JP5604045B2 - Automobile exhaust silencer and method for manufacturing the same - Google Patents

Description

  The present invention relates to a silencer installed in an exhaust system of an automobile and a method for manufacturing the silencer.

  As a silencer equipped in an exhaust system of an automobile, one that fixes an end plate to an axial end portion of an outer cylinder is known. The outer cylinder and the end plate are fixed in such a manner that the end portion of the end plate is overlapped over the entire circumference of the end portion in the axial direction of the outer cylinder, and a crimped portion is formed by pressing the overlapping winding portion. In addition, it is common to weld the inner end of the caulking portion in the axial direction of the cylinder and the outer cylinder (see Patent Document 1).

JP-A-8-21237

  However, in the structure for fixing the outer cylinder and the end plate of the silencer, a caulking part protrudes from the outer peripheral surface of the outer cylinder to form a protruding part, and the degree of freedom in the layout of the exhaust system is impaired due to the protruding part. There is a problem. In addition, from the viewpoint of reducing the weight of the vehicle body, the silencer is also strongly required to be lightened. However, the caulking part is formed by winding the outer cylinder and the end plate so that the weight becomes heavy and the weight is reduced. There is also a problem that it is not possible to respond to the request.

  The present invention is proposed in order to solve the above-mentioned problems, and it eliminates the protruding portion protruding outside the outer peripheral surface of the outer cylinder, enables a highly flexible exhaust system layout and is lightweight. It is an object of the present invention to provide a silencer that can be manufactured and a method for manufacturing the same.

Muffler of the present invention are a number of holes formed, the inner cylinder through which the noise in the exhaust, an outer cylinder provided outside the inner cylinder, both ends of the axial direction of the inner cylinder and the outer cylinder Provided with an end plate fixed to the inner cylinder and the outer cylinder, forming a stepped portion recessed inward at an end portion of the outer cylinder, and a fitting portion at an outer end portion of the end plate. Forming, fitting the fitting portion to the outside of the stepped portion, and fixing the fitting portion and the stepped portion, in a space surrounded by the inner cylinder, the outer cylinder, and the end plate , It is characterized by being equipped with a sound deadening material which is a long fiber material.

  Moreover, the silencer of the present invention is characterized in that an axial tip portion of the outer cylinder is bent inward.

  Moreover, the silencer of the present invention is characterized in that a silencer, which is a long fiber material, is provided between the inner cylinder and the outer cylinder. The long fiber material is preferably glass fiber, for example, but other long fiber materials may be used. Moreover, in this invention, when using a silencer, it is also possible to use a silencer other than a long fiber material.

  The silencer of the present invention is characterized in that the fitting portion and the stepped portion are fixed by laser welding. In the present invention, the welding of the fitting portion and the stepped portion is preferably laser welding, but other welding is also possible.

  The silencer of the present invention is characterized in that a curved portion is formed on the substrate of the end plate. More preferably, the curved portion is formed at a plurality of locations.

  Further, the silencer manufacturing method of the present invention is arranged such that the one end plate is arranged such that one end side in the axial direction of the inner cylinder is inserted into a sleeve formed at a substantially center of the one end plate. The first step of fixing the sleeve of the one end plate and the inner cylinder, and the stepped portion on one end side in the axial direction of the outer cylinder is fitted inside the fitting portion of the one end plate And inserting into the sleeve in which the other end side in the axial direction of the inner cylinder is formed substantially at the center of the other end plate. The other end plate is press-fitted so that the fitting portion of the other end plate is fitted to the outside of the stepped portion on the other end side in the axial direction of the outer cylinder. When the third step of placing and the sleeve of the other end plate and the inner cylinder are fixed together, The fitting portion of the one end plate and the step portion on one end side of the outer cylinder are fixed, the fitting portion of the other end plate and the step portion on the other end side of the outer cylinder, And a fourth step of fixing.

  Moreover, the method for manufacturing a silencer of the present invention includes a step of filling a silencer material, which is a long fiber material, between the inner cylinder and the outer cylinder after the second process and before the third process. It is characterized by providing.

  The automobile of the present invention is equipped with the silencer of the present invention or the silencer manufactured by the method of manufacturing a silencer of the present invention. The automobile of the present invention includes appropriate automobiles such as an automobile and a motorcycle.

