This application claims priority to German Application No. 10 2011 112 633.7, filed 5 Sep. 2011.
The invention relates to an exhaust pipe assembly and to a method of fastening a sheet-metal tab or a fastening panel to an exhaust pipe to obtain an exhaust pipe assembly.
It is generally known to weld a support to an exhaust pipe, which serves to mount the exhaust system to a vehicle, for example to the underbody of the vehicle by rubber bearings. It is disadvantageous that such a welded joint locally restricts the vibration resistance of the exhaust pipe, as a welded joint constitutes a cross-sectional change. The welded joint furthermore requires a comparatively large wall thickness to be used for the exhaust pipe, such that the so-called “fusion penetration”, which is necessary for the connection in the welding process, can develop but an undesired “burn through” of the pipe is reliably prevented.
The object of the invention is to permit the fastening of an exhaust pipe with little effort and at low costs.
An exhaust pipe assembly comprises an exhaust pipe extending along a pipe axis and a fastening panel mounted to the exhaust pipe. The cross-section of the fastening panel is configured in a curved manner. Two contact surfaces of the fastening panel, which are spaced apart in the circumferential direction, are soldered to the exhaust pipe. A support connected with the fastening panel is arranged between the two contact surfaces of the fastening panel.
A method of fastening a sheet-metal tab to an exhaust pipe is also provided, in which an exhaust pipe and a sheet-metal tab are at first provided, with the exhaust pipe extending along a pipe axis. A soldering material is then captively fixed to the sheet-metal tab, and the sheet-metal tab is placed on the exhaust pipe such that the soldering material contacts the exhaust pipe. The sheet-metal tab is then soldered to the exhaust pipe.
The concept is to use, with the fastening panel or the fastening tab, respectively, a comparatively large-surface component as an “adapter” that is arranged between the fastening element and the exhaust pipe. The fastening panel can transmit the loads occurring due to the soldered joint into the exhaust pipe over a very large surface, such that it is possible to use a smaller wall thickness for the exhaust pipe.
The fixing of the soldering material to the fastening panel increases the process reliability, as an undesired slipping or falling out of the soldering material, and thus an imperfect soldering of the components upon positioning of the fastening panel with respect to the exhaust pipe is reliably prevented.
In an embodiment of the exhaust pipe assembly, the two contact surfaces of the fastening panel are arranged opposite each other, i.e. the contact surfaces are arranged on opposite faces of the exhaust pipe. The longitudinal edges of the fastening panel can in particular be configured as a contact surface.
A solder strip, in particular a rectangular solder strip is preferably arranged along the contact surfaces of the fastening panel. The (rectangular) solder strip ensures a large-surface soldered joint which, on the one hand, withstands high loads and, on the other hand, does not adversely affect the vibration resistance of the exhaust pipe.
The solder strip is preferably larger than the contact region between the fastening panel and the exhaust pipe. As the solder strip is larger than the contact region (which is only linear as considered from a mathematical point of view) between the fastening panel and the exhaust pipe, it is possible to simply compensate tolerances by correcting the positioning of the fastening panel with respect to the exhaust pipe. The solder strip is large enough such that a reliable solder point can always be formed.
In a further embodiment, each contact surface of the fastening panel has a bead for receiving a soldering material, the soldering material being for example a solder wire. The bead preferably extends along the pipe axis or in the circumferential direction, i.e. in a plane perpendicular to the pipe axis.
The support is preferably firmly connected with, in particular welded or soldered to the fastening panel. For this firm connection, a desired fastening method can be chosen depending on the respective demands, wherein it is uncritical if a slightly larger wall thickness of the fastening panel is required for welding. The fastening panel has comparatively small dimensions so that the additional costs resulting therefrom are kept within narrow limits. Incidentally, in order to form a firm connection, the support and the fastening panel can also be compressed or bonded together. Alternatively, a detachable connection, for example a screwed connection between the support and the fastening panel is also conceivable.
The support can be connected with the fastening panel after, or also before, soldering the fastening panel to the exhaust pipe. In case the fastening element is to be welded to the fastening panel, it is advantageous in view of the accessibility of the welded point, to weld the fastening element prior to that.
