JP6215682B2 - Separator and manufacturing method thereof - Google Patents

Description

  The present invention relates to a separator as a component part of a muffler.

  As a muffler for reducing exhaust noise in an exhaust system of an internal combustion engine, a muffler having a structure including a muffler body that forms a space into which exhaust gas is introduced and a separator that partitions the interior of the muffler body into a plurality of rooms is known. (See Patent Document 1). The separator is formed with a wall portion that functions as a wall that partitions the interior of the muffler body into a plurality of rooms, and a flange portion that forms an outer peripheral surface facing the inner wall surface of the muffler body at the outer edge of the wall portion. In addition, a separator having a configuration in which a drain hole for discharging condensed water generated inside the muffler body is formed at the lower end in the vertical direction is also known (see Patent Document 2).

JP 2000-213328 A Japanese Utility Model Publication No. 63-150017

  The above-described separator can be manufactured by punching a plurality of sheets from a single sheet material, for example, by progressive press processing. In order to manufacture as many separators as possible from a single plate material, it is necessary to arrange the positions of the punched portions of the separator in the plate material so that adjacent separators are as close as possible. On the other hand, in the progressive press processing, it is necessary to perform processing while leaving a portion that connects adjacent separators, which is a restriction on arranging the separators close to each other.

  An object of this invention is to provide the technique for manufacturing many separators from one board | plate material.

  One aspect of the present invention includes a wall portion forming a wall for partitioning the interior of the muffler body into which exhaust gas is introduced into a plurality of rooms, and an outer peripheral surface facing the inner wall surface of the muffler body at the outer edge of the wall portion. A separator having a flange portion to be formed by punching a plurality of sheets from a single plate by progressive pressing, and a separator forming portion that is a portion for forming the separator in the plate is adjacent The separator forming portions adjacent to each other from the plate material arranged so that a part of the flange forming portion, which is a portion for forming the flange portion, overlaps with each other between the matching separator forming portions. A first step of removing unnecessary portions other than the connecting portion to be connected, and after the first step, the flange forming portion is processed to form the flange portion. And a third step of removing the connecting portion after the second step, and in the first step, the connecting portion is directly connected to the flange forming portion. Instead, it is formed so as to be connected to a wall forming portion which is a portion for forming the wall portion.

  The role of the separator to partition the inside of the muffler body into a plurality of rooms can be achieved even if a part of the flange portion is missing. Therefore, in the plate material used as the separator material, the separator forming portions adjacent to each other can be arranged so that the flange forming portions partially overlap each other. In addition, since the connecting portion that connects the separator forming portions adjacent to each other is not directly connected to the flange forming portion in order to enable progressive pressing, the flange forming portion is processed while maintaining the shape of the connecting portion. Thus, the flange portion can be formed. For this reason, although the notch which divides | segments a flange part and reaches a wall part is formed in the part from which the connection part in the separator was removed, this notch part can be utilized as a drain hole. Therefore, according to such a manufacturing method, many separators can be manufactured from one board | plate material.

  In the manufacturing method described above, a notch that divides the flange portion and reaches the wall portion is formed in a portion from which the connecting portion is removed, and the notch forms two slit portions on an outer edge of the wall portion. May be. According to such a manufacturing method, it is possible to prevent the connecting portion and the flange forming portion from being directly connected while forming the connecting portion with a relatively wide width. Moreover, two slit parts can be functioned as a drain hole.

  In the manufacturing method, the outer edge of the wall portion is formed with a protruding portion that protrudes outward relative to the two slit portions between the two slit portions formed by the notches, The protrusion may be formed in an outer shape that does not contact the inner wall surface of the muffler body. According to such a manufacturing method, it is possible to make it difficult for the separator to interfere with the inner wall surface of the muffler main body and hinder assembly.

  Another aspect of the present invention is a separator provided inside a muffler main body into which exhaust gas is introduced, a wall portion forming a wall for partitioning the inside of the muffler main body into a plurality of rooms, A flange portion that forms an outer peripheral surface facing an inner wall surface of the muffler body at an outer edge, and a notch that divides the flange portion and reaches the wall portion is formed, and the notch is formed on the wall portion. Two slit portions are formed on the outer edge. According to such a structure, since it can manufacture with the said manufacturing method, the effect similar to the effect acquired by the said manufacturing method can be acquired.

