EP0779418A1 - Exhaust manifold and method for its manufacture - Google Patents

Exhaust manifold and method for its manufacture Download PDF

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Publication number
EP0779418A1
EP0779418A1 EP96118747A EP96118747A EP0779418A1 EP 0779418 A1 EP0779418 A1 EP 0779418A1 EP 96118747 A EP96118747 A EP 96118747A EP 96118747 A EP96118747 A EP 96118747A EP 0779418 A1 EP0779418 A1 EP 0779418A1
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EP
European Patent Office
Prior art keywords
shell
tube
exhaust manifold
corrugation
outer shell
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Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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EP96118747A
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German (de)
French (fr)
Inventor
Gunther Hans Dipl.-Ing. Lühr
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Arvin Industries Deutschland GmbH
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Zeuna Starker GmbH and Co KG
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Publication date
Application filed by Zeuna Starker GmbH and Co KG filed Critical Zeuna Starker GmbH and Co KG
Publication of EP0779418A1 publication Critical patent/EP0779418A1/en
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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N13/00—Exhaust or silencing apparatus characterised by constructional features ; Exhaust or silencing apparatus, or parts thereof, having pertinent characteristics not provided for in, or of interest apart from, groups F01N1/00 - F01N5/00, F01N9/00, F01N11/00
    • F01N13/14—Exhaust or silencing apparatus characterised by constructional features ; Exhaust or silencing apparatus, or parts thereof, having pertinent characteristics not provided for in, or of interest apart from, groups F01N1/00 - F01N5/00, F01N9/00, F01N11/00 having thermal insulation
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N13/00—Exhaust or silencing apparatus characterised by constructional features ; Exhaust or silencing apparatus, or parts thereof, having pertinent characteristics not provided for in, or of interest apart from, groups F01N1/00 - F01N5/00, F01N9/00, F01N11/00
    • F01N13/08—Other arrangements or adaptations of exhaust conduits
    • F01N13/10—Other arrangements or adaptations of exhaust conduits of exhaust manifolds
    • F01N13/102—Other arrangements or adaptations of exhaust conduits of exhaust manifolds having thermal insulation
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N13/00—Exhaust or silencing apparatus characterised by constructional features ; Exhaust or silencing apparatus, or parts thereof, having pertinent characteristics not provided for in, or of interest apart from, groups F01N1/00 - F01N5/00, F01N9/00, F01N11/00
    • F01N13/18—Construction facilitating manufacture, assembly, or disassembly
    • F01N13/1883—Construction facilitating manufacture, assembly, or disassembly manufactured by hydroforming
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N2260/00—Exhaust treating devices having provisions not otherwise provided for
    • F01N2260/10—Exhaust treating devices having provisions not otherwise provided for for avoiding stress caused by expansions or contractions due to temperature variations
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N2470/00—Structure or shape of gas passages, pipes or tubes
    • F01N2470/12—Tubes being corrugated
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N2470/00—Structure or shape of gas passages, pipes or tubes
    • F01N2470/24—Concentric tubes or tubes being concentric to housing, e.g. telescopically assembled