  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, by fitting the fitting portion of the end plate to the outside of the step portion of the outer cylinder end portion and fixing the fitting portion and the step portion, the protruding portion protruding to the outer peripheral surface of the outer cylinder is eliminated. Therefore, the exhaust system can be laid out with a high degree of freedom. Further, by the flattening, it is possible not to provide a step in the jig that receives the shape of the outer cylinder or the end plate, and the jigs can be simplified. Furthermore, the flattening can improve the appearance and feel. Moreover, since the caulking part which winds up an outer cylinder and an end plate is not provided which increases in weight, a silencer can be reduced in weight and it can respond to the request for weight reduction. Moreover, since a member required for a crimping part can be reduced and a crimping process can be eliminated, a manufacturing cost can be reduced and a manufacturing process can be simplified.

  In addition, by bending the tip portion in the axial direction of the outer cylinder inward, fitting of the fitting portion to the outside of the stepped portion and press-fitting can be facilitated. In addition, when a silencer material, which is a long fiber material, is installed between the inner cylinder and the outer cylinder, the long fiber material is pressed by the bent outer cylinder at the time of filling with the long fiber material. Therefore, it is possible to prevent the long fiber material from being caught in an unintended portion such as a welding mating surface.

  In addition, although laser welding provides a very deep penetration depth and high strength fixation, it is difficult to achieve good welding when a gap is formed between the target members. By laser welding the stepped portion, it is possible to improve the alignment accuracy, laser weld the fitting portion and the stepped portion in a state of being in close contact with each other, and perform reliable fixing by laser welding.

  In addition, by forming a curved portion on the substrate of the end plate, it is possible to increase the strength of the end plate, and to absorb deformation due to thermal expansion and contraction of the inner cylinder. Durability can be improved. Furthermore, by forming the curved portion, the fitting portion of the end plate can be easily fitted into the step portion of the outer cylinder, and the accuracy required for the set dimensions for fitting the fitting portion and the step portion can be relaxed. Can do.

  Also, in the silencer manufacturing method of the present invention, the one end plate is fixed to the inner cylinder and the one end plate is arranged in the inner cylinder, and then the step portion of the outer cylinder is press-fitted into the fitting portion of the one end plate. By arranging the cylinder, the outer cylinder can be easily arranged at an accurate position. Further, the other end plate can be easily placed at an accurate position by press-fitting the fitting portion of the other end plate into the stepped portion of the arranged outer cylinder to place the other end plate. Can do. Furthermore, it is possible to securely fix the end plates to the accurately arranged inner cylinder and outer cylinder. Further, by filling the long fiber material between the inner tube and the outer tube after the outer tube is placed and before the other end plate is placed, the required long fiber material can be easily installed.

  The silencer and the manufacturing method thereof according to the embodiment of the present invention will be described.

[Muffler of the embodiment and manufacturing method thereof]
The silencer 10 of the present embodiment is a chamber provided in an exhaust system of an internal combustion engine of an automobile, and as shown in FIGS. 1 and 2, an inner cylinder 20 and an outer cylinder 30 provided outside the inner cylinder 20 The length of the end plate 40 that is provided at both end portions in the axial direction of the outer cylinder 30 and fixed to the inner cylinder 20 and the outer cylinder 30 and the length of the silencer that is installed between the inner cylinder 20 and the outer cylinder 30 Fiber material 50 is provided.

  The inner cylinder 20 has a cylindrical base portion 21, and a plurality of holes 211 are formed in the peripheral surface of the base portion 21 that is an intermediate portion thereof, and noise in the exhaust gas passing through the inner cylinder 20 passes through the holes 211. The long fiber material 50 is reached and the sound is muted. On both sides of the base portion 21, inclined portions 22, 22 having a tapered shape in cross section are formed so as to be tapered, respectively, and a cylindrical sleeve 23 having a smaller diameter than the base portion 21 is formed at the distal end portion of the inclined portion 22. Is formed.

  The outer cylinder 30 is a substantially cylindrical cylinder, and has step portions 32 at both ends in the axial direction of the base portion 31 that is an intermediate portion thereof. The stepped portion 32 is provided at a position recessed inward by an amount corresponding to the thickness of the fitting portion 43 of the end plate 40 from the outer peripheral surface of the base portion 31, and the diameter of the stepped portion 32 is reduced from the outer peripheral surface of the base portion 31. It is a flat surface portion. A bent portion 33 is formed at both tip portions of the outer cylinder 30 in the axial direction, that is, at each tip portion of the stepped portion 32, and is bent and inclined inward so as to be tapered.

