KR20130142893A

KR20130142893A - Process for producing muffler using arc brazing and muffler thereof

Info

Publication number: KR20130142893A
Application number: KR1020130032800A
Authority: KR
Inventors: 이문희; 박정규; 김석진; 최형권; 김윤수
Original assignee: 주식회사 세정
Priority date: 2012-06-19
Filing date: 2013-03-27
Publication date: 2013-12-30

Abstract

The present invention relates to a muffler manufacturing method using arc brazing and a muffler manufactured by the same and, more specifically, to a muffler manufacturing method using arc brazing and a muffler manufactured by the same which improves a production rate by reducing the weight of a muffler and a failure rate by bonding a main muffler composed of one among two-layered SUS clad or a multilayered member (SUS + aluminum + SUS clad) and a pipe using arc brazing. A first joining unit in which a pipe guiding exhaust gas exhausted from a center muffler is inserted into one portion of the main muffler composed of one among the two-layered SUS clad or the multilayered member (SUS + aluminum + SUS clad) by a predetermined length; and a second joining unit which is joined to the other side of the main muffler and a tail pipe which is joined for guiding the exhaust gas to an outer side of a vehicle body is inserted by a predetermined length are formed. The first and second joining units are covered by molten filler metal via an arc brazing and cooled so that the pipe and the tail pipe are joined to the main muffler.

Description

Process for producing muffler using arc brazing and muffler manufactured by the method

The present invention relates to a method of manufacturing a muffler using arc brazing, and to a muffler manufactured by the method. Arc brazing is performed on a main muffler formed of two layers of SUS or a clad of one layer of SUS + aluminum + SUS. The present invention relates to a muffler manufacturing method using arc brazing which reduces the weight of a muffler by joining a main muffler and a pipe, reduces a defective rate, and increases the production rate of the muffler, and a muffler manufactured by the method.

In general, a vehicle is composed of various driving devices such as an engine, a suspension system, a body frame, a steering system, and in particular, an engine is a power for driving a vehicle through suction, compression, expansion (explosion), and exhaust stroke. You get At this time, a certain amount of exhaust gas is generated during the expansion stroke of the engine, and the generated exhaust gas is discharged by the exhaust stroke, and a catalytic converter and a muffler are used as devices for discharging the exhaust gas to the outside.

As described above, in the process of exhausting the exhaust gas generated from the engine to the outside, carbon monoxide, hydrocarbons and nitrogen oxides are reduced by the catalyst by the catalytic converter, and the muffler is introduced into the muffler in a reduced state. The structure has a configuration in which the catalytic converter, the sub muffler and the main muffler are connected in communication with the exhaust manifold of the engine.

Therefore, the exhaust gas generated from the engine is discharged to the outside through the catalytic converter, the center muffler and the main muffler after being collected into the exhaust manifold, and passes through the catalytic converter, and the carbon monoxide and hydrocarbons of the exhaust gas. And nitrogen oxides are reduced by the catalyst, and noise is reduced in the course of passing through the sub muffler and the main muffler.

Such a muffler is an inflatable type that diffuses from a thin tube into a wide space to reduce sound, a resonance type that diffuses from a large number of holes in a thin tube into a large resonance chamber, and cancels each other out, and steel wool. Absorption type which absorbs a metal into a thread form, and the partition type which mixed the previous three methods are used.

When the muffler is manufactured, as shown in FIG. 1A, the welding pipe 4 is overlapped with each of the out pipe 2 and the in pipe 3 inside the case 1 composed of a plurality of thin plates. To weld the seam of the muffler.

However, the welding method uses a metal inert gas welding (MIG) welding method, and the following problems occur when the MIG welding is used.

First, as shown in FIGS. 1B and 1C, when MIG welding is performed at the joint, the welding wire is continuously supplied to the joint and the welding is performed by melting the base material. In this case, the welding wire supplied to the joint is physically separated from the joint. It is difficult, and because of this irregular spacing occurs spatter (see Fig. 2b) and soot (see Fig. 1c) is generated around the weld has a problem of poor appearance.

In addition, as the chromium and nickel plated on the surfaces of the case 1 and the pipes 2 and 3 are oxidized, soot is generated, resulting in poor aesthetics.

