A broadband muffler structure

Abstract

The present invention relates to a broadband muffler structure, comprising a pipeline upper plate (1) and a muffler porous plate (2), wherein the pipeline upper plate (1) is provided with a groove (11), and the muffler porous plate (2) is provided with a snap fastener (21) matching the groove (11). Compared with the prior art, the present invention has the advantages of low manufacturing cost, light weight, easy installation, high connection strength, etc.

Description

Technical Field

[0001] The present invention relates to the technical field of mufflers, and in particular to a broadband muffler structure. Background Art

[0002] Currently, many vehicle intake systems or fuel cell intake and exhaust systems require integrated broadband mufflers to eliminate or reduce medium and high frequency noises such as hissing, surging, turbocharger blowby, and fuel cell compressor noise generated during vehicle intake.

[0003] Existing broadband mufflers typically consist of three parts: an upper section, a lower section, and a muffler cover. The upper and lower sections are welded together to form a complete ventilation line, which is then welded to the muffler cover to form the integrated broadband muffler ventilation line.

[0004] In the existing technology, the structure of the broadband muffler includes a resonance cavity cover, an upper pipe piece of an integrated porous plate, and a lower pipe piece. The resonance cavity cover and the upper pipe piece need to be welded, and then the upper pipe piece and the lower pipe piece of the integrated porous plate need to be welded. Two welding processes are required to form the broadband muffler assembly.

[0005] The problems with this approach are:

[0006] 1. It requires two welding processes to form a complete ventilation pipeline with an integrated broadband muffler, which results in a high manufacturing cost.

[0007] Second: The sub-part shape requires two welded ribs, which is heavier. Summary of the Invention

[0008] The purpose of the present invention is to overcome the defects of the above-mentioned prior art and provide a broadband muffler structure, which can reduce weight and welding costs.

[0009] The purpose of the present invention can be achieved through the following technical solutions: a broadband muffler structure, including a pipeline upper piece, a muffler porous plate and a pipeline lower piece, the pipeline upper piece is provided with a groove, and the muffler porous plate is provided with a buckle matching the groove.

[0010] Furthermore, a resonance cavity is integrated on the pipeline upper plate, and the muffler porous plate is connected to the pipeline upper plate by a snap fastener and embedded in the opening of the resonance cavity. The muffler porous plate does not protrude from the inner wall of the pipeline.

[0011] Due to the limitations of the injection molding process, the existing technology often molds the muffler porous plate and the pipeline upper plate into one piece, with the other side open. It needs to be sealed with a resonance cavity cover to form a resonance cavity. Therefore, it is necessary to weld the resonance cavity cover and the pipeline upper plate with the muffler porous plate, and then weld the pipeline upper plate and the pipeline lower plate. Two welding processes are required to form a broadband muffler assembly.

[0012] The muffler porous plate in the present invention is a separate part, and the resonance cavity and the pipeline upper piece are formed in one piece, which avoids the welding process of the resonance cavity cover and the pipeline upper piece of the integrated porous plate in the prior art, simplifies the installation steps, reduces the use of welding ribs, and reduces weight. The opening side is connected to the muffler porous plate through a groove structure. The muffler porous plate is light in weight, simple in structure, and can be connected to the pipeline upper piece without welding, making it easy to install.

[0013] The groove is provided with a locating pin, and the clip is provided with a locating hole that matches the locating pin. During assembly, the locating hole of the muffler porous plate is aligned with the locating pin of the pipeline upper plate, and the muffler porous plate is installed into the pipeline upper plate. During this process, the shape of the locating pin and locating hole guides and positions the clip, allowing it to be installed into the groove. Once installed, the pipeline upper plate and the muffler porous plate form a single unit.

