Silencer Annular Cavity Weld Flash Containment
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Solution Overview
Problem
Existing silencers face issues with welding flash causing contamination, clearance problems, and increased packaging space due to protruding weld seams, which can lead to styling and functional issues, as well as potential engine damage from debris.
Innovation Solution
A silencer design featuring a tubular casing with two welded parts and an integrated third part that forms an annular cavity to contain weld flash, allowing for a clean production process without additional flash traps, and using spin welding to connect all parts in one process, ensuring the third part is positioned to prevent rattling noise and maintain acoustic tightness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If friction welding is used to join casing parts, then the casing can be securely connected, but welding flash is generated causing contamination and clearance problems
Solution Approach 1:
The patent utilizes the welding flash that would normally be harmful by directing it into the annular cavity where it serves as a seal between the casing parts and the acoustic insert. The flash material fills the gap and creates an effective seal, converting the contamination problem into a functional sealing solution.
Solution Approach 2:
The annular cavity acts as an intermediary space that captures and contains the welding flash, preventing it from contaminating the engine compartment while utilizing it for sealing purposes. The cavity mediates between the welding process and the external environment.
2Object-generated harmful factors
If flash traps are added to contain welding flash, then contamination is reduced, but the package space increases
Solution Approach 1:
The patent merges the flash trap function with the acoustic insert by integrating the annular cavity into the existing acoustic component structure. This eliminates the need for separate flash trap components, reducing overall package space while maintaining flash containment capability.
Solution Approach 2:
The acoustic insert serves multiple functions: it provides acoustic treatment for noise reduction and simultaneously acts as a flash trap through its annular cavity design. This multi-functionality eliminates the need for dedicated flash trap components.
3Object-generated harmful factors
If additional flash traps are installed to prevent debris, then contamination is reduced, but the device complexity increases
Solution Approach 1:
The patent combines the flash trap functionality with the acoustic insert structure, eliminating the need for separate debris prevention components. The annular cavity integrated into the acoustic insert serves both acoustic and debris containment functions.
Solution Approach 2:
The acoustic insert is designed to perform multiple functions simultaneously: acoustic noise reduction and debris containment through its annular cavity. This multi-functionality reduces overall device complexity by eliminating separate components.
4Object-generated harmful factors
If the third part is positioned to contain weld flash, then contamination is reduced, but the manufacturing precision requirements increase
Solution Approach 1:
The welding process itself generates the sealing material (flash) that fills the annular cavity, automatically creating the seal without requiring precise pre-positioning of the third part. The system uses the process byproduct to achieve the sealing function.
Solution Approach 2:
The patent changes the state of the sealing interface from requiring precise geometric alignment to accepting a range of positions where the flash material can effectively seal. The sealing mechanism transitions from mechanical contact to material-based sealing that accommodates positioning variations.
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
The solution allows for a more efficient and clean production of silencers with reduced clearance issues and packaging space, preventing debris from interfering with gas flow and ensuring effective noise reduction without additional flash traps, while maintaining acoustic performance.
Implementation Method 1
using spin welding to connect all parts in one process
Implementation Method 2
a third part for the compensation of gas noise is positioned inside the tubular casing, wherein said third part is adopted and positioned in the casing in such a way that a weld flash which protrudes from an inner surface of said outer casing wall is kept inside an annular cavity formed at least by the third part and by the outer casing wall
Implementation Method 3
a third part for the compensation of gas noise is positioned inside the tubular casing
Data Source
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AI summary
A silencer for the reduction of gas noise in an intake system for acombustion engine, wherein the silencer comprises a tubular casing with a longitudinal casing axis and with at least a first and a second casing part welded together,wherein the two casing parts form an outer casing wall, wherein a weld seam connecting the first and the second casing part is part of the outer casing wall and wherein a third part for the compensation of gas noise is positioned inside the tubular casing, wherein said third part is adopted and positioned in the casing in such a way that a weld flash which protrudes from an inner surface of said outer casing wall is kept inside an annular cavity formed at least by the third part and by the outer casing wall,and a method for the production of such a silencer. Fig.