EP2571636B1 - Method for manufacturing an exhaust gas muffler for internal combustion engines - Google Patents

Method for manufacturing an exhaust gas muffler for internal combustion engines Download PDF

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Publication number
EP2571636B1
EP2571636B1 EP11724995.3A EP11724995A EP2571636B1 EP 2571636 B1 EP2571636 B1 EP 2571636B1 EP 11724995 A EP11724995 A EP 11724995A EP 2571636 B1 EP2571636 B1 EP 2571636B1
Authority
EP
European Patent Office
Prior art keywords
shell
outer contour
contour
peripheral region
deep
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Not-in-force
Application number
EP11724995.3A
Other languages
German (de)
French (fr)
Other versions
EP2571636A1 (en
Inventor
Klaus Schröer
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Tenneco GmbH
Original Assignee
Tenneco GmbH
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Tenneco GmbH filed Critical Tenneco GmbH
Publication of EP2571636A1 publication Critical patent/EP2571636A1/en
Application granted granted Critical
Publication of EP2571636B1 publication Critical patent/EP2571636B1/en
Not-in-force legal-status Critical Current
Anticipated expiration legal-status Critical

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D22/00—Shaping without cutting, by stamping, spinning, or deep-drawing
    • B21D22/20—Deep-drawing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D22/00—Shaping without cutting, by stamping, spinning, or deep-drawing
    • B21D22/20—Deep-drawing
    • B21D22/26—Deep-drawing for making peculiarly, e.g. irregularly, shaped articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D51/00—Making hollow objects
    • B21D51/16—Making hollow objects characterised by the use of the objects
    • B21D51/18—Making hollow objects characterised by the use of the objects vessels, e.g. tubs, vats, tanks, sinks, or the like
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D53/00—Making other particular articles
    • B21D53/88—Making other particular articles other parts for vehicles, e.g. cowlings, mudguards
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N13/00—Exhaust or silencing apparatus characterised by constructional features ; Exhaust or silencing apparatus, or parts thereof, having pertinent characteristics not provided for in, or of interest apart from, groups F01N1/00 - F01N5/00, F01N9/00, F01N11/00
    • F01N13/18—Construction facilitating manufacture, assembly, or disassembly
    • F01N13/1872—Construction facilitating manufacture, assembly, or disassembly the assembly using stamp-formed parts or otherwise deformed sheet-metal
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D22/00—Shaping without cutting, by stamping, spinning, or deep-drawing
    • B21D22/20—Deep-drawing
    • B21D22/22—Deep-drawing with devices for holding the edge of the blanks
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N13/00—Exhaust or silencing apparatus characterised by constructional features ; Exhaust or silencing apparatus, or parts thereof, having pertinent characteristics not provided for in, or of interest apart from, groups F01N1/00 - F01N5/00, F01N9/00, F01N11/00
    • F01N13/18—Construction facilitating manufacture, assembly, or disassembly
    • F01N13/1861—Construction facilitating manufacture, assembly, or disassembly the assembly using parts formed by casting or moulding
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N13/00—Exhaust or silencing apparatus characterised by constructional features ; Exhaust or silencing apparatus, or parts thereof, having pertinent characteristics not provided for in, or of interest apart from, groups F01N1/00 - F01N5/00, F01N9/00, F01N11/00
    • F01N13/18—Construction facilitating manufacture, assembly, or disassembly
    • F01N13/1888—Construction facilitating manufacture, assembly, or disassembly the housing of the assembly consisting of two or more parts, e.g. two half-shells
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N13/00—Exhaust or silencing apparatus characterised by constructional features ; Exhaust or silencing apparatus, or parts thereof, having pertinent characteristics not provided for in, or of interest apart from, groups F01N1/00 - F01N5/00, F01N9/00, F01N11/00
    • F01N13/18—Construction facilitating manufacture, assembly, or disassembly
    • F01N13/1888—Construction facilitating manufacture, assembly, or disassembly the housing of the assembly consisting of two or more parts, e.g. two half-shells
    • F01N13/1894—Construction facilitating manufacture, assembly, or disassembly the housing of the assembly consisting of two or more parts, e.g. two half-shells the parts being assembled in longitudinal direction