Definitions

  • the present invention relates to an exhaust manifold with at least three connections, comprising an inner shell and an outer shell, which are connected to one another in the region of the connections, but are otherwise arranged at a distance from one another with the formation of an intermediate space, the inner shell to compensate for expansion relative to the outer shell at least one device for strain compensation.
  • the invention further relates to a method for producing such a double-shell, air-gap-insulated exhaust manifold.
  • the inner shell is constructed from a plurality of sections, each of which is connected to one another via a sliding seat in order to allow expansion compensation between the inner shell and the outer shell.
  • the outer shell consists of two half-shells welded together. In the area of the exhaust gas inlets, the inner shell and the outer shell are welded together and with a mounting flange. In the area of the exhaust outlet, on the other hand, a sliding seat acting between the inner shell and the outer shell is provided.
  • the present invention is therefore based on the object of an exhaust manifold of the type specified To create type that can be produced with much less effort and thus more cost-effectively.
  • this object is achieved in that the outer shell and the inner shell of the exhaust manifold are formed by internal high pressure deformation from the outer and the inner tube of a duplex tube and that the device for expansion compensation consists of a corrugation of the inner tube.
  • the outer shell must consist of two half-shells (or more partial shells) which are welded together for reasons of the mountability of the exhaust manifold
  • the exhaust manifold can be produced by internal high-pressure deformation of a duplex pipe in a weld-free design. This is made possible by the fact that the devices of the inner shell for expansion compensation are not designed as a sliding seat, as in the prior art, but rather as a corrugation of the inner shell.
  • the method for producing the exhaust manifold according to the invention can be reduced to three forming stages, namely pre-bending a duplex pipe, first internal high-pressure deformation for forming the third as well as possible further connections and for shaping the inner shell in accordance with its final shape and second internal high-pressure deformation for shaping (widening) the outer shell in accordance with its final shape.
  • this document relates to the production of an exhaust manifold from a tube using an internal high pressure deformation; however, this document is not concerned with the production of a double-shell, air-gap-insulated exhaust manifold, so that the problem of expansion compensation between the inner shell and the outer shell is naturally not touched.
  • the exhaust manifold shown in the drawing has four connections, namely three exhaust gas inlets 1 and one exhaust gas outlet 2. It comprises an inner shell 3 and an outer shell 4. These are in the area of Connections interconnected; otherwise they are arranged at a distance from one another, forming an intermediate space 5.
  • a flange 6 is provided, which is welded to the inner shell 3 and the outer shell 4.
  • the inner shell 3 has a corrugation 8. In this way, internal stresses of the exhaust manifold are kept low by thermal expansion of the inner shell 3 compared to the outer shell 4.
  • the outer shell 4 also has a wave structure 9. With large exhaust manifolds, this results in a reduction in sound radiation.
  • the exhaust manifold shown in the drawing was produced in the following manner from a duplex pipe: First, the duplex pipe was pre-bent in such a way that its course essentially corresponded to the shape of the finished manifold.
  • the reference number 7 indicates the center line of the correspondingly pre-bent pipe. After bending, the two ends of the duplex pipe assume a spatial position with respect to one another which corresponds to the spatial arrangement of the two outer inlets of the exhaust manifold relative to one another.
  • the duplex pipe pre-bent in this way is then inserted into a first die, in which a first internal high-pressure deformation takes place.
  • the die has two branches, which serve to form two further connections of the exhaust manifold, namely the middle exhaust gas inlet and the exhaust gas outlet, each by necking the duplex pipe.
  • the first die also has one corrugated surface which corresponds to the corrugated structure 8, which the inner shell of the finished exhaust manifold should have.
  • the forming pressure is introduced exclusively into the interior of the inner tube of the duplex tube.
  • the inner tube and outer tube of the duplex tube therefore deform together until they come into contact with the first die. This creates the two neckings mentioned above and corresponding corrugated structures of the inner tube and the outer tube.
  • the exhaust manifold preformed in this way is then inserted into a second die, the contour of which corresponds to the outer shape of the later outer shell 4.
  • the hydraulic pressure is introduced into the interior of the inner tube and between the inner tube and the outer tube.
  • the inner tube remains undeformed at this forming stage and maintains its shape which is in line with the design of the inner shell 3 of the finished exhaust manifold.
  • the outer tube is widened and takes on its shape corresponding to the shape of the outer shell 4 of the finished exhaust manifold.
  • the space 5 is created between the inner shell 3 and the outer shell 4.
  • the two neckings described above are finally opened to form the corresponding connections (exhaust gas inlet or exhaust gas outlet).

Abstract

The manifold has an inner (3) and an outer (4) shell joined to each other around the inputs (1,2). An space (5) is formed between them. The inner shell has at least one device for compensating expansion in relation to the outer shell. The shells are formed by inner high pressure deformation from the outer and inner tubes of a duplex tube. The device for expansion compensation comprises a corrugation (8) of the inner shell. The outer shell has a corrugation (9) reducing the sound radiation.

Description

Die vorliegende Erfindung betrifft einen Abgaskrümmer mit mindestens drei Anschlüssen, umfassend eine Innenschale und eine Außenschale, welche im Bereich der Anschlüsse miteinander verbunden, im übrigen jedoch unter Ausbildung eines Zwischenraumes mit Abstand zueinander angeordnet sind, wobei die Innenschale zum Dehnungsausgleich gegenüber der Außenschale mindestens eine Einrichtung zur Dehnungskompensation aufweist. Die Erfindung betrifft des weiteren ein Verfahren zur Herstellung eines derartigen doppelschaligen, luftspaltisolierten Abgaskrümmers.The present invention relates to an exhaust manifold with at least three connections, comprising an inner shell and an outer shell, which are connected to one another in the region of the connections, but are otherwise arranged at a distance from one another with the formation of an intermediate space, the inner shell to compensate for expansion relative to the outer shell at least one device for strain compensation. The invention further relates to a method for producing such a double-shell, air-gap-insulated exhaust manifold.

