High-performance muffler assembly with multiple modes of operation

• US 20070227807A1
• Filed: 03/02/2007
• Published: 10/04/2007
• Est. Priority Date: 03/02/2006
• Status: Active Grant

• Current Assignee: Pacbrake
• Original Assignee: Pacbrake
• Inventors: Sebring, Brad, Gavril, Gabriel, Meneely, Vincent
• Granted Patent: US 7,673,720 B2
• Time in Patent Office: Days
• US Class Current: 181/237
• CPC Class Codes: F01N 1/02 by using resonance
• CPC Class Codes: F01N 1/084 the gases flowing through the silencer two or more times longitudinally in opposite directions, e.g. using parallel or concentric tubes
• CPC Class Codes: F01N 1/089 using two or more expansion chambers in series F01N1/083, F01N1/084, F01N1/086 take precedence
• CPC Class Codes: F01N 1/165 for adjusting flow area
• CPC Class Codes: F01N 1/166 for changing gas flow path through the silencer or for adjusting the dimensions of a chamber or a pipe F01N1/165 takes precedence
• CPC Class Codes: F01N 1/168 for controlling or modifying silencing characteristics only
• CPC Class Codes: F01N 2210/04 Throttling-expansion and resonance
• CPC Class Codes: F01N 2230/02 Exhaust filters

Abstract

A high-performance muffler assembly for exhaust system of an internal combustion engine. The muffler assembly comprises an elongated casing having an inlet port and an exit port, a first pipe disposed within the casing and having an inlet end in fluid communication with the inlet port and an outlet end selectively fluidly connected to the exit port of the casing, and a first valve mounted within the casing. The first valve is selectively movable between a closed position and an open position for regulating an exhaust gas flow through the first pipe. The muffler assembly is operable in a number of different modes of operation including a high-performance mode, an exhaust braking mode, a reverse-flow mode, etc., determined by the positions of the first valve of the muffler assembly.

Claims

1. A muffler assembly for an internal combustion engine, said muffler assembly comprising:

an elongated casing having an inlet port and an exit port;

a first pipe disposed within said casing and having an inlet end in fluid communication with said inlet port and an outlet end selectively fluidly connected to said exit port of said casing; and

a first valve mounted within said casing, said first valve being selectively movable between a closed position and an open position for regulating an exhaust gas flow through said first pipe.

2. The muffler assembly as defined in claim 1, wherein said first valve is mounted within said first pipe.

3. The muffler assembly as defined in claim 1, wherein said first valve is a butterfly valve rotatably mounted within said first pipe.

4. The muffler assembly as defined in claim 1, further comprising a first actuator operably associated with said first valve for selectively moving said first valve between said closed and open positions.

5. The muffler assembly as defined in claim 4, wherein said first actuator is one of a pneumatic actuator, a vacuum actuator, a hydraulic actuator, an electromechanical actuator and an electromagnetic actuator.

6. The muffler assembly as defined in claim 5, further comprising an electronic control unit operably associated with said first actuator for operating said first actuator in response to at least one operating parameter of at least one of said muffler assembly and the internal combustion engine.

7. The muffler assembly as defined in claim 6, wherein said at least one operating parameter is one of speed of the internal combustion engine, inlet pressure of exhaust gas flow at said inlet port, outlet pressure of exhaust gas flow at said exit port, inlet temperature of exhaust gas flow at said inlet port, outlet temperature of exhaust gas flow at said exit port, acoustic energy generated by said muffler assembly, and vibration generated by said muffler assembly.

8. The muffler assembly as defined in claim 7, wherein the acoustic energy is monitored by an acoustic sensor detecting acoustic frequencies generated by said muffler assembly.

10. The muffler assembly as defined in claim 7, wherein the vibration is monitored by an accelerometer mounted to said muffler assembly.

