US20190360379A1 - Modular muffler assembly and method - Google Patents
Modular muffler assembly and method Download PDFInfo
- Publication number
- US20190360379A1 US20190360379A1 US16/415,238 US201916415238A US2019360379A1 US 20190360379 A1 US20190360379 A1 US 20190360379A1 US 201916415238 A US201916415238 A US 201916415238A US 2019360379 A1 US2019360379 A1 US 2019360379A1
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- United States
- Prior art keywords
- muffler
- endcap
- component
- open end
- annular body
- 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.)
- Abandoned
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
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- 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
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- 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
- F01N1/00—Silencing apparatus characterised by method of silencing
- F01N1/08—Silencing apparatus characterised by method of silencing by reducing exhaust energy by throttling or whirling
- F01N1/083—Silencing apparatus characterised by method of silencing by reducing exhaust energy by throttling or whirling using transversal baffles defining a tortuous path for the gases or successively throttling gas flow
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- 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
- F01N1/00—Silencing apparatus characterised by method of silencing
- F01N1/08—Silencing apparatus characterised by method of silencing by reducing exhaust energy by throttling or whirling
- F01N1/085—Silencing apparatus characterised by method of silencing by reducing exhaust energy by throttling or whirling using a central core throttling gas passage
-
- 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
- F01N1/00—Silencing apparatus characterised by method of silencing
- F01N1/08—Silencing apparatus characterised by method of silencing by reducing exhaust energy by throttling or whirling
- F01N1/089—Silencing apparatus characterised by method of silencing by reducing exhaust energy by throttling or whirling using two or more expansion chambers in series
-
- 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
- F01N13/002—Apparatus adapted for particular uses, e.g. for portable devices driven by machines or engines
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- 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
- F01N13/007—Apparatus used as intake or exhaust silencer
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- 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
-
- 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
-
- 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
- F01N2450/00—Methods or apparatus for fitting, inserting or repairing different elements
- F01N2450/30—Removable or rechangeable blocks or cartridges, e.g. for filters
-
- 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
- F01N2470/00—Structure or shape of gas passages, pipes or tubes
- F01N2470/02—Tubes being perforated
-
- 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
- F01N2470/00—Structure or shape of gas passages, pipes or tubes
- F01N2470/02—Tubes being perforated
- F01N2470/04—Tubes being perforated characterised by shape, disposition or dimensions of apertures
-
- 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
- F01N2470/00—Structure or shape of gas passages, pipes or tubes
- F01N2470/16—Plurality of inlet tubes, e.g. discharging into different chambers
-
- 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
- F01N2470/00—Structure or shape of gas passages, pipes or tubes
- F01N2470/18—Structure or shape of gas passages, pipes or tubes the axis of inlet or outlet tubes being other than the longitudinal axis of apparatus
-
- 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
- F01N2470/00—Structure or shape of gas passages, pipes or tubes
- F01N2470/24—Concentric tubes or tubes being concentric to housing, e.g. telescopically assembled
-
- 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
- F01N2490/00—Structure, disposition or shape of gas-chambers
- F01N2490/08—Two or more expansion chambers in series separated by apertured walls only
-
- 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
- F01N2590/00—Exhaust or silencing apparatus adapted to particular use, e.g. for military applications, airplanes, submarines
Definitions
- the present disclosure relates to mufflers for combustion engines and, more particularly, to methods for efficient muffler production and mufflers made by such methods.
- Mufflers also referred to as silencers
- silencers are used widely in devices which utilize internal combustion engines, such as for generator sets, construction equipment, agricultural equipment, on- and off-road vehicles, riding lawn tractors, zero-turn mowers, and garden tools, for example. Users of such devices have developed high expectations for muffler function, including noise reduction and emissions control.
- Existing mufflers are typically constructed from a single-component shell manufactured by roll-crimping or welding. This shell receives internal components, such as baffles, crossover tubes and/or manifold pipes. The shell is typically enclosed at its axial ends via plate-like end caps designed to fit over the open ends and, in some cases, admit the passage of a tube therethrough (e.g., an exhaust tube for example).
- a tube e.g., an exhaust tube for example.
- the present disclosure provides a modular system for muffler production and assembly, which allows various muffler designs to be produced from a common set of components.
- modular stamped muffler housing components including two endcap designs and an intermediate body component design, can be assembled in various ways to produce muffler shells of varying length and configuration, while also ensuring high performance of the finished product.
- Additional components such as crossover tubes, baffles and manifold pipes, may be integrated into a particular muffler design upon final assembly.
- the present disclosure provides a muffler including: a first endcap having a first annular body with a first closed end and a first open end opposite the first closed end, the first open end defining an outer periphery; a second endcap having a second annular body with a second closed end and a second open end opposite the second closed end having a lip defining an inner periphery commensurate with the outer periphery such that the lip is sealingly receivable over the first open end; a baffle configured to control a flow of gases through at least one of the first endcap and the second endcap; and a crossover tube extending through the baffle and configured to transmit at least a portion of the flow of gases from an intake port to an exhaust port of the muffler.
- the present disclosure provides a kit for building a muffler from a set of modular components, the kit including: a set of endcaps each having an annular body with a closed end and an open end opposite the closed end, at least a pair of the set of endcaps sealingly received upon one another; and at least one annular intermediate component sealingly receivable to the set of endcaps.
- the present disclosure provides a method of manufacturing a muffler, the method including: stamping a first muffler component from a first blank such that the first muffler component includes a first annular body with an open end and a closed end; and stamping a second muffler component from a second blank such that the second muffler component includes a second annular body with an open end and a closed end, the open end of the second muffler component sized to be sealingly received over the open end of the first muffler component.
- FIG. 1 is a perspective view of a muffler assembly made in accordance with the present disclosure
- FIG. 2 is a cross-section, perspective view of the muffler assembly shown in FIG. 1 , taken along line 2 - 2 of FIG. 1 ;
- FIG. 3 is an exploded, perspective view of the muffler assembly shown in FIG. 1 ;
- FIG. 4 is an elevation, cross-section view of the muffler assembly shown in FIG. 1 , taken along line 4 - 4 of FIG. 1 ;
- FIG. 5 is a perspective view of another muffler assembly made in accordance with the present disclosure.
- FIG. 6 is a cross-section, perspective view of the muffler assembly shown in FIG. 5 , taken along line 6 - 6 of FIG. 5 ;
- FIG. 7 is a perspective view of yet another muffler assembly made in accordance with the present disclosure.
