This disclosure relates to an exhaust system component with features for suppressing vehicle exhaust pipe resonances and further relates to a vehicle exhaust system with such as an exhaust system component for resonance attenuation and damping to reduce noise.
Vehicle exhaust systems direct exhaust gases generated by an internal combustion engine to the external environment. These systems are comprised of various components such as pipes, mufflers, catalytic converters, particle filters and other exhaust system components. All such vehicle exhaust systems have resonant frequencies, which are also referred to as natural frequencies of the exhaust system. The resonant frequencies are due to the physical structure or the layout of the exhaust systems. Resonant frequencies can be beneficial to a sound quality of some vehicle exhaust systems and yet can also be non-beneficial to the sound quality. The overall system and/or the components are capable of generating undesirable noise as a result of resonating frequencies.
Different approaches have been used to address undesirable noise as a result of resonating frequencies. Some ways to attenuate resonating frequencies include providing one or more muffler and or resonator. Locating the muffler and resonator where the resonance occurs can help attenuating the resonance frequency by splitting that frequency into two other frequencies or by shifting the frequencies. Packaging mufflers and resonators can be a challenge due to the size. A further disadvantage of adding additional components is that additional components add expense and increases weight. Adding components introduces new sources for noise generation.
There can be many design alternatives which can be used to suppress resonances such as, perforations on the pipes, resonators, mufflers, Helmholtz dampeners or resonators (Helmholtz), additional pipe length or shortened pipe lengths (if packaging permits it) etc. In some special cases, even Active Noise Cancellations (ANC) can be an alternative.
Incorporating a resonator unto the exhaust system relatively close or on the anti-node of the resonance frequency can suppress the resonant frequency, however, with the resonator, it can have packaging challenges.
Concentric or side branch Helmholtz can be one of the alternative structures and methods used. A Helmholtz could be used to shift a frequency to a higher or lower frequency, so the resonance frequency does not line up. Helmholtz works typically with an enclosed volume to be effective.
ANC systems utilize components such as microphones and speakers to generate noise that cancels out the undesirable noise. ANC can be integrated into the exhaust system to reduce the resonance frequencies' amplitude. The basic concept of ANC is to reduce unwanted sound by propagative sound waves at the same frequency by out of phase to cancel out or reduce the amplitude of response. This is somewhat similar in concept to the Helmholtz tuning but with speakers that can attenuate more frequencies.
A configuration with perforations on the pipes is disclosed in U.S. Pat. No. 9,970,340. A vehicle exhaust system includes a pipe having an outer surface and an inner surface that defines an internal exhaust component cavity configured to receive hot exhaust gases. The pipe extends along a center axis from a first pipe end to a second pipe end. At least one additional component is positioned upstream or downstream of the pipe. Plural bleed holes are formed in the pipe. One bleed hole is at a first anti-node position to reduce a resonance frequency. The bleed hole has an opening into the internal exhaust component cavity. A second bleed hole is formed in the additional component or in the pipe at a second anti-node position axially spaced from the first anti-node position along the center axis, to reduce resonant frequencies. A discontinuous member covers each bleed hole at the inner or outer surface. Perforations on pipe can be used to suppress resonance. However, such configurations present the potential of an acoustic error state, such as producing a whistling sound in the higher frequencies for some vehicle exhaust systems.
It is an object of the invention to provide an exhaust system component that reduces resonance frequencies, particularly without creating whistling sounds.
It is an object of the invention to provide an exhaust system component that reduces 1st and 2nd firing orders, such as with four cylinder engines with sound issues at lower frequencies.
According to the invention an exhaust system component is provided with a louver bridge configuration that reduces resonance frequencies and also reduces 1st and 2nd firing orders collectively, without creating whistling sounds.
The exhaust system component comprises a pipe having a pipe wall with an inner surface defining an exhaust gas passage and with an outer surface and a louver bridge portion formed in the pipe wall. The louver bridge portion has bridge ends transitioning from adjacent pipe wall portions to a bridge raised portion, with raised side edges detached from adjacent opening side edges of the pipe wall. Each bridge side edge is radially outward of the adjacent opening side edge of the pipe wall to define a louver opening at each of two opposite sides of the louver bridge portion. This provides fluid communication through the two louvered openings, between the exhaust gas passage and an exterior of the component and dampens resonant frequencies generated during operation of an exhaust system to which the exhaust system component is connected.
The bridge raised portion covers an open region partially defined by the opening side edges at the inner surface of the louver bridge portion. The covering position of the bridge raised portion is radially outward of the open region. The open region defines a flow path from the exhaust gas passage to each louver opening at the two opposite sides of the louver bridge portion. The louver opening at each of two opposite sides of the louver bridge portion forms a portion of the flow path and directs a portion of gas flowing in the pipe out of the pipe through the respective louver opening to produce a gas divergence of flow that is parallel to the exhaust gas flow within the pipe and which does not cause radial impingement of hot exhaust gas.