Definitions

  • the invention relates to a method for determining an inner and / or outer contour K Si , K Sa of an edge region B S of a shell for producing a muffler.
  • a method for determining an inner and / or outer contour K Si , K Sa of an edge region B S of a shell for producing a muffler is eg in the CA-A-2058136 disclosed.
  • CA 2,058,136 is formed from a pair of shell molds, wherein the two shell molds are crimped for connection to an edge surface.
  • tongues are provided, which serve for fastening a heat shield. The tongues are placed in excess areas of the respective shell mold, which would otherwise be cut off during cutting.
  • the DE 20 2008 016 200 U1 describes a two-part muffler whose basic shape has two corner regions, which are each extended beyond the length of the basic shape. With regard to the width, however, the corner areas are back relative to the basic shape. An optimized utilization of the sheet metal strip to be deformed is thus not achieved.
  • a shell muffler which, unlike a rectangular basic shape, has two corner regions which are widened in relation to the width of the rectangular basic shape.
  • a shell muffler which has several formations in the edge region for the purpose of forming an input or output dome for connecting an exhaust pipe.
  • the respective shape protrudes beyond the rectangular basic shape.
  • a pot silencer which is formed of two pot halves, which are connected using one or more shelves in the longitudinal direction.
  • an off-center opening for the purpose of forming a collar for connecting an exhaust pipe is provided.
  • a draft is assigned to the passage over a partial circumference.
  • the invention has the object of providing a method for producing a muffler from mold shells in such a way that a material savings and improved acoustic performance are guaranteed.
  • a box-shaped inner contour may be a method for producing a shell muffler for an internal combustion engine, which is formed of a first shell and at least a second shell, which to form said shell muffler circulating on the respective edge region B S are connected, K Si having four corner regions E1 - E4 and a width B and a length L and an outer contour K Sa and the respective shell is made from a shell blank R formed by forming a sheet metal strip by using a mold having the shape of the shell, wherein the blank R after forming has an edge region B R with an outer contour K R , and the edge region B R in the subsequent Cutting the blank R to form an outer contour K Sa of the edge portion B S of the shell is at least partially cut using an inner and / or outer contour K Si , K Sa , determined according to the method described above.
  • either the inner contour K Si of the edge region B S of the shell is provided in addition to the box-shaped basic shape G with at least one corner region E1 - E4, which is extended beyond the width B and the length L and thus at least partially to the outer contour K R of adapted to be trimmed edge region B R of the blank R and / or provided on the respective shell a molding A for forming an input or output dome for connecting an exhaust pipe, the molding A after forming relative to the basic shape G of the inner contour K Si of the edge region B S of the shell protrudes by a depth t1, wherein the depth t1 is selected such that in order to form the shape A, the size of the sheet metal strip must not be larger than in the absence of the molding A.
  • the edge region B to be cut off R of the blank in order to form the inner or outer contour K Si , KS a of the shell altogether gleichblei Bender is formed so that there is a material saving.
  • the volume of the respective shell can be increased overall.
  • the shell can be made less broad or less long overall in order to keep the same volume, which is accompanied by further material savings.
  • the metal strip used for deep drawing or the corresponding coil may be formed narrower.
  • a recess E is provided, which is provided in addition to the sidecut T, wherein the indentation E relative to the basic shape G of the inner contour K Si of the edge portion B S of the shell by a depth t2 is lagging behind.
  • the respective shell at least in the region of a longitudinal or transverse edge, has the shape A for an input or output dome.
  • the features described above relating to the maximum depth t1 of this configuration A ensure the previously described savings regarding the width or length of the metal strip used.
  • Due to the inventively provided indentation E the formation of a shape A is possible, which has a desired height h.
  • the indentation E ensures an increase in the size or height h of the shape A beyond the waisting T of the basic shape G addition.
  • the indentation E is provided in addition to the sidecut T.
  • the height h of the formation A can reach the total depth t1 plus t2. After the trimming of the shell, the depth t1 decreases and can also become zero when the formation is trimmed at the level of the inner contour K Si .
  • the outer contour K Sa has a shape deviating from the inner contour K Si .
  • the inner contour K Si and the outer contour K Sa each other.
  • the outer contour K Sa can be adjusted beyond the extension of the inner contour K Si to the contour K R of the blank or its corner regions, so that the acoustic properties can be favorably influenced.
  • the inner contour K Si and / or the outer contour K Sa of the edge region B S of the shell is formed from a first longitudinal edge L1, a second longitudinal edge L2, a first transverse edge Q1 and a second transverse edge Q2 and the four corner regions E1, E2, E3, E4, wherein the respective corner region E1, E2, E3, E4 connects a longitudinal edge L1, L2 with a transverse edge Q1, Q2 and the edge region B S of the shell at least in the region of a longitudinal edge L1, L2 and / or a Transverse edge Q1, Q2 has a sidecut T, which extends over at least 50% to 80% of a width w1 and / or a width w2 of the shell.
  • the picking up of a shape with a sidecut T is advantageous.
  • a sidecut is accompanied by the fact that the shell is narrower or shorter in the area of the sidecut than in the area of the respective corner, which justify the beginning and end of the sidecut.
  • the upper limit of the sidecut is probably in the range of 90% to 95%, depending on the radius of the corner to be applied. At 100% waist ratio no waist is no longer available.
  • the inner contour K Si and / or the outer contour K Sa of the edge region B S of the shell in the region of both longitudinal edges L1, L2 and / or in the region of both transverse edges Q1, Q2 has the sidecut T.
  • the waist can optionally be provided at different longitudinal or transverse edges. This is depending on the desired design and the associated resonance behavior on the one hand and the desired material savings to decide on the other hand. It may be favorable if the sidecut is provided both on both longitudinal and on both transverse edges, so that overall the aforementioned advantages add up to a maximum.
  • the inner contour K Si and / or the outer contour K Sa of the edge region B S of the shell establishes a bone-shaped basic shape G.
  • the waist is provided on all four longitudinal edges, resulting in an exemplary embodiment bone-shaped basic shape G, due to the extended corner areas the previously described maximum volume while minimizing the width of the sheet metal strip used on the one hand and minimizing the length of the metal strip to be used guaranteed on the other hand.
  • a first shell 1.1 of a shell muffler 1 is formed by deep-drawing a metal strip 2, which is formed rectangular starting from a metal strip coil.
  • a desired contour K S of the shell 1.1 with a basic shape G
  • the after Fig. 1 box-shaped, that is rectangular formed with rounded corners a so-called blank R is first obtained, the edge of which has a contour K R , on the one hand deviates from the rectangular shape of the sheet metal strip 2 and on the other hand deviates from the desired box-shaped contour K S of the shell 1.1.
  • the contour K R of the blank R is also referred to as bone-shaped, since in the region of the respective corner the remaining edge to be cut off for the purpose of forming the contour K S or outer contour K Sa of the shell 1.1 is substantially larger than in the region between the respective corner.
  • the shell 1.1 or contour K S has a basic shape G, in which corner regions E1-E4 are widened beyond the width B and the length L, so that the contour K S is at least partially adjacent to the contour K R of the edge region to be trimmed B R of the blank R is adjusted.
  • the contour K S or the basic shape G has a sidecut T.
  • the distance is the two longitudinal edges L1, L2 and the two transverse edges Q1, Q2 smaller than a length w1 of the shell 1.1 and a width w2 of the shell 1.1.
  • the shell 1.1 shown here has in the region of its longitudinal edge L2 a shape A for an input or output calotte 1.3 after Fig. 4 on.
  • a depression E of the depth t2 is provided in the region of the formation A.
  • the indentation E is essentially formed from a rounding radius V R 1 and an adjoining connecting portion V A 1.
  • the indentation E is provided in addition to the sidecut T.
  • the shape A extends over the aforementioned rounding radius V R 1 and the adjoining connecting portion V A 1 and a subsequent rounding radius V R 2 over a height h.
  • the formation A projects in the region of the longitudinal edge L2 only over a depth t1 beyond the bone-shaped inner contour K Si of the shell 1.1.
  • the depth t1 is selected such that the sheet-metal strip 2 does not have to be chosen wider because of the shape A than in the case without shape A.
  • the depth t1 accordingly corresponds approximately to the thickness of the edge region B S or the height of the rounding radius V R 2 which adjoins the connecting portion V A 1 and the rounding radius V R 1 of the molding A. Consequently, the shape A ends approximately at the level of the outer contour K Sa.
  • the waist T runs over approximately 84% of the length w1 and 66% of the width w2.
  • the sidecut T may also be provided only on a part of the respective longitudinal or transverse edges L1 to Q2.
  • FIG. 2b Sectional view SS off Fig. 2a (Partial sectional right half), the shell 1.1 a remaining edge portion B to S, the R of the blank R remains after the trimming of the edge area B with the outer contour K R.
  • this edge region B S the shell 1.1 with a corresponding second shell 1.2 after Fig. 4 connected. This can be done by welding or flanging.
  • the edge region B S has an inner contour K Si and an outer contour K Sa , according to the embodiment Fig. 2a . 2 B are the same. In principle, it is also possible that the inner contour K Si deviates from the outer contour K Sa.
  • the expression K S according to the invention is to be provided at least in the area of the inner contour K Si . Consequently follows at least a similar size or extension for the outer contour K Sa.
  • the expression or extension for the outer contour K Sa can also be greater than that of the inner contour K Si .
  • the illustrated deep-drawing tool 3 or drawing punch also has an outer contour K W with a bone-shaped basic shape G3 with four corner regions E1-E4.
  • the deep-drawing tool 3 also has two forms 3.1, 3.1 'to form a desired shape A for an input or output calotte 1.3 both in the region of the longitudinal edge as well as in the area of the transverse edge.
  • the forms 3.1, 3.1 ' are shown by a depth t3, t3' on the outer contour K W.
  • the depth t3, t3 ' is chosen such that the width of the available sheet metal strip 2 is sufficient for the formation of the shape A.
  • an offset 3.2, 3.2 ' is provided in addition to the sidecut T, the offset 3.2, 3.2' being set back by a depth t4 relative to the basic shape G of the outer contour Kw.
  • the shape 3.1 is thus over the depth t3 plus the depth t4 on the basic shape G of the outer contour Kw out.
  • both the first shell and the second shell 1.1 1.2 and the corresponding same basic shape or contour G K S, which in the corner areas E1 - E4 Fig. 2a in accordance with the generally remaining edge region B R or its contour K R of the blank R are formed or extended according to.
  • the two shells 1.1 and 1.2 are connected to each other in the edge region B S , so that they limit the total per shell guaranteed extended volume in duplicate form.
  • the bone-shaped design of the shell muffler 1 to be seen here also ensures the previously described acoustic advantages.
  • the shells 1.1, 1.2 are trimmed, so that the outer contour K Sa results.
  • the shape A is also cropped, so the depth t1 (not shown) is significantly smaller than after molding.
  • Fig. 5 shows the detail view D Fig. 2a concerning the shape A with the rounding radius V R1 of the indentation E, the rounding radius V R2 , the shape A and the connecting portion V A , via which the inner contour K Si is transferred into the contour of the shape A.
  • the height h of the shape A corresponds to the two depths t1 and t2.
  • the depth t1 is the extent to which the shape A projects in the region of the longitudinal edge L2 beyond the bone-shaped inner contour K Si or the basic shape G of the shell 1.1.
  • the depth t2 is the extent to which the indentation E is set back relative to the basic shape G of the inner contour K Si of the edge region B S of the shell 1.1, 1.2.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • General Engineering & Computer Science (AREA)
  • Exhaust Silencers (AREA)
  • Shaping Metal By Deep-Drawing, Or The Like (AREA)

