muffler

Abstract

A silencer (20) to be mounted on a panel (10) including a panel body portion and a protrusion (15), the silencer including a panel cover portion (23, 24) covering the panel body portion and a protrusion cover portion extending upward from the panel cover portion and folded to cover the protrusion. The protrusion cover portion includes a first flange cover portion (31) and a second flange cover portion (36) covering the protrusion. The first flange cover portion (31) includes a first flange cover body portion and a fitting portion (32) at an end portion of the first flange cover body portion, and the second flange cover portion (36) includes a second flange cover body portion and a stop portion (37) at an end portion of the second flange cover body portion. With the fitting portion (32) and the stop portion (37) fitted to each other, the protrusion cover portion has a bag shape covering the protrusion (15).

Description

Technical Field

[0001] This disclosure relates to a silencer. Background Technology

[0002] Sound-absorbing muffler pads are installed in various parts of a vehicle. For example, mufflers are installed on the under-engine cover (which is mounted on the lower surface of the engine compartment), the rear surface of the engine hood, and the dashboard that defines the engine compartment and the passenger compartment. Such a muffler is described in Japanese Unexamined Patent Publication No. 2014-51227.

[0003] The component on which the muffler pad is mounted may include a protrusion extending from the mounting surface of the component. For example, to mount the muffler on such a component including the protrusion, the muffler is folded as follows: The portion of the muffler corresponding to the protrusion is folded into a U-shape to form the protrusion. Then, the two ends of the U-shaped protrusion are closed by another component (such as a U-shaped stud) using a tucker, thereby forming a pocket-shaped protrusion. The protrusion of the component fits into the pocket-shaped protrusion of the muffler. Thus, the muffler is properly mounted on the component including the protrusion. Alternatively, one end of the U-shaped protrusion of the muffler can be closed with a fixing component such as a clip and a double-ended bolt.

[0004] However, using U-shaped pins or fixing components made of different materials than those used in the muffler increases the number of parts and material costs. Furthermore, mufflers made with U-shaped pins or fixing components involve different types of materials. This leads to recycling problems when the muffler is discarded. Summary of the Invention

[0005] The technology disclosed herein is characterized by providing a muffler that can be mounted on a component including protrusions without the use of separate mounting components.

[0006] The technology described herein relates to a muffler for mounting on a panel, the panel including a panel body and a protrusion projecting from the panel body. The muffler includes: a panel cover portion that covers the panel body portion; and a protrusion cover portion that extends upward from the panel cover portion and folds to cover the protrusion. The protrusion cover portion includes a first protrusion cover portion covering a first surface of the protrusion and a second protrusion cover portion covering a second surface of the protrusion that is the opposite surface of the first surface. The first protrusion cover portion has an elongated shape and includes a first protrusion cover body portion extending longitudinally and a mounting portion extending relative to the longitudinal direction from at least one end of the first protrusion cover body portion. The second protrusion cover portion has an elongated shape and includes a second protrusion cover body portion extending longitudinally and a stop portion extending relative to the longitudinal direction from at least one end of the second protrusion cover body portion. When the mounting portion and the stop portion are assembled with each other, the protrusion cover portion has a pocket shape covering the protrusion.

[0007] Based on the above construction, even in the case of a panel including protrusions for muffler mounting, the pocket-shaped portion protruding from the muffler's panel surface can be formed on the muffler without the use of additional components. This protrusion can be covered by the pocket-shaped portion. That is, a muffler made of a single material and with good recyclability can be provided.

[0008] The mounting portion may include a base extending from the first protruding cover body portion and a distal end extending from the base portion. The distal end portion may be wider than the base portion. The stop portion may include a stop hole in which the mounting portion is fitted and is narrower than the distal end portion of the mounting portion. With this configuration, a bag-shaped protruding cover portion can be easily obtained.

[0009] The first protruding cover, including the assembly part, and the second protruding cover, including the stop part, can be constructed as a single unitary member. With this construction, a well-recoverable muffler can be easily obtained.

