Multipart Muffler Pipe Assembly for Rattle-Free Exhaust Routing
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Solution Overview
Problem
Existing mufflers for internal combustion engines face challenges in achieving a stable and noise-free connection between exhaust-gas routing pipes and the muffler housing, leading to potential rattling noises due to relative movements.
Innovation Solution
The muffler design incorporates multi-part exhaust-gas routing pipes with overlapping pipe parts connected by radial widening and material closure, such as welding, to ensure stable and noise-free connections, with the second pipe part secured to the retaining wall and the first pipe part connected to the peripheral wall through a peripheral-wall opening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a one-piece exhaust-gas routing pipe is used, then the structure is simple, but relative movements between the pipe and muffler components cause rattling noises
Solution Approach 1:
The exhaust-gas routing pipe is divided into multiple separate parts (first pipe part and second pipe part) that can be independently connected to different muffler components. This segmentation allows each pipe part to be optimally positioned and secured, preventing relative movements that cause rattling noises while maintaining structural simplicity through modular design.
2Ease of manufacture
If pipe parts are connected by mechanical reshaping alone, then assembly is easy, but the connection may not be gas-tight
Solution Approach 1:
The connection method merges two approaches: mechanical reshaping (radial widening) for easy assembly and material closure (welding) for gas-tight sealing. The pipe parts are first mechanically reshaped to fit together, then welded to ensure both ease of assembly and reliable gas-tight connection.
3Reliability
If pipe parts overlap in longitudinal direction, then connection stability is improved, but manufacturing complexity increases
Solution Approach 1:
The pipe parts are designed to nest within each other in the longitudinal direction, with one pipe part inserted into the other. This nesting arrangement provides stable connection through overlapping while maintaining a compact structure that does not significantly increase overall assembly complexity.
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 design achieves a stable and noise-free muffler structure by preventing relative movements between pipe parts, ensuring a gas-tight seal and reducing rattling noises, while allowing for easy assembly and durability.
Implementation Method 1
the first pipe part and the second pipe part have been connected to one another by radial widening of at least the first pipe part at least in its longitudinal region overlapping with the second pipe part
Implementation Method 2
the second pipe part being connected to the at least one retaining wall via material closure
Data Source
AI summary
A muffler for an exhaust system of an internal combustion engine includes a muffler housing having a peripheral wall elongated along a longitudinal axis of the muffler housing. The peripheral wall has first and second end walls. A muffler insert is surrounded by the peripheral wall and is supported thereon. The muffler insert has a retaining wall extending in a direction of the longitudinal axis. The peripheral wall has a peripheral wall opening and a first exhaust-gas routing pipe has a first end region and is positioned with the first end region thereof engaging in the peripheral wall opening. The first exhaust-gas routing pipe has a second end region and is secured by the second end region thereof to the retaining wall. The first exhaust-gas routing pipe is of multi-part configuration and has a first pipe part and a second pipe part.