[0014] Furthermore, there are an even number of grooves, symmetrically arranged on the side walls of the pipeline upper plate. The number of clips is the same as the grooves, and they are symmetrically arranged on the edge of the muffler porous plate. The positioning pins and positioning holes are symmetrically arranged on both sides of the broadband muffler structure. The distance between the outer wall surfaces of each pair of positioning holes is slightly smaller than the distance between the outer side walls of each pair of positioning pins. The positioning holes and positioning pins are designed to slightly interfere with each other, with the interference between the outer wall surfaces of the positioning holes and the outer wall surfaces of the positioning pins being 0.1 to 0.5 mm, thereby achieving a tight connection between the muffler porous plate and the pipeline upper plate and preventing it from falling off during the welding process.

[0015] The positioning pin is vertically arranged on the groove and has a truncated cone structure. The positioning hole is an elliptical long hole structure and is vertically arranged on the buckle. This structure facilitates the positioning pin to pass through the positioning hole, improves the guidance and positioning efficiency, and strengthens the connection strength between the groove and the buckle.

[0016] Both the upper and lower pipe sections are equipped with welding ribs, connecting the two sections. These ribs are fused together through welding, completing the assembly of the parts. Welding techniques include vibration friction welding, hot plate welding, infrared welding, infrared vibration friction welding, hot air welding, and laser welding. The shape of the welding ribs must match the selected welding process.

[0017] Furthermore, a protrusion is provided on the outside of the buckle, and a transverse groove corresponding to the protrusion is provided on the groove. The arrangement of the protrusion and the transverse groove can further improve the accuracy of the connection position and the connection strength of the groove and the buckle.

[0018] Furthermore, the protrusion is a rectangular parallelepiped or cube structure with a length of 10 to 20 mm, a width of 2 to 3 mm, and a thickness of 2 to 3 mm. The length, width, and thickness of the transverse groove are respectively the same as those of the protrusion.

[0019] Alternatively, the protrusion and the transverse groove are matching arc surface structures.

[0020] The transverse groove is provided on the welding rib of the pipeline upper plate, and the protrusion is connected to the welding rib via the transverse groove. The protrusion acts as a portion of the welding rib within the length of the transverse groove. Once the muffler porous plate and pipeline upper plate are pre-assembled into a single unit, this portion of the protrusion of the muffler porous plate and the welding rib of the pipeline upper plate participate in welding to the pipeline lower plate, forming a solid assembly after welding.

[0021] The present invention designs the positioning holes and positioning pins to interfere slightly through the above method, thereby strengthening the connection strength of the grooves and the buckles, so that the muffler porous plate can be stuck in the pipeline upper piece after being pre-installed on the pipeline upper piece and will not fall off, making the subsequent welding process feasible.

[0022] After the broadband silencer is assembled, a closed Helmholtz resonance cavity is formed between the upper pipe piece of the integrated resonance cavity and the muffler porous plate. At the same time, a ventilation pipe is formed between the upper pipe piece, the muffler porous plate and the lower pipe piece. The muffler porous plate is integrated with round holes, square holes or holes of other shapes for silencer, thus forming a typical broadband silencer.

[0023] Compared with the prior art, the present invention has the following advantages:

[0024] 1. Low manufacturing cost: The existing design structure requires two welding operations, while the present invention only requires one welding operation to form a broadband muffler assembly, thus saving the manufacturing cost required for one welding operation.

[0025] 2. Lightweight: Existing design structures require the integration of welded ribs twice, while the present invention only requires the integration of welded ribs once, resulting in a lighter weight. This contributes to achieving component weight reduction goals and reducing raw material costs. The weight of existing broadband mufflers can be reduced by 6-8%;

[0026] 3. Easy installation: The muffler porous plate of the present invention is connected to the groove on the pipeline upper plate through a snap-fit ​​structure, and the positioning pins and positioning holes are used for guidance and positioning, so the installation is convenient and fast, and the positioning is accurate;

[0027] 4. High connection strength: The present invention uses a slight interference design of the positioning holes and the positioning pins to ensure a stable connection between the muffler porous plate and the upper piece of the pipeline, which is not easy to fall off, making the subsequent welding process feasible. The protrusion is connected to the welding rib through the transverse groove, so that the protrusion also has the function of a welding rib and can be firmly connected to the upper piece and the lower piece of the pipeline through welding. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] Figure 1 A perspective view of the broadband muffler structure of the present invention;

