Engine exhaust muffler

Abstract

A muffler for muffling engine operating sounds and including a cylindrical shell closed at opposite ends by double-walled closure caps. The space within the shell is partitioned into three axially contiguous chambers. A gas charging pipe projects through one end of the shell and axially within the shell, and has two pairs of facing discharge elbows for discharging gas from the charging pipe at locations in the first of the chambers. A first pair of gas transfer pipes extends from the first chamber into the central chamber to points of opposed gas discharge. A second pair of gas transfer pipes extends from the central chamber into the third or discharge chamber, and from this location, the gas passes out of the muffler via a discharge pipe.

Description

FIELD OF THE INVENTION

This invention relates to a large muffler which is connectable to the hot exhaust gas pipe from a large internal combustion engine, and which functions to muffle or attenuate the sound which is developed by the engine during operation.

BACKGROUND OF THE INVENTION

1. Brief Description Of The Prior Art

Various types of mufflers have heretofore been proposed for use in conjunction with large internal combustion engines for dampening or attenuating the sound made by the hot gases exhausted from the engine as these gases are vented to the atmosphere. In general, such mufflers include tubular elements which have various shapes, and often contain various numbers and configurations of baffles located on the inside of the external tubular member. The baffles are generally for the purpose of causing the gas to flow through a tortuous or circuitous route in passing from the inlet into the muffler to the exit thereof.

Many mufflers include some sort of packing material or sound absorbing material located in the interior of the muffler, or at least in the outer wall thereof, for dampening the sound made by the escaping hot gases which pass through the muffler when the engine to which it is attached is in use. In general, while certain isolated principles of sound attenuation have been recognized and utilized in various types of muffler designs, I believe that an optimum combination of these features has not been achieved, or at least has not worked as effectively as the combination which I have discovered, and which I now bring before the U.S. Patent and Trademark Office for evaluation, and, hopefully, issuance of a patent thereon.

U.S. Pat. No. 937,665 to Walton discloses a muffler which disposes of hot exhaust gases wherein the gas flow within the muffler is divided into two opposing streams by means of which the gases in the two streams are caused to impinge against each other at several points along the path of flow through the muffler. The muffler housing includes a plurality of baffle plates which include opposed nozzles through which the gas flows, and in being so directed by these nozzles, encounters opposing gas streams so that interference results. The baffle plates utilized in the muffler divide it into three substantially equal sized compartments.

Ronan U.S. Pat. No. 702,031 proposes to divide the hot exhaust gases entering the muffler into two opposing streams and these are then caused to impinge against each other and ultimately to escape into the air from one end of the muffler. The muffler is divided into two substantially equi-sized compartments, and the exhaust gases flow out through a volute located approximately in the center of the muffler.

U.S. Pat. No. 1,700,993 to Bernet et al depicts a plurality of concentric, opposing channels developed by partition plates located inside a muffler, with these channels lying in a substantially longitudinal direction. In these channels, the gas streams impinge against each other. Each concentric channel is defined within the muffler by a longitudinally disposed baffle plate. The flow within the muffler is from the outside flow path inwardly to the next radially inner flow path, and so forth, until the energy depleted exhaust gases reach the center of the muffler.

In Jackson U.S. Pat. No. 4,359,134, a sound-suppressor for air and hot gases is depicted in which the muffler or suppressor comprises a pair of aligned branch passages having a common inlet trunk, and having a common outlet trunk and having the appearance of an 0-shaped hollow member with arms projecting from the opposite sides thereof. One of the branch passages in the sound-suppressor contains a flow restricting orifice, and the other of the branch passages is unobstructed.

U.S. Pat. No. 2,229,913 to Blanchard proposes to divide the incoming hot gas flow into two pipes which diverge from each other as they project further inwardly toward the center of the muffler. The hot gases from these two divergent pipes are then re-merged by impinging the gases against each other at a location near the center of the muffler. From this location, the gases pass into the exhaust pipe from the muffler.

Schnell U.S. Pat. No. 1,844,105 describes a muffler in which a shell is filled with sound absorbing material, which can be any porous, sound deadening material, including "sized, crushed mineral matter", "mica", "exfoliated vermiculite", "brown slag", "coke", "pumice", or other porous aggregate material.

Other muffler patents include Rutt U.S. Pat. No. 4,137,993, Janeway U.S. Pat. No. 2,707,525 and U.S. Pat. No. 4,550,799 which locates a sound absorbing material between an inner skin and an outer skin disposed at the radially outer side of the hollow muffler body.

There has been no prior appreciation of which I am aware of the effect of sizing the several axially arranged contiguous chambers within a muffler according to a certain volumetric size ratio or dimensional correspondence, concurrently with the recognition that it is important to properly size the by-pass or pass through tubes or pipes which extend through partitions in the muffler in order to deliver an optimum relative amount of the hot gases from one chamber to the next in order to contribute to sound reduction optimization, along with a minimal interference with efficient engine operation.

