VEHICLE EXHAUST SYSTEM AND VEHICLE COMPRISING SAID SYSTEM

Description

1 / 10 VEHICLE EXHAUST SYSTEM AND VEHICLE COMPRISING SAID SYSTEM Field of Invention

[0001] The present invention falls within the technical field related to the development of exhaust systems for automotive vehicles, with an emphasis on solutions that offer a sporty sound signature while ensuring compliance with emissions and noise standards. The exhaust system of this invention was developed for application in a pickup truck, being adaptable to different internal combustion engine configurations and platforms, in addition to optimizing the acoustic experience by minimizing unwanted frequencies and enhancing others. Background of the Invention

[0002] Exhaust systems play a fundamental role in the proper functioning of internal combustion engine vehicles, especially in controlling emissions of gases and noise from the engine. In addition to ensuring compliance with stringent environmental and safety standards, these systems also directly influence the driving experience and the perception of vehicle performance.

[0003] The vehicle exhaust system can be divided into two parts: the hot end and the cold end. The first has the main function of controlling the emissions of pollutants generated by the engine, while the second is mainly responsible for dealing with the exhaust noise coming from it.

[0004] The hot section comprises the exhaust manifold, which connects the system to the engine, directing the gases out of the combustion chamber, and the catalytic converters, responsible for reducing or eliminating harmful gases, transforming them into harmless gases, such as H2O, CO2 and N2.

[0005] The cold end consists of the exhaust pipes, responsible for reducing exhaust gases to the atmosphere, and the mufflers, which are passive filters designed to obtain the desired exhaust noise for the vehicle. The exhaust pipe at the end of the system is called the tailpipe and, through its geometry, influences the exhaust noise.

[0006] A muffler (also known as a silencer or silencer) is conventionally classified as dissipative (also called resistive or Petition 870250015185, dated 25 / 02 / 2025, page 10 / 28 2 / 10 Absorptive) or reflective (also called reactive). Dissipative earmuffs typically have a simple internal configuration and use sound-absorbing materials, such as fiberglass wool, allowing sound waves to enter the porous material, which dissipates some of the sound energy as heat. Reflective earmuffs, on the other hand, consist of tubular elements and chambers of different dimensions, with the aim of reflecting sound energy back to the source through impedance mismatches.

[0007] Dissipative mufflers are efficient at attenuating noise at high frequencies, while reflective mufflers are ideal for attenuation at low frequencies. In practice, no muffler is completely dissipative or completely reactive, and both approaches are usually explored in the development of exhaust systems.

[0008] The connection between the hot and cold parts of the exhaust system is usually made through a flexible element. The main function of this component is to prevent vibrations produced by the engine from being transmitted to the entire exhaust system, as well as to protect the cold part against large displacements that can be caused not only by the engine, but also by track excitations, thermal expansions, and assembly tolerances.

[0009] In recent years, the demand for exhaust systems that offer a sporty sound signature has grown, especially in high-performance vehicles. These systems are designed to generate a harmonious acoustic experience, highlighting characteristics such as power and performance, without compromising compliance with regulatory standards.

[0010] The sports exhaust, for example, is a system specifically developed to intensify the sound experience of a vehicle. Unlike conventional systems, it is designed to produce more impactful and aggressive sounds, highlighting specific frequencies that enhance the acoustic identity of the vehicle.

[0011] In the context of this invention, the vehicle in question is a pickup truck. During its development, it was found that the sound pressure levels of the conventional exhaust, known as a muffler, did not meet the expectations for a truly sporty vehicle. This made it necessary to develop an exhaust system capable of meeting the desired acoustic characteristics. Petition 870250015185, dated 25 / 02 / 2025, page 11 / 28 3 / 10

[0012] Current exhaust solutions for the same engine have total muffler volumes exceeding 24 L, providing sound attenuation across wide frequency ranges. These solutions generate exhaust noise, also known as tailpipe noise, with reduced sound pressure levels and are classified as quiet. However, for the vehicle in question, a system is sought that produces tailpipe noise with higher sound pressure levels, especially in the second and main order of the engine, in order to obtain a deep sound.

[0013] The developed exhaust system includes a Y-shaped flow divider, two tailpipes and three small-volume mufflers, carefully tuned to attenuate high-frequency content and approximate the sound pressure level curves of the second, fourth and sixth orders of the engine. The resulting tailpipe noise is deep and intense, reflecting the power and sportiness of the vehicle, as desired, and also meets the PROCONVE L7, PL7 emissions legislation.