Therefore, in order to remove such aesthetic defects and to prevent corrosion of the weld, ICG (cold zinc plating agent) is applied to the welded portion, as shown in FIG. 1D. There is a risky problem because it can be absorbed.

Second, in recent years, muffler is made of a case and a pipe made of a thin plate according to the weight reduction of the vehicle, and each joint is joined by MIG welding. As described above, when MIG welding is performed, as shown in FIG. 1E, the thin plate is melted due to overheating heat, causing melting, resulting in a defect of the product.

In addition, in the case of the out pipe 2 joined to the inside of the case 1 as shown in FIG. Do not. However, when the case 1 is located inside the out pipe 2, as shown in FIG. 1E, the in pipe 3 melts to form a hole, and the melt flows into the hole. This melt is to stay inside the muffler to generate noise, thereby causing a problem of the product.

Third, when MIG welding, toxic fumes are generated in the working process, a separate ventilator must be provided to vent these fumes, which increases installation costs.

Fourth, in the case of MIG welding, as shown in FIG. 1F, the spatter generated during welding adheres to the welding gun to block the nozzle for supplying the wire to the welding gun and the gas nozzle for supplying the gas, thereby causing an abnormality in the equipment. Due to the need for repair, there was a problem that productivity is lowered.

The present invention has been invented to solve the above problems, the object is that the appearance of the spatter, soot and melting does not occur by joining the joints of each of the mufflers without melting the base material using arc brazing during the manufacture of the muffler It is an object of the present invention to provide a muffler manufacturing method using arc brazing and a muffler produced by the manufacturing method, which can be cleaned, thereby increasing the defect rate of the product and increasing productivity.

The present invention for achieving the above technical problem is a pipe for guiding the exhaust gas flowing out of the center muffler on one side of the main muffler formed of two layers of SUS, or one layer of cladding made of SUS + aluminum + SUS A first coupling portion inserted into a predetermined length and a second coupling portion coupled to the other side of the main muffler and coupled to guide the exhaust gas to the outside of the vehicle body are inserted into the predetermined length, and the first coupling portion and the second coupling portion are formed. The first and second coupling parts are melted and covered by melting the filler metal through arc brazing, and then cooled to join pipes and tailpipes to the main muffler.

In one embodiment, the arc brazing, characterized in that any one of the CuAl or CuSi used as filler metal.

According to another aspect of the present invention, a pipe for guiding the exhaust gas flowing out of the center muffler to a side of a main muffler formed of any one of two layers of SUS or one layer of cladding made of SUS + aluminum + SUS is provided with a predetermined length. Coupling part; The first and second coupling parts are coupled to the other side of the main muffler and coupled to guide the exhaust gas to the outside of the vehicle body through arc brazing on the second coupling part and the first and second coupling parts. It is characterized in that the pipe and the tail pipe are joined to the main muffler by cooling the coupling part to cover the molten filler material.

According to the muffler manufacturing method using the arc brazing of the present invention and the muffler produced by the manufacturing method, firstly, the main muffler is a clad of different materials by melting the filler material in the joining part, not by melting the base material and joining. By using ash, the weight of the muffler can be reduced by 35% compared to the existing muffler, thereby reducing the weight of the vehicle.

Second, there is no need for a subsequent process of removing the spatter or soot generated in the welding portion, such as MIG welding used in the conventional muffler manufacturing, there is an effect of reducing the manufacturing cost and productivity.

Third, because the fume does not occur during the welding work, the operator can perform a smooth operation, there is no effect to install the device for ventilating the fume has the effect of reducing the installation cost.

Fourth, since the welding part is melted, such as MIG welding used in the conventional muffler manufacturing is not formed, the defect rate of the muffler can be significantly reduced, thereby increasing the productivity.

Fifth, by forming the main muffler with a single layer of cladding made of SUS + aluminum + SUS, the heat dissipation effect due to the thermal conductivity effect of aluminum can be enhanced, the weight of the main muffler can be reduced, and the durability can be increased because it is strong against corrosion. It works.