11. The muffler assembly as defined in claim 1, further comprising a pressure relief valve disposed inside said casing upstream of said first valve, said pressure relief valve is selectively movable between a closed position and an open position for selectively fluidly connecting said inlet end of said first pipe to said exit port by bypassing said first valve, and said pressure relief valve moves into said open position when a pressure of exhaust gas acting on said pressure relief valve is higher than a predetermined value.

12. The muffler assembly as defined in claim 11, wherein said pressure relief valve is normally biased in said closed position by a bias spring.

13. The muffler assembly as defined in claim 12, wherein said pressure relief valve is mounted to said first pipe adjacent to said inlet end thereof.

14. The muffler assembly as defined in claim 11, further comprising a second valve mounted within said casing downstream of said first valve, said second valve is selectively movable between a closed position and an open position for preventing exhaust gas flow through said outlet end of said first pipe when said second valve is in said closed position.

15. The muffler assembly as defined in claim 14, wherein said first valve is disposed adjacent to said inlet end of said first pipe and said second valve is disposed adjacent to said outlet end thereof.

16. The muffler assembly as defined in claim 15, wherein said second valve is mounted within said first pipe.

17. The muffler assembly as defined in claim 16, wherein said second valve is a butterfly valve rotatably mounted within said first pipe.

18. The muffler assembly as defined in claim 14, wherein the internal combustion engine is operable in an engine compression release braking mode, and wherein said second valve is closed when the engine is in the engine compression release braking mode.

19. The muffler assembly as defined in claim 14, further including a second actuator for selectively moving said second valve between said closed and open positions.

20. The muffler assembly as defined in claim 19, further comprising an electronic control unit operably associated with said second actuator for operating said second actuator in response to at least one operating parameter of at least one of said muffler assembly and the internal combustion engine.

21. The muffler assembly as defined in claim 20, wherein said second actuator is one of a pneumatic actuator, vacuum actuator, a hydraulic actuator, electromechanical actuator and electromagnetic actuator.

22. The muffler assembly as defined in claim 14, wherein said casing includes a continuous outer wall extending along a central axis of said casing between a front wall defining said inlet port and a real wall defining said exit port.

23. The muffler assembly as defined in claim 22, wherein said casing extends along said central axis thereof, and wherein said first pipe extends substantially coaxially to said central axis of said casing so that said outlet end of said first pipe is axially spaced from said rear wall of said casing.

24. The muffler assembly as defined in claim 22, further comprising second and third pipes disposed within said casing and radially spaced from said first pipe, and further comprising first, second and third baffle plates dividing an internal cavity within said casing into a resonant chamber, an inlet chamber and a reverse-flow chamber;

said first baffle plate is axially spaced from said rear wall and disposed adjacent to said outlet end of said first pipe to define said resonant chamber within said casing between said first baffle plate and said rear wall of said casing so that said outlet end of said first pipe and an outlet end of said second pipe are open to said resonant chamber;

said second baffle plate is axially spaced from said front wall to define said inlet chamber within said casing between said second baffle plate and said front wall of said casing so that inlet ends of said second and third pipes are open to said inlet chamber;

said third baffle plate is disposed between said first and second baffle plates in axially spaced relationship to define said reverse-flow chamber within said casing between said first and third baffle plates so that an outlet end of said second pipe is open to said inlet chamber;

said inlet end of said first pipe is fluidly connected to said inlet chamber when said pressure relief valve in said open position; and

said first pipe has a bypass opening disposed between said first and second valve and open to said reverse-flow chamber.

25. The muffler assembly as defined in claim 24, wherein said muffler assembly is operable in a straight flow mode when both said first and second valves are in said open position.

26. The muffler assembly as defined in claim 24, wherein said muffler assembly is operable in said exhaust braking mode when both said first and second valves are in said closed position.

27. The muffler assembly as defined in claim 24, wherein said muffler assembly is operable in a reverse flow mode when said first valve is said open position and said second valve is in said closed position.

28. The muffler assembly as defined in claim 24, wherein said muffler assembly is operable in a warm-up mode when said first valve is in said closed position and said second valve is in said open position.

