EXHAUST SYSTEM FOR A VEHICLE AND METHOD FOR INSTALLING THE SAME

Description

[0001] The present invention relates to an exhaust system for a vehicle and a method for assembling the same. The present invention relates in particular to an exhaust system for an internal combustion engine of a vehicle, for example, a passenger car.

[0002] Conventional exhaust systems for a vehicle's internal combustion engine feature a catalyst with an exhaust pipe that is connected via a connecting element or directly to the vehicle's exhaust system to direct exhaust gas flowing from the catalyst's exhaust pipe out of the vehicle into the environment.

[0003] The location and orientation of the catalytic converter's exhaust pipe can depend on the specific configuration of the vehicle, particularly its engine compartment. For example, it may be a conventional vehicle with only a combustion engine or a hybrid vehicle with both a combustion engine and an electric motor. In such cases, different components are required to discharge the exhaust gas flowing from the catalytic converter into the environment, and potentially different tools are needed to assemble these components, thus increasing the vehicle's manufacturing costs.

[0004] The documents US 2008 / 277016 A1, US 2008 / 084065 A1 and GB 2 207 615 A ​​are known from the state of the art.

[0005] One object of an embodiment of the present invention is to improve an exhaust system for a vehicle and a method for assembling the same.

[0006] This problem is solved by a method with the features of claim 1 or an exhaust system with the features of claim 7. Advantageous embodiments of the invention are the subject of the dependent claims.

[0007] According to one aspect of the present invention, a method for assembling an exhaust system for a vehicle, in an embodiment for a passenger car, comprises the following steps: a) Providing an exhaust pipe of a catalyst, b) Providing a connecting piece with a passage for guiding exhaust gas flowing from the exhaust pipe during normal use of the exhaust system, c) Providing a connecting element with a passage for guiding exhaust gas flowing from the connecting piece during normal use of the exhaust system, d) At least partially fitting the connecting piece over the exhaust pipe or at least partially inserting the connecting piece into the exhaust pipe, e) Setting a predetermined tilt angle between a longitudinal axis of the connecting piece and a longitudinal axis of the exhaust pipe, f) Welding the exhaust pipe and the connecting piece at the set tilt angle, and g) Connecting the connecting element to the connecting piece.

[0008] This allows, in a single design for different positions and / or orientations of the catalytic converter's outlet pipe, the same connecting piece to be used to join the catalytic converter's outlet pipe to the connection element. This is achieved by adjusting the tilt angle between the longitudinal axis of the connecting piece and the longitudinal axis of the outlet pipe, and by welding the outlet pipe and connecting piece together at the set tilt angle. This reduces the vehicle's manufacturing costs. The tilt angle is the angle by which the connecting piece, and thus its longitudinal axis, would need to be rotated so that the longitudinal axis of the connecting piece and the longitudinal axis of the outlet pipe coincide or are at least parallel to each other.The outlet pipe, and thus its longitudinal axis, would have to be rotated around this angle so that the longitudinal axis of the connecting piece and the longitudinal axis of the outlet pipe coincide or are at least parallel to each other. In one embodiment, the specified tilt angle between the longitudinal axis of the connecting piece and the longitudinal axis of the outlet pipe is different from 0°, in another embodiment it is greater than 5°, in another embodiment it is greater than 10°, in another embodiment it is greater than 20°, and in another embodiment it is greater than 30°.

[0009] Furthermore, in one version, a gas-tight connection can be created between the outlet pipe and the connecting piece by welding the outlet pipe and the connecting piece.

[0010] In one embodiment, in step a) an outlet pipe with predetermined outer dimensions is provided, and in step b) a connecting piece with a passage with predetermined inner dimensions is provided, wherein the predetermined outer dimensions of the outlet pipe and the predetermined inner dimensions of the passage of the connecting piece are selected such that, in the at least partially fitted state of the connecting piece over the outlet pipe, the connecting piece is movable along the longitudinal axis of the outlet pipe and / or can be tilted at least by the predetermined tilting angle; or, in step a) an outlet pipe with a passage with predetermined inner dimensions is provided, and in step b) a connecting piece with predetermined outer dimensions is provided, wherein the predetermined outer dimensions of the connecting piece and the predetermined inner dimensions of the passage of the outlet pipe are selected such that...that, in the at least partially inserted state of the connecting piece into the outlet pipe, the connecting piece is movable along the longitudinal axis of the outlet pipe and / or at least tiltable by the specified tilting angle.

[0011] This allows the connecting piece to be welded to the exhaust pipe at different positions along the longitudinal axis of the catalyst's exhaust pipe, or the exhaust pipe of the catalyst to be welded to the connecting piece at different positions along the longitudinal axis of the catalyst's exhaust pipe.

