CA2593100A1

CA2593100A1 - Muffler insert

Info

Publication number: CA2593100A1
Application number: CA 2593100
Authority: CA
Inventors: Jason Swist
Original assignee: Individual
Current assignee: Individual
Priority date: 2007-05-30
Filing date: 2007-05-30
Publication date: 2008-11-30

Abstract

An insert assembly for a muffler having an perforated tube for allowing exhaust gases travelling through the inside of the tube to escape from the inside of the tube. The perforated muffler insert being shaped in a polygonal configuration to allow for increased tube surface area providing for overall greater tube square area which provides greater perforation open area allowing for more efficient release of the exhaust gases from the interior of the muffler insert.

Description

FIELD OF THE INVENTION:

This invention relates generally to mufflers and more particularly to a muffler insert for an exhaust system of an internal combustion engine.

BACKGROUND OF THE INVENTION:

While most mufflers are of two varieties, resonator type and absorption type, they both employ similar insert or core designs, that being a perforated tube that allows exhaust gases passing through the interior of the tube to exit through the perforations. In the case of the absorption type of muffler the exhaust exits through the perforations into some type of absorption material or space to diminish the noise associated with combustion. In the case of resonator style mufflers the exhaust gases exit the perforations into the interior chambers of the muffler where they are redirected to a separate exit port in the muffler body. In some resonator designs the perforated tube is employed on both the muffler intake port and the muffler exit port. In resonator style mufflers the perforations can also create opposing energy waves that act to cancel each wave out thereby reducing the sound exiting the muffler even further.

The proposed invention provides for a similar perforated muffler tube design however it is designed as a polygonal with vertices or raised profiles aligned in either the horizontal, vertical or lateral planes, or in combination of the three, with respect to the orientation of the tube. The polygonal shape providing for a much improved surface area for the tube itself thereby increasing the available perforations for the exiting of the exhaust gases from the interior of the insert. A secondary consideration of the proposed invention is that by designing the polygonal shape to be reflective, that is when the exhaust gases are exiting the perforations, by design they can collide on exit creating an effective energy wave cancelling effect, further reducing the sound emissions from the muffler exit port.
This type of cancelling effect is present in both resonator design and absorption design mufflers employing the polygonal shaped or raised profile perforated tube inserts.

DESCRIPTION OF PRIOR ART

Review of the Prior Art US Patent #6,585,078 describes an insert assembly for a muffler of a high-performance motor cycle, having an insert with a filling of compressed heat-resistant, sound-absorbing material mounted on a removable hollow tube having an inside diameter greater than the outside diameter of the perforated core of the muffler.

US Patent #6,241,043 describes a process for producing muffler inserts as well as novel muffler inserts.

US Patent #5,659,158 describes a sound attenuating muffler, preferably for marine applications, with an insert comprising an arrangement of annular sound reflecting surfaces defining an inner chamber into which engine exhaust gases flow in a first direction and one or more directors to divert the axial flow of gases and sound waves in a second direction past these sound reflecting surfaces US Patent #4,809,812 a compact, sound-attenuating muffler for an internal combustion engine is disclosed in which the muffler includes a stream dividing partition positioned proximate the inlet of the muffler to divide the incoming exhaust gases into two streams of substantially equal volume SUMMARY OF THE INVENTION

What is required is a muffler core with increased exhaust exit flow or release capabilities while still maintaining the current size and weight standards as dictated by the industry.
According to the present invention there is provided a perforated muffler core with increased surface area and increased flow capacity due to the polygonal vertices or raised profiles of the insert. The polygonal shape or raised profile providing for substantial increases in the overall surface area of the insert without a similar increase in the overall size of the insert.

BRIEF DESCRIPTION OF THE DRAWINGS

[018] These and other features of the invention will become more apparent from the following description in which reference is made to the appended drawings, the drawings are for the purpose of illustration only and are not intended to in any way limit the scope of the invention to the particular embodiment or embodiments shown, wherein:

Figure 1 shows the insert 10 with perforations 11 and triangular insert profiles 20.
Figure 2 shows the insert 10 insitu with perforations 11 muffler housing 12 muffler packing 13 and insert profiles 20 Figure 3 shows the insert 10 with perforations I lmuffler packing 13 and insert profiles 20.

Figure 4 shows the insert 10 with perforations 11 muffler housing 12 muffler and insert profiles 20 Figure 5 shows insert 10 with perforations 11 muffler packing 13 with variation on the insert profile shape 20.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The preferred embodiment, a muffler insert generally identified by reference numeral 10, will now be described with reference to FIGS. 1, 2, 3, 4, and 5.

Structure and Relationship of Parts The resonance muffler consists of the insert with a specific profile shape to be located in a muffler housing that has no sound absorption materials. The absorption muffler consists of the insert with a specific profile shape to be located in a muffler housing and surrounded or encased by sound absorption materials.

Referring to FIG. 1, there is provided a perforated insert with a specific profile to be used in either absorption style or resonance style mufflers.
Referring to FIG. 2 there is provided a perforated insert with a specific profile located in an absorption muffler housing encased with sound absorption materials.
Referring to FIG.3 there is provided a perforated insert with a specific profile located in an absorption muffler housing encased with sound absorption materials.
Referring to FIG.4 there is provided a perforated insert with a specific profile to be located in an absorption muffler housing.
Referring to FIG. 5 there is provided a perforated insert with a specific profile located in an absorption muffler housing encased with sound absorption materials.

Claims

1. A muffler insert for an exhaust muffler of the type including a perforated core, comprising a perforated hollow tube, said perforated hollow tube comprising of a multitude of vertices or raised profiles along its length or breadth.

2. The muffler insert of claim 1 comprising a perforated core shaped with a multitude of polygonal vertices or raised profiles aligned in the same plane as the exhaust gas flow.

3. The muffler insert of claim 1 comprising a perforated core shaped with continuous columns of raised polygonal vertices or raised profiles aligned at 180 degrees to the flow of the exhaust gas.

4. The muffler insert of claim 1 with a perforated core shaped with non-continuous columns of raised polygonal vertices or raised profiles aligned at 180 degrees to the flow of the exhaust gas.

5. The muffler insert of claim 1 with a perforated core shaped with polygonal vertices or raised profiles aligned inward towards the interior of the perforated pipe aligned in the same plane as the exhaust gas flow.

6. The muffler insert of claim 1 with a perforated core shaped with polygonal vertices or raised profiles aligned inward towards the interior of the perforated pipe aligned at 180 degrees to the flow of the exhaust gas.

7. The muffler insert of claim 1 with a perforated core shaped with polygonal vertices or raised profiles aligned in a spiral configuration with respect to the flow of the exhaust gas.

8. A muffler insert with a perforated core shaped with polygonal vertices or raised profiles aligned in such a fashion so as to provide for the cancellation of exhaust waves upon the gases exiting the perforations.

9. The muffler of claim 8 that provides for one or more perforations in one of the vertices or raised profile to be appropriately aligned with the corresponding perforations of a second vertices or raised profile so that when the exhaust gases exit the perforations in the vertices or raised profile they intersect or collide and provide a cancelling wave effect.

10. A muffler insert with a perforated core shaped with polygonal vertices or raised profiles aligned in a random fashion or pattern.