Method for manufacturing exhaust component

Abstract

To further facilitate positioning when forming an insulator.SOLUTION: A method for manufacturing an exhaust component of a vehicle includes: arranging first and second members included in an insulator; and jointing the first and second members to each other. The first member includes a first body part, a first joining part that is an end part of the body part and a first positioning part provided in the first joining part. The second member includes a second body part, a second joining part that is an end part of the second body part and two second positioning parts provided in the second joining part. When the first and second members are disposed, the first joining part faces the second joining part, and the first positioning part is located between the two second positioning parts. The first and second members are jointed to each other by caulking the first and second joining parts to each other.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present disclosure relates to a method for manufacturing exhaust components.

Background Art

[0002] An insulator that covers the outer peripheral surface of components such as a converter of a vehicle is known. The insulator of Patent Document 1 has an upper member and a lower member with a semi-circular cross-section. When joining the upper member and the lower member, first, these members are arranged so as to sandwich the converter in the vertical direction. Then, by caulking the flange portions of these members in a V-shape, these members are joined to form an insulator.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] However, in the technique disclosed in Patent Document 1, in the step of joining the upper member and the lower member, there is a risk that these members may shift in the direction of the axis of the converter. In one aspect of the present disclosure, it is desirable to make positioning easier when forming an insulator.

Means for Solving the Problems

[0005] One aspect of the present disclosure is a method for manufacturing an exhaust component of a vehicle, comprising arranging a first member and a second member, which are plate-like members included in an insulator surrounding a flow path member, so as to sandwich the flow path member, the flow path member being a member extending along an axis and having an exhaust flow path provided therein; and joining the first member and the second member. The first member has a first main body portion, a first joining portion, and a first positioning portion. The first main body portion is arranged to face the outer peripheral surface of the flow path member. The first joining portion is a flange-like portion located at a circumferential end of the first main body portion centered on the axis. The first positioning portion is provided on the first joining portion. The second member has a second main body portion, a second joining portion, and two second positioning portions. The second main body portion is arranged to face the outer peripheral surface of the flow path member. The second joining portion is a flange-like portion located at a circumferential end of the second main body portion. The two second positioning portions are provided on the second joining portion and are arranged in the direction of the axis. When the first and second members are arranged, the first joining portion faces the second joining portion, and the first positioning portion is located between the two second positioning portions. The first and second members are joined by caulking the first and second joining portions together. The first positioning portion is a plate-like portion provided at an end of the first joining portion on the side opposite to the first main body portion and protruding toward the second joining portion, and / or the two second positioning portions are plate-like portions provided at an end of the second joining portion on the side opposite to the second main body portion and protruding toward the first joining portion.

[0006] According to the above configuration, when the first and second members are arranged, the first positioning portion is likely to be arranged between the two second positioning portions. Therefore, when forming the insulator, the positioning of the first and second members becomes easier.

[0007] One aspect of the present disclosure may further include bending the first positioning portion and / or the two second positioning portions toward the first and second main body portions after arranging the first and second members so as to overlap the first and second joining portions.

[0008] According to the above configuration, it is possible to suppress the interference with operations such as the manufacture of the exhaust component and the attachment of the exhaust component by the first positioning portion and / or the two second positioning portions. In one aspect of the present disclosure, when joining the first and second members, the first and second joining portions and the bent first positioning portion and / or the two second positioning portions may be caulked.

[0009] According to the above configuration, the first and second members can be suitably joined.

Brief Description of the Drawings

[0010]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Figure 8

Modes for Carrying Out the Invention

[0011] Hereinafter, exemplary embodiments of the present disclosure will be described with reference to the drawings. [1. First Embodiment] [(1) Overview] The purification device 1 in the first embodiment is an example of an exhaust component that allows the exhaust from the vehicle engine to flow down (see Fig. 1). The purification device 1 is mounted on the vehicle and is configured to purify the exhaust by a catalyst as an example. The purification device 1 includes a catalyst case 2, a heat insulating material 3, and an insulator 4.

