The invention generally relates to exhaust systems of motorized vehicles and, more particularly, the invention relates to controlling the sound of the exhaust systems.
Motorized vehicles, such as automobiles, have exhaust systems to guide exhaust gases away from the controlled combustion taking place inside their engines. In addition to exhausting gases, exhaust systems also control engine noise. Specifically, much of the engine noise produced by the internal combustion process emanates through the exhaust system. In fact, that noise can be quite loud and, consequently, disturbing to the driver and people near the driver. Exhaust systems therefore typically have a muffler to reduce the engine noise, and the muffler is often configured to mitigate the noise to levels defined by state and local noise regulations.
Sports car and sport truck enthusiasts, however, may prefer to hear the full sound of their engines. For example, sports car enthusiasts often prefer to hear the “rumble” of their engines when riding their sports cars on a closed track. Indeed, the muffler function often is not legally necessary on a track in this instance since tracks generally are not subject to the municipal noise regulations. Some tracks, however, are subject to noise regulations and thus, also still must be muffled to some extent to comply with the noise regulations.
A first embodiment of the invention is a muffler for a motorized vehicle. The muffler includes a housing forming a housing interior having an inlet chamber and an outlet chamber, an exhaust inlet for receiving exhaust gas in the inlet chamber, and an exhaust outlet for directing exhaust gas from the outlet chamber. The muffler also includes a first channel within the housing interior to fluidly connect the inlet chamber and the outlet chamber. The first channel has a first noise dampening amount. The muffler includes second channel within the housing interior between the inlet chamber and the outlet chamber. The second channel has a second noise dampening amount, and the first noise dampening amount is greater than the second noise dampening amount. The muffler also includes a valve within the housing interior. The valve selectively fluidly connecting the inlet chamber and the outlet chamber thorough the second channel. It is further configured to variably obstruct the flow of exhaust gas through the second channel.
The muffler may also include a controller that is operatively coupled with the valve and configured to control the position of the valve. The controller is within the housing interior. The muffler may also include a motor within the housing interior, and the motor is configured to move the position of the valve in response to a signal from the controller. The valve may include a disk positioned within the second channel, and the disk may be configured to rotate about an axis to variably obstruct the flow of exhaust gas through the second channel.
In some embodiments, the exterior surface of the housing includes a top housing surface forming a recessed region. A motor that is configured to control the position of the valve may be positioned within the recessed region of the housing. The motor may include a top motor surface that is substantially flush with or below the top housing surface. The muffler may also include a third channel with noise damping material that connects the inlet chamber and the outlet chamber. The controller may be configured to receive a signal, from a user interface, corresponding to a level of obstruction selected by a user and control the position of the valve based on the signal. In some embodiments, the level of obstruction for the second channel may be a predefined level, and in other embodiments, the level of obstruction for the second channel may be based on dynamic parameters of the motorized vehicle. The dynamic parameters may include a throttle position of the motorized vehicle, a speed of the motorized vehicle, a load on the motorized vehicle engine, RPM of the engine, gear of a transmission system of the motorized vehicle, a position of the motorized vehicle in its environment, a local time, or any combination thereof.
A second embodiment of the invention is a method of controlling the sound of a muffler system for a motorized vehicle. The method includes flowing exhaust gas through a first channel inside a housing of a muffler. The first channel is configured to dampen exhaust noise and connect an inlet chamber of the housing and an outlet chamber of the housing. A second channel is inside the housing between the inlet chamber and the outlet chamber and configured to selectively receive exhaust gas from the inlet chamber of the housing. The method includes receiving, from a user interface outside of the housing, a signal corresponding to a selected level of obstruction for the second channel. The method includes controlling, based on the received signal, a position of a valve within the housing to vary the exhaust gas flow resistance through the second channel. The valve selectively fluidly connects the inlet chamber with the outlet chamber through the second channel.
In some embodiments, controlling the position of the valve includes determining, by a controller operatively coupled to the user interface, the position of the valve. Controlling the position of the valve may include operating a motor coupled to the valve to move the position of the valve and/or rotating a disk, positioned within the second channel, about an axis. Controlling the position of the valve may include determining a predefined position of the valve based on the selected level of obstruction for the second channel, or determining the position of the valve based on dynamic parameters of the motorized vehicle. The dynamic parameters may include a throttle position of the motorized vehicle, a speed of the motorized vehicle, a load on the motorized vehicle engine, RPM of the engine, gear of a transmission system of the motorized vehicle, a position of the motorized vehicle in its environment, a local time, or any combination thereof.