Ein Abgaskrümmer der eingangs genannten Art ist beispielsweise aus der europäischen Patentanmeldung 0 582 985 bekannt. Die Innenschale ist dabei aus einer Mehrzahl von Abschnitten aufgebaut, die jeweils über einen Schiebesitz miteinander verbunden sind, um einen Dehnungsausgleich zwischen der Innenschale und der Außenschale zu ermöglichen. Die Außenschale besteht aus zwei miteinander verschweißten Halbschalen. Im Bereich der Abgaseinlässe sind die Innenschale und die Außenschale miteinander sowie mit einem Befestigungsflansch verschweißt. Im Bereich des Abgasauslasses ist demgegenüber ein zwischen der Innenschale und der Außenschale wirkender Schiebesitz vorgesehen.An exhaust manifold of the type mentioned is known for example from European patent application 0 582 985. The inner shell is constructed from a plurality of sections, each of which is connected to one another via a sliding seat in order to allow expansion compensation between the inner shell and the outer shell. The outer shell consists of two half-shells welded together. In the area of the exhaust gas inlets, the inner shell and the outer shell are welded together and with a mounting flange. In the area of the exhaust outlet, on the other hand, a sliding seat acting between the inner shell and the outer shell is provided.

Bei dem bekannten Abgaskrümmer wird der hohe, mit beträchtlichen Fertigungskosten verbundene Fertigungsaufwand als nachteilig angesehen.In the known exhaust manifold, the high manufacturing costs associated with considerable manufacturing costs are regarded as disadvantageous.

Der vorliegenden Erfindung liegt somit die Aufgabe zugrunde, einen Abgaskrümmer der eingangs angegebenen Art zu schaffen, der mit einem deutlich geringeren Aufwand und somit kostengünstiger herstellbar ist.The present invention is therefore based on the object of an exhaust manifold of the type specified To create type that can be produced with much less effort and thus more cost-effectively.

Gemäß der vorliegenden Erfindung wird diese Aufgabe dadurch gelöst, daß die Außenschale und die Innenschale des Abgaskrümmers durch Innenhochdruckverformung aus dem Außen- bzw. dem Innenrohr eines Duplexrohres geformt sind und daß die Einrichtung zur Dehnungskompensation aus einer Wellung des Innenrohres besteht. Während beim Stand der Technik die Außenschale aus Gründen der Montierbarkeit des Abgaskrümmers aus zwei Halbschalen (oder mehreren Teilschalen) bestehen muß, welche miteinander verschweißt werden, kann gemäß der vorliegenden Erfindung der Abgaskrümmer durch Innenhochdruckverformung eines Duplexrohres in schweißnahtfreier Ausführung hergestellt werden. Dies wird möglich dadurch, daß die Einrichtungen der Innenschale zur Dehnungskompensation nicht, wie beim Stand der Technik, als Schiebesitz ausgebildet sind, sondern vielmehr als Wellung der Innenschale.According to the present invention, this object is achieved in that the outer shell and the inner shell of the exhaust manifold are formed by internal high pressure deformation from the outer and the inner tube of a duplex tube and that the device for expansion compensation consists of a corrugation of the inner tube. While in the prior art the outer shell must consist of two half-shells (or more partial shells) which are welded together for reasons of the mountability of the exhaust manifold, according to the present invention the exhaust manifold can be produced by internal high-pressure deformation of a duplex pipe in a weld-free design. This is made possible by the fact that the devices of the inner shell for expansion compensation are not designed as a sliding seat, as in the prior art, but rather as a corrugation of the inner shell.

