The subject invention relates to a passive valve comprised of a plurality of flexible members that provide a variable restriction in a vehicle exhaust system.
Exhaust systems are widely known and used with combustion engines. Typically, an exhaust system includes exhaust tubes or pipes that convey hot exhaust gases from the engine to other exhaust system components, such as catalysts, mufflers, resonators, etc. Exhaust components systems generate various forms of resonances, which result in undesirable noise. Spring/mass-like resonances occur at relatively low frequencies, e.g. below 100 Hz. This type of resonance occurs when the exhaust gas within a pipe acts as a mass and the exhaust gas in muffler volumes act as springs. The system also generates standing waves which comprise acoustic resonances in the pipes themselves. These standing waves are most prevalent in the longest pipes of the system. The frequency of these standing waves is a function of pipe length. Typically, these standing waves occur above 100 Hz. Addressing these standing wave and spring/mass noise issues increases system cost and weight.
Powertrain technology is continually pushing the exhaust sound that needs to be attenuated to lower and lower frequencies. Noise reducing solutions traditionally have included increasing volume or utilizing valves. Mufflers and resonators include acoustic volumes that cancel out sound waves carried by the exhaust gases. Although effective, these components are often relatively large in size and provide limited nose attenuation. Valves have also been used to provide noise attenuation; however, the use of valves further increases cost as well as having additional drawbacks. Current active and passive valve solutions used to address system resonances all suffer from one or more of noise, vibration, harshness (NVH) issues such as flutter, rattle, impact, and squeaking for example. Thus, solutions are needed to more effectively attenuate lower frequency noise without increasing cost and weight, and without introducing the aforementioned NVH issues.
In one exemplary embodiment, a valve assembly for a vehicle exhaust system includes a rigid mount structure that is configured to be mounted within an exhaust component that defines an exhaust gas passage. The valve assembly further includes a plurality of flexible members that each extend from a first end to a second end. One of the first ends and second ends of the flexible members is fixed to the rigid mount structure and the other of the first ends and second ends is free to move such that the plurality of flexible members creates a variable restriction to flow through the exhaust component that varies in response to pressure difference upstream and downstream of the plurality of flexible members.
In a further embodiment of the above, at least some of the flexible members partially overlap each other, and the freely movable ends bend from an initial position to increase an open area within the exhaust gas passage in response to increased exhaust gas pressure above a predetermined level, and the freely moveable ends return to the initial position when exhaust gas pressure falls below the predetermined level.
In a further embodiment of any of the above, when in the initial position, the freely movable ends of the plurality of flexible members are spaced apart from each other to define an open space radially inward of the freely movable ends, and the freely movable ends bend from the initial position to increase the open space within the exhaust gas passage in response to increased exhaust gas pressure above the predetermined level.
In a further embodiment of any of the above, the rigid mount structure comprises an outer band defining an inner surface surrounding the exhaust gas passage, and wherein the flexible members extend outwardly from the inner surface toward a center of the exhaust gas passage.
In a further embodiment of any of the above, the rigid mount structure comprises an inner mount positioned within the exhaust gas passage to define a mount interface that is spaced from an inner surface of the exhaust component, and wherein the flexible members extend outwardly from the mount interface toward the inner surface of the exhaust gas passage.
In a further embodiment of any of the above, the plurality of flexible members comprises a plurality of stiffener members that are inside a flexible material.
In a further embodiment of any of the above, the plurality of flexible members comprises a plurality of bristles.
In another exemplary embodiment, a vehicle exhaust component assembly includes an exhaust component body having an inner surface defining an exhaust gas passage, a rigid mount structure positioned within the exhaust gas passage, and a plurality of flexible members each extending from a first end to a second end. The plurality of flexible members comprise a plurality of bristles or stiffeners. The first ends of the flexible members are fixed to the rigid mount structure and the second ends are free to move such that the plurality of flexible members creates a variable restriction to flow through the exhaust component body that varies in response to a pressure difference upstream and downstream of the plurality of flexible members. The freely movable ends bend from an initial position to increase an open area within the exhaust gas passage in response to increased exhaust gas pressure above a predetermined level, and the freely moveable ends return to the initial position when exhaust gas pressure falls below the predetermined level.
