JP2009024650A - Muffler and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a muffler excellent in durability, suppressing a radiated sound without generation of abnormal noise such as chattering noise, and preventing deformation of a shell caused by evaporation of moisture between plates. <P>SOLUTION: The muffler 1 has a shell 2 formed by rolling and overlapping a plate member 21. A rib 24 protruded from a rolling end 23 of the plate 21 to the outside along a rolling direction are formed. A clearance 25 opened at the rolling end 23 of the rib 24 and approximately closed to the inside of the shell 2 is formed along the rib 24. Suitably, the clearance 25 may be formed within a range from a half circumference or more to less than a circumference from the rolling end 23 of the plate 21 toward the rolling direction. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to a silencer provided in an exhaust system or the like of an automobile engine, and more particularly to a silencer in which a shell is formed by winding a plate material and a manufacturing method thereof.

  As a silencer provided in an exhaust system of an automobile engine, a silencer is known in which a plate material is wound to form a shell. In the silencer, a capillary tube is interposed between plate materials on which moisture in the exhaust gas is wound. You may enter depending on the phenomenon. The entering water is heated to high temperature by exhaust gas during driving of the automobile and evaporates, and there is a possibility that the shell is deformed by rapid volume expansion at that time. Therefore, a silencer that escapes evaporated water vapor and prevents deformation of the shell has been proposed (see Patent Documents 1 and 2).

  In Patent Document 1, a gap (relief passage) is formed between the rolled plate members, and the gap is communicated with the inside of the shell through a through hole formed in the inner plate member. And the silencer which escapes to the inside of a shell through a through-hole is disclosed.

  In Patent Document 2, a bead that protrudes outward is formed on an inner plate material, the bead is pressed inward by an outer plate material, a deformed bead is formed so as to protrude inside the shell, and a double bead is formed by the deformed bead. A silencer is disclosed in which a gap is formed between plate members wound around, an inner end of the gap is opened inside the shell, and water vapor evaporated between the plate members is released into the shell through the gap and opening. The silencer is formed by winding a plate material around an intermediate assembly including an end plate, a partition plate, an inlet pipe, and an outlet pipe.

JP 2004-285969 A JP 2006-266215 A

  However, in the silencer of Patent Document 1, the condensed water accumulated between the plate materials corrodes the through holes and the durability is lowered. Further, the shell is composed of a single plate material at the positions of the through holes, and the radiated sound is not generated. There is a problem of increasing. Moreover, in the silencer of patent document 2, although the contact pressure of the part which the outer board | plate material and the bead contact | connect is high, since the contact pressure of the circumference | surroundings of a clearance gap by a deformation | transformation bead is low, there exists a possibility that noises, such as a chatter noise, may generate | occur | produce. There is. Furthermore, in a silencer that wraps a plate material to form a shell, as described in Patent Document 2, in addition to a manufacturing process in which a plate material is wound around an intermediate assembly, the intermediate assembly is mounted on a cylindrical shell. Although it is often manufactured by press-fitting, in the configuration in which the deformed bead of Patent Document 2 protrudes to the inside of the shell, the deformed bead is caught. Therefore, it is possible to use the method of press-fitting and manufacturing the intermediate assembly into the shell. Can not.

  The present invention is proposed in view of the above problems, and is excellent in durability, can suppress radiated sound without generating abnormal noise such as chatter noise, and deforms the shell by evaporation of moisture between the plate materials. It is an object to provide a silencer capable of preventing noise and a method for manufacturing the same. Another object of the present invention is to provide a silencer that can be manufactured by press-fitting an intermediate assembly into the shell without a portion locally projecting inside the shell, and a method for manufacturing the silencer.

  The silencer of the present invention is a silencer having a shell on which plate materials are wound, and forms a rib protruding outward from the winding end end of the plate material along the winding direction, and opens at the winding end end of the rib. And the clearance gap closed inside the said shell is formed along this rib, It is characterized by the above-mentioned. It is preferable that a plurality of gaps are formed by separating the gaps formed by the ribs.

  Moreover, the silencer of the present invention is characterized in that the gap is formed in a range of not less than one turn and less than one turn in the winding direction from the winding end of the plate material.

  Moreover, the automobile of the present invention includes the silencer of the present invention. The automobile includes a motorcycle and the like in addition to the automobile.

  The silencer manufacturing method of the present invention also includes a method of forming a rib that is rolled up from a winding end of the plate, and that protrudes outward in the winding direction from the winding end of the plate. An intermediate having an end plate, a partition plate, and a pipe that penetrates the end plate and the partition plate and serves as an inlet and an outlet for the gas, in a shell in which a gap that is substantially closed inside the shell is formed along the rib A step of press-fitting the assembly is provided.