[0012] The catalyst case 2 is a cylindrical member extending along the axis A and is configured as a flow path member in which an exhaust flow path is formed inside. Further, a catalyst (not shown) is disposed inside the catalyst case 2, and the exhaust flows down inside the catalyst case 2 along the direction of the axis A. The axis A passes through the approximate center of a cross section (hereinafter simply referred to as a cross section) of the catalyst case 2 that is perpendicular to the axis A. The catalyst case 2 has a central portion 20, two tapered portions 21, and two openings 22.

[0013] The central portion 20 is a cylindrical portion with a substantially constant cross-sectional area. The two tapered portions 21 are provided adjacent to both ends of the central portion 20 in the direction of the axis A. The tapered portion 21 is inclined so as to reduce the cross section as it moves away from the central portion 20.

[0014] The two openings 22 are located at both ends of the catalyst case 2 and are cylindrical portions with a substantially constant cross-sectional area. These openings 22 are adjacent to the tapered portions 21 and form the exhaust inlet and outlet in the catalyst case 2.

[0015] The heat insulating material 3 is a member disposed between the catalyst case 2 and the insulator 4 and has heat insulating properties and cushioning properties. The heat insulating material 3 may be composed of, for example, alumina fiber, glass wool, etc. as an example. The heat insulating material 3 has a first portion 30 and a second portion 31, and as an example, it abuts on the entire outer peripheral surface of the catalyst case 2 and the entire inner peripheral surface of the insulator 4 and is disposed so as to fill the space between the catalyst case 2 and the insulator 4. The heat insulating material 3 has a first portion 30 and a second portion 31 with a semi-circular cross section. Note that the heat insulating material 3 may be configured, for example, by winding a plate-like member into a cylindrical shape.

[0016] [(2) Insulator] The insulator 4 is a cylindrical member arranged to surround the outer peripheral surface of the catalyst case 2, and suppresses heat radiation from the catalyst case 2 (see FIG. 1). As an example, the insulator 4 is cylindrical, arranged to face the entire outer peripheral surface of the catalyst case 2, and a gap having a substantially constant thickness is formed between the catalyst case 2 and the insulator 4. Of course, it is not limited to this, and the insulator 4 may be arranged to face a part of the outer peripheral surface of the catalyst case 2. Further, the insulator 4 is not limited to a cylindrical shape and may have various shapes. Also, as described above, the heat insulating material 3 is arranged in the gap between the insulator 4 and the catalyst case 2, but it may be configured such that the heat insulating material 3 is not arranged in the gap.

[0017] The insulator 4 has a central portion 40, two tapered portions 41, and two openings 42. The central portion 40 faces the outer peripheral surface of the central portion 20 of the catalyst case 2 and is a cylindrical portion having a substantially constant cross-sectional area.

[0018] The two tapered portions 41 each face the outer peripheral surface of the tapered portion 21 of the central portion 20 of the catalyst case 2 and are inclined so as to reduce the cross-section as they move away from the central portion 40. The two openings 42 each face the outer peripheral surface of the opening 22 of the catalyst case 2 and are cylindrical portions having a substantially constant cross-sectional area.

[0019] Further, the insulator 4 has first and second members 43, 45 which are plate-shaped members having a semi-circular cross-section, and the insulator 4 is formed by joining these members with their inner peripheral surfaces facing each other.

[0020] [(3) First and second joining portions] The first member 43 has a first main body portion 44 and a first joining portion 45 (see FIGS. 1 to 3). The first main body portion 44 is a portion facing the outer peripheral surface of the catalyst case 2.

[0021] The first joint portion 45 is a flange-like portion located at the circumferential direction (hereinafter simply referred to as the circumferential direction) end of the first main body portion 44 centered on the axis A. The second member 46 also has a second main body portion 47 and a second joint portion 48 configured in the same manner as the first main body portion 44 and the first joint portion 45 of the first member 43.