  In the separator, the notch may be formed at a position that is at least the lower end in the vertical direction in the state provided in the muffler body. According to such a structure, two slit parts can be functioned as a drain hole.

  In the separator, on the outer edge of the wall portion, a protruding portion that protrudes outward relative to the two slit portions is formed between the two slit portions formed by the notches, The protrusion may be formed in an outer shape that does not contact the inner wall surface of the muffler body. According to such a configuration, it is possible to make it difficult for the separator to interfere with the inner wall surface of the muffler main body and hinder assembly.

It is sectional drawing in the side view of the muffler of embodiment. It is II-II sectional drawing of FIG. It is a figure which shows the punching plan part of the separator in a board | plate material. It is a figure which shows the processing content by progressive press processing.

Embodiments to which the present invention is applied will be described below with reference to the drawings.
[1. Constitution]
A muffler 1 shown in FIG. 1 includes an outer shell 10, a through pipe 20, and two separators 30.

  The outer shell 10 is provided between the upstream side exhaust pipe 2 and the downstream side exhaust pipe 3, and includes a cylindrical body 11, an upstream side closing plate 12, and a downstream side closing plate 13. The cylindrical body 11 is formed in a cylindrical shape (cylindrical shape in this embodiment) having a larger diameter than the upstream exhaust pipe 2 and the downstream exhaust pipe 3. The upstream closing plate 12 closes the upstream opening in the cylindrical body 11. The downstream closing plate 13 closes the downstream opening in the cylindrical body 11.

  The through pipe 20 connects the upstream side exhaust pipe 2 and the downstream side exhaust pipe 3. Specifically, the through pipe 20 is provided so as to penetrate the outer shell 10 from the upstream opening 121 provided in the upstream closing plate 12 of the outer shell 10 to the downstream opening 131 provided in the downstream closing plate 13. ing. A large number of small holes 21 are formed in a portion of the through pipe 20 existing in the outer shell 10, and exhaust gas from the upstream side exhaust pipe 2 is introduced into the outer shell 10.

  As shown also in FIG. 2, the separator 30 is a substantially disk-shaped member for partitioning the inside of the outer shell 10 into a plurality of rooms. In the present embodiment, the inside of the outer shell 10 is partitioned into three rooms by two separators 30.

The separator 30 includes a wall portion 31 and an outer flange portion 32.
The wall portion 31 forms a wall (in this embodiment, a disk-like wall) for partitioning the inside of the outer shell 10 into a plurality of rooms. A through hole 311 through which the through pipe 20 is inserted and an inner flange portion 312 that forms a joint surface for joining (for example, welding) to the through pipe 20 are formed at the center of the wall portion 31.

  The outer flange portion 32 forms an outer peripheral surface facing the inner wall surface of the outer shell 10 (specifically, the cylindrical body 11) at the outer edge of the wall portion 31. The separator 30 is joined (for example, welded) to the outer shell 10 (tubular body 11) using the outer peripheral surface of the outer flange portion 32 as a joining surface.

  The separator 30 is formed with a notch 33 that divides the outer flange portion 32 to reach the wall portion 31. In the present embodiment, a notch 33 having the same shape is formed at each of a position that becomes a vertical lower end (lower end in FIG. 2) and a position that becomes a vertical upper end (upper end in FIG. 2). Yes. The notch 33 is formed with two slit portions 313 on the outer edge of the wall portion 31, and between the two slit portions 313, a protruding portion 314 that protrudes outward relative to the slit portion 313 is formed. Yes. The slit portion 313 forms a drain hole between the slit portion 313 and the inner wall surface of the outer shell 10 (tubular body 11). The protruding portion 314 is formed in an outer shape that does not contact the inner wall surface of the outer shell 10 (tubular body 11).

[2. Production method]
Next, a method for manufacturing the separator 30 will be described.
As shown in FIG. 3, the separator 30 is manufactured by punching a plurality of sheets from a single metal plate 4 (plate wound in a coil shape) by progressive pressing. In the board | plate material 4, the arrangement | positioning of the separator formation part 40 which is a part (punching plan part) for forming the separator 30 is made into the staggered arrangement | positioning (staggered arrangement | positioning). Specifically, the separator forming portions 40 adjacent to each other are arranged such that a part of the flange forming portion 42 which is a portion for forming the outer flange portion 32 overlaps each other. In addition, it does not overlap to the wall formation part 41 which is a part for forming the wall part 31. FIG.

