MUFFLER AND METHOD FOR MAKING A MUFFLER
20220389848 · 2022-12-08
Inventors
Cpc classification
F01N2470/18
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01N2470/24
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01N1/082
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01N2490/155
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01N2470/14
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01N13/18
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01N1/003
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01N13/1872
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
Abstract
A muffler for an exhaust system of an internal combustion engine includes a muffler housing having a peripheral wall elongated along a longitudinal axis of the muffler housing. The peripheral wall has first and second end walls. A muffler insert is surrounded by the peripheral wall and is supported thereon. The muffler insert has a retaining wall extending in a direction of the longitudinal axis. The peripheral wall has a peripheral wall opening and a first exhaust-gas routing pipe has a first end region and is positioned with the first end region thereof engaging in the peripheral wall opening. The first exhaust-gas routing pipe has a second end region and is secured by the second end region thereof to the retaining wall. The first exhaust-gas routing pipe is of multi-part configuration and has a first pipe part and a second pipe part.
Claims
1. A muffler for an exhaust system of an internal combustion engine, the muffler comprising: a muffler housing defining a longitudinal axis (L) and having a peripheral wall elongated along said longitudinal axis (L); said peripheral wall having first and second end regions and first and second end walls at said first and second end regions, respectively; a muffler insert surrounded by said peripheral wall and supported thereon; said muffler insert having at least one retaining wall extending substantially in a direction of said longitudinal axis (L); said peripheral wall having a peripheral wall opening; at least one first exhaust-gas routing pipe having a first end region and being positioned with said first end region thereof engaging in said peripheral wall opening and being secured to said peripheral wall; said at least one first exhaust-gas routing pipe having a second end region and being secured by said second end region thereof to said at least one retaining wall; said at least one first exhaust-gas routing pipe having a first pipe part defining said first end region and positioned so as to engage in said peripheral wall opening and being secured to said peripheral wall; said at least one first exhaust-gas routing pipe having a second pipe part defining said second end region thereof secured to said at least one retaining wall; said first pipe part and said second pipe part having respective mutually adjoining longitudinal regions and having been pushed one into the other at said longitudinal regions thereof; said first pipe part and said second pipe part mutually overlapping in a longitudinal direction of said at least one first exhaust-gas routing pipe; and, said second pipe part being connected to said at least one retaining wall via material closure.
2. The muffler of claim 1, wherein one of the following applies: a) wherein said first pipe part has been inserted into said second pipe part; and, said first pipe part and said second pipe part are mutually connected by radial widening of at least said first pipe part at least in said longitudinal region of overlapment thereof with said second pipe part; or, b) wherein said second pipe part has been inserted into said first pipe part to define a longitudinal region of overlapment; and, said first pipe part and said second pipe part are mutually connected by radial widening of at least said second pipe part at least in the longitudinal region of overlapment with said first pipe part.
3. The muffler of claim 1, wherein said at least one retaining wall has a retaining-wall opening formed therein assigned to said at least one first exhaust-gas routing pipe; said at least one retaining wall has a bent fastening-edge region in at least some regions of said retaining-wall opening; and, said second pipe part of said at least one first exhaust-gas routing pipe has been positioned so as to engage in said retaining-wall opening and has been connected to said at least one retaining wall in the region of said fastening-edge region by material closure.
4. The muffler of claim 1, wherein at least one of the following applies: a) said first pipe part has been connected to said peripheral wall by welding; and, b) said second pipe part has been connected to said at least one retaining wall by welding.
5. The muffler of claim 1, wherein said muffler insert includes at least two partitions arranged so as to be substantially orthogonal to said longitudinal axis (L) and supported on said peripheral wall; and, said at least one retaining wall has first and second opposite end regions and is secured thereat to corresponding ones of said partitions.
6. The muffler of claim 5, wherein said muffler insert includes at least one second exhaust-gas routing pipe and a partition opening assigned to said at least one second exhaust-gas routing pipe in at least one of said partitions connected to said at least one retaining wall; an end wall opening is provided in one of said end walls; and, said at least one second exhaust-gas routing pipe is positioned so as to engage in said partition opening and in said end wall opening and is secured by material closure in at least one of the following: a) in the region of said end wall opening to said end wall; and, b) in the region of at least one partition opening to said partition having said opening.