A third embodiment of the invention is a muffler for a motorized vehicle. The muffler includes a housing forming a housing interior having an inlet chamber, an exhaust inlet for receiving exhaust gas in the inlet chamber, a first exhaust outlet, and a second exhaust outlet. The muffler also includes a first channel with noise damping material that is within the housing interior, fluidly connecting the inlet chamber with the first exhaust outlet. The muffler also includes a second channel within the housing interior. The muffler also includes a valve within the housing interior configured to variably obstruct the flow of exhaust gas through the second channel. The valve selectively fluidly connecting the inlet chamber and second exhaust outlet through the second channel. The valve may be within the second channel or outside of the second channel. The muffler may include any of the other features described herein.
Illustrative embodiments of the invention are implemented as a computer program product having a computer usable medium with computer readable program code thereon. The computer readable code may be read and utilized by a computer system, including mobile devices, such as mobile telephones, smartphones, tablets, smartwatches, etc., in accordance with conventional processes.
Those skilled in the art should more fully appreciate advantages of various embodiments of the invention from the following “Description of Illustrative Embodiments,” discussed with reference to the drawings summarized immediately below.
Some drivers prefer to have control of the noise level and sound of their motorized vehicles. For example, drivers of high performance sports cars, such as the popular Ford Mustang™ (distributed by Ford Motor Company), may prefer to hear the “rumble” of the engine when they rapidly accelerate. To that end, illustrative embodiments described herein depict an automobile or other motorized vehicle that has controls for enabling a user to easily alter the sound of the vehicle. In particular, the vehicle has a muffler with noise dampening and non-noise dampening channels and a controller coupled to a valve for selectively re-directing the flow of exhaust gas from the engine through these channels.
As shown, the exhaust system 18 generally has a main pipe 20 terminating at a tail pipe 22 that is exposed to the environment. As known by those in the art, much of the noise produced by the engine 16 generally is transmitted to the external environment through the exhaust system 18. Accordingly, the main pipe 20 also has a muffler 23 configured to at least partially mitigate the noise of the exhaust gas.
The automobile 10 also has a central computer 13 that controls many automobile systems, such as, among other things, the safety system (e.g., traction control and airbag safety), emission control, the ignition system, and the general operation of the automobile 10. Indeed, mention of these computer functions is merely illustrative of but a few of the many different functions performed by the central computer 13. Accordingly, discussion of such functions is for descriptive purposes only and not intended to limit various embodiments of the invention. Those skilled in the art understand the many functions of the central computer 13.
Moreover, the central computer 13 is coupled to a controller 30 configured to control a position of a valve 21 in the muffler 23. As explained below, the position of this valve 21 determines the flow of exhaust gas through the channels of the muffler 23 and consequently, the level of noise for the engine sound. Although
Thus, unlike the conventional mufflers known to the inventors, an exemplary muffler 23 of the invention has a housing 11 whose interior includes a plurality of internal chambers that direct exhaust gas from an inlet tube 12 toward an outlet tube 15. Also unlike other conventional mufflers known to the inventors, the housing 11 has a top surface that forms an exterior recessed region 17 configured to contain a valve motor 19, which controls the position of a valve 21 within the housing 11 to selectively vary the output sound of the muffler 23. Some embodiments may have the same functionality without the recessed region 17.
Although the embodiment of
Moreover, the parallel muffler channels may have different noise dampening amounts, e.g., each channel has noise dampening material that may dampen the noise of exhaust gas flowing through itself by a different amount. In some embodiments, the amount may be represented by a percentage (e.g., 0%, 50%, 90%), and in other embodiments, the amount may be represented by a decibel level (e.g., 0 dB, 15 dB, 20 dB, 30 dB). When a channel has a noise dampening amount that is zero or close to zero, the channel allows exhaust gas to flow through uninhibited and either does not dampen its noise, or dampens the noise by a negligible amount. However, when a channel has a higher noise dampening amount, the channel muffles at least part of the noise of the flowing exhaust gas via a noise dampening material, or other means described herein.
In contrast, the third of the three parallel channels, the bypass channel 28, allows exhaust gas to flow through without any substantially mitigation of its noise. The bypass channel has no or minimal noise damping material within its interior or along its interior walls.