Description

Die Erfindung bezieht sich auf ein Verfahren zum Ermitteln einer Innen- und/oder Außenkontur KSi, KSa eines Randbereichs BS einer Schale zum Herstellen eines Schalldämpfers. Solch ein Verfahren ist z.B. in der CA-A-2058136 offenbart. Es ist bereits ein Abgasschalldämpfer aus der CA 2,058,136 bekannt, der aus einem Paar Formschalen gebildet ist, wobei die beiden Formschalen zwecks Verbindung an einer Randfläche gebördelt werden. Im Bereich der Randfläche sind weitere Zungen vorgesehen, die zum Befestigen eines Hitzeschildes dienen. Die Zungen sind in überschüssigen Bereichen der jeweiligen Formschale platziert, die sonst beim Zuschnitt abgeschnitten würden.The invention relates to a method for determining an inner and / or outer contour K Si , K Sa of an edge region B S of a shell for producing a muffler. Such a method is eg in the CA-A-2058136 disclosed. It is already an exhaust silencer from the CA 2,058,136 known, which is formed from a pair of shell molds, wherein the two shell molds are crimped for connection to an edge surface. In the area of the edge surface further tongues are provided, which serve for fastening a heat shield. The tongues are placed in excess areas of the respective shell mold, which would otherwise be cut off during cutting.

Die DE 20 2008 016 200 U1 beschreibt einen zweiteiligen Schalldämpfer, dessen Grundform zwei Eckbereiche aufweist, die jeweils über die Länge der Grundform hinaus erweitert sind. Bezüglich der Breite stehen die Eckbereiche jedoch relativ zur Grundform zurück. Eine optimierte Ausnutzung der zu verformenden Blechstreifen wird damit jedoch nicht erreicht.The DE 20 2008 016 200 U1 describes a two-part muffler whose basic shape has two corner regions, which are each extended beyond the length of the basic shape. With regard to the width, however, the corner areas are back relative to the basic shape. An optimized utilization of the sheet metal strip to be deformed is thus not achieved.

Aus der DE 198 49 118 A1 ist ein Schalenschalldämpfer bekannt, der abweichend von einer rechteckförmigen Grundform zwei Eckbereiche aufweist, die bezüglich der Breite der rechteckförmigen Grundform erweitert sind.From the DE 198 49 118 A1 a shell muffler is known, which, unlike a rectangular basic shape, has two corner regions which are widened in relation to the width of the rectangular basic shape.

Aus der EP 1 316 462 A1 ist ein Schalenschalldämpfer bekannt, der im Randbereich mehrere Ausformungen zwecks Bildung einer Ein- oder Ausgangskalotte zum Anschließen eines Abgasrohres aufweist. Die jeweilige Ausformung steht über die rechteckförmige Grundform hervor.From the EP 1 316 462 A1 a shell muffler is known, which has several formations in the edge region for the purpose of forming an input or output dome for connecting an exhaust pipe. The respective shape protrudes beyond the rectangular basic shape.

Aus der EP 0 395 540 A1 ist ein Topfschalldämpfer bekannt, der gebildet ist aus zwei Topfhälften, die unter Anwendung von einem oder mehreren Zwischenböden in Längsrichtung verbunden werden. Im endseitigen Topfboden ist ein außermittiger Durchbruch zwecks Bildung eines Kragens zum Anschließen eines Abgasrohres vorgesehen. Zwecks Gewährleistung eines gleichmäßig hohen Kragenrandes ist dem Durchzug über einen Teilumfang ein Einzug zugeordnet.From the EP 0 395 540 A1 is known a pot silencer, which is formed of two pot halves, which are connected using one or more shelves in the longitudinal direction. In the end-side pot bottom an off-center opening for the purpose of forming a collar for connecting an exhaust pipe is provided. In order to ensure a uniformly high collar edge a draft is assigned to the passage over a partial circumference.

Der Erfindung liegt die Aufgabe zugrunde, ein Verfahren zur Herstellung eines Abgasschalldämpfers aus Formschalen derart auszubilden, dass eine Materialersparnis und ein verbessertes akustisches Verhalten gewährleistet sind.The invention has the object of providing a method for producing a muffler from mold shells in such a way that a material savings and improved acoustic performance are guaranteed.

Gelöst wird die Aufgabe erfindungsgemäß durch die Verfahren nach Patentanspruch 1 und Patentanspruch 2.The object is achieved according to the invention by the method according to claim 1 and claim 2.

Die Ermittlung der Außen- bzw. Innenkontur KSa, KSi auf iterativem Wege gewährleistet eine optimale Ausbildung der gewünschten Kontur.The determination of the outer or inner contour K Sa , K Si in an iterative way ensures optimum formation of the desired contour.