BRIEF DESCRIPTION OF THE PRESENT INVENTION

The present invention provides an elongated compact cylindrical muffler for use in muffling the sound of operation of a large internal combustion engine. The muffler is connected to a discharge pipe carrying the exhaust gases from the engine, and by direction and selective treatment of these gases, effectively attenuates the sound of operation of the engine. Moreover, the muffler does not impair the efficient operation of the engine due to excessive increase in back pressure or the like.

Broadly described, the muffler of the invention includes an elongated cylindrical body which is of a double-walled construction. A particulate solid material of good sound attenuating properties is located between two relatively thin skins of metal forming the double walls. The interior of the double-walled shell is divided into three compartments which are critically sized relative to each other and relative to the cross-sectional area of the incoming hot gas exhaust pipe in a way important to the achievement of maximum sound attenuation.

The gas entering the muffler is divided into multiple streams at several points with these streams being directed back against each other so that the impinging hot gases dissipate a substantial portion of their kinetic energy by such impingement. The sound thus tends to be attenuated both by impacting the gases from multiple outlets against each other, as well as from the circuitous route through which the gases are made to pass.

An important object of the invention is to provide an improved sound attenuating muffler which can be used on large internal combustion engines to achieve very effective sound suppression or attenuation.

A further object of the invention is to provide an effective muffling system which can receive the hot exhaust gases from a large internal combustion engine, and by direction and treatment of these hot exhaust gases, eliminate a substantial part of the gases and attenuate the sound developed during the operation of the engine.

Another object of the invention is to provide a muffler system for attachment to an internal combustion engine, which muffler system is relatively economical in construction and relatively compact in size.

Additional objects and advantages of the invention will become apparent as the following detailed description of the o invention is read in conjunction with the accompanying drawings which illustrate a preferred embodiment of the invention.

GENERAL DESCRIPTION OF THE DRAWINGS

FIG. 1 is a vertical sectional view through the exterior shell of the muffler of the invention, and illustrating the internal piping within the shell in elevation.

FIG. 2 is a view similar to FIG. 1 but illustrating the muffler as it appears when rotated about its vertical axis through 90.degree. from the position shown in FIG. 1.

FIG. 3 is a sectional view taken along line 3--3 of FIG. 1.

FIG. 4 is a sectional view taken along line 4--4 of FIG. 1.

FIG. 5 is a sectional view taken along line 5--5 of FIG. 1.

FIG. 6 is a schematic illustration of an interconnected engine and muffler constructed in accordance with the present invention, indicating the spacial relationship between the two and showing the general location of a temperature sensor utilized to sense the temperature of the hot gases being exhausted from the engine to the muffler.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT OF THE INVENTION

The muffler of the invention includes a generally cylindrical double-walled external shell, designated generally by reference numeral 10. The double-walled shell 10 includes an elongated cylindrical central portion 12 which is closed at its opposite ends by a pair of double-walled concavo-convex closure caps. These include a bottom closure cap 14 and an upper or top closure cap 16.

The construction of the cylindrical central portion 12 of the double-walled shell 10 includes an outer metallic cylindrical skin 18 and an inner metallic cylindrical skin 20. The space between the outer skin 18 and inner skin 20 is filled with a solid particulate material having good sound absorbing qualities. Fine dry cement can be effectively employed.

The upper end closure cap 16 includes a concavo-convex outer skin 26 which has a central circular opening 28 therethrough to accommodate a discharge pipe provided for the discharge of gases passed through the muffler in a manner hereinafter described. Around the central circular opening, the outer shell or skin 18 is provided with a plurality of circumferentially spaced openings 30 (see FIGS. 1 and 3). The openings 30 are provided to permit the space between the inner and outer skins of the external shell to be filled with the solid particulate sound absorbing material 22 previously mentioned. A short cylindrical neck 32 is secured to the outer side of the outer skin 26 of the end cap 16 and projects axially therefrom in a concentric relationship to the circular opening 28 through the outer skin. A centrally apertured end plate 33 extends transversely across the open outer end of the neck 32. The outer skin 26 of the upper closure cap 16 carries an axially extending circumferential flange 34 which is dimensioned to provide a press fit within the outer skin 18 of the tubular central section 12.

The top closure cap 16 also includes a concavo-convex inner skin 35 which is spaced from the outer skin and defines a centrally positioned circular opening 37 for the accommodation of a cylindrical discharge pipe hereinafter described. The inner skin 35, like the outer skin 26 of the upper end closure cap 16, carries an axially extending circumferential flange 38. The flange 38 projects substantially parallel to the flange 34 and is dimensioned to provide a press fit within the inner skin 20 of the elongated cylindrical central portion 12 of the double-walled external shell.