Under direction by the valve motor 19 and valve controller 30, the valve 21 controls the proportion of exhaust gas flowing through each of the dampening channels 26 and bypass channel 28. The valve 21 may be positioned at any location within the interior of the bypass channel 28. The embodiments of
The valve 21 is configured to variably obstruct the flow of exhaust gas through the bypass channel 28. Exhaust entering the inlet mixing chamber 33 can enter the outlet mixing chamber 24 through the three parallel channels. The position of the valve 21, however, controls the volume of exhaust passing through the damping channels 26 and the bypass channel 28.
When the valve 21 is open, the valve 21 allows exhaust gas to freely pass through the bypass channel 28. As a result, a maximum amount of exhaust gas may pass through the bypass channel 28. In this state, some amount of exhaust still is expected to pass through the damping channels 26. As such, the muffler 23 thus provides minimum noise damping function because the maximum amount of exhaust gas is directed through the bypass channel 28, which has little or no damping function.
When the valve 21 is closed or fully obstructs the bypass channel 28, a maximum amount of exhaust gas is diverted to the dampening channels 26 to the outlet mixing chamber 24. In the state, the muffler 23 thus preferably provides its maximum noise damping function because the maximum amount of exhaust is directed toward and through the damping channels 26.
The valve 21 may also assume any intermediate, partially open position, further altering the proportion of exhaust gas flowing through the three channels 26, 28 and the resulting amount of engine noise. During testing, the inventors discovered that the position of the valve does not have a linear relationship with the range of sounds and noise levels, i.e., the amount of exhaust gas permitted to flow through the bypass channel 28 does not necessarily correspond to a precise, linear change in the noise and sound level.
In some embodiments, the valve 21 includes a simple movable disk (or plate), or other structure. In the embodiment of
For example, when the disk is oriented so its edge is generally along the axis of the bypass channel 28, the bypass channel 28 may be substantially open, thereby allowing a maximum amount of exhaust gas to flow through. Alternatively, when the disk is in the position shown in
Alternative embodiments may permit some amount of exhaust gas to flow through the bypass channel 28. The valve 21 may be configured to selectively block no more than a maximum amount of the bypass channel 28. For example, the valve 21 may include a disk with perforations, or cut-out geometric shapes. Thus, even when the face of the disk is substantially normal to the axis of the bypass channel 28, the perforations or cut-outs prevent the disk from sealing the bypass channel 28. Instead, the disk acts as an obstruction. In some embodiments, the valve 21 may effectively obstruct 90% or less of the bypass channel 28 when in the valve 21 is in maximum obstructing position, though the percentage may vary based on the configuration of the valve 21.
Any of a wide variety of motors may be used to control the position of the valve 21. In some embodiments, the motor 19 is a brushless electric direct current (DC) motor controlled by various inputs, such as logic from the motorized vehicle 10. Furthermore, the motorized vehicle 10 may be equipped with a user interface that enables a user to control the amount of engine noise released, and the computer 13 may interpret signals from the user interface to operate the valve controller 30 and, by extension, the motor 19 and position of the valve 21.
For example, the user may move a switch within the automobile, which causes the valve 21 to move in a prescribed manner in a variety of modes. See, for example, incorporated U.S. patent application Ser. No. 14/797,791 for additional examples of such logic, hardware, and software components.
In illustrative embodiments, those modes may include:
Various embodiments may use any of a variety of mechanical devices for switching between modes. Some embodiments may use pushbuttons for different modes similar to preselect buttons of a car radio. Those skilled in the art can select any of a variety of other mechanical or virtual switches. Rather than using the above noted switch 32 or other manual or mechanical device, such as that in
Moreover, as shown in
By offsetting the longitudinal axis of the bypass channel 28 toward the outside of the housing 11 (discussed below), the motor 19 is can be “flush” to or below the housing 11. This configuration delivers a unique appearance, enhanced packaging capability, and design flexibility to achieve desired volume and sound quality outputs.
Discussion of the motor 19 being mounted in this manner is but one of a variety of examples. Other embodiments may position the motor 19 at another location, such as at a location that causes the motor 19 to add to the overall profile of the muffler 23.
In alternative embodiments, the bypass channel 28 is not positioned between the damping channels 26. Other embodiments may use only one damping channel 26, or three or more damping channels 26. In yet other embodiments, the muffler 23 may have more than one bypass channel 28. Those skilled in the art can select the appropriate number of bypass channels 28 and damping channels 26 for a given application.