Vorteilhaft kann sein ein Verfahren zum Herstellen eines Schalenschalldämpfers für eine Brennkraftmaschine, der gebildet wird aus einer ersten Schale und mindestens einer zweiten Schale, die zwecks Bildung des Schalenschalldämpfers am jeweiligen umlaufenden Randbereich BS verbunden werden, wobei der jeweilige Randbereich BS eine kastenförmige Innenkontur KSi mit vier Eckbereichen E1 - E4 und einer Breite B und eine Länge L sowie eine Außenkontur KSa aufweist und die jeweilige Schale aus einem Schalenrohling R hergestellt wird, der durch Umformung eines Blechstreifens durch Anwendung eines die Form der Schale aufweisenden Tiefziehwerkzeugs gebildet wird, wobei der Rohling R nach dem Umformen einen Randbereich BR mit einer äußeren Kontur KR aufweist, und der Randbereich BR beim anschließenden Zuschnitt des Rohlings R zwecks Bildung einer Außenkontur KSa des Randbereichs BS der Schale zumindest teilweise abgeschnitten wird unter Anwendung einer Innen- und/oder Außenkontur KSi, KSa, ermittelt nach dem vorgehend beschriebenen Verfahren. Hierbei wird entweder die Innenkontur KSi des Randbereichs BS der Schale ergänzend zu der kastenförmigen Grundform G mit mindestens einem Eckbereich E1 - E4 versehen, der über die Breite B und die Länge L hinaus erweitert ist und somit zumindest teilweise an die Außenkontur KR des zu beschneidenden Randbereichs BR des Rohlings R angepasst und/oder an der jeweiligen Schale eine Ausformung A zwecks Bildung einer Ein- oder Ausgangskalotte zum Anschließen eines Abgasrohres vorgesehen, wobei die Ausformung A nach dem Umformen relativ zu der Grundform G der Innenkontur KSi des Randbereichs BS der Schale um eine Tiefe t1 hervorsteht, wobei die Tiefe t1 derart gewählt ist, dass zwecks Bildung der Ausformung A die Größe des Blechstreifens nicht größer gewählt werden muss als bei einem Ausbleiben der Ausformung A. Hierdurch wird erreicht, dass der abzuschneidende Randbereich BR des Rohlings zwecks Bildung der Innen- bzw. Außenkontur KSi, KSa der Schale insgesamt gleichbleibender ausgebildet ist, so dass eine Materialeinsparung vorliegt. Ferner kann durch die Ausnutzung dieser Eck-Volumina das Volumen der jeweiligen Schale insgesamt vergrößert werden. Vor dem Hintergrund einer solchen Volumenvergrößerung kann die Schale insgesamt weniger breit bzw. weniger lang ausgebildet werden, um gleiches Volumen zu halten, womit eine weitere Materialeinsparung einhergeht. Im Falle der Anwendung einer vorstehend beschriebenen geringeren Breite der Schale kann auch der zum Tiefziehen verwendete Blechstreifen bzw. der entsprechende Coil schmaler ausgebildet sein.Advantageously, wherein the respective edge region B S a box-shaped inner contour may be a method for producing a shell muffler for an internal combustion engine, which is formed of a first shell and at least a second shell, which to form said shell muffler circulating on the respective edge region B S are connected, K Si having four corner regions E1 - E4 and a width B and a length L and an outer contour K Sa and the respective shell is made from a shell blank R formed by forming a sheet metal strip by using a mold having the shape of the shell, wherein the blank R after forming has an edge region B R with an outer contour K R , and the edge region B R in the subsequent Cutting the blank R to form an outer contour K Sa of the edge portion B S of the shell is at least partially cut using an inner and / or outer contour K Si , K Sa , determined according to the method described above. In this case, either the inner contour K Si of the edge region B S of the shell is provided in addition to the box-shaped basic shape G with at least one corner region E1 - E4, which is extended beyond the width B and the length L and thus at least partially to the outer contour K R of adapted to be trimmed edge region B R of the blank R and / or provided on the respective shell a molding A for forming an input or output dome for connecting an exhaust pipe, the molding A after forming relative to the basic shape G of the inner contour K Si of the edge region B S of the shell protrudes by a depth t1, wherein the depth t1 is selected such that in order to form the shape A, the size of the sheet metal strip must not be larger than in the absence of the molding A. This ensures that the edge region B to be cut off R of the blank in order to form the inner or outer contour K Si , KS a of the shell altogether gleichblei Bender is formed so that there is a material saving. Furthermore, by exploiting these corner volumes, the volume of the respective shell can be increased overall. Against the background of such an increase in volume, the shell can be made less broad or less long overall in order to keep the same volume, which is accompanied by further material savings. In the case of the application of a smaller width of the shell described above, the metal strip used for deep drawing or the corresponding coil may be formed narrower.

Zudem wird durch die Ausnutzung dieser Eck-Bereiche des Randbereichs BR des Rohlings eine von der üblichen kastenförmigen Grundform G abweichende Innen- bzw. Außenkontur KSi bzw. KSa der Schale bzw. des Randbereichs BS erhalten, mit der ein günstiges Resonanzverhalten bzw. akustisches Verhalten einhergeht.In addition, by exploiting these corner regions of the edge region B R of the blank, an inner or outer contour K Si or KS a of the shell or of the edge region B S deviating from the usual box-shaped basic shape G is obtained, with which a favorable resonance behavior resp acoustic behavior goes along.

Ergänzend hierzu kann es vorteilhaft sein, wenn im Bereich der Ausformung A eine Einformung E vorgesehen wird, die ergänzend zu der Taillierung T vorgesehen ist, wobei die Einformung E relativ zu der Grundform G der Innenkontur KSi des Randbereichs BS der Schale um eine Tiefe t2 zurücksteht.In addition, it may be advantageous if in the region of the molding A a recess E is provided, which is provided in addition to the sidecut T, wherein the indentation E relative to the basic shape G of the inner contour K Si of the edge portion B S of the shell by a depth t2 is lagging behind.

In der Regel weist die jeweilige Schale zumindest im Bereich einer Längs- oder Querkante die Ausformung A für eine Ein- oder Ausgangskalotte auf. Die vorstehend beschriebenen Merkmale betreffend die maximale Tiefe t1 dieser Ausformung A gewährleisten die vorgehend beschriebenen Einsparungen betreffend die Breite bzw. Länge des verwendeten Blechstreifens. Aufgrund der erfindungsgemäß vorgesehenen Einformung E ist die Bildung einer Ausformung A möglich, die eine wunschgemäße Höhe h aufweist. Die Einformung E gewährleistet eine Erhöhung der Größe bzw. Höhe h der Ausformung A über die Taillierung T der Grundform G hinaus. Insoweit ist gemäß Definition der Erfindung die Einformung E ergänzend zur Taillierung T vorgesehen. Die Höhe h der Ausformung A kann insgesamt die Tiefe t1 plus t2 erreichen. Nach dem Beschneiden der Schale verringert sich die Tiefe t1 und kann auch Null werden, wenn die Ausformung auf der Höhe der Innenkontur KSi beschnitten wird.As a rule, the respective shell, at least in the region of a longitudinal or transverse edge, has the shape A for an input or output dome. The features described above relating to the maximum depth t1 of this configuration A ensure the previously described savings regarding the width or length of the metal strip used. Due to the inventively provided indentation E, the formation of a shape A is possible, which has a desired height h. The indentation E ensures an increase in the size or height h of the shape A beyond the waisting T of the basic shape G addition. In that regard, according to the definition of the invention, the indentation E is provided in addition to the sidecut T. The height h of the formation A can reach the total depth t1 plus t2. After the trimming of the shell, the depth t1 decreases and can also become zero when the formation is trimmed at the level of the inner contour K Si .

Vorteilhaft kann es hierzu auch sein, wenn die Außenkontur KSa eine von der Innenkontur KSi abweichende Form aufweist. Vorzugsweise entsprechen die Innenkontur KSi und die Außenkontur KSa einander. Jedoch kann die Außenkontur KSa über die Erweiterung der Innenkontur KSi hinaus an die Kontur KR des Rohlings bzw. dessen Eckbereiche angepasst werden, so dass auf die akustischen Eigenschaften günstig Einfluss genommen werden kann.It can also be advantageous for this purpose if the outer contour K Sa has a shape deviating from the inner contour K Si . Preferably, the inner contour K Si and the outer contour K Sa each other. However, the outer contour K Sa can be adjusted beyond the extension of the inner contour K Si to the contour K R of the blank or its corner regions, so that the acoustic properties can be favorably influenced.