[0010] The first protruding cover, including the mounting portion, and the second protruding cover, including the stop portion, can be made of the same material. With this construction, a well-recycling muffler can be easily obtained.

[0011] The first protruding cover portion may have a first outer surface and a first inner surface, and the second protruding cover portion may have a second outer surface and a second inner surface. When the mounting portion and the stop portion are assembled together, and the protrusion is sandwiched between the first and second protruding cover body portions, the first inner surface may face the second inner surface; and in the mounting portion and the stop portion, the first outer surface may face the second outer surface. With this configuration, the end of the protruding cover portion is definitively closed using a simple structure.

[0012] The base may extend from the first protruding cover body portion along the extending direction and have a first width measured in a width direction perpendicular to the extending direction. The distal end portion may have a second width measured in the width direction, and the second width may be greater than the first width. The distal end portion may have an edge extending from the base portion along the width direction. When the mounting portion and the stop portion are assembled with each other, the edge of the distal end portion of the mounting portion may stop at the edge of the stop hole. According to this configuration, the end of the protruding cover portion is definitively closed with a simple structure.

[0013] According to the technology described herein, a muffler can be provided that can be mounted on a component including protrusions without the use of separate mounting components. Attached Figure Description

[0014] Figure 1 It is a 3D view of a muffler installed on the rear wheel arch panel.

[0015] Figure 2 It is along Figure 1 The cross-sectional view of line II-II in the diagram.

[0016] Figure 3 It is along Figure 1 The cross-sectional view of line III-III in the diagram.

[0017] Figure 4 It is a diagram illustrating the mesh of the protruding cover.

[0018] Figure 5 yes Figure 4 An enlarged view of a portion of the protruding cover.

[0019] Figure 6 It is an enlarged view of a portion of the modified protruding cover.

[0020] Figure 7 This is an enlarged view of a portion of the protruding cover based on another variant.

[0021] Figure 8 This is an enlarged view of a portion of the protruding cover based on another variant. Detailed Implementation

[0022] Reference Figures 1 to 5 One embodiment of this technology will be described. A muffler 20 covering the rear wheel arch panel 10, in which the rear tire of the vehicle is housed, will be described.

[0023] The rear wheel arch panel 10 includes a retractable portion located on the outer side of the vehicle and houses the rear tire within the retractable portion. The rear wheel arch panel 10 is configured as part of the body panel of the vehicle body. The rear wheel arch panel 10 includes at least two panels. Each panel includes a panel body and a flange portion projecting from the edge of the panel body. By joining the flange portions with their surfaces, the panels are configured as a single component. Specifically, as shown in Figure 2, the rear wheel arch panel 10 includes panels, the panels including a first panel 11 and a second panel 13. The first panel 11 includes a first panel body portion 11A and a first flange portion 12 projecting upward from a portion of the edge of the first panel body portion 11A. The second panel 13 includes a second panel body portion 13A and a second flange portion 14 projecting upward from a portion of the edge of the second panel body portion 13A. The first flange portion 12 and the second flange portion 14 are joined to each other with opposing surfaces and are configured as protrusions 15 projecting from the plate surfaces of the first panel body portion 11A and the second panel body portion 13A.

[0024] The protrusion 15 has a rectangular plate shape and dimensions that can be held by the operator. In this embodiment, the protrusion 15 has a protrusion height of approximately 5 cm from the first panel body portion 11A and the second panel body portion 13A and a length extending longitudinally of approximately 15 cm.

[0025] The silencer 20 has sound-absorbing properties and is made of glass wool or felt. The silencer 20 is a flexible padding component. For example... Figure 2 As shown, the muffler 20 has a two-layer structure and includes a soft layer 21 and a hard layer 22 that is harder than the soft layer 21. The muffler 20 is mounted on the rear wheel arch panel 10 with the soft layer 21 in contact with the inner surface of the rear wheel arch panel 10.

