welds stacked part.Therefore, outer shell 21 and inner layer case 22 are fixed to separator 31,33,34.

Next, with reference to figure 6 and Fig. 7, explain the manufacture method of muffler 1.

Fig. 6 illustrates the state before coverboard 23 reels around end cap 11,12 and separator 31 to 34.Downtake pipe 41 is connected with end cap 11,12 and separator 31 to 34 with second exhaust pipe 42.Fig. 7 is the view from coverboard 23 seen by the arrow C direction shown in Fig. 6 and intermediate plate 50.In the figure 7, end cap 11,12 and separator 31 to 34 is omitted.

First, coverboard 23 is soldered to end cap 11,12 at P11 place, position.Then, by making end cap 11,12 and separator 31 to 34 rotate along the arrow R1 direction shown in Fig. 6, coverboard 23 reels around end cap 11,12 and separator 31 to 34.Along with coverboard 23 reels until the position P12 of coverboard 23 around end cap 11,12 and separator 31 to 34 from the position P11 of coverboard 23, end cap 11,12 and separator 31 to 34 are surrounded by coverboard 23, thus form tubular inner layer case 22.

Next, along with coverboard 23 reels until the position P13 of coverboard 23 around end cap 11,12 and separator 31 to 34 from the position P12 of coverboard 23, form tubular outer shell 21.Coverboard 23 is soldered to end cap 11,12 at P13 place, position.As described up to now, by making coverboard 23 relative to end cap 11,12 and separator 31 to 34 two important place winding, shell 20 is formed.

Each in two intermediate plates 50 is all stacked in the region between the position P12 of coverboard 23 and position P13.In the region between the position P12 and position P13 of coverboard 23, multiple curved part 21a is pre-formed, and each in curved part 21a enters the inner side in each hole 51 in intermediate plate 50.Therefore, it is possible to make intermediate plate 50 locate relative to coverboard 23.

When outer shell 21 is formed by winding coverboard 23, intermediate plate 50 is clipped between inner layer case 22 and outer shell 21.Now, while giving coverboard 23 pulling force, coverboard 23 reels around end cap 11,12 and separator 31 to 34.So, intermediate plate 50 easily with outer shell 21 and inner layer case 22 close contact.

At shell 20 by coverboard 23 is reeled around end cap 11,12 and separator 31 to 34 and after formation, carries out such as laser bonding from the outside of shell 20 at curved part 21a.Therefore, following part is welded: the described part that the flange of each separator in curved part 21a, inner layer case 22 and corresponding separator 31 to 34 is stacked on top of each other.Therefore, muffler 1 is completed.Because curved part 21a is formed in outer shell 21, therefore when carrying out laser bonding, curved part 21a can be used as mark.

Manufacture method for muffler 1 is not restricted to above-mentioned method.In the other manufacture method for muffler 1 explained hereinafter.

First, the shell 20 of tubular is formed by the coverboard 23 being stacked with intermediate plate 50 that only reels.Now, end cap 11,12 and separator 31 to 34 are not assembled into shell 20.When the shell 20 of tubular is formed, intermediate plate 50 is clipped between outer shell 21 and inner layer case 22.

Next, each in separator 31 to 34 all inserts the inner side of the shell 20 of tubular.Now, each in separator 31 to 34 is all inserted, so that the flange of each separator in separator 31 to 34 is stacked on curved part 21a by inner layer case 22.Next, a pair fixture layout is in following position: the position flange of each separator in separator 31 to 34, inner layer case 22 and curved part 21a are clipped in the middle, and electric current flows between described a pair fixture, thus the flange of each separator in separator 31 to 34, inner layer case 22 and curved part 21a are welded to one another.

A separator in separator 31 to 34 inserts the inner side of shell 20 and after welding, next separator inserts the inner side of shell 20 and welds.Like this, separator 31 to 34 inserts the inner side of shell 20 and sequentially welds.So, after the welding completing separator 31 to 34, end cap 11,12 is soldered to the shell 20 of tubular.After this, downtake pipe 41 can be assembled into end cap 11 and separator 31 to 34, and second exhaust pipe 42 can be assembled into end cap 12 and separator 31 to 34.Thus, complete muffler 1.

