EP2184462A1 - Exhaust manifold - Google Patents

Abstract

The system has a single walled exhaust manifold (11) with inlet pipes (15-17) for connection to exhaust gas outlets of an internal combustion engine. The manifold has a collection unit (19) for combining the pipes. The collection unit has an outlet opening, which is connected with subsequent elements of the system. The collection unit is designed in bend-proof manner, and the pipes are bendable against the collecting unit. The collection unit has a bend-proof inlet pipe support (25) for direct connection with an exhaust outlet of the engine. The pipes are formed as a sheet metal part.

Description

The present invention relates to an exhaust system with an exhaust manifold, in particular a single-wall exhaust manifold, which comprises a plurality of inlet pipes for connection to exhaust gas exhaust of an internal combustion engine and a collecting means for combining the intake pipes, wherein the collecting means comprises an outlet opening which is connected to subsequent elements of the exhaust system, wherein the Collection device is rigid and the inlet pipes relative to the collecting device are relatively flexible.

The invention has for its object to improve an exhaust system of the type mentioned in terms of manufacturing costs and weight.

This object is achieved in that the collecting device comprises a likewise rigid inlet pipe socket, which is designed for direct connection to an exhaust gas outlet of an internal combustion engine.

By connecting the rigid inlet pipe socket to the exhaust outlet of an internal combustion engine, this nozzle serves as a support element for the collecting device and for the entire exhaust manifold, which, of course, can also have further support elements. A separate support or connection of the exhaust manifold can be saved. As a result, both the weight of the exhaust manifold and its manufacturing costs are reduced.

The collecting device with the rigid inlet pipe socket thus assumes the support function, while the more flexible inlet pipes serve in addition to their sealing function of the compensation of different expansions due to the temperature changes.

The inlet pipe socket can in particular be formed on the collecting device. The collecting device preferably consists of rigid material. The flexural rigidity can be achieved not only by the choice of material but also by the material thickness or the cross-sectional shape of the collector. The collecting device thus forms a self-supporting component for integration into the exhaust system.

The inlet pipes may be made of relatively flexible material with respect to the collector. The relatively high bendability of the inlet pipes can be achieved except by selecting the material but also by the material thickness and / or the cross-sectional shape of the tubes. The inlet pipes can thereby be preferably formed without decoupling or compensation element. The tubes can also be made of different materials among each other or have different wall thicknesses, depending on how high the respective load is by thermal expansion of the respective tube. Thus, a longer tube may be formed with greater wall thickness or made of a high strength material, while shorter tubes may be made of thinner material or less expensive simply solid material.

The collecting device may in particular be formed as a one-piece collector housing and it can be connected in different ways to subsequent parts of an exhaust system, for example by welding, screwing, soldering, by means of V-band clamp or a flat band clamp.

The collecting device can be designed in particular as a cast part. It is also possible to form the collecting device as hydroforming part with a large wall thickness. By contrast, the inlet pipes are preferably designed as sheet metal parts or built pipes.

According to one embodiment, the collecting device is connected to a turbocharger and / or to a catalyst close to the engine. In particular, the collecting device can be designed for connection to a monoscroll or twin scroll turbocharger. For a twin scroll loader, the collector is provided with a divider wall to the outlet port. For a Monoscrolllader a previous merger is provided, so the partition in particular omitted. Incidentally, the exhaust gas guide is preferably separate, so that the exhaust manifold is designed as a Zündfolgekrümmer, in which exhaust gas outlets are combined with the largest possible Zündfolgeabstand.

The collecting device may form at least part of a subsequent turbine housing of a turbocharger. As a result, further costs and components can be saved. Furthermore, the collecting device may have a particularly integrally formed receptacle for a lambda probe. Likewise, further formations may be provided on the collecting device, via which components can be fastened, for example shielding surfaces for heat-shielding surrounding components.

According to one embodiment, the inlet pipes and the pipe socket of the collector are connected to one or more engine flanges. The engine flanges may be sheet metal flanges, with which the collecting device is connected on the side of the exhaust gas inlets. This is advantageous from the manufacturing cost and the weight.

The welded joints, in particular between the inlet pipes and the engine flange and between the inlet pipes and the collecting device are preferably designed such that the welding takes place from the outside. This allows welding spatter inside the exhaust manifold to be avoided.