In the method described above of fastening a fastening panel or a sheet-metal tab to an exhaust pipe, the soldering material is preferably applied to the sheet-metal tab as a solder paste, or is applied to the sheet-metal tab as a solder powder using a printing method, in particular a screen-printing method. When it has an appropriate suitability, the soldering material can also be applied using a spraying method or a dipping method. It is furthermore of course also conceivable to apply the soldering material manually. In these cases, the adhesion between the soldering material and the sheet-metal tab is sufficient to ensure a captive connection.
Alternatively, the soldering material can be configured as a solder strip or as a solder wire and can be fixed captively to the sheet-metal tab by at least one weld or solder point. In some variant embodiments, it is also conceivable that the solder wire is configured in a resilient manner and can be clipped in the sheet-metal tab, in particular in a bead of the sheet-metal tab.
In a variant method, the sheet-metal tab provided has a curved cross-section and at least one contact surface to which the soldering material is captively fixed.
Preferably, substantially opposite longitudinal edges of the sheet-metal tab are configured as contact surfaces, wherein in the initial state of the sheet-metal tab, the longitudinal edges are arranged opposite each other at a distance which is smaller than the diameter of the exhaust pipe. In this configuration, the elasticity of the curved sheet-metal tab can be used both to cause an automatic compensation of tolerances and to ensure that the soldering material of the sheet-metal tab rests against the outer wall of the exhaust pipe. In this way, a correct solder point is reliably obtained.
As already mentioned above, a support can be connected with, in particular soldered or welded to the sheet-metal tab.
In the exhaust pipe assembly obtained from the method mentioned above, the sheet-metal tab can be configured as a hollow cylinder having a closed cross-section, at least the exhaust pipe, and in some variant embodiments also the support extending through the hollow cylinder. This box section of the sheet-metal tab provides for a comparatively low stress of the soldered joint in particular in case of loads perpendicular to the pipe axis.
In some embodiments of the exhaust pipe assembly, it turned out that a flat configuration of the exhaust pipe and of the sheet-metal tab, at least in the region of the adjacent soldering material, has an advantageous effect on the soldered joint.
The sheet-metal tab of the exhaust pipe assembly obtained from the method mentioned above can have at least one bead for receiving the soldering material, the bead preferably extending in the axial direction or in the circumferential direction. Such a bead can be configured with low expenditure and contributes in a simple manner to the captive fixing of the soldering material to the sheet-metal tab before soldering the sheet-metal tab and the exhaust pipe.
These and other features may be best understood from the following drawings and specification.
The invention is described below with reference to various embodiments which are illustrated in the accompanying drawings, which show:
The figures show various embodiments of an exhaust pipe assembly 8. The exhaust pipe 8 respectively comprises an exhaust pipe 10 which is part of an exhaust system as is, for example, used in motor vehicles. The exhaust pipe 10 extends along a pipe axis A and is mounted to a support 20 by a fastening panel 12 or a sheet-metal tab 12, the support fastening the exhaust pipe 10 and thus the exhaust system to an underbody of the motor vehicle, for example.
In the example embodiment according to
Each of the legs 12A, 12B comprises at its free end facing away from a vertex S of the fastening panel 12, a respective longitudinal edge 14, with the two longitudinal edges 14 being arranged opposite each other. Each of the longitudinal edges 14 is provided with a soldering material 15 on the side facing the other longitudinal edge 14, i.e. on the inside of the fastening panel 12, the soldering material 15 being captively fixed to the fastening panel 12.
The soldering material 15 configured as a solder strip 16 is, for example, applied to the fastening panel as a solder paste or as a solder powder using a printing method, preferably a screen-printing method. Depending on the properties, in particular on the consistence, an application of the soldering material 15 using a spaying or dipping method is also conceivable. However, the soldering material 15 can of course also be applied manually. In the mentioned cases, the adhesion between the soldering material 15 and the fastening panel 12 is sufficient to ensure the desired, captive connection. Alternatively, the soldering material 15 can also be a strip-like solder film which is however then fixed to the fastening panel 12 by at least one weld or solder point to ensure a captive connection.
The longitudinal edges 14 according to
The fastening panel 12 is connected with the exhaust pipe 10 by arranging the exhaust pipe between the two longitudinal edges 14 that are arranged opposite each other (and thus between the two solder strips 16), the region to be soldered being then heated, for example, by an induction device such that the soldering material 15 fuses.