At the opposite end of the generally cylindrical double-walled external shell 10, the bottom closure cap 14 includes a concavo-convex outer skin 40 which carries an axially extending circumferential flange 42 which is dimensioned to provide a press fit within the outer skin 18 of the tubular central section 12. The bottom closure cap 14 also includes a concavo-convex inner skin 44 which carries an axially extending circumferential flange 46 which is dimensioned to provide a press fit within the inner skin 20 of the tubular central section 12.

The interior of the muffler is divided into three contiguous chambers denominated by reference numerals 50, 52 and 54. The first or entrance chamber 50 is located between the bottom closure cap 14 and a concavo-convex partition plate 56 which carries a peripheral flange 58 by means of which the partition plate can be welded or otherwise suitably secured to the inner skin 20 of the double-walled cylindrical portion 12 of the shell 10. The intermediate compartment or chamber 52 is defined between the partition plate 56 and a second concavo-convex partition plate 60 which carries a peripheral flange 62 facilitating joinder of this partition plate to the inner skin 20 of the central cylindrical section 12. The discharge chamber or third compartment 54 is defined between the partition plate 60 and the top closure cap 16.

As will be subsequently explained, the volumetric ratio of the three axially contiguous chambers or compartments 50, 52 and 54 within the interior of the muffler is important to the achievement of one of the major objects of the invention, i.e. maximization of sound reduction commensurate with an acceptable level of back pressure to the engine to which the muffler is connected. The volumetric ratios of the three compartments to each other is actually best stated in terms of the volumetric ratio of each of the compartments to the cross-sectional area of the exhaust line from the engine at the point where the exhaust line enters the muffler, and thus, at that point, constitutes the intake or charging line to the muffler.

The engine exhaust line or pipe which constitutes the intake pipe or line entering the muffler is best illustrated in FIGS. 1 and 2 of the drawings, and is there denominated by reference numeral 64. The exhaust line 64 from the engine carries a connecting flange 66 at its outer end, and is generally cylindrical in configuration. It is mounted on the bottom closure cap 14 by means of a plurality of gusset plates 68. The exhaust pipe 64 passes through a circular opening in the bottom end cap 14 and then flares to a slightly larger diameter as it extends axially toward the center of the chamber or compartment 50.

The engine exhaust pipe 64 is oriented along the central axis of the generally cylindrical muffler, and thus it is positioned primarily in the center of the entrance chamber or compartment 50. At this location, the exhaust pipe has an end portion which is closed by a closure plate 72. The exhaust pipe 64 is ported around its periphery for connection thereto of a plurality of circumferentially-spaced L-shaped elbow fittings 74-80. The elbow fittings are mounted in pairs, 74-76 and 78-80 on the closed exhaust pipe 64 within the chamber 50, so that the discharge from the elbow fittings in each pair impinges, or is directed against, the discharge from the oppositely facing fitting in the other pair. This arrangement is best illustrated in FIGS. 1, 2 and 5. Here, the open ends of the elbows in each pair of elbows are oppositely turned so that their discharge openings face each other within each of the pairs. Thus, the hot gases which are being discharged from the two elbows in each pair of elbows impinge against each other at a point approximately midway between the two facing elbows.

Reference to FIGS. 1, 2 and 5 will thus reveal that the elbow 76 discharges hot gases from the exhaust pipe 64 against hot gases being discharged upwardly from the oppositely facing elbow 80. In the same fashion, hot gases discharged downwardly from the elbow 74 impinge against hot gases discharged upwardly from the elbow 78.

After the gases from the two pairs of elbows 74-80 have passed into the chamber 50, these gases pass radially outwardly and are able to enter axially extending elongated openings 90 and 92 formed in a pair of upwardly extending generally cylindrical transfer pipes 94 and 96. It will be noted that the transfer pipes 94 and 96 are located 180.degree. around the chamber 50 from each other, and are offset 90.degree. from the elbows 74-80. In order to engender turbulence in the gas flow within the chamber or compartment 50, and prior to the time the hot gases enter the elongated openings 90 and 92, a pair of radially outwardly extending elongated baffle plates 98 and 100 are disposed on opposite sides of the opening 90 in the transfer pipe 96, and a pair of elongated upwardly extending, radially outwardly projecting baffle plates 102 and 104 are located on opposite sides of the opening 92 into the transfer pipe 94. The bottom of the transfer pipe 94 is closed by a suitable closure plate 106, as shown in FIGS. 1 and 2, and a similar closure plate 108 closes the upwardly extending transfer pipe 96.

The transfer pipes 94 and 96 both pass through the partition plate 56 into the compartment or chamber 52. At the upper end of the cylindrical transfer pipe 96, it is curved through a 90.degree. angle so as to discharge hot gases in a horizontal direction across the chamber 52. Similarly, after the transfer pipe 94 projects through the partition 56 into the chamber 52, it carries a curved end which discharges hot exhaust gases in a horizontal direction which is directly opposite the direction of flow of gases from the transfer pipe 96. Thus, the hot gases from the transfer pipes 94 and 96 impinge upon each other by being directed in the opposite direction from the oppositely facing openings at the upper ends of these transfer pipes. It may be commented at this point that the diametric sizes of the two transfer pipes 94 and 96 is of some criticality to the proper functioning of the muffler of the invention, and this dimensional desiderata will be explained hereinafter.