29. The muffler assembly as defined in claim 1, further including a particulate filter disposed within said casing.

30. The muffler assembly as defined in claim 29, wherein said particulate filter is disposed downstream of said inlet end of said first pipe.

31. The muffler assembly as defined in claim 29, wherein said muffler assembly is operable in a regeneration mode for regenerating said particulate filter.

32. The muffler assembly as defined in claim 31, wherein said first valve is closed in said regeneration mode.

33. The muffler assembly as defined in claim 31, further comprising at least one heating element operably associated with said particulate filter.

34. The muffler assembly as defined in claim 33, wherein said at least one heating element is disposed upstream of said particulate filter for heating exhaust gas in said regeneration mode.

35. The muffler assembly as defined in claim 33, wherein said at least one heating element is disposed in said particulate filter for heating said particulate filter in said regeneration mode.

36. The muffler assembly as defined in claim 1, wherein said first valve is disposed adjacent to said outlet end of said first pipe.

37. The muffler assembly as defined in claim 36, wherein said casing includes a continuous outer wall extending along a central axis of said casing between a front wall defining said inlet port and a real wall defining said exit port.

38. The muffler assembly as defined in claim 37, wherein said casing extends along said central axis thereof, and wherein said first pipe extends substantially coaxially to said central axis of said casing.

39. The muffler assembly as defined in claim 37, further comprising second and third pipes disposed within said casing and radially spaced from said first pipe, and further comprising first, second and third baffle plates dividing an internal cavity within said casing into a resonant chamber, an inlet chamber and a reverse-flow chamber;

said first baffle plate is axially spaced from said rear wall and disposed adjacent to said outlet end of said first pipe to define said resonant chamber within said casing between said first baffle plate and said rear wall of said casing so that said outlet end of said first pipe and an outlet end of said second pipe are open to said resonant chamber;

said second baffle plate is axially spaced from said front wall to define said inlet chamber within said casing between said second baffle plate and said front wall of said casing so that inlet ends of said second and third pipes are open to said inlet chamber;

said third baffle plate is disposed between said first and second baffle plates in axially spaced relationship to define said reverse-flow chamber within said casing between said first and third baffle plates so that an outlet end of said second pipe is open to said inlet chamber; and

said first pipe has a bypass opening disposed upstream of said first valve and open to said reverse-flow chamber.

40. The muffler assembly as defined in claim 39, wherein said muffler assembly is operable in an reverse flow mode when said first valve is in said closed position.

41. The muffler assembly as defined in claim 39, wherein said muffler assembly is operable in a straight flow mode when said first valve is in said open position.

42. The muffler assembly as defined in claim 14, wherein said casing includes a continuous outer wall extending along a central axis of said casing between a front wall defining said inlet port and a real wall defining said exit port.

43. The muffler assembly as defined in claim 42, wherein said casing extends along said central axis thereof, said first pipe extends substantially coaxially to said central axis of said casing, and said outlet end of said first pipe is attached said rear wall of said casing.

44. The muffler assembly as defined in claim 42, further comprising a first perforated baffle plate axially spaced from said rear wall so as to define a resonant chamber within said casing between said first perforated baffle plate and said rear wall of said casing, and a second perforated baffle plate axially spaced from said front wall and said first baffle plate so as to define an inlet chamber within said casing between said second perforated baffle plate and said front wall of said casing;

said first and second perforated baffle plates further define a central chamber therebetween; and

said inlet end of said first pipe is fluidly connected to said inlet chamber when said pressure relief valve in said open position.

45. The muffler assembly as defined in claim 44, wherein said first pipe further includes at least one aperture positioned between said first perforated baffle plate and said rear wall of said casing downstream of said second valve so as to provide fluid communication between said resonant chamber and said exit port through said outlet end of said first pipe;

said first pipe further includes at least one aperture positioned between said first and second valves so as to provide fluid communication between said central chamber and said first pipe between said first and second valves; and

said inlet end of said first pipe is fluidly connected to said inlet chamber when said pressure relief valve in said open position.