Ferner kann es vorteilhaft sein, wenn die Innenkontur KSi und/oder die Außenkontur KSa des Randbereichs BS der Schale gebildet ist aus einer ersten Längskante L1, einer zweiten Längskante L2, einer ersten Querkante Q1 und einer zweiten Querkante Q2 sowie den vier Eckbereichen E1, E2, E3, E4, wobei der jeweilige Eckbereich E1, E2, E3, E4 eine Längskante L1, L2 mit einer Querkante Q1, Q2 verbindet und der Randbereich BS der Schale zumindest im Bereich einer Längskante L1, L2 und/oder einer Querkante Q1, Q2 eine Taillierung T aufweist, die sich über mindestens 50 % bis 80 % einer Weite w1 und/oder einer Weite w2 der Schale erstreckt. Ausgehend von einer üblichen Kontur KR eines Rohlings, die im Bereich der jeweiligen Ecke der auszuprägenden Schale einen deutlich größeren Überstand über die erwünschte Grundform G begründet als in dem Bereich zwischen der jeweiligen Ecke, ist das Aufgreifen einer Form mit einer Taillierung T vorteilhaft. Mit einer solchen Taillierung geht die Tatsache einher, dass die Schale im Bereich der Taillierung schmaler bzw. kürzer ausgebildet ist als im Bereich der jeweiligen Ecke, die jeweils Beginn und Ende der Taillierung begründen. Die obere Grenze der Taillierung ist je nach anzusetzendem Radius der Ecke wohl im Bereich von 90 % bis 95 % zu sehen. Bei 100 % Taillierungsanteil ist keine Taillierung mehr vorhanden.Furthermore, it can be advantageous if the inner contour K Si and / or the outer contour K Sa of the edge region B S of the shell is formed from a first longitudinal edge L1, a second longitudinal edge L2, a first transverse edge Q1 and a second transverse edge Q2 and the four corner regions E1, E2, E3, E4, wherein the respective corner region E1, E2, E3, E4 connects a longitudinal edge L1, L2 with a transverse edge Q1, Q2 and the edge region B S of the shell at least in the region of a longitudinal edge L1, L2 and / or a Transverse edge Q1, Q2 has a sidecut T, which extends over at least 50% to 80% of a width w1 and / or a width w2 of the shell. Starting from a usual contour K R of a blank, which in the region of the respective corner of the tray to be imputed a significantly larger projection on the desired basic form G justified than in the area between the respective corner, the picking up of a shape with a sidecut T is advantageous. With such a sidecut is accompanied by the fact that the shell is narrower or shorter in the area of the sidecut than in the area of the respective corner, which justify the beginning and end of the sidecut. The upper limit of the sidecut is probably in the range of 90% to 95%, depending on the radius of the corner to be applied. At 100% waist ratio no waist is no longer available.

Vorteilhaft kann es auch sein, wenn die Innenkontur KSi und/oder die Außenkontur KSa des Randbereichs BS der Schale im Bereich beider Längskanten L1, L2 und/oder im Bereich beider Querkanten Q1, Q2 die Taillierung T aufweist. Die Taillierung kann wahlweise an verschiedenen Längs- bzw. Querkanten vorgesehen sein. Dies ist je nach gewünschter Ausgestaltung und dem damit einhergehenden Resonanzverhalten einerseits sowie der gewünschten Materialersparnis andererseits zu entscheiden. Günstig kann es sein, wenn die Taillierung sowohl an beiden Längs- als auch an beiden Querkanten vorgesehen ist, so dass sich insgesamt die vorgenannten Vorteile auf ein Maximum addieren.It may also be advantageous if the inner contour K Si and / or the outer contour K Sa of the edge region B S of the shell in the region of both longitudinal edges L1, L2 and / or in the region of both transverse edges Q1, Q2 has the sidecut T. The waist can optionally be provided at different longitudinal or transverse edges. This is depending on the desired design and the associated resonance behavior on the one hand and the desired material savings to decide on the other hand. It may be favorable if the sidecut is provided both on both longitudinal and on both transverse edges, so that overall the aforementioned advantages add up to a maximum.

Dabei kann es vorteilhafterweise vorgesehen sein, dass die Innenkontur KSi und/oder die Außenkontur KSa des Randbereichs BS der Schale eine knochenförmige Grundform G begründet. Für den Fall, dass die Taillierung an allen vier Längskanten vorgesehen ist, ergibt sich eine nach Ausführungsbeispiel knochenförmige Grundform G, mit der aufgrund der erweiterten Eckbereiche das vorgehend beschriebene maximale Volumen unter Minimierung der Breite des verwendeten Blechstreifens einerseits sowie Minimierung der Länge des zu verwendenden Blechstreifens andererseits gewährleistet ist.It can advantageously be provided that the inner contour K Si and / or the outer contour K Sa of the edge region B S of the shell establishes a bone-shaped basic shape G. In the event that the waist is provided on all four longitudinal edges, resulting in an exemplary embodiment bone-shaped basic shape G, due to the extended corner areas the previously described maximum volume while minimizing the width of the sheet metal strip used on the one hand and minimizing the length of the metal strip to be used guaranteed on the other hand.

Weitere Vorteile und Einzelheiten der Erfindung sind in den Patentansprüchen und in der Beschreibung erläutert und in den Figuren dargestellt. Es zeigen:

Figur 1
eine Draufsicht einer Schale nach dem Stand der Technik;
Figur 2a
eine Draufsicht einer erfindungsgemäßen Schale;
Figur 2b
eine Schnittdarstellung S-S aus Figur 2a;
Figur 3
eine perspektivische Ansicht eines Tiefziehwerkzeugs;
Figur 4
eine perspektivische Ansicht eines Schalenschalldämpfers.
Further advantages and details of the invention are explained in the patent claims and in the description and illustrated in the figures. Show it:
FIG. 1
a plan view of a shell according to the prior art;
FIG. 2a
a plan view of a shell according to the invention;
FIG. 2b
a sectional view SS FIG. 2a ;
FIG. 3
a perspective view of a thermoforming tool;
FIG. 4
a perspective view of a shell muffler.

Eine erste Schale 1.1 eines Schalenschalldämpfers 1 nach dem Stand der Technik wird gebildet durch Tiefziehen eines Blechstreifens 2, der ausgehend von einem Blechband-Coil rechteckförmig ausgebildet ist. Durch Tiefziehen einer gewünschten Kontur KS der Schale 1.1 mit einer Grundform G, die nach Fig. 1 kastenförmig, also rechteckförmig mit abgerundeten Ecken ausgebildet ist, wird zunächst ein sogenannter Rohling R erhalten, dessen Rand eine Kontur KR aufweist, die einerseits von der rechteckigen Form des Blechstreifens 2 abweicht und andererseits von der gewünschten kastenförmigen Kontur KS der Schale 1.1 abweicht. Die Kontur KR des Rohlings R wird auch als knochenförmig bezeichnet, da im Bereich der jeweiligen Ecke der verbleibende und zwecks Bildung der Kontur KS bzw. Außenkontur KSa der Schale 1.1 abzuschneidende Rand wesentlich größer ist als in dem Bereich zwischen der jeweiligen Ecke.A first shell 1.1 of a shell muffler 1 according to the prior art is formed by deep-drawing a metal strip 2, which is formed rectangular starting from a metal strip coil. By deep drawing a desired contour K S of the shell 1.1 with a basic shape G, the after Fig. 1 box-shaped, that is rectangular formed with rounded corners, a so-called blank R is first obtained, the edge of which has a contour K R , on the one hand deviates from the rectangular shape of the sheet metal strip 2 and on the other hand deviates from the desired box-shaped contour K S of the shell 1.1. The contour K R of the blank R is also referred to as bone-shaped, since in the region of the respective corner the remaining edge to be cut off for the purpose of forming the contour K S or outer contour K Sa of the shell 1.1 is substantially larger than in the region between the respective corner.