- FIG. 8 is a cross-section, perspective view of the muffler assembly shown in FIG. 7 , taken along line 8 - 8 of FIG. 5 ;
- FIG. 9 is a perspective view of a muffler endcap made in accordance with the present disclosure and including apertures and a lip for assembly to other muffler components;
- FIG. 10 is a left side, elevation view of the muffler endcap shown in FIG. 9 ;
- FIG. 11 is a right side, elevation view of the muffler endcap shown in FIG. 9 ;
- FIG. 12 is top plan view of the muffler endcap shown in FIG. 9 ;
- FIG. 13 is a bottom plan view of the muffler endcap shown in FIG. 9 ;
- FIG. 14 is a front, elevation view of the muffler endcap shown in FIG. 9 ;
- FIG. 15 is a rear, elevation view of the muffler endcap shown in FIG. 9 ;
- FIG. 16 is a perspective view of another muffler endcap made in accordance with the present disclosure, after an initial stamping process but before creation of additional features for assembly to other muffler components;
- FIG. 18 is a right side, elevation view of the muffler endcap shown in FIG. 16 ;
- FIG. 19 is top plan view of the muffler endcap shown in FIG. 16 ;
- FIG. 20 is a bottom plan view of the muffler endcap shown in FIG. 16 ;
- FIG. 21 is a front, elevation view of the muffler endcap shown in FIG. 16 ;
- FIG. 22 is a rear, elevation view of the muffler endcap shown in FIG. 16 ;
- FIG. 23 is a perspective view of a riding mower incorporating a muffler made in accordance with the present disclosure.
- FIG. 24 is a perspective view of a zero-turn mower incorporating a muffler made in accordance with the present disclosure.
- muffler assemblies such as assemblies 10 , 110 and 210 shown in FIGS. 1, 5 and 7 respectively, which can be modularly assembled from a set of common components including endcap 12 ( FIG. 9 ), endcap 14 ( FIG. 16 ) and intermediate body component 16 ( FIG. 3 ).
- endcaps 12 and 14 may be modularly assembled to one another with or without one or more body components 16 in order to create a muffler shell having any desired length.
- Other muffler components may be assembled to the modular muffler shell by creating holes or other apertures at desired locations and assembling the components to one another to create a desired finished muffler configuration. As shown in FIG.
- such additional muffler components may include, for example, baffles 18 , crossover tubes 20 , and manifold pipes 30 , 32 .
- endcaps 12 and 14 and body component 16 are stamped components, which provides a high level of dimensional accuracy at a minimal cost. These stamped components may be produced in bulk and stored in a blank form, such as the blank version of endcap 14 shown in FIGS. 16-22 , for modification upon assembly of a muffler in a desired configuration. High production efficiency is enabled by the use of stamping for component manufacture, combined with modular assembly from stock component blanks.
- muffler assembly 10 includes a pair of endcaps 12 each attached to a central, intermediate body component 16 , such that the body component 16 is functionally and spatially interposed between the endcaps 12 .
- Each endcap 12 has a cylindrical body with an open first axial end 44 ( FIG. 3 ) and an opposing closed end 42 .
- Each open end 44 also includes lip 40 around the opening periphery, and which extends radially and axially outwardly from the cylindrical body of the endcap 12 as shown.
- muffler designs having cylindrical or substantially cylindrical outer profiles are shown and described as exemplary illustrations of the principles of the present invention.
- the present methods and structures are equally applicable to non-cylindrical muffler designs, and may be applied to such non-cylindrical designs in the same manner as described herein with respect to cylindrical components (e.g., endcaps 12 , 14 and body component 16 ).
- cylindrical components e.g., endcaps 12 , 14 and body component 16
- muffler designs having an oval cross-section may be produced in accordance with the present disclosure.
- any annular cross-sectional shape may be employed, as required or desired for a particular application. In the interest of efficiency, cylindrical components are described and shown herein, it being understood that any annular shape may take the place of the cylindrical shapes described and shown.
- non-cylindrical annular components define a periphery whose “diameter” is the diameter of the smallest circumscribing circle around that periphery.
- the “diameter” of a non-cylindrical annular muffler component is defined as the diameter of this circumscribing circle.
- body component 16 includes closed end 50 which is stepped down to pass by lip 40 and into the inner cavity defined by the cylindrical wall of endcap 12 .
- the interface between the stepped-down portion of closed end 50 and the abutting inner surface of the cylindrical wall of endcap 12 may be substantially fluid-tight, such that the closed end 50 may effectively operate as a baffle.
- Body component 16 has an open end 52 ( FIG. 3 ) opposite closed end 50 and sized to interfit with lip 40 of the other endcap 12 used in muffler 10 .
- the tight fit between lips 40 and the adjacent cylindrical walls of body component 16 may create a “sealed” interface via a substantially or entirely fluid-tight fit.
- a substantially fluid-tight fit may be, for example a fit which allows leakage of less than 5% of gases from the shell of muffler 10 during normal operation at typical internal pressures.
- a fully fluid-tight seal i.e., with zero leakage
- These fluid-tight seals among the shell components of muffler assembly 10 may cooperate with other fluid-tight junctions (as described below) to creates a fluid-tight inner cavity of muffler 10 , which in turn promotes smooth functioning and reduces noise during operation of the muffler.
- muffler 10 includes various internal and external components designed to facilitate the flow of exhaust gases through the muffler shell. Some or all of these components may also provide for noise reduction and back pressure modulation as the gases pass through muffler 10 .
- gases enter the interior cavity defined by the shell of muffler 10 via a pair of manifold pipes 30 and 32 , which include manifold flanges 31 at the upstream ends thereof.
- Flanges 31 are configured to attach to exhaust ports on an internal combustion engine, such that exhaust gases are conveyed by manifold pipes 30 , 32 into muffler 10 .
- the left endcap 12 (as viewed in FIG. 2 ) defines a left intake chamber having an intake aperture 46 ( FIG. 3 ), through which gases are received from pipe 30 .
- the left chamber is separated from the central chamber by closed end 50 of body component 16 ( FIG. 3 ), which is integrally formed together with the cylindrical body portion of component 16 as part of a monolithic component. Closed end 50 includes apertures 26 formed therethrough to facilitate a controlled flow of gases from the left intake chamber to the intermediate chamber defined by body component 16 .
- the baffle portion of body component 16 at closed end 50 , has an exterior periphery abutting the adjacent interior wall of endcap 12 , thereby creating a partial or complete seal which may also be supplemented by the weld or other sealant applied at lip 40 .
- closed end 50 serves the function of an interior baffle.
- baffle 18 has a similarly plurality of apertures 26 therethrough to control the flow of gases from the right endcap chamber into the intermediate chamber, similar to apertures 26 formed in closed end 50 of body component 16 .
- the exterior periphery of baffle 18 abuts the adjacent interior wall of intermediate component 16 , and may create a fluid-tight seal therewith in some applications.
- baffle(s) 18 and/or the baffle configuration formed in closed end 50 of body component 16 , is shown and described herein for illustration of certain exemplary internal muffler configurations, it being understood that other configurations may be used as required or desired for a particular application.
- some mufflers made in accordance with the present disclosure may exclude baffles which abut the outer muffler shell, and instead include “tube-in-tube” type baffles in which muffler chambers are formed between at least two coaxial tubes of differing diameters.
- crossover tube 20 Gases discharged to the intermediate chamber from the left and right intake chambers then pass into crossover tube 20 via an array of apertures 22 formed therein.
- apertures 22 may be louvered, and one end of crossover tube 20 is formed as a closed crimped end 24 .
- these features facilitate efficient production of crossover tube 20 , while ensuring that gases flow into crossover tube 20 from the intermediate chamber and out of muffler 10 via exhaust port 25 .
