Method for manufacturing exhaust system component

Abstract

To provide a method for manufacturing an exhaust system component equipped with a valve device which can be easily assembled.SOLUTION: A method for manufacturing an exhaust system component that includes an exhaust member forming a flow channel of an exhaust gas and a valve device configured to adjust an opening degree of the flow channel, the manufacturing method including: disposing a shaft in a valve body; and disposing an elastic member in a natural length state in the valve body such that a first end is connected to the first connection part of the valve body and a second end is not connected to the second connection part of the shaft, and the manufacturing method further including: rotating the valve body about the shaft so as to transition the shaft from a non-connected state in which the second connection part is not connected to the second end to a connected state in which the second connection part is connected to the second end; and inserting both ends of the shaft into insertion portions of the exhaust member so as to attach the valve device to the exhaust member.SELECTED DRAWING: Figure 6

Description

Technical Field

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

Background Art

[0002] There is known a valve device that opens and closes an exhaust pipe through which exhaust gas flows down from an engine of a vehicle. As an example, Patent Document 1 discloses a valve device including a shaft portion provided so as to penetrate an exhaust pipe, a valve body that rotates about the shaft portion to open and close the exhaust pipe, and a telescopic member that biases the valve body so as to rotate toward a closed position. The valve device is assembled by hooking one end of the telescopic member on the valve body, hooking the other end of the telescopic member on the shaft portion, and moving the shaft portion while pulling the telescopic member so that the shaft portion is inserted into a hole provided in the valve body.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] However, in the valve device of Patent Document 1, when assembling the telescopic member and the shaft portion to the valve body, it is necessary to move the shaft portion against the biasing force of the telescopic member, so there is a problem that the assembly of the valve device is not easy.

[0005] One aspect of the present disclosure aims to provide a method for manufacturing an exhaust system component including a valve device that can be easily assembled.

Means for Solving the Problems

[0006] One aspect of the present disclosure is a method for manufacturing an exhaust system component including an exhaust member that forms a flow path for exhaust gas and a valve device configured to adjust the opening degree of the flow path. The valve device includes a shaft portion, a valve body, and an expansion and contraction member. The shaft portion extends in an extending direction intersecting the direction in which the exhaust gas flows and is configured to be fixed to the exhaust member. The valve body is a portion rotatable about the shaft portion, and is configured to rotate in a closing direction to reduce the opening degree and rotate in an opening direction to increase the opening degree by the exhaust gas flowing through the flow path. The expansion and contraction member has a first end connected to the valve body and a second end opposite to the first end connected to the shaft portion, and is a member expandable and contractible between the first end and the second end. The exhaust member includes an insertion portion into which both ends in the extending direction of the shaft portion can be inserted. The valve body has a first connection portion configured such that the first end is connected. The shaft portion has a second connection portion configured such that the second end is connected. The shaft portion is rotatable about the axis with respect to the valve body so as to transition from a non-connected state in which the second connection portion is not connected to the second end to a connected state in which the second connection portion is connected to the second end. The method for manufacturing the exhaust system component includes disposing the shaft portion on the valve body. Further, the method for manufacturing the exhaust system component includes disposing the expansion and contraction member in a natural length state on the valve body by connecting the first end to the first connection portion and not connecting the second end to the second connection portion. Further, the method for manufacturing the exhaust system component includes rotationally rotating the shaft portion about the axis with respect to the valve body so as to transition from the non-connected state to the connected state. Further, the method for manufacturing the exhaust system component includes inserting both ends of the shaft portion into the insertion portion and attaching the valve device to the exhaust member.

[0007] In such a configuration, by rotationally rotating the shaft portion disposed on the valve body with respect to the valve body to transition from the non-connected state to the connected state, the second end of the expansion and contraction member disposed on the valve body in the natural length state is connected to the shaft portion. Then, by inserting both ends of the shaft portion into the insertion portion of the exhaust member, the valve device in a state where the connected state of the shaft portion is maintained is fixed to the exhaust member. Therefore, an exhaust system component including a valve device that can be easily assembled can be manufactured.

[0008] In one aspect of the present disclosure, the expansion and contraction member may bias the valve body to rotate in the closing direction when the shaft portion is in the connected state. According to such a configuration, an urging force can be generated in the expansion and contraction member by a simple method of rotationally moving the shaft portion about the valve body.

[0009] In one aspect of the present disclosure, the valve device may further include a suppression portion. The suppression portion may be capable of suppressing a transition in a second rotation direction opposite to the first rotation direction in which the shaft portion transitions from a non-connected state to a connected state by coming into contact with the shaft portion.

[0010] According to such a configuration, since the transition of the shaft portion in the second rotation direction is suppressed, it is possible to suppress an incorrect assembly of the valve device in which the second end of the expansion and contraction member and the second connection portion may not be caught.

Brief Description of the Drawings

[0011]

Figure 1

Figure 2

Figure 3

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Figure 11

Figure 12

Figure 13

[0012] Hereinafter, exemplary embodiments of the present disclosure will be described with reference to the drawings. [1. Configuration] [1-1. Overall Configuration] The exhaust system component 100 shown in FIGS. 1 and 2 includes an exhaust member 1 and a valve device 2. The exhaust system component 100 is used, for example, in an exhaust system that constitutes an exhaust gas flow path of an internal combustion engine mounted on a vehicle.

