DE102006056073A1 - Manifold for an exhaust system - Google Patents

Abstract

In a manifold (10) for an exhaust system is provided that an input flange (12), an output flange (16) and a housing part (14) are designed and connected as separate parts.

Description

The The invention relates to a manifold for an exhaust system, in particular an exhaust manifold, the is bolted directly to an internal combustion engine and on in turn, the other components of the exhaust system are attached.

Exhaust manifolds are known in a variety of configurations. All exhaust manifolds in common is, that you are exposed to very high thermal and vibration loads.

The The object of the invention is to provide an exhaust manifold which is characterized by particularly low production costs, while he at the same time the usual Requirements for thermal and mechanical strength met.

to solution This object is inventively a manifold for an exhaust system provided with an input flange, an output flange and a housing part, which are executed as separate parts and connected to each other. In other words, it is in the inventive manifold order a composite component in which the individual components are different accomplished are so they are optimally adapted to the respective requirements. This concerns both the material for the individual components as well as the manufacturing process and / or the wall thickness. That way you can especially low production costs are obtained.

The housing part may consist of sheet metal and in particular be a drawn part. This allows especially low production costs.

Preferably is the housing part soldered to the input flange. this makes possible a process-safe Production of the manifold with high clock rates.

Preferably is provided that the housing part has a fret, the area abuts the input flange. The collar of the housing part reinforces the Input flange, so that this can be made of a material with a smaller wall thickness. So far had to the input flange is manufactured with a material thickness of at least 3 mm be ensured with it is that he just applied to the engine block. With the manifold according to the invention it is possible to perform the input flange with a smaller thickness, for example 2.5 mm or even thinner (e.g., 2.0 mm or 1.7 mm), and yet, due to the fact that the Federal Government of housing part effected reinforcement, the areal Ensure system on the engine block. The collar of the housing part namely causes a reinforcement the inlet flange exactly where it is needed, namely along the outer circumference. In the middle of the entrance elbow, So between the outlet openings of the engine, the smaller wall thickness of the intake manifold is not Problem, since it is not on a surface area in this area of the input flange arrives.

According to one embodiment is provided that the housing part an inner shell and an outer shell having. So it's a double-shell manifold created in the example an air gap is provided between the inner shell and the outer shell can be.

Also the outlet flange of the manifold can with the housing part soldered be. If in this way the necessary strength values are not achieved can also be a weld be used.

Of the Output flange is preferably a solid part or a sintered part. By contrast, the input flange can be a sheet-metal stamped part. This too leads to low production costs.

The Invention will be described below with reference to various embodiments described in the attached Drawings are shown. In these show:

1 a cross section through a manifold according to a first embodiment of the invention;

2 the manifold of 1 in a partially sectioned side view;

3 a bottom view of the inlet flange of the manifold of 1 ;

4 a variant of the input flange;

5 a cross section through a manifold according to a second embodiment of the invention;

6 a cross section through a manifold according to a third embodiment of the invention;

7 a partially sectioned side view of a manifold according to a fourth embodiment of the invention; and

8th a partially sectioned side view of a manifold according to a fifth embodiment of the invention.

In the 1 to 3 is a manifold 10 shown that is part of an exhaust system for internal combustion engines, especially for motor vehicles. The manifold 10 has as essential components an input flange 12 , a housing part 14 and an output flange 16 on. All three are made as separate components and then joined together.

The input flange 12 is the component that will later be attached to the cylinder head of the engine. It is designed as a substantially flat component made of sheet metal, whose edge portions are bent by 90 °, so that four webs 13 are formed, which extend in the direction of the output flange and increase the rigidity. The input flange 12 consists in particular of a stamped and bent sheet metal part.

The housing part 14 consists of sheet metal and is designed as a drawn part. It points to the input flange 12 facing side a covenant 18 on, the surface at the entrance flange 12 is applied, in the area between the bent edges and the through holes 17 , Both the input flange 12 as well as the federal government 18 of the housing part 14 are with several openings 20 provided, through which later fastening screws can extend, with which the manifold 10 can be attached to the engine block.

The input flange 12 is centered with several openings 17 provided, through which later the exhaust gas from the outlet channels of the cylinder head can flow into the manifold.

The housing part 14 and the input flange 12 are soldered together, especially with a high temperature solder. The formed solder seam is denoted by the reference numeral 22 Mistake. It extends between the fret 18 of the housing part 14 and the input flange 12 , The fixed to the input flange 12 affiliated federation 18 causes, together with the webs 13 , Such reinforcement of the input flange in the area in which arrives on a flat contact with the cylinder head of the engine, namely in the region of the openings 20 so that the input flange 12 can be performed with a smaller wall thickness than usual. In particular, sheet metal with a wall thickness in the range of 1.7 to 2.0 mm can be used.

