This invention generally relates to mufflers designed for small engines and more specifically small engines as used in the propulsion of unmanned aerial vehicles, radio-controlled model aircraft, watercraft, and powered hand tools.
Over the past several decades, muffler designs aiming at compactness and light weight have been introduced in order to accommodate the demands of modern vehicle designs. Being primarily directed to use with four-stroke engines in automobiles and motorcycles, prior art muffler designs have been focused on reducing the size of the muffler system and for enhancing engine efficiency by maintaining low back pressure while adequately reducing exhaust noise by different means. In these designs, the exhaust pipe is partially or wholly enclosed within the body of the muffler to accommodate a duct shaped in a “jellyroll” or spiral passageway enclosed in an outer shell comprising the muffler housing. The spiral passageway is of reduced cross section relative to the header pipe in which exhaust gases increase in velocity and reduced pressure in a gradual manner, thereby greatly reducing the noise associated with the expansion of these gases, while maintaining low pressure and forward flow within the muffler so as greatly lower the backpressure on the engine.
More recently, streamlining muffler systems for two-stroke engines has been addressed. For a two-stroke engine, backpressure is an issue, but in the opposite sense in relation to four-stroke engines, and efforts have been made to design an exhaust system to maintain a certain level of backpressure so that the air/fuel mixture does not empty too quickly from the cylinder on the down-stroke of the piston. The quintessential exhaust processing system for a two-stroke engine has been the tuned straight pipe, adding to the passive backpressure control of the air/fuel charge in the cylinder by sending positive pressure pulses to the cylinder synchronized with the down-stroke to push fresh un-combusted air/fuel charge that had escaped into the exhaust system back into the cylinder just before the compression/combustion stroke of the piston. While the straight tuned pipe works well to enhance two-stroke engine efficiency, and reduce exhaust system noise, in the case of small vehicles and hand tools powered by small two-stroke engines, tuned pipes are in many instances longer and bulkier than the very vehicle or devices on which they are mounted, adding significant weight as well.
The present invention provides a conventional single pipe exhaust system designed to enhance engine performance and provide noise attenuation packaged into a unique form factor which is integrated into the engine design, and provides enhanced aerodynamic properties without the use of additive engine shrouding.
A first aspect of the present invention is directed to a muffler assembly. This muffler assembly includes a muffler body that may be characterized as having first and second end portions. The muffler body proceeds about a first reference axis proceeding from the first end portion to the second end portion. A first flow path is located within the interior of the muffler body and also proceeds about the first reference axis. An exhaust inlet port to the muffler body is in fluid communication with this first flowpath. There is also a first exhaust outlet port from the muffler body that is also in fluid communication with the first flowpath. The muffler assembly further includes what may be characterized as an engine assembly receptacle that is in the form of an open space. This open space is disposed inwardly of the muffler body in relation to the noted first reference axis such that the muffler body may be characterized as wrapping around at least a portion of an engine assembly in an installed configuration for the muffler assembly (e.g., when the muffler assembly is incorporated by an engine assembly, and where the engine assembly would be disposed within the noted engine assembly receptacle).
A second aspect of the present invention is directed to a muffler assembly that includes a muffler body. There is an exhaust inlet port to an interior of this muffler body, a first exhaust outlet port from the interior of this muffler body, and a second exhaust outlet port from the interior of this muffler body. The first exhaust outlet port and the second exhaust outlet port are oriented to discharge an exhaust flow from the interior of the muffler body in different directions.
A third aspect of the present invention is directed to an engine assembly that includes a propeller, an internal combustion engine, and a muffler assembly. The muffler assembly is arcuately-shaped proceeding about a first reference axis, and this first reference axis is co-linear with or parallel to a rotational axis of the propeller.
A number of feature refinements and additional features are separately applicable to each of above-noted first, second, and third aspects of the present invention. These feature refinements and additional features may be used individually or in any combination in relation to each of the first, second, and third aspects. Initially, the muffler assembly in accordance with each of the first and second aspects may be utilized by the third aspect.
The muffler body may be characterized as being arcuately-shaped proceeding between its first and second end portions and about the noted first reference axis. One embodiment has the first and second end portions of the muffler body being spaced more than 180° apart proceeding about the first reference axis (e.g., the muffler proceeds more than 180° about the first reference axis).
