JP2006300041A - Silencer outer cylinder and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To actualize reliable fixation of the multilayer-wound outer cylinder of a silencer to a partition plate. <P>SOLUTION: A multilayer-wound portion of the outer cylinder 10 is formed integrally with a partition portion 5 by giving at least 360° rotation to the partition portion 5 of a plate material 1 being held in a core material 2. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to an outer cylinder used for a silencer such as an internal combustion engine and a method for manufacturing the same.

  2. Description of the Related Art Conventionally, a multi-layer outer cylinder in which a single metal plate is wound in close contact is generally used for a silencer interposed in the middle of an exhaust pipe of an internal combustion engine. Various pipes and a partition plate (separator) are arranged in the outer cylinder, and both end surfaces of the outer cylinder are closed with end plates (outer plates) to constitute a silencer.

  In vehicles equipped with an internal combustion engine, it is customary to horizontally suspend an exhaust pipe with a plurality of silencers below the floor. Positioning is required, and the silencer needs to be flattened accordingly. However, since a certain volume is required for noise reduction, the silencer must be extended in the longitudinal direction (perpendicular to the flat cross section) along with flattening if the noise reduction is maintained. As a result, a substantially flat surface (a curved surface having a very small curvature) that is long in the longitudinal direction is formed on the upper and lower surfaces of the flat silencer. In general, the outer cylinder of a silencer is constructed with a curved surface around the outer cylinder to improve the rigidity in order to suppress radiated sound caused by membrane vibration. There is concern about sound deterioration.

  As a means for increasing the rigidity of a flat outer cylinder, Patent Document 1 discloses a structure in which a partition plate extending in the longitudinal direction is fixed to the inner surface of the outer cylinder. According to this structure, the upper surface and the lower surface, which are radiation surfaces, are mutually fastened by the partition plate in the longitudinal direction, and high rigidity can be expected. However, it is extremely difficult in manufacturing to insert the partition plate into the formed outer cylinder without a gap and to fix it to an accurate position by welding. Further, distortion due to welding is unavoidable, and durability at high temperatures is not preferable. Furthermore, application to a silencer having a multilayer outer cylinder is unclear. On the other hand, although it is not an outer cylinder, the manufacturing method which integrally forms a partition plate in the exhaust pipe of a circular cross section is disclosed by patent document 2. FIG. According to this, the circular exhaust pipe and the partition plate can be integrally formed by sandwiching the plate material with the core material of the divided structure and pushing the end of the plate material while rotating the core material.

Japanese Utility Model Publication No. 3-047424 JP-A-9-323119

  However, aside from an exhaust pipe of a relatively thick plate (t1.0 or more), a silencer outer cylinder that winds a thin plate (about t0.6) in multiple layers is buckled when the end is pushed. Moreover, it is unclear about the application to the outer cylinder wound in the multilayer and the application to the non-circular cross section. Accordingly, it is an object of the present invention to provide a structure in which fixing of a partition plate is reliably maintained even with an outer cylinder having a thin multilayer structure and a flat cross section, and a manufacturing method thereof.

  In order to solve the above-mentioned problems, the present invention has a multilayer that adheres in a wound shape as described in claim 1, and an innermost layer and a partition plate extending in the longitudinal direction are integrally formed therein. The outer cylinder of the silencer.

  Invention of Claim 2 is a manufacturing method of the outer cylinder of the silencer of Claim 1, Comprising: A part of board | plate material is width | variety with the some core material which comprises the cross section approximated with the desired cross section of an outer cylinder. A plurality of core members are rotated at least 360 degrees or more, and the plate material is wound into a plurality of layers to integrally form the innermost layer and a partition plate extending in the longitudinal direction therein. It is the manufacturing method of the outer cylinder of the silencer characterized by the above.

  As in the third aspect of the invention, in the manufacturing method of the second aspect, the plurality of core members may have different cross-sections and may be rotated about an axis passing through the sandwiched portion of the plate members.

