Muffler, manufacturing method thereof and fuel cell system

Abstract

The invention relates to a muffler, in particular for a fuel cell system, comprising a tubular muffler housing (24) made of plastic material and extending longitudinally in the direction of a muffler longitudinal axis (L), a first muffler end piece made of plastic material and fastened to the muffler housing (24) at a first axial end (26) of the muffler housing (24), and a second muffler end piece made of plastic material and fastened to the muffler housing (24) at a second axial end (26) of the muffler housing (24), the invention relates to a muffler (22) for a motor vehicle, comprising a muffler housing (24), a second muffler end part (28) made of a plastic material, which is fastened to the muffler housing (24) at a second axial end (30) of the muffler housing (24), and at least one fastening element (41) on at least one muffler end part (28, 32) for fastening the muffler (22) to a support structure (T). The invention also relates to a fuel cell system, in particular for a vehicle, and to a method for producing a muffler (22).

Description

Technical Field

[0001] The present invention relates to a muffler, which is particularly useful in the exhaust system of a fuel cell system in a vehicle, for reducing noise generated in the fuel cell system and propagating through the exhaust gas of the fuel cell. Background Technology

[0002] Noise generated during the operation of a fuel cell system, for example by a compressor or other equipment, is strongly dependent on the structure of the fuel cell itself, such as a PEM fuel cell, which is constructed as a fuel cell stack or comprises one or more fuel cell stacks, and especially on the dimensions chosen for the fuel cell power to be generated. Efficient reduction of noise generated during fuel cell operation and transmitted or propagated in the fuel cell exhaust requires a corresponding design of the dimensions of the muffler installed in the exhaust system of such a fuel cell system. For example, the available structural space in a vehicle is also a factor influencing the design of the muffler's dimensions. Summary of the Invention

[0003] The objective of this invention is to provide a muffler, particularly for use in fuel cell systems, which can be constructed in a simple manner and method to suit different purposes or environments.

[0004] According to a first aspect of the invention, this task is accomplished by a muffler, particularly for fuel cell systems, comprising:

[0005] - A tubular muffler housing made of plastic material extending longitudinally along the longitudinal axis of the muffler.

[0006] - A first muffler end component made of plastic material, fixed to the first axial end of the muffler housing.

[0007] - A second muffler end component made of plastic material, fixed to the second axial end of the muffler housing.

[0008] - At least one fixing element on at least one muffler end component for securing the muffler to the supporting structure.

[0009] The muffler constructed according to the invention is modularly constructed with a muffler housing made of plastic material and two muffler end components also made of plastic material. Since the noise reduction characteristics of such a muffler are essentially determined by the volume enclosed by the muffler housing, the length of the muffler housing extending between the two muffler end components can be selected accordingly to accommodate such a muffler. The muffler housing, selected or provided in accordance with a specific operating environment, can be connected to the muffler end components, which are constructed as standard components, and the composite of the muffler housing and muffler end components thus constructed can be integrated into the operating environment, i.e., in a vehicle, by means of fixing elements also constructed as standard components.

[0010] To facilitate a simple and reliable connection between the muffler end components and the muffler housing, and similarly to easily integrate the muffler thus constructed into the intended operating environment, it is proposed that at least one of the first and second muffler end components, preferably each muffler end component, includes an end component plate connected to the muffler housing and an end component fitting extending from the end component plate in a direction away from the muffler housing.

[0011] Especially when considering the exhaust temperature generated during fuel cell operation, the stable connection of the muffler components can be achieved, for example, by having at least one of the first and second muffler end components, preferably each muffler end component, connected to the muffler housing by material locking, preferably bonding or welding, such as friction welding or ultrasonic welding.

[0012] Alternatively to or attached to a material locking connection, in another connection method used on one or two muffler end components of the muffler housing, at least one of the first and second muffler end components, preferably each muffler end component, is connected to the muffler housing by form-locking.

[0013] To simply provide this shape-locking connection, it is proposed that at least one shape-locking engagement opening for a shape-locking engagement mechanism is provided on at least one of the first muffler end components and the second muffler end component and / or on the muffler housing, and at least one shape-locking engagement mechanism is engaged in at least one shape-locking engagement opening, preferably in each shape-locking engagement opening.

[0014] In order to establish a shape-locking engagement according to the type of locking mechanism, at least one shape-locking engagement opening may be provided on the muffler housing in relation to at least one of the first and second muffler end components, and at least one shape-locking engagement mechanism may be provided on the at least one of the first and second muffler end components in relation to at least one shape-locking engagement opening, preferably each shape-locking engagement opening.

[0015] To achieve an airtight structure, at least one of the first and second muffler end components may have a shape-locking edge that overlaps the muffler housing on the outer or inner side in the direction of the muffler's longitudinal axis. The at least one shape-locking fitting mechanism may extend from the shape-locking edge toward the muffler housing as an integrated component of the at least one muffler end component and fit into a corresponding shape-locking fitting opening.

[0016] In the case of using a shape-locking fitting mechanism constructed as a separate component, an alternative design for the shape-locking connection is proposed to provide at least one shape-locking fitting opening for the shape-locking fitting mechanism on at least one of the first muffler end components and the muffler housing, and the shape-locking fitting mechanism is fittedly into at least one pair of overlapping shape-locking fitting openings on the muffler housing and on at least one of the first and second muffler end components.

