Vehicle Muffler Deep-Drawn Coupling Integration
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Solution Overview
Problem
Existing silencer designs face challenges in manufacturing complexity, particularly with modular structures requiring precise positioning and high accuracy, and the use of plastic materials limits applications where metal components are necessary.
Innovation Solution
A silencer design featuring a coupling device with a coupling body made from deep-drawn sheet metal parts, integrated into a one-piece housing with a step-tapered inflow opening, allowing for easy connection and sealing with a radial sealing ring, facilitating mass production and reducing production costs and complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If modular structure with multiple internal resonator elements is used, then sound absorption performance is improved, but manufacturing complexity and positioning accuracy requirements increase
Solution Approach 1:
The patent combines multiple resonator chambers into a single integrated housing structure rather than using separate modular elements. The housing (1, 2) contains multiple resonator chambers (3, 4, 5, 6) that are formed as part of the overall structure, eliminating the need for separate resonator elements and reducing assembly complexity while maintaining sound absorption performance.
2Ease of operation
If plastic materials with pivotable mounting are used for half-shells, then ease of assembly is improved, but production cost and complexity increase significantly
Solution Approach 1:
The patent merges the housing into a single integrated structure formed from sheet metal, eliminating the need for separate half-shells with pivotable mounting mechanisms. This single-piece construction reduces assembly steps and eliminates the complex pivotable mounting requirements while maintaining ease of manufacture through standard sheet metal forming processes.
Solution Approach 2:
The patent changes the material parameter from plastic to sheet metal, and changes the manufacturing method from injection molding with pivotable mounting to sheet metal forming with welded joints. This parameter change enables the use of standard industrial manufacturing processes and reduces production costs while maintaining assembly feasibility.
3Productivity
If deep-drawn sheet metal parts are used for housing and coupling body, then manufacturing efficiency and mass production suitability are improved, but geometric complexity may be limited
Solution Approach 1:
The patent utilizes the depth dimension in sheet metal forming to create complex three-dimensional resonator chambers within the housing structure. The resonator chambers (3, 4, 5, 6) are formed by deep-drawing processes that create intricate internal geometries while maintaining external simplicity, allowing complex shapes to be achieved through dimensional transformation in the forming process.
Data Source
Figure 1~3
Figure 2
Figure 4
AI summary
The invention relates to a muffler (1), in particular a vehicle muffler, comprising at least one resonator chamber (12), which is bounded at least by a first housing part (2) having a first outer jacket (15) and having a first end wall (16) arranged on the inflow side (25), in which first end wall an inflow opening (19) is arranged, and by a first internal pipe segment (20). Furthermore, at least one coupling device (6) for coupling to a turbocharger (9) is formed, which coupling device is accommodated in the first end wall (16) of the first housing part (2). The coupling device (6) comprises a coupling body (7), which is designed as a deep-drawn part. The first housing part (2) is likewise formed by a deep-drawn part, wherein the inflow opening (19) of the first housing part (2) has an extension (23) which is tapered in steps in an axial section, in which extension the coupling body (7) and a sealing element (27), such as a radial sealing ring, are accommodated.