  Moreover, like the invention of Claim 4, in the manufacturing method of Claim 2 or Claim 3, it is good to give the force opposite to the said winding direction to a board | plate material during rotation.

  And like invention of Claim 5, in the manufacturing method in any one of Claim 2 thru | or 4, a board | plate material may join the several board | plate material from which thickness differs.

  According to the first aspect of the present invention, since the partition plate is formed integrally with the innermost layer in the multilayer outer cylinder of the silencer, the partition plate is firmly held in the longitudinal direction. In addition, there is no problem of distortion or durability due to welding.

  According to the second aspect of the present invention, since the partition plate to the multi-layer winding portion are integrally formed, there are no problems with the insertion of the partition plate through positioning to assembling accuracy in manufacturing, and problems with welding. do not do. Moreover, since it can be formed only by a series of core material rotations, the working efficiency is extremely good. If the rotation angle is increased, it is possible to cope with further multilayering of the wound layer.

  According to invention of Claim 3, even if the center of a flat cross section and a partition plate are offset, it can form.

  According to the fourth aspect of the present invention, a force opposite to the winding direction (tension) is continuously applied to the plate during rotation, that is, when the partition plate is formed and during winding, so that the plate is in close contact with the core and the inner layer. Thus, an outer cylinder with high shape accuracy can be formed.

  According to the invention described in claim 5, the plate thickness can be changed for each part in accordance with the required strength of each part of the outer cylinder.

  The best mode for carrying out the present invention will be described based on the embodiment shown in FIGS. The manufacture of the outer cylinder 10 of the silencer of the first embodiment shown in FIG. 1 includes the steps shown in FIGS. First, in a preparation step (not shown), the material is bent into a crank shape to form the plate 1 shown in FIG. The plate 1 is composed of a central partition 5 (corresponding to a partition plate) extending across the plate width and a general surface 3 extending at right angles from both ends thereof, and rectangular and circular communication holes 12 are also formed. The general surface 3 is a portion that is wound in a subsequent process.

  (A) A process is a set process in preparation for winding. Two core members 2 having the same cross section are supported by a device (not shown) so as to be rotatable around a central rotation center 4 and to be close to and away from each other. The core material 2 has a cross-sectional shape substantially equivalent to a desired outer cylinder cross-section in a state where the partition portion 5 is sandwiched between the opposing pressing surfaces 9. The core material 2 is separated from each other to form a slight gap between the pressing surfaces 9, and the partition portion 5 of the plate material 1 is disposed in the gap. Thereafter, the core material 2 is brought close to each other, and the partition portion 5 is firmly sandwiched between the pressing surfaces 9. Then, the side of the bent portion is pressed in a substantially centripetal direction by the pressing roller 6, and the plate material 1 is brought into close contact with the core material 2. The both pressing rollers 6 are always pressed with a constant load by the pressing device 7, and in the winding process described later, the pressing device 7 strokes according to the reaction force from the plate material 1, thereby both pressing rollers 6. 6 follows its position freely. Then, along with the application of the bending load in the centripetal direction, a force (tension) in the counter-winding direction is always applied to the plate material 1, thereby ensuring the close contact of the plate material 1 with the core material 2. (A) From the set state of the figure, the plate material 1 and the core material 2 are rotated in the α direction around the axis passing through the rotation center 4 while maintaining the holding of the partition portion 5, and the next process is reached. The rotation center 4 is the center of the state in which both the core members 2 are combined, and preferably penetrates the center of the partition portion 5.

  The step (b) is a state in the middle of being rotated 180 degrees in the α direction from the step (a), and the general surface 3 of the plate 1 is tightly wound around the winding surfaces 8 of the two core members 2 to form the innermost layer. That's right. Here, it can be seen that the partition portion 5 and the innermost layer are integrally formed, and the cross section thereof has a substantially θ shape. And the comparatively big bending R14 (after-mentioned) is formed in the both ends of the partition part 5. FIG. The rotation in the α direction is continued as it is, and the next process is reached.