[0017] In this shape-locking design, at least one of the first and second muffler end components can be provided with a shape-locking edge that overlaps the muffler housing on the outer or inner side in the direction of the muffler's longitudinal axis. At least one shape-locking fitting opening can be provided in the shape-locking edge, which is provided in the at least one of the first and second muffler end components.

[0018] In a design scheme where the shape-locking fitting mechanism is a separate component, at least one shape-locking fitting mechanism, preferably each shape-locking fitting mechanism, may include a screw or a rivet.

[0019] To improve stability and support airtight sealing, a sealing edge is provided on at least one of the first and second muffler end components, with a radially spaced sealing edge, and the axial end of the muffler housing is embedded between the shape-locking edge and the sealing edge.

[0020] In order to design the structure as cost-effectively as possible by using common components, the first muffler end component and the second muffler end component can be constructed identically to each other.

[0021] For the purpose of fixing the element, it is proposed that at least one of the first muffler end components and the second muffler end component, preferably each muffler end component, is provided with at least one fixing area for fixing the fixing element to the at least one muffler end component.

[0022] To improve variability and / or stability when integrating the muffler constructed according to the invention into the operating environment, two fixing regions can be provided on the at least one muffler end component, respectively for fixing fixing elements to the at least one muffler end component.

[0023] In order to support the corresponding fixing elements on the muffler end members, it is proposed that each fixing region provided on at least one muffler end member has at least one fixing element abutment surface, and the fixing element abutment surfaces assigned to two fixing regions are oriented substantially away from each other relative to the longitudinal axis of the muffler.

[0024] A stable connection of the fixing element to the corresponding muffler end component can be ensured, for example, by having at least two fixing points in each fixing area, wherein at each fixing point, the fixing element can be fixed to the at least one muffler end component by a fixing mechanism, preferably a screw.

[0025] Here, a reliable connection is ensured even under strong mechanical loads by the following method: each fixing part includes an internal thread mechanism embedded in the plastic material of the at least one muffler end component, preferably, the internal thread mechanism is constructed of metal material.

[0026] Each fixed area may include at least one fixed protrusion connected to the end component plate and end component pipe joint of the at least one muffler end component. Therefore, the structural strength of the muffler end component in the area of ​​the end component plate or end component pipe joint is not affected by the connection of one or more fixed elements. More specifically, such fixed protrusions contribute to improving the stability of the muffler end component.

[0027] If, as specified herein, each fixed area and each fixed part is associated with a fixed protrusion, wherein the fixed protrusions associated with the fixed area are arranged at intervals, then despite the high structural strength, excessive plastic material is avoided in constructing the muffler end components.

[0028] For connection to or on a fixed area of ​​a muffler end component, each fixing element may include a mating fixing area for fixing to the fixed area.

[0029] To improve noise reduction characteristics, noise reduction material can be arranged in the muffler housing. This noise reduction material may include, for example, porous and / or foamed materials and / or fibrous materials and / or may at least partially cover the inner surface of the muffler housing.

[0030] Because water is generated during the operation of the fuel cell or is contained in the fuel cell exhaust gas, for example in the form of steam, a liquid collection molding section, preferably extending along the longitudinal axis of the muffler, can be provided on the circumferential area of ​​the muffler housing in order to collect condensed or deposited water in the area of ​​such a muffler.

[0031] To improve the stability of the muffler constructed according to the present invention, at least one reinforcing rib, preferably multiple reinforcing ribs arranged successively in the direction of the longitudinal axis of the muffler and / or multiple reinforcing ribs arranged successively in the circumferential direction around the longitudinal axis of the muffler can be provided on the outer side of the muffler housing.

[0032] Alternatively or additionally, at least one reinforcing rib, preferably multiple reinforcing ribs arranged successively in the direction of the longitudinal axis of the muffler and / or multiple reinforcing ribs arranged successively in the circumferential direction around the longitudinal axis of the muffler may be provided on the inner side of the muffler housing.

[0033] If at least one reinforcing rib, preferably each reinforcing rib, extends substantially in the direction of the muffler's longitudinal axis and / or if at least one reinforcing rib, preferably each reinforcing rib, extends substantially in the circumferential direction around the muffler's longitudinal axis, then the most uniform reinforcement can be achieved when the muffler housing is easily manufactured.

[0034] The present invention also relates to a fuel cell system, particularly for use in vehicles, comprising at least one fuel cell and a fuel cell exhaust device for containing the exhaust gas of the at least one fuel cell, the fuel cell exhaust device having at least one muffler constructed according to the present invention.

[0035] According to another aspect, the task mentioned at the beginning is solved by a method for manufacturing a muffler constructed according to the present invention, the method comprising the following measures:

[0036] a) A muffler housing is provided by separating the longitudinal section from the muffler housing blank.

[0037] b) Provide a first muffler end component and a second muffler end component.

[0038] c) Fix the first muffler end component to the first axial end of the muffler housing and fix the second muffler end component to the second axial end of the muffler housing.

[0039] To facilitate the simple and cost-effective provision of muffler housings, the muffler housing blanks used in measure a) for providing muffler housings may be manufactured by extrusion or blow molding.

[0040] Because the muffler end components can have relatively complex shapes compared to the muffler housing, it is advantageous that the first and second muffler end components are manufactured using plastic casting methods.

[0041] To define the noise reduction characteristics in a specific way, measure a) may include measure a1 for arranging noise reduction material in the muffler housing.