[0012] In one embodiment, the outlet pipe provided in step a) and the connecting piece provided in step b) are arranged such that in step d) When a predetermined section of the connecting piece is placed over the outlet pipe, or when a predetermined section of the connecting piece is inserted into the outlet pipe, the connecting piece can be tilted relative to the outlet pipe according to the predetermined tilting angle between the longitudinal axis of the connecting piece and the longitudinal axis of the outlet pipe.

[0013] This allows the outlet pipe and the connecting piece to be welded together in one embodiment, either in a state where the specified section of the connecting piece is placed over the outlet pipe, or in which the specified section of the connecting piece is inserted into the outlet pipe.

[0014] In one embodiment, in step g) the connecting element is connected to the connecting piece by means of a clamp, in one embodiment wherein the clamp encompasses a radially projecting section of the connecting piece and a radially projecting section of the connecting element.

[0015] This allows for a simple, detachable connection between the connecting element and the connector in one version.

[0016] According to the invention, in step b) a connecting piece with a first section is provided which in step d) is at least partially fitted over the outlet pipe, wherein the first section of the connecting piece tapers at least section by section towards one end of the connecting piece, in one embodiment tapering conically, which in step d) is fitted over the outlet pipe, or in step a) an outlet pipe with a section is provided into which in step d) the connecting piece is at least partially inserted, wherein the section of the outlet pipe tapers at least section by section towards one end of the outlet pipe, in one embodiment tapering conically, into which in step d) the connecting piece is at least partially inserted.

[0017] This allows a larger tilting angle between the longitudinal axis of the connecting piece and the longitudinal axis of the outlet pipe to be specified and set in one embodiment compared to cases where the first section of the connecting piece is designed as a circular cylinder or the section of the outlet pipe is designed as a circular cylinder.

[0018] According to the invention, in step b) a connecting piece with a second section adjoining the first section of the connecting piece and tapering at least partially towards the first section of the connecting piece, in one embodiment tapering conically, is provided; in step c) a connecting element with a first section and a second section adjoining the first section, which has a smaller outer dimension than an end of the first section of the connecting element adjoining the second section of the connecting element, wherein the first section of the connecting element tapering at least partially away from the end adjoining the second section of the connecting element, in one embodiment tapering conically, is provided; in step g) the first section of the connecting element is inserted at least partially into the second section of the connecting piece.wherein the method further comprises the following step: h) connecting the connecting element to the connecting piece by means of a clamp, in particular wherein the clamp encompasses the end of the first section of the connecting element and an end of the second section of the connecting piece facing away from the first section of the connecting piece.

[0019] This allows for a simple, detachable, and gas-tight connection between the connector and the connecting element in one design.

[0020] In one embodiment, the tilt angle is set in step e) using a gauge. The gauge may, for example, include devices for holding the outlet pipe and the connecting piece, which are designed to hold or fix the connecting piece in a predetermined position with respect to the orientation and position of the catalyst outlet pipe, wherein the predetermined position corresponds to the predetermined tilt angle.

[0021] This allows the specified tilt angle to be easily adjusted in one version.

[0022] In one embodiment, the outlet pipe provided in step a) and / or the connector provided in step b) and / or the connection element provided in step c) comprises a metal or consists of at least one metal. In another embodiment, the connection element may be designed as a flexible, hose-like element, which may, for example, comprise plastic.

[0023] This allows the connecting piece, in a version where it has a metal component or consists of at least one metal component, to be used in situations where ambient temperatures in the engine compartment or temperatures of the exhaust gas flowing from the exhaust pipe are in the range of approximately 600°C to approximately 1000°C.

[0024] According to another aspect of the present invention, an exhaust system is mounted for a vehicle according to a method for mounting an exhaust system described above.

[0025] According to another aspect of the present invention, a vehicle, in one embodiment a passenger car, has an exhaust system for a vehicle as described above.

[0026] Further advantageous embodiments of the present invention will become apparent from the dependent claims and the following description of preferred embodiments.

[0027] This is shown, partly schematically: Fig. 1 a flowchart to illustrate a method for assembling an exhaust system for a vehicle according to one embodiment of the present invention, Fig. 2 parts of an exhaust system for a vehicle according to one embodiment of the present invention in an incomplete assembly state, Fig. 3 parts of an exhaust system for a vehicle according to another embodiment of the present invention in an incomplete assembly state, and Fig. 4 parts of an exhaust system for a vehicle.

[0028] Fig. 1Figure 1 shows a flowchart to illustrate a method for assembling an exhaust system 100 for a vehicle, in an embodiment for a passenger car, according to an embodiment of the present invention.