  The invention disclosed in this specification includes, in addition to the configurations of each invention and each embodiment, those specified by changing these partial configurations to other configurations disclosed in this specification, or these configurations. To which other configurations disclosed in the present specification are added and specified, or those partial configurations deleted and specified to the extent that partial effects can be obtained are included.

  In the present invention, it is possible to release moisture that enters between the rolled plate materials from the gap between the ribs and the opening at the end of the winding to the outside of the shell, and the steam that has been heated by exhaust gas or the like to expand its volume. Can escape. Therefore, deformation of the shell due to the volume expansion of water vapor can be prevented.

  Further, since the gap along the rib is substantially closed with respect to the inside of the shell, it is possible to prevent or inhibit the condensed water accumulated inside the shell from flowing out between the inner plate material and the outer plate material. Therefore, corrosion caused by accumulation of water between the inner and outer plate materials can be prevented, and excellent durability can be obtained.

  Further, since it is not necessary to receive the exhaust pressure or the like at a low rigidity portion where the shell is formed of a single plate material, it is possible to effectively reduce radiated sound. Furthermore, since the contact pressure between the plate members does not become locally low around the gap or the like, it is possible to prevent the generation of abnormal noise such as chatter noise.

  Further, the rib is formed so as to protrude outward, and there is no need to provide a portion protruding locally inside the shell. Accordingly, the inside of the shell can be made to have a uniform cross-sectional shape, and the intermediate assembly can be press-fitted into the shell.

  The silencer of embodiment of this invention is demonstrated based on FIGS.

  The silencer 1 of the present embodiment is a silencer provided, for example, in an exhaust system of an engine of a four-wheeled vehicle. As shown in FIGS. 1 and 5, an end plate is provided at a front end opening of a substantially elliptical cylindrical shell 2. 3 is airtightly fixed, and the end plate 4 is airtightly fixed to the rear end opening of the shell 2. The shell 2 and the end plate 3 are fixed by a caulking portion 31 by caulking the end portion of the end plate 3 so as to wind the end portion of the shell 2. Similarly, the shell 2 and the end plate 4 are fixed by a caulking portion 41 by caulking the end portion of the end plate 4 so as to wind the end portion of the shell 2. In addition, the fixing method of the shell 2 and the end plates 3 and 4 is appropriate other than the caulking, and may be fixed by welding, for example.

  Inside the shell 2, partition plates 5 and 6 are provided substantially parallel to the end plates 3 and 4. The end plate 3 and the partition plate 5, the partition plate 5 and the partition plate 6, and the partition plate 6 and the end plate 4 are arranged at predetermined intervals, and chambers 11, 12, and 13 are formed therebetween.

  An inlet pipe 7 is disposed through the end plate 3 and the partition plates 5 and 6, and the inlet pipe 7 is supported by the end plate 3 and the partition plates 5 and 6. One end opening of the inlet pipe 7 is opened in the chamber 13, and the other end opening is opened to the outside of the end plate 3 and is connected to a pipe on the upstream side of the exhaust system of the engine. An exit pipe 8 is disposed through the end plate 4 and the partition plates 6 and 5, and the exit pipe 8 is supported by the end plate 4 and the partition plates 6 and 5. One end opening of the outlet pipe 8 is opened in the chamber 11, and the other end opening is opened to the outside of the end plate 4 and connected to a pipe on the downstream side of the engine exhaust system. Exhaust gas introduced from the inlet pipe 7 into the chamber 13 is led to the chamber 11 through the communication holes of the partition plates 6 and 5 (not shown) and led out from the outlet pipe 8 to the outside.

  As shown in FIGS. 1 to 4, the shell 2 is formed by winding the plate material 21 approximately twice from the winding start end 22 to the winding end end 23, and the winding direction from the winding end end 23 of the plate material 21. A rib 24 projecting outward along the line is formed in a linear shape. The rib 24 is formed in a substantially trapezoidal cross-sectional view on the plate material 21 disposed on the outermost side (see FIG. 5), and is formed in a range from a half turn to less than one turn in the winding direction from the winding end 23 of the plate material 21. In this example, it is formed with a length of about 3/4 round. The ribs 24 are formed in a plurality of strips spaced apart by a predetermined interval. The ribs 24 in this example are formed in three strips, near the center between the partition plates 5 and 6, near the center between the end plate 3 and the partition plate 5, and at the end. It is provided near the center of the plate 4 and the partition plate 6, respectively.