[0014] Some prior art documents have attempted to solve this problem, as can be seen below:

[0015] US9212593 - A dual exhaust system structure for a cylinder deactivation (CDA) engine may include two intake pipes, two outlet pipes, each of which projects and extends from within the respective main muffler to outside the respective main muffler, where each of the two outlet pipes releases the exhaust gases passing through the respective main muffler out of the vehicle, a connecting pipe arranged in the direction of the width of the vehicle and connecting the two main mufflers, and a valve mounted on one of the two outlet pipes to open and close this outlet pipe, where, when the valve is closed, the exhaust gases passing through one of the main mufflers may be directed to the other main muffler through the connecting pipe and then emitted out of the vehicle.

[0016] Existing solutions fail to offer an effective alternative for exhaust systems that balance an appropriate sound signature with the required sporty characteristics, using low-volume mufflers and without resorting to the use of active or passive valves, which increase the cost and production time. Objectives of the Invention Petition 870250015185, dated 25 / 02 / 2025, p. 12 / 28 4 / 10

[0017] The present invention aims to provide an exhaust system designed to offer a suitable sound signature, with sporty characteristics of deep and intense noise.

[0018] The invention also aims to meet the expectations of consumers of high-performance vehicles, in addition to ensuring compliance with PROCONVE L7, PL7 emissions and noise legislation, using an exhaust system composed of three dissipative mufflers with reduced volumes. Brief Description of the Invention

[0019] The present invention discloses a vehicle exhaust system, characterized by comprising a cold end. The cold end of the exhaust system comprises: at least one front assembly, configured to connect the hot end of the exhaust system to the cold end; at least one center assembly, configured to connect the center muffler to the front and rear assemblies; at least one rear assembly, with a Y-shaped flow divider, configured to have two tailpipes; at least one center muffler, configured to have a triangular profile; at least two rear mufflers, configured with a circular profile; and two tailpipes, configured to allow the exhaust gases to exit.

[0020] Also, the center muffler is located in the center assembly and the rear mufflers are located in the rear assembly.

[0021] The front and rear assemblies are attached to the vehicle using hooks or hangers.

[0022] The front assembly tubing has an outer diameter between 65 mm and 75 mm and a wall thickness between 0.8 mm and 1.5 mm.

[0023] The piping of the central assembly has an outside diameter between 50 mm and 70 mm and a wall thickness between 0.8 mm and 1.5 mm.

[0024] The piping of the rear assembly has an outside diameter between 50 mm and 60 mm and a wall thickness between 0.8 mm and 1.5 mm.

[0025] In addition, the front, center and rear piping is made of high-strength steel and has an external coating against corrosion.

[0026] The central muffler is of the dissipative type and contains between 200 grams and 400 grams of fiberglass wool.

[0027] The center muffler is configured to have a volume between 2 liters and 3 liters. Petition 870250015185, dated 25 / 02 / 2025, page 13 / 28 5 / 10

[0028] The rear mufflers are of the dissipative type and contain between 100 grams and 300 grams of fiberglass wool.

[0029] The rear mufflers are configured to have a volume between 1 liter and 2 liters.

[0030] The inner tubing of the central muffler has a diameter between 50 mm and 65 mm, a wall thickness between 0.8 mm and 1.5 mm, and has 500 to 600 holes, with a diameter between 3 mm and 5 mm.

[0031] The internal tubing of the rear mufflers has a diameter between 45 mm and 65 mm, a wall thickness between 0.8 mm and 1.5 mm, and has 200 to 300 holes, with a diameter between 3 mm and 5 mm.

[0032] The central muffler and the rear mufflers have their volumes defined by the shells that surround them.

[0033] The present invention further discloses a vehicle comprising an exhaust system. Brief Description of the Drawings

[0034] The present invention will be described in more detail after the presentation of the figures, which show a preferred configuration. The figures show: Figure 1 illustrates the complete cold end of the exhaust system that is the subject of this invention. Figure 2 illustrates a perspective view of the front assembly, highlighting the flexible element and the hooks. Figure 3 illustrates a perspective view of the central assembly, highlighting the central damper. Figure 4 illustrates a perspective view of the rear assembly, with a Y-shaped flow divider, highlighting the rear mufflers and hooks. Figure 5 illustrates a perspective view of the central muffler, highlighting its internal tubing. Figure 6 illustrates a perspective view of the rear muffler, highlighting its internal tubing. Figure 7a shows a graph highlighting the overall sound difference generated by the present invention. Petition 870250015185, dated 25 / 02 / 2025, p. 14 / 28 6 / 10 Figures 7b, 7c, and 7d reveal graphs highlighting the sound difference generated by the present invention in the second, fourth, and sixth orders, respectively.