[0029] With further reference to the Figures 2 , 3 and 4 , which show parts of an exhaust system 100 for a vehicle according to embodiments of the present invention, are referred to Fig. 1 The individual steps of the procedure for assembling the exhaust system 100 for a vehicle, in an embodiment for a passenger car, are explained.

[0030] In step S10, an outlet pipe 11 of a catalyst 10, which is connected to the catalyst or is intended to be connected to the catalyst 10 at a later time, is provided. The catalyst 10 can, for example, be connected via appropriate connecting elements to an internal combustion engine (not shown) of the vehicle and be configured to clean the exhaust gas produced by the internal combustion engine.

[0031] In step S20, a connecting piece 20 with a passage for guiding exhaust gas flowing from the outlet pipe 11 during normal use of the exhaust system 100, which is produced by the combustion engine or internal combustion machine not shown, is provided.

[0032] In step S30, a connection element 30 with a passage for guiding the exhaust gas flowing from the connecting piece 20 during the intended use of the exhaust system 100 is provided.

[0033] In one embodiment, the outlet pipe 11 and / or the connecting piece 20 and / or the connection element 30 is made of metal or consists of at least one metal. In another embodiment, the connection element 30 can be designed as a flexible, hose-like element, which may, for example, be made of plastic.

[0034] This allows the connecting piece 20, in a version where the connecting piece 20 has a metal or consists of at least one metal, to be used in situations where ambient temperatures in the engine compartment or temperatures of the exhaust gas flowing from the outlet pipe 11 are in the range of about 600°C to about 1000°C.

[0035] In step S40, the connecting piece 20 is as described in the Figures 2 , 3 and 4 The illustration shows the connecting piece being at least partially placed over the outlet pipe 11 of the catalyst 10. In an embodiment not shown, the connecting piece can alternatively be inserted at least partially into the outlet pipe of the catalyst in step S40.

[0036] In step S50, a predetermined tilt angle is set, in the version in Fig. 2 for example, a tilt angle + α, as explained in the Figures 3 and 4 for example a tilt angle - α, between a longitudinal axis L2 of the connecting piece 20 and a longitudinal axis L1 of the outlet pipe 11 of the catalyst 10 is set.

[0037] Here, the tilt angle + α, - α is an angle by which the connecting piece 20, and thus its longitudinal axis L2, would have to be rotated so that the longitudinal axis L2 of the connecting piece 20 and the longitudinal axis L1 of the exhaust pipe 11 of the catalyst 10 coincide or are at least parallel to each other, or by which the exhaust pipe, and thus its longitudinal axis, would have to be rotated so that the longitudinal axis of the connecting piece and the longitudinal axis of the exhaust pipe coincide or are at least parallel to each other. In one embodiment, the specified tilt angle between the longitudinal axis L2 of the connecting piece 20 and the longitudinal axis L1 of the exhaust pipe 11 is other than 0°, in one embodiment greater than 5°, in one embodiment greater than 10°, in one embodiment greater than 20°, and in one embodiment greater than 30°.

[0038] In one embodiment, the tilt angle + α, - α is set using a gauge. The gauge may, for example, include devices for holding the outlet pipe 11 and the connecting piece 20, which are designed to hold or fix the connecting piece 20 in a predetermined position with respect to the orientation and position of the outlet pipe 11 of the catalyst 10, wherein the predetermined position corresponds to the predetermined tilt angle + α, - α.

[0039] In the Figures 2 , 3 and 4In the embodiment shown, in step S10 an outlet pipe 11 with predetermined outer dimensions is provided, and in step S20 a connecting piece 20 with a passage having predetermined inner dimensions is provided. In this case, the predetermined outer dimensions of the outlet pipe 11 and the predetermined inner dimensions of the passage of the connecting piece 20 can be selected such that, in the at least partially inserted state of the connecting piece 20 over the outlet pipe 11, the connecting piece 20 is movable along the longitudinal axis L1 of the outlet pipe 11 and / or can be tilted at least by the predetermined tilting angle + α, - α.

[0040] In the not in the Figures 2 , 3 and 4In the embodiment shown, an outlet pipe with a passage of predetermined internal dimensions can alternatively be provided in step S10, and a connecting piece with predetermined external dimensions can be provided in step S20. In this case, the predetermined external dimensions of the connecting piece and the predetermined internal dimensions of the passage of the outlet pipe can be selected such that, in the at least partially inserted state of the connecting piece into the outlet pipe, the connecting piece is movable along the longitudinal axis L1 of the outlet pipe and / or tiltable at least by the predetermined tilting angle + α, - α.