  (A) In the step (c) rotated 360 degrees from the step, the rotation is stopped. As a result, a two-layer wound outer cylinder was formed, and only the vicinity of the terminal end 13 had three layers. The outer cylinder may be completed by this, but in order to fix the shape, the laser beam 11 may be emitted near the terminal end 13 and temporarily fixed by laser welding. Alternatively, the outer cylinder may be completed by continuously welding (main welding) the same position in the longitudinal direction. Further, the winding layers may be appropriately fixed by spot welding or the like. At the time of stopping and welding, it is desirable for the press roller 6 to press the vicinity of the terminal end 13 for welding in order to maintain close contact with the wound layer. When the outer cylinder formation is completed, the holding of the core material 2 is loosened and the outer cylinder 10 is extracted from one side of the core material 2. It is preferable that the core material 2 be cantilevered only when the core material is extracted, and the (longitudinal direction) both sides of the core material 2 are normally held rotatably. Furthermore, if the core material 2 itself can be slightly reduced in diameter, the outer cylinder 10 can be easily extracted.

  FIG. 3 is an overall perspective view of the outer cylinder 10 formed according to the first embodiment. The partition portion 5 continues to the innermost layer of the outer cylinder through a large R14, the inner layer continues to the outer layer, and the terminal end 13 of the outer layer is welded and fixed to itself. In actual use as a silencer, the partition portion 5 exposed to the high-temperature gas thermally expands in the radial direction and generates stress between the innermost layer, but the larger R14 absorbs and relaxes the partition portion. 5 and the innermost layer can be prevented from being deformed or damaged. Thus, the partition portion 5 can be firmly held with respect to the innermost layer while relaxing the thermal expansion stress. Furthermore, since the partition part 5 is not fixed by welding, there is no problem caused by welding.

  FIG. 4 is an example in which the outer cylinder 10 of the first embodiment is incorporated in the silencer 15. Two separators (partition walls) 21 having communication holes (not shown) are press-fitted into the outer cylinder 10, and the inlet pipe 17 and the outlet pipe 18 are press-fitted into each separator 21. Then, the end pipe 16 is fitted and fixed to both ends of the outer cylinder 10 through the inlet pipe 17 and the outlet pipe 18. Small holes 19 and 20 are formed in the inlet pipe 17 and the outlet pipe 18, respectively.

In the above configuration, the exhaust gas that has flowed into the inlet pipe 17 is discharged from the tube end opening while partly leaking from the small hole group 19. The leaked and released exhaust gas passes through the communication holes 12 of the partition portion 5, flows into the tube end opening of the outlet pipe 18 and the small hole group 20, and is eventually discharged out of the silencer 15. In this flow-down process, the sound is silenced by the expansion action / resonance action. At this time, the upper and lower surfaces of the outer cylinder are vibrated by the exhaust gas pulsation, but are firmly fastened to each other in the longitudinal direction by the partition portion 5, so that the membrane vibration is suppressed and the generation of radiated sound is prevented.
In addition, a present Example is only an example at the time of applying the outer cylinder 10 to a silencer, The combination of a silencer structure and an end plate is arbitrary.

  FIG. 5 to FIG. 7 show a second embodiment of the outer cylinder manufacturing method. First, a plate material 31 shown in FIG. 6 is formed in a preparation step (not shown). The plate material 31 is a so-called tailored blank material in which a partition portion 35, which is a thick plate (t1.0), is arranged at the tip, and then the general surface of the thin plate (t0.6) is welded. A plurality of communication holes 38 are formed in the partition portion 35 bent in a substantially crank shape, and rectangular notches 32 are also formed at both ends in the width direction.