[0035] The reference elements present in the figures are: Exhaust system (100); front assembly (1); flange (2); inlet section of the front assembly (3); flexible element (4); outlet section of the front assembly (5); front mounting brackets (6); center assembly (7); clamp of the center assembly (A); inlet section of the center assembly (8); center muffler (9); internal piping of the center muffler (10); outlet section of the center assembly (11); rear assembly (12); clamp of the rear assembly (B); inlet section of the rear assembly (13); Y-shaped flow divider (14); mounting brackets of the rear assembly (15); outlet section of the rear assembly (16); rear mufflers (17); internal piping of the rear mufflers (18); and exhaust tips (19). Detailed Description of the Invention

[0036] Before the invention is detailed, it is important to understand that it is not limited to the specific components of the described device, as such components may vary. It is also relevant to emphasize that the terminology employed herein serves only to describe particular embodiments and should not be seen as limiting. It should be noted that, as used in this descriptive report and associated claims, the singular forms a, an, and may refer to both singular and plural elements, unless the context clearly indicates otherwise. Furthermore, when ranges of numerical parameters are provided, they are considered to include limit values.

[0037] It should also be understood that the modalities presented here should not be viewed in isolation or disconnected. The characteristics described for one modality are equally applicable to the other modalities mentioned. If a specific characteristic is mentioned in one modality but not in another, the specialist in the field would understand that this does not necessarily imply that the characteristic should not be considered for the other modality. The specialist would understand that the objective of this application is to reveal the characteristic also for other modalities, but, for the sake of clarity and conciseness, this has not been explicitly stated in each case.

[0038] The present invention discloses a vehicle exhaust system (100), comprising a cold end. The cold end of the exhaust system (100) Petition 870250015185, dated 25 / 02 / 2025, p. 15 / 28 7 / 10 comprises: at least one front assembly (1), at least one center assembly (7) and at least one rear assembly (12).

[0039] The front assembly (1) comprises an inlet section (3) with flange (2), a flexible element (4), an outlet section (5) and front mounting brackets (6).

[0040] The front assembly piping (1) has an outside diameter between 65 mm and 75 mm and a wall thickness between 0.8 mm and 1.5 mm. More preferably, said piping has an outside diameter of 70 mm and a wall thickness of 1.5 mm.

[0041] The flange (2) of the front assembly connects it to the hot end of the exhaust system (not shown).

[0042] The flexible element (4) of the front assembly is responsible for decoupling, in terms of vibrations, the two parts of the exhaust system, protecting the cold side from excessive displacement.

[0043] The central assembly (7) is configured to connect the central muffler (9) to the front assembly (1) and to the rear assembly (12), and the central assembly, in its initial portion, is provided with a clamp (A).

[0044] The central assembly piping (7) has an outside diameter between 50 mm and 70 mm and a wall thickness between 0.8 mm and 1.5 mm. More preferably, said central assembly piping (7) has an outside diameter of 65 mm in its inlet section (8) and an outside diameter of 55 mm in its outlet section (11), both with a wall thickness of 1.0 mm.

[0045] The rear assembly (12) comprises an initial section fitted with a clamp (B), a Y-shaped flow divider (14), rear mounting brackets (15), two rear mufflers (17) and is terminated by two exhaust tips (19), which allow the exhaust system gases to exit.

[0046] The pipe of the back assembly (12) has an outside diameter between 50 mm and 60 mm and a wall thickness between 0.8 mm and 1.5 mm. More preferably, said pipe of the back assembly (12) has an outside diameter of 55 mm in its inlet section (13) and an outside diameter of 50 mm in its outlet section (16), both with a wall thickness of 1.0 mm.

[0047] In a preferred embodiment of the present invention, said vehicle exhaust system (100) is made of high-strength steel and has an external coating against corrosion. Petition 870250015185, dated 25 / 02 / 2025, page 16 / 28 8 / 10

[0048] In a preferred configuration of the present invention, the connections between the front assembly (1), the central assembly (7) and the rear assembly (12) are made by clamps, made before the exhaust system (100) is fixed to the vehicle.

[0049] The central muffler (9) and the rear mufflers (17) have their volumes defined by the shells, and inside the shell, the sound-absorbing materials and their respective internal tubing (10, 18) are applied.