[0041] Furthermore, the outlet pipe 11 provided in step S10 and the connecting piece 20 provided in step S20 can be configured such that in step S40, during the Figures 2 , 3 and 4The embodiment shown is achieved when a predetermined section of the connecting piece 20 is placed over the outlet pipe 11 or when inserted into the Figures 2 , 3 and 4 In the embodiment not shown, when a predetermined section of the connecting piece is inserted into the outlet pipe, the connecting piece 20 can be tilted relative to the outlet pipe 11 according to the predetermined tilting angle + α, - α between the longitudinal axis L2 of the connecting piece 20 and the longitudinal axis L1 of the outlet pipe 11.

[0042] In step S60, the outlet pipe 11 and the connecting piece 20 are welded together at the set tilting angle + α, - α, as indicated by the arrows and the reference symbol S, which illustrate the corresponding weld joint or welding location. Figures 2 , 3 and 4 This is illustrated. Here, in a way that is Figures 2 , 3 and 4In the embodiment shown, in particular an end 24 of a first section 21 of the connecting piece 20 is welded to the outlet pipe 11. In the embodiment not shown, in which the connecting piece 20 is at least partially inserted into the outlet pipe 11, in particular an exposed end of the outlet pipe 11 is welded to the connecting piece 20. By welding the outlet pipe 11 to the connecting piece 20, a gas-tight connection between the outlet pipe 11 and the connecting piece 20 can be established in one embodiment.

[0043] In step S70, the connecting element 30 is connected to the connecting piece 20. In one embodiment, the connecting element 30 can be connected to the connecting piece 20 by means of a clamp 40, as shown in Fig. 4As illustrated, the connection is made so that in the exhaust system 100 for the vehicle, the connecting element 30 is connected to the connecting piece 20. In one embodiment, the clamp 40 can encompass a radially projecting section of the connecting piece 20 and a radially projecting section of the connecting element 30, so that in the exhaust system 100 for the vehicle, the connecting element 30 is connected to the connecting piece 20 by means of a clamp 40, wherein the clamp 40 particularly encompasses a radially projecting section of the connecting piece 20 and a radially projecting section of the connecting element 30.

[0044] In one in the Figures 2 , 3 and 4In the embodiment shown, a connecting piece 20 with a first section 21 can be provided in step S20, which is at least partially fitted over the outlet pipe 11 in step S40. The first section 21 of the connecting piece 20 can taper at least partially towards an end 24 of the connecting piece 20, or in one embodiment, taper conically, before being fitted over the outlet pipe 11 in step S40.

[0045] Furthermore, in step S20 a connecting piece 20 with a second section 22, which connects to the first section 21 of the connecting piece 20 and tapers at least section by section towards the first section 21 of the connecting piece 20, in particular conically, can be provided.Furthermore, in step S30, a connection element 30 can be provided with a first section 31 and a second section 32 adjoining the first section 31, which has a smaller external dimension than an end 33 of the first section 31 of the connection element 30 adjoining the second section 32 of the connection element 30, wherein the first section 31 of the connection element 30 tapers at least section by section, in particular conically, in the direction away from the end 33 adjoining the second section 32 of the connection element 30, and in step S70 the first section 31 of the connection element 30 is inserted at least section by section into the second section 22 of the connecting piece 20.

[0046] In this case, the method may further include step S80 in which the connecting element 30 is connected to the connecting piece 20 by means of a clamp 40, wherein in one embodiment the clamp 40 encompasses the end 33 of the first section 31 of the connecting element 30 and an end 23 of the second section 22 of the connecting piece 20 facing away from the first section 21 of the connecting piece.

[0047] In the Figures 2 , 3 and 4 In the embodiment not shown, an outlet pipe with a section can be provided in step S10, into which the connecting piece is at least partially inserted in step S40. Here, the section of the outlet pipe can taper, at least partially, towards one end of the outlet pipe, in particular conically, into which the connecting piece is at least partially inserted in step S40. Reference symbol list

[0048] 10 Catalyst 11 Exhaust pipe 20 Connecting piece 21 First section of the connecting piece 22 Second section of the connecting piece 23 End of the second section of the connecting piece 24 End of the first section of the connecting piece 30 Connection element 31 First section of the connection element 32 Second section of the connection element 33 End of the first section of the connection element 40 Clamp 100 Exhaust system L1 Longitudinal axis of the exhaust pipe L2 Longitudinal axis of the connecting piece S Welded joint α Tilt angle