[0022] Hereinafter, the first and second main body portions 44, 47 and the first and second joint portions 45, 48 will also be simply referred to as the main body portion and the joint portion, respectively. The joint portion is plate-shaped and, as an example, is a rectangular portion extending in the direction of the axis A. Two joint portions are provided at each edge forming both ends in the circumferential direction of each main body portion. Although details will be described later, the first and second joint portions 45, 48 are arranged to face each other, and the first and second members 43, 44 are joined by caulking the facing first and second joint portions 45, 48.

[0023] Furthermore, a first positioning portion 45A, which is a plate-shaped portion, is provided at the end of the first joint portion 45 on the opposite side of the first main body portion 44. The first positioning portion 45A is located substantially at the center in the direction of the axis A in the first joint portion 45. The first joint portion 45 and the first positioning portion 45A are L-shaped when viewed in the direction of the axis A, and the first positioning portion 45A protrudes toward the second joint portion 48 side (in other words, the second member 46 side).

[0024] Also, two second positioning portions 48A, which are plate-shaped portions, are provided at the end of the second joint portion 48 on the opposite side of the second main body portion 47. These second positioning portions 48A are arranged side by side in the direction of the axis A so as to leave a substantially central portion in the direction of the axis A in the second joint portion 48. The second joint portion 48 and each second positioning portion 48A are L-shaped when viewed in the direction of the axis A, and the second positioning portion 48A protrudes toward the first joint portion 45 side (in other words, the first member 43 side).

[0025] Incidentally, the angles formed by the first joint portion 45 and the first positioning portion 45A, and the angles formed by the second joint portion 48 and the respective second positioning portions 48A are, as an example, approximately 90°, but these angles are not limited to this and can be determined as appropriate. Hereinafter, the first and second positioning portions 45A and 48A will also be simply referred to as positioning portions.

[0026] [(4) Manufacturing method of purification device] The manufacturing method of the purification device 1 includes an arrangement step, a bending step, and a joining step. By these steps, the insulator 4 is attached to the catalyst case 2.

[0027] In the arrangement step, the first and second members 43 and 46 are arranged so as to sandwich the catalyst case 2 therebetween (see FIG. 1). At this time, the first portion 30 of the heat insulating material 3 is arranged between the first member 43 and the catalyst case 2, and the second portion 31 of the heat insulating material 3 is arranged between the second member 46 and the catalyst case 2. As an example, the first and second members 43 and 46 are located on the upper side and the lower side respectively, and these members face each other in the vertical direction. However, the positions of these members and the direction in which these members face each other can be determined as appropriate.

[0028] Specifically, the inner peripheral surfaces of the first and second members 43 and 46 face the catalyst case 2. Also, the portions corresponding to the central portions 40, the respective tapered portions 41, and the respective openings 42 in the first and second members 43 and 46 face the central portion 20, the respective tapered portions 21, and the respective openings 22 of the catalyst case 2 respectively.

[0029] Also, at this time, each first joint portion 45 of the first member 43 faces the second joint portion 48 of the second member 46 (see FIGS. 2 and 3). Note that these joint portions may be in contact with each other, or a slight gap may be formed between these joint portions.

[0030] Then, the first positioning portion 45A at each first joint portion 45 is disposed between two second positioning portions 48A of the second joint portion 48 facing the first joint portion 45 (see FIG. 3). Specifically, both ends of the first positioning portion 45A in the direction of the axis A abut against these second positioning portions 48A, or a slight gap is formed between both ends and these second positioning portions 48A. Further, each first positioning portion 45A and each second positioning portion 48A extend in a direction substantially coinciding with the direction in which the first and second members 43 and 46 face each other.

[0031] In the subsequent bending step, each first positioning portion 45A and each second positioning portion 48A are bent toward the main body portion side (see FIG. 4). As a result, each first positioning portion 45A overlaps the first and second joint portions 45 and 48, and each second positioning portion 48A also overlaps the first and second joint portions 45 and 48. At this time, the overlapping positioning portion and joint portion may be in contact with each other, or a slight gap may exist between them.