[0029] Figure 2 An exploded view of the broadband muffler structure of the present invention;

[0030] Figure 3 This is a schematic diagram of the pipeline upper section structure;

[0031] Figure 4 This is the front view of the pipeline;

[0032] Figure 5 Schematic diagram of the muffler porous plate structure;

[0033] Figure 6 This is the front view of the muffler porous plate;

[0034] Figure 7 Schematic diagram of the lower pipe structure Figure 1 ;

[0035] Figure 8 Schematic diagram of the lower pipe structure Figure 2 ;

[0036] Figure 9 This is the installation diagram of the upper and lower pipe pieces;

[0037] Figure 10 Installation front view of the upper and lower pipe pieces;

[0038] Figure 11 Exploded view of the broadband muffler of Comparative Example 1;

[0039] In the figure: 1- pipeline upper piece, 10- positioning pin, 11- groove, 12- transverse groove, 13- resonance cavity, 2- muffler porous plate, 20- positioning hole, 21- buckle, 22- bump, 3- pipeline lower piece, 31- tubular structure, 32- outer retaining rib, 33- inner retaining rib, 4- welding rib, 5- resonance cavity cover. DETAILED DESCRIPTION

[0040] The present invention is described in detail below with reference to the accompanying drawings and specific embodiments. The following embodiments are implemented based on the technical solution of the present invention, and provide detailed implementation methods and specific operating processes, but the protection scope of the present invention is not limited to the following embodiments.

[0041] Example 1

[0042] A broadband muffler structure, such as Figures 1-2 As shown, it includes an upper pipeline piece 1, a lower pipeline piece 3 and a muffler porous plate 2 located therebetween.

[0043] like Figures 3-4As shown, four grooves 11 are symmetrically arranged on the side wall of the pipeline upper piece 1, a positioning pin 10 is provided in the groove 11, and a transverse groove 12 is provided on the top of the groove 11. A circle of welding ribs 4 is provided on the pipeline upper piece 1, and the transverse groove 12 is located on the reinforcing rib 4. The pipeline upper piece 1 is integrated with a resonance cavity 13.

[0044] like Figures 5-6 As shown, the muffler porous plate 2 is provided with a plurality of muffler circular holes, and four buckles 21 matching the groove 11 are symmetrically arranged on the edge. The buckle 21 is provided with a positioning hole 20 matching the positioning pin 10, which plays a guiding and positioning role so that the buckle 21 can be installed in the groove 11. The distance between the outer wall surfaces of each pair of positioning holes 20 on both sides of the broadband muffler structure is slightly smaller than the distance between the outer side walls of each pair of positioning pins 10. A protrusion 22 is provided on the outer side of the buckle 21, corresponding to the transverse groove 12, as shown in FIG. Figures 9-10 As shown, after the installation is completed, the pipeline upper piece 1 and the muffler porous plate 2 form a whole, the muffler porous plate 2 is embedded in the opening of the resonance cavity 13, and the positioning pin 10 and the positioning hole 20 form a slight interference, so that the muffler porous plate 2 and the pipeline upper piece 1 are stably connected and not easy to fall off, and the protrusion 22 is connected to the welding rib 4 after installation, and has the function of a welding rib, and can be firmly connected to the pipeline upper piece 1 and the pipeline lower piece 3 through welding.

[0045] like Figures 7-8 As shown, the pipeline lower plate 3 includes a tubular structure 31 , a circle of outer stop ribs 32 , a circle of inner stop ribs 33 and a circle of welding ribs 4 .