Explain the effect of this example.

In muffler 1, the curved part 21a of outer shell 21 enters the inner side in the hole 51 of intermediate plate 50, and is soldered to each separator in inner layer case 22 and separator 31 to 34.In intermediate plate 50, hole 51 is formed in the region of curved part 21a.Therefore, when the inner side of curved part 21a access aperture 51, hole 51 is located around curved part 21a.

Therefore, hole 51 is unlikely moved relative to the curved part 21a of welding.Thus, can prevent intermediate plate 50 from moving between outer shell 21 and inner layer case 22.By preventing intermediate plate 50 from moving, intermediate plate 50 can be made to keep being arranged in given position, and intermediate plate 50 can be used thus to play given function (above-mentioned vibration-damping function and sound absorption function).

In this example, because curved part 21a is set in advance in outer shell 21, therefore, it is possible to make the flange of each separator in curved part 21a, inner layer case 22 and separator 31 to 34 easily weld each other, and easily can guarantee the intensity of welding portion thus.In addition, the distortion of the outer shell 21 when outer shell 21 and inner layer case 22 are welded to one another can be prevented.

When outer shell 21 and inner layer case 22 curved part 21a be not formed in be welded to one another under the condition in outer shell 21 time, can it is contemplated that the part distortion of outer shell 21 and the inner side of patchhole 51.In this case, when outer shell 21 is out of shape, intermediate plate 50 may be damaged by pressure and may be chapped from hole 51.When outer shell 21 a part distortion and soldered time, because a part for outer shell 21 is welded in the expanded state, therefore the welding portion of outer shell 21 becomes thinner, and the intensity of outer shell 21 likely reduces.

In this example, as mentioned above, because curved part 21a is used, outer shell 21 therefore need not be made to be out of shape.Therefore, it is possible to prevent intermediate plate 50 from being damaged by pressure by outer shell 21, and prevent be full of cracks from occurring from hole 51.Further, due to weld time outer shell 21 a part do not stretch, therefore, it is possible to guarantee the intensity of outer shell 21.

Meanwhile, by using curved part 21a, a part for outer shell 21 can be made under the condition not changing outer shell 21 thickness to give prominence to towards inner layer case 22.In other words, being similar to prior art, muffler 1 can being constructed by using the outer shell 21 with uniform thickness.

Arranging at least two holes 51 makes it possible to prevent intermediate plate 50 from moving along the longitudinal direction (substantially horizontal in Fig. 4) of muffler 1 and the circumference of shell 20.Two holes 51 only need to be formed in the position do not lined up each other along the longitudinal direction of muffler 1 and the circumference of shell 20.Such as, as shown in Figure 8, in intermediate plate 50, two hole 51A for locating intermediate plate 50 can be formed and be not the multiple hole 51B for locating intermediate plate 50.Fig. 8 is the view corresponding to Fig. 4.

Hole 51A is identical with the hole 51 illustrated by this example.Two hole 51A are formed in the position do not lined up each other along the longitudinal direction (substantially horizontal in Fig. 8) of muffler 1 and the circumference (vertical direction in Fig. 8) of shell 20.Therefore, by using two hole 51A, intermediate plate 50 can be made along the longitudinal direction of muffler 1 and always locating in week of shell 20.

The position of providing holes 51A is not restricted to the position shown in Fig. 8.As mentioned above, when arranging at least two hole 51A, these two hole 51A only need to be formed in the position do not lined up each other along the longitudinal direction of muffler 1 and the circumference of shell 20.In addition, can exist only one for locating the hole 51A of intermediate plate 50.In this case, also can prevent intermediate plate 50 from moving because hole 51A fixes.

In intermediate plate 50, hole 51B is formed in large region, the region of specific surface to curved part 21a, and does not have the function of location intermediate plate 50.Hole 51B is formed as allowing curved part 21a contact with inner layer case 22 and allow the flange of each separator in curved part 21a, inner layer case 22 and separator 31 to 34 to be welded to one another.

