BRIEF DESCRIPTION OF THE DRAWINGS
A preferred embodiment of the present invention is described below with reference to the accompanying drawings, in which:
FIG. 1 is a perspective view of an embodiment of the muffler diffuser of the present invention;
FIG. 2 is a top view of the embodiment of the muffler diffuser shown in FIG. 1;
FIG. 3 is a front view of the embodiment of the muffler diffuser shown in FIG. 1, the muffler diffuser being shown in place within a muffler exhaust, and about to be secured thereto with screws tightened by an Allen key; and
FIG. 4 is an exploded cut away view of the muffler diffuser of the present invention in place within a muffler, and which illustrates how sound and exhaust from the muffler are directed through the muffler diffuser to the outside atmosphere.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 broadly illustrates the muffler diffuser insert 1 of the present invention, which essentially comprises a body portion 5 integrally connected to a cap end 3, in a preferred embodiment, or which connection can be accomplished through welding or through other means which would be apparent to a worker skilled in the art. It can also be seen in FIG. 1 that the cap end is perpendicularly positioned in relation to the body portion. Preferably, the body portion 5 is elongated, and is perpendicularly positioned in relation to the cap end 3. As can be seen in FIG. 2, the body portion 5 also defines therein an opening 15, which will be described hereinafter, and possesses an insertion end 9, distally opposed from the cap end 3, which is meant for placement within a muffler. Further, the insertion end 9 further possesses sound deflection portions 7, which are positioned on either side of the outmost point of insertion end 9, such angled portions being placed, preferably, at a 45° angle in relation to the outmost end of the insertion end 9, though again it will be readily apparent that slight modifications or alternative configurations to this could also be utilized, as would be apparent to a worker skilled in the art. The purpose of the sound deflection portions 7 is to deflect sound waves in the exhaust flow and direct them into the packing of the muffler, so as to effect noise reduction of the engine, as will be later hereinafter described.
It should be noted that a thickness of cap end 3 needs to be of adequate thickness so that the muffler diffuser insert of the present invention does not warp, or become fused or lodged in the muffler due to excessive heat from the exhaust gases. It will be readily apparent that this thickness could be varied to a certain degree, as would be apparent to a worker skilled in the art. The cap end 3 also further defines therein a flow exit opening 13, which can be seen with reference to FIGS. 1 and 3. This is the exit portion of the muffler diffuser insert of the present invention which allows for the sound to be reduced but does not restrict the exhaust flow. It will also be understood that a plurality of openings could also be utilized in the cap end, as would be apparent to a worker skilled in the art. In a preferred embodiment, a length of opening 15 is to be greater than three (3) times a diameter of the flow exit opening 13, though it will be readily apparent that slight modifications or alternative configurations to this could also be utilized, as would be apparent to a worker skilled in the art. It will be readily understood that the diameter of the flow exit opening can be varied slightly, depending upon the size of the muffler diffuser used for particular differing brands of mufflers (as different manufacturers use various sizes of internal perforated tubes), provided that the length of opening 15 is also correspondingly varied so as to, preferably, be greater than three (3) times a diameter of the flow exit opening 13.
With reference to FIG. 3, the muffler diffuser of the present invention is fastened to the internal inner construction of the muffler with, in one possibility, screws inserted by allen key set screws 17, though it will be apparent that other variations as to this securement are possible. These screws can be inserted through threaded screw openings 11 in the muffler diffuser, as can be seen with reference to FIGS. 1 and 2. In the example shown in FIG. 3, these two set screws will not allow the silencer to fall out while being operated. Preferably, the hardware (set screws) are manufactured from stainless steel so that they will not corrode or seize in the muffler diffuser, though it will be readily apparent that other similar configurations may be utilized, as would be apparent to a worker skilled in the art. Also, in a preferred embodiment, the muffler diffuser insert of the present invention is manufactured from aluminum, which helps to dissipate heat more readily, and for its particular characteristics, such as resistance to moisture and corrosion, while still remaining lightweight, though it will be readily apparent that other materials may also be utilized, as would be apparent to a worker skilled in the art.
In utilizing the muffler diffuser of the present invention, and with reference to FIG. 4, the muffler diffuser can be inserted and attached into a muffler having an inner perforated tube diameter. In doing do, insertion end 9 is inserted first into the muffler, and, when fully inserted, distally opposed cap end 3 abuts up against the exterior end of the muffler exhaust opening, as can be seen in FIG. 4, and the muffler diffuser is longitudinally mounted and aligned within a longitudinal axis of the muffler. With reference to FIG. 3, the muffler diffuser of the present invention can then be fastened to the internal inner construction of the muffler with screws inserted by allen key set screws 17. With reference again to FIG. 4 for exhaust flow, and starting from the inlet side of the muffler, the exhaust flow 19 exiting the muffler will encounter the insertion end 9 and sound deflection portions 7 of the muffler diffuser, which help to deflect the sound waves from the exhaust flow into the body (packing) of the stock muffler 21. Once the sound has been deflected into the body of the stock muffler the sound decibels will accordingly be reduced.
It is important to note that the exhaust flow 19 will travel the path of least resistance will travel around the sound deflection portions 7, entering into and being neutralized in the opening 15 of the muffler diffuser. At this point, the exhaust flow is then evacuated through the flow exit opening 13 in the cap end 3 of the muffler diffuser. As noted previously, a diameter of this exhaust opening is a calculation that depends on the internal diameter of the factory muffler. The diameter of the hole is a critical factor as this also helps in the scavenging effect on the muffler. For example, at this point the sanctioning body (Motorcycle Industry Council) for motorcycle racing has established that the SAE J1287 JUL98 Noise Testing Procedure requires that all motorcycles operate at a 96 db or less. This measurement is taken from 20″ behind the exhaust centerline on a 45 degree angle. With respect to use of the muffler diffuser of the present invention, and through the muffler diffuser having sound deflection portions 7 and the length of opening 15 being greater than three (3) times a diameter of the exhaust outlet into which the muffler diffuser is placed, decibel levels can usually be reduced anywhere from 4 to 10 dB, through use of this muffler diffuser, and without increasing the exhaust back pressure to a point where it will cause premature engine failure.
The present invention has been described herein with regard to preferred embodiments. However, it will be obvious to persons skilled in the art that a number of variations and modifications can be made without departing from the scope of the invention as described herein.
Patent Application
20080035419