After the hot gases have entered the chamber 52 after impinging against each on discharge from the facing openings of the transfer pipes 94 and 96, the gases change direction and move radially outwardly, as well as upwardly, in the chamber 52. By such movements, the gases are able to ultimately enter the open ends of the two horizontally extending pickup pipe sections forming the cross bar of T-shaped transfer pipe subassemblies, designated generally by reference numerals 110 and 112. The pickup sections of the transfer pipe assemblies 110 and 112 are denominated by reference numerals 114 and 116, respectively, and are illustrated in FIGS. 1, 2 and 4.

Each of the pickup sections 114 and 116 has an opening at its center where it is joined to a respective upwardly extending leg 118 and 120 of the respective transfer pipe subassembly 110 or 112. At its opposite ends, each of the pickup sections 114 and 116 is cut on a bias or bevel, as perhaps is best shown in FIG. 4. This angulation of the opening into the respective pickup section in each case orients the opening to face toward the walls of the chamber or compartment 52. This causes the hot gases to flow through a greater distance in order to enter the openings formed in the end of the pickup sections than would be the case, if, for example, the openings were disposed in a diametric plane of the pickup sections.

In the case of each of the horizontally extending pickup sections 114 and 116, a pair of flow restrictor plates are located inwardly from the opening and define a restricted opening of relatively smaller diameter through which the gases must pass in order to reach the ascending or vertically extending legs of the transfer pipe subassemblies. Thus, in the pickup section 114, a pair of restrictor plates 126 and 128 are located inwardly from the opposite ends of the pickup section 114, and in the pick up section 116, a pair of similar restrictor plates 122 and 124 are similarly positioned. Of these, plates 124 and 126 can perhaps be best perceived where they are shown in FIG. 2 of the drawings. After the hot exhaust gases have passed into the ends of the pickup sections 114 and 116, and then passed through the restrictor plates 122-128, the hot gases enter the upwardly extending leg 118 in the case of the transfer pipe subassembly 112, and the upwardly extending leg 120 in the case of the transfer pipe subassembly 110.

The upper end of the upwardly extending leg 118 of the transfer pipe 112 is also cut on an angle or bias, and is covered by a closure plate 132. In similar fashion, the angled opening at the upper end of the upwardly extending leg 120 of the transfer pipe 110 is closed by a closure plate 134. A gas discharge opening is formed at the radially inwardly facing side of the upwardly extending leg 118 of the transfer pipe subassembly 112, and is denominated by reference numeral 136. Similarly, a gas discharge opening facing radially inwardly is formed at the upper end of the upwardly extending leg 120 of the transfer pipe subassembly 110 and is denominated by reference numeral 138.

It will again be noted by reference to FIGS. 1 and 2 that hot gases discharged from the upper ends of the two transfer pipe subassemblies 110 and 112 are caused to impinge against each other, inducing substantial turbulence in the gases and thereby aiding in noise reduction and heat dissipation. The transfer pipe subassemblies 110 and 112, as shown in FIGS. 1 and 2, function to transfer hot gases from the central compartment 52 to the compartment or chamber 54 in the upper end of the muffler.

The hot gases discharged through the openings 136 and 138 at the facing upper ends of the upwardly extending legs 118 and 120 of the transfer pipe subassemblies 110 and 112, respectively, impinge to a small degree against each other. These gases also impinge against the side of a horizontally extending pickup leg 140 of a T-shaped discharge pipe subassembly, designated generally by reference numeral 142. The discharge pipe subassembly 142 includes, in addition to the pickup leg 140, a vertically extending discharge leg 144. The discharge leg 144 extends through the opening 37 in the inner shell 20 of the double-skinned housing and on through the opening 28 formed through the outer skin 26, and finally through a central opening 146 formed through the closure 33 at the upper end of the muffler. Gases discharged into the upper chamber or compartment 54 from the transfer pipe subassemblies 110 and 112 exit the muffler via the T-shaped discharge pipe subassembly 142. In undergoing such discharge, the hot gases enter the openings at the opposite ends of the horizontally extending pickup leg 140, then move to a central location where, after impinging against each other, the hot gases enter the vertically extending discharge leg 144, and from there pass out at the top of the muffler to the atmosphere.

OPERATION

In the operation of the muffler of the invention, sound attenuation is accomplished in several ways. The sound of the engine operation from which the hot gases originate is attenuated in part by the fine particulate material 22 which is packed between the internal and external skin of the wall of the muffler. This material has a relatively low coefficient of sound transfer and accomplishes significant damping and attenuation of the sound.

