Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
  • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
  • B21D39/00—Application of procedures in order to connect objects or parts, e.g. coating with sheet metal otherwise than by plating; Tube expanders
  • B21D39/04—Application of procedures in order to connect objects or parts, e.g. coating with sheet metal otherwise than by plating; Tube expanders of tubes with tubes; of tubes with rods
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T29/00—Metal working
  • Y10T29/49—Method of mechanical manufacture
  • Y10T29/4935—Heat exchanger or boiler making
  • Y10T29/49373—Tube joint and tube plate structure
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T29/00—Metal working
  • Y10T29/49—Method of mechanical manufacture
  • Y10T29/49398—Muffler, manifold or exhaust pipe making
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T29/00—Metal working
  • Y10T29/49—Method of mechanical manufacture
  • Y10T29/49826—Assembling or joining
  • Y10T29/49908—Joining by deforming
  • Y10T29/49915—Overedge assembling of seated part
  • Y10T29/49917—Overedge assembling of seated part by necking in cup or tube wall
  • Y10T29/49918—At cup or tube end
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T29/00—Metal working
  • Y10T29/49—Method of mechanical manufacture
  • Y10T29/49826—Assembling or joining
  • Y10T29/49908—Joining by deforming
  • Y10T29/49915—Overedge assembling of seated part
  • Y10T29/49922—Overedge assembling of seated part by bending over projecting prongs

Definitions

• This invention relates to exhaust system manufacturing and more particularly to a method of mechanically locking components of exhaust treatment devices.
• exhaust treatment devices including mufflers and after-treatment devices, are formed from multiple components which are coupled together.
• An exhaust treatment device often includes a pipe component which passes through another component and is coupled thereto.
• a louvered pipe passes through apertures formed in baffle plates enclosed in a muffler shell. The louvered pipe is coupled to the baffle plate during assembly and manufacture of the muffler.
• Exhaust treatment devices are disclosed in Herold, U.S. Patent No. 5,801,344, issued September 1, 1998, and Howe et al., U.S. Patent No. 4, 961,314, issued October 9, 1990, which are hereby incorporated by reference herein.
• the exhaust system includes a method of assembling exhaust components that includes, among other things, the steps of providing an exhaust component with an aperture and providing a mating exhaust component having an end sized to be received through the aperture.
• a stop is formed on the mating exhaust component which will serve as a first half of a coupling mechanism prior to insertion of the mating exhaust component in the aperture of the exhaust component.
• the end of the mating exhaust component is urged through the aperture in the exhaust component until the stop engages the exhaust component and is simultaneously deformed to form a second half of the coupling mechanism.
• the components of such an exhaust device may be coupled by forming a stop on the exterior of a component to be inserted through an aperture in second component prior to insertion of the first component.
• the first component is a pipe and the second component is a baffle plate.
• the pipe is inserted through the aperture formed in the baffle plate until the stop contacts a first wall of the baffle plate. After the stop engages the first wall of the baffle plate, the end of the pipe extends only slightly beyond a second wall of the baffle plate.
• the end of the pipe is flared until the flared end contacts the second wall of the baffle plate, thereby mechanically locking the two components.
• the method in accordance with the present invention provides several advantages over existing coupling or locking systems, the method in accordance with the present invention is more efficient and effective than the above method and other heretofore known existing methods.
• the method of the present invention provides a stronger and more durable bond than existing methods for coupling or locking together exhaust components, and is easier and less expensive to use than existing methods.
• the tooling that can be used to perform the method in accordance with the present invention is more economical and more durable than tooling used in connection with existing methods.
• the method of the present invention can be readily used with exhaust pipes having small diameters, such as those having diameters less than 1-1/2 inches, and still provide a strong and durable bond.
• the present invention provides a method of assembling exhaust components comprising the steps of: (a) providing an exhaust plate or other exhaust component having a first side, a second side, and an embossment, the embossment defining an aperture and a void contiguous with the aperture; (b) providing an exhaust pipe or other mating exhaust component having an end portion including a leading end, the end portion sized to be received by the void; (c) inserting the end portion of the exhaust pipe into the void; and (d) bending a portion of the embossment over the leading end of the end portion to lock the exhaust plate to the exhaust pipe.
• step (d) includes flaring the embossment and a leading portion of the end portion of the exhaust pipe.
• the method also may include the step of forming the embossment in the exhaust component prior to step (a).
• the forming step may include punching the exhaust plate with a tool to form the embossment in the exhaust component.
• step (d) is performed by punching the embossment with a punch to deform the embossment and the leading portion of the end portion of the exhaust pipe.
• the punch may be aligned with the embossment and with a passage defined by the exhaust pipe and punching the embossment bends a portion of the embossment over the leading end of the end portion and into the passage and desirably also flares outwardly the embossment and the leading portion of the exhaust pipe.
• the aperture desirably is generally circular and the embossment is disposed substantially about the aperture.
• the void desirably is generally cylindrical to receive the exhaust pipe- Accordingly, the method of locking together exhaust components in accordance with a preferred embodiment causes a strong and durable coupling between the components. Moreover, the method is efficient and inexpensive and does not require a mandrel to expand any components; rather, a single punch causes the components to lock together in accordance with a preferred embodiment. Still further, the method can readily be used with pipes having diameters less than 1-1/2".
• FIGURE 1 is a broken sectional view, schematic in nature, of an exhaust treatment device in the form of a muffler including a plurality of exhaust components and mating exhaust components locked together by a method in accordance with a preferred embodiment of the present invention
• FIGURE 2 is a broken sectional view, schematic in nature, of one of the exhaust pipes and one of the exhaust baffle plates of FIGURE 1 in an initial stage before being locked together;
• FIGURE 3 is a view similar to FIGURE 2 after the exhaust baffle plate has been deformed to include an embossment and to define an aperture and a void;
• FIGURE 4 is a view similar to FIGURE 3 showing the end portion of the exhaust pipe received by the void defined by the exhaust baffle plate;
• FIGURE 5 is a view similar to FIGURE 4 after the embossment has been punched causing the embossment and the leading portion of the exhaust pipe to be deformed to thereby lock together the exhaust baffle plate and the exhaust pipe.
• FIGURE 1 illustrates an example of an exhaust treatment device or processor 10 that includes a plurality of exhaust components 12 and a plurality of mating exhaust components 14 locked together in accordance with a preferred embodiment of the invention.
• the exhaust treatment device 10 may be in the form of a muffler as illustrated in FIGURE 1, or, alternatively, may have any other suitable configuration or construction.
• the exhaust treatment device 10 may also have any suitable number and arrangement of exhaust components 12 and mating exhaust components 14.
• the exhaust components 12 and mating exhaust components 14 themselves may have any suitable configuration or construction.
• FIGURES 2 - 5 illustrate a method for locking one of the exhaust components 12 to one of the mating exhaust components 14 of FIGURE 1 in accordance with a preferred embodiment of the invention.
• the exhaust component and mating exhaust component are illustrated in the form of, respectively, an exhaust plate in the form of a baffle plate 18 and an exhaust pipe 20.
• FIGURE 2 illustrates the baffle plate 18 and the exhaust pipe 20 in an initial uncoupled and undeformed stage.
• the baffle plate 18 and the exhaust pipe 20 may have any suitable configuration.
• the baffle plate 18 is illustrated as initially being generally flat with an outer lip 22, and includes a first side 24 and a second side 26.
• the exhaust pipe 20 is illustrated as being generally cylindrical and defines a generally cylindrical passage 28.
• FIGURE 3 illustrates the baffle plate 18 after it has been deformed to form an embossment 32 and to define an aperture 34 and a void 36 contiguous with the aperture.
• the embossment 32 may have any suitable configuration and construction.
• the embossment 32 is generally circular, and includes an L- shaped cross section and is disposed substantially about the aperture 34.
• the embossment 32 may instead have any other suitable configuration or cross section.
• the embossment 32 may, if desired, extend less than completely around the aperture 34.
• the aperture 34 is generally circular
• the void 36 is generally cylindrical.
• the embossment 32 may be formed in any suitable manner such as, for example, by a punch tool (not shown) that forms the embossment and void 36 and pierces the baffle plate 18 to define the aperture 34 with a single stroke of the tool.
• FIGURE 4 illustrates an end portion 40 of the exhaust pipe 20 inserted into the void 34 defined by the baffle plate 18.
• a leading end 42 of the exhaust pipe 20 desirably is contacting the second side 26 of the baffle plate 18.
• FIGURE 5 illustrates the baffle plate 18 and the exhaust pipe 20 after they have been punched by a tool 44 to lock together the baffle plate and exhaust pipe.
• the tool 44 is aligned generally with the embossment 32 and passage 28 of the exhaust pipe 20 and punches the first side 24 of the embossment 32. Punching of the embossment 32 causes the embossment and the leading end 42 of the exhaust pipe 20 to deform, thereby locking together the baffle plate 18 and the exhaust pipe.
• FIGURE 5 illustrates an example of the baffle plate 18 and the exhaust pipe 20 locked together by a method in accordance with a preferred embodiment of the invention.
• the invention in accordance with a preferred embodiment provides an efficient and cost effective method for locking together exhaust components that results in a strong and durable lock.
• the tooling necessary to achieve the method is minimal and the method can be performed in minimal steps.
• the method also can readily be performed on pipes having diameters less than 1-1/2".