Next, when manufacturing muffler 1, intermediate plate 50 can be located relative to coverboard 23 by allowing curved part 21a access aperture 51.So under the state that intermediate plate 50 is positioned on coverboard 23, coverboard 23 and intermediate plate 50 reel around end cap 11,12 and separator 31 to 34.

This makes it possible to, while winding coverboard 23, prevent intermediate plate 50 from moving relative to coverboard 23.Intermediate plate 50 can be made thus to be arranged in given position between outer shell 21 and inner layer case 22, and easily to use intermediate plate 50 to play given function (above-mentioned vibration-damping function and sound absorption function).As described earlier, by arranging at least two holes 51, can prevent intermediate plate 50 from moving along the longitudinal direction of muffler 1 and the circumference of shell 20 relative to coverboard 23.

Further, by making coverboard 23 reel around end cap 11,12 and separator 31 to 34 while giving coverboard 23 pulling force, intermediate plate 50 and outer shell 21 and inner layer case 22 close contact can be allowed.Therefore, it is possible to easily use intermediate plate 50 to play given function (above-mentioned vibration-damping function and sound absorption function).

Muffler according to the second example of the present invention is described.In this example, identical reference character for having the component of the function identical with the component illustrated by the first example, and omits detailed description.Hereafter main, the difference with the first example is described.

With reference to figure 9, the muffler 1 according to this example is described.Fig. 9 is the view corresponding to Fig. 5.As shown in Figure 9, outer shell 21 comprises main part 21b and protuberance (corresponding to according to processing department of the present invention) 21c.Outer shell 21 comprises the part of the thickness only with main part 21b and has the part of the thickness of main part 21b and the thickness of protuberance 21c.

Protuberance 21c is formed as the shape protruded from main part 21b towards inner layer case 22.Protuberance 21c enters the inner side in the hole 51 of intermediate plate 50, and contacts with inner layer case 22.The thickness of protuberance 21c equals the thickness of intermediate plate 50.Hole 51 be formed in intermediate plate 50 in the face of protuberance 21c region in.Main part 21b and protuberance 21c can be formed integral with one anotherly, or main part 21b and protuberance 21c is configured to separably, and protuberance 21c can be fixed to main part 21b.

The muffler 1 according to this example can be manufactured by the method being similar to the first example.It is just enough that protuberance 21c replaces curved part 21a to be previously formed in the coverboard 23 shown in Fig. 6 and Fig. 7.

According to this example, be similar to the first example, by using hole 51, when can prevent in use or manufacture muffler 1, intermediate plate 50 moves.In addition, be similar to the first example, by allowing the inner side of protuberance 21c access aperture 51 and contacting with inner layer case 22, the flange of each separator in outer shell 21, inner layer case 22 and separator 31 to 34 can be made easily to weld each other.Therefore, it is possible to easily guarantee the intensity of welding portion.

Muffler according to the 3rd example of the present invention is described.In this example, identical reference character for having the component of the function identical with the component illustrated by the first example, and omits detailed description.Hereafter main, the difference with the first example is described.

In the first example, curved part 21a is formed in outer shell 21.But, in this example, as shown in Figure 10, eliminate the curved part 21a of outer shell 21, and curved part 22a is formed in inner layer case 22.Figure 10 is the view corresponding to Fig. 5.Curved part 22a is formed by a part for bending inner layer case 22.The thickness of curved part 22a equals the thickness of the inner layer case 22 not comprising curved part 22a.Curved part 22a is formed as the shape protruded towards outer shell 21, enters the hole 51 in intermediate plate 50, and contacts with outer shell 21.

As shown in Figure 10, the flange 32b of separator 32 contacts with curved part 22a.The flange 32b of separator 32 is formed as the shape stretched along inner layer case 22.Particularly, separator 32 is formed as the shape shown in Figure 11.Figure 11 is the view of the longitudinally seen separator 32 from muffler 1.Figure 11 not only shows separator 32 but also shows downtake pipe 41 and second exhaust pipe 42.

As shown in figure 11, the position that separator 32 is corresponding to curved part 22a has protuberance 32c.Because curved part 22a gives prominence to towards outer shell 21, therefore protuberance 32c is also formed in separator 32.Therefore, the flange 32b be formed in the outward edge of separator 32 arranges along the inner layer case 22 comprising curved part 22a.