  The end plate 40 includes a substantially circular substrate 41, and a cylindrical sleeve 42 penetrating substantially at the center of the substrate 41 is formed so as to protrude to one side (outside) in the vertical axis direction with respect to the substrate 41. A fitting portion 43 is formed by bending the outer end portion of the substrate 41 corresponding to the outer end portion of the plate 40 at a substantially right angle, and the fitting portion 43 is the other in the vertical axis direction with respect to the substrate 41 opposite to the sleeve 42. It protrudes and extends to the side (inner side). The intermediate portion between the sleeve 42 and the fitting portion 43 of the substrate 41 is formed with a curved portion 44 having an arcuate sectional view so as to protrude to the other side (inner side). It is formed in a circumferential shape so as to make one round along. In the present embodiment, the curved portions 44 and 44 are formed at two locations in a cross-sectional view, but the curved portions 44 can be formed at a plurality of three locations or a single location.

  A glass fiber material is preferably used for the long fiber material 50 that is a sound deadening material, but a long fiber material that functions as a sound deadening material other than the glass fiber material may be used. In the present invention, it is also possible to use a silencer other than the long fiber material.

  The outer cylinder 30 of the silencer 10 is disposed outside the base 21 and the inclined portion 22 of the inner cylinder 20, and a long fiber material 50 is filled between the outer cylinder 30 and the inner cylinder 20. Yes. End plates 40 and 40 are respectively disposed at both ends of the outer cylinder 30 in the axial direction, and the opening between the distal end portion of the outer cylinder 30 in the axial direction and the inner cylinder 20 is closed by the end plate 40.

  The end plate 40 is fitted to the outer side of the sleeve 23 of the inner cylinder 20 such that the fitting portion 43 is on the inner side in the axial direction of the inner cylinder 20 and the sleeve 42 is on the outer side in the axial direction of the inner cylinder 20. The fitting portion 43 is fitted to the outside of the step portion 32 of the outer cylinder 30. The sleeve 42 and the sleeve 23 are fixed by MIG welding or spot welding or the like of the welding site W1, and the fitting portion 43 and the stepped portion 32 are preferably fixed by laser welding or the like of the welding site W2, and the end plate 40 is an inner plate. The cylinder 20 and the outer cylinder 30 are fixed to each other.

  As an example of the process of manufacturing the silencer 10 of the present embodiment, as shown in FIG. 3, first, one end plate 40 is disposed on one end side in the axial direction of the inner cylinder 20. When one end plate 40 is disposed, the sleeve 42 of the one end plate 40 is disposed so that the outer side in the axial direction of the inner cylinder 20 and the fitting portion 43 are on the inner side in the axial direction. The sleeve 42 of one end plate 40 is externally fitted to the sleeve 23 on one end side of the inner cylinder 20 from one end side in the axial direction of the inner cylinder 20, in other words, the sleeve 23 of the inner cylinder 20 on one end side is the one end plate 40. To be inserted into the sleeve 42. Then, the sleeve 42 of the one end plate 40 and the sleeve 23 of the inner cylinder 20 are fixed by MIG welding or spot welding welding or the like at the welding site W1, and a fitting portion 43 is formed on the inner side of the inner cylinder 20 in the axial direction. One end plate 40 and the inner cylinder 20 are fixed so as to extend.

  Thereafter, as shown in FIG. 4, the outer cylinder 30 is extrapolated from the other end side in the axial direction of the inner cylinder 20 to the outside of the inner cylinder 20, and the stepped portion 32 on one end side in the axial direction of the outer cylinder 30 is set at one end. The outer cylinder 30 is positioned and arranged outside the inner cylinder 20 by being press-fitted so as to be fitted inside the fitting portion 43 of the plate 40. The contact surface between the fitting portion 43 of the one end plate 40 and the stepped portion 32 of the outer cylinder 30 that are closely fitted together is welded and fixed to one end plate 40 and the outer cylinder 30 described later. This becomes the welding surface.

  Next, as shown in FIG. 5, a long fiber that is a silencer in the space between the inner cylinder 20 and the outer cylinder 30, that is, in the space surrounded by the inner cylinder 20, the outer cylinder 30, and one end plate 40. The material 50 is filled by blowing or the like. In the filling process of the long fiber material 50, the long fiber material 50 is held by the bent portion 33 that is bent inwardly formed at the axial end portion of the outer cylinder 30, and the fitting portion 43 of the one end plate 40 that is in close contact with the long fiber material 50. And the long fiber material 50 can be prevented from entering the welded joint surface or the like by the step portion 32.