[0042] Here, if measure a1) includes arranging the silencing material blank in the muffler housing blank before separating the longitudinal section, a muffler housing with silencing material integrated into the muffler housing can be provided in a simple manner. Alternatively or additionally, measure a1) may include arranging at least one silencing material body in the longitudinal section after separating the longitudinal section.

[0043] To ensure a stable connection between the muffler housing and the muffler end components, measure c) includes securing the first and second muffler end components to the muffler housing by material locking, preferably adhesive or welding, and / or by form locking.

[0044] In order to configure the muffler for installation in the operating environment, and in addition to measure d) which is preferably performed after measure c), at least one fixing element may preferably be fixed on at least one of the first muffler end components and the second muffler end components, preferably each muffler end component, by screwing. Attached Figure Description

[0045] The present invention will now be described in detail with reference to the accompanying drawings. It is shown that:

[0046] Figure 1 A side view of a muffler used in an exhaust system for a fuel cell system is shown.

[0047] Figure 2 Show Figure 1 A three-dimensional view of the muffler.

[0048] Figure 3 Show Figure 1 and Figure 2 muffler along Figure 2 Axial view in line of sight III;

[0049] Figure 4 It shows a fixing element that is fixed to the end component of the muffler. Figure 1 and 2 A three-dimensional view of the muffler;

[0050] Figure 5 Show Figure 1 and 2 The muffler housing is connected to only one muffler end component;

[0051] Figure 6 Showing the use of Figure 1 and 2 The fixed components of the muffler;

[0052] Figure 7 The alternative design options for the muffler housing are shown below. Figure 5 The illustration;

[0053] Figure 8 The alternative design options for the muffler housing are shown below. Figure 5 Another illustration;

[0054] Figure 9 The alternative design options for the muffler housing are shown below. Figure 5 Another illustration;

[0055] Figure 10 The alternative design options for the muffler housing are shown below. Figure 5 Another illustration;

[0056] Figure 11 An alternative method for connecting the muffler end components to the muffler housing is shown;

[0057] Figure 12 Shown in Figure 11 Detailed views of the design method shown in the image;

[0058] Figure 13 This illustrates an alternative method for connecting the muffler end components to the muffler housing;

[0059] Figure 14 A schematic diagram of a fuel cell system is provided. Detailed Implementation

[0060] In the following reference Figures 1 to 13 Before describing the structure of the muffler in detail, refer to Figure 14 The structure of fuel cell system 10 is explained, and this silencer can be used in fuel cell system.

[0061] The fuel cell system 10 includes, for example, a fuel cell 12 configured as a fuel cell stack, particularly a PEM fuel cell, having an anode region 14 and a cathode region 18 separated from the anode region 14 by a polymer membrane 16. The anode region 14 is supplied with hydrogen (H2) or a hydrogen-containing gas as the anode gas. The cathode region 18 is supplied with oxygen or an oxygen-containing gas, such as air (L), as the cathode gas. The cathode exhaust gas and / or anode exhaust gas generated during fuel cell operation are supplied as fuel cell exhaust gas to the exhaust gas device 20 of the fuel cell system 10 and discharged into the environment through the exhaust gas device 20.

[0062] The exhaust gas treatment device 20 may include various system areas. In particular, the exhaust gas treatment device 20 may include a muffler 22 mounted on a supporting structure T, such as the underside of a vehicle, for reducing noise generated during the operation of the fuel cell system 10, so that such noise is emitted into the environment through the fuel cell exhaust gas with little or no noise. Additional system areas may also be provided in the exhaust gas treatment device 20, such as a separate water separator for separating water or vapor contained in the fuel cell exhaust gas.

[0063] The following reference Figures 1 to 13 The structure of the silencer 22 or the process of manufacturing the silencer 22 of the exhaust gas equipment 20 are explained in combination with different design methods of such silencer 22.

[0064] The muffler 22 extends substantially longitudinally in the direction of the muffler's longitudinal axis L and has a tubular muffler housing 24 extending longitudinally in the direction of the muffler's longitudinal axis L. Since the temperature of the fuel cell exhaust gas typically does not exceed 120°C, the fuel cell housing 24 is made of plastic material for cost and weight reasons.

[0065] The first muffler end component 28 is fixed to the first axial end 26 of the fuel cell housing 24. The first muffler end component 28 is also made of plastic material and can be firmly and airtightly connected to the muffler housing 24 by material locking, such as by bonding or welding, especially friction welding or ultrasonic welding.

[0066] A second muffler end component 32 is fixed to the second axial end 30 of the muffler housing 24. The second muffler end component 32, which has the same structure as the first muffler end component 28 (i.e., the same construction as the first muffler end component), is also connected to the muffler housing 24 by material locking. Since the two muffler end components 28 and 32 are identically constructed, and preferably, the muffler housing 24 has a cylindrical shape in the direction of the muffler's longitudinal axis L (i.e., a shape with a constant cross-section), the entire muffler 22 is constructed to be substantially mirror-symmetrical with respect to the muffler center plane E, which is orthogonal to the muffler's longitudinal axis L.

[0067] As in Figure 2 and 3 As can be seen by means of a first muffler end member 28 fixed to the first end 26 of the muffler housing 24, each of the two muffler end members 28, 32 with identical construction has an end member plate 34 connected to the muffler housing 24 and an end member connector 36 extending from the end member plate 34 toward the muffler housing 24. Further tubular or flexible exhaust gas guiding assemblies of the exhaust gas device 20 can be connected to the end member connector 36.