In a further embodiment of any of the above, a guide is positioned downstream from the plurality of flexible members to define a bend stop position for the flexible members when the exhaust gas pressure exceeds the predetermined level.
These and other features of the present invention can be best understood from the following specification and drawings, the following of which is a brief description.
As shown in
In the example shown in
In one example, the valve 30 includes a plurality of flexible members 36 that are configured to deflect away from a high pressure location towards a low pressure location. This results in a more open, i.e. less restrictive, exhaust gas passage 34 for the exhaust gas to flow through. This will provide a significantly higher back pressure than normal at low flow levels when the pressure drop is low enough such that the valve is mostly closed; however, as the pressure drop increases, the restriction will decrease such that the pressure drop (while still higher than at the low flow levels) is much lower than it would be for a fixed restriction.
In the example shown in
In one example, the valve 30 further includes an optional guide 52 that is positioned downstream of the bristles 36a. The guide 52 comprises a flange or rim that is bent or curved to define a bend stop position for the bristles 36a when the exhaust gas pressure exceeds the predetermined level. The guide 52 also serves to reduce stress on the bristles. This will prevent the bristles 36a from becoming permanently deformed. The guide 52 is mounted to the inner surface 46 of the band 40a, or optionally can be mounted to the inner surface 32 of the pipe 20.
In the example shown in
As discussed above, the open space 48 or annulus can be in the middle of the band 40a, can comprise two or more spaces 48, can be offset from a center axis A, or an opening may not be required such that the configuration relies solely on the porosity/density of the fibers. The initial size of the open space 48 can be adjusted to control the restriction within the pipe. A larger open space will mean less initial restriction and the restriction will change more slowly as a function of pressure. A smaller open space will mean more initial restriction and the restriction will change more quickly as a function of pressure. The valve 30 includes an optional guide component 52 to control deflection of the bristles 36a and prevent mechanical stresses that can cause bristles to permanently deform, which is a risk during high temperature exposure.
As discussed above, to provide the variable restriction, the members are configured to bend from an initial position, e.g. a low flow or no flow condition, to increase an open area within the exhaust gas passage in response to increased exhaust gas pressure above a predetermined level, and then return to the initial position when the exhaust gas pressure falls below the predetermined level. When the members are bent or fully-deformed, a max flow condition is provided.
As one example, a 70 mm round pipe, or other shaped pipe with an equivalent area, which includes the variable restriction will have the following characteristics. For example, the open area with the no-flow (non-deformed) condition will have a range of 300 to 700 mm2 and the open area with the max-flow (fully deformed) condition will have a range of 1590 to 2400 mm2. In one example, the bristle area (length×diameter×#of bristles) as a function of the total inner cross-sectional area of the pipe will be within a range of 45% to 260%. In one example, the bristles are made from steel and includes a width/diameter range of 0.1 to 0.5 mm. It should be understood that these are just examples and other configurations could be used dependent upon the application and design parameters.
One or more ridge stops 94 are provided within the flow path to create a positioned feature that the bristles 84 will push up against under low flow conditions. Under high flow conditions, the free ends 88 of the bristles 84 will push past, e.g. deform over, the ridge stops 94. The ridge stops 94 can be created by using ridge-lock or sizing tooling to produce a protrusion extending radially inwardly from the wall of the pipe 20 to provide the positive feature to interact with the bristles 84.
The described interferences/contact areas will create friction, which will increase the force required to move, distort, or bend the bristles 84. When exposed to an external force/flow, and depending on the force value, the bristles 84 will overcome the friction forces at the wall of the pipe 20, at the ridge stops 94, and also overcome the friction generated due to interference between the bristles 84 themselves.
The subject valve 30 provides several advantages over traditional valves. The subject valve is significantly lower in cost than current active and passive valve configurations. Further, the subject valve 30 does not suffer from the NVH issues that typically plague active and passive valves. Additionally, the subject valve can be located in many different locations including mufflers, for example, which makes it the valve.
Although a preferred embodiment of this invention has been disclosed, a worker of ordinary skill in this art would recognize that certain modifications would come within the scope of this invention. For that reason, the following claims should be studied to determine the true scope and content of this invention.
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