[0013] The exhaust member 1 is, for example, a cylindrical member that extends substantially linearly and forms a flow path through which exhaust gas flows. In the present embodiment, the exhaust member 1 is, for example, an inner pipe of a muffler shell. The valve device 2 is provided in the exhaust member 1 and is configured to adjust the opening degree of the flow path of the exhaust member 1.

[0014] [1-2. Configuration of Valve Device] The valve device 2 includes a shaft portion 3, a valve body 4, and an expansion member 5. <Shaft portion> The shaft portion 3 is an elongated member extending in an extending direction intersecting the direction in which the exhaust gas flows (hereinafter simply referred to as the flow direction), and is non-rotatably fixed to the exhaust member 1 by welding or the like. As shown in FIGS. 3 and 4, the shaft portion 3 has a first extending portion 31, a second extending portion 32, an intermediate portion 33, and a second connecting portion 34. These first extending portion 31, second extending portion 32, intermediate portion 33, and second connecting portion 34 are integrally formed. For example, the first extending portion 31, second extending portion 32, intermediate portion 33, and second connecting portion 34 may be integrally formed by cutting or casting, or may be integrally formed by welding or the like after being separate members.

[0015] The first extending portion 31 and the second extending portion 32 are each a rod-shaped portion having a substantially circular cross-section (hereinafter simply referred to as a cross-section) perpendicular to the extending direction, and rotatably support the valve body 4. The first extending portion 31 and the second extending portion 32 each extend in the extending direction and are arranged on the same straight line. Hereinafter, the central axes extending in the extending direction of the first extending portion 31 and the second extending portion 32 are collectively referred to as the axis A. The first extending portion 31 and the second extending portion 32 are arranged at intervals at substantially the center of the cross-section perpendicular to the flow direction in the exhaust member 1. For example, the first extending portion 31 and the second extending portion 32 are preferably symmetrically shaped and provided at symmetric positions with respect to the center of the cross-section perpendicular to the flow direction in the exhaust member 1, but this is not limiting.

[0016] The first extending portion 31 has a flattened and crushed end 311. The second extending portion 32 also has a flattened and crushed end 321. Each of the crushed ends 311, 321 is located at the end of the shaft portion 3 in the extending direction. Each of the crushed ends 311, 321 is a portion having a substantially oval cross-section. Each of the crushed ends 311, 321 has a major axis L1 and a minor axis L2. The major axis L1 extends through the axis A. The minor axis L2 extends through the axis A and is perpendicular to the major axis L1. As shown in FIG. 2, each of the crushed ends 311, 321 penetrates the exhaust member 1 and is fixed to the exhaust member 1.

[0017] As shown in FIGS. 3 and 4, the intermediate portion 33 is located between the first extension portion 31 and the second extension portion 32 and is fixed to the first extension portion 31 and the second extension portion 32. The intermediate portion 33 is a rod-shaped portion with a substantially circular cross-section at the end in the stretching direction. The intermediate portion 33 extends in the stretching direction and is located on substantially the same straight line as the first extension portion 31 and the second extension portion 32. The outer diameter of the end portion of the intermediate portion 33 in the stretching direction is larger than that of the first extension portion 31 and the second extension portion 32. The central portion of the intermediate portion 33 in the stretching direction is thinner than the end portion in the stretching direction.

[0018] The second connecting portion 34 is provided at the central portion of the intermediate portion 33 and is hook-shaped. That is, the second connecting portion 34 has a substantially U-shaped cross-section and includes a fixing portion 341, a bottom portion 342, and a non-fixing portion 343. The fixing portion 341 extends from the intermediate portion 33 in the direction in which the minor axis L2 of each crushed end 311, 321 extends. The non-fixing portion 343 is located opposite to the fixing portion 341 with a space therebetween and extends in the direction in which the minor axis L2 of each crushed end 311, 321 extends. The bottom portion 342 connects the fixing portion 341 and the non-fixing portion 343. The second end 52 of the telescopic member 5 described later is connected to the second connecting portion 34. Note that the non-fixing portion 343 is located upstream of the fixing portion 341 in the flow direction when the valve device 2 is attached to the exhaust member 1.

[0019] As shown in FIG. 3, bearing portions 35 are provided on the first extension portion 31 and the second extension portion 32, respectively. The bearing portion 35 is a substantially cylindrical member that covers the outer peripheral surfaces of the first extension portion 31 and the second extension portion 32. That is, the bearing portion 35 is disposed between the first extension portion 31 and the second extension portion 32 and the valve body 4, and supports the valve body 4 rotatably together with the first extension portion 31 and the second extension portion 32. Specifically, the end portion of the first extension portion 31 with a substantially circular cross-section on the side opposite to the crushed end 311 is accommodated in the bearing portion 35. Also, the end portion of the second extension portion 32 with a substantially circular cross-section on the side opposite to the crushed end 321 is accommodated in the bearing portion 35.