Nach Fig. 2a ist die erfindungsgemäße Kontur KS, also Außenkontur KSa und Innenkontur KSi der Schale 1.1 an die knochenförmige Kontur KR des Rohlings R angepasst. Die Schale 1.1 bzw. Kontur KS weist hierzu eine Grundform G auf, bei der Eckbereiche E1 - E4 über die Breite B und die Länge L hinaus erweitert sind, so dass die Kontur KS zumindest teilweise an die Kontur KR des zu beschneidenden Randbereichs BR des Rohlings R angepasst ist. Somit ergeben sich zwei gegenüberliegenden Längskanten L1, L2 und zwei wiederum gegenüberliegenden Querkanten Q1, Q2, die jeweils über einen Eckbereich E1, E2, E3, E4 miteinander verbunden sind. Zwischen den jeweiligen Eckbereichen E1 bis E4 weist die Kontur KS bzw. die Grundform G eine Taillierung T auf. Im Bereich der jeweiligen Taillierung T ist der Abstand der beiden Längskanten L1, L2 bzw. der beiden Querkanten Q1, Q2 kleiner als eine Länge w1 der Schale 1.1 bzw. eine Breite w2 der Schale 1.1. Mit der Erweiterung des jeweiligen Eckbereichs E1 bis E4 in die Eckzone eines Randbereichs BR des Rohlings R ergeben sich eine Volumenvergrößerung des durch die Schale 1.1 einseitig begrenzten Volumens und eine Verkleinerung des abzuschneidenden Randbereichs BR des Rohlings R. Durch diese Volumenvergrößerung kann die Gesamtweite w2 bzw. die Gesamtweite w1 zwecks Gewährleistung des gleichen Volumens der jeweiligen Schale 1.1 verkleinert werden.To Fig. 2a is the inventive contour K S , ie outer contour K Sa and inner contour K Si of the shell 1.1 adapted to the bone-shaped contour K R of the blank R. For this purpose, the shell 1.1 or contour K S has a basic shape G, in which corner regions E1-E4 are widened beyond the width B and the length L, so that the contour K S is at least partially adjacent to the contour K R of the edge region to be trimmed B R of the blank R is adjusted. This results in two opposite longitudinal edges L1, L2 and two again opposite transverse edges Q1, Q2, which are connected to each other via a corner region E1, E2, E3, E4. Between the respective corner regions E1 to E4, the contour K S or the basic shape G has a sidecut T. In the area of the respective sidecut T, the distance is the two longitudinal edges L1, L2 and the two transverse edges Q1, Q2 smaller than a length w1 of the shell 1.1 and a width w2 of the shell 1.1. With the extension of the respective corner region E1 to E4 in the corner zone of an edge region B R of the blank R, there is an increase in volume of the volume limited by the shell 1.1 and a reduction of the edge region B R of the blank R to be cut off. By this increase in volume, the total width w2 or the total width w1 in order to ensure the same volume of the respective shell 1.1 be reduced.

Die hier dargestellte Schale 1.1 weist im Bereich ihrer Längskante L2 eine Ausformung A für eine Ein- bzw. Ausgangskalotte 1.3 nach Fig. 4 auf. Zwecks Bildung dieser Ausformung A ist im Bereich der Ausformung A eine Einformung E der Tiefe t2 vorgesehen. Die Einformung E ist im Wesentlichen gebildet aus einem Verrundungsradius VR1 und einem daran anschließenden Verbindungsabschnitt VA1. Die Einformung E ist ergänzend zu der Taillierung T vorgesehen. Die Ausformung A erstreckt sich über den vorgenannten Verrundungsradius VR1 und den daran anschließenden Verbindungsabschnitt VA1 sowie einen daran anschließenden Verrundungsradius VR2 über eine Höhe h. Aufgrund der Einformung E steht die Ausformung A im Bereich der Längskante L2 lediglich über eine Tiefe t1 über die knochenförmige Innenkontur KSi der Schale 1.1 hervor. Die Tiefe t1 ist derart gewählt, dass der Blechstreifen 2 allein aufgrund der Ausformung A nicht breiter gewählt werden muss als in dem Fall ohne Ausformung A. Die Tiefe t1 entspricht demnach etwa der Dicke des Randbereichs BS bzw. der Höhe des Verrundungsradius VR2, der an den Verbindungsabschnitt VA1 und den Verrundungsradius VR1 der Ausformung A anschließt. Mithin endet die Ausformung A etwa auf Höhe der Außenkontur KSa.The shell 1.1 shown here has in the region of its longitudinal edge L2 a shape A for an input or output calotte 1.3 after Fig. 4 on. For the purpose of forming this formation A, a depression E of the depth t2 is provided in the region of the formation A. The indentation E is essentially formed from a rounding radius V R 1 and an adjoining connecting portion V A 1. The indentation E is provided in addition to the sidecut T. The shape A extends over the aforementioned rounding radius V R 1 and the adjoining connecting portion V A 1 and a subsequent rounding radius V R 2 over a height h. Due to the indentation E, the formation A projects in the region of the longitudinal edge L2 only over a depth t1 beyond the bone-shaped inner contour K Si of the shell 1.1. The depth t1 is selected such that the sheet-metal strip 2 does not have to be chosen wider because of the shape A than in the case without shape A. The depth t1 accordingly corresponds approximately to the thickness of the edge region B S or the height of the rounding radius V R 2 which adjoins the connecting portion V A 1 and the rounding radius V R 1 of the molding A. Consequently, the shape A ends approximately at the level of the outer contour K Sa.

Die Taillierung T verläuft über etwa 84 % der Länge w1 und 66 % der Breite w2. In einem nicht dargestellten Ausführungsbeispiel kann die Taillierung T auch nur an einem Teil der jeweiligen Längs- bzw. Querkanten L1 bis Q2 vorgesehen sein.The waist T runs over approximately 84% of the length w1 and 66% of the width w2. In an embodiment not shown, the sidecut T may also be provided only on a part of the respective longitudinal or transverse edges L1 to Q2.

Nach Fig. 2b, Schnittdarstellung S-S aus Fig. 2a (Teilschnitt rechte Hälfte) weist die Schale 1.1 einen verbleibenden Randbereich BS auf, der nach dem Beschneiden des Randbereichs BR des Rohlings R mit der Außenkontur KR verbleibt. In diesem Randbereich BS wird die Schale 1.1 mit einer korrespondierenden zweiten Schale 1.2 nach Fig. 4 verbunden. Dies kann durch Verschweißung oder Umbördelung erfolgen. Letztlich weist der Randbereich BS eine Innenkontur KSi sowie eine Außenkontur KSa auf, die nach Ausführungsbeispiel Fig. 2a, 2b gleich sind. Grundsätzlich ist es auch möglich, dass die Innenkontur KSi von der Außenkontur KSa abweicht. Zwecks Gewährleistung eines erfindungsgemäßen maximalen Volumens ist die erfindungsgemäße Ausprägung der Kontur KS zumindest im Bereich der Innenkontur KSi vorzusehen. Mithin folgt zumindest eine ähnlich große Ausprägung bzw. Erweiterung für die Außenkontur KSa. Die Ausprägung bzw. Erweiterung für die Außenkontur KSa kann auch größer sein als die der Innenkontur KSi.To Fig. 2b , Sectional view SS off Fig. 2a (Partial sectional right half), the shell 1.1 a remaining edge portion B to S, the R of the blank R remains after the trimming of the edge area B with the outer contour K R. In this edge region B S , the shell 1.1 with a corresponding second shell 1.2 after Fig. 4 connected. This can be done by welding or flanging. Finally, the edge region B S has an inner contour K Si and an outer contour K Sa , according to the embodiment Fig. 2a . 2 B are the same. In principle, it is also possible that the inner contour K Si deviates from the outer contour K Sa. In order to ensure a maximum volume according to the invention, the expression K S according to the invention is to be provided at least in the area of the inner contour K Si . Consequently follows at least a similar size or extension for the outer contour K Sa. The expression or extension for the outer contour K Sa can also be greater than that of the inner contour K Si .