  Thereafter, as shown in FIG. 6, the other end plate 40 is disposed on the other end side in the axial direction of the inner cylinder 20. When the other end plate 40 is disposed, the sleeve 42 of the other end plate 40 is disposed on the outer side in the axial direction of the inner cylinder 20 and the fitting portion 43 is disposed on the inner side in the axial direction. The sleeve 42 of the other end plate 40 is externally fitted to the sleeve 23 on the other end side of the inner cylinder 20 from the other end side in the axial direction of the inner cylinder 20, in other words, the sleeve 23 of the inner cylinder 20 on the other end side is the other end side. It is inserted into the sleeve 42 of the end plate 40. At the same time, the fitting portion 43 of the other end plate 40 is press-fitted to the outside of the stepped portion 32 on the other end side in the axial direction of the outer cylinder 30 being positioned, and the other end plate 40 is fitted into the inner cylinder. It positions and arranges outside 20. The contact surface between the fitting portion 43 of the other end plate 40 and the stepped portion 32 of the outer cylinder 30 that are closely fitted together is welded and fixed to one end plate 40 and the outer cylinder 30 described later. This becomes the welding surface.

  After that, the sleeve 42 of the other end plate 40 and the sleeve 23 of the inner cylinder 20 are fixed by MIG welding or spot welding welding or the like at the welding site W1, and the fitting portion 43 of the one end plate 40 and the outer cylinder are fixed. 30 is welded to the stepped portion 32 on one end side by laser welding in the welded portion W2, and welded between the fitting portion 43 of the other end plate 40 and the stepped portion 32 on the other end side of the outer tube 30. The mating surfaces are fixed by laser welding at the welding site W2. Thereby, the silencer 10 is completed.

  The silencer 10 of the present embodiment is configured so that the fitting portion 43 of the end plate 40 is fitted to the outside of the step portion 32 at the end portion of the outer cylinder 30 and the fitting portion 43 and the step portion 32 are fixed. By making the outer peripheral surface of the base portion 31 of the tube 30 and the outer peripheral surface of the fitting portion 43 substantially flat and flattening, etc., it becomes possible to eliminate the protruding portion protruding outside the peripheral surface of the outer tube 30, thereby An exhaust system layout with a high degree of freedom is possible. Furthermore, by the flattening, it is possible not to provide a step in the jig for receiving the shape of the outer cylinder 30 or the end plate 40, it is possible to simplify the jigs, and also to feel the aesthetics and feel. Can be improved. Moreover, since the caulking part which rolls up the outer cylinder 20 and the end plate 40 which does increase the weight is not provided, the silencer 10 can be reduced in weight, the members necessary for the caulking part can be reduced, and the caulking process can be performed. Since it can be eliminated, the manufacturing cost can be reduced and the manufacturing process can be simplified.

  In addition, by providing a bent portion 33 that bends inward at the axial tip portion of the outer cylinder 30, the fitting portion 43 can be easily fitted and pressed into the outside of the step portion 31. In addition, in the interior of the long fiber material 50 between the inner cylinder 20 and the outer cylinder 30, the long fiber material 50 can be pressed by the bent portion 33 when the long fiber material 50 is filled. Can be prevented from being caught in unintended locations such as welded surfaces. In addition, when the fitting portion 43 and the stepped portion 32 are fixed by laser welding, the fitting portion 43 and the stepped portion 32 in the fitted state are laser welded to improve the alignment accuracy and ensure close contact. It becomes possible to laser-weld the fitting part 43 and the step part 32 in a state, and reliable fixation can be performed. Further, by forming the curved portion 44 on the substrate 41 of the end plate 40, the strength of the end plate 40 can be increased, and the deformation due to the thermal expansion and contraction of the inner cylinder 20 can be absorbed. The strength and durability of the silencer 10 can be improved.

  Further, in the above silencer manufacturing method, one end plate 40 is fixed to the inner cylinder 20 and disposed on the inner cylinder, and then the stepped portion 31 of the outer cylinder 30 is fitted to the fitting portion 43 of the one end plate 40. By press-fitting and arranging the outer cylinder 30, the outer cylinder 30 can be easily arranged at an accurate position. Further, the other end plate 40 is placed in an accurate position by press-fitting the fitting portion 43 of the other end plate 40 into the stepped portion 32 of the arranged outer cylinder 30 to place the other end plate 40. Can be easily arranged. Further, the end plate 40 is fixed to the accurately disposed inner cylinder 20 and outer cylinder 30, so that reliable fixing is possible. In addition, by placing the long fiber material 50 between the inner tube 20 and the outer tube 30 before the other end plate 40 is disposed after the outer tube 30 is disposed, the required long fiber material 50 can be easily obtained. Can be decorated.