[0020] The bearing portion 35 has a main body portion 351 and a large-diameter portion 352. The large-diameter portion 352 is located at one end of the main body portion 351 and has an outer diameter larger than that of the main body portion 351. Each bearing portion 35 is fixed to the first extending portion 31 and the second extending portion 32 such that the large-diameter portion 352 is located on the side of the intermediate portion 33. The large-diameter portion 352 abuts against the intermediate portion 33. Each large-diameter portion 352 suppresses the movement of the valve body 4 of the shaft portion 3 in the extending direction. That is, the diameter of each large-diameter portion 352 is larger than the length in the direction orthogonal to the hole portion 411 provided in the valve body 4 described later. The bearing portion 35 has at least one of the functions of cushioning or sealing, and is formed of, for example, a wire mesh.

[0021] <Valve body> As shown in FIGS. 1 and 2, the valve body 4 is a substantially circular flat hollow portion when viewed from the front. The valve body 4 is a portion rotatable about the shaft portion 3 (more specifically, the axis A), and rotates in the closing direction in which the opening degree of the flow path of the exhaust member 1 is reduced, and rotates in the opening direction in which the opening degree is increased by the exhaust gas flowing down the flow path. The position of the valve body 4 when the flow rate of the exhaust gas flowing through the flow path is the lowest is defined as the closed position. As shown in FIG. 1, the valve body 4 located at the closed position is arranged so as to have an inclination with respect to the cross section orthogonal to the flow direction. Specifically, the valve body 4 is inclined such that, in the direction orthogonal to the extending direction, the end on the side to which the first end 51 of the telescopic member 5 described later is connected is located downstream of the end on the opposite side of the end. Further, the position of the valve body 4 when the flow rate of the exhaust gas flowing through the flow path is the highest is defined as the open position. As shown in FIG. 5, the valve body 4 located at the open position is arranged along the flow direction.

[0022] As shown in FIGS. 1 and 5, the valve body 4 includes a first housing 41 and a second housing 42. The first housing 41 is a thin-walled container-like portion, and has a curved portion when viewed from the side. In the present embodiment, the first housing 41 bulges toward the downstream side in the flow direction, and a space is formed inside.

[0023] The second housing 42 is a portion arranged to cover the above-described internal space of the first housing 41, and when viewed from the side, it is a plate-shaped part with a bulged central portion on the outside. The valve body 4 is formed by overlapping and joining the first housing 41 and the second housing 42. An internal space 40 is formed by the first housing 41 and the second housing 42. In this internal space 40, the intermediate portion 33 of the shaft portion 3, the first extension portion 31 and the second extension portion 32 to which the bearing portion 35 is fixed, and most of the telescopic member 5 described later are accommodated. When the valve body 4 is in the closed position, the first housing 41 is located on the downstream side, and the second housing 42 is located on the upstream side.

[0024] As shown in FIG. 3, the first housing 41 has a shape that is line-symmetric with respect to the center line B extending in the orthogonal direction. The first housing 41 has two hole portions 411, a first connecting portion 412, a contact portion 413, two joining seat surfaces 414, and a suppressing portion 415. Each hole portion 411 is a groove into which the shaft portion 3 can be inserted. Each hole portion 411 extends in the extending direction and is a portion whose cross section is curved in an arc shape, and is located opposite to each other at the end portion of the first housing 41 in the extending direction. In each hole portion 411, the first extension portion 31 or the second extension portion 32 is inserted with the bearing portion 35 fixed. Specifically, the main body portion 351 of the bearing portion 35 is inserted into the hole portion 411, and the large-diameter portion 352 of the bearing portion 35 is arranged inside the first housing 41 from the hole portion 411.

[0025] The first connecting portion 412 is a groove to which the first end 51 of the telescopic member 5 is connected. The first connecting portion 412 is located at one end portion of the first housing 41 in the orthogonal direction and extends in the orthogonal direction. In the present embodiment, the first connecting portion 412 is located on the center line B. The first end 51 of the telescopic member 5 described later is in a hook shape curved in an arc shape, and the first connecting portion 412 has an arc shape whose cross-sectional shape matches the hook shape. Thereby, the first end 51 of the telescopic member 5 and the first connecting portion 412 can rotate without getting caught. As a result, when the valve body 4 moves between the closed position and the open position, the first end 51 of the telescopic member 5 rotates along the first connecting portion 412.

[0026] The contact portion 413 is a portion that contacts the inner peripheral surface of the exhaust member 1, specifically, the stopper portion 14 of the first member 11 described later, either directly or via another member. The contact portion 413 is located at the end of the first housing 41 in the orthogonal direction, on the side opposite to the side where the first connecting portion 412 is provided. The contact portion 413 is a planar portion having a certain length in the extending direction. The contact portion 413 contacts the second housing 42 on the surface opposite to the surface facing the inner peripheral surface of the exhaust member 1. The contact portion 413 is a portion for forming a welded portion when, for example, spot-welding the first housing 41 and the second housing 42.