46. The muffler assembly as defined in claim 45, wherein said muffler assembly is operable in an exhaust braking mode when both said first and second valves are in said closed position.

47. The muffler assembly as defined in claim 45, wherein said muffler assembly is operable in a straight flow mode when both said first and second valves are in said open position.

48. The muffler assembly as defined in claim 45, wherein said muffler assembly is operable in a bypass mode when said first valve is said open position and said second valve is in said closed position.

49. The muffler assembly as defined in claim 11, wherein said casing includes a continuous outer wall extending along a central axis of said casing between a front wall defining said inlet port and a real wall defining said exit port.

50. The muffler assembly as defined in claim 49, wherein said casing extends along said central axis thereof, said first pipe extends substantially coaxially to said central axis of said casing, and said outlet end of said first pipe is attached said rear wall of said casing.

51. The muffler assembly as defined in claim 49, further comprising a perforated baffle plate axially spaced from said rear wall so as to define a resonant chamber within said casing between said perforated baffle plate and said rear wall of said casing and an inlet chamber within said casing between said perforated baffle plate and said front wall of said casing;

and

said inlet end of said first pipe is fluidly connected to said inlet chamber when said pressure relief valve in said open position.

52. The muffler assembly as defined in claim 51, wherein said first pipe further includes at least one aperture positioned between said perforated baffle plate and said rear wall of said casing downstream of said first valve so as to provide fluid communication between said resonant chamber and said exit port through said outlet end of said first pipe.

53. The muffler assembly as defined in claim 52, wherein said muffler assembly is operable in said exhaust braking mode when said first valve is in said closed position.

54. The muffler assembly as defined in claim 52, wherein said muffler assembly is operable in a straight flow mode when said first valve is in said open position.

55. The muffler assembly as defined in claim 11, wherein said casing includes a continuous outer wall extending along a central axis of said casing between a front wall defining said inlet port and a real wall defining said exit port.

56. The muffler assembly as defined in claim 55, wherein said casing extends along said central axis thereof, and wherein said first pipe extends substantially coaxially to said central axis of said casing so that said outlet end of said first pipe is axially spaced from said rear wall of said casing.

57. The muffler assembly as defined in claim 55, further comprising second and third pipes disposed within said casing and radially spaced from said first pipe, and further comprising first, second and third baffle plates dividing an internal cavity within said casing into a resonant chamber, an inlet chamber and a reverse-flow chamber;

said first baffle plate is axially spaced from said rear wall and disposed adjacent to said outlet end of said first pipe to define said resonant chamber within said casing between said first baffle plate and said rear wall of said casing so that said outlet end of said first pipe is closed to said resonant chamber and an outlet end of said second pipe is open to said resonant chamber;

said second baffle plate is axially spaced from said front wall to define said inlet chamber within said casing between said second baffle plate and said front wall of said casing so that inlet ends of said second and third pipes are open to said inlet chamber;

said third baffle plate is disposed between said first and second baffle plates in axially spaced relationship to define said reverse-flow chamber within said casing between said first and third baffle plates so that an outlet end of said second pipe is open to said reverse-flow chamber;

said first pipe has a bypass aperture downstream said first valve and open to said reverse-flow chamber; and

said inlet end of said first pipe is fluidly connected to said inlet chamber when said pressure relief valve in said open position.

58. The muffler assembly as defined in claim 57, wherein said first valve is disposed adjacent to said pressure relief valve and said inlet end of said first pipe.

59. The muffler assembly as defined in claim 58, wherein said muffler assembly is operable in an exhaust braking mode when said first valve is in said closed position.

60. The muffler assembly as defined in claim 58, wherein said muffler assembly is operable in a reverse flow mode when said first valve is in said open position.

61. The muffler assembly as defined in claim 1, wherein said casing includes a continuous outer wall extending along a central axis of said casing between a front wall defining said inlet port and a real wall defining said exit port.