[0050] In a preferred embodiment of the present invention, the sound-absorbing material is made of fiberglass wool.

[0051] In an alternative embodiment of the present invention, the sound-absorbing material is composed of one of the following materials: fibrous porous materials or cellular porous materials.

[0052] In a preferred embodiment of the present invention, the central damper (9) is configured to have a triangular profile, is of the dissipative type, and has between 200 and 400 grams of sound-absorbing material. More preferably, the central damper (9) contains 250 grams of sound-absorbing material.

[0053] In a preferred embodiment of the present invention, the central muffler (9) has a volume between 2 and 3 liters. More preferably, the central muffler (9) has a volume of 2.4 liters.

[0054] In a preferred embodiment of the present invention, the inner tubing of the central muffler (9) has a diameter between 50 mm and 65 mm, a wall thickness between 0.8 mm and 1.5 mm, and is perforated by 500 to 600 holes, each with a diameter between 3 mm and 5 mm. More preferably, the inner tubing of the central muffler (9) has a diameter of 60 mm, a wall thickness of 1.0 mm and 540 perforations, each with a diameter of 3.5 mm.

[0055] In a preferred embodiment of the present invention, the rear dampers (17) are configured with circular profiles, are of the dissipative type, and contain between 100 and 300 grams of sound-absorbing material. More preferably, each rear damper (17) has 100 grams of fiberglass wool.

[0056] In a preferred embodiment of the present invention, the rear mufflers (17) have a volume between 1 and 2 liters. More preferably, each rear muffler (17) has a volume of 1.0 liter. Petition 870250015185, dated 25 / 02 / 2025, page 17 / 28 9 / 10

[0057] In a preferred embodiment of the present invention, the internal tubing of the rear mufflers (17) has a diameter between 45 and 65 mm, a wall thickness between 0.8 mm and 1.5 mm, and is perforated by 200 to 300 holes, each with a diameter between 3 mm and 5 mm. More preferably, the internal tubing of the rear mufflers (17) has a diameter of 50 mm, a wall thickness of 1.0 mm and 280 perforations, each with a diameter of 4.0 mm.

[0058] The present invention discloses three dampers, one central and two rear, which together act on a wide frequency range, filtering mainly those above 500 Hz.

[0059] The present invention further discloses a vehicle comprising at least one vehicle exhaust system (100), as described in this descriptive report.

[0060] The present invention results in an exhaust noise with timbre, tone and intensity suitable for the sports vehicle for which it was developed, being able to transmit all the necessary power and aggressiveness. High frequencies, above 500 Hz, are efficiently attenuated, while low frequencies, especially those below 200 Hz, are emphasized, highlighting the second and main order of the engine, and also bringing the fourth and sixth orders closer to it, which differentiates the presented solution from other solutions.

[0061] In the graph in Figure 7, the highlighted curves correspond to the sporty exhaust noise obtained by the present invention, while the other curves represent existing silent solutions. The measurement condition is: acceleration in fourth gear with WOT (Wide Open Throttle). In Figure 7a, the overall results are presented. In Figure 7b, the results correspond to the second order of the engine. In Figure 7c, the results refer to the fourth order of the engine. In Figure 7d, the sixth-order engine results are presented. The existing solutions do not reflect the necessary sportiness.

[0062] In the context of the present invention, the vehicle's sporty sound signature refers to the acoustic characteristic of the exhaust system, which enhances deep, harmonious and intense sounds, capable of conveying sensations of power and performance, differentiating the vehicle from conventional models. This sound signature is designed to meet the expectations of high-performance vehicle consumers, ensuring a balance between volume and frequency. Petition 870250015185, dated 25 / 02 / 2025, page 18 / 28 10 / 10

[0063] The present invention, by offering an exhaust system configured to provide a sporty sound signature to the vehicle, achieves its objectives by combining elements designed to balance acoustic performance and regulatory compliance. The use of optimized pipes and mufflers, along with durable materials and adjusted dimensional configurations, provides a unique sound experience, consistent with the vehicle's sporty profile. Furthermore, the invention complies with the noise emission limits established by the PROCONVE L7, PL7 standard.

[0064] All combinations of elements that perform the same function in a substantially similar manner, using equivalent methods and producing the same results as the elements specified in the claims, are encompassed within the scope of this invention. This means that even if a variation of elements performs the function in a slightly different way, as long as the result is essentially the same, these variations are also protected by the patent. Furthermore, it is important to emphasize that the protection conferred by this invention is not limited only to the literal content of the claims described, but also covers variations or modifications that may be considered equivalent.