7. The muffler of claim 6, wherein at least one of the following applies: a) said at least one second exhaust-gas routing pipe is an outlet pipe; and, b) said muffler further comprises an additional second exhaust-gas routing pipe; and, said end walls have respective end wall openings formed therein for accommodating corresponding ones of said second exhaust-gas routing pipes.
8. The muffler of claim 1, wherein said at least one first exhaust-gas routing pipes is an inlet pipe.
9. A method for making an exhaust muffler, comprising the steps of: a) providing at least one muffler insert with at least one retaining wall and with at least one retaining-wall opening in the at least one retaining wall; b) providing at least one multi-part first exhaust-gas routing pipe with a first pipe part and with a second pipe part; c) arranging the second pipe part of the at least one first exhaust-gas routing pipe so as to cause said at least one first exhaust-gas routing pipe to be positioned to engage in a retaining-wall opening of the at least one retaining wall of the at least one muffler insert; d) securing the second pipe part of the at least one first exhaust-gas routing pipe to the at least one retaining wall by material closure, e) surrounding the at least one muffler insert and the second pipe part, secured to the at least one muffler insert, of the at least one first exhaust-gas routing pipe by a peripheral wall of a muffler housing, a peripheral-wall opening being provided in the peripheral wall, assigned to the at least one first exhaust-gas routing pipe; f) arranging the first pipe part of the at least one first exhaust-gas routing pipe so as to cause the at least one first exhaust-gas routing pipe to be positioned to engage in the peripheral-wall opening provided, assigned to the at least one exhaust-gas routing pipe, and in that the first pipe part and the second pipe part, secured to the at least one retaining wall of the at least one muffler insert, of the at least one first exhaust-gas routing pipe are inserted into one another and overlap in a longitudinal direction of the at least one first exhaust-gas routing pipe; and, g) connecting the first pipe part to the second pipe part of the at least one first exhaust-gas routing pipe by at least one of the following: radial widening of the first pipe part; and, radial widening of the second pipe part at least in their overlapping longitudinal regions.
10. The method of claim 9, wherein: in step a) the at least one retaining wall is provided in such a manner that a bent fastening-edge region, surrounding the retaining-wall opening at least in some regions, of the at least one retaining wall is formed, assigned to the at least one retaining-wall opening; and, in step d) the second pipe part of the at least one first exhaust-gas routing pipe is secured to the at least one retaining wall in the region of the fastening-edge region.
11. The method of claim 9, wherein: in step d) the second pipe part of the at least one first exhaust-gas routing pipe is secured to the at least one retaining wall by welding.
12. The method of claim 9, wherein: in step f) the first pipe part is inserted into the second pipe part, and in the course of step g) the first pipe part and the second pipe part are connected to one another by radial widening of at least the first pipe part at least in its longitudinal region overlapping with the second pipe part; or; in step f) the second pipe part is inserted into the first pipe part, and in step g) the first pipe part and the second pipe part are connected to one another by radial widening of at least the second pipe part at least in its longitudinal region overlapping with the first pipe part.
13. The method of claim 9, wherein in step a) the at least one muffler insert is provided so as to cause the at least one retaining wall to be connected, in each of two opposite end regions thereof, to a corresponding one of the partitions.
14. The method of claim 13, wherein: in step a) the at least one muffler insert is provided in such a manner that at least one second exhaust-gas routing pipe on each of the partitions connected to the at least one retaining wall engages in a partition opening and extends with a coupling portion beyond one of the partitions.
15. The method of claim 9, wherein: in step e) the at least one muffler insert is surrounded by the peripheral wall by winding of a plate-like peripheral-wall blank around the at least one muffler insert; or, in step e) the at least one muffler insert is surrounded by providing the peripheral wall with a structure that is closed in the peripheral direction and by inserting the at least one muffler insert into the peripheral wall provided with a structure that is closed in the peripheral direction.
16. The method of claim 9, wherein: a step h) is provided for securing an end wall to each of the axial end regions of the peripheral wall, elongated in the direction of a longitudinal axis (L) of the housing, by at least one of the following: material closure and positive closure.