[0046] After the muffler porous plate 2 is connected to the pipe upper piece 1 via a clip 21, the pipe upper piece 1 and the pipe lower piece 3 are connected by welding ribs 4, completing the assembly. A closed Helmholtz resonant cavity is formed between the pipe upper piece 1 and the muffler porous plate 2. A ventilation line is also formed between the pipe upper piece 1, the muffler porous plate 2, and the pipe lower piece 3. The muffler porous plate 2 is integrated with circular holes for sound absorption, forming a broadband muffler structure. This broadband muffler has an inner diameter of 55 mm, a pipe length of 412 mm, a resonant cavity volume of 0.35 L, and a structural weight of 416 g.

[0047] Comparative Example 1

[0048] The structure of the broadband muffler in the prior art is as follows Figure 11As shown, the broadband muffler assembly includes a resonant cavity cover 5, an integrated porous plate upper pipe section 1, and a lower pipe section 3. Each of these sections is provided with welding ribs 4. The resonant cavity cover 5 and the upper pipe section 1 of the integrated porous plate are welded together, followed by welding the upper pipe section 1 and the lower pipe section 3. This requires two welding steps to complete the broadband muffler assembly. The broadband muffler has the same pipe inner diameter, pipe length, and resonant cavity volume as the new broadband muffler, and weighs 447g.

[0049] Compared with comparative example 1, embodiment 1 reduces weight by 7%. It can be seen that the broadband muffler structure of the present invention can reduce weight of the broadband muffler in the prior art, and can contribute to achieving the goal of reducing component weight and reducing raw material costs.

[0050] The above description of the embodiments is intended to facilitate understanding and use of the invention by those skilled in the art. It will be apparent that those skilled in the art can readily make various modifications to these embodiments and apply the general principles described herein to other embodiments without requiring inventive effort. Therefore, the present invention is not limited to the above-described embodiments. Improvements and modifications made by those skilled in the art based on the disclosure of the present invention, without departing from the scope of the present invention, should be within the scope of protection of the present invention.

Claims

1. A broadband muffler structure, comprising a pipeline upper plate (1), a muffler porous plate (2) and a pipeline lower plate (3), characterized in that: The pipeline upper plate (1) is provided with a groove (11), and the muffler porous plate (2) is provided with a buckle (21) matching the groove (11); A positioning pin (10) is provided in the groove (11), and a positioning hole (20) matching the positioning pin (10) is provided on the buckle (21); The grooves (11) are in an even number and are symmetrically arranged on the side wall of the pipeline upper plate (1). The number of the buckles (21) is the same as that of the grooves and they are symmetrically arranged on the edge of the muffler porous plate (2). The positioning pins (10) and the positioning holes (20) are symmetrically arranged on both sides of the broadband muffler structure. The distance between the outer side walls of each pair of positioning holes (20) is slightly smaller than the distance between the outer side walls of each pair of positioning pins (10). The positioning pin (10) is vertically arranged on the groove (11) and has a truncated cone structure. The positioning hole (20) has an elliptical long hole structure and is vertically arranged on the buckle (21). The pipeline upper piece (1) and the pipeline lower piece (3) are both provided with welding ribs (4), and the pipeline upper piece (1) and the pipeline lower piece (3) are connected via the welding ribs (4); The buckle (21) is provided with a protrusion (22) on the outside, and the groove (11) is provided with a transverse groove (12) corresponding to the protrusion (22); The transverse groove (12) is provided on the welding rib (4) of the pipeline upper plate (1), and the protrusion (22) is connected to the welding rib (4) through the transverse groove (12).

2. The broadband muffler structure according to claim 1, characterized in that: The pipeline upper piece (1) is integrated with a resonance cavity (13), and the muffler porous plate (2) is connected to the pipeline upper piece (1) through a buckle (21) and is embedded in the opening of the resonance cavity (13).

3. The broadband muffler structure according to claim 1, characterized in that: The protrusion (22) is a rectangular parallelepiped or cube structure with a length of 10 to 20 mm, a width of 2 to 3 mm, and a thickness of 2 to 3 mm. The length, width, and thickness of the transverse groove (12) are respectively the same as those of the protrusion (22).

4. The broadband muffler structure according to claim 1, characterized in that: The protrusion (22) and the transverse groove (12) are matching arc surface structures.

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