  In the setting step of FIG. 5, the core members 32 and 33 are firmly sandwiched across the width direction of the partition portion 35. The core members 32 and 33 have non-identical cross sections, and the partition portion 35 is offset from the center of the cross section when combined. And it rotates to (alpha) direction around the central axis which passes along the center 36 of the partition part 35, and the general part of the board | plate material 31 is wound around both core materials. At this time, the vicinity of the winding portion is pressed by the pressing roller 6 as in the first embodiment, but the winding is performed only on one side, and therefore the pressing roller 6 may be only on one side (upper side in the figure). Furthermore, if the terminal end 40 of the plate material 31 is gripped by the clamp device 37 and followed by applying a certain tension in the anti-winding direction β, the degree of adhesion of the winding portion is further improved.

  FIG. 7 is an overall perspective view of the outer cylinder 39 formed by the manufacturing method of the second embodiment. A thick plate partitioning portion 35 is integrally formed with the innermost layer of the thin plate outer cylinder, the inner layer is integrally continuous with the outer layer, and the end 40 of the outer layer is fixed by welding to the outer layer itself. Further, the tip (lower end in the figure) of the partition portion 35 may be fixed by welding to the innermost layer, but since the integrated portion is sufficient for strength, the fixing of this portion may be minimal. As described above, when the core material cannot be divided into the same cross section due to the outer cylinder cross-sectional shape, or when it is desired to increase the wall thickness of the partition portion to provide strength, this embodiment is suitable.

  The third embodiment shown in FIG. 8 is a manufacturing method in the case of omitting the preparation step of bending the plate material (partition part) in the first embodiment. A portion where the partition portion 5 is to be formed of the plate material 1 is sandwiched between the core materials 2. The pressing roller 6 may be disposed at an optimal position, but consideration is given so that the pressing device 7 does not interfere with the core material 2. From such a set state, winding is performed in the same manner as in the first embodiment. At this time, as in the second embodiment, it is preferable that the end of the general surface 3 is gripped by the clamp device 37 and followed by applying a constant tension in the counter-winding direction. According to the manufacturing method of the present embodiment, there is a merit that the preparation step can be omitted, but since bending requires more force than winding, it is necessary to increase the clamping force and the rotational force of the core material 2. .

  The fourth embodiment shown in FIG. 9 is a manufacturing method in the case where the partition 53 is non-planar in the first embodiment or the third embodiment. In the preparation step, the partition portion 53 is formed in a curved surface in advance, or the partition member 53 is formed in a curved surface by sandwiching the plate member 50 between the core members 51 and 52. And it winds from the set state which clamped the partition part 53 similarly to the 1st Example. Thus, by adapting the shape of the sandwiching surface of the core material to the desired surface of the partition portion, any shape of the partition portion can be handled.

  The fifth embodiment shown in FIG. 10 is another method for manufacturing the outer cylinder of the silencer of the first embodiment shown in FIG. In the first embodiment, the separator to be inserted after the outer cylinder 10 is formed is previously fixed to the plate material before the outer cylinder is formed. As in the first embodiment, the plate material 60 having the partition portions 61 is formed by bending the plate material in the preparation step. Thereafter, the separators 62 are fixed to both surfaces of the partition part 61 by spot welding or the like. Each separator 62 is provided with two communication holes 66. If necessary, the side surface of the separator 62 and the general surface of the plate member 60 may be fixed by welding.

  Then, the plate member 60 is wound in the same manner as in FIG. 1, but the outer peripheral surface of the separator 62 may coincide with the outer peripheral surface of each core member or be slightly larger in diameter. In addition, since the separator 62 is interposed, the core material is divided in the longitudinal direction. Therefore, it is preferable that the core material is held in the longitudinal direction so that the core material can be freely separated and separated. Thus, when the separator 62 exists at the time of winding, the outer peripheral surface of the separator 62 and the board | plate material 61 contact | adhere reliably. In addition, since the partition 61 and the separator 62 are fixed, the upper and lower surfaces are firmly fastened in the longitudinal direction and the width direction, so that the membrane vibration is further suppressed and the generation of radiated sound is reliably prevented. The The number of separators 22, the arrangement interval, and the shape of the communication holes are arbitrary.