Der erfindungsgemäße doppelschalige, luftspaltisolierte Abgaskrümmer läßt sich in Anwendung eines Verfahrens herstellen, das die folgenden Schritte umfaßt:

  • Ein Duplexrohr wird in der Weise gebogen, daß sein Verlauf im wesentlichen der Gestalt des fertigen Krümmers entspricht, wobei seine Enden im wesentlichen entsprechend der räumlichen Anordnung zweier der Anschlüsse des fertigen Krümmers zueinander gestellt werden.
  • Das vorgebogene Duplexrohr wird in ein erstes Gesenk eingelegt, dessen Gravur mindestens eine Abzweigung sowie zumindest in Teilbereichen eine Wellung aufweist.
  • Anschließend werden das Innenrohr und das Außenrohr des vorgebogenen Duplexrohres in dem ersten Gesenk gemeinsam mittels Innenhochdruckverformung aufgeweitet, um in dem Duplexrohr mindestens eine Aushalsung auszuformen sowie zumindest bereichsweise eine Wellung auszubilden.
  • Sodann wird der vorgeformte Krümmer in ein zweites Gesenk eingelegt, dessen Gravur der Außenform der Außenschale des fertigen Krümmers entspricht; die Gravur des zweiten Gesenks ist dabei in den von den späteren Anschlüssen des Krümmers entfernten Bereichen weiter als das erste Gesenk.
  • Abschließend wird das Außenrohr in seinen von den späteren Anschlüssen des Krümmers entfernten Bereichen durch Innenhochdruckverformung aufgeweitet, um in diesen Bereichen einen Zwischenraum zwischen dem Innenrohr und dem Außenrohr auszubilden.
The double-shell, air-gap-insulated exhaust manifold according to the invention can be produced using a method which comprises the following steps:
  • A duplex pipe is bent in such a way that its course corresponds essentially to the shape of the finished elbow, its ends being placed in relation to one another essentially in accordance with the spatial arrangement of two of the connections of the finished elbow.
  • The pre-bent duplex tube is placed in a first die, the engraving of which is at least one Branch and at least in some areas has a corrugation.
  • The inner tube and the outer tube of the pre-bent duplex tube are then expanded together in the first die by means of internal high-pressure deformation in order to form at least one neck in the duplex tube and to form a corrugation at least in some areas.
  • The preformed elbow is then placed in a second die, the engraving of which corresponds to the outer shape of the outer shell of the finished elbow; the engraving of the second die is wider than the first die in the areas distant from the later connections of the manifold.
  • Finally, the outer tube is widened in its regions remote from the later connections of the bend by internal high-pressure deformation in order to form an intermediate space between the inner tube and the outer tube in these regions.

Ersichtlich entfällt bei diesem Verfahren, verglichen mit dem zur Herstellung bekannter gattungsgemäßer Abgaskrümmer angewandten Verfahren, jeglicher Montageaufwand, der mit dem Zusammenfügen der einzelnen Abschnitte der Innenschale, dem Einlegen der vormontierten Innenschale in die geöffnete Außenschale sowie dem Schließen der Außenschale verbunden ist. Im wesentlichen läßt sich das Verfahren zur Herstellung des erfindungsgemäßen Abgaskrümmers auf drei Umformstufen reduzieren, nämlich Vorbiegen eines Duplexrohres, erste Innenhochdruckverformung zur Ausformung des dritten sowie möglicher weiterer Anschlüsse und zur Formgebung der Innenschale entsprechend ihrer endgültigen Gestalt sowie zweite Innenhochdruckverformung zur Formgebung (Aufweitung) der Außenschale entsprechend ihrer endgültigen Gestalt.Obviously, in this method, compared to the method used to produce known generic exhaust manifolds, any assembly effort associated with assembling the individual sections of the inner shell, inserting the preassembled inner shell into the open outer shell and closing the outer shell is eliminated. Essentially, the method for producing the exhaust manifold according to the invention can be reduced to three forming stages, namely pre-bending a duplex pipe, first internal high-pressure deformation for forming the third as well as possible further connections and for shaping the inner shell in accordance with its final shape and second internal high-pressure deformation for shaping (widening) the outer shell in accordance with its final shape.