At the entrance from the flange 12 opposite side of the housing part 14 is the output flange 16 appropriate. In the embodiment shown here, the output flange 16 with a breakthrough 24 provided in the housing part 14 is plugged in. For attachment is a circumferential weld 26 intended. The output flange 16 may be a solid metal component, such as sheet metal with a high wall thickness, or a sintered part.

In 4 is a variant of the input flange 12 in the 1 to 3 shown first embodiment shown. The difference is that at the input flange of 4 the passageways 17 not round, but elliptical.

In 5 a manifold according to a second embodiment is shown. The difference from the first embodiment is that in the second embodiment, the output flange 16 a sintered part is. This is with a neck 30 provided on the housing part 14 is plugged. For connection between the housing part 14 and the output manifold 16 becomes a solder seam 32 used, for example, from Hochtemperaturlot.

In 6 a manifold according to a third embodiment is shown. The difference from the second embodiment is that the outlet manifold designed as a sintered part 16 a neck 30 which has a groove 34 is provided. In the groove 34 is the housing part 14 plugged in and soldered there. The result is a solder seam with a U-shaped cross-section.

The second and the third embodiment are characterized by a particularly secure and easy to produce connection between the housing part 14 and the outlet nozzle 16 out. Since a solder joint is used both on the input flange and on the output flange, all seams can be produced simultaneously. This allows very high clock rates.

In 7 a fourth embodiment of the manifold is shown. The difference from the previous embodiments is that the housing part 14 bivalve is formed, so from an outer shell 14A and an inner shell 14B consists.

by virtue of The double-walled shell results in an improvement of the acoustics.

In 8th a manifold according to a fourth embodiment is shown. The difference from the third embodiment is that the outer shell 14A and the inner shell 14B are spaced apart so that therebetween an insulating gap 40 located. The insulating gap may be filled with an inert gas, such as argon, when the manifold has been soldered under inert gas, or there may be a vacuum in the insulating gap when the manifold is under vacuum was soldered. In this way, in addition to the improvement of the acoustics, there is also a good heat insulation, which exceeds the thermal insulation, which would be achieved with an insulating gap filled with air.

10

elbow

12

inlet flange

13

web

14

housing part

16

output flange

17

Through opening

18

Federation

20

opening

22

soldered seam

24

breakthrough

26

Weld

30

Support

32

soldered seam

34

groove

40

insulating gap

Claims (19)

Manifold ( 10 ) for an exhaust system, with an input flange ( 12 ), an output flange ( 16 ) and a housing part ( 14 ), which are designed as separate parts and connected to each other. Manifold according to claim 1, characterized in that the housing part ( 14 ) consists of sheet metal. Manifold according to Claim 1 or Claim 2, characterized in that the housing part ( 14 ) is a drawn part. Manifold according to one of the preceding claims, characterized in that the housing part ( 14 ) with the input flange ( 12 ) is soldered. Manifold according to one of the preceding claims, characterized in that the housing part ( 14 ) a covenant ( 18 ), the flat at the input flange ( 12 ) is present. Manifold according to claim 5, characterized in that the inlet flange ( 12 ) with openings ( 20 ) is provided for fastening screws and that the openings ( 20 ) by the Confederation ( 18 ). Manifold according to one of the preceding claims, characterized in that the input flange ( 12 ) has a maximum thickness of 2.5 mm. Manifold according to one of the preceding claims, characterized in that the input flange ( 12 ) web-like bent edge regions ( 13 ) having. Manifold according to one of the preceding claims, characterized in that the housing part ( 14 ) an inner shell ( 14B ) and an outer shell ( 14A ) having. Manifold according to claim 9, characterized in that between the inner shell ( 14B ) and the outer shell ( 14A ) an insulating gap ( 40 ) is located. Manifold according to claim 10, characterized in that the insulating gap ( 40 ) Contains a vacuum or a protective gas. Manifold according to one of the preceding claims, characterized in that the outlet flange ( 16 ) with the housing part ( 14 ) is soldered. Manifold according to one of claims 1 to 11, characterized in that the outlet flange ( 16 ) with the housing part ( 14 ) is welded. Manifold according to one of the preceding claims, characterized in that the outlet flange ( 16 ) a breakthrough ( 24 ), in which the housing part ( 14 ) is inserted. Manifold according to one of claims 1 to 13, characterized in that the outlet flange ( 16 ) a nozzle ( 30 ), on which the housing part ( 14 ) is attached. Manifold according to one of claims 1 to 13, characterized in that the outlet flange ( 14 ) a nozzle ( 30 ) which is provided with a groove ( 32 ), in which the housing part ( 14 ) is inserted. Manifold according to one of the preceding claims, characterized in that the outlet flange ( 16 ) is a solid part. Manifold according to one of claims 1 to 16, characterized in that the outlet flange ( 16 ) is a sintered part. Manifold according to one of the preceding claims, characterized in that the input flange ( 12 ) is a sheet metal stamping.