- crossover tube 20 extends through central apertures formed in baffle 18 and in the closed end 50 of body component 16 , and is substantially sealingly engaged with these central apertures such that gases are substantially directed to pass between internal chambers primarily through baffle apertures 26 .
- baffle 18 and the baffle created by closed end 50 primarily control the flow of gases between the interior chambers of the shell of muffler 10
- crossover tube 20 extends through baffle 18 and the baffle portion of body component 16 to receive a flow of gases from the shell interior and transmit the flow to the ambient area outside the muffler 10 .
- crossover tube 20 may be omitted.
- gases are allowed to flow from chamber to chamber and to the ambient area outside the muffler shell via perforations, such as holes through internal baffles and/or perforations and/or holes formed in the muffler shell itself.
- the respective endcaps 12 are adapted from a blank form (described further below) to their differing roles at opposing ends of muffler 10 by processing each blank form differently.
- the left endcap 12 (as viewed in FIG. 2 ) includes radial aperture 46 formed within the cylindrical sidewall thereof, and sized to receive a downstream end of manifold pipe 30 .
- the longitudinal axis AP of radial aperture 46 and the downstream end of pipe 30 is spaced from the central longitudinal axis AM defined by the cylindrical body of endcap 12 (and by the muffler shell more generally, after assembly).
- radial aperture 46 takes on an egg shape, as best illustrated in FIG. 13 .
- longitudinal axis AP of radial aperture 46 may intersect with the central longitudinal axis AM, producing a more circular shape.
- longitudinal axis AP may intersect central axis AM, or may be spaced from central axis AM by any amount as required or desired for a particular application.
- the right side endcap 12 includes both radial aperture 46 , which has a similar but mirror-image position and configuration to the left side endcap 12 , but further includes axial aperture 48 formed in closed end 42 and sized to sealingly receive crossover tube 20 as shown in FIGS. 2 and 4 . Closed end 42 of the left side endcap 12 is allowed to remain completely sealed, as best seen in FIGS. 2 and 4 .
- endcaps 12 may be identical components prior to the formation of apertures 46 and/or 48 , such that endcaps 12 can each be drawn from a common inventory of stamped endcap components and then modified to suit their individual functions within a larger muffler configuration, such as muffler assembly 10 .
- a reinforcement place 36 may be provided at the interior or exterior of the cylindrical wall of endcap 12 about radial aperture 46 .
- Reinforcement plate 36 is placed against the cylindrical wall of endcap 12 and bonded thereto, such as by welding, adhesives, mechanical fasteners, or any other suitable fixation method.
- Reinforcement plate 36 effectively thickens the cross-sectional wall thickness of the cylindrical body in the vicinity of aperture 46 . This thickening spreads forces on the cylindrical wall of endcap 12 by manifold pipes 30 and/or 32 after assembly of muffler 10 and during its operational service. This spreading of forces, in turn, reduces the stresses experienced by the cylindrical wall of endcap 12 at and around the junction between apertures 46 and pipe 30 or 32 .
- reinforcement plate 36 is placed in the interior cavity of endcap 12 in the illustrated embodiment, reinforcement plate 36 may similarly be placed along the exterior of the cylindrical body of endcap 12 with the same functional result.
- muffler assembly 110 is shown with a different configuration from muffler assembly 10 described in detail above.
- Mufflers 10 , 110 share several common components, and components and features of muffler 110 have reference numbers which correspond to similar or identical structures of muffler 10 , except with 100 added thereto for structures with modifications.
- endcaps 12 are mounted to body component 16 in the same manner as muffler 10 described above.
- the internal and external components associated with muffler 110 have a different configuration.
- only one of endcaps 12 includes aperture 46 , and only one manifold pipe 32 is connected to the muffler shell assembly.
- muffler assembly 110 is a type which is configured for an engine in which all cylinders exhaust to a single pipe (e.g., a single cylinder engine, or a multi-cylinder engine with header pipes that combine into a single pipe).
- muffler 10 has two apertures 46 fed by separate manifold pipes 30 , 32 , as shown in FIG. 1 and describe above, and therefore is configured for a multi-cylinder engine.
- Crossover tube 120 of muffler 110 is also configured differently from crossover tube 20 .
- apertures 122 are formed near the closed axial end of crossover tube 120 , and are therefore positioned within the muffler cavity defined by the left endcap 12 rather than the muffler cavity within body component 16 as shown in FIG. 2 and described above.
- gases enter muffler 110 via aperture 46 , pass through apertures 26 formed in the baffle portion of body component 16 , and then enter crossover tube 120 via apertures 122 . These gases are then exhausted at exhaust port 125 .
- the closed axial end of crossover tube 120 includes cap 124 to seal the axial end, rather than a crimped end such as end 24 as shown in FIG. 2 .
- Cap 124 may be used, for example, in configurations where the apertures 122 are positioned too close to the axial end of tube 120 to make use of a crimped end.
- mounting bracket 34 is also included along the exterior of the shell of muffler assembly 110 .
- Bracket 34 may be welded, riveted or otherwise fixed to the exterior of muffler 110 , and may span multiple components such as endcap 12 and body component 16 as shown.
- Mounting bracket 34 may be used to help support the weight of muffler 110 when attached to a vehicle, for example, and may be similarly used with any muffler design in accordance with the present disclosure, including mufflers 10 and 210 .
- FIGS. 7 and 8 yet another muffler assembly 210 made in accordance with the present disclosure is shown.
- Mufflers 10 and 210 share several common components, and components and features of muffler 210 have reference numbers which correspond to similar or identical structures of muffler 10 , except with 200 added thereto for structures with modifications.
- muffler 210 excludes body component 16 such that endcaps 12 and 14 are directly connected to one another with no intervening components.
- endcap 14 excludes lip 40 , as shown in FIGS. 16-20 .
- endcap 14 includes a cylindrical body with open end 44 ( FIGS. 17-20 ) having the same outer diameter as open end 52 of body component 16 ( FIG. 3 ). In this way, endcap 14 may be sealingly connected to endcap 12 in the same manner as body component 16 described above, with a similarly tight fit and similar options for creating a substantially fluid tight seal.
- Muffler assembly 210 includes manifold pipes 30 , 32 which transmit gases from an internal combustion to the interior of muffler 210 in the same manner as described above with respect to muffler 10 .
- crossover tube 220 rather than passing crossover tube 220 through closed end 42 of one of the endcaps 12 , 14 (as shown and described above with respect to muffler 10 and 110 ), crossover tube 220 makes a 90-degree bend within the cavity of the shell of muffler 210 , and then passes through a radial-type aperture 46 formed in the sidewall of endcap 14 as shown in FIG. 7 , rather than an axial aperture 48 (shown, e.g., in FIG. 3 ).
- exhaust port 225 exits muffler 210 radially rather than axially as described above with respect to mufflers 10 and 110 .
- the other axial end of crossover tube 220 is closed, via crimped end 224 similar to crossover tube 20 described above.
- Apertures 222 are formed in a central chamber within muffler 210 , with two baffles 18 used to delineate the three chambers within the internal volume of muffler 210 as shown in FIG. 8 .