[0027] Each joint seat surface 414 is a planar portion that contacts the second housing 42 and forms a welded portion. Each joint seat surface 414 is located opposite to each other at the end of the first housing 41 in the extending direction, and is provided between the hole portion 411 and the first connecting portion 412. In the present embodiment, the joint seat surface 414 is provided such that the end in the extending direction partially extends outward.

[0028] The restraining portion 415 is located near the center of the first housing 41 and on the side of the contact portion 413 rather than the hole portion 411 in the orthogonal direction, and is a portion where a part of the first housing 41 protrudes toward the internal space 40 side of the valve body 4. Although details will be described later, in the valve device 2 before being attached to the exhaust member 1, the shaft portion 3 is rotatable about the axis A with respect to the valve body 4. The restraining portion 415 contacts the second connecting portion 34 of the shaft portion 3 when the shaft portion 3 shifts in the second rotation direction C2 shown in FIG. 6. Thereby, the restraining portion 415 can restrain the shift of the shaft portion 3 with respect to the valve body 4 in the second rotation direction C2.

[0029] <Expansion and contraction member> The telescopic member 5 is a telescopic member, for example, a tension coil spring. As shown in FIGS. 1 and 3, the first end 51 and the second end 52 of the telescopic member 5 are formed in a hook shape that is curved in an arc shape. In the present embodiment, the first end 51 is in a state where the tip is directed backward along the cross section (that is, in a state where it faces the downstream side when the valve body 4 of the valve device 2 is in the closed position), and the second end 52 is in a state where the tip is sideways along the cross section perpendicular to the flow direction (that is, in a state where it faces the direction along the shaft portion 3). That is, the first end 51 and the second end 52 are in directions that are approximately 90 degrees different. The first end 51 is connected to the valve body 4. Specifically, the first end 51 is hooked on the first connecting portion 412 of the valve body 4. The second end 52 is connected to the shaft portion 3. Specifically, the second end 52 is hooked on the second connecting portion 34 of the shaft portion 3.

[0030] <Regarding the axial rotation of the shaft portion with respect to the valve body> The shaft portion 3 is axially rotatable about the axis A with respect to the valve body 4 so as to transition from the unconnected state shown in FIG. 6 where the second connecting portion 34 is not connected to the second end 52 to the connected state shown in FIG. 1 where the second connecting portion 34 is connected to the second end 52.

[0031] As shown in FIG. 6, when the shaft portion 3 is in the unconnected state, the major axis L1 of each crushed end 311, 321 of the shaft portion 3 is in a state substantially parallel to the inner surface 416 of the first housing 41 facing the shaft portion 3. At this time, the non-fixed portion 343 of the second connecting portion 34 in the shaft portion 3 is in a state substantially perpendicular to the inner surface 416 of the first housing 41, and the bottom portion 342 of the second connecting portion 34 is located on the side of the first housing 41. In the present embodiment, the direction of transition of the shaft portion 3 from the unconnected state to the connected state is referred to as the first rotation direction C1, and the direction opposite to the first rotation direction C1 is referred to as the second rotation direction C2. When the shaft portion 3 is rotated in the first rotation direction C1, the bottom portion 342 of the second connecting portion 34 moves away from the first housing 41 and moves below the second end 52, and the second end 52 is inserted between the fixed portion 341 and the non-fixed portion 343 of the second connecting portion 34. As a result, as shown in FIG. 1, the shaft portion 3 becomes in the connected state. As shown in FIG. 7, in a state where the valve device 2 in which the shaft portion 3 is in the connected state is attached to the exhaust member 1, the major axis L1 of each crushed end 311, 321 becomes substantially parallel to the flow direction.

[0032] In this embodiment, the first housing 41 of the valve body 4 has a restraining portion 415. Therefore, as shown in FIG. 6, when the shaft portion 3 is rotated in the second rotation direction C2, the second connecting portion 34 of the shaft portion 3 and the restraining portion 415 come into contact with each other, and the rotation of the shaft portion 3 in the second rotation direction C2 stops. Thereby, the restraining portion 415 can restrain the valve body 4 from shifting in the second rotation direction C2 of the shaft portion 3.

[0033] [1-3. Configuration of Exhaust Member] As shown in FIGS. 1 and 2, the exhaust member 1 includes a first member 11 and a second member 12. The first member 11 and the second member 12 are each a substantially semi-cylindrical portion. By combining and joining the first member 11 and the second member 12 so as to face each other, a substantially cylindrical exhaust member 1 is formed.

[0034] As shown in FIGS. 1 and 7, the first member 11 includes two insertion portions 13 and a stopper portion 14. Each insertion portion 13 is a circumferential end portion that circulates around the central axis of the exhaust member 1 in the first member 11, and is a slit formed in each joint end portion 111 that joins with the second member 12. The insertion portions 13 are positioned opposite to each other in the extending direction. Each crushed end 311, 321 of the shaft portion 3 is inserted into each insertion portion 13, and the shaft portion 3 is fixed to the first member 11.