[0026] like Figure 1 and Figure 2 As shown, the muffler 20 includes a first cover 23, a second cover 24, and a protruding cover 30. The first cover 23 covers the inner surface of the first panel body 11A. The second cover 24 covers the inner surface of the second panel body 13A. The protruding cover 30 connects the first cover 23 and the second cover 24 and covers the protrusion 15 of the rear wheel arch panel 10.

[0027] Figure 4 This is a plan view illustrating the mesh of the muffler 20 according to this embodiment. The protruding cover portion 30 includes a first flange cover portion 31, a second flange cover portion 36, and a folded portion 35 serving as the boundary between the first flange cover portion 31 and the second flange cover portion 36. The protruding cover portion 30 is folded at the folded portion 35, such that the first flange cover portion 31 and the second flange cover portion 36 are as follows... Figure 2The first flange cover portion 31 is shown opposite to each other. It includes a first flange cover body portion 31A and two mounting portions 32. The first flange cover body portion 31A is continuous from the first cover portion 23. The first flange cover body portion 31A has a rectangular shape and covers the first surface of the protrusion 15 (the first surface of the first flange portion 12). The two mounting portions 32 protrude from both ends of the first flange cover body portion 31A, respectively.

[0028] The second flange cover portion 36 includes a second flange cover body portion 36A and two stops 37. The second flange cover body portion 36A is continuous with the second cover portion 24. The second flange cover body portion 36A has a rectangular shape and covers the second surface of the protrusion 15 (the first surface of the second flange portion 14). The two stops 37 extend from both ends of the second flange cover body portion 36A. The stops 37 have the same width as the second flange cover body portion 36A.

[0029] The first flange cover body portion 31A and the second flange cover body portion 36A have the same dimensions. According to the above configuration, the first flange cover portion 31, including the mounting portion 32, and the second flange cover portion 36, including the stop portion 37, are constructed as a single integral component. The first flange cover portion 31, including the mounting portion 32, and the second flange cover portion 36, including the stop portion 37, are made of the same material.

[0030] The first flange cover body portion 31A and the second flange cover body portion 36A together have a size slightly larger than the size of the protrusion 15 of the rear wheel arch panel 10.

[0031] The mounting portion 32 of the first flange cover portion 31 includes a base 33 and a distal end portion 34 (an example of a distal end portion). The base 33 extends from the middle of each end of the first flange cover body portion 31A with respect to the width direction. The distal end portion 34 further extends from the base 33. The distal end portion 34 is wider than the base 33. In this embodiment, the distal end portion 34 has an isosceles trapezoidal shape. The distal end portion 34 has a bottom base portion that is a long side and continues to the base 33, and an upper base portion that is a short side and is shorter than the bottom base portion. The upper base portion corresponds to the distal end of the mounting portion 32. The distal end portion 34 has a tapered shape.

[0032] The stop portion 37 of the second flange cover 36 includes a stop hole 38 extending through the stop portion 37. The stop hole 38 is opposite to the base 33 of the mounting portion 32 when the protruding cover 30 is folded along the fold portion 35. The stop hole 38 has an isosceles trapezoidal shape. Figure 4 and Figure 5 As shown, the stop hole 38 has a bottom base hole edge that serves as the short side hole edge and is close to the second flange cover body portion 36A, and an upper base hole edge that serves as the long side hole edge, is longer than the bottom base hole edge, and is close to the distal end of the stop portion 37. The bottom base hole edge and the upper base hole edge are opposite to each other.

[0033] Reference Figure 5 The assembly portion 32 and the stop portion 37 will be described in more detail. The dimensions of the stop hole 38 are defined to satisfy the following relationships. Hereinafter, with respect to the hole edges of the stop hole 38, the length of the first hole edge 38A, which is the upper base hole edge, is defined as length C; the length of the hole edges other than the first hole edge 38A is defined as length A; and the length between the first hole edge 38A and the second hole edge 38B is defined as length E. Length A is the sum of the length A2 of the second hole edge 38B, which is the bottom base hole edge, and the lengths A1 and A3 of the two hole edges 38C and 38D between the first hole edge 38A and the second hole edge 38B, which are opposite to each other. With respect to the assembly portion 32, the length of the edge 34A, which is the bottom base of the distal end portion 34 and is close to the first flange cover body portion 31A, is defined as length B; the width of the distal end portion 34, which is the length between the edge 34A and the outer edge 34B, is defined as width D; and the thickness of the distal end portion 34 is defined as F.