  A substantially trapezoidal gap 25 is formed between the inner plate 21 adjacent to the outermost plate 21 and the rib 24 (see FIG. 5), and the gap 25 extends along the rib 24 in the rib 24. It is formed in a linear shape. One end of the gap 25 is opened to the outside of the shell 2 through the opening 26 of the winding end 23, and the other end is closed by a blocking portion 27 where the outermost plate member 21 and the adjacent inner plate member 21 are brought into close contact by press-fitting or the like. The gap 25 is closed with respect to the inside of the shell 2 by a closing portion 27. The gap 25 is formed in a range of not less than one turn and less than one turn in the winding direction from the winding end 23 of the plate material 21 corresponding to the rib 24, and is formed with a length of about 3/4 turn in this example, Further, a plurality of strips are formed at predetermined intervals, and three strips are formed in this example.

  When the silencer 1 of the above embodiment is manufactured, a plurality of substantially trapezoidal ribs 24 are formed on the rectangular plate material 21 by press molding or roll molding. Each rib 24 is formed along the winding direction from a position corresponding to the winding end 23 of the plate material 21 to a position corresponding to the closing portion 27. Thereafter, the plate material 21 is wound from the winding start end 22 so that the ribs 24 protrude outward, and the shell 2 having a substantially elliptical cylindrical shape is formed by double wrapping. In the state in which the shell 2 is formed by the winding, the opening 2 is opened at the winding end end 23, and the outer plate member 21 and the outer plate member 21 and the adjacent plate member 21 are in close contact with each other at the closing portion 27. A closed gap 25 is formed inside. Thereafter, spot welding is performed at a plurality of predetermined intervals in the axial direction (for example, around 35 mm) at a position near the winding end 23 such as a position around 8 mm in the circumferential direction from the winding end 23 to complete the shell 2. .

  Thereafter, the intermediate assembly is press-fitted into the completed substantially elliptical cylindrical shell 2 (see FIG. 5). The intermediate assembly is provided through the end plates 3 and 4, the end plate 3 and the partition plates 5 and 6, and the inlet pipe 7 fixed to the end plate 3 and the partition plates 5 and 6, and the end The plate 3 and the partition plates 6 and 5 are provided so as to penetrate through the end plate 4 and the outlet pipe 8 fixed to the partition plates 6 and 5. The intermediate assembly is press-fitted into the shell 2 from one open end in the longitudinal direction of the shell 2. After the press-fitting arrangement of the intermediate assembly into a predetermined position, the end of the end plate 3 is caulked so that one end of the shell 2 is rolled up, and the shell 2 and the end plate 3 are fixed by the caulking portion 31. The end of the end plate 4 is caulked so that the other end is wound, and is fixed by the shell 2, the end plate 4, and the crimping portion 41, and the silencer 1 is completed.

  The silencer 1 of the above embodiment and the silencer having the same configuration as the silencer 1 except that the rib 24 and the gap 25 are not formed (the silencer of the comparative example) are submerged for a specified time, respectively. A cycle of mounting on a bench and operating for a specified time at a specified temperature (maximum temperature by actual vehicle operation) was repeated, and each deformation was confirmed. As a result, the silencer of the comparative example was deformed as a whole, and remarkable deformation (maximum shell deformation height of 14 mm) was observed particularly in the vicinity of the shell and the caulking portion, whereas the silencer 1 of the above embodiment. No deformation was seen.

  The present invention can be used, for example, as a silencer provided in an exhaust system of an automobile engine.

The perspective view of the silencer of an embodiment. The AA arrow directional cross-sectional view of the shell in the silencer of FIG. FIG. 3 is a cross-sectional view of the shell taken along line B-B in the silencer of FIG. 1. The CC sectional view taken on the line of the shell in the silencer of FIG. The cross-sectional view of the silencer of FIG.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 ... Silencer 11, 12, 13 ... Chamber 2 ... Shell 21 ... Plate material 22 ... Winding start end 23 ... Winding end end 24 ... Rib 25 ... Gap 26 ... Opening 27 ... Closure part 3, 4 ... End plate 31, 41 ... Caulking section 5, 6 ... Partition plate 7 ... Inlet pipe 8 ... Outlet pipe

Claims (4)

A silencer comprising a shell wound with plate materials,
Forming a rib protruding outward along the winding direction from the winding end of the plate,
A silencer characterized in that a gap is formed along the rib that opens at the end of winding of the rib and is substantially closed inside the shell.   The silencer according to claim 1, wherein the gap is formed in a range of not less than one half and less than one turn in the winding direction from the winding end of the plate material.   An automobile comprising the silencer according to claim 1 or 2. A rib is formed by laminating a plate material, a rib protruding outward from the winding end of the plate material along the winding direction is formed, and a gap that opens at the winding end of the rib and is substantially closed inside the shell To the shell that is formed along the
A method of manufacturing a silencer, comprising: an end plate, a partition plate, and a step of press-fitting an intermediate assembly having a pipe that penetrates the end plate and the partition plate and serves as an inlet and an outlet of gas.

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