Muffler Tube Bayonet Joint for Rattle-Free Exhaust Assembly
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Solution Overview
Problem
Existing muffler production methods face challenges in creating a stable and rattle-free connection between muffler tubes and walls in exhaust systems without requiring additional material joining measures.
Innovation Solution
A bayonet connector is used to connect muffler tubes to muffler walls, featuring bayonet connector receptacles and projections, ensuring defined positioning and stability, with optional additional material or force-locking measures for enhanced security.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If material joining measures (welding) are used to connect muffler tubes to muffler walls, then connection strength is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The connection system is segmented into distinct functional elements: the bayonet connector projection on the muffler tube and the corresponding receptacle in the muffler wall. This segmentation allows for modular assembly where the tube can be inserted and locked independently without requiring complex joining processes.
Solution Approach 2:
Instead of using traditional welding where the wall penetrates and joins to the tube, the invention inverts the approach by having the tube carry the active bayonet connector projection that inserts into and locks within the wall's receptacle. This reversal simplifies the joining mechanism while maintaining connection strength.
2Reliability
If traditional welding is used to connect muffler tubes to walls, then connection stability is improved, but manufacturing time and productivity are reduced
Solution Approach 1:
The bayonet connector projection is pre-formed on the muffler tube during tube manufacturing, and the receptacle is pre-formed in the muffler wall during wall manufacturing. This preliminary preparation of connection features eliminates the need for post-assembly welding operations, significantly improving manufacturing speed while ensuring connection stability through the mechanical locking design.
Solution Approach 2:
The bayonet connector design allows the muffler tube to self-position and self-lock within the muffler wall through the insertion and rotation motion of the bayonet projection within the receptacle. This self-servicing connection mechanism eliminates the need for external joining operations, improving both productivity and connection reliability.
3Reliability
If additional joining measures are used to prevent rattling, then connection stability is improved, but device complexity increases
Solution Approach 1:
The invention merges the positioning function and the anti-rattle locking function into a single integrated bayonet connector mechanism. The projection-receptacle design simultaneously provides defined positioning during insertion and positive locking to prevent rattling, eliminating the need for separate positioning features and additional securing elements.
Solution Approach 2:
The bayonet connector projection serves multiple functions: it guides the tube into proper alignment during insertion, engages with the receptacle to provide defined positioning, and locks through rotational motion to prevent rattling. This multi-functional design achieves rattle-free connection stability without increasing device complexity through additional components.
Data Source
AI summary
A muffler for an exhaust system includes a circumferential wall surrounding a muffler interior, at least one muffler wall, which adjoins the circumferential wall and/or is arranged in the muffler interior, at least one muffler tube, which extends in the direction of a tube axis and passes through a tube passage opening in at least one muffler wall. At least one muffler tube passing through a tube passage opening in a muffler wall is connected to the muffler wall by a bayonet connector.