[0034] A>B>C and D>E>F

[0035] Under the condition that the above relationship is satisfied, the assembly part 32 can be inserted into the stop hole 38 and stop at the edge of the stop hole 38.

[0036] In this embodiment, dimensions A, B, C, D, and E can represent the following dimensions: Length C is the length of the first hole edge 38A of the stop hole 38 closest to the end of the second flange cover 36 relative to the longitudinal direction. The first hole edge 38A extends linearly along the end of the second flange cover 36. Length C is the largest dimension of the hole edge of the stop hole 38 relative to the width direction of the second flange cover 36. Length A is the total length of the hole edge of the stop hole 38 excluding the length C of the first hole edge 38A. Length E is the maximum opening size of the stop hole 38 relative to the longitudinal direction of the second flange cover 36. Length B is the maximum dimension of the distal end portion 34 relative to the width direction of the first flange cover 31. Length D is the maximum dimension of the distal end portion 34 relative to the longitudinal direction of the first flange cover 31.

[0037] The steps for making the muffler 20 to be installed on the rear wheel arch panel 10 will be explained. First, as... Figure 2As shown, the protruding cover 30 is folded along the fold 35 using a mountain fold, thereby forming a ridge on the side of the hard layer 22. The muffler 20 is folded along the boundary 25 between the first cover 23 and the first flange cover 31 and along the boundary 26 between the second cover 24 and the second flange cover 36 using a valley fold, thereby forming a groove on the side of the hard layer 22. As a result, the first flange cover 31 and the second flange cover 36 protrude upward from the first cover 23 and the second cover 24, respectively, and the first cover 23 and the second cover 24 extend in opposite directions from the boundaries 25 and 26, respectively. Next, the base 33 and the distal end 34 of the mounting portion 32 are inserted into the stop hole 38 in the case of deformation. After being inserted through the stop hole 38, the distal end 34 elastically returns to its shape. Then, as Figure 3 As shown, the base 33 is arranged in the stop hole 38 and the distal end 34 stops at the edge of the stop hole 38. The protruding cover 30 protrudes upward from the first cover 23 and the second cover 24 and is closed at both ends in the longitudinal direction, thus the protruding cover 30 is formed in the shape of a bag.

[0038] The first flange cover portion 31 has a first outer surface and a first inner surface, which respectively serve as the surface of the hard layer 22 and the surface of the soft layer 21. The second flange cover portion 36 has a second outer surface and a second inner surface, which respectively serve as the surface of the hard layer 22 and the surface of the soft layer 21. When the mounting portion 32 and the stop portion 37 are assembled together, and the protrusion 15 is sandwiched between the first flange cover body portion 31A and the second flange cover body portion 36A, the first inner surface faces the second inner surface, and in the mounting portion 32 and the stop portion 37, the first outer surface faces the second outer surface. The base portion 33 extends from the first flange cover body portion 31A along the extending direction (the longitudinal direction of the first flange cover portion 31) and has a first width measured in the width direction perpendicular to the extending direction. The distal end portion 34 has a second width measured in the width direction, and the second width is greater than the first width. The distal end portion 34 has an edge 34A extending from the base portion 33 along the width direction. When the assembly part 32 and the stop part 37 are assembled together, the edge 34A of the distal end 34 of the assembly part 32 stops at the edge 38B of the second hole of the stop hole 38.

[0039] The protruding cover 30 is preferably press-formed before the folded muffler 20. When the protruding cover 30 is press-formed, due to the elastic restoring force of the muffler 20, the assembly 32 that is bent and stopped at the stop hole 38 and the protruding cover 30 that is folded along the fold 35 and the boundaries 25, 26 are not easily restored to their initial state (flat state).