Aus dem Stand der Technik (EP-A-0 627 272) ist zwar ein Verfahren zur Herstellung eines doppelschaligen, luftspaltisolierten Rohres bekannt, bei welchem ein Duplexrohr zunächst vorgebogen und anschließend unter Anwendung einer zweistufigen Innenhochdruckverformung in seine entgültige Gestalt gebracht wird. Jedoch befaßt sich diese Druckschrift weder mit der Herstellung von Abgaskrümmern, noch mit dem Problem des Dehnungsausgleichs des Innenrohres gegenüber dem Außenrohr. Und auch das deutsche Gebrauchsmuster 94 07 812 vermag zur Lösung des angegebenen Problems keine Anregung zu geben. Zwar betrifft diese Druckschrift die Herstellung eines Abgaskrümmers aus einem Rohr unter Anwendung einer Innenhochdruckverformung; jedoch befaßt sich diese Druckschrift nicht mit der Herstellung eines doppelschaligen, luftspaltisolierten Abgaskrümmers, so daß naturgemäß das Problem des Dehnungsausgleichs zwischen der Innenschale und der Außenschale nicht berührt ist.From the prior art (EP-A-0 627 272) a method for producing a double-shell, air-gap-insulated tube is known, in which a duplex tube is first pre-bent and then brought into its final shape using a two-stage internal high-pressure deformation. However, this document is concerned neither with the production of exhaust manifolds, nor with the problem of expansion compensation of the inner tube with respect to the outer tube. And the German utility model 94 07 812 is unable to provide any suggestion for solving the stated problem. Although this document relates to the production of an exhaust manifold from a tube using an internal high pressure deformation; however, this document is not concerned with the production of a double-shell, air-gap-insulated exhaust manifold, so that the problem of expansion compensation between the inner shell and the outer shell is naturally not touched.

Im folgenden wird die Erfindung anhand der Zeichnung näher erläutert. Diese zeigt eine bevorzugte Ausführungsform des erfindungsgemäßen Krümmers in teilweise gebrochener Seitenansicht.The invention is explained in more detail below with reference to the drawing. This shows a preferred embodiment of the manifold according to the invention in a partially broken side view.

Der in der Zeichnung dargestellte Abgaskrümmer weist vier Anschlüsse auf, nämlich drei Abgaseinlässe 1 sowie einen Abgasauslaß 2. Er umfaßt eine Innenschale 3 sowie eine Außenschale 4. Diese sind im Bereich der Anschlüsse miteinander verbunden; im übrigen sind sie jedoch unter Ausbildung eines Zwischenraumes 5 mit Abstand zueinander angeordnet.The exhaust manifold shown in the drawing has four connections, namely three exhaust gas inlets 1 and one exhaust gas outlet 2. It comprises an inner shell 3 and an outer shell 4. These are in the area of Connections interconnected; otherwise they are arranged at a distance from one another, forming an intermediate space 5.

Im Bereich der drei Abgaseinlässe 1 ist jeweils ein Flansch 6 vorgesehen, der mit der Innenschale 3 und der Außenschale 4 verschweißt ist.In the area of the three exhaust gas inlets 1, a flange 6 is provided, which is welded to the inner shell 3 and the outer shell 4.

Die Innenschale 3 weist eine Wellung 8 auf. Auf diese Weise werden innere Spannungen des Abgaskrümmers durch thermische Dehnung der Innenschale 3 gegenüber der Außenschale 4 gering gehalten. Auch die Außenschale 4 weist eine Wellenstruktur 9 auf. Dies bewirkt bei großflächigen Abgaskrümmern eine Reduzierung der Schallabstrahlung.The inner shell 3 has a corrugation 8. In this way, internal stresses of the exhaust manifold are kept low by thermal expansion of the inner shell 3 compared to the outer shell 4. The outer shell 4 also has a wave structure 9. With large exhaust manifolds, this results in a reduction in sound radiation.

Der in der Zeichung dargestellte Abgaskrümmer wurde in der folgenden Weise aus einem Duplexrohr hergestellt: Zunächst wurde das Duplexrohr in der Weise vorgebogen, daß sein Verlauf im wesentlichen der Gestalt des fertigen Krümmers entsprach. Mit dem Bezugszeichen 7 ist die Mittellinie des entsprechend vorgebogenen Rohres angegeben. Die beiden Enden des Duplexrohres nehmen nach dem Biegen eine räumliche Stellung bezüglich einander ein, die der räumlichen Anordnung der beiden äußeren Einlässe des Abgaskrümmers zueinander entspricht.The exhaust manifold shown in the drawing was produced in the following manner from a duplex pipe: First, the duplex pipe was pre-bent in such a way that its course essentially corresponded to the shape of the finished manifold. The reference number 7 indicates the center line of the correspondingly pre-bent pipe. After bending, the two ends of the duplex pipe assume a spatial position with respect to one another which corresponds to the spatial arrangement of the two outer inlets of the exhaust manifold relative to one another.