- mufflers 10 , 110 and 210 may be assembled from a kit of standardized components which can be modularly combined in order to create a wide array of finished muffler configurations.
- a kit may include, for example, a set of endcaps 12 including lip 40 , as shown in FIG. 9 , but excluding any apertures 46 or 48 .
- endcaps 12 may be stored and ready for further processing prior to integration into a variety of muffler configurations.
- endcaps 12 may have an undisturbed cylindrical body and completely closed end 42 , together with lip 40 and the associated open end 44 .
- endcaps 14 shown in FIG.
- endcap 16 may include an undisturbed cylindrical body, no lip 40 , and a completely closed end 42 , with open end 44 sized to be received within lip 40 of endcap 12 .
- Intermediate body components 16 may also be provided with open end 52 ( FIG. 3 ), a completely closed end 50 (i.e., without apertures 26 or a central aperture for receiving a crossover tube), and an undisturbed cylindrical body extending between the open and closed ends 52 , 50 .
- the cylindrical body of endcap 14 and body component 16 have the same outer diameter at their respective open ends 44 and 52 , such that either endcap 14 or body component 16 may be modularly mated to endcap 12 via lip 40 as described and shown herein.
- any length of muffler shell can be created.
- a particular internal muffler volume and overall muffler size may be modularly created from “off-the-shelf” components without the need to design or produce dedicated components for a particular muffler design.
- these components may be cut shorter to modify the overall dimensions and characteristics of the finished shell assembly.
- dedicated sets of endcaps 12 , 14 and body component(s) 16 may be provided for various nominal muffler shell diameters, e.g., a set of 4-inch nominal components may be used to modularly create various 4-inch muffler shells, a separate set of 6-inch nominal components may be used to modularly create various 6-inch muffler shells, and so on.
- a set of 4-inch nominal components may be used to modularly create various 4-inch muffler shells
- 6-inch nominal components may be used to modularly create various 6-inch muffler shells, and so on.
- Baffles 18 and tube stock sized to create crossover tubes 20 , 120 or 220 may also be stocked as part of the modular muffler assembly kit. As described above, baffles 18 may be used as needed to delineate the inner chambers of any muffler configuration, either alone or in combination with the baffle portion of body component 16 , if the desired muffler design includes body component 16 . Different sizes of baffles 18 may be included in the kit to fit the various nominal sizes of muffler shells.
- the tube stock included with the modular muffler kit may be appropriately sized to sealingly connected to the central apertures formed through baffles 18 , closed end 50 of body component 16 , or axial aperture 28 through closed end 42 of endcaps 12 or 14 .
- Different tube stock sizes may be stocked for the various nominal muffler diameters provided for in the modular muffler kit, as appropriate.
- an aperture or an array of apertures may be created through the exterior surface of a piece of the tube stock at an appropriate axial location and in an appropriate array.
- crossover tubes 20 , 120 and 220 all include louvered apertures 22 , 122 , 222 which can be created by a piercing tool at any axial location and in any array pattern quickly and efficiently in accordance with the needs of a particular muffler configuration.
- a crimped end such as crimped end 24
- caps 124 FIG. 6
- apertures e.g., apertures 122
- endcaps 12 , 14 and body component 16 may be stamped components. That is, blanks may be provided which are sized and configured to be stamped into a cylindrical die to create the basic stamped shape of endcap 12 , endcap 14 or intermediate body 16 .
- the stamping dies may include a bottom surface configured to create closed end 42 with the distinctive design of stepped surfaces shown in FIG. 16 , and the substantially cylindrical outer shell extending from closed end 42 to open end 44 .
- lip 40 may also be formed by a separate stamping operation. Apertures, such as radial apertures 46 and/or axial apertures 48 , may be subsequently pierced using a separate stamping operation, or other piercing or machining operations.
- the bottom of the stamping die may include a step for creation of the baffle portion of closed end 50 described in detail above.
- Apertures 26 and/or a central aperture sized to sealing receive a crossover tube may be created using a separate stamping operation, or other piercing or machining operations.
- the stamping operations described above provide a high degree of dimensional precision and accuracy, particularly at the open ends of the various components and around lip 40 of endcap 12 .
- This tight fit can then create an affirmative fluid-tight seal by welding, adhesives, sealant or the like around the periphery of lip 40 , as described above.
- mating components of the muffler shell are pressed together to seat the axial end of one piece (e.g., endcap 14 or intermediate component 16 ) firmly against the interior shoulder formed at the inner end of lip 40 (e.g., of endcap 12 ).
- the components become aligned with a high degree of coaxiality.
- Endcaps 12 , 14 and intermediate component 16 have an axial extent long enough to serve as components which defined the interior volume of the muffler shell, as opposed to traditional endcaps which merely close the axial end of an interior volume formed by a separate (non-stamped) shell component.
- endcaps 12 , 14 and intermediate component 16 all define a ratio of axial depth to overall diameter which is between 0.5 and 1.5. That is, the axial depth of endcaps 12 , 14 and intermediate component 16 is at least half of its diameter, and may be as large as 1.5 times its diameter. This contrasts with an endcap used in a traditional muffler design, which would define a depth:diameter ratio much less than 0.5.
- the outer components of muffler assembly 10 are formed from aluminized steel. Painted, coated or plated cold rolled steel may also be used as required or desired for a particular application. A stainless steel material may also be used, providing the best corrosion and weather resistance for a long service life in outdoor environments.
- Mufflers made in accordance with the present disclosure may be used on any vehicle or other equipment using an internal combustion engine.
- muffler 210 may be mounted to riding lawn mower 300 having engine compartment 302 in front of operator controls 304 and operator seat 306 .
- Muffler 210 is mounted below the engine compartment 302 and directs exhaust fumes downwardly.
- the operator controls wheels 308 and mower deck 310 of mower 300 from seat 306 .
- mufflers 10 or 110 may be mounted to a zero-turn type mower 400 having engine compartment 402 behind operator controls 404 and operator seat 406 .
- Mufflers 10 or 110 is mounted at the rear of the engine compartment 302 and directs exhaust fumes backwardly.
- the operator controls wheels 408 and mower deck 410 of mower 400 from seat 406 .
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Abstract
Description
- This application claims priority to Chinese Patent Application No. 201810507989.3, entitled MANUFACTURING METHOD AND MUFFLER CONSTRUCTION and filed on May 24, 2018, the entire disclosure of which is hereby expressly incorporated by reference herein.
- The present disclosure relates to mufflers for combustion engines and, more particularly, to methods for efficient muffler production and mufflers made by such methods.
- Mufflers, also referred to as silencers, are used widely in devices which utilize internal combustion engines, such as for generator sets, construction equipment, agricultural equipment, on- and off-road vehicles, riding lawn tractors, zero-turn mowers, and garden tools, for example. Users of such devices have developed high expectations for muffler function, including noise reduction and emissions control.
