Vehicle Exhaust Tail Trim Assembly with Integrated Bracket
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Solution Overview
Problem
The existing tail trim assembly for vehicle exhaust pipes is complex, increasing manufacturing costs and noise due to multiple components and processes, and the coating on the brackets is prone to removal by heat, affecting appearance and efficiency.
Innovation Solution
A simplified tail trim assembly with a streamlined shape formed through hydroforming and heat treatment, eliminating the need for multiple brackets and welding, and incorporating a carbonized film to reduce noise and improve heat resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple brackets and welding processes are used to attach tail trim to exhaust pipe, then the assembly ensures sealed space and proper positioning, but the manufacturing cost increases and the number of components and processes increases
Solution Approach 1:
The patent integrates the bracket structure directly into the tail trim component, merging two separate parts (bracket and tail trim) into a single integrated component. This eliminates the need for separate brackets and welding processes while maintaining the sealed space function, thereby reducing manufacturing complexity and cost.
Solution Approach 2:
The tail trim is designed to perform multiple functions: it provides aesthetic coverage, creates a sealed space with the exhaust pipe, and serves as a mounting structure. By making the tail trim multi-functional, the patent eliminates the need for separate brackets, reducing the number of components while maintaining all necessary functions.
2Manufacturing precision
If multiple pressing and welding processes are used to manufacture tail trim assembly, then the assembly achieves proper structure and function, but the manufacturing cost increases and productivity decreases
Solution Approach 1:
The patent combines multiple manufacturing operations into a single pressing process. The tail trim is formed with integrated bracket structures and attachment features in one operation, eliminating the need for subsequent welding and assembly steps, thereby improving manufacturing efficiency while maintaining structural precision.
Solution Approach 2:
The tail trim is designed with pre-formed attachment structures and sealing features that are created during the initial pressing process. This preliminary formation of all necessary structures eliminates the need for subsequent welding and assembly operations, improving productivity while ensuring manufacturing precision.
3Shape
If coating is applied to second bracket for aesthetic appearance, then the outer appearance of rear portion is improved, but the coating is removed due to heat from exhaust gas
Solution Approach 1:
The patent eliminates the bracket structure that requires coating from the design. By integrating the bracket function into the tail trim and using materials or structures that do not require protective coating, the patent removes the source of the coating durability problem while maintaining aesthetic appearance.
Solution Approach 2:
The patent uses the tail trim as a sacrificial or replaceable component that can be easily replaced if damaged or faded, rather than attempting to create a permanent, heat-resistant coating on brackets. This approach prioritizes overall system reliability and cost-effectiveness over permanent coating durability.
4Strength
If first bracket forms step between exhaust pipe and tail trim, then the assembly provides structural support, but noise is caused by running wind
Solution Approach 1:
The patent designs the tail trim and exhaust pipe interface with smooth, curved transitions instead of sharp steps or angles. This streamlined geometry reduces turbulence and wind noise while maintaining the necessary structural support, eliminating the harmful noise effect without sacrificing strength.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution reduces manufacturing costs, improves productivity and quality by simplifying the assembly process, decreasing noise, and enhancing heat resistance, while ensuring efficient exhaust gas discharge.
Implementation Method 1
forming a first tail trim assembly along the pipe section by a hydroforming process for injecting fluid into the pipe section at high pressure
Implementation Method 2
forming a first tail trim assembly along the pipe section by a hydroforming process for injecting fluid into the pipe section at high pressure
Implementation Method 3
performing a heat treatment process in the first tail trim assembly... a carbonized film formed along an inner surface of the first and second tail trim portions
Data Source
AI summary
The present invention relates to a tail trim assembly of an exhaust pipe for a vehicle of which shape is simplified to reduce the number of portions and process is changed to simplify processes so that manufacturing cost is reduced and productivity and quality are improved, and a method of manufacturing the tail trim. According to the present invention, a tail trim of an exhaust pipe for a vehicle includes a first tail trim portion of which one end is attached to an exhaust pipe at the rear portion of a vehicle, and a second tail trim portion that has an inner diameter increased in a streamlined shape toward the outside and is integrally formed with the other end of the first tail trim portion.