[0032] In the subsequent joining step, the facing first and second joint portions 45 and 48, and the first positioning portion 45A and the two second positioning portions 48A overlapping these joint portions are caulked, whereby these joint portions are joined to each other (FIGS. 5 and 6). As a result, the first and second members 43 and 46 are joined to each other, and the insulator 4 is formed.

[0033] As an example, the joint portion and the positioning portion are joined by V-bending. Specifically, V-bending is performed by pressing the joint portion and the positioning portion with a protruding portion protruding in a V-shape in the caulking unit 5. Of course, the present invention is not limited to this, and the joint portion and the positioning portion may be caulked in various ways.

[0034] [2. Second Embodiment] [(1) Overview] The purification device 1 of the second embodiment is different from the first embodiment in the configuration of the joint portion. Hereinafter, the differences will be described.

[0035] [(2) First and Second Joint Portions] The first joint portion 45 is configured in the same manner as in the first embodiment, and a first positioning portion 45A is provided.

[0036] On the other hand, instead of the two second positioning portions 48A, the second joint portion 48 is provided with a slit 48B, which is an elongated hole penetrating the second joint portion 48, along the end portion on the opposite side of the main body portion (see FIG. 7). The slit 48B is located substantially at the center in the direction of the axis A in the second joint portion 48. The slit 48B extends along the direction of the axis A and enables the insertion of the first positioning portion 45A.

[0037] [(3) Method for manufacturing the purification device] In the arrangement step, in the same manner as in the first embodiment, the catalyst case 2, the heat insulating material 3, and the first and second members 43 and 46 are arranged, and as in the first embodiment, each first joint portion 45 and each second joint portion 48 face each other (see FIG. 1). At this time, the first positioning portion 45A of each first joint portion 45 penetrates through the slit 48B of the facing second joint portion 48 and protrudes from the surface of the second joint portion 48 on the opposite side of the first joint portion 45.

[0038] That is, in the second joint portion 48, the portions located on both sides of the slit 48B in the direction of the axis A function as the second positioning portions 48A, and the first positioning portion 45A is arranged between these second positioning portions 48A (see FIG. 7).

[0039] In the subsequent bending step, each first positioning portion 45A that penetrates through the slit 48B and protrudes from the surface of the second joint portion 48 on the opposite side of the first joint portion 45 is bent toward the main body portion side. As a result, in the same manner as in the first embodiment, each first positioning portion 45A overlaps with the joint portion.

[0040] Then, in the subsequent joining step, in the same manner as in the first embodiment, the facing first and second joint portions 45 and 48 and the first positioning portion 45A overlapping with the joint portion are caulked, so that the first and second members 43 and 46 are joined together.

[0041] [3. Third Embodiment] [(1) Summary] The purification device 1 of the third embodiment is different from the first embodiment in the configuration of the joint part. The differences will be described below.

[0042] [(2) First and second joint parts] The second joint part 48 is configured in the same manner as in the first embodiment, and two second positioning parts 48A are provided.

[0043] On the other hand, instead of the first positioning part 45A, the first joint part 45 is provided with two slits 45B which are elongated holes penetrating the first joint part 45 along the end part on the opposite side of the main body part (see Fig. 8). These slits 45B extend along the direction of the axis A, leave a substantially central part of the first joint part 45 in the direction of the axis A, and are arranged in the direction of the axis A. Also, these slits 48B enable the insertion of each second positioning part 48A.

[0044] [(3) Manufacturing method of the purification device] In the arrangement step, in the same manner as in the first embodiment, the catalyst case 2, the heat insulating material 3, and the first and second members 43, 46 are arranged, and as in the first embodiment, each first joint part 45 and each second joint part 48 face each other (see Fig. 1). At this time, the two second positioning parts 48A of each second joint part 48 penetrate through the respective slits 45B of the facing first joint part 45 and protrude from the surface of the first joint part 45 on the opposite side of the second joint part 48.