Ein in Fig. 3 dargestelltes Tiefziehwerkzeug 3 bzw. Ziehstempel weist ebenfalls eine Außenkontur KW mit einer knochenförmigen Grundform G3 mit vier Eckbereichen E1 - E4 auf. Das Tiefziehwerkzeug 3 weist zudem zwei Formen 3.1, 3.1' zur Bildung einer gewünschten Ausformung A für eine Ein- bzw. Ausgangskalotte 1.3 sowohl im Bereich der Längskante als auch im Bereich der Querkante auf. Die Formen 3.1, 3.1' stehen um eine Tiefe t3, t3' über die Außenkontur KW hervor. Die Tiefe t3, t3' ist derart gewählt, dass die Breite des zur Verfügung stehenden Blechstreifens 2 zur Ausbildung der Ausformung A ausreicht. Zudem ist im Bereich der Form 3.1 ergänzend zu der Taillierung T ein Versatz 3.2, 3.2' vorgesehen ist, wobei der Versatz 3.2, 3.2' relativ zu der Grundform G der Außenkontur Kw um eine Tiefe t4 zurücksteht. Die Form 3.1 steht somit über die Tiefe t3 plus die Tiefe t4 über die Grundform G der Außenkontur Kw hervor.An in Fig. 3 The illustrated deep-drawing tool 3 or drawing punch also has an outer contour K W with a bone-shaped basic shape G3 with four corner regions E1-E4. The deep-drawing tool 3 also has two forms 3.1, 3.1 'to form a desired shape A for an input or output calotte 1.3 both in the region of the longitudinal edge as well as in the area of the transverse edge. The forms 3.1, 3.1 'are shown by a depth t3, t3' on the outer contour K W. The depth t3, t3 'is chosen such that the width of the available sheet metal strip 2 is sufficient for the formation of the shape A. In addition, in the area of the form 3.1, an offset 3.2, 3.2 'is provided in addition to the sidecut T, the offset 3.2, 3.2' being set back by a depth t4 relative to the basic shape G of the outer contour Kw. The shape 3.1 is thus over the depth t3 plus the depth t4 on the basic shape G of the outer contour Kw out.

Nach Fig. 4 weisen sowohl die erste Schale 1.1 als auch die zweite Schale 1.2 die korrespondierende und gleiche Grundform G bzw. Kontur KS auf, die in den Eckbereichen E1 - E4 nach Fig. 2a entsprechend dem in der Regel verbleibenden Randbereich BR bzw. dessen Kontur KR des Rohlings R nach ausgebildet bzw. erweitert sind. Die beiden Schalen 1.1 und 1.2 sind im Randbereich BS miteinander verbunden, so dass sie insgesamt das pro Schale gewährleistete erweiterte Volumen in doppelter Form begrenzen. Die hier zu sehende knochenförmige Ausbildung des Schalenschalldämpfers 1 gewährleistet auch die vorgehend beschriebenen akustischen Vorteile. Darüber hinaus sind im Bereich der jeweiligen Schale Rippen 1.4, 1.4' vorgesehen, die ergänzend das akustische Verhalten bzw. Resonanzverhalten verbessern. Die Rippen 1.4, 1.4' verlaufen etwa parallel zur jeweiligen Querkante. Daneben können diese auch mehrfach vorgesehen sein und alternativ in einem nicht dargestellten Ausführungsbeispiel auch in andere Richtungen, insbesondere parallel zur jeweiligen Längskante, verlaufen. Die Schalen 1.1, 1.2 sind beschnitten, so dass sich die Außenkontur KSa ergibt. Die Ausformung A ist ebenfalls beschnitten, so dass die Tiefe t1 (nicht dargestellt) deutlich kleiner ist als nach dem Ausformen.To Fig. 4 , both the first shell and the second shell 1.1 1.2 and the corresponding same basic shape or contour G K S, which in the corner areas E1 - E4 Fig. 2a in accordance with the generally remaining edge region B R or its contour K R of the blank R are formed or extended according to. The two shells 1.1 and 1.2 are connected to each other in the edge region B S , so that they limit the total per shell guaranteed extended volume in duplicate form. The bone-shaped design of the shell muffler 1 to be seen here also ensures the previously described acoustic advantages. In addition, ribs 1.4, 1.4 'are provided in the region of the respective shell, which additionally improve the acoustic behavior or resonance behavior. The ribs 1.4, 1.4 'extend approximately parallel to the respective transverse edge. In addition, these can also be provided several times and alternatively in an embodiment not shown in other directions, in particular parallel to the respective longitudinal edge, run. The shells 1.1, 1.2 are trimmed, so that the outer contour K Sa results. The shape A is also cropped, so the depth t1 (not shown) is significantly smaller than after molding.

Fig. 5 zeigt die Detailansicht D aus Fig. 2a betreffend die Ausformung A mit dem Verrundungsradius VR1 der Einformung E, dem Verrundungsradius VR2, der Ausformung A und dem Verbindungsabschnitt VA, über die die Innenkontur KSi in die Kontur der Ausformung A überführt wird. Die Höhe h der Ausformung A entspricht den beiden Tiefen t1 und t2. Dabei ist die Tiefe t1 das Maß, mit dem die Ausformung A im Bereich der Längskante L2 über die knochenförmige Innenkontur KSi bzw. die Grundform G der Schale 1.1 hervorsteht. Die Tiefe t2 ist das Maß, mit dem die Einformung E relativ zu der Grundform G der Innenkontur KSi des Randbereichs BS der Schale 1.1, 1.2 zurücksteht. Fig. 5 shows the detail view D Fig. 2a concerning the shape A with the rounding radius V R1 of the indentation E, the rounding radius V R2 , the shape A and the connecting portion V A , via which the inner contour K Si is transferred into the contour of the shape A. The height h of the shape A corresponds to the two depths t1 and t2. In this case, the depth t1 is the extent to which the shape A projects in the region of the longitudinal edge L2 beyond the bone-shaped inner contour K Si or the basic shape G of the shell 1.1. The depth t2 is the extent to which the indentation E is set back relative to the basic shape G of the inner contour K Si of the edge region B S of the shell 1.1, 1.2.

