EP0765994B1 - Exhaust manifold - Google Patents

Abstract

The invention relates to an exhaust manifold (1) for motor vehicle engines. The exhaust manifold (1) is formed by stamping, bending and welding sheet metal (16; 5-7). It has a top flange (3) on the multi-channel inflow side and a pipe flange (4) extending at right angles to the top flange (3) on the single-channel outflow side. The inflow channels (8-10) and the outflow channel (11) are formed by punching and bending only one plate (16) and by welding stamped and bent guide plates (5-7). The channels (8-11) can have a rectangular or U-shaped cross section. The majority of the longitudinal edges (61-68) of the V-shaped baffles (6, 7) are inserted into carrier slots (31-38) of the manifold housing (2) and welded along the carrier slots (31-38). <IMAGE> <IMAGE>

Description

The invention relates to an exhaust manifold according to the features in the preamble of claim 1.

So far, exhaust manifolds for automotive engines in the vast majority made of cast steel. Herewith is inevitably associated with a high weight, what then just as logically to a high total weight of Motor vehicle leads. In addition, the heat capacity of thick-walled exhaust manifold high. Such an exhaust manifold is e.g. known from DE-A-38 15 408.

But exhaust manifolds are also part of the state of the Technology by punching, bending and welding sheet metal are formed. These are so-called Half-shell manifold. Each bowl is one of one Sheet steel stamped board ahead, which is then under half of the inflow channels and the outflow channel be deformed. The two shells will then to form the manifold housing with its edges placed on top of each other and then along the edges welded. Ultimately, a head flange becomes on the inflow side and a pipe flange on the outlet side Welding attached. Such an exhaust manifold is e.g. out EP-A-0 582 985.

It is obvious that the manufacture of such Exhaust manifold associated with a relatively high cost is. Each bowl requires its own stamping and embossing tool, the arcuate walls of the inflow channels and the one that extends at right angles to it Outflow channel mean an additional effort. The Welds are comparatively long and in particular complicated between the two outer inflow channels to manufacture.

After welding, go to the multi-channel inflow side the top flange and to the single-channel outflow side the pipe flange is welded. The head flange serves to attach the exhaust manifold to the engine block while the pipe flange for the connection of the exhaust gases Exhaust pipe is provided.

The invention is based on the prior art Task to create an exhaust manifold that formed by punching, bending and welding sheet metal is, however, a lower manufacturing cost with improved Exhaust gas routing required.

According to the invention, this object is achieved in those listed in the characterizing part of claim 1 Characteristics.

The essential aspect of the invention is in that the housing of the exhaust manifold is now complete is made from a single board. For this is to provide only one follow-up tool, which initially the board is stamped from a steel sheet and this board then formed into the manifold housing. The manifold housing points both with regard to the inflow channels and the outflow channel one resulting from the bending geometry Cross section on.

After bending the manifold housing, the in Depends on the number of inflow channels in one baffles made in parallel tool Manifold housing inserted and welded to it.

The particular advantage of the invention lies in the comparison to the well-known half-shell manifold significantly cheaper Construction with significantly less Weld length. Exhaust gas routing can now also be targeted be optimized. As a result of the cheaper Construction is also with reduced use of materials Weight of the exhaust manifold has been reduced. Its firmness is nevertheless larger because the weld seam length is reduced has been.

According to claim 2, the inflow channels and the outflow channel have a rectangular cross section. Cross sections that differ from one another are also conceivable. Furthermore, the inflow channels and / or the outflow channel have a U-shaped cross section.

A particularly advantageous embodiment of the invention is seen in the features of claim 3. After that are some baffles bent in a V-shape with the predominant part of their longitudinal edges in carrier slots the circuit board bent to the manifold housing and welded along the carrier slots.

The V-shape of the baffles enables the corresponding Curvature of the side walls an optimal fluidic Design of the inflow channels with a corresponding one Transition into the outflow channel. Are welding work easy to do from the outside and nothing special Associated effort.