Next, by using Figure 12 explanation according to the manufacture method of the muffler 1 of this example.Figure 12 is the view corresponding to Fig. 6.

First, coverboard 23 is soldered to end cap 11,12 at P21 place, position.Then, by along the arrow R2 direction rotating end cap 11,12 in Figure 12 and separator 31 to 34, coverboard 23 reels around end cap 11,12 and separator 31 to 34.Downtake pipe 41 is connected with end cap 11,12 and separator 31 to 34 with second exhaust pipe 42.

By making coverboard 23 reel until the position P22 of coverboard 23 around end cap 11,12 and separator 31 to 34 from the position P21 of coverboard 23, the inner layer case 22 of tubular is formed.Two intermediate plates 50 are stacked in the region between the position P21 of coverboard 23 and position P22 respectively.

In region between position P21 in coverboard 23 and position P22, multiple curved part 22a is pre-formed.Each curved part 22a enters the inner side in the hole 51 of intermediate plate 50.Therefore, intermediate plate 50 is located relative to coverboard 23.When inner layer case 22 is formed, the protuberance 32c of the separator 32 shown in Figure 11 enters the inner side of curved part 22a (in brief, recess).Further, when inner layer case 22 is formed, intermediate plate 50 is arranged on the outer surface of inner layer case 22.

Next, by making coverboard 23 reel until the position P23 of coverboard 23 around end cap 11,12 and separator 31 to 34 from the position P22 of coverboard 23, the outer shell 21 of tubular is formed.Coverboard 23 is soldered to end cap 11,12 at P23 place, position.When outer shell 21 is formed, intermediate plate 50 is clipped between inner layer case 22 and outer shell 21.By making coverboard 23 reel around end cap 11,12 and separator 31 to 34 while giving coverboard 23 pulling force, intermediate plate 50 easily with outer shell 21 and inner layer case 22 close contact.

Reel and after formation, carry out such as laser bonding from the outside of shell 20 by making coverboard 23 around end cap 11,12 and separator 31 to 34 at shell 20.Therefore, the part that the flange of each separator in outer shell 21, curved part 22a and separator 31 to 34 is stacked on top of each other is welded.Therefore, muffler 1 is completed.

According to this example, due to hole 51 be formed in intermediate plate 50 in the face of curved part 22a region in, therefore when the inner side of curved part 22a access aperture 51, hole 51 is located around curved part 22a.Therefore, hole 51 is unlikely moved relative to the curved part 22a of welding.So be similar to the first example, when can prevent in use or manufacture muffler 1, intermediate plate 50 moves.

By allowing the inner side of curved part 22a access aperture 51 and contacting with outer shell 21, the flange of each separator in outer shell 21, inner layer case 22 and separator 31 to 34 easily welds each other, thus easily guarantees the intensity of welding portion.In addition, by using curved part 22a, a part for inner layer case 22 can be allowed under the condition of thickness not changing inner layer case 22 to give prominence to towards outer shell 21.In other words, being similar to prior art, muffler 1 can being constructed by using the inner layer case 22 with uniform thickness.

By the variation using Figure 13 that this example is described.Figure 13 is the view corresponding to Fig. 9.As shown in figure 13, inner layer case 22 has main part 22b and protuberance 22c.Inner layer case 22 comprises the part of the thickness only with main part 22b and has the part of the thickness of main part 22b and the thickness of protuberance 22c.

Protuberance 22c is formed as the shape protruded from main part 22b towards outer shell 21.Protuberance 22c enters the inner side in the hole 51 of intermediate plate 50 and contacts with outer shell 21.The thickness of protuberance 22c equals the thickness of intermediate plate 50.Main part 22b and protuberance 22c can be formed integral with one anotherly, or main part 22b and protuberance 22c is configured to separably, and then protuberance 22c can be fixed to main part 22b.

With the muffler 1 of method manufacture according to this variation being similar to the first example.This means that muffler 1 manufactures around end cap 11,12 and separator 31 to 34 winding by making coverboard 23, or muffler 1 manufactures by separator 31 to 34 and end cap 11,12 are assembled into the shell 20 being formed as tubular.Only be necessary to replace the protuberance 22c of curved part 22a to be previously formed in the coverboard 23 shown in Figure 12.