17. The method of claim 16, wherein: in step h) at least one of the end walls is secured to the peripheral wall in such a manner that an end-wall opening provided in this end wall is positioned in such a way that the coupling portion of a second exhaust-gas routing pipe is positioned so as to engage in the end-wall opening.
18. An exhaust system for an internal combustion engine, the exhaust system comprising: a muffler including a muffler housing defining a longitudinal axis (L) and having a peripheral wall elongated along said longitudinal axis (L); said peripheral wall having first and second end regions and first and second end walls at said first and second end regions, respectively; a muffler insert surrounded by said peripheral wall and supported thereon; said muffler insert having at least one retaining wall extending substantially in a direction of said longitudinal axis (L); said peripheral wall having a peripheral wall opening; at least one first exhaust-gas routing pipe having a first end region and being positioned with said first end region thereof engaging in said peripheral wall opening and being secured to said peripheral wall; said at least one first exhaust-gas routing pipe having a second end region and being secured by said second end region thereof to said at least one retaining wall; said at least one first exhaust-gas routing pipe having a first pipe part defining said first end region and positioned so as to engage in said peripheral wall opening and being secured to said peripheral wall; said at least one first exhaust-gas routing pipe having a second pipe part defining said second end region thereof secured to said at least one retaining wall; said first pipe part and said second pipe part having respective mutually adjoining longitudinal regions and having been pushed one into the other at said longitudinal regions thereof; said first pipe part and said second pipe part mutually overlapping in a longitudinal direction of said at least one first exhaust-gas routing pipe; and, said second pipe part being connected to said at least one retaining wall via material closure.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] The invention will now be described with reference to the drawings wherein:
[0031]
[0032]
[0033]
[0034]
[0035]
[0036]
[0037]
[0038]
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0039] In
[0040] A muffler insert, designated generally by 26, has been provided in the interior of the muffler housing 14. In the embodiment represented, the insert includes two partitions 28, 30, also shown in
[0041] The muffler insert further includes a retaining wall 38 extending substantially in the direction of the longitudinal axis L of the housing and oriented substantially so as to be orthogonal to the two partitions 28, 30. In its two axial end regions 40, 42 the retaining wall 38 has been firmly connected to the two partitions 28, 30, for instance by welding.
[0042] In the case of the muffler 12 shown in
[0043] Each of the second exhaust-gas routing pipes 46, 48 extends beyond one of the partitions 28, 30 with a coupling portion 56, 58. An end-wall opening 60 has been provided, assigned to the coupling or connecting portion 56, in the end wall 22 arranged on the axial end region 18 of the peripheral wall 16, into which the coupling portion 56 of second exhaust-gas routing pipe 48 has been positioned in engaging manner. Also in the region of this end-wall opening 60, an outwardly bent-over fastening-edge region, for instance, may have been provided on the end wall 22. The coupling portion 56 may have been connected to the end wall 22 in the region of this fastening-edge region by a preferentially circumferential weld seam. Equally, an end-wall opening 62 surrounded by an outwardly bent-over fastening-edge region has been formed on the end wall 24 provided on the axial end region 20 of the peripheral wall 16, into which the coupling portion 58 of second exhaust-gas routing pipe 46 has been positioned in engaging manner. Here too, a completely circumferential welded joint may have been formed for a gas-tight seal between the coupling portion 58 and the end wall 24.
[0044] In the muffler insert 26 including the two partitions 28, 30, the retaining wall 38 and the two second exhaust-gas routing pipes 46, 48, second exhaust-gas routing pipe 46 is open to chamber 32 in the region of its linkage to partition 28 and is open to chamber 36 in the region of its coupling portion 58 via several openings provided therein. Equally, second exhaust-gas routing pipe 48 is open to chamber 36 in the region of its coupling to partition 30 and is open to chamber 32 in the region of its coupling portion 56 via several openings provided therein. The exhaust gas introduced into chamber 34 via the first exhaust-gas routing pipe 44 can be emitted from chamber 34 into chambers 32, 36 through the openings provided in the partitions 28, 30, and, via these chambers, can be emitted from the muffler housing 14 through the two second exhaust-gas routing pipes 46, 48, for instance into tailpipes adjoining the muffler 12, which may adjoin the coupling portions 56, 58 of the two second exhaust-gas routing pipes 46, 48 in the region of the end walls 22, 24.