[0045] That is, the part between the two slits 45B in the first joint part 45 functions as the first positioning part 45A, and the first positioning part 45A is arranged between the two second positioning parts 48A penetrating through the respective slits 45B.

[0046] In the subsequent bending step, each second positioning part 48A that penetrates through the slit 45B and protrudes from the surface of the first joint part 45 on the opposite side of the second joint part 48 is bent toward the main body part side. Thereby, in the same manner as in the first embodiment, each second positioning part 48A overlaps with the joint part.

[0047] Then, in the subsequent joining step, in the same manner as in the first embodiment, the first and second joining portions 45 and 48 facing each other and the second positioning portion 48A overlapping the joining portion are caulked, whereby the first and second members 43 and 46 are joined together.

[0048] [4. Effects] (1) According to the above embodiment, at least one of the first joining portion 45 and the first positioning portion 45A, and the second joining portion 48 and the second positioning portion 48A is formed in an L shape. For this reason, in the arrangement step, the first positioning portion 45A is likely to be arranged between the two second positioning portions 48A. Therefore, in the arrangement step, the positioning of the first and second members 43 and 46 becomes easier.

[0049] (2) Further, in the bending step, the first positioning portion 45A and / or the two second positioning portions 48A are bent so as to overlap the joining portion. For this reason, it is possible to suppress the work such as the manufacture of the purification device 1 and the attachment of the purification device 1 from being hindered by the first positioning portion 45A and / or the two second positioning portions 48A.

[0050] (3) Further, in the joining step, the joining portion is caulked with the first positioning portion 45A and / or the two second positioning portions 48A bent so as to overlap the joining portion. For this reason, the first and second members 43 and 46 can be suitably joined together.

[0051] (4) Further, the insulator 4 of the purification device 1 of the above embodiment is formed by caulking the joining portion. For this reason, it becomes easy to adjust the interval between the insulator 4 and the catalyst case 2, and the filling density of the heat insulating material 3 between the insulator 4 and the catalyst case 2 can be suitably adjusted. As a result, it becomes possible to give sufficient repulsive force to the heat insulating material 3, and the insulator 4 and the heat insulating material 3 can be fixed to the catalyst case 2 without using bolts, nuts, or the like.

[0052] In addition, since bolts, nuts, etc. are not required, the number of components can be reduced, and the size of the purification device 1 can be suppressed. For this reason, the purification device 1 can be lightened, and the mountability of the purification device 1 on a vehicle is improved.

[0053] [5. Other Embodiments] (1) The exhaust component in the first to third embodiments is configured as a purification device 1 that purifies exhaust by a catalyst as an example. However, the purification device 1 may be configured to purify exhaust using other than a catalyst. Further, not limited to the purification device 1, for example, in exhaust components such as a muffler and an exhaust pipe, the same insulator as in the above embodiment can be provided, and further, by the same manufacturing method as in the above embodiment, an exhaust component provided with such an insulator can be manufactured.

[0054] (2) In the second embodiment, instead of the slit 48B, a notch may be formed at the end of the main body portion on the opposite side of the second joint portion 48. That is, a portion recessed toward the main body portion side may be formed at the end portion.

[0055] Then, in the placement step, the first positioning portion 45A may be placed in the notch of the second joint portion 48, and the first positioning portion 45A may be protruded from the surface on the opposite side of the first joint portion 45 in the second joint portion 48. Thereby, in the second joint portion 48, two portions located on both sides of the notch in the direction of the axis A function as the second positioning portion, and the first positioning portion 45A is disposed between these second positioning portions.

[0056] In addition, in the subsequent bending step, each first positioning portion 45A may be bent toward the main body portion side in the same manner as in the second embodiment. And also in the subsequent joining step, the first and second members 43, 46 may be joined by caulking the joint portion and the first positioning portion 45A in the same manner as in the second embodiment.

[0057] (3) In the third embodiment, instead of the two slits 45B, notches may be formed at the end of the main body portion on the opposite side of the first joint portion 45. That is, two portions recessed toward the main body portion side may be formed at the end.