  According to such an arrangement of the separator forming portions 40, the plate material 4 is sequentially processed as shown in FIG. Note that FIG. 4 shows an arrangement in which the separator forming portions 40 do not overlap each other for easy understanding of the processing contents, but the processing contents are the same even if the separator forming portions 40 overlap each other. .

  First, the area | region 51 except the connection part 44 which connects these is stamped out among the area | regions pinched | interposed between the separator formation parts 40 mutually adjacent along a progressive feed direction. The connection part 44 here is a part that is not included in the final product (separator 30) and that is left to maintain the connection between the separators 30 adjacent to each other.

  Subsequently, the shape of the connecting portion 44 is adjusted so that the connecting portion 44 is not directly connected to the flange forming portion 42 but connected to the wall forming portion 41. Specifically, regions 52 extending from one wall forming portion 41 to the other wall forming portion 41 of the two separator forming portions 40 connected by the connecting portion 44 are removed on both sides of the connecting portion 44. Then, the connecting portion 44 and the flange forming portion 42 are divided.

Subsequently, the circular region 53 at the center in the wall forming portion 41 is punched to form a through hole 311.
Subsequently, processing for raising the flange forming portion 42 (for example, drawing processing) is performed, and the outer flange portion 32 is formed. Since the flange forming portion 42 is not directly connected to the connecting portion 44, it is possible to perform processing while maintaining the state of the connecting portion 44.

Subsequently, processing (for example, drawing processing) for raising the inner edge of the through hole 311 of the wall forming portion 41 is performed, and the inner flange portion 312 is formed.
Subsequently, the connecting portion 44 is punched, and the separator 30 is completed.

[3. effect]
According to the embodiment detailed above, the following effects can be obtained.
[3A] In the method of manufacturing the separator 30 according to the present embodiment, unnecessary portions other than the connecting portion 44 are removed from the plate member 4 on which the separator forming portion 40 is arranged so that the flange forming portions 42 partially overlap each other. (First step). Thereafter, the flange forming portion 42 is processed to form the outer flange portion 32 (second step). Thereafter, the connecting portion 44 is removed (third step). In the first step, the connecting portion 44 is formed not to be directly connected to the flange forming portion 42 but to be connected to the wall forming portion 41.

  The role of the separator 30 to partition the inside of the outer shell 10 into a plurality of chambers can be achieved even if a part of the outer flange portion 32 is missing. Therefore, in the plate member 4 as the material of the separator 30, the separator forming portions 40 adjacent to each other can be arranged so that the flange forming portions 42 partially overlap each other. In addition, since the connecting portion 44 that connects the separator forming portions 40 adjacent to each other in order to enable progressive pressing is not directly connected to the flange forming portion 42, the flange is maintained while maintaining the shape of the connecting portion 44. The outer flange portion 32 can be formed by processing the forming portion 42. For this reason, the notch 33 which divides the outer flange part 32 and reaches the wall part 31 is formed in the part of the separator 30 where the connecting part 44 is removed. The notch 33 part is used as a drain hole. be able to. Therefore, according to the manufacturing method of this embodiment, many separators 30 can be manufactured from the one board | plate material 4. FIG.

  [3B] A notch 33 that divides the outer flange portion 32 and reaches the wall portion 31 is formed in a portion from which the connecting portion 44 is removed (at least a position that becomes the lower end in the vertical direction). Two slit portions 313 are formed on the outer edge of the wall portion 31 by the notch 33. Therefore, it is possible to prevent the connecting portion 44 and the flange forming portion 42 from being directly connected while forming the connecting portion 44 with a relatively wide width. In addition, the two slit portions 313 can function as drain holes.

  [3C] On the outer edge of the wall portion 31, a protruding portion 314 is formed between the two slit portions 313 formed by the notches 33 and protrudes outward relative to the two slit portions 313. . Further, the protruding portion 314 is formed in an outer shape that does not contact the inner wall surface of the outer shell 10. Accordingly, it is possible to make it difficult for the separator 30 to interfere with the inner wall surface of the outer shell 10 to hinder the assembly.