Landscapes

• Engineering & Computer Science (AREA)
• Mechanical Engineering (AREA)
• Exhaust Silencers (AREA)
• Gasket Seals (AREA)
• Filters For Electric Vacuum Cleaners (AREA)

Priority Applications (3)

Applications Claiming Priority (2)

Publications (1)

Family

ID=25249172

Family Applications (1)

Country Status (7)

Families Citing this family (5)

Citations (7)

Family Cites Families (12)

• 2001
  • 2001-04-06 US US09/827,418 patent/US6453558B1/en not_active Expired - Fee Related
• 2002
  • 2002-04-05 EP EP02715281A patent/EP1387728B1/en not_active Expired - Lifetime
  • 2002-04-05 DE DE60227362T patent/DE60227362D1/de not_active Expired - Fee Related
  • 2002-04-05 JP JP2002579145A patent/JP2004528986A/ja active Pending
  • 2002-04-05 WO PCT/US2002/010941 patent/WO2002081117A1/en not_active Ceased
  • 2002-04-05 AT AT02715281T patent/ATE399608T1/de not_active IP Right Cessation
  • 2002-04-05 ES ES02715281T patent/ES2309156T3/es not_active Expired - Lifetime
• 2007
  • 2007-03-27 JP JP2007083118A patent/JP2007222945A/ja active Pending

Patent Citations (7)

Also Published As

Similar Documents

Legal Events