Das in dieser Weise vorgebogene Duplexrohr wird anschließend in ein erstes Gesenk eingelegt, in welchem eine erste Innenhochdruckverformung stattfindet. Das Gesenk weist zwei Abzweigungen auf, welche der Ausformung zweier weiterer Anschlüsse des Abgaskrümmers, nämlich des mittleren Abgaseinlasses sowie des Abgasauslasses, durch jeweils eine Aushalsung des Duplexrohres dienen. Das erste Gesenk weist im übrigen eine gewellt Oberfläche auf, welche der Wellenstruktur 8 entspricht, die die Innenschale des fertigen Abgaskrümmers aufweisen soll. Bei der in dem ersten Gesenk stattfindenden ersten Stufe der Innenhochdruckverformung wird der Umformdruck ausschließlich in das Innere des Innenrohres des Duplexrohres eingebracht. Innenrohr und Außenrohr des Duplexrohres verformen sich daher gemeinsam bis zur Anlage an dem ersten Gesenk. Dabei entstehen die beiden vorstehend erwähnten Aushalsungen sowie zueinander korrespondierende Wellenstrukturen des Innenrohres und des Außenrohres.The duplex pipe pre-bent in this way is then inserted into a first die, in which a first internal high-pressure deformation takes place. The die has two branches, which serve to form two further connections of the exhaust manifold, namely the middle exhaust gas inlet and the exhaust gas outlet, each by necking the duplex pipe. The first die also has one corrugated surface which corresponds to the corrugated structure 8, which the inner shell of the finished exhaust manifold should have. In the first stage of the internal high-pressure deformation taking place in the first die, the forming pressure is introduced exclusively into the interior of the inner tube of the duplex tube. The inner tube and outer tube of the duplex tube therefore deform together until they come into contact with the first die. This creates the two neckings mentioned above and corresponding corrugated structures of the inner tube and the outer tube.

Der in dieser Weise vorgeformte Abgaskrümmer wird anschließend in ein zweites Gesenk eingelegt, dessen Kontur der Außenform der späteren Außenschale 4 entspricht. Bei der in diesem zweiten Gesenk stattfindenden zweiten Stufe der Innenhochdruckverformung wird der Hydraulikdruck in das Innere des Innenrohres sowie zwischen das Innenrohr und das Außenrohr eingebracht. Infolge des Druckgleichgewichts bleibt das Innenrohr bei dieser Umformstufe unverformt und behält seine der Gestaltung der Innenschale 3 des fertigen Abgaskrümmers einsprechende Form bei. Das Außenrohr wird hingegen aufgeweitet und nimmt seine der Gestalt der Außenschale 4 des fertigen Abgaskrümmers entsprechende Form an. Dabei entsteht zwischen der Innenschale 3 und der Außenschale 4 der Zwischenraum 5. Die beiden oben beschriebenen Aushalsungen werden abschließend geöffnet, um die entsprechenden Anschlüsse (Abgaseinlaß bzw. Abgasauslaß) zu bilden.The exhaust manifold preformed in this way is then inserted into a second die, the contour of which corresponds to the outer shape of the later outer shell 4. In the second stage of internal high pressure deformation taking place in this second die, the hydraulic pressure is introduced into the interior of the inner tube and between the inner tube and the outer tube. As a result of the pressure equilibrium, the inner tube remains undeformed at this forming stage and maintains its shape which is in line with the design of the inner shell 3 of the finished exhaust manifold. The outer tube, on the other hand, is widened and takes on its shape corresponding to the shape of the outer shell 4 of the finished exhaust manifold. The space 5 is created between the inner shell 3 and the outer shell 4. The two neckings described above are finally opened to form the corresponding connections (exhaust gas inlet or exhaust gas outlet).