62. The muffler assembly as defined in claim 61, wherein said casing extends along said central axis thereof, and wherein said first pipe extends substantially coaxially to said central axis of said casing.

63. The muffler assembly as defined in claim 61, further comprising a perforated baffle plate axially spaced from said front and rear walls so as to define a resonant chamber within said casing between said perforated baffle plate and said rear wall of said casing and an inlet chamber within said casing between said perforated baffle plate and said front wall of said casing.

64. The muffler assembly as defined in claim 63, wherein said first pipe further includes at least one aperture positioned between said perforated baffle plate and said rear wall of said casing downstream of said second valve so as to provide fluid communication between said resonant chamber and said exit port through said outlet end of said first pipe;

and

wherein said first pipe further includes at least one aperture positioned between said perforated baffle plate and said front wall of said casing upstream of said first valve so as to provide fluid communication between said inlet chamber and said first pipe.

65. The muffler assembly as defined in claim 64, wherein said muffler assembly is operable in a straight flow mode when said first valve is in said open position.

66. The muffler assembly as defined in claim 64, wherein said muffler assembly is operable in a bypass mode when said first valve is said closed position.

67. The muffler assembly as defined in claim 1, wherein said casing includes a continuous outer wall extending along a central axis of said casing between a front wall defining said inlet port and a real wall defining said exit port.

68. The muffler assembly as defined in claim 67, wherein said casing extends along said central axis thereof, and wherein said first pipe extends substantially coaxially to said central axis of said casing.

69. The muffler assembly as defined in claim 67, further comprising a second pipe extending between said front and rear walls so as to enclose said first pipe therewithin;

an inlet end of said second pipe is in fluid communication with said inlet port of said casing and an outlet end of said second pipe is in fluid communication with said exit port of said casing; and

said inlet end of said first pipe is axially spaced from said front wall of said casing and said outlet end of said first pipe is axially spaced from said front wall thereof.

70. The muffler assembly as defined in claim 69, wherein said second pipe has a front section adjacent to said front wall of said casing and upstream of said first valve, a rear section adjacent to said rear wall of said casing and a central section extending between said front and rear sections of said second pipe;

said front section of said second pipe having at least one aperture so as to provide fluid communication between said second pipe and an internal cavity within said casing;

said rear section of said second pipe having at least one aperture so as to provide fluid communication between said second pipe and said internal cavity within said casing; and

said central section of said second pipe is impervious for exhaust gas flow.

71. The muffler assembly as defined in claim 70, further comprising a baffle plate dividing said internal cavity within said casing so as to define a resonant chamber between said baffle plate and said rear wall of said casing and an inlet chamber between said baffle plate and said front wall of said casing;

said baffle plate having at least one aperture so as to provide fluid communication between said inlet chamber and said resonant chamber.

72. The muffler assembly as defined in claim 71, further comprising at least one baffle member in said resonant chamber between said outer wall of said casing and said second pipe, said at least one baffle member defines a tortuous path of the exhaust gas flow through said resonant chamber.

73. The muffler assembly as defined in claim 72, wherein said muffler assembly comprises a plurality of baffle members.

75. The muffler assembly as defined in claim 72, wherein said muffler assembly is operable in a straight flow mode when said first valve is in said open position.

76. The muffler assembly as defined in claim 72, wherein said muffler assembly is operable in a bypass mode when said first valve is said closed position.

9. The muffler assembly as defined in claim 9, wherein said acoustic sensor is mounted to said muffler assembly.

74. The muffler assembly as defined in claim 74, wherein each of said baffle members is a semi-annular plate, and wherein said baffle members are disposed opposite to each other in an alternating manner.

77. A method for muffling a vehicle engine, said method comprising the steps of:

a) providing a muffler assembly comprising an inlet, an outlet and a pipe extending between said inlet and outlet, and a valve operably associated with said pipe for allowing exhaust gas to selectively flow from said inlet to said outlet; and

b) opening said valve to allow selective flow of exhaust gas through said pipe.