Figur 1

in perspektivischer Explosionsdarstellung einen Abgaskrümmer;

Figur 2

in der Draufsicht eine aus einem Stahlblech gestanzte Platine vor dem Biegen zu einem Krümmergehäuse;

Figur 3

den Abgaskrümmer der Figur 1 in der Seitenansicht;

Figur 4

einen Querschnitt durch die Darstellung der Figur 3 entlang der Linie IV-IV;

Figur 5

eine ausgestanzte Platine für ein Leitblech des Abgaskrümmers der Figuren 1 und 3 und

Figur 6

in der Draufsicht eine weitere ausgestanzte Platine für ein Leitblech des Abgaskrümmers der Figuren 1 und 3.

The invention is explained below with reference to an embodiment shown in the drawings. Show it:

Figure 1

in an exploded perspective view of an exhaust manifold;

Figure 2

in plan view a blank stamped from a steel sheet before bending to a manifold housing;

Figure 3

the exhaust manifold of Figure 1 in side view;

Figure 4

a cross section through the representation of Figure 3 along the line IV-IV;

Figure 5

a punched out board for a baffle of the exhaust manifold of Figures 1 and 3 and

Figure 6

in plan view a further punched-out circuit board for a guide plate of the exhaust manifold of FIGS. 1 and 3.

1 in Figures 1, 3 and 4 is an exhaust manifold for called a six-cylinder engine. The exhaust manifold 1 comprises a manifold housing 2, a head flange 3 on the multi-channel inflow side and one at right angles to the head flange 3 extending pipe flange 4 on the single-channel Outflow side. Furthermore, the exhaust manifold 1 Baffles 5, 6, 7 on that together with the manifold housing 2 three inflow channels 8, 9, 10 and one outflow channel 11 form. The inflow channels 8, 9, 10 are in alignment adapted recesses 12, 13, 14 in the head flange 3, while the outflow channel 11 with a recess 15 in Pipe flange 4 is aligned.

In the head flange 3 there are bores 69 for fixing the exhaust manifold 1 provided on an engine block.

In the manufacture of the manifold housing 2 is first 2, a blank 16 is stamped from a steel sheet. The board 16 has one of three web sections 17, 18, 19 existing central web wall 20 and laterally the leg sections 17, 18, 19 lying leg walls 21, 22 or 23, 24 or 25, 26. The leg walls 21-24 are with starting from the thigh margins 27-30 Carrier slots 31-38 provided.

The leg walls 21-26 are then around the bend lines 39, 40 at an angle α of 90 ° to the web sections 17, 18, 19 folded. The longitudinal edges 41 are rounded (Figure 4).

Then the leg walls 23 and 24 together with the web section 18 by the between the two Web sections 17, 18 bending line 42 folded so far, that the leg edges 43, 44 of the leg walls 23, 24 to the leg edges 45, 46 of the leg walls 21, 22 come across.

In parallel or in a previous or subsequent one The leg walls 25, 26 and the web portion 19 around the between the two Web sections 18, 19 bending line 47 folded so far, that the leg edges 48, 49 of the leg walls 25, 26 on the front to the leg edges 50, 51 of the Thigh walls 23, 24 meet.

To ensure a perfect bending process, are at the intersection of the bend line 39 with the Leg edges 43, 45 or the leg edges 48, 50 and at the intersection of the bending line 40 with the Leg edges 44, 46 and 49, 51 circular recesses 52 provided.

The manifold housing 2 already has the configuration according to FIGS. 1, 3 and 4.

Regardless of the punching and bending of the manifold housing 2 the three guide plates 5, 6 and 7 are generated. The baffle 5 is curved in an arc and is curved with the Leg edges 53 of the leg walls 21, 22 welded, which the leg edges 27, 28 of the leg walls 21, 22 connect to the U-shaped end edge 54.

The other two illustrated in FIGS. 5 and 6 stretched Baffles 6, 7 each consist of three Surface sections 55, 56, 57 and 58, 59, 60, respectively middle surface sections 56, 59 narrower than the outer Surface sections 55, 57 and 58, 60 are dimensioned. The width B of the outer surface sections 55, 57 and 58, 60 corresponds to the outer width B1 of the manifold housing 2, while the width B2 of the middle surface sections 56, 59 of the inner width B3 of the manifold housing 2 corresponds (Figures 1 and 4).

As can also be seen in FIGS. 1 and 3 the guide plates 6, 7 corresponding to the carrier slots 31, 33 or 32, 34 or 35, 37 or 36, 38 in the leg walls 21-24 curved and bent into a V-shape and then with their edges 61, 62 or 63, 64 or 65, 66 and 67, 68 of the outer surface sections 55, 57, 58, 60 inserted into the carrier slots 31-38. Form here then the V-shaped middle surface sections 56, 59 only spacer elements between the leg walls 21 and 22 or 23 and 24.