[0058] Then, in the arranging step, the two second positioning portions 48A may be arranged in these notches of the first joint portion 45, and each second positioning portion 48A may protrude from the surface on the opposite side of the second joint portion 48 in the first joint portion 45. Thereby, in the first joint portion 45, the portion between the notches functions as the first positioning portion, and the first positioning portion is arranged between the second positioning portions 48A.

[0059] Also, in the subsequent bending step, in the same manner as in the third embodiment, each second positioning portion 48A may be bent toward the main body portion side. And in the subsequent joining step, in the same manner as in the third embodiment, the joint portion and the second positioning portion 48A may be caulked to join the first and second members 43, 46 together.

[0060] (4) In the method for manufacturing the purification device in the above embodiment, the bending step may be omitted, and in the joining step, the first and second members 43, 46 may be joined together by caulking the first and second joint portions 45, 48 overlapped in the arranging step.

[0061] In addition to this, after performing the arranging step and the joining step, the bending step may be performed. That is, the first and second members 43, 46 may be joined together by caulking the first and second joint portions 45, 48 overlapped in the arranging step in the joining step. Then, the bending step may be performed, the positioning portion may be bent toward the main body portion side, and the positioning portion may overlap the first and second joint portions 45, 48 caulked.

[0062] (5) The multiple functions of one component in the above-described embodiment may be realized by a plurality of components, or one function of one component may be realized by a plurality of components. Also, the multiple functions of a plurality of components may be realized by one component, or one function realized by a plurality of components may be realized by one component. Further, a part of the configuration of the above-described embodiment may be omitted. Also, at least a part of the configuration of the above-described embodiment may be added to or replaced with the configuration of another of the above-described embodiments.

Explanation of Signs

[0063] Purification device... 1, Axis... A, Catalyst case... 2, Central part... 20, Taper part... 21, Opening... 22, Heat insulating material... 3, First part... 30, Second part... 31, Insulator... 4, Central part... 40, Taper part... 41, Opening... 42, First member... 43, First main body part... 44, First joint part... 45, First positioning part... 45A, Slit... 45B, Second member... 46, Second main body part... 47, Second joint part... 48, Second positioning part... 48A, Slit... 48B, Crimping unit... 5.

Claims

1. A method for manufacturing an exhaust component of a vehicle, comprising: disposing first and second members, which are plate-like members included in an insulator surrounding the flow path member, so as to sandwich the flow path member, the flow path member being a member extending along an axis and having an exhaust flow path provided therein; joining the first and second members to each other; The first member has a first main body portion disposed to face an outer peripheral surface of the flow path member, a first joint portion that is a flange-like portion located at a circumferential end portion of the first main body portion about the axis, and a first positioning portion provided at the first joint portion; The second member has a second main body portion disposed to face an outer peripheral surface of the flow path member, a second joint portion that is a flange-like portion located at the circumferential end portion of the second main body portion, and two second positioning portions provided at the second joint portion and arranged in the direction of the axis; When the first and second members are disposed, the first joint portion faces the second joint portion, and the first positioning portion is located between the two second positioning portions; The first and second members are joined to each other by caulking the first and second joint portions; The first positioning portion is a plate-like portion provided at an end portion of the first joint portion on the side opposite to the first main body portion and protruding toward the second joint portion, and / or the two second positioning portions are plate-like portions provided at an end portion of the second joint portion on the side opposite to the second main body portion and protruding toward the first joint portion; A method for manufacturing an exhaust component.

2. The method for manufacturing an exhaust component according to claim 1, further comprising: after disposing the first and second members, bending the first positioning portion and / or the two second positioning portions toward the first and second main body portions so as to overlap the first and second joint portions; A method for manufacturing an exhaust component.

3. The method for manufacturing an exhaust component according to claim 2, comprising: When joining the first and second members, caulking is performed on the first and second joint portions and the bent first positioning portion and / or the two second positioning portions. A method for manufacturing an exhaust component.

Images