The muffler body includes a first flowpath within the interior of the muffler body. The first flowpath may be characterized as proceeding more than 180° about the first reference axis in flowing from the exhaust inlet port toward an opposite end of the muffler body. The first flowpath may be characterized as including first and second portions. One embodiment has the first portion of the first flowpath extending more than 180° proceeding about the first reference axis in a first direction, while the second portion of the first flowpath extends more than 180° proceeding about the same first reference axis in a second direction that is directly opposite of the first direction. Another embodiment has this first portion of the first flowpath proceeding from the first end portion of the muffler body to the second end portion of the muffler body, while the second portion of the first flowpath proceeds from the second end portion of the muffler body back to the first end portion of the muffler body.
The exhaust inlet port and the first exhaust outlet port may be incorporated at the first end portion of the muffler body. The muffler body may further include a second exhaust outlet port. Such a second exhaust outlet port may also be incorporated at the first end portion of the muffler body. The first and second exhaust outlet ports may be incorporated by the muffler body so as to discharge an exhaust flow out of the body in different directions, for instance in directions that are orthogonal to one another. The first exhaust outlet port may be utilized for a first aircraft configuration (e.g., a pull-type configuration), while the second exhaust outlet port may be used for a second aircraft configuration (e.g., a push-type configuration). A plug may be disposed in one of the first or second exhaust outlet ports, for instance depending upon the application (e.g., aircraft configuration) in which the muffler assembly is being used. That is, the muffler assembly will typically be configured such that only one of the first exhaust outlet port and the second exhaust outlet port will be in use for a given application.
The muffler body may include first, second, and third chambers. The exhaust inlet port may direct a flow of exhaust into the first chamber, while an exhaust flow may be directed out of the third chamber (more generally out of the muffler body) through the first exhaust outlet port. A packing material (e.g., a sound-dampening material) of any appropriate type may be included in the second chamber. There is a first partition between the first chamber and the second chamber, with this first partition including at least one first flow port. There is a second partition between the second chamber and the third chamber, with this second partition including at least one second flow port. Each of the first chamber, second chamber and third chamber extend from the first end portion of the muffler body to the second end portion of the muffler body and proceed about the first reference axis.
The second chamber is located between the first chamber and the third chamber in a dimension corresponding with the direction in which the first reference axis extends. The first chamber, second chamber, and third chamber may be characterized as being stacked in a dimension that corresponds with the dimension in which the first reference axis extends, with the second chamber being located between the first chamber and the third chamber within this stack. The first and third chambers are connected to each other. This path represents the primary, low frequency pressure, high volumetric flow rate path. The first chamber may be characterized as being a lower chamber, the third chamber may be characterized as being an upper chamber, and the second chamber may be characterized as being an intermediate chamber.
The exhaust gas pressure wave flowing into the first chamber through the exhaust inlet port is directed into the second chamber through an array of one or more first flow ports in the first partition between the first chamber and the second chamber. The exhaust gas pressure wave within the second chamber flows into the third chamber through an array of one or more second flow ports in the second partition between the second chamber and the third chamber. Exhaust gases exit the muffler body through the third chamber and the first exhaust outlet port. There may be a plurality of first ports that fluidly connect the first chamber with the second chamber, and there may be a plurality of second ports that fluidly connect the second chamber with the third chamber. One embodiment has the total cross-sectional area of the first ports (between the first chamber and the second chamber) being less than the total cross-sectional area of the second ports (between the second chamber and the third chamber), where a cross-sectional area is taken perpendicular to a flow through a given port.
The muffler assembly may be used by an appropriate engine assembly, such as an engine assembly that uses an internal combustion engine. A vehicle of any appropriate type may utilize such an engine assembly and the muffler assembly. In one embodiment, the engine assembly utilizes a propeller having a rotational axis. The muffler assembly may be incorporated such that the first reference axis is either co-linear with or parallel to this rotational axis. The muffler assembly may be incorporated such that it does not protrude beyond an outermost perimeter of the engine assembly.
Any feature of any other various aspects of the present invention that is intended to be limited to a “singular” context or the like will be clearly set forth herein by terms such as “only,” “single,” “limited to,” or the like. Merely introducing a feature in accordance with commonly accepted antecedent basis practice does not limit the corresponding feature to the singular. Moreover, any failure to use phrases such as “at least one” also does not limit the corresponding feature to the singular. Use of the phrase “at least generally” or the like in relation to a particular feature encompasses the corresponding characteristic and insubstantial variations thereof. Finally, a reference of a feature in conjunction with the phrase “in one embodiment” does not limit the use of the feature to a single embodiment.