Each louver opening has a height corresponding to a radial distance of an associated bridge side edge from the adjacent opening side edge of the pipe wall. Each louver opening has a length from one bridge end to another bridge end wherein the length of the louver opening is greater than the height of the louver opening. This may be provided based on the bridge raised portion extending along an bridge arc over the open region. The open region has an opening area preferably greater than about 50 mm2, and advantageously between about 50 mm2 and 100 mm2, such as about 87.65 mm2. This open region may vary depending upon the size of the pipe but has an area that is preferably larger than a corresponding circular opening having an 8 mm diameter (i.e., larger than 50.27 mm2). The adjacent pipe wall portions extend mostly along an arc having a diameter smaller than the diameter of a bridge diameter circle that defines the bridge arc. With the open region having an area of about 87.65 mm2, the two louver openings have an opening area of about 31.35 mm2. The louver openings are preferably in proportion with the size of the open region and preferably at about the same ration as provided by the above discussed example.
The exhaust system component may advantageously further comprise at least an additional louver bridge portion that is essentially the same as the first mentioned louver bridge portion to provide a plurality of louver bridge portions. The plurality of louver bridge portions may be disposed circumferentially spaced from each other. The plurality of louver bridge portions may alternatively be disposed longitudinally spaced from each other.
The configuration of the plural bridge portions may be such that the plurality of louver bridge portions are disposed in multiple rows of bridge portions. The plurality of louver bridge portions may alternatively be disposed in staggered rows of bridge portions.
The pipe wall and the louver bridge portion is advantageously formed of a single sheet metal piece. This may be formed by creating a tubular pipe portion as is generally known and making two shearing cuts. The strip may be bent out of the metal piece to form the raised portion of each louver bridge.
According to a further aspect of the invention, an exhaust system is provided comprising an exhaust treatment component and an exhaust pipe connected to the exhaust treatment component. The exhaust pipe comprises an exhaust pipe component as discussed above.
The various features of novelty which characterize the invention are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and specific objects attained by its uses, reference is made to the accompanying drawings and descriptive matter in which preferred embodiments of the invention are illustrated.
In the drawings:
Referring to the drawings in particular,
Downstream of the exhaust gas treatment component 3, the exhaust pipe portion 2 comprises a plurality of pipe section components 6 and an exhaust system component to attenuate resonant frequencies that is generally designated 10. The exhaust pipe portion 2 may be formed by a single pipe section that includes the exhaust system component 10 as an integral portion of the single pipe section. Instead of numerous pipe section components 6, a single pipe section component 6 may be provided between the exhaust gas treatment device 3 and the exhaust system component 10. In this case a downstream further pipe section component 6 or plural pipe section components 6 follow the exhaust system component 10 in the direction of exhaust gas flow (from left to right in
In the configuration shown in the Figures, each of the regions 14, 15, 16 has a generally circular shape. However, these regions may be provided with a modified shape such as an oval configuration or even a rectangular configuration. The widening of the pipe wall 12 from central region 15, via angled regions 16 to flange ends 14 allows for each flange end 14 to be easily connected with upstream and downstream pipe section components 6 of a slightly smaller diameter (dimension).
The pipe wall 12 has an outer surface 28 and has an inner surface 26, which inner surface 26 defines an exhaust gas passage for an exhaust gas flow 60. This exhaust gas passage of component 10 cooperates with passage portions formed by the other components of the exhaust system, in particular in combination with the pipe sections 6 and the gas treatment component 3 as well as further upstream pipe sections and further gas components to provide a system exhaust gas flow path. The pipe wall 12 further includes louver bridge portions (louver bridges) 18 which are formed integrally with the pipe wall 12.
Each of the louver bridges 18 includes a central bridge raised portion 19 connected to the remainder of the pipe wall 12 via bridge ends 21. The bridge ends 21 provide a shape transition from the adjacent pipe wall 12 to the bridge raised portion 19 with the side edges 22 of the louver bridge portion 18 detached from adjacent opening side edges 20 of the pipe wall 12. The shape transition from the adjacent pipe wall 12 to the bridge raised portion 19 includes a first concave portion (curved oppositely to the curve the remainder of the pipe wall 12) with a radius of 1.5 mm in the example followed by a second convex portion (curved in the same direction as the curve the remainder of the pipe wall 12) that has a radius of 4 mm in the embodiment shown in the Figures. The bridge raised portion 19 itself follows a curve of a bridge circle having an internal diameter of 76.6 mm. In the embodiment shown, the central region 15 of the pipe wall 12 also follows the path of a circle with an outer diameter which is smaller than the bridge circle diameter. The remainder of the pipe wall 12 in the central region 15 has an internal diameter of 70 mm.