[0045] In the following, it will be described how the muffler represented in
[0046] Firstly, the muffler insert 26 is provided with the two partitions 28, 30, with the retaining wall 38 and with the second exhaust-gas routing pipes 46, 48. In this regard, before or after the connecting of the retaining wall 38 to the two partitions 28, 30, the second pipe part 66 of the first exhaust-gas routing pipe 44 can be connected to the retaining wall 38 by material closure.
[0047] For the connection to the second pipe part 66 of the first exhaust-gas routing pipe 44, the retaining wall 38 may exhibit a retaining-wall opening 68 which is surrounded by a fastening-edge region 70 provided on the retaining wall 38 by forming of the latter by a pull-through, for instance. The second pipe part 66 is inserted into the retaining-wall opening 68 with an end portion providing a second end region 72 of the first exhaust-gas routing pipe 44, so that, for instance, it lies flush with an end wall of the fastening-edge region 70 or protrudes slightly beyond it. A firm connection between the second pipe part 66 and the retaining wall 68 is generated by welding—for instance, by a circumferential weld seam—in the region where the second end region 72 of the pipe adjoins the fastening-edge region 70, or by several welding spots succeeding one another in the peripheral direction. In the second end region 72 the first exhaust-gas routing pipe 44 is open to chamber 34.
[0048] After the muffler insert 26, which has already been assembled with the second pipe part 66, has been constructed, the muffler insert 26 is surrounded by the peripheral wall 16. This can be done, for instance, by the peripheral wall 16 being wound around the muffler insert 26. In this case, the peripheral wall 16 may be provided as a plate-like sheet-metal blank in which a peripheral-wall opening 74 for the first exhaust-gas routing pipe 44, or for the first pipe part 64 thereof, for instance in the form of an outwardly directed pull-through, has already been provided with a fastening-edge region 76. The peripheral-wall blank may be pre-bent already prior to being connected to the muffler insert 26, so that it can be positioned surrounding the muffler insert 26. In this state, axially bent-over edge regions of the partitions 28, 30 abut the inner peripheral surface of the peripheral wall 16. In its two end regions situated in the peripheral direction, the peripheral wall 16 is provided as a closed, ring-like structure by material closure—that is, for instance, by a weld seam—or/and by positive closure, for instance by flanging. The muffler insert 26 is held in place in defined manner in this ring-like structure. In addition, there is the possibility of generating a firm connection between one or both of the partitions 28, 30 and the peripheral wall 16 by welding. In an alternative procedure, a plate-like peripheral-wall blank, for instance, can firstly be bent into a tube-like structure, closed in the peripheral direction, and connected in its opposing or overlapping peripheral end regions by material closure—for instance, welding—or/and positive closure—for instance, flanging. The muffler insert 26 can then be inserted into the structure, closed in the peripheral direction, of the peripheral wall 16 and arranged in a position designated for its incorporation. In this position the second pipe part 66, already supported on the muffler insert 26, has been positioned in such a way that it is situated opposite the peripheral-wall opening 74 provided in the peripheral wall 16. Also with this procedure, the muffler insert 26 may be held in the peripheral wall 16 by clamping—that is, substantially frictional interaction. In addition, there is the possibility of establishing a firm connection between the muffler insert 26 and the peripheral wall 16 by material closure, for instance welding.