The exhaust manifold according to the invention can be used for example for a four-cylinder engine. The motor flange can be formed divided. As a result, thermal expansion can be reduced.

The wall thickness of the inlet pipes is preferably at most about 1.2 mm. The wall thickness of the collecting device is preferably at least about 1.5 mm, in particular between about 2 mm and about 3 mm.

Fig. 1

zeigt eine Draufsicht auf einen Abgaskrümmer einer erfindungsgemäßen Abgasanlage.

Fig. 2

zeigt eine Draufsicht auf den Abgaskrümmer von Fig. 1 um 90° gedreht.

Fig. 3

zeigt eine Draufsicht auf den Abgaskrümmer von Fig. 1 um weitere 90° gedreht.

Fig. 4a

zeigt eine Seitenansicht des Abgaskrümmers von Fig. 1.

Fig. 4b

zeigt eine teilweise Draufsicht auf den Abgaskrümmer von Fig. 1 in Schnittdarstellung.

Fig. 5

zeigt eine teilweise Seitenansicht auf den Abgaskrümmer von Fig. 1 in Schnittdarstellung.

Fig. 6

zeigt eine weitere teilweise Schnittdarstellung des Abgaskrümmers von Fig. 1.

Fig. 7

zeigt eine weitere teilweise Schnittdarstellung des Abgaskrümmers von Fig. 1.

Fig. 8

zeigt eine weitere teilweise Schnittdarstellung des Abgaskrümmers von Fig. 1.

Fig. 9

zeigt eine weitere teilweise Schnittdarstellung des Abgaskrümmers von Fig. 1.

Fig. 10

zeigt eine perspektivische Teilansicht des Abgaskrümmers von Fig. 1.

The invention will be described below with reference to an embodiment with reference to the drawings.

Fig. 1

shows a plan view of an exhaust manifold of an exhaust system according to the invention.

Fig. 2

shows a plan view of the exhaust manifold of Fig. 1 turned by 90 degrees.

Fig. 3

shows a plan view of the exhaust manifold of Fig. 1 turned by another 90 °.

Fig. 4a

shows a side view of the exhaust manifold of Fig. 1 ,

Fig. 4b

shows a partial plan view of the exhaust manifold of Fig. 1 in section.

Fig. 5

shows a partial side view of the exhaust manifold of Fig. 1 in section.

Fig. 6

shows a further partial sectional view of the exhaust manifold of Fig. 1 ,

Fig. 7

shows a further partial sectional view of the exhaust manifold of Fig. 1 ,

Fig. 8

shows a further partial sectional view of the exhaust manifold of Fig. 1 ,

Fig. 9

shows a further partial sectional view of the exhaust manifold of Fig. 1 ,

Fig. 10

shows a partial perspective view of the exhaust manifold of Fig. 1 ,

In the figures, a four-jet, single-walled exhaust manifold 11 is shown, which forms part of an exhaust system for a four-cylinder internal combustion engine. The exhaust manifold 11 is connected on the inlet side with a divided motor flange 13, 13 'and on the outlet side with a turbocharger, not shown. At the exhaust manifold 11, three inlet pipes 15, 16, 17 are provided, which are made of relatively flexible material and the exhaust gas inlet side in an opening of the associated motor flange 13, 13 'are added. Exhaust gas outlet side the inlet pipes 15, 16, 17 are connected to a header housing 19. The collector housing 19 is designed as a rigid cast part and has walls, in which connection pieces 20, 21, 22 are formed for receiving the inlet pipes 15, 16, 17.

To the collector housing 19, an inlet pipe socket 25 is further formed, the exhaust gas inlet side is received in an opening of the motor flange 13, 13 '. The internal combustion engine has four exhaust gas outlets. Three of the exhaust gas outlets each open into one of the inlet pipes 15, 16, 17, while an exhaust gas outlet opens into the inlet pipe socket 25. The accumulator housing 19 defines a first plenum 27, into which the exhaust gas streams from two of the inlet pipes 15, 16, 17 are guided, and a second plenum 29, in which the exhaust gas streams from the remaining of the inlet pipes 15, 16, 17 and from the inlet pipe stub 25 be guided. Further, the collector housing 19 has two recesses 31, 33, in each of which one - not shown for clarity - Lambda probe is used. The collecting chambers 27, 29 are designed such that each lambda probe is flown by the exhaust gas flow of two exhaust gas outlets.

