Segmented Muffler Jacket for Gas-Tight Tube Connection
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Solution Overview
Problem
The existing design of jacketed mufflers for exhaust systems faces challenges in creating a gas-tight connection between the inner tube and the jacket, making it difficult to introduce the interior tube into a prefabricated jacket and complicating the later attachment of the jacket, especially when the muffler is mounted transversely.
Innovation Solution
The muffler is segmented circumferentially into a separate jacket segment with a collar and a remaining jacket, allowing the inner tube to be joined to the jacket segment for a high-quality connection, which can be preassembled and then complemented with the remaining jacket, simplifying manufacturing and enabling a gas-tight seal through a circumferential weld seam.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the inner tube is led from the inside through the jacket opening to the outside for gas-tight connection, then the connection quality is improved, but the difficulty of introducing the inner tube into a prefabricated jacket increases
Solution Approach 1:
The jacket is divided into a jacket segment containing the jacket opening and a remaining jacket. The jacket segment is manufactured separately as a preassembly unit, allowing the inner tube to be connected to the jacket segment before final assembly with the remaining jacket. This segmentation enables easier introduction of the inner tube while maintaining gas-tight connection quality.
Solution Approach 2:
The jacket segment with the jacket opening is preassembled with the inner tube before the final assembly with the remaining jacket. This preliminary action allows the inner tube to be introduced and connected in a more accessible configuration, simplifying the manufacturing process while ensuring gas-tight connection.
2Ease of manufacture
If the jacket is segmented into a separate jacket segment and remaining jacket, then the ease of manufacture is improved, but the device complexity increases
Solution Approach 1:
The jacket is segmented into a jacket segment and a remaining jacket, where the jacket segment contains the jacket opening and is manufactured separately. This segmentation simplifies manufacturing by allowing the jacket segment to be preassembled with the inner tube using simpler tools, while the overall device complexity is managed through modular assembly.
3Ease of manufacture
If the inner tube is connected from the outside through the jacket opening, then the manufacturing process is simplified, but the connection quality and gas-tight seal are compromised
Solution Approach 1:
By segmenting the jacket into a jacket segment with the opening and a remaining jacket, the inner tube can be connected to the jacket segment from the outside in a simplified manner, while the preassembly unit maintains the capability for high-quality gas-tight connection through the collar structure.
Solution Approach 2:
The collar structure acts as an intermediary element between the inner tube and the jacket segment. It provides a dedicated connection interface that simplifies the manufacturing process while ensuring gas-tight sealing, mediating between the simplified external connection approach and the requirement for high connection quality.
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 simplifies the manufacturing process, allows for a high-quality, gas-tight connection, and facilitates easier assembly, reducing manufacturing costs and improving the reliability of the connection between the inner tube and the exhaust system.
Implementation Method 1
A gas-tight connection can be established by these measures between the inner tube and the collar in an especially simple manner, as a result of which the jacket opening can be sealed in an especially simple manner and with an especially high quality. At the same time, the connection to the exhaust system can also be embodied in a simple and gas-tight manner due to this mode of construction. For example, a tube of the exhaust system can be inserted into or attached to the inner tube and rigidly and tightly connected to the inner tube and/or to the collar by means of a circumferential weld seam.
Data Source
AI summary
A muffler (1) for an exhaust system of an internal combustion engine, especially of a motor vehicle, with a housing (2), which has a jacket (3) and an end bottom each at two mutually spaced longitudinal ends of the jacket (3). At least one jacket opening (7) is provided, which passes through the jacket (3) and through which an inner tube (8) arranged in the interior of housing (2) can be connected to a tube of the exhaust system. The manufacture of the muffler (1) can be simplified if the jacket (3) is segmented in the circumferential direction (5) and has a jacket segment (11), which is manufactured as a separate component in relation to the remaining jacket (12). The separate component jacket segment (11) is rigidly connected to the remaining jacket (12) and has the at least one jacket opening (7).