- Existing mufflers are typically constructed from a single-component shell manufactured by roll-crimping or welding. This shell receives internal components, such as baffles, crossover tubes and/or manifold pipes. The shell is typically enclosed at its axial ends via plate-like end caps designed to fit over the open ends and, in some cases, admit the passage of a tube therethrough (e.g., an exhaust tube for example).
- While such existing muffler designs may be fit for their purpose, their cost and complexity can lead to expensive and/or time-consuming manufacturing. For example, dedicated muffler shell components may be needed for each muffler design, leading to large component inventories, material waste and low production efficiency for muffler manufacturers. In addition, component tolerances can be expensive to maintain using known manufacturing methods, particularly where a reliable restriction of airflow at component joints and junctions is required for noise reduction.
- What is needed is an improvement over the foregoing.
- The present disclosure provides a modular system for muffler production and assembly, which allows various muffler designs to be produced from a common set of components. In particular, modular stamped muffler housing components, including two endcap designs and an intermediate body component design, can be assembled in various ways to produce muffler shells of varying length and configuration, while also ensuring high performance of the finished product. Additional components, such as crossover tubes, baffles and manifold pipes, may be integrated into a particular muffler design upon final assembly.
- In one form thereof, the present disclosure provides a muffler including: a first endcap having a first annular body with a first closed end and a first open end opposite the first closed end, the first open end defining an outer periphery; a second endcap having a second annular body with a second closed end and a second open end opposite the second closed end having a lip defining an inner periphery commensurate with the outer periphery such that the lip is sealingly receivable over the first open end; a baffle configured to control a flow of gases through at least one of the first endcap and the second endcap; and a crossover tube extending through the baffle and configured to transmit at least a portion of the flow of gases from an intake port to an exhaust port of the muffler.
- In another form thereof, the present disclosure provides a kit for building a muffler from a set of modular components, the kit including: a set of endcaps each having an annular body with a closed end and an open end opposite the closed end, at least a pair of the set of endcaps sealingly received upon one another; and at least one annular intermediate component sealingly receivable to the set of endcaps.
- In yet another form thereof, the present disclosure provides a method of manufacturing a muffler, the method including: stamping a first muffler component from a first blank such that the first muffler component includes a first annular body with an open end and a closed end; and stamping a second muffler component from a second blank such that the second muffler component includes a second annular body with an open end and a closed end, the open end of the second muffler component sized to be sealingly received over the open end of the first muffler component.
- The above mentioned and other features and objects of this invention, and the manner of attaining them, will become more apparent and the invention itself will be better understood by reference to the following description of embodiments of the invention taken in conjunction with the accompanying drawings, wherein:
-
FIG. 1 is a perspective view of a muffler assembly made in accordance with the present disclosure; -
FIG. 2 is a cross-section, perspective view of the muffler assembly shown inFIG. 1 , taken along line 2-2 ofFIG. 1 ; -
FIG. 3 is an exploded, perspective view of the muffler assembly shown inFIG. 1 ; -
FIG. 4 is an elevation, cross-section view of the muffler assembly shown inFIG. 1 , taken along line 4-4 ofFIG. 1 ; -
FIG. 5 is a perspective view of another muffler assembly made in accordance with the present disclosure; -
FIG. 6 is a cross-section, perspective view of the muffler assembly shown inFIG. 5 , taken along line 6-6 ofFIG. 5 ; -
FIG. 7 is a perspective view of yet another muffler assembly made in accordance with the present disclosure; -
FIG. 8 is a cross-section, perspective view of the muffler assembly shown inFIG. 7 , taken along line 8-8 ofFIG. 5 ; -
FIG. 9 is a perspective view of a muffler endcap made in accordance with the present disclosure and including apertures and a lip for assembly to other muffler components; -
FIG. 10 is a left side, elevation view of the muffler endcap shown inFIG. 9 ; -
FIG. 11 is a right side, elevation view of the muffler endcap shown inFIG. 9 ; -
FIG. 12 is top plan view of the muffler endcap shown inFIG. 9 ; -
FIG. 13 is a bottom plan view of the muffler endcap shown inFIG. 9 ; -
FIG. 14 is a front, elevation view of the muffler endcap shown inFIG. 9 ; -
FIG. 15 is a rear, elevation view of the muffler endcap shown inFIG. 9 ; -
FIG. 16 is a perspective view of another muffler endcap made in accordance with the present disclosure, after an initial stamping process but before creation of additional features for assembly to other muffler components; -
FIG. 17 is a left side, elevation view of the muffler endcap shown inFIG. 16 ; -
FIG. 18 is a right side, elevation view of the muffler endcap shown inFIG. 16 ; -
FIG. 19 is top plan view of the muffler endcap shown inFIG. 16 ; -
FIG. 20 is a bottom plan view of the muffler endcap shown inFIG. 16 ; -
FIG. 21 is a front, elevation view of the muffler endcap shown inFIG. 16 ; -
FIG. 22 is a rear, elevation view of the muffler endcap shown inFIG. 16 ; -
FIG. 23 is a perspective view of a riding mower incorporating a muffler made in accordance with the present disclosure; and -
FIG. 24 is a perspective view of a zero-turn mower incorporating a muffler made in accordance with the present disclosure. - Corresponding reference characters indicate corresponding parts throughout the several views. Although the exemplifications set out herein illustrate embodiments of the invention, in several forms, the embodiments disclosed below are not intended to be exhaustive or to be construed as limiting the scope of the invention to the precise forms disclosed.
