The present disclosure relates to a muffler, and more specifically relates to a muffler assembly with sound absorbing member.
The statements in this section merely provide background information related to the present disclosure and may not constitute prior art.
It is known to provide mufflers in exhaust systems to reduce engine exhaust noise. However, conventional mufflers may not reduce exhaust noise sufficiently in some operating conditions. For instance, low frequency exhaust noise can be created in the exhaust system at low engine speeds, and conventional muffler designs may not sufficiently reduce the low frequency sound. Also, standing waves, i.e., resonances within the exhaust system, can be created causing excessive noise. It can be difficult to reduce these standing waves using a muffler because standard reflective muffler tuning techniques are typically not useful for these purposes.
Accordingly, there remains a need for a muffler that more effectively reduces exhaust noise—including low frequency exhaust noise and/or standing waves—within the exhaust system.
A vehicular exhaust system muffler includes a housing having an input wall and an output wall. First and second apertured partitions inside the housing define an input chamber with one of the input and output walls and an output chamber with another one of the input and output walls. An intermediate chamber is defined by the housing between the first and second partitions. A sound absorbing member is positioned in the intermediate chamber. An inlet pipe enters the housing through the input wall and terminates in the input chamber. An outlet pipe has an end positioned in the output chamber and has another end exiting the housing through the output wall.
Further areas of applicability will become apparent from the description provided herein. It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.
The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.
The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses.
Referring to
The muffler 14 includes a housing 16. The housing 16 includes a first wall 18, a second wall 20, and an outer wall 22. The first wall 18, second wall 20, and the outer wall 22 can each be made out of sheet metal. The first and second walls 18, 20 are substantially flat and ovate in shape as shown in
The muffler 14 also includes an inlet pipe 26. The inlet pipe 26 is axially straight and can be made out of metal tubing. The inlet pipe 26 includes a first end 28 and a second end 30. The first end 28 extends through the inlet aperture 23. The first end 28 is also in fluid communication with the engine (not shown) of the vehicle 10 and receives exhaust gases therefrom. The second end 30 of the inlet pipe 26 is disposed within the housing 16. As such, exhaust gases are able to flow from the engine of the vehicle 10, through the inlet pipe 26 and into the interior space 24 of the muffler 14 as represented by dashed arrows in
Furthermore, the muffler 14 includes an outlet pipe 32. The outlet pipe 32 is axially straight and can be made out of metal tubing. The outlet pipe 32 includes a first end 34 and a second end 36. The first end 34 is disposed within the housing 16. The second end 36 extends through the outlet aperture 25. The second end 36 could also be in fluid communication with a tailpipe (not shown) of the vehicle 10. Accordingly, exhaust gases from the engine of the vehicle 10 enters the muffler 14 through the inlet pipe 26 and exits the muffler through the outlet pipe 32 as represented by dashed arrows in
The muffler 14 further includes a first partition 38. The first partition 38 is substantially flat and ovate in shape as shown in
In addition, the muffler 14 includes a second partition 46. The second partition 46 is substantially flat and ovate in shape. The second partition 46 can be made out of metal sheet. The periphery of the second partition 46 is coupled to the outer wall 22 so as to create a seal between the second partition 46 and the outer wall 22. In the embodiment shown, the second partition 46 is substantially parallel to the first wall 18, the second wall 20, and the first partition 38. Also, the second partition 46 is disposed in spaced relationship with the first wall 18, the second wall 20, and the first partition 38. More specifically, the second partition 46 is disposed between the first wall 18 and the first partition 38. Accordingly, the second partition 46 and the housing 16 cooperate to define a second chamber 48 between the second partition 46, the first wall 18, and the outer wall 22. The second partition 46 also includes an inlet aperture 50 and an outlet aperture 52. The inlet pipe 26 extends through the inlet aperture 50. The first end 34 of the outlet pipe 32 extends through the outlet aperture 52, and the first end 34 of the outlet pipe 32 terminates within the second chamber 48. Accordingly, the outlet pipe 32 is in fluid communication with the second chamber 48.
As stated, the first and second partitions 38, 46 are disposed in spaced relationship to each other. As such, the first partition 38, the second partition 46, and the housing 16 cooperate to define an intermediate chamber 54 between the first partition 38, the second partition 46, and the outer wall 22.
The first partition 38 includes a plurality of first apertures 56 as shown in
The muffler 14 also includes a sound absorbing member 60 represented by cross hatching in
The sound absorbing member 60 is disposed in and substantially encapsulated within the intermediate chamber 54 as shown in
It should be appreciated that sound created by the engine (exhaust noise) travels through the exhaust system in a substantially similar path. More specifically, exhaust noise enters the muffler 14 through the inlet pipe 26. The sound then enters the first chamber 40 and travels into the intermediate chamber 54 through the first apertures 56 of the first partition 38. The sound then travels through the intermediate chamber 54 and through the sound absorbing member 60. The sound next moves into the second chamber 48 through the second apertures 58 and into the outlet pipe 32 to be expelled from the vehicle 10.
Accordingly, the sound absorbing member 60 is disposed directly within the path of the majority of the exhaust noise. Advantageously, exhaust noise is substantially reduced as it passes through the sound absorbing member 60. The sound absorbing member 60 is especially effective in reducing low frequency sound from the engine. Furthermore, the sound absorbing member 60 reduces standing waves created by the engine.
It should be appreciated that by increasing the density of the sound absorbing member 60 within the intermediate chamber 54, exhaust noise reduction can be further improved. However, increasing the density of the sound absorbing member 60 can also increase back pressure within the exhaust system 12. Accordingly, the density of the sound absorbing member 60 can be adapted to reduce exhaust noise while maintaining an acceptable range of back pressure within the exhaust system 12. In one embodiment, the volume of the intermediate chamber 54 is approximately 5.7 L, and the mass of the sound absorbing member 60 is approximately 500 g, making the density of the sound absorbing member 60 approximately 88 g/L.