[0035] As shown in FIG. 7, the insertion portion 13 extends substantially in an L shape from the joint end portion 111. The insertion portion 13 has an inlet portion 131 and a mounting portion 132. The mounting portion 132 is located on the downstream side of the inlet portion 131 and extends substantially parallel to the flow direction and longer than the major axis L1 of each crushed end 311, 321. The width of the inlet portion 131 in the flow direction is longer than the major axis L1 of each crushed end 311, 321 of the shaft portion 3. The width of the mounting portion 132 in the direction perpendicular to the flow direction is substantially the same as the minor axis L2 of each crushed end 311, 321. Note that the width of the mounting portion in the direction perpendicular to the flow direction may be longer than the minor axis L2 and shorter than the major axis L1. Thereby, each crushed end 311, 321 inserted from the inlet portion 131 is non-rotatably fixed to the mounting portion 132.

[0036] As shown in FIG. 1, the stopper portion 14 is a portion where the contact portion 413 of the first housing 41 of the valve body 4 abuts directly or via another member. The stopper portion 14 is located near the center in the circumferential direction of the first member 11, and a part of the first member 11 protrudes toward the outside of the exhaust member 1. The stopper portion 14 has an inclined surface 141 that inclines toward the downstream side from the protruding apex portion. By the contact portion 413 abutting directly or via another member against the inclined surface 141 of the stopper portion 14, the closed position of the valve body 4 is maintained, and the valve body 4 is configured not to rotate further in the closing direction. In the present embodiment, a cushioning material 7 formed by, for example, a wire mesh is provided between the inclined surface 141 and the contact portion 413. Note that the cushioning material 7 may not be provided between the inclined surface 141 and the contact portion 413.

[0037] [2. Manufacturing method of exhaust system components] Next, with reference to FIGS. 1, 6, 7, and 8A to 8D, a manufacturing method of the exhaust system component 100 will be described. The manufacturing method of the exhaust system component 100 includes an assembling step of the valve device 2 and an attaching step of the valve device 2 to the exhaust member 1.

[0038] [2-1. Assembling step of valve device] First, as shown in FIG. 8B, the shaft portion 3 in a state where the bearing portions 35 are fixed to the first extending portion 31 and the second extending portion 32 is disposed on the inner surface 416 side of the first housing 41 shown in FIG. 8A. Specifically, the main body portion 351 of the bearing portion 35 is inserted into the hole portion 411 so that the second connecting portion 34 is disposed closer to the first connecting portion 412 side of the first housing 41 than the intermediate portion 33. At this time, the large-diameter portion 352 of the bearing portion 35 is located inside the hole portion 411. Also, at this time, as in the shaft portion 3 shown in FIG. 6, it is preferable that the bottom portion 342 of the second connecting portion 34 is located on the inner surface 416 side and the non-fixed portion 343 is substantially perpendicular to the inner surface 416.

[0039] Next, as shown in FIG. 8C, the telescopic member 5 is disposed in the first housing 41 in its natural length state. Specifically, the first end 51 of the telescopic member 5 is hooked on the first connecting portion 412 of the first housing 41, and the second end 52 of the telescopic member 5 is disposed without being connected to the second connecting portion 34 of the shaft portion 3. Disposing the second end 52 without connecting it to the second connecting portion 34 means, as shown in FIG. 6, that the second end 52 is positioned in the vicinity of the second connecting portion 34, specifically, above the second connecting portion 34, and the second end 52 is not inserted between the fixed portion 341 and the non-fixed portion 343. That is, when the second end 52 is disposed without being connected to the second connecting portion 34, the telescopic member 5 is in a state where the second end 52 is not pulled in a direction away from the first end 51 by the second connecting portion 34.

[0040] Next, as shown in FIG. 8D, the first housing 41 and the second housing 42 are overlapped and joined to form the valve body 4. Specifically, the second housing 42 is disposed above the first housing 41 such that the bulged portion projects outward, and the first housing 41 and the second housing 42 are joined by spot welding. The welded portion 8 is formed at a portion where the abutting portion 413 and each joining seat surface 414 of the first housing 41 abut against the second housing 42. Thereby, the assembly of the valve device 2 in which the shaft portion 3, the bearing portion 35, and the telescopic member 5 are disposed in the internal space 40 of the valve body 4 is completed. At this time, the shaft portion 3 is in a non-connected state.

[0041] [2-2. Mounting process of the valve device to the exhaust member] The valve device 2 assembled as described above, that is, the valve device 2 before being attached to the exhaust member 1, the shaft portion 3 is axially rotatable about the axis A with respect to the valve body 4. In the present embodiment, first, the shaft portion 3 is axially rotated in the first rotation direction C1 with respect to the valve body 4 so that the shaft portion 3 transitions from the unconnected state to the connected state. Specifically, first, the shaft portion 3 in the unconnected state is axially rotated in the first rotation direction C1, the second end 52 is inserted between the fixed portion 341 and the non-fixed portion 343 of the second connecting portion 34, and the second connecting portion 34 is connected to the second end 52 of the telescopic member 5 in the natural length state. Then, the shaft portion 3 is further rotated in the first rotation direction C1, and the second connecting portion 34 pulls the second end 52 in a direction away from the first end 51, generating a biasing force on the telescopic member 5. That is, in the connected state of the shaft portion 3, there are a state where the telescopic member 5 is in the natural length state (that is, a state without a biasing force) and the second connecting portion 34 is connected to the second end 52, and a state where the telescopic member 5 has a biasing force and the second connecting portion 34 is connected to the second end 52.