Further attenuation is accomplished by "beating" the hot gases against each other, or, stated differently, discharging the hot gases from openings at the end of the transfer pipes which face each other, so that some of the energy of the gases is dissipated in the impingement of the gases against each other and in the turbulence which is thus generated. As has been earlier pointed out herein, a certain overall optimum attenuation has been found to be accomplished by the sizing of the internal chambers within the muffler relative to the discharge pipe from the internal combustion engine which is connected to the muffler, and by the sizing of the various tubes, conduits and pipes by which the discharge gases are conveyed through the muffler.

Considering the various dimensional relationships and ratios which are required to achieve enhancement of the sound attenuation constituting the primary function of the muffler, the various volumetric dimensions of the several internal chambers or compartments 50, 52 and 54 can best be related to the size of the engine exhaust line or pipe 64. Thus, the first chamber or compartment 50 is the largest of the three compartments, and it has been found that this chamber or compartment should have a volume in cubic inches which is from about 580 to 780 times the area in square inches of the engine exhaust line or pipe 64 at the place where it first enters the muffler through the lower end cap 14.

The second or intermediate chamber 52 is smaller than the first chamber 50, but larger than the final chamber or compartment 54. The intermediate or central chamber 52 should be, for most effective sound suppression, between about 420 and 445 times the area, in square inches, of the gas discharge pipe 64 where it enters the muffler. Preferably, the central chamber is about 340 times the described cross-sectional area of the engine exhaust pipe.

The discharge chamber or compartment 54 is from about 340 to 360 times the cross-sectional area of the engine exhaust pipe, with the optimum size being about 340 times the cross-sectional area of the exhaust pipe. These volume to area ratios of the several compartment volumes-to-engine exhaust pipe cross-sectional areas have been found to be the best ratios for achieving optimum noise suppression, with no unacceptable effect on the back pressure developed to the engine in terms of its effect on engine longevity or operating life and economy and efficiency of operation. If the back pressure to the engine is too low, this will cause a reduction in horsepower developed by the engine. If it is too high the engine will run hot, and the service life will be reduced.

In another way of describing the relationship of the three compartments to each other, in terms of their volumetric size, the total volume within the muffler shell 10 is divided as between the three chambers so that from 39% to 51% of the total volume is allocated to the chamber or compartment 50. A relatively smaller intermediate or central chamber 52 contains from 26% to 32% of the total volume within the shell, and the final discharge chamber or compartment 54 occupies from about 21% to 31% of the total volume.

Through a series of observations, experiments and accumulated data evaluations, I have now ascertained that a relatively universally applicable method can be used for calculating the approximate total volume which should be contained within the shell 10. Such total volume represents the sum of the volumes within each of the three contiguous internal chambers. Stated differently, I have discovered a relationship between several parameters which will permit calculation of the total muffler volume which should be used. I have found that the total volume which can be optimally employed in the muffler for containing the gases moving through all three of the chambers can be related, first, to the total engine cylinder displacement in cubic inches. This parameter is generally relatively specifically identified by the manufacturer in the specifications for the engine, or will certainly be generally provided upon request.

This factor of engine cylinder displacement, in cubic inches, is then multiplied by a second factor which, when used, exceeds unity, or, stated differently, exceeds 100%. This factor will be used in those instances where there is, in fact, additional air put through the engine, and into the exhaust pipe from the engine as a result, for example, of certain supercharging or bypass systems or scavenging systems used with some types of engines. Thus, for example, in one type of engine, 15% more air than is necessary to fill the cylinders (engine cylinder displacement) during one cycle of the engine is passed through the engine per cycle. Therefore the engine cylinder displacement in cubic inches would, for such engines, be multiplied by the second factor, which in this case is 115%.

In another way of stating these two parameters (total engine cylinder displacement, as modified by additional gas moving through the engine per cycle), a single factor, which is the total gas moved into the exhaust pipe per cycle of the engine may instead be used. This would thus include gaseous products of combustion, plus the volume of any scavenging gas or the like put into the exhaust pipe during each cycle of the engine.

A third and final factor constituting a multiplier in the relationship used to calculate the total muffler volume in cubic inches is necessitated by the thermal expansion of the gas passed through the engine. This is caused by heating the gas during combustion, followed by some slight cooling as the combustion gases are exhausted into the exhaust pipe leading to the muffler. On most types of large oil field service engines, a point of temperature measurement is provided at a location just downstream from the exhaust manifold of the engine where the hot gases are just entering the exhaust pipe. From available data, a multiplier factor can be derived, based upon the increase in volume which will occur as the gases (air and gaseous products of combustion) are heated from ambient temperature (the temperature at which they are charged to the engine), to the temperature of the gases as they enter the exhaust pipe. Thus, for example, in a standard, single cylinder Ajax-type engine, which is fairly typical of the types of engines here in question, the volume of gas is expanded about 25 times when the gas is heated to about 700.degree. F.-- a typical exhaust temperature. Thus, the mixture of air and products of combustion from the hydrocarbon fuel burned in the engine, if determined to have a temperature of 700.degree. F. upon entering the exhaust pipe, require that the two previously described factors in the described relationship be multiplied by a factor of at least 25 in order to compensate for the heat-caused expansion of the gases, and a substantial increase in volumetric displacement.