[0049] The state represented in
[0050] For the purpose of integrating the first pipe part 64 into the muffler, the first pipe part 64 is pushed through the peripheral-wall opening 74. The first pipe part 64, can preferentially be provided with a cylindrical structure, has a smaller cross-sectional dimension than the second pipe part 66, likewise can preferentially be provided with a cylindrical structure. Consequently, the first pipe part 64 can be pushed so far through the peripheral-wall opening 74 that it is inserted into the second pipe part 66 and overlaps with the latter, in some regions, in a longitudinal direction of the first exhaust-gas routing pipe 44, oriented substantially in the direction of a longitudinal axis R of the pipe. In this state represented in
[0051] In a subsequent working step, the first pipe part 64 is spread apart radially, preferentially in the region of its entire axial length, by a spreading tool. As a result, the first pipe part 64 is pressed radially outward against the fastening-edge region 76, and consequently a defined positioning of the first pipe part 64 with respect to the peripheral wall 16 is also obtained. Moreover, the first pipe part 64 is spread apart radially outward in its longitudinal region overlapping with the second pipe part 66, this spreading, for providing a stable connection between the two pipe parts 64, 66, preferentially being effected to such an extent that, as can be discerned in
[0052] In order to obtain a gas-tight coupling of the first pipe part 64 to the peripheral wall 16 in the region of the first end region 78 of the pipe, a completely circumferential weld seam can be generated which links the fastening-edge region 76 to the first pipe part 64. In the course of this operation, a further exhaust-gas routing pipe 44, adjacent to the first exhaust-gas routing pipe 44, which can be inserted into the first pipe part 64 from outside can, for instance, be linked to the peripheral wall 16 and also to the first pipe part 64, so that three parts can be connected to one another with a single weld seam. Alternatively, after the weld seam connecting the first pipe part 64 to the peripheral wall 16 has been generated, such a further exhaust-gas routing pipe can also be linked to the muffler 12 by a further weld seam preferentially completely encircling the longitudinal axis R of the pipe.
[0053] An alternative procedure for integrating the first pipe part 64 into the muffler is illustrated in
[0054] In the course of passing through the peripheral-wall opening 74, the first pipe part 64 is pushed over the second pipe part 66, already surrounded by the peripheral wall 16, so that these parts overlap, in some regions, in the direction of the longitudinal axis R of the pipe or in the longitudinal direction of the first exhaust-gas routing pipe 44. Subsequently a spreading operation is carried out, in which the two pipe parts 64, 66 are spread apart radially at least in their overlapping longitudinal regions, and optionally the first pipe part is also spread apart in its remaining longitudinal region, in particular in the longitudinal region situated in the peripheral-wall opening 74. Also by this means, a firm connection can be generated between the two pipe parts 64, 66, and subsequently the first pipe part 64 can be connected in stable and gas-tight manner to the peripheral wall 16 in the region of the fastening-edge region 76 with a weld seam preferentially completely encircling the longitudinal axis R of the pipe.
[0055] If the first exhaust-gas routing pipe 44 is firstly integrated into the muffler, the state represented in
[0056] With the structure, described in the foregoing, of a muffler, and with the procedure, described in the foregoing, for producing such a muffler, it becomes possible to provide a muffler that, with a structure that is easy to realize, enables a stable linkage—produced, in particular, by material closure—of the first exhaust-gas routing pipe—acting, for instance, as an inlet pipe—to a muffler insert. In the region where the first exhaust-gas routing pipe adjoins the retaining wall of the muffler insert, consequently no relative movements can arise that might result in rattling noises or impact noises. Since the two pipe parts of the first exhaust-gas routing pipe, connected to one another merely by radial spreading, overlap one another in a comparatively large longitudinal region of the pipe and have been pressed against one another by being spread apart, there is no risk of relative movements and of the generating of rattling noises in this overlapping region.
[0057] Finally, it should be pointed out that in various detailed aspects the muffler may, of course, be implemented otherwise than as set forth above. For instance, the second exhaust-gas routing pipes may exhibit a different contour or may have been integrated into the muffler in a different manner. Also, the number of second exhaust-gas routing pipes might differ from the number represented. The muffler might also exhibit more than one first exhaust-gas routing pipe, and the direction of flow through the muffler might be different, so that the first exhaust-gas routing pipe(s) might act as outlet pipes. The number of partitions in the muffler or on the muffler insert might also differ from the number represented, and several such muffler inserts interacting with a first exhaust-gas routing pipe might have been provided in succession in the direction of the axis of the muffler housing, and surrounded by a common peripheral wall.
[0058] It is understood that the foregoing description is that of the preferred embodiments of the invention and that various changes and modifications may be made thereto without departing from the spirit and scope of the invention as defined in the appended claims.