For a loadable solder point, it is necessary that the two longitudinal edges 14 of the fastening panel 12 contact the outer surface of the exhaust pipe 10 or are arranged at a small distance therefrom. To ensure this, it can be provided that in the initial state, the distance of the longitudinal edges 14 from each other is slightly smaller than the outer diameter of the exhaust pipe 10. As a result, the two legs 12A, 12B are slightly bent elastically when the fastening panel 12 is mounted to the exhaust pipe 10. It is thus ensured that the solder strips 16 contact the exhaust pipe 10. It may also be provided that the two longitudinal edges 14 are adjusted to be slightly oblique, i.e. to have a funnel-shaped cross-section, so that they are automatically positioned on the outer surface of the exhaust pipe 10 similar to two insertion bevels when the fastening panel 12 is mounted thereto.
The two solder strips 16 extend over nearly the entire length of the longitudinal edges 14 and have a width B which is slightly larger than the width for which a proper solder point would actually be sufficient. In this way, a certain free play is permitted within which the fastening panel 12 can be positioned with respect to the exhaust pipe 10. With respect to
Connected with the fastening panel 12 is a support 20 which in the example embodiment according to
Alternatively, the support 20 can also be made of plastic material, in particular of fiber reinforced plastic material. In other variant embodiments, the support 20 can be compressed with, or bonded to, the fastening panel 12. Apart from the firm connections between the support 20 and the fastening panel 12 mentioned above, a detachable connection is furthermore also conceivable, in which the fastening panel 12 is, for example, screwed to the support 20.
The support 20 serves first of all to mount the exhaust pipe 10 or the exhaust system to the underbody of a vehicle. However, the support 20 can also take further functions, and for example can be configured as a vibration absorber or as a pressure pipe for fluids.
In a further embodiment of the exhaust pipe assembly 8 shown in
The variant embodiment according to
In contrast to
Although an embodiment of this invention has been disclosed, a worker of ordinary skill in this art would recognize that certain modifications would come within the scope of this invention. For that reason, the following claims should be studied to determine the true scope and content of this invention.
Number | Date | Country | Kind |
---|---|---|---|
10 2011 112 633 | Sep 2011 | DE | national |
Number | Name | Date | Kind |
---|---|---|---|
3270992 | Cassel | Sep 1966 | A |
3888439 | Tuttle | Jun 1975 | A |
3960232 | Hubbell, III | Jun 1976 | A |
4019599 | Strunk | Apr 1977 | A |
4465252 | Donovan et al. | Aug 1984 | A |
4638965 | De Bruine et al. | Jan 1987 | A |
4730800 | Engman | Mar 1988 | A |
5890685 | Takahashi | Apr 1999 | A |
6123143 | Insalaco | Sep 2000 | A |
6145212 | Geise et al. | Nov 2000 | A |
6209844 | Brucker et al. | Apr 2001 | B1 |
6298935 | Steenackers et al. | Oct 2001 | B1 |
6572070 | Arciero et al. | Jun 2003 | B2 |
6758300 | Kromis et al. | Jul 2004 | B2 |
6981567 | Stodolka | Jan 2006 | B2 |
7510043 | Cerri | Mar 2009 | B2 |
7571880 | Perez | Aug 2009 | B2 |
7644911 | Rodecker | Jan 2010 | B2 |
7753335 | Ogimura | Jul 2010 | B2 |
8100438 | Grimm | Jan 2012 | B2 |
8572949 | Wirth | Nov 2013 | B2 |
8651218 | Okada | Feb 2014 | B2 |
8991773 | Guthke | Mar 2015 | B2 |
9103476 | Geese | Aug 2015 | B2 |
9243734 | Aubert | Jan 2016 | B2 |
20010047897 | Steenackers et al. | Dec 2001 | A1 |
20030155169 | Kromis et al. | Aug 2003 | A1 |
20050184201 | Komitsu et al. | Aug 2005 | A1 |
20090211832 | Grimm | Aug 2009 | A1 |
20090261574 | Blueml et al. | Oct 2009 | A1 |
20110114216 | Blueml et al. | May 2011 | A1 |
20120012731 | Johnson | Jan 2012 | A1 |
Number | Date | Country |
---|---|---|
57160149 | Apr 1984 | JP |
59-129401 | Mar 1986 | JP |
H9-4448 | Jan 1997 | JP |
2010258362 | Nov 2010 | JP |
Entry |
---|
English translation of JP office action, dated Jan. 31, 2017. |
English summary of CN office action dated Jun. 12, 2016. |
Translated JP office action. |
Number | Date | Country | |
---|---|---|---|
20130056589 A1 | Mar 2013 | US |