According to this variation, by using protuberance 22c and hole 51, when can prevent in use or manufacture muffler 1, intermediate plate 50 moves.Further, by allowing the inner side of protuberance 22c access aperture 51 and contacting with outer shell 21, the flange of each separator in outer shell 21, inner layer case 22 and separator 31 to 34 easily welds each other, thus easily guarantees the intensity of welding portion.

Muffler according to the 4th example of the present invention is described.In this example, identical reference character for having the component of the function identical with the component illustrated by the first example to the 3rd example, and omits detailed description.Illustrate with the first example to the difference of the 3rd example hereafter main.

At the first example in the 3rd example, outer shell 21 and inner layer case 22 reel by making a coverboard 23 around end cap 11,12 and separator 31 to 34 and are formed.Meanwhile, in this example, outer shell 21 formed by the coverboard be separated with inner layer case 22.

As shown in figure 14, intermediate plate 50 is arranged between the coverboard 23A forming the outer shell 21 and coverboard 23B forming inner layer case 22, and coverboard 23A, coverboard 23B and intermediate plate 50 are stacked on top of each other.Here, the curved part 21a illustrated in the first example or the protuberance 21c illustrated in the second example can be formed in coverboard 23A.In this case, as illustrated in the first example or the second example, intermediate plate 50 can be located relative to coverboard 23A by allowing curved part 21a or protuberance 21c to enter the inner side in the hole 51 of intermediate plate 50.

Meanwhile, the curved part 22a illustrated in the 3rd example or protuberance 22c can be formed in coverboard 23B.In this case, as illustrated in the 3rd example, intermediate plate 50 can be located relative to coverboard 23B by allowing the inner side of curved part 22a or protuberance 22c access aperture 51.

As shown in figure 14, by along arrow R3 direction rotating end cap 11,12 and separator 31 to 34, coverboard 23A, 23B and intermediate plate 50 can be made to reel around end cap 11,12 and separator 31 to 34.Therefore, as shown in figure 15, the outer shell 21 of tubular is formed by coverboard 23A, and the inner layer case 22 of tubular is formed by coverboard 23B.Further, intermediate plate 50 is arranged between outer shell 21 and inner layer case 22.Figure 15 is the sectional view of the structure that shell 20 and intermediate plate 50 are shown, and corresponds to Fig. 2.In fig .15, the separator 31 to 34 being arranged in the inner side of shell 20 is omitted.

Coverboard 23A, 23B can be made while giving coverboard 23A, 23B pulling force to reel around end cap 11,12 and separator 31 to 34.Therefore, intermediate plate 50 easily with outer shell 21 and inner layer case 22 close contact, thus easily use intermediate plate 50 play given function (above-mentioned vibration-damping function and sound absorption function).

After this, as the first example illustrates to the 3rd example, be only necessary outer shell 21 and inner layer case 22 to be soldered to each in separator 31 to 34 and end cap 11,12.Coverboard 23A, 23B P31, P32 place, position shown in Figure 14 is soldered to end cap 11,12.

The two ends at P31, P32 place, position of coverboard 23A can near each other and weld, and the two ends at P31, P32 place, position of coverboard 23B can near each other and weld.Replace making the two ends of each coverboard in coverboard 23A, 23B near each other, when reel stratiform (layered) main body time, can being stacked at the two ends at P31, P32 place, position of laminated body of coverboard 23A, 23B is gone up each other and is welded to one another.

Manufacture method for muffler 1 is not restricted to above-mentioned method.As illustrated in the first example, when curved part 21a (the first example) or protuberance 21c (the second example) is formed in coverboard 23A, or protuberance 22c (the 3rd example) is when being formed in coverboard 23B, by the laminated body of reel coverboard 23A, 23B and intermediate plate 50 stratification, the shell 20 of tubular can be pre-formed.Then, each in separator 31 to 34 all can insert the inner side of the shell 20 of tubular, and each in separator 31 to 34 all can be soldered to shell 20.