Claims (3)

Abgaskrümmer mit mindestens drei Anschlüssen (1, 2), umfassend eine Innenschale (3) und eine Außenschale (4), welche im Bereich der Anschlüsse miteinander verbunden, im übrigen jedoch unter Ausbildung eines Zwischenraumes (5) mit Abstand zueinander angeordnet sind, wobei die Innenschale zum Dehnungsausgleich gegenüber der Außenschale mindestens eine Einrichtung zur Dehnungskompensation aufweist,
dadurch gekennzeichnet,
daß die Außenschale (4) und die Innenschale (3) durch Innenhochdruckverformung aus dem Außen- bzw. dem Innenrohr eines Duplexrohres geformt sind und daß die Einrichtung zur Dehnungskompensation aus einer Wellung (8) der Innenschale (3) besteht.Exhaust manifold with at least three connections (1, 2), comprising an inner shell (3) and an outer shell (4), which are connected to one another in the region of the connections, but are otherwise arranged at a distance from one another, forming an intermediate space (5), the Inner shell for expansion compensation compared to the outer shell has at least one device for expansion compensation,
characterized,
that the outer shell (4) and the inner shell (3) are formed by internal high pressure deformation from the outer or inner tube of a duplex tube and that the device for expansion compensation consists of a corrugation (8) of the inner shell (3). Abgaskrümmer nach Anspruch 1,
dadurch gekennzeichnet,
daß die Außenschale eine die Schallabstrahlung reduzierende Wellung (9) aufweist.Exhaust manifold according to claim 1,
characterized,
that the outer shell has a corrugation (9) which reduces sound radiation. Verfahren zur Herstellung eines doppelschaligen, luftspaltisolierten Abgaskrümmers gemäß Anspruch 1, umfassend die folgenden Schritte: - Biegen eines Duplexrohres in einen im wesentlichen der Gestalt des fertigen Krümmers entsprechenden Verlauf, wobei seine Enden im wesentlichen der räumlichen Anordnung zweier der Anschlüsse des fertigen Krümmers zueinander entsprechend gestellt werden; - Einlegen des vorgebogenen Duplexrohres in ein erstes Gesenk, dessen Gravur mindestens eine Abzweigung sowie zumindest teilweise eine Wellung aufweist; - gemeinsames Verformen von Innenrohr und Außenrohr des vorgebogenen Duplexrohres mittels Innenhochdruckverformung zur Ausbildung einer Wellung sowie zur Ausformung mindestens einer Aushalsung; - Einlegen des vorgeformten Krümmers in ein zweites Gesenk, dessen Gravur der Außenform der Außenschale des fertigen Krümmers entspricht; - Aufweiten des Außenrohres in seinen von den späteren Anschlüssen entfernten Bereichen mittels Innenhochdruckverformung zur Ausbildung eines Zwischenraumes zwischen Innenrohr und Außenrohr. A method of manufacturing a double-shell, air-gap insulated exhaust manifold according to claim 1, comprising the following steps: - Bending of a duplex pipe in a course substantially corresponding to the shape of the finished elbow, its ends essentially the spatial arrangement of two of the connections of the finished Krümmers are placed accordingly to each other; - Inserting the pre-bent duplex tube into a first die, the engraving of which has at least one branch and at least partially a corrugation; - joint deformation of the inner tube and outer tube of the pre-bent duplex tube by means of internal high pressure deformation to form a corrugation and to form at least one neck; - Inserting the preformed elbow into a second die, the engraving of which corresponds to the outer shape of the outer shell of the finished elbow; - Widening of the outer tube in its areas distant from the later connections by means of internal high pressure deformation to form an intermediate space between the inner tube and the outer tube.
EP96118747A 1995-12-13 1996-11-22 Exhaust manifold and method for its manufacture Withdrawn EP0779418A1 (en)

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DE1995146509 DE19546509A1 (en) 1995-12-13 1995-12-13 Exhaust manifold and process for its manufacture
DE19546509 1995-12-13

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DE10112707C1 (en) * 2001-03-16 2002-06-06 Zeuna Staerker Kg Exhaust manifold production, for internal combustion motor, is composed of an inner and outer shell each of part-shells joined together with a gas-tight seam without welding sprays
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EP0789137B1 (en) * 1996-02-07 2002-01-16 Benteler Ag Exhaust pipe
DE10112707C1 (en) * 2001-03-16 2002-06-06 Zeuna Staerker Kg Exhaust manifold production, for internal combustion motor, is composed of an inner and outer shell each of part-shells joined together with a gas-tight seam without welding sprays
FR2905979A1 (en) * 2006-09-15 2008-03-21 Faurecia Sys Echappement Combustion gas exhaust manifold for motor vehicle, has cover with walls that are superimposed and connected between them by soldering and in contact with one another in all points to form half-shells, where walls are made of embossed steel

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