Vehicle Filter Pipe with Pre-Formed Furrows for Expanded Tube
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional filter pipe manufacturing processes require expanding the tube after welding, which limits the size of the expanded portion due to weight reduction trends in vehicles, causing issues with exhaust pipe insertion and potentially damaging welded portions.
Innovation Solution
A method involving forming furrows on one end of a mother member, bending it into a tubular shape, and spreading these furrows to create an expanded tube portion during the bending process, eliminating the need for post-welding expansion and allowing for increased expansion ratios.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If the tube is expanded after welding using conventional methods, then the expanded portion can be formed, but the expansion ratio is limited due to weight reduction trends in vehicles, preventing proper exhaust pipe insertion
Solution Approach 1:
The invention forms furrows on the tube surface before welding and expanding operations. These pre-formed furrows serve as expansion zones that enable greater expansion ratios when the tube is subsequently expanded after welding, allowing the exhaust pipe to be properly inserted without requiring additional shrinking processes.
2Shape
If the tube is expanded after welding, then the expanded portion is formed, but the welding portion may be damaged by the force applied during the expanding process
Solution Approach 1:
The invention creates localized furrows at specific positions on the tube surface before welding. During the expanding process, these furrowed portions serve as designated expansion zones that concentrate the deformation in specific areas, thereby protecting the welded portions from damage while still achieving the required expansion for exhaust pipe insertion.
3Weight of moving object
If the tube thickness is decreased for weight reduction, then vehicle weight is reduced, but the expanding ratio is limited and additional shrinking processes are required
Solution Approach 1:
The invention forms furrows on the tube surface before welding and expanding operations. These pre-formed furrows serve as expansion zones that enable greater expansion ratios when the tube is subsequently expanded after welding, allowing the exhaust pipe to be properly inserted without requiring additional shrinking processes.
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
This approach reduces manufacturing costs, prevents damage to welded portions, and enhances engine performance by ensuring sufficient flow passage without the need for additional shrinking processes.
Implementation Method 1
bending the planar member in a tubular shape
Implementation Method 2
spreading the furrows to form an area where the furrows are formed in an expanded tube shape
Implementation Method 3
adhering both end portions to one another by welding
Data Source
AI summary
A method of manufacturing a filter pipe for vehicles which has an expanded tube portion with a different diameter at one side and is provided with a plurality of through holes formed along a circumferential direction includes: forming the plurality of through holes in a mother member; forming furrows at one end portion of the mother member; forming a planar member having the plurality of through holes and the furrows by a shearing process of the mother member; bending the planar member in a tubular shape and spreading the furrows to form an area where the furrows are formed in an expanded tube shape; and adhering both facing end portions of the planar member so as to form a body having the expanded tube portion at one side thereof.