[0040] Specifically, such as Figure 3As shown, when the protruding cover 30 is folded along the fold 35 and the boundaries 25, 26, the base 33 of the mounting portion 32 bends from the first flange cover body portion 31A side of the base 33 and is inclined towards the stop portion 37. The base of the stop portion 37, including the stop hole 38, bends from the second flange cover body portion 36A and is inclined towards the mounting portion 32. With this configuration, the mounting portion 32 can be easily inserted into the stop hole 38 and can be stably maintained through the stop hole 38. When the distal end of the mounting portion 32 is made thinner, the distal end can be easily deformed and the mounting portion 32 can be easily inserted into the stop hole 38.

[0041] Next, the operation and effects will be explained. The muffler 20 of this embodiment is a pad-type muffler and is mounted on the rear wheel arch panel 10, which includes a protrusion 15 projecting from the surface of the rear wheel arch panel 10. The muffler 20 includes a first cover 23, a second cover 24, a first flange cover 31, and a second flange cover 36. The first cover 23 covers the surface of the first panel body portion 11A, and the second cover 24 covers the surface of the second panel body portion 13A. The first flange cover 31 extends upward from the first cover 23, and the second flange cover 36 extends upward from the second cover 24. The first flange cover 31 and the second flange cover 36 engage at their extended ends. The first surface of the protrusion 15 is covered by the first flange cover 31, and the second surface of the protrusion 15 opposite to the first surface is covered by the second flange cover 36. The first flange cover 31 includes mounting portions 32 at both ends relative to the longitudinal direction. The second flange cover 36 includes a stop 37 at both ends relative to the longitudinal direction. The stop 37 includes a stop hole 38 for mounting the assembly part 32. When the assembly part 32 is mounted in the stop hole 38, the first flange cover 31 and the second flange cover 36 are connected to each other to form a bag shape and cover the protrusion 15.

[0042] Based on the above construction, even in the case of a rear wheel arch panel 10 including the protrusion 15 on which the muffler 20 is to be installed, the pocket-shaped portion protruding from the panel surface of the muffler 20 can be formed on the muffler 20 without the use of additional components. The protrusion 15 can be covered by the pocket-shaped portion. That is, a muffler 20 made of a single material and with good recyclability can be provided.

[0043] The assembly portion 32 includes a base 33 and a distal end portion 34 extending from the base 33 and being wider than the base 33. The stop hole 38 is narrower than the distal end portion 34 and the distal end portion 34 is stopped by the edge of the stop hole 38.

[0044] <Variation>

[0045] The structure of the assembly part and the stop hole is not limited to the structure described in the above embodiments, but can be as follows: Figures 6 to 8The variation shown. The assembly and stop hole can have any construction, as long as dimensions A to F satisfy the above relationships. In Figures 6 to 8 In the construction, symbols A to F represent dimensions similar to those in the first embodiment.

[0046] exist Figure 6 In the illustrated configuration, the distal end 44 of the mounting portion 42 has a triangular shape, and the apex of the triangle is arranged relative to the longitudinal direction of the end of the first flange cover 41. Length D is the maximum longitudinal length of the distal end 44 relative to the first flange cover 41. The stop hole 48 has a similar triangular shape to the distal end 44. The apex of the triangular hole edge of the stop hole 48 is arranged relative to the longitudinal direction of the end of the second flange cover 46. Length E is the maximum opening width of the stop hole 48 relative to the longitudinal direction of the second flange cover 46. The length A of the hole edge of the stop hole 48 is the sum of lengths A1 and A2.

[0047] exist Figure 7 In the illustrated configuration, the distal end 54 of the mounting portion 52 has a semi-circular shape and its end is curved. That is, the end of the first flange cover 51 is curved relative to the longitudinal direction. Length D is the maximum length of the distal end 54 relative to the longitudinal direction of the first flange cover 51. The stop hole 58 has a semi-circular shape similar to the distal end 54. The curved opening edge of the stop hole 58 is arranged to be away from the end of the second flange cover 56 relative to the longitudinal direction. Length E is the maximum opening width of the stop hole 58 relative to the longitudinal direction of the second flange cover 56. The length A of the hole edge of the stop hole 58 is the length of the curved opening edge.