Referring to
In a preferred embodiment, the muffler assembly 100 is mounted to a two-stroke engine assembly at the flange associated with the exhaust intake port 102 and at three positions corresponding with the engine mounting flanges 104. The muffler assembly 100 then becomes an integral and aerodynamic component of the engine module assembly (
The exhaust intake port 102 is integrally cast into the muffler body 100a. The exhaust intake port 102 may form a slightly constricted duct through which exhaust gas are ported to the lower half or portion of the muffler body 100a. The terminus end of the duct may be lined with an aggregation of perforations designed as an initial disruption point for the entering gases, hence enabling the further optimization of back pressure values to the cylinder chamber.
The exhaust gases travel through a lower chamber along the length of the muffler body 100a and then return to the inception end of the chamber along an upper chamber, approaching the exit aperture and the atmosphere by means of an exhaust port stinger (connected with either the exhaust outlet port 103 (e.g., stinger 107 in
The exhaust port stinger may be covered/blocked by the rotary exhaust valve 106 (
The ceiling of the lower half and the floor of the upper half (
The exact placement and pattern of the perforations along the upper chamber unit allow for the exhaust gas duct to function as an internal header pipe. The placement of the perforation pattern as well as the internal header is optimized to produce maximum performance of the example two-stroke engine to which the muffler 100 may be attached.
The design of the conformal muffler 100 allows for an equivalent length of the exhaust path as compared to straight-line traditional packed mufflers as known in the art. The curved exhaust path from the lower to upper muffler chambers in the conformal muffler 100 creates an exhaust path length approximately two times the length of the perceived exhaust path.
The design of the conformal muffler 100 includes two cast ports 103, 105 for the venting of exhaust gases into the atmosphere. This innovative feature allows for the conformal muffler 100 to be used on either tractor or pusher configuration propulsion systems. In either configuration, a single port is used to vent exhaust gases into the environment near the propeller assembly. This configuration enables optimum exhaust flow to the atmosphere while minimizing exhaust initiated turbulence in each of the propulsion directional configurations. When the conformal muffler 100 is applied to a tractor-type small engine configuration, the stinger exit is positioned to accept an exhaust flow out of the muffler body 100a through the exhaust outlet port 105 (e.g., where the exhaust flow would be discharged at least substantially parallel to a plane in which the associated propeller is rotating; where the exhaust flow would be discharged orthogonal to a direction of travel of a vehicle that incorporates the muffler 100). The second exhaust outlet port 103 is then blocked via a plug 116 (e.g., an aluminum standard threaded pipe fitting plug).
The conformal muffler 100, when applied to a pusher-type small engine configuration, allows for the stinger insertion into the exhaust outlet port 103 (e.g., located about 90 degrees from the exhaust outlet port 105; stinger 107 in
The muffler body 100a discussed above may be characterized as having a first end portion 110 and a second end portion 112 that are spaced from one another by the muffler body 100a proceeding about a reference axis 114. The muffler body 100a may be characterized as being arcuately-shaped in a plan view (where this reference axis 114 is represented by a dot or point, such as in
The above-described ports 102, 103, 105 of the muffler 100 may be characterized as being disposed at the first end portion 110 of the muffler body 100a. An exhaust flow entering the interior of the muffler body 100a through the exhaust inlet port 102 may flow more than 180° about/relative to the reference axis 114 in proceeding toward the second end portion 112 of the muffler body 100a (through a lower or first chamber 130a of the muffler 100), and the exhaust gas within the muffler body 100a may also flow more than 180° about/relative to the reference axis 114 in proceeding back to the first end portion 110 to exit the muffler body 100a either through the exhaust outlet port 103 or the exhaust outlet port 105 (through an upper or third chamber 130c of the muffler 100). A plate with perforations may separate the lower chamber 130a from an intermediate or second chamber 130b, while another plate (spaced along or relative to the reference axis 114) separates the intermediate chamber 130b from the upper chamber 130c, all as shown in
A schematic of the muffler body 100a to further illustrate the above-noted chambers 130a, 130b, and 130c is presented in
A first partition or plate 132a is disposed between the lower chamber 130a and the intermediate chamber 130b, while a second partition or plate 132b is disposed between the intermediate chamber 130b and the upper chamber 130c. A plurality of first perforations or ports 134a extend through the first partition 132a to allow fluid communication between the lower chamber 130a and the intermediate chamber 130b. A plurality of second perforations or ports 134b extend through the second partition 132b to allow fluid communication between the intermediate chamber 130b and the upper chamber 130c.
