GB2575060A

GB2575060A - Tubular Component and Method of Manufacture Thereof

Info

Publication number: GB2575060A
Application number: GB201810519A
Authority: GB
Inventors: John Henry Nicholas
Original assignee: Ss Tube Technology Ltd; Ss Tube Tech Ltd
Current assignee: Ss Tube Technology Ltd; Ss Tube Tech Ltd
Priority date: 2018-06-27
Filing date: 2018-06-27
Publication date: 2020-01-01
Anticipated expiration: 2038-06-27
Also published as: GB2575060B; GB201810519D0

Abstract

A tubular component, such as an exhaust collector, comprises at least first and second members 12, 14, at least one of which is of generally C-shaped cross-section. The first and second members 12, 14 are secured to one another, preferably by welding, to define an outlet 20 of enclosed, tubular form. An insert 24 is secured to the first and second members 12, 14, preferably by welding, such that the insert 24 and first member 12 together define a first inlet 26a of enclosed, tubular form and the insert 24 and the second member 14 together define a second inlet 26b of enclosed, tubular form. The first and second inlets 26a, 26b communicate with the outlet 20. The insert may have a wall thickness which is non-uniform and/or different to that of the first and second members. In a method of manufacturing, the insert may be fabricated using an additive process.

Description

TUBULAR COMPONENT AND METHOD OF MANUFACTURE THEREOF

This invention relates to a tubular component, and to a method of manufacture or fabrication thereof. In particular, it relates to a tubular component in the form of a Y-piece or the like, in which two or more pipes, tubes or the like merge with one another such that, for example, two or more inlets merge with one another and communicate with a single outlet. However, this represents just one example of an application in which the invention may be used, and the invention is not restricted in this regard.

Exhaust collectors, as used in automotive applications, typically comprise several pipes which are welded to one another, the assembly being shaped so as to define a plurality of inlets each connected to a single, common outlet. By way of example, often three or four inlets may be present. The manner in which the collector is formed involves appropriately shaping the ends of a series of pipes such that each includes an inlet end of circular, tubular form and an outlet end of part circular cross sectional shape. Seams are formed between the individual pipes, for example by welding the pipes to one another. The welded structure includes an outlet opening made up of sections of each of the individual pipes, and individual inlet openings defined by the respective ones of the pipes.

In practise, certain of the seams are difficult to access, for example being located between the respective inlets, and so fabrication of the collector is not simple and there is the risk of the component failing if incorrectly fabricated. Furthermore, expansion of parts of the collector and pipes connected, in use, thereto, and vibrations and other loads applied thereto in use, can result in parts of the collector being exposed to relatively large loads, and the collector has to be designed and fabricated in such a manner as to be able to withstand such loads. Typically, the regions that, in use, experience some of the most significant loads are within the more inaccessible parts of the collector.

Rather than manufacture exhaust collectors by welding together pipes or tubes in the manner set out hereinbefore, another approach involves using an additive manufacturing process to fabricate the entire exhaust collector. Whilst the use of such a technique avoids the need to form weld joints in relatively inaccessible parts of the exhaust collector, and provides the design freedom to use increased wall thicknesses or the like in regions that, in use, experience significant loads, such fabrication or manufacturing techniques are expensive and relatively slow, and use expensive manufacturing equipment. Accordingly, manufacturing a complete exhaust collector using such techniques is undesirable.

It is an object of the invention to provide a tubular component and associated method of manufacture or fabrication in which at least some of the disadvantages associated with known arrangements are overcome or are of reduced impact.

According to the present invention there is provided a tubular component comprising at least first and second members, at least one of which is of generally C-shaped cross-sectional shape, the first and second members being secured to one another to define an outlet of enclosed, tubular form, and an insert secured to the first and second members such that the insert and first member together define a first inlet of enclosed, tubular form and the insert and the second member together define a second inlet of enclosed, tubular form, the first and second inlets communicating with the outlet.

The terms inlet and outlet are used for convenience only and it will be appreciated that, depending upon the application in which the tubular component is used, flow through the tubular component could be in the opposite direction to that suggested by the normal meanings of these expressions.

Preferably the first and second members are welded to one another. Preferably, the insert is welded to the first and second members.

Such an arrangement is advantageous in that the welds or other connections between the parts of the tubular component are relatively easy to access, and so manufacture or fabrication of the tubular component is relatively straightforward.

Conveniently, the insert is fabricated using an additive manufacturing process. As a result, the insert may be fabricated in such a manner as to be of non-uniform wall thickness, having increased wall thicknesses in areas which experience the most significant loads, in use. Alternatively, or additionally, it may be of a different wall thickness to the members.

Such an arrangement has the advantages associated with the use of an additive manufacturing method in the manufacture of the tubular member. However, as only a relatively small part of the tubular component is manufactured using the additive manufacturing method, the disadvantages of using such a manufacturing method of increased manufacturing time, complexity and cost are reduced.