Figure 1 is a view for explaining the prior art Figure 1a is a view schematically showing the appearance of welding the muffler using MIG welding, Figure 1b is a view showing the appearance of spatter of the muffler manufactured through MIG welding Figure 1c is a view showing the appearance of soot produced muffler produced by MIG welding, Figure 1d is a view showing the appearance of the ICG applied to cover the spatter and soot generated in Figures 1b and 1c Figure 1e is a view showing a hole formed by melting the phosphor pipe, Figure 1f is a spatter generated during welding to the welding gun is stuck to the nozzle for supplying a wire to the welding gun and the gas nozzle for supplying gas is clogged It is a figure showing the state.
2 is a perspective view showing a muffler produced by the arc brazing of the present invention.
3A and 3B are schematic views illustrating arc brazing of each coupling unit of FIG. 2.
4 is a view showing a coupling portion of the muffler manufactured by the arc brazing of the present invention.

For a better understanding of the present invention, a preferred embodiment of the present invention will be described with reference to the accompanying drawings. The embodiments of the present invention may be modified into various forms, and the scope of the present invention should not be construed as being limited to the embodiments described in detail below. This embodiment is provided to more completely explain the present invention to those skilled in the art. Therefore, the shapes and the like of the elements in the drawings can be exaggeratedly expressed to emphasize a clearer description. It should be noted that in the drawings, the same members are denoted by the same reference numerals. In addition, detailed descriptions of well-known functions and configurations that are determined to unnecessarily obscure the subject matter of the present invention are omitted.

Hereinafter, by describing a preferred embodiment of the present invention with reference to the accompanying drawings, it will be described in detail a muffler manufacturing method using the arc brazing of the present invention and a muffler manufactured by the method.

Before we begin, let's take a quick look at arc brazing.

In general, arc brazing is a welding process in which a filler material having a lower melting point than a base material is infiltrated into the gap between the raw materials by using capillary phenomena without melting the base metal to be welded. One way.

Such arc brazing is most widely used when welding raw materials composed of thin plates, and is one of low cost and easy welding methods.

In addition, clad is a high-grade new material that combines various metals together and takes advantage of each metal. Among them, clad is aluminum with excellent thermal conductivity, heat preservation rate and thermal efficiency, and stainless steel with excellent flame resistance, acid resistance, alkali resistance and corrosion resistance. Steel bonded materials are the most widely used.

In the clad manufacturing method, aluminum is inserted between two or more layers of stainless steel and pressed together with heat to prepare a joint. The thermal conductivity of stainless steel is 0.04cal / cm.sec ℃, but the thermal conductivity of clad is 0.35cal / cm.sec ℃, so it is widely used in pressure cookers, heat exchangers, building interior and exterior materials, and kitchen utensils.

In the present invention is to increase the heat dissipation effect of the muffler to the maximum by configuring the main muffler by using a clad of one layer consisting of two layers of SUS or SUS + aluminum + SUS.

Figure 2 is a perspective view showing a muffler manufactured by the arc brazing of the present invention, Figures 3a and 3b is a view schematically showing the appearance of arc brazing in each coupling portion of Figure 2, Figure 4 is an arc of the present invention The figure which shows the coupling part of the muffler manufactured by brazing.

The muffler manufactured by the arc brazing of the present invention includes a first coupling part 12 into which a pipe 11 for guiding exhaust gas flowing out of the center muffler is inserted into a predetermined length on one side of the main muffler 10, and the main The second coupling portion 14 and the first and second coupling portions 12 and 14 into which a tail pipe 13 coupled to the other side of the muffler 10 and coupled to guide the exhaust gas to the outside of the vehicle body is inserted a predetermined length. Pipe 11 and tail pipe 13 are joined to the main muffler 10 by cooling the first and second coupling parts 12 and 14 to cover the molten filler material through arc brazing. It is composed.

The main muffler 10 can be formed using any one of two layers of SUS or one layer of cladding made of SUS + aluminum + SUS, and can be selectively used according to the type of vehicle.

As such, when the arc brazing is performed on the first and second coupling parts 12 and 14 through any one of CuAl or CuSi as the filler material in the main muffler, the joint part as shown in FIG. 4 is generated.

Hereinafter, a muffler manufactured by the arc brazing of the present invention manufactured by the above method will be described.