[Modifications of Embodiment, etc.]
The present invention is not limited to the silencer 10 and the method of manufacturing the silencer 10 of the above embodiment, and various modifications are possible. For example, although the silencer of the above embodiment is a chamber, the present invention includes an appropriate silencer such as a silencer, and also includes a silencer without the long fiber material 50. Further, the basic shapes of the inner cylinder 20 and the outer cylinder 30 can be appropriately cylindrical shapes such as a cylinder, an elliptic cylinder, a polygonal cylinder such as a square cylinder or a hexagon cylinder. Further, the fixing between the inner cylinder 20 and the end plate 40 or the fixing between the outer cylinder 30 and the end plate 40 is not limited to the above-mentioned fixing by welding, and can be fixed by an appropriate method. 20 or the outer cylinder 30 is preferably fixed in a circumferential shape along the circumferential direction, but the strength is preferably increased. Further, the silencer 10 can be installed in an exhaust system of an appropriate automobile such as a motorcycle or an automobile.

  INDUSTRIAL APPLICABILITY The present invention can be used for a silencer equipped in an automobile exhaust system or the like and for manufacturing the silencer.

The partial vertical side view which shows the silencer of embodiment. FIG. 3 is a longitudinal side view showing an end plate of the silencer of FIG. 1 and its peripheral region. The longitudinal side view which shows the state which attached the one end plate to the one end side of an inner cylinder. The longitudinal side view which shows the state which attached the outer cylinder to the structure comprised by an inner cylinder and one end plate. The longitudinal side view which shows the state which filled the long fiber material in the structure comprised by an inner cylinder, one end plate, and an outer cylinder. The longitudinal side view which shows the state which comprised the inner cylinder, one end plate, and the outer cylinder, and attached the other end plate to the structure filled with the long fiber material.

DESCRIPTION OF SYMBOLS 10 ... Silencer 20 ... Inner cylinder 21 ... Base 211 ... Hole 22 ... Inclined part 23 ... Sleeve 30 ... Outer cylinder 31 ... Base 32 ... Step part 33 ... Bending part 40 ... End plate 41 ... Substrate 42 ... Sleeve 43 ... Fitting Part 44 ... Curved part 50 ... Long fiber material W1, W2 ... Welded part

Claims (7)

A large number of holes, an inner cylinder through which noise in the exhaust passes,
An outer cylinder provided outside the inner cylinder;
Provided at both ends in the axial direction of the inner cylinder and the outer cylinder, comprising the inner cylinder and an end plate fixed to the outer cylinder,
Forming a stepped portion recessed inward at the end of the outer cylinder,
Forming a fitting portion on the outer end of the end plate;
Fitting the fitting portion to the outside of the stepped portion and fixing the fitting portion and the stepped portion,
An exhaust silencer for an automobile , wherein a silencer, which is a long fiber material, is provided in a space surrounded by the inner cylinder, the outer cylinder, and the end plate. 2. The exhaust system silencer for an automobile according to claim 1, wherein an axial front end portion of the outer cylinder is bent inward. The exhaust system silencer according to claim 1 or 2, wherein the fitting portion and the stepped portion are fixed by laser welding. The automobile exhaust system silencer according to any one of claims 1 to 3, wherein a curved portion is formed on a substrate of the end plate. A method for manufacturing an automobile exhaust system silencer according to any one of claims 1 to 4,
The one end plate is disposed so that one end side in the axial direction of the inner cylinder is inserted into a sleeve formed at substantially the center of the one end plate, and the sleeve of the one end plate and the inner A first step of fixing the tube;
A second step in which the stepped portion on one end side in the axial direction of the outer cylinder is press-fitted so as to be fitted inside the fitting portion in the one end plate, and the outer cylinder is disposed outside the inner cylinder; Process,
The other end side in the axial direction of the inner cylinder is inserted into a sleeve formed at the approximate center of the other end plate, and the fitting portion in the other end plate is inserted in the axial direction of the outer cylinder. A third step in which the other end plate is press-fitted and arranged so as to fit outside the step portion on the other end side;
The sleeve of the other end plate and the inner cylinder are fixed, the fitting portion of the one end plate and the stepped portion on one end side of the outer cylinder are fixed, and the sleeve of the other end plate is fixed. A method of manufacturing an automobile exhaust system silencer, comprising: a fourth step of fixing the fitting portion and the stepped portion on the other end side of the outer cylinder. 6. The method according to claim 5, further comprising a step of filling a silencer material, which is a long fiber material, between the inner tube and the outer tube after the second step and before the third step. Manufacturing method for automobile exhaust silencer. An automobile exhaust system silencer according to any one of claims 1 to 4, or an automobile exhaust system silencer manufactured by the automobile exhaust system silencer manufacturing method according to claim 5 or 6. A car characterized by

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