In some embodiments, from a user interface of the motorized vehicle, a user can select between at least two modes of operation: a static mode that controls exhaust flow direction independently of dynamic parameters of the vehicle, or a dynamic mode that controls exhaust flow direction as a function of the dynamic parameters of the vehicle. Among other things, the dynamic parameters may include the accelerator pedal (also referred to as the “throttle position”) and/or speed of the vehicle.
The Custom Mode and Auto Mode described above are considered to be “dynamic modes” because, when the valve controller 30 is in one of those modes, the controller 30 controls movement of the valve 21 about a plurality of positions as a function of at least one dynamic parameter (e.g., accelerator pedal position, speed, and/or other parameters discussed herein). In contrast, the Track Mode and Closed Mode are considered to be “static modes” because, when the valve controller 30 is in one of those modes, the controller 30 sets the valve 21 to a prescribed position independent of any dynamic parameter of the motorized vehicle 10. In other words, when the user selects a static mode, the valve 21 is set to a prescribed position that does not change in response to speed changes, throttle position changes, etc. Although not discussed above, other static modes may position the valve 21 in a partly open/closed position.
In some embodiments, the user can change underlying valve positional data in any of a variety of manners. For example, the user may enter the values of certain parameters and how much the valve 21 should be open during those times. For example, the user may program the valve controller 30 to open the valve 21 about 40 percent (of the full amount it can be opened) when it detects an automobile speed of 35 miles per hour. As another example, the user may program the valve controller 30 to open the valve 21 about 70 percent when it detects that the throttle is depressed 90 percent of its potential range.
Other embodiments may not be so simple. In particular, such embodiments may program the valve controller 30 to set the valve 21 to a specified position in response to receipt of two or more input parameters. This valve opening amount can be based on any of a variety of techniques, such as a simple look-up-table, or a formula that weights or does not weight the parameters. Among other things, illustrative embodiments may control valve position based on individual or combinations of any of the following parameters:
Since some of these parameters may change while the motorized vehicle 10 is moving, such parameters are referred to as “dynamic variables.” Moreover, it should be noted that this list is illustrative and not intended to be an exhaustive list of dynamic variables. Accordingly, those skilled in the art may use other dynamic variables to control output sound.
The valve controller 30 receives input parameters from the central computer 13 (or other data source) and responsively controls the amount/pressure of exhaust gas that the valve 21 permits through the bypass channel 28. Those skilled in the art may use any of a variety of conventional technologies to implement the valve controller 30. For example, a conventional engine/electronic control module (“ECM,” sometimes part of a larger engine/electronic control unit or “ECU”) may be programmed to control the position of the valve 28. Other embodiments may use one or more microprocessors, digital signal processors, and/or other electronics to implement that valve controller 30.
In alternative embodiments, instead of or in addition to being within the bypass channel 28, the valve 21 can be positioned to open and close chambers within the muffler 23. This alternative embodiment affects noise, back pressure, and drone.
Although the embodiments described herein depict mufflers 23 whose channels 26, 28 fluidly connect to an inlet mixing chamber 33 and an outlet mixing chamber 24, in some embodiments, the muffler 23 may omit the chambers 33, 24. Such an embodiment is depicted in
Although the above discussion discloses various exemplary embodiments of the invention, it should be apparent that those skilled in the art can make various modifications that will achieve some of the advantages of the invention without departing from the true scope of the invention.
This patent application is a continuation of U.S. patent application Ser. No. 15/340,476, filed Nov. 1, 2016, entitled, “MUFFLER WITH SELECTED EXHAUST PATHWAYS,” and naming Christopher W. Creager and Justin G. Schroeder as inventors, the disclosure of which is incorporated herein, in its entirety, by reference. This patent application also claims priority to U.S. Provisional Patent Application No. 62/249,529, filed Nov. 2, 2015 and entitled “MUFFLER WITH SELECTED EXHAUST PATHWAYS,” the disclosure of which is incorporated herein, in its entirety, by reference. This patent application is also related to U.S. patent application Ser. No. 14/797,791, filed Jul. 13, 2015, entitled, “EXHAUST CONTROL SYSTEM,” and naming Erin M. Dmytrow, Ryan L. Martin, and Justin G. Schroeder as inventors, the disclosure of which is incorporated herein, in its entirety, by reference.
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20190055867 A1 | Feb 2019 | US |
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Number | Date | Country | |
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Parent | 15340476 | Nov 2016 | US |
Child | 16115916 | US |