BezugszeichenlisteLIST OF REFERENCE NUMBERS

11
Schalenschalldämpfershell muffler
1.11.1
erste Schalefirst shell
1.21.2
zweite Schalesecond shell
1.31.3
Ein- oder AusgangskalotteInput or output dome
1.41.4
Rippenribs
1.4'1.4 '
Rippenribs
22
Blechstreifenmetal strip
33
TiefziehwerkzeugThermoforming mold
3.13.1
Form für Ein- oder AusgangskalotteForm for input or output dome
3.1'3.1 '
Form für Ein- oder AusgangskalotteForm for input or output dome
3.23.2
Versatzoffset
3.2'3.2 '
Versatzoffset
AA
Ausformungformation
w1w1
Längelength
w2w2
Breitewidth
BB
Breitewidth
BR B R
Randbereichborder area
BS B s
Randbereichborder area
DD
Detailansichtdetailed view
Ee
Einformungindentation
E1E1
Eckbereichcorner
E2E2
Eckbereichcorner
E3E3
Eckbereichcorner
E4E4
Eckbereichcorner
GG
GrundformBasic form
G3G3
GrundformBasic form
hH
Höheheight
KR K R
Kontur RohlingContour blank
KSi K Si
Innenkontur SchaleInner contour shell
KSa K Sa
Außenkontur SchaleOuter contour shell
KW K W
Außenkontur TiefziehwerkzeugOuter contour thermoforming tool
LL
Längelength
L1L1
erste Längskantefirst longitudinal edge
L2L2
zweite Längskantesecond longitudinal edge
Q1Q1
erste Querkantefirst transverse edge
Q2Q2
zweite Querkantesecond transverse edge
RR
Schalenrohlingbowl Blanks
TT
Taillierungsidecut
t1t1
Tiefedepth
t2t2
Tiefedepth
VA V A
Verbindungsabschnittconnecting portion
VR1V R 1
VerrundungsradiusRounding radius
VR2V R 2
VerrundungsradiusRounding radius
w1w1
Weitewidth
w2w2
Weitewidth

Claims (4)

  1. Method for determining an inner contour and/or an outer contour KSi, KSa of a peripheral region BS of a shell (1. 1, 1.2) for producing a silencer (1) with the following method steps:
    a) Deep-drawing of a shell (1.1, 1.2) from a sheet strip (2) with a deep-drawing tool (3) with a box-shaped outer contour Kw;
    b) determining the outer contour KR of the deep-drawn blank R produced in this way;
    c) extension of at least one of the corner regions E1-E4 of the deep-drawing tool (3) in such a way that the outer contour Kw, and therefore the inner contour and/or outer contour KSi, KSa which are to be produced are brought into proximity with the outer contour KR;
    d) at least one repetition of the method steps a) to c).
  2. Method for determining an inner contour and/or outer contour KSi, KSa of a peripheral region BS of a shell (1. 1, 1.2) for producing a silencer (1) with the following method steps:
    a) Deep-drawing of a shell (1.1, 1.2) from a sheet strip (2) with a deep-drawing tool (3) with an outer contour Kw, wherein the outer contour Kw has a shape (3.1) for forming a cut-out aperture A for the purpose of forming an inlet or outlet connection opening (1.3) for connecting an exhaust pipe;
    b) determining the depth t1, t2 of the cut-out aperture A of the deep-drawn blank R produced in this way;
    c) optimising the depth t3, t3' of the shape (3.1) of the outer contour Kw of the deep-drawing tool (3) and therefore of the inner contour and/or outer contour KSi, KSa which are to be produced, in such a way that,
    for the purpose of forming the cut-out aperture A, the size of the sheet strip (2) must be selected as not greater than if the cut-out aperture A were to be omitted.
  3. Method for producing a shell silencer (1) for an internal combustion engine, formed from a first shell (1.1) and at least one second shell (1.2), which are connected at the respective peripheral region BS, wherein the respective peripheral region BS has a box-shaped inner contour KSi with four corner regions E1-E4 and a width B and a length L, as well as an outer contour KSa, and the respective shell (1.1, 1.2) is produced from a shell blank R, which is formed by the shaping of a sheet strip (2) by using a deep-drawing tool (3) having the shape of the shell (1.1, 1.2), wherein the blank R, after shaping, has a peripheral region BR with an outer contour KR, and the peripheral region BR, at the subsequent cutting of the blank R for the purpose of forming the outer contour KSa of the peripheral region BS of the shell (1.1, 1.2) is at least partially removed by using an inner contour and/or outer contour KSa, determined in accordance with the method according to Claim 1, wherein
    a) the inner contour KSi of the peripheral region BS of the shell (1.1, 1.2), as a supplement to the box-shaped basic form G, is provided with at least one corner region E1-E4, which is extended beyond the width B and the length L of the box-shaped basic form G, and therefore the inner contour KS is adjusted to the contour KR of the intersecting peripheral region BR of the blank R and/or
    b) at the respective shell (1.1, 1.2), the cut-out aperture A is provided for the purpose of forming an inlet or outlet connection opening (1.3) for connecting an exhaust pipe, wherein the cut-out aperture A projects relative to the basic form G of the inner contour KS of the peripheral region BS of the shell (1.1, 1.2) by a depth t1, and the depth t1 is selected in such a way that, for the purpose of forming the cut-out aperture A, the size of the sheet strip (2) must be selected as not greater than if the cut-out aperture A were to be omitted.
  4. Method according to Claim 3,
    characterized in that
    a recess E is provided as complementary to the shaped region T, wherein the recess E is set back relative to the basic form G of the inner contour KSi of the peripheral region BS of the shell (1.1, 1.2) by a depth t2.
EP11724995.3A 2010-05-18 2011-05-17 Method for manufacturing an exhaust gas muffler for internal combustion engines Not-in-force EP2571636B1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE201010020826 DE102010020826B4 (en) 2010-05-18 2010-05-18 Exhaust silencer for internal combustion engines and thermoforming tool for this and method for producing such a silencer
PCT/EP2011/057983 WO2011144621A1 (en) 2010-05-18 2011-05-17 Exhaust gas muffler for internal combustion engines and deep drawing tool therefor

Publications (2)

Publication Number Publication Date
EP2571636A1 EP2571636A1 (en) 2013-03-27
EP2571636B1 true EP2571636B1 (en) 2018-03-14

Family

ID=44626973

Family Applications (1)

Application Number Title Priority Date Filing Date
EP11724995.3A Not-in-force EP2571636B1 (en) 2010-05-18 2011-05-17 Method for manufacturing an exhaust gas muffler for internal combustion engines

Country Status (6)

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US (1) US9440276B2 (en)
EP (1) EP2571636B1 (en)
CN (1) CN102985194B (en)
BR (1) BR112012029354A2 (en)
DE (1) DE102010020826B4 (en)
WO (1) WO2011144621A1 (en)

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP3431732B1 (en) 2017-07-21 2020-04-22 Bosal Emission Control Systems NV Method for forming a collar in a muffler housing
CN108266254A (en) * 2018-01-17 2018-07-10 无锡曙光模具有限公司 A kind of automobile silencing half-shell and its processing method

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Also Published As

Publication number Publication date
CN102985194B (en) 2015-12-09
CN102985194A (en) 2013-03-20
BR112012029354A2 (en) 2017-12-05
WO2011144621A1 (en) 2011-11-24
DE102010020826A1 (en) 2011-11-24
DE102010020826B4 (en) 2013-06-06
US9440276B2 (en) 2016-09-13
EP2571636A1 (en) 2013-03-27
US20130056298A1 (en) 2013-03-07

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