As a safety factor which I have found it desirable and useful to employ, the amount of volumetric expansion of the gas which can be expected to occur for a certain increase in temperature should be increased by a factor of 50% in order to allow for gas exhaust temperature variations which may occur. Thus, even though a manufacturer may specify that the exhaust temperature as measured at a certain point in the exhaust line should run around 700.degree. F. on a fairly constant basis during normal engine operations, slight fluctuations up or down may occur, and one engine coming from even the same manufacturer may have some variation from this specified exhaust temperature. By contemplating a possible increase in volumetric expansion of as much as 50%, such variations can be accommodated without the creation of excessive back pressure "seen" at the engine, or too little back pressure at the engine. In the example under discussion, an engine which develops a temperature of 700.degree. F. at the point of measurement of the hot gases just entering the exhaust pipe, should thus provide a basis for inclusion in the described relationship used to calculate the muffler shell volume of a multiplier factor of 37.5 (expansion of 25 times plus 50%).

When the described parameters are utilized, that is, (a) total engine cylinder displacement in cubic inches, multiplied by (b) a factor, when appropriate, in excess of 100% representing any uncombusted fuel and/or air in excess of the total cylinder displacement volume which is passed through, or around the engine, and then merged into the exhaust stream, multiplied finally by (c) the temperature expansion corrective factor, which is the multiplier indicative of the expansion which will occur at a certain temperature increased by a tolerance or variance factor of 50%, the product of these three values is substantially the muffler volume which should be provided to realize optimum engine operation, and maximum muffling of the sound.

Stated in another way, the expression used to calculate the muffler volume in cubic inches can be written as:

ECD X AGV/cycle* X TEM=Total Volumetric Capacity of Muffler *As earlier stated, the expression ECD X AGV/cycle can be replaced by the total gas passed into the exhaust pipe per cycle of the engine, TGE/cycle. where ECD is the total engine cylinder displacement in cubic inches; and AGV/cycle is, in terms of a total percentage of ECD, any additional gas, including air, passed through the exhaust pipe to the muffler on each cycle; and TEM is a thermal expansion multiplier which is the factor by which the gas volume (ECD X AGV/cycle) is expanded by heating in the engine, increased by 50%.

Validity of the described relationship and its universality depend upon a certain generally used spacial relationship and orientation of the engine relative to the muffler, and the length of the exhaust line by which they are interconnected. Thus, as shown in FIG. 6, the hot exhaust gases leave the engine 150 and pass through a large radiused elbow 152 into the exhaust line 154. The hot gases then pass through a large radiused elbow 156 and through a flanged fitting 158 into the muffler 160. An exhaust gas temperature sensor 162 is, in general, located at about the location of the elbow 152. In order for the temperature factor used in the relationship employed above to calculate the optimum total muffler volume to be valid, the distance separating the longitudinal axis of the muffler from the axis of the elbow 152 where it enters the engine (as this distance is shown in FIG. 6) should be not more than about 24 feet and not less than about 7 feet. This further assures that exhaust gases from various engines do not vary greatly in their temperature (and thus volume) as they enter the muffler 160 from their temperature sensed at the sensor 162 as a result of the distance separating the engine from the muffler. This assures that the third factor used in the described calculation can be used to validly calculate to an acceptable approximation the total volume to ba contained in the three chambers located within the muffler. The same proportional sizing will be used on the three chambers within the muffler as has been previously described.

The transfer pipes 94 and 96 by which gases are transferred from the compartment 50 to the intermediate chamber or compartment 52, should preferably have a cumulative or total cross-sectional area (that is, the cross-sectional areas of the two pipes added together) which is 125%.+-.5% of the cross-sectional area, in square inches, of the engine exhaust pipe 64.

Similarly, the total cross-sectional area of the vertical or upwardly extending legs 118 and 120 of the transfer pipes 110 and 112 in cumulative cross-sectional area of the openings through the restrictor plates 122 and 126 is preferably 125%.+-.5% of the total cross-sectional area of the transfer tubes 94 and 96 from chamber 50 to chamber 52.

Finally, the discharge pipe 144 from the final or uppermost chamber or compartment 54 to the atmosphere should equal 175%.+-.5% of the cross-sectional area in square inches of the engine exhaust pipe 64 where it enters the lower end of the muffler.

It should be pointed out that in instances where the transfer pipe or the discharge pipe is not within the dimensional requirements to satisfy the preferred ratios, the next larger pipe size available should be used, and then a suitable restrictor cap or plate (such as 122 and 126) may be used in the inlet of the transfer pipe or exhaust pipe in order to meet the required cross-sectional area ratios.