- The present disclosure is directed to muffler assemblies, such as
assemblies FIGS. 1, 5 and 7 respectively, which can be modularly assembled from a set of common components including endcap 12 (FIG. 9 ), endcap 14 (FIG. 16 ) and intermediate body component 16 (FIG. 3 ). As described in detail below,endcaps more body components 16 in order to create a muffler shell having any desired length. Other muffler components may be assembled to the modular muffler shell by creating holes or other apertures at desired locations and assembling the components to one another to create a desired finished muffler configuration. As shown inFIG. 3 , such additional muffler components may include, for example,baffles 18,crossover tubes 20, andmanifold pipes endcaps body component 16 are stamped components, which provides a high level of dimensional accuracy at a minimal cost. These stamped components may be produced in bulk and stored in a blank form, such as the blank version ofendcap 14 shown inFIGS. 16-22 , for modification upon assembly of a muffler in a desired configuration. High production efficiency is enabled by the use of stamping for component manufacture, combined with modular assembly from stock component blanks. - Turning now to
FIG. 1 ,muffler assembly 10 includes a pair ofendcaps 12 each attached to a central,intermediate body component 16, such that thebody component 16 is functionally and spatially interposed between theendcaps 12. Eachendcap 12 has a cylindrical body with an open first axial end 44 (FIG. 3 ) and an opposing closedend 42. Eachopen end 44 also includeslip 40 around the opening periphery, and which extends radially and axially outwardly from the cylindrical body of theendcap 12 as shown.Lip 40 defines an inner diameter with is commensurate with the outer diameter of the adjacent cylindrical body of body component 16 (orendcap 14, as described below), such thatbody component 16 may be interfitted withendcap 12 to form a tight interface between the inner surface oflip 40 and the mating outer surface ofbody component 16. For example,lip 40 may define a transition fit or an interference fit with the cylindrical outer surface ofbody component 16 orendcap 14. - For purposes of the present disclosure, muffler designs having cylindrical or substantially cylindrical outer profiles are shown and described as exemplary illustrations of the principles of the present invention. However, the present methods and structures are equally applicable to non-cylindrical muffler designs, and may be applied to such non-cylindrical designs in the same manner as described herein with respect to cylindrical components (e.g.,
endcaps - As best shown in
FIG. 2 ,body component 16 includesclosed end 50 which is stepped down to pass bylip 40 and into the inner cavity defined by the cylindrical wall ofendcap 12. As further described below, the interface between the stepped-down portion ofclosed end 50 and the abutting inner surface of the cylindrical wall ofendcap 12 may be substantially fluid-tight, such that theclosed end 50 may effectively operate as a baffle.Body component 16 has an open end 52 (FIG. 3 ) oppositeclosed end 50 and sized to interfit withlip 40 of theother endcap 12 used inmuffler 10. The tight fit betweenlips 40 and the adjacent cylindrical walls ofbody component 16 may create a “sealed” interface via a substantially or entirely fluid-tight fit. A substantially fluid-tight fit may be, for example a fit which allows leakage of less than 5% of gases from the shell ofmuffler 10 during normal operation at typical internal pressures. In addition, a fully fluid-tight seal (i.e., with zero leakage) may be affirmatively created at the interface betweenlips 40 andintermediate component 16 after assembly, such as by welding, application of adhesive or sealant or any other suitable sealing method. These fluid-tight seals among the shell components ofmuffler assembly 10 may cooperate with other fluid-tight junctions (as described below) to creates a fluid-tight inner cavity ofmuffler 10, which in turn promotes smooth functioning and reduces noise during operation of the muffler. - Turning now to
FIGS. 2-4 ,muffler 10 includes various internal and external components designed to facilitate the flow of exhaust gases through the muffler shell. Some or all of these components may also provide for noise reduction and back pressure modulation as the gases pass throughmuffler 10. In the illustrated embodiment, gases enter the interior cavity defined by the shell ofmuffler 10 via a pair ofmanifold pipes manifold flanges 31 at the upstream ends thereof.Flanges 31 are configured to attach to exhaust ports on an internal combustion engine, such that exhaust gases are conveyed bymanifold pipes muffler 10. - These exhaust gases are then discharged into respective intake ports of the separate chambers defined by the
respective endcaps 12. The left endcap 12 (as viewed inFIG. 2 ) defines a left intake chamber having an intake aperture 46 (FIG. 3 ), through which gases are received frompipe 30. The left chamber is separated from the central chamber byclosed end 50 of body component 16 (FIG. 3 ), which is integrally formed together with the cylindrical body portion ofcomponent 16 as part of a monolithic component.Closed end 50 includesapertures 26 formed therethrough to facilitate a controlled flow of gases from the left intake chamber to the intermediate chamber defined bybody component 16. The baffle portion ofbody component 16, atclosed end 50, has an exterior periphery abutting the adjacent interior wall ofendcap 12, thereby creating a partial or complete seal which may also be supplemented by the weld or other sealant applied atlip 40. In this way,closed end 50 serves the function of an interior baffle. - For the right intake chamber defined by the
right endcap 12, gases are received frompipe 32 via an intake port at aperture 46 (FIG. 3 ). The gases then pass into the intermediate chamber ofbody component 16 via aseparate baffle component 18 sealingly received withinbody component 16.Baffle 18 has a similarly plurality ofapertures 26 therethrough to control the flow of gases from the right endcap chamber into the intermediate chamber, similar toapertures 26 formed inclosed end 50 ofbody component 16. In the illustrated embodiment, the exterior periphery ofbaffle 18 abuts the adjacent interior wall ofintermediate component 16, and may create a fluid-tight seal therewith in some applications. - The use of baffle(s) 18, and/or the baffle configuration formed in
closed end 50 ofbody component 16, is shown and described herein for illustration of certain exemplary internal muffler configurations, it being understood that other configurations may be used as required or desired for a particular application. For example, some mufflers made in accordance with the present disclosure may exclude baffles which abut the outer muffler shell, and instead include “tube-in-tube” type baffles in which muffler chambers are formed between at least two coaxial tubes of differing diameters. - Gases discharged to the intermediate chamber from the left and right intake chambers then pass into
crossover tube 20 via an array ofapertures 22 formed therein. In the exemplary embodiment ofFIGS. 2-4 ,apertures 22 may be louvered, and one end ofcrossover tube 20 is formed as a closedcrimped end 24. As described below, these features facilitate efficient production ofcrossover tube 20, while ensuring that gases flow intocrossover tube 20 from the intermediate chamber and out ofmuffler 10 viaexhaust port 25. As best seen inFIGS. 2 and 4 ,crossover tube 20 extends through central apertures formed inbaffle 18 and in theclosed end 50 ofbody component 16, and is substantially sealingly engaged with these central apertures such that gases are substantially directed to pass between internal chambers primarily throughbaffle apertures 26. In this way, baffle 18 and the baffle created byclosed end 50 primarily control the flow of gases between the interior chambers of the shell ofmuffler 10, whilecrossover tube 20 extends throughbaffle 18 and the baffle portion ofbody component 16 to receive a flow of gases from the shell interior and transmit the flow to the ambient area outside themuffler 10. - In some embodiments,
crossover tube 20 may be omitted. In these embodiments, gases are allowed to flow from chamber to chamber and to the ambient area outside the muffler shell via perforations, such as holes through internal baffles and/or perforations and/or holes formed in the muffler shell itself. - Turning now to