[0068] Each of the two muffler end components 28 and 30 has two fixing regions 38 and 40. Fixing is possible in each fixing region 38 and 40. Figure 6 The fixing element 41 is shown. With the aid of this fixing element 41, the muffler 22 can be fixed to the supporting structure T.

[0069] Each fixed region 38, 40 includes two fixed portions 42, 44 or 46, 48. Each fixed portion 42, 44, 46, 48 includes fixed protrusions 50, 52, 54, 56 configured as integrated components of the corresponding muffler end components 28, 32, which extend into or connect to the end component plate 34 in the adjacent region of the end component connector 36. Figure 3 As can be seen, there is a gap between the two fixed protrusions 50, 52 or 54, 56 that are assigned to the corresponding fixed areas 38, 40. This avoids the excessive use of plastic materials in constructing the muffler end parts 28, 32 while maintaining high structural strength.

[0070] In each of the said fixing protrusions 50, 52, 54, 56, to provide the corresponding fixing portion 42, 44 or 46, 48, an internally threaded mechanism 58, 60, 62, 64 constructed in the manner of a nut is provided. The internally threaded mechanisms 58, 60, 62, 64 can be cast, for example, during the plastic casting process of the muffler end components 28, 32 by the plastic construction material for the muffler end components 28, 32. Alternatively, the internally threaded mechanisms 58, 60, 62, 64 can be subsequently introduced into the muffler end components 28, 32 and fixed therein, for example, by adhesive bonding. In another alternative design, the fixing portions 42, 44, 46, 48 can include openings provided in the respective fixing protrusions 50, 52, 54, 56, which can be, for example, constructed with internal threads, or can accommodate the insertion of the fixing element 41 and... Figure 4 The visible fixing mechanism 66, for example, a screw screwed into the opening.

[0071] Each of the fixing regions 38 and 40 provides a fixing element abutment surface 68, 70 or 72, 74 on its two fixing protrusions 50, 52 or 54, 56, to which a corresponding plate-shaped mating fixing region 76 of the fixing element 41 can abut. A through opening 78, 80 is provided in the mating fixing region 76, through which a fixing mechanism 66 can be inserted into the fixing protrusions 50, 52, 54, 56. The fixing mechanism 66 is used to fix the corresponding fixing element 41 to one of the fixing regions 38 and 40.

[0072] For connection to the load-bearing structure T, preferably, the fastening elements 41 with identical structures, i.e., identical constructions, may have an arm 82 extending from the mating fastening region 76, with a connecting element 84, for example, constructed of an elastic material, at the end of the arm away from the mating fastening region 76. Another fastening mechanism, such as a screw, can be introduced into the load-bearing structure T through this connecting element, thereby ensuring that the corresponding fastening element 41 is securely connected to the load-bearing structure T.

[0073] As in Figure 5 As clearly seen, the muffler housing 24, preferably cylindrical in shape, is constructed along the longitudinal axis L of the muffler and has a bottom region 86 in its circumferential area. An arcuate region 88 providing another circumferential area of ​​the muffler housing 24 is adjacent to this bottom region. The bottom region 86 is sloped on both sides toward the liquid collection and forming section 90, so that liquid deposited in the internal region of the muffler 22 collects in the bottom region 86 or the liquid collection and forming section 90, which is vertically positioned below. Apart from the openings in the end member connectors 36 of the muffler end members 28, 32 for introducing and discharging fuel cell exhaust gas, the muffler 22 has no other openings in the muffler housing 24 or the muffler end members 28, 32. During fuel cell operation in the muffler 22, the liquid collected in the region of the liquid collection and forming section 90 is discharged from the muffler again through the relatively hot fuel cell exhaust gas flowing through the muffler 22.

[0074] Figure 5 It is also shown that a sound-absorbing material 92 is arranged inside the muffler 22. The sound-absorbing material 92 may, for example, cover the inner surface 94 of the muffler housing 24 in the arcuate region 88. The sound-absorbing material 24 may be constructed using a porous material such as open-cell foam and thus contribute efficiently to reducing noise propagating in the fuel cell exhaust gas through absorption. In an alternative design, the sound-absorbing material 92 may be constructed using a fibrous material, such as PET nonwoven fabric.

[0075] When manufacturing the muffler 22, the two muffler end components 28 and 32, which have the same structure as previously described, can be manufactured as standard components using a plastic casting method (e.g., injection molding). This allows the muffler end components 28 and 32 to be provided in a simple and precise manner using relatively complex shapes.

[0076] The muffler housing 24 can be provided by separating the longitudinal section A from the muffler housing blank. The muffler housing blank can be manufactured, for example, by extrusion or blow molding, and has substantially any cross-sectional geometry and length. From this muffler housing blank, a muffler housing 24 with a longitudinal section A of a length suitable for the corresponding use and the noise reduction characteristics to be achieved therefor can be separated and provided for further manufacturing of the muffler 22.

[0077] On the muffler housing 24 thus provided, two muffler end parts 28, 32 can be connected to two axial ends 26, 30 by material locking. Preferably, after the muffler end parts 28, 32 are connected to the muffler housing 24, the fixing element 41 is mounted on one or two fixing areas 38, 40 on the two muffler end parts 28, 30.

[0078] The sound-absorbing material 92 can be provided inside the muffler housing 24, for example, by incorporating it into the muffler housing blank during its manufacture. For instance, during the manufacture of the muffler housing blank, the sound-absorbing material blank can be formed using the structural material of the muffler housing 23, or it can be pressed into the muffler housing blank. Then, the corresponding longitudinal section of the sound-absorbing material is separated from the sound-absorbing material blank when the longitudinal section A is separated from the muffler housing blank.