I have determined that when the various dimensional ratios are kept within the indicated ranges, and preferably near the stated preferred values, the engine can be made to run relatively cool and develop maximum horsepower, while having most of the sound developed at the exhaust pipe absorbed by the muffler of the invention.

Although a preferred embodiment of the invention has been herein described in order to enable those skilled in the art to understand the principles of the invention and to practice the invention, it will be understood that various changes can be effected in the described and illustrated embodiment without departure from the basic principles which underlie the invention. Changes of this character are therefore deemed to be circumscribed by the spirit and scope of the invention, except as the same may be necessarily limited by the appended claims or reasonable equivalents thereof.

Claims

1. A muffler for attenuating the sound developed during, and as a result of, operation of an internal combustion engine, said muffler comprising:

a cylindrical shell having two opposed closed ends and defining a first opening through one of said closed ends for receiving an exhaust gas pipe from an engine, and defining a second opening in the second closed end of said shell for extending a discharge pipe therethrough;

a plurality of partition plates within said cylindrical shell and partitioning the shell into three axially contiguous compartments;

an exhaust gas pipe projecting through said first opening in the first end of said cylindrical shell into a first of said three compartments;

two pairs of elbow pipes connected to said exhaust gas pipe, each of said pairs of elbow pipes having opposed, facing gas discharge openings so that the gas streams discharged therefrom are caused to impinge against each other;

two gas transfer pipes extending through one of said partition plates, and each of said two gas transfer pipes having an intake opening located in said first compartment, and having a bent over end portion terminating in a discharge opening located in a second of said compartments contiguous to said first compartment, said discharge openings of said two gas transfer pipes facing toward each other in said second compartment so as to direct gas discharged from one of said two gas transfer pipes against gas discharged from the other of said two gas transfer pipes as said discharged gases from the transfer pipes commingle in said second compartment;

a pair of T-shaped transfer pipes each comprising:

an elongated pick up section in said second compartment and forming the cross bar of the respective T-shaped transfer pipe, said pick up section having a center and a pair of opposite ends and having gas intake openings at each of said opposite ends thereof; and

an elongated leg having a pair of opposite ends and having one of said opposite ends joined to the pick up section about the center thereof, and said elongated leg projecting through a second of said partition plates into a third of said compartments, and having the other end of said elongated leg opposite from that which is connected to said pick up section defining a gas discharge opening; and

a gas discharge pipe subassembly including a discharge pipe extending through the opening in the closed second end of said shell, and having gas intake means within said third compartment, and having a discharge opening outside of said cylindrical shell.

2. A muffler for attenuating the sound developed during, and as a result of, operation of an internal combustion engine as defined in claim 1 wherein the volumetric ratios of the first compartment, second compartment and third compartment to the total volume contained within all three of the components is as follows:

first compartment=39% to 51% of total volume;

second compartment=26% to 32% of total volume; and

3. A muffler for attenuating the sound developed during, and as a result of, operation of an internal combustion engine as defined in claim 1 wherein said shell has a double wall, and said two walls of the shell define an insulation containing space therebetween.

4. A muffler for attenuating the sound developed during, and as a result of, operation of an internal combustion engine as defined in claim 3 wherein said insulation containing space contains solid particles of a sound attenuating material.

5. A muffler for attenuating the sound developed during, and as a result of, operation of an internal combustion engine as defined in claim 1 wherein the gas discharge openings in the outlet ends of said elongated legs of said f-shaped transfer pipes face toward each other so that the gases discharged through said discharge openings from said f-shaped transfer pipes and within said third compartment impinge against each other, and the energy of said gases is dissipated by such mutual impingement as the gases are discharged from said facing gas discharge openings in said other ends of said elongated legs.

6. A muffler for attenuating the sound developed during, and as a result of, operation of an internal combustion engine as defined in claim 5 wherein the volumetric ratios of the first compartment, second compartment and third compartment to the total volume contained within all three of the compartments is as follows:

first compartment=39% to 51% of total volume;

second compartment=26% to 32% of total volume; and

third compartment=21% to 31% of total volume.

7. A muffler for attenuating the sound developed during, and as a result of, operation of an internal combustion engine as defined in claim 2 wherein said shell has a double wall, and said double walls of the shell define an insulation containing space therebetween.

8. A muffler for attenuating the sound developed during, and as a result of, operation of an internal combustion engine as defined in claim 7 wherein the gas discharge openings in the outlet ends of said elongated legs of said T-shaped transfer pipes face toward each other so that the gases discharged through said discharge openings from said T-shaped transfer pipes and within said third compartment impinge against each other, and the energy of said gases is dissipated by such mutual PG,33 impingement as the gases are discharged from said facing gas discharge openings in said other ends of said elongated legs.