[0042] After the shaft portion 3 is in the connected state, while maintaining the connected state, as shown in FIG. 7, each crushed end 311, 321 of the shaft portion 3 is inserted into each insertion portion 13 of the first member 11, and the valve device 2 is attached to the exhaust member 1. Specifically, while the contact portion 413 of the first housing 41 is brought into contact with the cushioning material 7 fixed to the stopper portion 14 of the first member 11 shown in FIG. 1, the major axis L1 of each crushed end 311, 321 is inserted into the inlet portion 131 of the insertion portion 13 in a state parallel to the flow direction. Then, the valve device 2 is moved downstream so that each crushed end 311, 321 is inserted into the mounting portion 132 while maintaining the state where the major axis L1 is parallel to the flow direction. Thereby, the valve device 2 is attached to the first member 11 while the connected state of the shaft portion 3 is maintained.

[0043] In this embodiment, as described above, by rotating the shaft portion 3 in the first rotation direction C1 with respect to the valve body 4, a biasing force is generated in the expansion and contraction member 5. Therefore, when the shaft portion 3 is in the connected state, the expansion and contraction member 5 biases the valve body so as to rotate in the closing direction. That is, when the valve body 4 is in the closed position in the state where the valve device 2 is attached to the exhaust member 1, the expansion and contraction member 5 biases the valve body 4 so as to rotate in the closing direction.

[0044] Thereafter, the second member 12 is joined to the first member 11 so that the valve device 2 is disposed between the first member 11 and the second member 12. Thereby, the exhaust system component 100 in which the valve device 2 is disposed in the exhaust member 1 is manufactured.

[0045] [3. Effects] According to the embodiment described in detail above, the following effects can be obtained. (3a) In this embodiment, the expansion and contraction member 5 is disposed on the valve body 4 in a natural length state. Then, by rotating the shaft portion 3 disposed on the valve body 4 in the first rotation direction C1 with respect to the valve body 4, the second end 52 of the expansion and contraction member 5 disposed on the valve body 4 in the natural length state is caught by the second connecting portion 34 of the shaft portion 3. As a result, the second end 52 is easily connected to the second connecting portion 34. Thereby, compared with the case where it is necessary to dispose the expansion and contraction member on the valve body against the biasing of the expansion and contraction member, the work load is reduced, so that the valve device 2 can be easily assembled. Then, by inserting each of the crushed ends 311, 321 of the shaft portion 3 into the insertion portion 13 of the exhaust member 1, the valve device 2 in the state where the connected state of the shaft portion 3 is maintained is fixed to the exhaust member 1. Therefore, it is possible to manufacture the exhaust system component 100 including the valve device 2 that can be easily assembled.

[0046] (3b) In this embodiment, the expansion and contraction member 5 biases the valve body so as to rotate in the closing direction when the shaft portion 3 is in the connected state. Therefore, a biasing force can be generated in the expansion and contraction member 5 by a simple method of rotating the shaft portion 3 with respect to the valve body 4.

[0047] (3c) In this embodiment, the first housing 41 of the valve body 4 has a suppression portion 415. Thereby, even when the shaft portion 3 is rotated in the second rotation direction C2, the second connecting portion 34 of the shaft portion 3 and the suppression portion 415 come into contact with each other, and the rotation of the shaft portion 3 in the second rotation direction C2 stops. Thereby, the rotation of the shaft portion 3 in the wrong direction is suppressed. For this reason, it is possible to suppress an incorrect assembly of the valve device 2 in which the second end 52 of the telescopic member 5 and the second connecting portion 34 may not be caught.

[0048] Note that in this embodiment, each crushed end 311, 321 corresponds to an example of both ends in the extending direction of the shaft portion.

[0049] [4. Other Embodiments] As described above, the embodiments of the present disclosure have been described. Needless to say, the present disclosure is not limited to the above embodiments and can take various forms.

[0050] (4a) In the above embodiment, the second connecting portion 34 of the shaft portion 3 is hook-shaped, but the shape of the second connecting portion is not limited to this. For example, as shown in FIGS. 9 and 10, the shaft portion 3a of the first modification may have a first extending portion 31, a second extending portion 32, two protruding portions 33a, and a second connecting portion 34a. These first extending portion 31, second extending portion 32, two protruding portions 33a, and second connecting portion 34a may be integrally formed. Since the first extending portion 31 and the second extending portion 32 have the same shape as those in the above-described embodiment, the description thereof is omitted.

[0051] Each protruding portion 33a is a portion having a substantially circular cross section, and is located at an end opposite to the crushed end 311 of the first extending portion 31 and an end opposite to the crushed end 321 of the second extending portion 32, respectively, and is fixed to the first extending portion 31 and the second extending portion 32. Each protruding portion 33a has an outer diameter larger than the outer diameter of the first extending portion 31 and the outer diameter of the second extending portion 32. Each protruding portion 33a abuts against the large-diameter portion 352 of the bearing portion 35 fixed to the first extending portion 31 and the second extending portion 32, respectively.