[0079] Alternatively, after separating the longitudinal section A from the muffler housing blank, a sound-absorbing material body can be pushed or pressed into the longitudinal section A. This sound-absorbing material body can be provided, for example, by separating the sound-absorbing material blank. Multiple such sound-absorbing material bodies can also be arranged in the muffler housing 24, and there is a possibility of combining the two alternatives described above for providing sound-absorbing material 92 in the muffler housing 24.

[0080] The sound-absorbing material 92 is axially and firmly held in the muffler housing 24 by two muffler end parts 28, 32 connected to its axial ends 26, 30, so that no additional fixing measures are required.

[0081] Utilizing the muffler constructed according to the invention, or the method for manufacturing it, it is possible in a simple manner to adapt the muffler to different operating environments by using standard components. Specifically, a muffler housing with a length configured for the desired noise reduction characteristics is provided, adapted to the corresponding operating environment, and muffler end components, constructed as universal parts, are connected to the two axial ends of the muffler housing. Standard manufacturing methods and, in particular, standard materials can be used to manufacture all components of the muffler. This results in a simple and reliable manufacturing process and, on the other hand, a muffler structure suitable for the intended use without significant additional adaptation measures.

[0082] Since the muffler end components mounted on the axial ends of the muffler housing are used to connect fixing elements configured to secure the muffler to the load-bearing structure, no structural measures are required on the muffler housing itself for attaching such fixing elements. This supports the simple manufacturability of the muffler housing by separating the longitudinal sections from the prefabricated muffler housing blank.

[0083] Figure 7 The alternative design of the muffler housing 24 is shown in the diagram. Figure 5 The diagram shows that a plurality of reinforcing ribs 100 extending outward from the outer surface 98 and substantially in the direction of the muffler's longitudinal axis L are provided on the outer side 96 of the muffler housing 24. The reinforcing ribs 100 provided in the arcuate region 88 have substantially uniform spacing from each other in the circumferential direction surrounding the muffler's longitudinal axis L. Such reinforcing ribs 100 extending in the direction of the muffler's longitudinal axis L may also be provided in the bottom region 86, for example, in the region of the collection forming section 90. For example, a plurality of reinforcing ribs 100 extending substantially in the direction of the muffler's longitudinal axis L in a laterally parallel arrangement may also be provided in the bottom region 86.

[0084] exist Figure 8 In the alternative design shown, the reinforcing ribs 100 on the arcuate region 88 and the bottom region 86 are configured to extend inwardly from the inner surface 94 on the inner side 102 of the muffler housing 24. These reinforcing ribs 100 also extend substantially in the direction of the muffler's longitudinal axis L. The reinforcing ribs 100 provided on the arcuate region 88 are embedded in the sound-absorbing material 92 and thus help to additionally and shape-lock the sound-absorbing material.

[0085] Because Figure 7 and 8In the design of the muffler housing 24 shown, the reinforcing ribs 100 extend substantially in the direction of the muffler longitudinal axis L, which also substantially corresponds to the manufacturing direction when the muffler housing blank is manufactured during the extrusion process, so these reinforcing ribs 100 can be formed together when the muffler housing blank is extruded.

[0086] Since end faces are also formed in the region of the reinforcing ribs 24 when the longitudinal sections are separated from the muffler housing blank used to provide the muffler housing 24, a larger total surface area is provided for the material-locking connection of the muffler end members 28, 32 to the muffler housing 24. For this purpose, it is particularly advantageous when the reinforcing ribs 100 are provided on the outer side 96 of the muffler housing 24 (as is especially true in...). Figure 7 As can be seen in the image, the end member plates 34 of the muffler end members 28 and 32 protrude radially outward beyond the outer side 96 of the muffler housing 24, preferably to such an extent that they terminate radially outward flush with the reinforcing ribs 100.

[0087] It should be emphasized that such reinforcing ribs 100, which extend substantially in the direction of the muffler's longitudinal axis L, can be provided not only on the outer side 96 but also on the inner side 102 of the muffler housing 24.

[0088] Alternative design options for the muffler housing 24 are as follows: Figure 9 As shown in the figure. In this design, a reinforcing rib 104 is provided on the outer side 96, projecting radially outward from the outer surface 98 relative to the longitudinal axis L of the muffler and extending substantially in a circumferential direction around the longitudinal axis L of the muffler. The reinforcing ribs 104 arranged successively in the direction of the longitudinal axis L of the muffler preferably have a uniform spacing from each other.

[0089] exist Figure 10 In a variation of this design shown, the reinforcing ribs 104, extending circumferentially around the longitudinal axis L of the muffler, are arranged radially inward on the inner side 102 relative to the inner surface 94. To make these visible, in... Figure 10 The sound-absorbing material 92 is shown in a transparent manner.

[0090] The reinforcing ribs 104 extending in the circumferential direction around the longitudinal axis L of the muffler preferably extend uninterruptedly along the outer side 96 or the inner side 102 of the muffler housing 24. It is also feasible in this design to provide such reinforcing ribs 104 extending in the circumferential direction around the longitudinal axis L of the muffler not only at the outer side 96 but also at the inner side 102.