The inlet pipes 15, 16, 17 are respectively welded to the motor flange 13, 13 'and to one of the connecting pieces 20, 21, 22. The inlet pipe socket 25 is also welded to the motor flange 13, 13 '. A necessary during heating length compensation can take place via the inlet pipes 15, 16, 17. These are in fact built pipes that have a relatively high flexibility or deformability. About the integrally formed with the collector housing 19 inlet pipe stub 25 is a direct connection between the motor flange 13, 13 'and the rigid collector housing 19 so that despite the flexible inlet pipes 15, 16, 17 a high strength the manifold structure is achieved. In particular, there is a connection between the internal combustion engine and the turbine housing of the turbocharger, which is based exclusively on relatively dimensionally stable and rigid structures. The exhaust manifold 11 thus forms a self-supporting component even at high temperatures, for which no separate support elements are required. The collector housing 19 and the inlet pipes 15, 16, 17 are each quite simple and can be produced with relatively high accuracy, so that the exhaust manifold 11 is inexpensive to manufacture.

LIST OF REFERENCE NUMBERS

11

exhaust manifold

13, 13 '

motor flange

15, 16, 17

inlet pipe

19

collector housing

20, 21, 22

spigot

25

Inlet pipe connection

27, 29

plenum

31, 33

recess

Claims (15)

Exhaust system with an exhaust manifold (11), in particular a single-wall exhaust manifold, which comprises a plurality of inlet pipes (15, 16, 17) for connection to exhaust gas outlets of an internal combustion engine and a collecting device (19) for combining the inlet pipes (15, 16, 17), wherein the collecting means (19) having an exhaust port connected to subsequent elements of the exhaust system, the collector (19) being rigid and the inlet pipes (15, 16, 17) being relatively flexible with respect to the collector (19),
characterized in that
the collecting device (19) comprises a likewise rigid inlet pipe socket (25), which is designed for direct connection to an exhaust gas outlet of an internal combustion engine. Exhaust system according to claim 1,
characterized in that
the inlet pipe socket (25) is integrally formed on the collecting device (19). Exhaust system according to claim 1 or 2,
characterized in that
the collecting device (19) consists of rigid material. Exhaust system according to at least one of the preceding claims,
characterized in that
the inlet pipes (15, 16, 17) are made of relatively flexible material with respect to the collecting means (19). Exhaust system according to at least one of the preceding claims,
characterized in that
the collecting device (19) is designed as a one-piece collector housing. Exhaust system according to at least one of the preceding claims,
characterized in that
the collecting device (19) is designed as a casting. Exhaust system according to at least one of the preceding claims,
characterized in that
the collecting device (19) is designed as a hydroforming part with a large wall thickness. Exhaust system according to at least one of the preceding claims,
characterized in that
the inlet pipes (15, 16, 17) are formed as sheet metal parts. Exhaust system according to at least one of the preceding claims,
characterized in that
the collecting device (19) is connected to a turbocharger and / or to a catalyst close to the engine. Exhaust system according to claim 9,
characterized in that
the collecting device (19) forms at least part of a subsequent turbine housing of a turbocharger. Exhaust system according to at least one of the preceding claims,
characterized in that
the collecting device (19) has a particularly integrally formed receptacle (31, 33) for a lambda probe. Exhaust system according to at least one of the preceding claims,
characterized in that
the exhaust manifold (11) is designed as Zündfolgekrümmer. Exhaust system according to at least one of the preceding claims,
characterized in that
the inlet pipes (15, 16, 17) and the pipe socket (25) of the collecting device (19) are connected to one or more motor flanges (13, 13 '). Exhaust system according to at least one of the preceding claims,
characterized in that
the wall thickness of the inlet pipes (15, 16, 17) is at most 1.2 mm. Exhaust system according to at least one of the preceding claims,
characterized in that
the wall thickness of the collecting device (19) is at least 1.5 mm, in particular between approximately 2 mm and approximately 3 mm.

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