The invention further relates to a method of manufacture of a tubular component comprising providing first and second members, at least one of which is of generally C-shaped crosssectional shape, securing the first and second members to one another to define an outlet of tubular form, securing an insert to the first and second members such that the insert and first member together define a first inlet of tubular form and the insert and the second member together define a second inlet of tubular form, the first and second inlets communicating with the outlet.

The insert is preferably fabricated using an additive manufacturing technique.

The tubular component conveniently takes the form of an exhaust collector, and preferably includes three or more inlets, the tubular component being fabricated from three or more members of generally C-shaped cross-section and an insert.

The invention will further be described, by way of example, with reference to the accompanying drawings, in which:

Figure 1 is a partly exploded view of a tubular component in accordance with an embodiment of the invention; and

Figure 2 is a view illustrating the tubular component.

Referring to Figures 1 and 2, a tubular component 10 in the form of an exhaust collector is illustrated. The component 10 comprises first, second and third members 12, 14, 16, each of which is of generally C-shaped cross-sectional shape, the cross-sectional shapes of the members 12,14,16 not being constant along their lengths. Each of the members 12,14,16 is conveniently of a suitable steel material, but it will be appreciated that the invention is not restricted in this regard, and that other materials may be used without departing from the scope of the invention. The members 12,14,16 are secured to one another by being welded to one another along parts of their edges 18. The assembly of the members 12,14, 16 is such that the members 12,14,16 together define an outlet 20 of generally circular cross-sectional shape. The outlet 20 is thus in the form of an enclosed tube, enclosed about its full periphery.

As illustrated, reinforcing members 22 may be welded to the members 12, 14, 16, across the joints therebetween, to assist in rigidly securing the members 12, 14, 16 to one another.

At the inlet end of the tubular component 10, the C-shaped members 12, 14,16 are not directly welded to one another, but rather the edges of the C-shaped members 12, 14, 16 are spaced apart from one another.

The tubular component 10 further comprises an insert 24 fabricated by an additive manufacturing method, the insert being shaped to define a first part 24a which cooperates with the first member 12 to define a first inlet 26a of generally circular cross-sectional shape, the first inlet 26a being of fully enclosed tubular form. Similarly, the insert 24 defines second and third parts 24b, 24c shaped to cooperate, respectively, with the second and third members 14,16 to define second and third inlets 26b, 26c, each of which is of generally circular cross-sectional shape, and each of which is of fully enclosed, tubular form. The first, second and third inlets 26a, 26b, 26c each communicate with the outlet 20. The insert 24 is conveniently secured to the first, second and third members 12, 14, 16 by being welded to the edges of the members 12, 14, 16.

The insert 24 is of a relatively complex shape, and may be of varying wall thickness selected taking into account the loads likely to be experienced, in use, to enhance the ability of the tubular component 10 to bear the loads applied thereto, in use. Even if the insert 24 is of uniform wall thickness, it may be of increased wall thickness compared to the members 12, 14, 16 to enhance the load bearing capacity of this part of the tubular component 10.

The tubular component 10 of this embodiment of the invention thus includes, effectively, three pipes which merge into a single pipe. It will be appreciated that the invention is not restricted in this regard and is also applicable to arrangements in which more or fewer pipes merge into a single outlet.

Whilst a specific embodiment of the invention is described herein and illustrated in the accompanying drawing, it will be appreciated that a wide range of modifications and alterations may be made without departing from the scope of the invention as defined by the appended claims.

Claims

CLAIMS:

1. A tubular component comprising at least first and second members, at least one of which is of generally C-shaped cross-sectional shape, the first and second members being secured to one another to define an outlet of enclosed, tubular form, and an insert secured to the first and second members such that the insert and first member together define a first inlet of enclosed, tubular form and the insert and the second member together define a second inlet of enclosed, tubular form, the first and second inlets communicating with the outlet.

2. A component according to Claim 1, wherein the first and second members are welded to one another.

3. A component according to Claim 1 or Claim 2, wherein the insert is welded to the first and second members.

4. A component according to any of the preceding claims, wherein the insert is fabricated using an additive manufacturing process.

5. A component according to Claim 4, wherein the insert is of non-uniform wall thickness.

6. A component according to Claim 4 or Claim 5, wherein the insert is of a different wall thickness to the first and second members.

7. A component according to any of the preceding claims and taking the form of an exhaust collector.

8. A component according to any of the preceding claims and including three or more inlets, the tubular component being fabricated from three or more members of generally Cshaped cross-section and the insert.

5

9. A method of manufacture of a tubular component comprising providing first and second members, at least one of which is of generally C-shaped cross-sectional shape, securing the first and second members to one another to define an outlet of tubular form, securing an insert to the first and second members such that the insert and first member together define a first inlet of tubular form and the insert and the second member together define a second inlet of tubular 10 form, the first and second inlets communicating with the outlet.

10. A method according to Claim 9, wherein the insert is fabricated using an additive manufacturing technique.