[0091] To manufacture the muffler housing 24 with reinforcing ribs 104 or the muffler housing blank for this purpose, a blow molding process is preferably used, which is also capable of manufacturing a muffler housing blank with a profile that varies in its longitudinal direction.

[0092] about Figures 7 to 10 The design of the muffler housing 24 shown herein should be further noted, as these four different design approaches can be combined with each other in any desired manner. Any type of reinforcing ribs 100, 104 can be provided on the outer side 96 and the inner side 102, such that, for example, a grid-like pattern of the reinforcing ribs 100, 104 is also present on the outer side 96 and / or the inner side 102. The reinforcing ribs 100 or 104 can also have an orientation deviating precisely from the orientation in the direction of the muffler's longitudinal axis L or in the circumferential direction around the muffler's longitudinal axis, such that, for example, the reinforcing rib 100 forms a spiral reinforcing pattern. In this case, a blow molding process is particularly suitable for manufacturing such a muffler housing 24 or a muffler housing blank.

[0093] Figure 11 and 12 Alternative methods of connecting each muffler end component 28, 32 to the muffler housing 24 are exemplarily shown by means of the muffler end component 28. Figure 11 In the muffler end component 28 visible in the image, a shape-locking edge 106 protruding from the end component plate 34 of the muffler end component in the direction of the muffler longitudinal axis L is constructed as an integrated component of the muffler end component 28. The shape-locking edge 106 overlaps the muffler housing 24 at the outer side 96 of the muffler housing.

[0094] In the shape-locking edge 106 and the muffler housing 24, the shape-locking fitting openings 108 and 110 are preferably arranged successively at uniform intervals in the circumferential direction, such that when the shape-locking edge 106 axially overlaps the muffler housing 24, the shape-locking fitting opening 108 corresponding to 112 is formed in the shape-locking edge 106 and the shape-locking fitting opening 110 is formed in the muffler housing 24.

[0095] The form-locking action, acting in the direction of the muffler's longitudinal axis L, is achieved by form-locking engagement mechanisms 114 constructed as screws in the design example shown. These form-locking engagement mechanisms extend radially outward through the overlapping form-locking engagement openings 108, 110 of these pairs 112. The form-locking engagement mechanism 114, constructed as a screw, may have, for example, self-tapping threads on its shank 116 that cut into the plastic construction material of the form-locking edge 106 and / or the plastic construction material of the muffler housing 24, and if necessary, also into the silencing material 92, thus creating a stable lock on the form-locking engagement mechanism 114. The head 118 of the form-locking engagement mechanism 114 covers the corresponding through-through form-locking engagement opening 108 in the form-locking edge 106 and creates a substantially airtight seal at that location.

[0096] To achieve a hermetically tight connection between the muffler end components 28, 32 and the muffler housing 24, essentially through form-locking, the form-locking edge 106 can be constructed in a manner consistent with the dimensions of the muffler housing 24, such that the muffler housing 24 is received in a tight fit within its respective form-locking edge using its corresponding axial ends 26, 30. Additionally, a sealing edge 120 projecting along the longitudinal axis L of the muffler can be constructed radially inward of the form-locking edge 106 on the end component plate 34, the radial distance between the sealing edge and the form-locking edge 106 being sized such that the axial ends 26 of the muffler housing 24 are received in a tight fit between the sealing edge 120 and the form-locking edge 106, thus forming a labyrinth seal.

[0097] As an alternative to using screws as the shape-locking fitting mechanism, rivets can also be used, which cause the shape-locking fitting openings 108, 110 of the corresponding pair 112 to overlap and deform, thus creating a stable connection on the one hand and an airtight seal on the other hand through the corresponding rivet head.

[0098] This shape-locking connection is an alternative design option in Figure 13 The muffler end member 28 is shown in the diagram. In the muffler housing 24, a plurality of shape-locking engagement openings 110 are configured in a circumferential direction around the longitudinal axis L of the muffler, corresponding to the muffler end member 28. Corresponding to at least a portion of the shape-locking engagement openings 110 on the muffler housing 24, preferably corresponding to each shape-locking engagement opening 110, a shape-locking engagement mechanism 122 is configured as an integrated component of the shape-locking edge 106 in the form of an engagement protrusion, and thus as an integrated component of the muffler end member 28.

[0099] To achieve form engagement, the muffler end member 28 is axially pushed against the muffler housing 24. Because the muffler housing is constructed of a substantially deformable plastic material, the muffler housing 24 is initially compressed radially inward until the form engagement engagement mechanism 122 engages radially outward into the corresponding form engagement engagement opening 110. However, it can also be specified, for example, that the form engagement edge 106 is constructed intermittently along the circumferential direction and has multiple tongue-shaped edge segments, wherein, for example, the form engagement engagement mechanism 122 can be provided on each edge segment. Upon being pushed against the muffler housing 24, these edge segments of the form engagement edge 106 can deform radially outward and spring back radially inward when the form engagement engagement protrusion 102 engages into the corresponding form engagement engagement opening 110.

[0100] An airtight seal can also be achieved or supported in this design by providing a sealing edge 120 radially inside the shape-locking edge 106, which preferably overlaps the muffler housing 24 axially on the inner side 102 of the muffler housing 24 in such a way that the sealing edge 102 abuts against the inner surface 94 and thereby creates a seal, for example, in the form of a labyrinth seal.