When outer shell 21 and inner layer case 22 construct discretely, also can be similar to the first example and locate intermediate plate 50 like that to each example in the 3rd example.Therefore, when preventing in use or manufacture muffler 1, intermediate plate 50 moves.Further, be similar to the first example to the 3rd example, the flange of each separator in outer shell 21, inner layer case 22 and separator 31 to 34 easily welds each other, thus easily guarantees the intensity of welding portion.

At the first above-mentioned example in the 4th example, hole 51 is formed in intermediate plate 50, but the present invention is not restricted to this.Particularly, as shown in figure 16, recess (corresponding to receiving portion of the present invention) 52 can be formed in intermediate plate 50.Figure 16 is the sectional view on the thickness direction of intermediate plate 50, and corresponds to Fig. 5, Fig. 9, Figure 10 and Figure 13.In the structure shown in Figure 16, recess 52 upward opening in figure 16.

Recess 52 can be formed in the position identical with the hole 51 shown in Fig. 5 with Fig. 9.In this case, recess 52 is towards outer shell 21 opening.The protuberance 21c shown in curved part 21a or Fig. 9 shown in Fig. 5 can enter the inner side of recess 52.By allowing curved part 21a or protuberance 21c to enter recess 52, preventing recess 52 from moving relative to curved part 21a or protuberance 21c, and intermediate plate 50 can be positioned between outer shell 21 and inner layer case 22 thus.

Recess 52 also can be formed in the position identical with the hole 51 shown in Figure 10 or Figure 13.Now, recess 52 is towards inner layer case 22 opening.The protuberance 22c shown in curved part 22a or Figure 13 shown in Figure 10 can enter the inner side of recess 52.By allowing curved part 22a or protuberance 22c to enter recess 52, preventing recess 52 from moving relative to curved part 22a or protuberance 22c, and intermediate plate 50 can be positioned between outer shell 21 and inner layer case 22 thus.

As shown in figure 16, when recess 52 is formed in intermediate plate 50, the flange of each separator in outer shell 21, inner layer case 22 and separator 31 to 34 is unlikely made to be welded to one another in the position forming recess 52.In this case, the flange of each separator in outer shell 21, inner layer case 22 and separator 31 to 34 can be made to be welded to one another at the position not arranging intermediate plate 50.The position of layout intermediate plate 50 is such as top or the bottom of the muffler 1 in Fig. 2.

Hole 51 and recess 52 can also be formed in intermediate plate 50.In this case, intermediate plate 50 can be located by using hole 51 and recess 52, and the flange of each separator in outer shell 21, inner layer case 22 and separator 31 to 34 also can be made to be welded to one another in the position forming hole 51.

Replace hole 51A illustrated in fig. 8, recess 52 can be formed in the position identical with the position of hole 51A.Recess 52 can be used as substituting of all well 51A, or can be used as substituting of a part of hole in the 51A of hole.

Claims

1. a muffler, the exhaust of discharging from the internal-combustion engine of vehicle is imported into described muffler, it is characterized in that comprising:

The outer shell of tubular, its outer surface being arranged in described muffler extends along assigned direction;

The inner layer case of tubular, it is arranged in the inner side of the described outer shell in described muffler and extends along described assigned direction; And

Intermediate plate, it to be arranged between described outer shell and described inner layer case and to be used as damping material or sound-absorbing material, wherein

A shell in described outer shell and described inner layer case comprises processing department, and described processing department is processed to the shape protruded towards another shell, and

Described intermediate plate is included in the receiving portion in the region of described processing department, and described receiving portion is formed as allowing described processing department to enter the shape of described receiving portion.

2. muffler according to claim 1, wherein

A described shell comprises multiple described processing department,

Described intermediate plate comprises the multiple described receiving portion corresponding respectively with described multiple processing department, and

Described multiple receiving portion is formed in the position that the circumference along described assigned direction and described outer shell and described inner layer case does not line up each other.

3. muffler according to claim 1 and 2, wherein

Described processing department is the curved part formed by a part for a bending described shell.