Claims

1. Method for assembling an exhaust system (100) for a vehicle, in particular a passenger car, comprising the steps of: a) providing an outlet pipe (11) of a catalytic converter (10), b) providing a connecting piece (20) with a passage for guiding an exhaust gas flowing from the outlet pipe (11) during intended use of the exhaust system (100), c) providing a connecting element (30) with a passage for guiding the exhaust gas flowing from the connecting piece (20) during intended use of the exhaust system (100), d) at least partially placing the connecting piece (20) over the outlet pipe (11) or at least partially inserting the connecting piece into the outlet pipe, e) setting a predefined tilting angle (+ α, - α) between a longitudinal axis (L2) of the connecting piece (20) and a longitudinal axis (L1) of the outlet pipe (11), f) welding the outlet pipe (11) and the connecting piece (20) at the set tilting angle (+ α, - α), and g) connecting the connecting element (30) to the connecting piece (20), characterized in that in step b) a connecting piece (20) with a first section (21) is provided, which in step d) is at least partially placed over the outlet pipe (11), wherein the first section (21) of the connecting piece (20) tapers at least in sections toward an end (24) of the connecting piece (20), in particular tapers conically, which in step d) is placed over the outlet pipe (11), or in step a) an outlet pipe is provided with a section into which the connecting piece is at least partially inserted in step d), wherein the section of the outlet pipe tapers at least in sections toward an end of the outlet pipe, in particular tapers conically, into which in step d) the connecting piece is at least partially inserted, in step b) a connecting piece (20) with a second section (22) adjoining the first section (21) of the connecting piece (20) and tapering at least in sections toward the first section (21) of the connecting piece (20), in particular tapering conically, is provided, in step c) a connecting element (30) with a first section (31) and a second section (32) adjoining the first section (31) is provided, wherein the second section (32) has a smaller outer dimension than an end (33) of the first section (31) of the connecting element (30) adjoining the second section (32), wherein the first section (31) of the connecting element (30) tapers at least in sections in a direction away from the end (33) adjoining the second section (32) of the connecting element (30), in particular tapers conically, in step g) the first section (31) of the connecting element (30) is at least partially inserted into the second section (22) of the connecting piece (20), and the method further comprises the following step: h) connecting the connecting element (30) to the connecting piece (20) by means of a clamp (40), in particular wherein the clamp (40) engages the end (33) of the first section (31) of the connecting element (30) and an end (23) of the second section (22) of the connecting piece (20) facing away from the first section (21) of the connecting piece (20).

2. Method according to claim 1, wherein in step a) an outlet pipe (11) having predetermined outer dimensions is provided, in step b) a connecting piece (20) having a passage with predetermined inner dimensions is provided, and the predetermined outer dimensions of the outlet pipe (11) and the predetermined inner dimensions of the passage of the connecting piece (20) are selected such that, in the state where the connecting piece (20) is at least partially placed over the outlet pipe (11), the connecting piece (20) is movable along the longitudinal axis (L1) of the outlet pipe (11) and / or tiltable at least by the predefined tilting angle (+ α, - α), or in step a) an outlet pipe having a passage with predetermined inner dimensions is provided, in step b) a connecting piece having predetermined outer dimensions is provided, and the predetermined outer dimensions of the connecting piece and the predetermined inner dimensions of the passage of the outlet pipe are selected such that, in the state where the connecting piece is at least partially inserted into the outlet pipe, the connecting piece is movable along the longitudinal axis of the outlet pipe and / or tiltable at least by the predefined tilting angle (+ α, - a).

3. Method according to claim 1 or 2, wherein the outlet pipe (11) provided in step a) and the connecting piece (20) provided in step b) are configured such that in step d) when a predefined section of the connecting piece (20) is placed over the outlet pipe (11), or when a predefined section of the connecting piece is inserted into the outlet pipe, the connecting piece (20) is tiltable relative to the outlet pipe (11) according to the predefined tilting angle (+ α, - α) between the longitudinal axis (L2) of the connecting piece (20) and the longitudinal axis (L1) of the outlet pipe (11).

4. Method according to one of claims 1 to 3, wherein in step g) the connecting element (30) is connected to the connecting piece (20) by means of a clamp (40), in particular wherein the clamp (40) engages a radially projecting section of the connecting piece (20) and a radially projecting section of the connecting element (30).

5. Method according to one of the preceding claims, wherein in step e) the tilting angle (+ α, - α) is set using a gauge.

6. Method according to one of the preceding claims, wherein the outlet pipe (11) provided in step a) and / or the connecting piece (20) provided in step b) and / or the connecting element (30) provided in step c) comprise a metal or consist of at least one metal.

7. Exhaust system (100), assembled according to a method according to one of claims 1 to 6.

8. Vehicle, in particular a passenger car, comprising an exhaust system (100) according to claim 7.