  In all the embodiments, not limited to this embodiment, the winding layer may be three or more layers, and the cross-sectional shape and the dividing position of the core material are arbitrary. Moreover, the board | plate material to wind may not be a single | mono layer but may be a multilayer, and a heat insulating material etc. may be pinched | interposed between the multilayer board | plate materials previously. Moreover, you may form an opening, a rib, an unevenness | corrugation, etc. also in a board | plate general surface in a preparatory process. Further, a tailored blank material may be applied to the general surface of the plate material, and the thickness may be set to be different between the inner layer and the outer layer after winding. Further, the communication pipe may be fitted and fixed in the communication hole of the partition part or the separator, or a valve (valve element) for arbitrarily controlling the open / close state of the communication hole or the communication pipe may be provided. Furthermore, the fixing of the end is not limited to continuous or intermittent laser welding in the longitudinal direction, and may be appropriately used such as seam welding or spot welding.

  Although the embodiments of the present invention have been described above, the present invention is not limited to the above-described embodiments, and design changes within a range not departing from the gist of the present invention are also included in the present invention. Moreover, you may accommodate an exhaust gas purification apparatus and a heat exchanger in an outer cylinder. The application target is not limited to an internal combustion engine such as an automobile, but can be applied to the outer cylinder of a silencer of any exhaust gas generator such as a general-purpose engine or a stationary combustion device.

The side view which shows the manufacturing method of a 1st Example. The perspective view which shows the board | plate material used for the manufacturing method of a 1st Example. The perspective view which shows the outer cylinder manufactured with the manufacturing method of the 1st Example. The top view of the silencer using the outer cylinder manufactured with the manufacturing method of the 1st Example. The side view which shows the manufacturing method of a 2nd Example. The perspective view which shows the board | plate material used for the manufacturing method of a 2nd Example. The perspective view which shows the outer cylinder manufactured with the manufacturing method of the 2nd Example. The side view which shows the manufacturing method of a 3rd Example. The side view which shows the manufacturing method of a 4th Example. The perspective view which shows the board | plate material used for the manufacturing method of a 5th Example.

Explanation of symbols

1, 31, 50, 60 Plate material 2, 32, 33, 51, 52 Core material 3, 54 General surface 4, 36, 55 Center of rotation 5, 35, 53, 61 Partition 6 Press roller 7 Press device 8 Winding surface 9 Press surface 10, 39 Outer cylinder 11 Laser beam 12, 38, 63, 64, 65, 66 Communication hole 13, 40 Terminal 14 R
15 Muffler 16 End plate 17 Inlet pipe 18 Outlet pipe 19, 20 Small hole group 21, 62 Separator 37 Clamp device α Winding direction β Anti-winding direction

Claims (5)

It has a multilayer that adheres in a wound shape,
An outer cylinder of a silencer, wherein the innermost layer of the multilayer and a partition portion extending in the longitudinal direction are integrally formed therein. A part of the plate material is sandwiched across the width direction with a plurality of core materials constituting an approximate cross section with a desired outer cylinder,
Rotating the plurality of core materials at least 360 degrees or more and winding the plate material to form a multilayer,
A method of manufacturing an outer cylinder of a silencer, wherein the innermost layer of the multilayer and a partition extending in the longitudinal direction are integrally formed therein. The cores have different cross sections from each other,
The method of manufacturing an outer cylinder of a silencer according to claim 2, wherein the outer cylinder rotates around an axis passing through the sandwiched portion of the plate material.   The method for manufacturing a silencer outer cylinder according to claim 2 or 3, wherein a force in a direction opposite to the winding direction is applied to the plate during the rotation.   5. The method for manufacturing a silencer outer cylinder according to claim 2, wherein the plate member is formed by joining a plurality of plate members having different thicknesses.

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