4. the muffler according to any one in claims 1 to 3, wherein

Described muffler comprises the separator with the flange that the inner peripheral surface along described inner layer case is formed, and the space of the inner side being formed in described inner layer case is divided into the multiple spaces arranged along described assigned direction by described separator, and

Described receiving portion has hole, and described hole allows described processing department to pass, and described processing department and another shell joint described are touched, and described flange, described processing department and another shell described are stacked on top of each other and be welded to one another.

5. the muffler according to any one in Claims 1-4, wherein

Described receiving portion is located around described processing department, and described intermediate plate is located by using described processing department and described receiving portion.

6., for a manufacture method for muffler, the exhaust of discharging from the internal-combustion engine of vehicle is imported into described muffler, and the feature of described method is to comprise:

Processing department is formed in the coverboard forming outer shell and inner layer case;

Entering receiving portion by allowing described processing department makes intermediate plate be stacked on described coverboard; And

Described outer shell and described inner layer case that described intermediate plate is clipped in the middle is formed, wherein by the described coverboard being stacked with described intermediate plate is formed tubular

Described muffler comprises: the outer shell of tubular, and its outer surface being arranged in described muffler extends along assigned direction; The inner layer case of tubular, it is arranged in the inner side of the described outer shell in described muffler and extends along described assigned direction; And described intermediate plate, it to be arranged between described outer shell and described inner layer case and to be used as damping material or sound-absorbing material, a shell in described outer shell and described inner layer case comprises described processing department, described processing department is processed to the shape protruded towards another shell, and described intermediate plate is included in the described receiving portion in the region of described processing department, and described receiving portion is formed as allowing described processing department to enter the shape of described receiving portion.

7. the manufacture method for muffler according to claim 6, wherein

Described muffler comprises the separator with the flange that the inner peripheral surface along described inner layer case is formed, and the space of the inner side being formed in described inner layer case is divided into the multiple spaces arranged along described assigned direction by described separator, and,

When forming described outer shell and described inner layer case, by making described coverboard reel around described separator while giving described coverboard pulling force, described coverboard is made to form tubular.

8., for a manufacture method for muffler, the exhaust of discharging from the internal-combustion engine of vehicle is imported into described muffler, and the feature of described method is to comprise:

Processing department is formed in the first coverboard forming a shell in shell;

Allow described processing department to enter receiving portion, and intermediate plate is clipped in forms between the second coverboard of another shell and described first coverboard; And

Described first coverboard that described intermediate plate is clipped in the middle and described second coverboard are formed as tubular, thus form outer shell and inner layer case respectively, wherein

Described muffler comprises: the outer shell of tubular, and its outer surface being arranged in described muffler extends along assigned direction; The inner layer case of tubular, it is arranged in the inner side of the described outer shell in described muffler and extends along described assigned direction; And described intermediate plate, it to be arranged between described outer shell and described inner layer case and to be used as damping material or sound-absorbing material,

A described shell in described outer shell and described inner layer case comprises described processing department, described processing department is processed to the shape protruded towards another shell described, and described intermediate plate is included in the described receiving portion in the region of described processing department, and described receiving portion is formed as allowing described processing department to enter the shape of described receiving portion.

9. the manufacture method for muffler according to claim 8, wherein

When forming described outer shell and described inner layer case, by making described first coverboard and described second coverboard reel around described separator while giving described first coverboard and described second coverboard pulling force, described first coverboard and described second coverboard is made to form tubular.

10. the manufacture method for muffler according to any one in claim 6 to 9, wherein

Described intermediate plate comprises multiple receiving portion, and described multiple receiving portion is formed in the position that the circumference along described assigned direction and described outer shell and described inner layer case does not line up each other, and

A described shell comprises the multiple described processing department corresponding respectively with described multiple receiving portion, and

Enter each in described receiving portion by each allowing in described processing department, come along the described intermediate plate of described assigned direction and described circumference location.

11. manufacture methodes for muffler according to claim 7 or 9, wherein

Described receiving portion has hole, and described hole allows described processing department to pass, and described processing department and another shell joint described are touched, and

After described outer shell and described inner layer case are formed, weld the part that described flange, described processing department and another shell described are stacked on top of each other.