[0101] exist Figure 11-13 In the design shown, the shape-locking edge 106 can also be constructed on the corresponding muffler end parts 28, 32 in such a way that the shape-locking edge is embedded in the respective axial ends 26, 30 of the muffler housing 24 during axial splicing and thus axially overlaps the muffler housing 24 on the inner side 102 of the muffler housing 24. Figure 11 and 12 The design is configured as a single-component shape-locking engagement mechanism 114, which first passes radially outward through the shape-locking engagement opening 110 of the muffler housing 24 and then through the shape-locking engagement opening 108 in the shape-locking edge 106. It is configured as... Figure 13 The shape-locking edge 106 of the design is an integrated component of the shape-locking engagement mechanism 122, which protrudes radially outward from the shape-locking edge 106 and engages with the corresponding shape-locking engagement opening 110 of the muffler housing when joined radially inward.

Claims

1. A muffler, particularly for use in fuel cell systems, comprising: - A tubular muffler housing (24) made of plastic material, extending longitudinally along the direction of the muffler's longitudinal axis (L). - A first muffler end component made of plastic material is fixed to the first axial end (26) of the muffler housing (24). - A second muffler end component (32) made of plastic material is fixed to the second axial end (30) of the muffler housing (24). - At least one fixing element (41) on at least one muffler end component (28, 32) for fixing the muffler (22) to the support structure (T).

2. The silencer according to claim 1, Its features are, At least one of the first muffler end component (28) and the second muffler end component (32), preferably each muffler end component (28, 32) includes an end component plate (34) connected to the muffler housing (24) and an end component pipe joint (36) extending from the end component plate (34) in a direction away from the muffler housing (24).

3. The silencer according to claim 1 or 2, Its features are, At least one of the first muffler end component (28) and the second muffler end component (32), preferably each muffler end component (28, 32) is connected to the muffler housing (24) by material locking, preferably by bonding or welding.

4. The muffler according to any one of claims 1 to 3, Its features are, At least one of the first muffler end component (28) and the second muffler end component (32), preferably each muffler end component (28, 32) is connected to the muffler housing (24) by form-fitting.

5. The silencer according to claim 4, Its features are, At least one form-locking opening (108, 110) for a form-locking fitting mechanism (114, 122) is provided on at least one muffler end component (28, 32) in the first muffler end component (28) and / or on the muffler housing (24), and at least one form-locking fitting mechanism (114, 122) is fitted into at least one form-locking fitting opening (108, 110), preferably each form-locking fitting opening (108, 110).

6. The silencer according to claim 5, Its features are, On the muffler housing (24), in relation to at least one of the muffler end components (28, 32) of the first muffler end component (28) and the second muffler end component (32), at least one shape-locking engagement opening (110) for the shape-locking engagement mechanism (122) is provided, and on the at least one muffler end component (28, 32) of the first muffler end component (28) and the second muffler end component (32), in relation to at least one shape-locking engagement opening (110), preferably each shape-locking engagement opening (110), at least one shape-locking engagement mechanism (122) is provided.

7. The silencer according to claim 6, Its features are, At least one of the first muffler end components (28, 32) in the first muffler end component (28) and the second muffler end component (32) is provided with a shape-locking edge (106) that overlaps the muffler housing (24) on the outer side (96) or inner side (102) in the direction of the muffler longitudinal axis (L), and the at least one shape-locking fitting mechanism (122) protrudes from the shape-locking edge (106) toward the muffler housing (24) and fits into the corresponding shape-locking fitting opening (110).

8. The silencer according to claim 5, Its features are, At least one shape-locking opening (108, 110) for a shape-locking fitting mechanism (114) is provided on at least one muffler end member (28, 32) in the first muffler end member (28) and the muffler housing (24), and the shape-locking fitting mechanism (114) is positioned in a fitting manner in at least one pair (112) of shape-locking fitting openings (108, 110) on the muffler housing (24) and the at least one muffler end member (28, 32) in the first muffler end member (28, 32) and the muffler housing (24), which are positioned overlapping each other.

9. The silencer according to claim 8, Its features are, At least one of the first muffler end components (28, 32) in the first muffler end component (28) and the second muffler end component (32) is provided with a shape-locking edge (106) that overlaps the muffler housing (24) on the outer side (96) or inner side (102) in the direction of the longitudinal axis (L) of the muffler, and the shape-locking edge (106) is provided with at least one shape-locking fitting opening (108) provided in the at least one muffler end component (28, 32) in the first muffler end component (28, 32) and the second muffler end component (32).

10. The silencer according to claim 8 or 9, Its features are, At least one shape-locking fitting mechanism (114), preferably each shape-locking fitting mechanism (114) includes a screw or rivet.

11. The muffler according to claim 7 or 9, or claim 10 where claim 9 is referenced. Its features are, A sealing edge (120) is provided on at least one of the first muffler end components (28, 32) and the second muffler end component (32) at a radial distance from the shape-locking edge (106), and an axial end (26, 30) of the muffler housing (24) is arranged in an interlocking manner between the shape-locking edge (106) and the sealing edge (120).

12. The silencer according to any one of claims 1 to 11, Its features are, The first muffler end component (28) and the second muffler end component (32) are constructed identically to each other.

13. The silencer according to any one of claims 1 to 12, Its features are, At least one of the first muffler end component (28, 32) and the second muffler end component (32), preferably each muffler end component (28, 32), is provided with at least one fixing area (38, 40) for fixing the fixing element (41) to the at least one muffler end component (28, 32).