The muffler manufacturing method using the arc brazing of the present invention, the first coupling portion 12 is a predetermined length is inserted into the pipe 11 for guiding the exhaust gas flowing out of the center muffler on one side of the main muffler 10, and the main A second coupling part 14 is formed to which a tail pipe 13 coupled to the other side of the muffler 10 and coupled to guide the exhaust gas to the outside of the vehicle body is inserted a predetermined length.

The first and second coupling parts 12 and 14 are melted and covered by melting one of CuAl or CuSi with a filler metal through arc brazing, and then cooled. The pipe 11 and the tail pipe 13 are joined to the main muffler 10.

When the arc brazing to the first and second coupling portion 12, 14 through such filler material, the junction as shown in FIG. Therefore, spatters and soot are not generated around the joint, and the appearance is clear, and subsequent steps such as applying a conventional ICG are unnecessary.

In addition, since the joining of the pipe 11 and the tail pipe 13, which are the base metals, is performed in the shape of covering the joining portion by arc brazing, not by melting the joining method, smooth melting is possible.

In addition, since the bonding portion is formed in gold, it is possible to produce a luxurious atmosphere.

Meanwhile, as described in the above two embodiments, the main muffler 10 may be formed using any one of two layers of SUS or one layer of cladding made of SUS + aluminum + SUS. This will be described in detail.

When the main muffler is composed of two layers of SUS, as shown in FIG. 3A, the deformation and damage (melting) of the external shape hardly occur during arc brazing because it is resistant to heat, and the entire muffler is lighter than the conventional main muffler. It is possible to reduce the weight of.

In addition, as shown in Figure 3b, one layer of the clad made of SUS + aluminum + SUS is made of a cladding by diffusion bonding of SUS, Al and SUS, which is composed of three layers but physically bonded to each other It is a state. Therefore, as described above, when the clad of one layer made of SUS + aluminum + SUS is used in the main muffler, the thermal conductivity, heat preservation rate, thermal efficiency, flame resistance, acid resistance, alkali resistance and corrosion resistance are excellent. The deformation and damage of the muffler appearance are not caused, and the heat dissipation effect is also excellent, so that the heat generated from the main muffler can be quickly released to the outside.

Embodiments of the muffler manufacturing method using the arc brazing of the present invention described above and the muffler manufactured by the manufacturing method are merely exemplary, and those skilled in the art to which the present invention pertains It will be appreciated that other variations and equivalent embodiments are possible. Therefore, it is to be understood that the present invention is not limited to the above-described embodiments. Accordingly, the true scope of the present invention should be determined by the technical idea of the appended claims. It is also to be understood that the invention includes all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims.

10: main muffler 11: pipe
12; First coupling portion 13: tail pipe
14: second coupling part

Claims

A first coupling part into which a pipe 11 for guiding the exhaust gas flowing out of the center muffler is inserted into one side of the main muffler 10 formed of any one of two layers of SUS or one layer of SUS + aluminum + SUS cladding ( 12 and a second coupling part 14 coupled to the other side of the main muffler 10 to insert a tail pipe 13 coupled to guide the exhaust gas to the outside of the vehicle body by a predetermined length,
The first and second coupling parts 12 and 14 are arc brazed to cover the first and second coupling parts 12 and 14 by melting the filler metal, and then cooled and piped to the main muffler 10. (11) and the tail pipe 13, the muffler manufacturing method using the arc brazing, characterized in that for bonding.

The method according to claim 1,
The arc brazing is,
Muffler manufacturing method using the arc brazing, characterized in that any one of CuAl or CuSi as a filler material.

The first coupling portion in which a pipe 11 for guiding the exhaust gas flowing out of the center muffler is inserted into one side of the main muffler 10 formed of either the two-layer SUS cladding or the first-layer SUS + aluminum + SUS cladding. (12);
The second coupling portion 14 is coupled to the other side of the main muffler 10, the tail pipe 13 is coupled to guide the exhaust gas to the outside of the vehicle body a predetermined length and
The first and second coupling parts 12 and 14 are arc brazed to cover the first and second coupling parts 12 and 14 by melting the filler metal, and then cooled and piped to the main muffler 10. A muffler produced by arc brazing, characterized in that (11) and tailpipes (13) are joined.

The method of claim 3,
The arc brazing is,
A muffler produced by arc brazing, characterized in that either CuAl or CuSi is used as the filler metal.