[0048] exist Figure 8 In the illustrated configuration, the distal end portion 64 of the mounting portion 62 has a rectangular shape and is arranged such that the short side of the distal end portion 64 corresponds to the longitudinal direction of the first flange cover portion 61. Length D is the maximum length of the distal end portion 64 relative to the longitudinal direction and is the length of the short side of the distal end portion 64. The stop hole 68 has a similar rectangular shape to the distal end portion 64. Length E is the maximum opening width of the stop hole 68 relative to the longitudinal direction of the second flange cover portion 66 and is the length of the short side of the distal end portion 64.

[0049] <Other Implementation Methods>

[0050] The techniques described herein are not limited to the embodiments and variations shown in the accompanying drawings. The scope of this disclosure may include the following embodiments and all variations within the scope of the claims or their equivalents.

[0051] (1) In the above embodiments and variations, the muffler 20 is configured to cover the protrusion 15, which is formed by combining the first flange portion 12 and the second flange portion 14 of the two panels 11, 13. However, the technique described herein can be applied to rib-like protrusions protruding from the surface of a plate.

[0052] (2) In the above embodiments and variations, the assembly portion, including the distal end, is inserted into the stop hole; however, the construction of the assembly portion and the stop portion is not limited to those constructions in the above embodiments and variations, and can be appropriately modified. For example, a slit may be included instead of the stop hole.

[0053] (3) In the above embodiments and variations, the two ends of the protruding cover 30 are closed by the mounting part (32) and the stop part (stop hole 38). However, the following bag-shaped structure can be included in this technology: one end of the protruding cover is closed by the mounting part and the stop part, and the other end is not closed by such a structure but is fixedly closed.

Claims

1. A muffler for mounting on a panel, the panel including a panel body and a protrusion projecting from the panel body, the muffler comprising: A panel cover that covers the panel body; as well as A protruding cover portion, which extends upward from the panel cover portion and folds to cover the protrusion, the protruding cover portion including a first protruding cover portion covering a first surface of the protrusion and a second protruding cover portion covering a second surface of the protrusion that is the opposite surface of the first surface. The first protruding cover has an elongated shape and includes a first protruding cover body extending longitudinally and a mounting portion extending from at least one end of the first protruding cover body relative to the longitudinal direction. The second protruding cover has an elongated shape and includes a second protruding cover body extending along the longitudinal direction and a stop extending from at least one end of the second protruding cover body relative to the longitudinal direction, wherein When the mounting portion and the stop portion are assembled together, the protruding cover portion has a bag shape that covers the protrusion. The assembly portion includes a base extending from the first protruding cover body portion and a distal end extending from the base. The distal end is wider than the base, and The stop portion includes a stop hole for mounting the assembly portion and narrower than the distal end of the assembly portion.

2. The silencer according to claim 1, wherein, The first protruding cover portion including the assembly portion and the second protruding cover portion including the stop portion are constructed as a single integral component.

3. The silencer according to claim 1 or 2, wherein, The first protruding cover, including the assembly portion, and the second protruding cover, including the stop portion, are made of the same material.

4. The silencer according to claim 1 or 2, wherein, The first protruding cover has a first outer surface and a first inner surface, and the second protruding cover has a second outer surface and a second inner surface. When the assembly portion and the stop portion are assembled together, in the first protruding cover body portion and the second protruding cover body portion, the first inner surface and the second inner surface face each other while the protrusion is clamped, and in the assembly portion and the stop portion, the first outer surface and the second outer surface face each other.

5. The silencer according to claim 1, wherein, The base extends from the first protruding cover body portion along the extending direction and has a first width measured in a width direction perpendicular to the extending direction. The distal end has a second width measured in the width direction, and the second width is greater than the first width. The distal end has an edge extending from the base along the width direction, and When the assembly part and the stop part are assembled together, the edge of the distal end of the assembly part stops at the edge of the stop hole.

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