9. A system for developing power from an internal combustion engine with maximum sound attenuation comprising:

an internal combustion engine having an exhaust manifold;

an elongated muffler having an inlet end and an outlet end;

an exhaust pipe connected between that exhaust manifold of the engine and the inlet end of the muffler; and

a temperature sensing device in the exhaust pipe adjacent the location where hot exhaust gases enter the exhaust pipe from the engine;

said muffler comprising:

an elongated, cylindrical shell having an internal volume, V, and having an inlet end corresponding to the inlet end of the muffler, said inlet end defining an opening for receiving exhaust gases from said exhaust pipe, and said shell having an outlet end corresponding to the outlet end of said muffler, said outlet end defining an opening for passing a gas discharge pipe therethrough;

a pair of partition plates within said cylindrical shell and partitioning the shell into three axially contiguous compartments, the sum of the volumes in said three compartments being substantially equivalent to the internal volume, V, of the shell, said exhaust pipe having one end projecting through the opening in the inlet end of said shell and into a first of said three compartments;

two pairs of elbow pipes connected to said exhaust pipe within said first compartment for receiving hot exhaust gases therefrom, the two elbow pipes in each of said pairs of said elbow pipes having opposed, facing gas discharge openings so that the gas streams discharged therefrom are caused to impinge against each other; and

two gas transfer pipes extending through one of said partition plates, each of said two gas transfer pipes having an intake opening located in said first compartment, and having a bent over end portion terminating in a discharge opening located in a second of said compartments, said discharge openings of said two gas transfer pipes facing toward each other in said second compartment so as to direct gas discharged from one of said two gas transfer pipes against gas discharged from the other of said two gas transfer pipes a said discharged gases from the transfer pipes co-mingle in said second compartment;

a pair of T-shaped transfer pipes each comprising:

an elongated pickup section in said second compartment and forming the cross bar of the respective T-shaped transfer pipe and said pickup section having a center and having a pair of opposite ends and having gas intake openings at each of said opposite ends thereof; and

an elongated leg having a pair of opposite ends and having one of said opposite ends joined to the pickup section at about the center thereof for receiving gas from said pickup section, and said elongated leg projecting through a second of said partition plates into third of said compartments, and having the other end of said elongated leg opposite from that one which is connected to said pickup section defining a gas discharge opening; and

a gas discharge pipe subassembly including a pipe extending through the opening in the outlet end of said elongated cylindrical shell, and having gas intake means within said third compartment, and having a discharge opening outside of said cylindrical shell;

and wherein the internal volume, V, of said cylindrical shell is substantially equivalent to (a) the total engine cylinder displacement in cubic inches, of said internal combustion engine, multiplied by (b) a factor when appropriate, in excess of 100% representing any vaporized fuel or air in excess of the total cylinder displacement volume which is passed through, or around the engine, and then merged into the exhaust stream per cycle of the engine, multiplied finally by (c) a temperature expansion corrective factor which is the amount by which the total engine cylinder displacement in cubic inches is caused to expand in volume at the elevated temperature measured at the point where the exhaust pipe is connected to the engine, increased by at least 50%.

10. A system for developing power from an internal combustion engine with maximum sound attenuation as defined in claim 9 wherein the distance separating the longitudinal axis of said elongated muffler from the point of discharge of hot gases from said engine into the exhaust pipe is from about 7 feet to about 24 feet.

11. A muffler for attenuating the sound developed during, and as a result of, operation of an internal combustion engine, comprising:

a cylindrical shell;

means closing one end of said cylindrical shell and defining an opening for receiving an exhaust gas pipe from an internal combustion engine;

means closing the second end of said shell and defining an opening for passing a gas discharge pipe therethrough;

a pair of partition plates within said cylindrical shell and partitioning the shell into three axially contiguous compartments;

an engine exhaust pipe projecting through the opening in said first end closure cap into a first of said three compartments;

two pairs of elbow pipes connected to said exhaust pipe within said first compartment for receiving hot exhaust gases therefrom, the two elbow pipes in each of said pairs of elbow pipes having opposed, facing gas discharge openings so that gases discharged therefrom are caused to impinge against each other;

a plurality of gas transfer pipes extending through one of said partition plates, each of said gas transfer pipes having an intake opening located in said first compartment, and having a bent over end portion terminating in a discharge opening located in a second of said compartments which is adjacent said first compartment;

a pair of T-shaped transfer pipes each comprising:

an elongated pickup section in said second compartment and forming the cross bar of the respective T-shaped transfer pipe, said pickup section having a center and having a pair of opposite ends and having gas intake openings at each of said opposite ends thereof; and

an elongated leg having a pair of opposite ends and having one of said opposite ends joined to the pickup section at about the center thereof for receiving gas therefrom, and said elongated leg projecting through a second of said partition plates into a third of said compartments, and having the other end of said elongated leg opposite from that one end which is connected to said pickup section defining a gas discharge opening; and

a gas discharge pipe subassembly including a pipe extending through the closure means at the second end of said shell and having gas intake means within said third compartment, and having a gas discharge opening outside said cylindrical shell.