Now the edges 61, 62 or 63, 64 or 65, 66 or 67, 68 of the wider surface sections 55, 57, 58, 60 of the guide plates 6, 7 from the outside in the carrier slots 31-38 welded.

Furthermore, the abutting leg edges 43, 45 or 44, 46 or 48, 50 or 49, 51 of the leg walls 23, 21 or, 24, 22 or 25, 23 or 26, 24 with each other welded.

After welding, the are manufactured separately Head flange 3 and the pipe flange 4 on the front side of the inflow channels 8, 9, 10 and at the end of the outflow channel 11 welded. The finished exhaust manifold 1 is then located according to Figures 1, 3 and 4 before.

In FIG. 4, 70 is in dash-dotted lines still indicated that the inflow channels 8, 9 and 10th and / or the outflow channel 11 also has a U-shaped cross section can have.

List of reference symbols

1 -

Exhaust manifold

2 -

Manifold housing

3 -

Head flange

4 -

Pipe flange

5 -

Baffle

6 -

Baffle

7 -

Baffle

8th -

Inflow channel

9 -

Inflow channel

10 -

Inflow channel

11 -

Outflow channel

12 -

Recess in 3

13 -

Recess in 3

14 -

Recess in 3

15 -

Recess in 4

16 -

circuit board

17 -

Web section

18 -

Web section

19 -

Web section

20 -

Dock wall

21 -

Thigh wall

22 -

Thigh wall

23 -

Thigh wall

24 -

Thigh wall

25 -

Thigh wall

26 -

Thigh wall

27 -

Thigh v. 21

28 -

Thigh v. 22

29 -

Thigh v. 23

30 -

Thigh v. 24th

31 -

Carrier slot in 21st

32 -

Carrier slot in 21st

33 -

Carrier slot in 22nd

34 -

Carrier slot in 22nd

35 -

Carrier slot in 23

36 -

Carrier slot in 23

37 -

Carrier slot in 24

38 -

Carrier slot in 24

39 -

Bending line

40 -

Bending line

41 -

Longitudinal edges from 2nd

42 -

Bending line

43 -

Thigh v. 23

44 -

Thigh v. 24th

45 -

Thigh v. 21

46 -

Thigh v. 22

47 -

Bending line

48 -

Thigh v. 25th

49 -

Thigh v. 26

50 -

Thigh v. 23

51 -

Thigh v. 24th

52 -

Recesses

53 -

curved thigh margins v. 21, 22

54 -

Front edge

55 -

Surface section v. 6

56 -

Surface section v. 6

57 -

Surface section v. 6

58 -

Surface section v. 7

59 -

Surface section v. 7

60 -

Surface section v. 7

61 -

Edge of 55

62 -

Edge of 55

63 -

Edge of 57

64 -

Edge of 57

65 -

Edge of 58

66 -

Edge of 58

67 -

Edge of 60

68 -

Edge of 60

69 -

Holes in 3

70 -

dash-dotted lines

α -

Bending angle

B -

Width of 55, 57, 58, 60

B1 -

outer width v. 2nd

B2 -

Width of 56, 59

B3 -

inner width v. 2nd

Claims (3)

1. An exhaust gas manifold formed by stamping,
   bending and welding metal sheets (16; 5 - 7), and which has a head flange (3) at the multi-duct inlet side and a pipe flange (4) at the single-duct exit side, said pipe flange (4) extending at right angles to the head flange (3), characterised in that the inlet ducts (8, 9, 10) and the exit duct (11) are formed by stamping and bending just one plate (16) and by welding stamped and bent baffle plates (5, 6, 7) into the bent plate (16).
2. An exhaust gas manifold according to claim 1,
   characterised in that the inlet ducts (8, 9, 10) and/or the exit duct (11) have a rectangular or a U-shaped cross-section.
3. An exhaust gas manifold according to claim 1 or 2, characterised in that baffle plates (6, 7) bent V-shaped are inserted with the major part of their longitudinal edges (61 - 68) in carrier slots (31 - 38) in the bent plate (16) and are welded along the carrier slots (31 - 38).

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