FIG. 3 , therespective endcaps 12 are adapted from a blank form (described further below) to their differing roles at opposing ends ofmuffler 10 by processing each blank form differently. In particular, the left endcap 12 (as viewed inFIG. 2 ) includesradial aperture 46 formed within the cylindrical sidewall thereof, and sized to receive a downstream end ofmanifold pipe 30. In the illustrative embodiment ofFIG. 3 , the longitudinal axis AP ofradial aperture 46 and the downstream end ofpipe 30 is spaced from the central longitudinal axis AM defined by the cylindrical body of endcap 12 (and by the muffler shell more generally, after assembly). Thus,radial aperture 46 takes on an egg shape, as best illustrated inFIG. 13 . In other embodiments (not shown), the longitudinal axis AP ofradial aperture 46 may intersect with the central longitudinal axis AM, producing a more circular shape. Moreover, longitudinal axis AP may intersect central axis AM, or may be spaced from central axis AM by any amount as required or desired for a particular application. - By contrast, the
right side endcap 12 includes bothradial aperture 46, which has a similar but mirror-image position and configuration to theleft side endcap 12, but further includesaxial aperture 48 formed inclosed end 42 and sized to sealingly receivecrossover tube 20 as shown inFIGS. 2 and 4 .Closed end 42 of theleft side endcap 12 is allowed to remain completely sealed, as best seen inFIGS. 2 and 4 . Advantageously, and as further described below,endcaps 12 may be identical components prior to the formation ofapertures 46 and/or 48, such thatendcaps 12 can each be drawn from a common inventory of stamped endcap components and then modified to suit their individual functions within a larger muffler configuration, such asmuffler assembly 10. - In one exemplary embodiment, a reinforcement place 36 (
FIG. 3 ) may be provided at the interior or exterior of the cylindrical wall ofendcap 12 aboutradial aperture 46.Reinforcement plate 36 is placed against the cylindrical wall ofendcap 12 and bonded thereto, such as by welding, adhesives, mechanical fasteners, or any other suitable fixation method.Reinforcement plate 36 effectively thickens the cross-sectional wall thickness of the cylindrical body in the vicinity ofaperture 46. This thickening spreads forces on the cylindrical wall ofendcap 12 bymanifold pipes 30 and/or 32 after assembly ofmuffler 10 and during its operational service. This spreading of forces, in turn, reduces the stresses experienced by the cylindrical wall ofendcap 12 at and around the junction betweenapertures 46 andpipe apertures 46, such that the sealed, fluid-tight connection betweenpipes apertures 46 is maintained even whenmuffler 10 is installed and/or experiences bumping or jostling during operational service. Althoughreinforcement plate 36 is placed in the interior cavity ofendcap 12 in the illustrated embodiment,reinforcement plate 36 may similarly be placed along the exterior of the cylindrical body ofendcap 12 with the same functional result. - Turning now to
FIGS. 5 and 6 muffler assembly 110 is shown with a different configuration frommuffler assembly 10 described in detail above.Mufflers muffler 110 have reference numbers which correspond to similar or identical structures ofmuffler 10, except with 100 added thereto for structures with modifications. - As best seen in
FIG. 6 ,endcaps 12 are mounted tobody component 16 in the same manner asmuffler 10 described above. However, the internal and external components associated withmuffler 110 have a different configuration. In particular, only one ofendcaps 12 includesaperture 46, and only onemanifold pipe 32 is connected to the muffler shell assembly. Thus,muffler assembly 110 is a type which is configured for an engine in which all cylinders exhaust to a single pipe (e.g., a single cylinder engine, or a multi-cylinder engine with header pipes that combine into a single pipe). By contrast,muffler 10 has twoapertures 46 fed byseparate manifold pipes FIG. 1 and describe above, and therefore is configured for a multi-cylinder engine. - Crossover tube 120 of
muffler 110 is also configured differently fromcrossover tube 20. In particular, apertures 122 are formed near the closed axial end of crossover tube 120, and are therefore positioned within the muffler cavity defined by theleft endcap 12 rather than the muffler cavity withinbody component 16 as shown inFIG. 2 and described above. Thus, gases entermuffler 110 viaaperture 46, pass throughapertures 26 formed in the baffle portion ofbody component 16, and then enter crossover tube 120 via apertures 122. These gases are then exhausted atexhaust port 125. As also shown inFIG. 6 , the closed axial end of crossover tube 120 includescap 124 to seal the axial end, rather than a crimped end such asend 24 as shown inFIG. 2 .Cap 124 may be used, for example, in configurations where the apertures 122 are positioned too close to the axial end of tube 120 to make use of a crimped end. - As shown in
FIG. 5 , mountingbracket 34 is also included along the exterior of the shell ofmuffler assembly 110.Bracket 34 may be welded, riveted or otherwise fixed to the exterior ofmuffler 110, and may span multiple components such asendcap 12 andbody component 16 as shown. Mountingbracket 34 may be used to help support the weight ofmuffler 110 when attached to a vehicle, for example, and may be similarly used with any muffler design in accordance with the present disclosure, includingmufflers - Turning now to
FIGS. 7 and 8 , yet anothermuffler assembly 210 made in accordance with the present disclosure is shown.Mufflers muffler 210 have reference numbers which correspond to similar or identical structures ofmuffler 10, except with 200 added thereto for structures with modifications. - However,
muffler 210 excludesbody component 16 such thatendcaps endcap 14 excludeslip 40, as shown inFIGS. 16-20 . Instead, endcap 14 includes a cylindrical body with open end 44 (FIGS. 17-20 ) having the same outer diameter asopen end 52 of body component 16 (FIG. 3 ). In this way,endcap 14 may be sealingly connected toendcap 12 in the same manner asbody component 16 described above, with a similarly tight fit and similar options for creating a substantially fluid tight seal. -
Muffler assembly 210 includesmanifold pipes muffler 210 in the same manner as described above with respect tomuffler 10. However, rather than passingcrossover tube 220 throughclosed end 42 of one of theendcaps 12, 14 (as shown and described above with respect tomuffler 10 and 110),crossover tube 220 makes a 90-degree bend within the cavity of the shell ofmuffler 210, and then passes through a radial-type aperture 46 formed in the sidewall ofendcap 14 as shown inFIG. 7 , rather than an axial aperture 48 (shown, e.g., inFIG. 3 ). That is,exhaust port 225 exitsmuffler 210 radially rather than axially as described above with respect tomufflers crossover tube 220 is closed, viacrimped end 224 similar tocrossover tube 20 described above.Apertures 222 are formed in a central chamber withinmuffler 210, with twobaffles 18 used to delineate the three chambers within the internal volume ofmuffler 210 as shown inFIG. 8 . - As noted above,
mufflers endcaps 12 includinglip 40, as shown inFIG. 9 , but excluding anyapertures endcaps 12 may be stored and ready for further processing prior to integration into a variety of muffler configurations. In particular, endcaps 12 may have an undisturbed cylindrical body and completelyclosed end 42, together withlip 40 and the associatedopen end 44. Similarly,endcaps 14, shown inFIG. 16 for example, may include an undisturbed cylindrical body, nolip 40, and a completelyclosed end 42, withopen end 44 sized to be received withinlip 40 ofendcap 12.Intermediate body components 16 may also be provided with open end 52 (FIG. 3 ), a completely closed end 50 (i.e., withoutapertures 26 or a central aperture for receiving a crossover tube), and an undisturbed cylindrical body extending between the open and closed ends 52, 50. In an exemplary embodiment, the cylindrical body ofendcap 14 andbody component 16 have the same outer diameter at their respective open ends 44 and 52, such that eitherendcap 14 orbody component 16 may be modularly mated to endcap 12 vialip 40 as described and shown herein. - With a set of