In one embodiment, the sound absorbing member 60 is disposed within the intermediate chamber 54 by spraying the fibers of the sound absorbing member 60 directly into the intermediate chamber 54. In another embodiment, the sound absorbing member 60 is first encapsulated within a disposable container, such as a bag made out of polyethylene. The containers are disposed between the first and second partitions 38, 46, and then the first and second partitions 38, 46 and the containers are inserted into the housing 16. During operation, the containers reduce, for instance by burning away, and the sound absorbing member 60 remains within the intermediate chamber 54.
In the embodiment shown, the inlet pipe 26 includes a plurality of transverse apertures 62. The transverse apertures 62 extend through the second end 30 of the inlet pipe 26 so as to be in fluid communication with the intermediate chamber 54. There can be any number of transverse apertures 62 of any suitable size and arranged in any suitable pattern. The outlet pipe 32 also includes a plurality of transverse apertures 64. The transverse apertures 64 extend through the first end 34 of the outlet pipe 32 so as to be in fluid communication with the intermediate chamber 54. As such, exhaust gasses and exhaust noise enters the muffler 14 through the inlet pipe 26 and can move through the transverse apertures 62 of the inlet pipe 26, through the intermediate chamber 54, through the transverse apertures 64 of the outlet pipe 32, and exit the muffler 14 through the outlet pipe 32. As such, some of the exhaust gasses and exhaust noise bypasses the first and second chambers 40, 48 for improved exhaust noise reduction. In one embodiment, most of the exhaust gasses and exhaust noise travels through the first and second chambers 40 as described above, and only a small percentage bypasses the first and second chambers 40, 48. It will be appreciated that the transverse apertures 62 of the inlet pipe 26 and the transverse apertures 64 of the outlet pipe 32 are optional and that the muffler 14 can function without the transverse apertures 62, 64.
Referring now to
Turning now to
As shown in
Accordingly, exhaust gasses travel from the inlet pipe 126 into the first chamber 140 as described above. When pressure in the first chamber 140 is relatively low, the biasing member 178 biases the flap 176 such that the flap 176 remains in position covering the opening in the second terminal end 172 of the flow-through pipe 166. Thus, substantially all of the exhaust gas and exhaust noise passes through the sound absorbing member 160 and out of the muffler 114 through the outlet pipe 132 as described above. However, when pressure in the first chamber 140 is relatively high, the flap 176 pivots against the force of the biasing member 178 to allow exhaust gas and exhaust noise to pass through the flow-through pipe 166 from the first chamber 140 to the second chamber 148 and bypass the sound absorbing member 160.
In one embodiment, the pressure in the first chamber 140 remains low enough to keep the flap 176 closed when the vehicle engine is operating at relatively low RPMs. As such, low frequencies and/or standing waves that result from low engine RPMs are reduced by the sound absorbing member 160. The pressure in the first chamber 140 increases enough to open the flap 176 when the vehicle operates at higher RPMs. It will be appreciated that the biasing member 178 can be adapted to cause the valve 174 to open at any desired engine exhaust flow rate. As such, back pressure within the exhaust system 112 can be reduced for improved engine performance at higher RPMs. It will also be appreciated that the exhaust noise will be less noticeable at these high RPMs because of other external noise, such as wind noise and the like.
Referring to
Referring now to
Accordingly, exhaust gases and exhaust noise pass from the inlet pipe 226, into the first chamber 240, through the first apertures 256, into the intermediate chamber 254, through the sound absorbing member 260, through the second apertures 258, into the second chamber 248, and out through the outlet pipe 232. It is appreciated that exhaust noise is reduced as it passes through the sound absorbing member 260. It is also appreciated that the cross sectional area of the housing 216 of the muffler 214 is substantially larger than the cross sectional area of the inlet pipe 226 and the outlet pipe 232. This reduces the amount of back pressure created within the exhaust system 212 during operation.
Referring now to
Referring now to
The muffler 414 also includes a third partition 491 that is disposed within the housing 416 such that an absorbing chamber 492 is defined between the third partition 491, the first wall 418, and the outer wall 422. A second sound absorbing member 461 is disposed within the absorbing chamber 492.
The muffler 414 also includes a fourth partition 493 that divides the first chamber 440 into an input chamber 494 and a return chamber 495. Furthermore, the muffler 414 includes a return pipe 496 that extends through the fourth partition 493 such that the input chamber 494 and the return chamber 495 are in fluid communication.
The inlet pipe 426 extends through the outer wall 422 and into the input chamber 494. The inlet pipe 426 terminates in the input chamber 494. The outlet pipe 432 extends through the first wall 418, through the third partition 491, through the first partition 438, and through the second partition 446. The outlet pipe 432 terminates within the second chamber 448. Also, the outlet pipe 432 includes a plurality of transverse apertures 464 such that the outlet pipe 432 and the absorbing chamber 492 are in fluid communication. It should be appreciated that the absorbing chamber 492 is completely enclosed but for the transverse apertures 464.
During operation, exhaust gas and exhaust noise flow through the muffler 416 as represented by dashed arrows in
In summary, the muffler 14, 114, 214, 314, 414 disclosed above reduces exhaust noise in an effective manner by causing the majority of exhaust noise to move through the sound absorbing member 60, 160, 260, 360, 460, 461. This can reduce undesirable low frequency exhaust noise and/or standing waves within the exhaust system 12, 112, 212, 312, 412.
This application claims priority from provisional application No. 60/741,114, filed Dec. 1, 2005, which is hereby incorporated herein by reference.
Number | Date | Country | |
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60741114 | Dec 2005 | US |