Exhaust gases are directed into the lower chamber 130a through the exhaust inlet port 102 at the first end portion 110 of the muffler body 100a (represented by the arrow A in
Each port 134a and 134b has a cross-sectional area that is taken perpendicularly to a flow through the corresponding port 134a, 134b. The collective cross-sectional area of the first ports 134a (e.g., the sum of the cross-sectional area of each first port 134a in the first partition 132a) is less than the collective cross-sectional area of the second ports 134b (e.g., the sum of the cross-sectional area of each second port 134b in the second partition 132b). In one embodiment, the collective cross-sectional area of the first ports 134a is no more than about fifteen percent (15%) of the collective cross-sectional area of the second ports 134b. This accommodates the lower chamber 130a being located closer to the exhaust being discharged from the corresponding engine.
A representative engine assembly that may incorporate the muffler 100 is illustrated in
A representative engine assembly is illustrated in
The engine assembly 200 further includes an engine mounting system in the form of a plurality of mounting legs 230 that extend between the crankcase housing 210 and a mounting ring 260. The mounting ring 260 may be appropriately secured to an airframe of an aircraft or aerial vehicle (as well as to a bulkhead of a watercraft or power equipment). The engine assembly 300 shown in
Each mounting leg 230 includes an upper section 240 that may be integrally formed with the crankcase housing 210, as well as a lower section 250. The lower section 250 for each mounting leg 230 is in the form of a vibration damping or isolation subassembly, and each such lower section 250 may be of any appropriate configuration to provide the desired/required support and/or vibration damping/isolation effects. The engine assembly 200 of
The muffler 100 discussed above in relation to
The exhaust system 360 for the engine 310 includes a muffler 362 that receives a discharge or exhaust/exhaust flow from the cylinder 340 during operation of the engine 310 and via an exhaust header 376 that fluidly interconnects the cylinder 340 and the muffler 362. The muffler 100 addressed herein may be used in place of the muffler 362. In this case, the reference axis 114 of the muffler 100 could be integrated such that its reference axis 114 is either aligned with (e.g., collinear) or parallel to the crankshaft 316.
An exhaust conduit 364 (e.g., a tailpipe or stinger) extends from the muffler 362 and includes an open end or exhaust discharge port 366. As such, exhaust from the cylinder 340 flows into/through the header 376, then into/through the muffler 362, and then into/through the exhaust conduit 364 such that the exhaust exits through the open end 366 of the exhaust conduit 364 and into the atmosphere 378.
The exhaust flowing out of the exhaust system 360 through the open end 366 of the exhaust conduit 364 may be characterized as including two primary components—a bulk exhaust gas flow and acoustic emissions (e.g., one or more acoustic waves). The exhaust system reflector 380 is used by the engine 310 to force at least a part of the acoustic emissions (after having exited the exhaust system 360 through the open end 366 of the exhaust conduit 364, or at least after having reached the open end 366 of the exhaust conduit 364 back into the exhaust conduit 364 (via its open end 366) and preferably then back into the muffler 362. This reflection and/or obstruction of at least part of the acoustic emissions should dampen the acoustic emissions (e.g., further lower the acoustic emissions from operation of the engine 310; accommodate additional acoustic wave destructive interference) more than if the acoustic emissions make a single pass through the muffler 362 in proceeding from the cylinder 340 to the exhaust conduit 364. In addition to the foregoing, the reflector 380 should also be sized and timed (relative to the position of the open end 366 of the exhaust conduit 364) to reduce the potential of an unacceptable amount of the bulk exhaust gas flow being redirected or obstructed by the reflector 380, which could generate a back pressure in the muffler 362 and the cylinder 340, which in turn could adversely affect the operational performance of the engine 310. Preferably at most only a very minor amount of the bulk exhaust gas flow is reflected or obstructed by the exhaust system reflector 380 at any time. As such, the reflector 380 may also be referred to as an acoustic emissions valve 380 that is positioned downstream of the exhaust system 360. Such an acoustic emissions valve 380 may be moved into a position (by the crankshaft 316) so as to reflect or obstruct acoustic emissions, but may be moved out of this position (by the crankshaft 316) so as to not obstruct the bulk exhaust gas flow that has exited the exhaust system 360.