[0052] The second connecting portion 34a is located between the respective protruding portions 33a and is fixed to each protruding portion 33a. The second connecting portion 34a is a curved rod-shaped portion with a substantially circular cross-section. The second connecting portion 34a protrudes in the direction in which the major axis L1 of each of the crushed ends 311, 321 extends. That is, the central axis of the second connecting portion 34a does not coincide with the axis A. The second connecting portion 34a has a central portion 341a and two bent portions 342a. The central portion 341a is located away from the axis A and extends in the extending direction. Each bent portion 342a connects the end of the central portion 341a in the extending direction and each protruding portion 33a.

[0053] As shown in FIG. 10, the shaft portion 3a and the telescopic member 5a of the first modification in a state where the bearing portion 35 is fixed are arranged in the first housing 41 in the same manner as the valve device 2 of the above-described embodiment. In the case of the shaft portion 3a of the first modification, the main body portion 351 of the bearing portion 35 is inserted into the hole portion 411 so that the protruding direction of the second connecting portion 34a faces the first connecting portion 412 side of the first housing 41. The first end 51a and the second end 52a of the telescopic member 5a are formed in a hook shape in the same manner as the telescopic member 5 of the above-described embodiment. In the example shown in FIG. 11, the tip of the first end 51a faces backward along the cross-section, and the tip of the second end 52a faces forward along the cross-section. That is, the first end 51a and the second end 52a are in directions that are approximately 180 degrees different. In the telescopic member 5a, although the tip of the first end 51a and the tip of the second end 52a are located on opposite sides in the flow direction, the tip of the first end 51a and the tip of the second end 52a may be located on the same side in the flow direction.

[0054] The shaft portion 3a, similar to the shaft portion 3 of the above-described embodiment, is axially rotatable about the axis A with respect to the valve body 4 so as to transition from the unconnected state shown in FIGS. 10 and 11 where the second connecting portion 34a is not connected to the second end 52a to the connected state shown in FIG. 12 where the second connecting portion 34a is connected to the second end 52a. As shown in FIG. 11, when the shaft portion 3a is in the unconnected state, the central portion 341a of the second connecting portion 34a is located away from the second end 52a. When the shaft portion 3a is rotated in the first rotation direction C1, the central portion 341a moves so as to approach the second end 52a, and the central portion 341a abuts against the second end 52a. Thereby, as shown in FIG. 12, the shaft portion 3a is in the connected state. As shown in FIGS. 9 and 10, in the present embodiment, the portion of the central portion 341a that abuts against the second end 52a is slightly recessed toward the axis A so as to be able to suppress the movement of the second end 52a in the extending direction with respect to the central portion 341a.

[0055] The valve device 2a including the shaft portion 3a of the first modification is attached to the exhaust member 1, similar to the valve device 2 of the above-described embodiment. Thereby, even in the case of the shaft portion 3a of the first modification, the same effects as those of (3a) and (3b) of the above-described embodiment can be obtained.

[0056] (4b) In the above-described embodiment, the insertion portion 13 formed in the first member 11 was L-shaped, but the shape of the insertion portion is not limited to this. For example, as shown in FIG. 13, the insertion portion 13b formed in the first member 11b may extend straight in the circumferential direction from the joint end portion 111b of the first member 11b. The width of the insertion portion 13b in the flow direction is substantially constant. In this case, the direction in which each crushed end is crushed is changed so that the major axis L1 of each crushed end 311, 321 in the shaft portion 3 of the above-described embodiment and the shaft portion 3a of the first modification becomes the minor axis and the minor axis L2 becomes the major axis. Thereby, the valve device 2 and the valve device 2a can be attached to the first member 11b while maintaining the connected state of the shaft portion 3.

[0057] (4c) In the above embodiment, after the shaft portion 3 was axially rotated in the first rotation direction C1 with respect to the valve body 4 to bring the shaft portion 3 into the connected state, each of the crushed ends 311, 321 was inserted into the insertion portion 13, and the valve device 2 was attached to the exhaust member 1. However, the method of attaching the valve device 2 to the exhaust member 1 is not limited to this. For example, while axially rotating the shaft portion 3 with respect to the valve body 4, by inserting each of the crushed ends 311, 321 into the insertion portion 13, the valve device 2 in which the shaft portion 3 is in the connected state may be attached to the exhaust member 1. Further, for example, after inserting each of the crushed ends 311, 321 of the shaft portion 3 in the unconnected state into the insertion portion 13, the shaft portion 3 is axially rotated with respect to the valve body 4, and the valve device 2 in which the shaft portion 3 is in the connected state may be attached to the exhaust member 1.