endcaps endcaps endcaps - Baffles 18 and tube stock sized to create
crossover tubes 20, 120 or 220 (or other crossover tube designs), may also be stocked as part of the modular muffler assembly kit. As described above, baffles 18 may be used as needed to delineate the inner chambers of any muffler configuration, either alone or in combination with the baffle portion ofbody component 16, if the desired muffler design includesbody component 16. Different sizes ofbaffles 18 may be included in the kit to fit the various nominal sizes of muffler shells. - Similarly, the tube stock included with the modular muffler kit may be appropriately sized to sealingly connected to the central apertures formed through
baffles 18,closed end 50 ofbody component 16, or axial aperture 28 throughclosed end 42 ofendcaps crossover tubes louvered apertures crimped end 24, may be put into an axial end of any crossover tube where the design permits enough free axial end space for crimping, or alternatively, caps 124 (FIG. 6 ) may be used where apertures (e.g., apertures 122) are too close to the axial end to create a crimped end. - As noted above,
endcaps body component 16 may be stamped components. That is, blanks may be provided which are sized and configured to be stamped into a cylindrical die to create the basic stamped shape ofendcap 12,endcap 14 orintermediate body 16. In the case ofendcaps closed end 42 with the distinctive design of stepped surfaces shown inFIG. 16 , and the substantially cylindrical outer shell extending fromclosed end 42 to openend 44. Forendcap 12,lip 40 may also be formed by a separate stamping operation. Apertures, such asradial apertures 46 and/oraxial apertures 48, may be subsequently pierced using a separate stamping operation, or other piercing or machining operations. - In the case of
intermediate body component 16, the bottom of the stamping die may include a step for creation of the baffle portion ofclosed end 50 described in detail above. Apertures 26 and/or a central aperture sized to sealing receive a crossover tube (such ascrossover tube 20 shown inFIG. 2 ) may be created using a separate stamping operation, or other piercing or machining operations. - Advantageously, the stamping operations described above provide a high degree of dimensional precision and accuracy, particularly at the open ends of the various components and around
lip 40 ofendcap 12. This allows the various components to be mated to one another as described above with a high degree of coaxiality and a tight interface therebetween, such as a transition fit or interference fit. This tight fit can then create an affirmative fluid-tight seal by welding, adhesives, sealant or the like around the periphery oflip 40, as described above. During assembly, mating components of the muffler shell are pressed together to seat the axial end of one piece (e.g.,endcap 14 or intermediate component 16) firmly against the interior shoulder formed at the inner end of lip 40 (e.g., of endcap 12). When so assembled, the components become aligned with a high degree of coaxiality. -
Endcaps intermediate component 16 have an axial extent long enough to serve as components which defined the interior volume of the muffler shell, as opposed to traditional endcaps which merely close the axial end of an interior volume formed by a separate (non-stamped) shell component. In the illustrated embodiment, for example,endcaps intermediate component 16 all define a ratio of axial depth to overall diameter which is between 0.5 and 1.5. That is, the axial depth ofendcaps intermediate component 16 is at least half of its diameter, and may be as large as 1.5 times its diameter. This contrasts with an endcap used in a traditional muffler design, which would define a depth:diameter ratio much less than 0.5. - In one embodiment, the outer components of
muffler assembly 10, such asendcaps body component 16, are formed from aluminized steel. Painted, coated or plated cold rolled steel may also be used as required or desired for a particular application. A stainless steel material may also be used, providing the best corrosion and weather resistance for a long service life in outdoor environments. - Mufflers made in accordance with the present disclosure may be used on any vehicle or other equipment using an internal combustion engine. For example, in one particular exemplary embodiment shown in
FIG. 23 ,muffler 210 may be mounted to ridinglawn mower 300 havingengine compartment 302 in front of operator controls 304 andoperator seat 306.Muffler 210 is mounted below theengine compartment 302 and directs exhaust fumes downwardly. The operator controlswheels 308 andmower deck 310 ofmower 300 fromseat 306. - In another particular exemplary embodiment shown in
FIG. 24 ,mufflers turn type mower 400 havingengine compartment 402 behind operator controls 404 andoperator seat 406.Mufflers engine compartment 302 and directs exhaust fumes backwardly. The operator controlswheels 408 andmower deck 410 ofmower 400 fromseat 406. - While this invention has been described as having an exemplary design, the present invention can be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains and which fall within the limits of the appended claims.
Claims (26)
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CN201810507989.3A CN108942092A (en) | 2018-05-24 | 2018-05-24 | A kind of manufacturing method and muffler of muffler |
CN201810507989.3 | 2018-05-24 |
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US20190360379A1 true US20190360379A1 (en) | 2019-11-28 |
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US16/415,238 Abandoned US20190360379A1 (en) | 2018-05-24 | 2019-05-17 | Modular muffler assembly and method |
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CN (1) | CN108942092A (en) |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20210219492A1 (en) * | 2020-01-17 | 2021-07-22 | Andreas Stihl Ag & Co. Kg | Riding Lawn Mower |
Families Citing this family (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE102019100741A1 (en) * | 2019-01-14 | 2020-07-16 | Faurecia Emissions Control Technologies, Germany Gmbh | Method of manufacturing a silencer, silencer and vehicle |
DE102019100739A1 (en) * | 2019-01-14 | 2020-07-16 | Faurecia Emissions Control Technologies, Germany Gmbh | Muffler for an exhaust system of a motor vehicle and method of manufacture |
Family Cites Families (12)
Publication number | Priority date | Publication date | Assignee | Title |
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MY121635A (en) * | 1996-07-11 | 2006-02-28 | Honda Motor Co Ltd | Exhaust muffler |
CN2479218Y (en) * | 2001-05-17 | 2002-02-27 | 康捷环保科技股份有限公司 | Modular structural catalytic silencer |
CN202544966U (en) * | 2012-05-04 | 2012-11-21 | 河北元道通信技术有限公司 | Silencer |
CN202673421U (en) * | 2012-06-21 | 2013-01-16 | 武汉佛吉亚通达排气系统有限公司 | Welded muffler for vehicle |
CN103506807A (en) * | 2012-06-21 | 2014-01-15 | 浙江三花制冷集团有限公司 | Method for manufacturing silencer of split-type structure |
KR20140066508A (en) * | 2012-11-23 | 2014-06-02 | 현대자동차주식회사 | Muffler for motor vehicle |
CN103557064A (en) * | 2013-10-29 | 2014-02-05 | 湖北省红安县滤通机械制品厂 | Diesel engine muffler and flanging rolling technology thereof |
CN203730104U (en) * | 2014-03-13 | 2014-07-23 | 光阳工业股份有限公司 | Exhaust muffler for engine |
CN104675478A (en) * | 2015-03-11 | 2015-06-03 | 河南柴油机重工有限责任公司 | Exhaust muffler for box type generating unit |
CN204884547U (en) * | 2015-07-27 | 2015-12-16 | 广西汽车集团有限公司 | Silencer and barrel thereof |
CN206111276U (en) * | 2016-11-01 | 2017-04-19 | 新昌县泰斗机械有限公司 | Automobile silencer |
CN106285837A (en) * | 2016-11-02 | 2017-01-04 | 苏州工业园区职业技术学院 | Single-cylinder diesel engine silencer that a kind of noise reduction reduces discharging and preparation method thereof |
-
2018
- 2018-05-24 CN CN201810507989.3A patent/CN108942092A/en active Pending
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2019
- 2019-05-17 US US16/415,238 patent/US20190360379A1/en not_active Abandoned
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20210219492A1 (en) * | 2020-01-17 | 2021-07-22 | Andreas Stihl Ag & Co. Kg | Riding Lawn Mower |
US11622503B2 (en) * | 2020-01-17 | 2023-04-11 | Andreas Stihl Ag & Co. Kg | Riding lawn mower |
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CN108942092A (en) | 2018-12-07 |
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