The exhaust system reflector 380 may be integrated with the crankshaft 316 in any appropriate manner so that the exhaust system reflector 380 and the crankshaft 316 rotate in unison—the reflector 380 will rotate 360° each time that the crankshaft 316 rotates 360° in the case of an engine with a single cylinder head. The reflector 380 could be separately attached to the crankshaft 316 in any appropriate manner, the reflector 380 could actually be part of the crankshaft 316, or the like. The counterweight 390 may also be incorporated by the crankshaft 316 in any appropriate manner so that the counterweight 390 and the crankshaft 316 also rotate in unison—the counterweight 390 will rotate 360° each time that the crankshaft 316 rotates 360°. The counterweight 390 could be separately attached to the crankshaft 316 in any appropriate manner, the counterweight 390 could actually be part of the crankshaft 316, or the like. In the illustrated embodiment, the counterweight 390 is mounted 180° from the reflector 380 relative to a rotational axis of the crankshaft 316 (e.g., the counterweight 390 and reflector 380 are disposed in opposing relation relative to the crankshaft 316). The counterweight 390 functions to maintain an appropriate rotational balance for the crankshaft 316. Other configurations where rotation of the crankshaft 316 moves the reflector 380 in the manner to be described herein may be utilized by the engine 310.
The reflector 380 is located outside of the exhaust system 360. The exhaust system 360 discharges to the atmosphere 378. As such, the reflector 380 is located within the atmosphere 378. In order to reflect at least part of the acoustic emissions back into the exhaust system 360, but to not reflect any substantial portion of the bulk exhaust gas flow back into the exhaust system 360, the reflector 380 is rotated into and out of alignment with the open end 366 of the exhaust conduit 364 through rotation of the crankshaft 316. “In alignment” in relation to the relative positioning of the reflector 380 and the open end 366 of the exhaust conduit 364 means that at least part the flow out of the open end 366 of the exhaust conduit 364 impacts the reflector 380 in a manner that reflects at least part of this flow back into the exhaust system 360 (where this flow is in the form of acoustic emissions in this instance). “Out of alignment” in relation to the relative positioning of the reflector 380 and the open end 366 of the exhaust conduit 364 means that the flow out of the open end 366 of the exhaust conduit 364 does not impact the reflector 380 in a manner that obstructs flow out of the exhaust system 360 (where this flow is in the form of the bulk exhaust gas flow in this instance). It should be appreciated that in certain instances the reflector 380 will be blocking/reflecting only a portion of the flow exiting the exhaust system 360 (e.g., as the reflector 380 is being rotated into alignment with the open end 366 of the exhaust conduit 364, and where the flow in this instance is in the form of acoustic emissions).
A schematic of a portion of the internal combustion engine 310 is presented in
The cylinder 340 includes an intake port 344 and an exhaust port 346. One or more valves may be associated with one or more of the ports 344, 346. An air/fuel mixture may be directed into the engine case 314 through the intake port 344 during movement of the piston 330 from a bottom dead center position toward a top dead center position (after the piston 330 passes the intake port 344). This movement of the piston 330 also compresses the air/fuel mixture that is contained within the combustion chamber 350 (located between the piston 330 and a closed end 352 of the cylinder 340, and directed into the chamber 350 through the intake port 344/engine case 314). At some point in time during the movement of the piston 330 toward its top dead center position, the piston 330 will isolate the exhaust port 346 from the combustion chamber 350.
When the piston 330 reaches (or is at least near) its top dead center position, a spark plug or igniter 348 ignites the air/fuel mixture within the combustion chamber 350, which drives the piston 330 from its top dead center position back toward its bottom dead center position. At some point in time during the movement of the piston 330 toward its bottom dead center position, the exhaust port 346 will be exposed to the combustion chamber 350 to allow a flow of exhaust out of the combustion chamber 350, through the exhaust port 346, and into the above-discussed exhaust system 360 (e.g., into/through the exhaust header 376, and then into/through the muffler 362, and then into/through the exhaust conduit 364). Movement of the piston 330 toward its bottom dead center position will at some point in time compress the air/fuel mixture that has previously entered the engine case 314 through the intake port 344.
A representative engine assembly is illustrated in
The muffler 436 in
The engine assembly 400 further includes an engine assembly mounting system in the form of a plurality of mounting legs 422 (for instance at least generally in accordance with mounting legs 230—
The engine assembly 400 of
The invention has been described in an illustrative manner and it is to be understood that the terminology which has been used is intended to be in the nature of words of description rather than of limitation. Other embodiments and configurations of the invention are possible during the continued development of the current desired engine configuration and alternative applications. The following claims are also in accordance with the invention.
This patent application claims the benefit of U.S. Provisional Patent Application No. 62/330,792, that was filed on May 2, 2016, and the entire disclosure of which is hereby incorporated by reference herein.
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Number | Date | Country |
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840646 | Apr 1939 | FR |
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Number | Date | Country | |
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62330792 | May 2016 | US |