[0058] (4d) In the above embodiment, an urging force is generated in the elastic member 5 by the axial rotation of the shaft portion 3 in the first rotation direction C1, and when the shaft portion 3 is in the connected state, the second connecting portion 34 and the second end 52 are connected with the elastic member 5 having the urging force. Thereby, the elastic member 5 urges the valve body to rotate in the closing direction when the shaft portion 3 is in the connected state. That is, when the valve body 4 is in the closed position in the state where the valve device 2 is attached to the exhaust member 1, the elastic member 5 urges the valve body 4 to rotate in the closing direction. However, for example, an urging force may not be generated in the elastic member 5 by the axial rotation of the shaft portion 3 in the first rotation direction C1, and when the shaft portion 3 is in the connected state, the second connecting portion 34 and the second end 52 may be connected with the elastic member 5 remaining in the natural length state. Thereby, the elastic member 5 may not urge the valve body 4 to rotate in the closing direction when the shaft portion 3 is in the connected state. That is, when the valve body 4 is in the closed position, the elastic member 5 is in the natural length state and may not urge the valve body 4.

[0059] (4e) In the above embodiment, the first housing 41 of the valve body 4 had the restricting portion 415, but the location where the restricting portion is provided is not limited to this. For example, the restricting portion may be provided at the second connecting portion of the shaft portion, and when the second connecting portion rotates in the second rotation direction C2, the restricting portion may abut against the inner surface of the first housing. Further, for example, the valve device may not have the restricting portion.

[0060] (4f) In the above-described embodiment, the cross-sectional shape of each crushed end 311, 321 was substantially oval. However, for example, the cross-sectional shape of the crushed end may be substantially elliptical, substantially polygonal, or the like. (4g) In the above-described embodiment, the insertion portion 13 is a slit formed in the first member 11, and each crushed end 311, 321 of the shaft portion 3 penetrates the exhaust member 1. However, for example, the insertion portion may be a through-hole formed in the first member. Further, for example, the insertion portion may be a groove formed on the inner surface side of the first member. In this case, each crushed end of the shaft portion may be inserted into the groove and may not penetrate the exhaust member.

[0061] (4h) The functions of one component in the above-described embodiment may be distributed among a plurality of components, or the functions of a plurality of components may be integrated into one component. Further, a part of the configuration of the above-described embodiment may be omitted. Further, at least a part of the configuration of the above-described embodiment may be added to, replaced with, etc. the configuration of other above-described embodiments.

Description of Reference Numerals

[0062] 1... Exhaust member, 2... Valve device, 3, 3a... Shaft portion, 4... Valve body, 5, 5a... Expansion member, 7... Buffer material, 8... Weld portion, 11, 11b... First member, 12... Second member, 13, 13b... Insertion portion, 14... Stopper portion, 31... First extension portion, 32... Second extension portion, 33... Intermediate portion, 33a... Protrusion portion, 34, 34a... Second connection portion, 35... Bearing portion, 40... Internal space, 41... First housing, 42... Second housing, 51, 51a... First end, 52, 52a... Second end, 100... Exhaust system component, 111, 111b... Joint end portion, 131... Inlet portion, 132... Mounting portion, 141... Inclined surface, 311, 321... Crushed end, 412... First connection portion, 341... Fixed portion, 341a... Central portion, 342... Bottom portion, 342a... Bent portion, 343... Non-fixed portion, 351... Main body portion, 352... Large diameter portion, 411... Hole portion, 413... Contact portion, 414... Joint seat surface, 415... Suppression portion, 416... Inner surface, A... Axis, B... Center line, L1... Major axis, L2... Minor axis.

Claims

1. A method for manufacturing an exhaust system component, comprising an exhaust member that forms a flow path for exhaust gas and a valve device configured to adjust the opening degree of the flow path, wherein the valve device includes a shaft portion that extends in an extending direction intersecting the flowing direction of the exhaust gas and is configured to be fixed to the exhaust member, a valve body that is rotatable about the shaft portion, and is configured to rotate in a closing direction to reduce the opening degree and rotate in an opening direction to increase the opening degree by the exhaust gas flowing down the flow path, a telescopic member having a first end connected to the valve body and a second end opposite to the first end connected to the shaft portion, and being telescopic between the first end and the second end, the exhaust member includes an insertion portion into which both ends of the shaft portion in the extending direction can be inserted, the valve body has a first connection portion configured to have the first end connected thereto, the shaft portion has a second connection portion configured to have the second end connected thereto, and is axially rotatable with respect to the valve body so as to transition from a non-connected state where the second connection portion is not connected to the second end to a connected state where the second connection portion is connected to the second end, disposing the shaft portion on the valve body, connecting the first end to the first connection portion and disposing the telescopic member in a natural length state on the valve body without connecting the second end to the second connection portion, axially rotating the shaft portion with respect to the valve body so as to transition from the non-connected state to the connected state, inserting both ends of the shaft portion into the insertion portion and attaching the valve device to the exhaust member, A method for manufacturing an exhaust system component, comprising the above steps.

2. The method for manufacturing an exhaust system component according to claim 1, wherein the telescopic member biases the valve body to rotate in the closing direction when the shaft portion is in the connected state.

3. The method for manufacturing an exhaust system component according to claim 1 or claim 2, wherein the valve device further includes a suppression portion capable of suppressing a transition of the shaft portion in a second rotation direction opposite to a first rotation direction from the non-connected state to the connected state by coming into contact with the shaft portion.

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