As indicated in
The embodiment shown in the Figures provides a preferred construction in which a plurality of louver bridges 18 are provided spaced apart in a circumferential row with each louver bridge 18 following another in the circumferential direction. Five such louver bridges are shown that have a center of the raised portions 19 spaced apart by 72 degrees. This presents one aligned row of circumferentially distributed louver bridge portions 18. The plurality of louver bridge portions 18 may instead be disposed longitudinally spaced from each other, for example extending in an axial direction along the pipe wall 12. Instead of a single row of louver bridge elements 18, multiple rows of bridge portions 18 may be provided. Further, instead of providing an aligned row of bridges 18, a staggered row of bridges may be provided wherein the bridge portions 18 are spaced apart radially and also spaced apart axially. The exhaust system component 10 preferably has plural louver bridge elements 18 to best provide resonant frequency attenuation.
Besides providing a higher insertion loss for the exhaust system portion 1 with the exhaust system component 10 according to a preferred embodiment as compared to a pipe section component having the eight 5.0 mm perforations (
Beside significantly attenuating resonant frequencies, the exhaust system component 10 and the exhaust system and exhaust system portion 1 with the exhaust system component 10 according to the invention provides further significant advantages. The configuration is particularly advantageous as the configuration does not create packaging issues as the exhaust system component 10 can be put anywhere along the exterior of the exhaust pipe system 1. The louver bridges 18 can be put on any exhaust gas component, anywhere along a length of the exhaust flow path of the exhaust system 1 that is not prohibited by emissions requirements. For example, the louver bridge portions 18 may placed on any portion of exhaust system 1, including pipe section components 6 upstream of the exhaust treatment component 3 (e.g., upstream of muffler 3) or anywhere along exhaust pipe portion 2, such as on any of the pipe section components 6.
The louver bridges 18 are particularly advantageous as louver bridges 18 act to produce a divergence of flow 40 that is parallel to the exhaust gas flow 60 while dampening pressure pulses within the pipe 12. The flow 40 is parallel to the direction of the pipe 12 itself. The flow 40 does not cause radial impingement of hot exhaust gas. This is illustrated in
The divergent flow 40 of the louver bridges 18 provides resonance attenuation and damping to reduce noise without causing an error state as to higher frequencies. In particular, pipe section components having perforations, such as the pipe section component having 5.0 mm perforations discussed above, may produce whistle noises at higher frequencies. The louver bridges 18 prevents such whistle noises due to the geometry of the openings 30 with the produced divergent flow 40 of the openings 30. This configuration mitigates any edge effects that are present at the edges 20 and 22 of the openings 30 and which may cause whistling.
The louver bridges 18 are compact and manufacturing friendly. A metal sheet is rolled or otherwise shaped and edges are laser welded to form a tubular pipe. The louver bridges 18 are manufactured by shearing the formed pipe section central portion 15 of pipe 12 to detach bridge raised portion 19, with the side edges 22, from the adjacent opening side edges 20 of the pipe wall 12. This extruding (bending) of the bridge raised portion 19 is such that the inner surface 31 of the raised portion 19 is spaced from the adjacent surface regions 28 of the outer surface 24 of the pipe wall 12. This forms the two openings 30 and the open region 32. Collectively, all louver bridges 18 can be formed in one three step process.
The configuration of the component 10 with louver bridges 18 provides the advantageous resonant frequency attenuation while presenting less overall structure. The exhaust system component 10 is made from sheet-metal, such as sheet steel and otherwise does not include any structural features apart from those discussed above. This is significant as the exhaust component 10 with louver bridges 18 has less overall content compared to a bottle resonator. The louver bridges 18 have a lower mass as compared to a conventional bottle resonator.
The louver bridges 18 also attenuate frequencies so as to lower 1st and 2nd firing orders of a typical exhaust systems' SPL response, as discussed above.
The configuration of the exhaust system component 10 with louver bridges 18 is particularly advantageous with regard to overall assembly of an exhaust system. The louver bridges 18 do not require extra welding processes compared to other resonances damping concepts.
The louver bridges 18 require only a small axial extent along the length of pipe. This is particularly the case with the aligned row of circumferentially distributed louver bridge portions 18 of the disclosed embodiment. However, even with axially distributed louver bridge portions 18, the overall length of the exhaust system component 10 is rather short as compared to prior art arrangements with features to dampen resonance frequencies.
While specific embodiments of the invention have been shown and described in detail to illustrate the application of the principles of the invention, it will be understood that the invention may be embodied otherwise without departing from such principles.
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Number | Date | Country | |
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20210148261 A1 | May 2021 | US |