14. The silencer according to claim 13, Its features are, Two fixing areas (38, 40) are provided on the at least one muffler end component (28, 32), respectively for fixing the fixing element (41) on the at least one muffler end component (28, 32).

15. The silencer according to claim 14, Its features are, Each fixed region (38, 40) provided on the at least one muffler end component (28, 32) has at least one fixing element abutment surface (68, 70, 72, 74), and the fixing element abutment surfaces (68, 70, 72, 74) assigned to the two fixed regions (38, 40) are oriented substantially away from each other relative to the longitudinal axis (L) of the muffler.

16. The muffler according to any one of claims 13 to 15, Its features are, Each fixed area (38, 40) has at least two fixed locations (42, 44, 46, 48), wherein at each fixed location (42, 44, 46, 48), a fixing element (41) can be fixed to the at least one muffler end component (28, 32) by a fixing mechanism (66), preferably a screw.

17. The silencer according to claim 16, Its features are, Each fixed part (42, 44, 46, 48) includes an internally threaded mechanism (58, 60, 62, 64) embedded in the plastic material of the at least one muffler end component (28, 32), preferably, the internally threaded mechanism (58, 60, 62, 64) is constructed of metal material.

18. The muffler according to any one of claims 13 to 17, with reference to claim 2. Its features are, Each fixed region (38, 40) includes at least one fixed protrusion (50, 52, 54, 56) connected to the end member plate (34) and end member pipe joint (36) of the at least one muffler end member.

19. The muffler according to claim 18, where reference is made to claim 16 or 17. Its features are, Each fixed area (38, 40) and each fixed part (42, 44, 46, 48) are associated with fixed protrusions (50, 52, 54, 56), wherein the fixed protrusions (50, 52, 54, 56) associated with the fixed area (38, 40) are arranged at intervals from each other.

20. The silencer according to any one of claims 13 to 19, Its features are, Each fixing element (41) includes a mating fixing area (76) for fixing to the fixing area (38, 40).

21. The silencer according to any one of claims 1 to 20, Its features are, The sound-absorbing material (92) is disposed in the muffler housing (24), preferably the sound-absorbing material (92) comprises porous and / or foamed material and / or fibrous material, and / or the sound-absorbing material (92) at least partially covers the inner surface (94) of the muffler housing (24).

22. The silencer according to any one of claims 1 to 21, Its features are, A liquid collection and forming part (90) is provided on the circumferential area of ​​the muffler housing, preferably extending in the direction of the longitudinal axis (L) of the muffler.

23. The silencer according to any one of claims 1 to 22, Its features are, At least one reinforcing rib (100, 104) is provided on the outer side (96) of the muffler housing (24), preferably multiple reinforcing ribs (104) arranged successively in the direction of the longitudinal axis (L) of the muffler and / or multiple reinforcing ribs (100) arranged successively in the circumferential direction around the longitudinal axis (L) of the muffler.

24. The silencer according to any one of claims 1 to 23, Its features are, At least one reinforcing rib (100, 104) is provided on the inner side (102) of the muffler housing (24), preferably multiple reinforcing ribs (104) arranged successively in the direction of the longitudinal axis (L) of the muffler and / or multiple reinforcing ribs (100) arranged successively in the circumferential direction around the longitudinal axis (L) of the muffler.

25. The silencer according to claim 23 or 24, Its features are, At least one reinforcing rib (100), preferably each reinforcing rib (100) extends substantially in the direction of the longitudinal axis (L) of the muffler, and / or at least one reinforcing rib (104), preferably each reinforcing rib (104) extends substantially in the circumferential direction around the longitudinal axis (L) of the muffler.

26. A fuel cell system, particularly for vehicles, comprising at least one fuel cell (12) and a fuel cell exhaust device (20) for containing exhaust gas from the at least one fuel cell (12), the fuel cell exhaust device having at least one muffler (22) according to any one of claims 1 to 25.

27. A method for manufacturing a muffler (22) according to any one of claims 1 to 25, comprising the following steps: a) A muffler housing (24) is provided by separating the longitudinal section (A) from the muffler housing blank. b) Provide a first muffler end component (28) and a second muffler end component (32). c) Fix the first muffler end component (28) to the first axial end (26) of the muffler housing (24) and fix the second muffler end component (32) to the second axial end (30) of the muffler housing (24).

28. The method according to claim 27, Its features are, In measure a), the muffler housing blank used to provide the muffler housing (24) is manufactured by extrusion or blow molding.

29. The method according to claim 27 or 28, Its features are, The first muffler end component (28) and the second muffler end component (32) are manufactured using a plastic casting method.

30. The method according to any one of claims 27 to 29, Its features are, The measure a) includes measure a1 for arranging sound-absorbing material (92) in the muffler housing (24).

31. The method according to claim 30, Its features are, The measure a1) includes arranging a sound-absorbing material blank in the muffler housing blank before separating the longitudinal section (A), and / or the measure a1) includes arranging at least one sound-absorbing material body in the longitudinal section (A) after separating the longitudinal section (A).

32. The method according to any one of claims 27 to 31, Its features are, Measure c) includes securing the first muffler end component (28) and the second muffler end component (32) to the muffler housing (24) by material locking, preferably adhesive or welding and / or by form locking.

33. The method according to any one of claims 27 to 32, Its features are, In measure d), which is preferably performed after measure c), at least one fixing element (41) is preferably fixed by screwing on at least one of the first muffler end parts (28, 32) and the second muffler end parts (32), preferably on each muffler end part (28, 32).

Images