  In the present embodiment, the outer shell 10 corresponds to an example of a muffler body. The separator 30 corresponds to an example of a separator, the wall 31 corresponds to an example of a wall, the slit 313 corresponds to an example of a slit, the protrusion 314 corresponds to an example of a protrusion, and the outer flange. The part 32 corresponds to an example of a flange part, and the notch 33 corresponds to an example of a notch. Further, the plate material 4 corresponds to an example of a plate material, the separator forming portion 40 corresponds to an example of a separator forming portion, the wall forming portion 41 corresponds to an example of a wall forming portion, and the flange forming portion 42 is an example of a flange forming portion. The connecting portion 44 corresponds to an example of a connecting portion.

[4. Other Embodiments]
As mentioned above, although embodiment of this invention was described, it cannot be overemphasized that this invention can take a various form, without being limited to the said embodiment.

  [4A] The shape of the separator is not limited to the shape of the separator 30 exemplified in the above embodiment. For example, the shape of the separator itself and the number and shape of notches formed in the separator may be changed as appropriate. Further, for example, one or more communication holes may be further provided in the wall portion 31 of the above embodiment.

  [4B] The functions of one component in the above embodiment may be distributed as a plurality of components, or the functions of a plurality of components may be integrated into one component. Further, at least a part of the configuration of the above embodiment may be replaced with a known configuration having the same function. Moreover, you may abbreviate | omit a part of structure of the said embodiment as long as a subject can be solved. In addition, at least a part of the configuration of the above embodiment may be added to or replaced with the configuration of the other embodiment. In addition, all the aspects included in the technical idea specified from the wording described in the claims are embodiments of the present invention.

  DESCRIPTION OF SYMBOLS 1 ... Muffler, 4 ... Board | plate material, 10 ... Outer shell, 11 ... Cylindrical body, 12 ... Upstream side obstruction board, 13 ... Downstream side obstruction board, 30 ... Separator, 31 ... Wall part, 32 ... Outer flange part, 33 ... Cutting Notches, 40 ... separator forming part, 41 ... wall forming part, 42 ... flange forming part, 44 ... connecting part, 313 ... slit part, 314 ... projecting part.

Claims (6)

A wall portion that forms a wall for partitioning the interior of the muffler body into which the exhaust gas is introduced into a plurality of rooms, and a flange portion that forms an outer peripheral surface facing the inner wall surface of the muffler body at the outer edge of the wall portion. A method of manufacturing a separator provided with a plurality of punched sheets from a single plate by progressive pressing,
The separator forming portion which is a portion for forming the separator in the plate material is part of the flange forming portion which is a portion for forming the flange portion between the separator forming portions adjacent to each other. A first step of removing unnecessary portions other than the connecting portion that connects the separator forming portions adjacent to each other from the plate material arranged to overlap; and
A second step of forming the flange portion by processing the flange forming portion after the first step;
A third step of removing the connecting portion after the second step;
With
In the first step, the connecting part is formed not to be directly connected to the flange forming part but to be connected to a wall forming part which is a part for forming the wall part. Separator manufacturing method. The manufacturing method according to claim 1,
In the portion where the connecting portion is removed, a notch is formed that divides the flange portion and reaches the wall portion,
The said notch forms two slit parts in the outer edge of the said wall part. The manufacturing method of the separator characterized by the above-mentioned. It is a manufacturing method of Claim 2, Comprising:
On the outer edge of the wall portion, a protruding portion is formed between the two slit portions formed by the notches, and protrudes outward relative to the two slit portions.
The protrusion is formed in an outer shape that does not contact the inner wall surface of the muffler body. A separator provided inside a muffler body into which exhaust gas is introduced,
A wall portion forming a wall for partitioning the interior of the muffler body into a plurality of rooms;
A flange portion that forms an outer peripheral surface facing the inner wall surface of the muffler body at the outer edge of the wall portion;
With
A notch that divides the flange portion and reaches the wall portion is formed,
The said notch forms two slit parts in the outer edge of the said wall part. The separator characterized by the above-mentioned. The separator according to claim 4,
The said notch is formed in the position used as the lower end part of a perpendicular direction at least in the state provided in the said muffler main body. The separator characterized by the above-mentioned. The separator according to claim 4 or 5, wherein
On the outer edge of the wall portion, a protruding portion is formed between the two slit portions formed by the notches, and protrudes outward relative to the two slit portions.
The said protrusion part is formed in the external shape which does not contact | abut to the inner wall face of the said muffler main body.

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