[0065] It is important to note that, although the attached drawings represent the ideas and concepts of the invention, they have not necessarily been drawn to scale and are intended only to conceptually illustrate the possible configurations of the elements. This choice aims to facilitate the understanding of the invention without, however, restricting the interpretation of the claims to a specific or exact dimension. Furthermore, all combinations of elements that perform the same function in an essentially equivalent way, even if they operate slightly differently, are protected by the scope of the invention. Thus, patent protection covers a wide range of potential variations, which may differ in their specific characteristics but produce the same results.This flexibility allows the invention to protect not only the exact forms described, but also other possible variations and modifications, including so-called equivalents, which fall within the broader scope of the claims. Petition 870250015185, dated 25 / 02 / 2025, page 19 / 28

Claims

1 / 3 Claims 1.Vehicle exhaust system (100), characterized by comprising a cold end; wherein, the cold end of the exhaust system (100) comprises: at least one front assembly (1), configured to connect the hot end of the exhaust system (100) with the cold end; at least one center assembly (7), configured to connect the center muffler (9) to the front (1) and rear (12) assemblies; at least one rear assembly (12), configured to have a Y-shaped flow divider (14) and two exhaust tips (19); at least one center muffler (9), configured to have a triangular profile; at least two rear mufflers (17), configured to have circular profiles, and two tips (19), configured to allow the exhaust gases (100) to exit; wherein, the center muffler (9) is located in the center assembly (7); and the rear mufflers (17) are located in the rear assembly (12).

2. Vehicle exhaust system (100), according to claim 1, characterized in that the front assembly (1) includes a flexible element (4), flange (2) and front mounting brackets (6).

3. Vehicle exhaust system (100), according to claim 1, characterized in that the central assembly (7) includes a clamp (A) in its initial portion and has a central muffler (9).

4. Vehicle exhaust system (100), according to claim 1, characterized in that the rear assembly (12) includes an initial section provided with a clamp (B), a Y-shaped flow divider (14), rear mounting brackets (15), two rear mufflers (17), ending with two exhaust tips (19), which allow the exhaust gases to exit.

5. Vehicle exhaust system (100), according to claim 2, characterized in that the front assembly piping (1) has an outer diameter between 65 mm and 75 mm and a wall thickness between 0.8 mm and 1.5 mm. Petition 870250015185, dated 25 / 02 / 2025, page 20 / 28 2 / 3 6. Vehicle exhaust system (100), according to claim 2, characterized in that the flange (2) of the front assembly (1) connects to the hot end of the exhaust.

7. Vehicle exhaust system (100), according to claim 2, characterized in that the flexible element (4) of the front assembly (1) acts as an absorber of vibrations from the engine.

8. Vehicle exhaust system (100), according to claim 3, characterized in that the clamp (A) of the central assembly (7) fixes it to the front assembly (1).

9. Vehicle exhaust system (100), according to claim 3, characterized in that the central assembly piping (7) has an outer diameter between 50 mm and 70 mm and a wall thickness between 0.8 mm and 1.5 mm.

10. Vehicle exhaust system (100), according to claim 4, characterized in that the clamp (B) of the rear assembly (12) fixes it to the central assembly (7).

11. Vehicle exhaust system (100), according to claim 4, characterized in that the piping of the rear assembly (12) has an outer diameter between 50 mm and 60 mm and a wall thickness between 0.8 mm and 1.5 mm.

12. Vehicle exhaust system (100), according to claim 3, characterized in that the central muffler is of the dissipative type, with a volume between 2 and 3 liters.

13. Vehicle exhaust system (100), according to claim 13, characterized in that the central muffler has between 200 and 400 grams of fiberglass wool.

14. Vehicle exhaust system (100), according to claim 13, characterized in that the central muffler has an internal tubular segment, with a diameter between 50 mm and 65 mm, a wall thickness between 0.8 mm and 1.5 mm, containing 500 to 600 holes, with a diameter between 3 mm and 5 mm.

15. Vehicle exhaust system (100), according to claim 4, characterized in that the rear mufflers are of the dissipative type, with a volume between 1 and 2 liters. Petition 870250015185, dated 25 / 02 / 2025, page 21 / 28 3 / 3 16. Vehicle exhaust system (100), according to claim 16, characterized in that the rear mufflers have between 100 and 300 grams of fiberglass wool.

17. Vehicle exhaust system (100), according to claim 16, characterized in that the rear mufflers have internal tubular segments, with diameters between 45 mm and 65 mm, containing 200 to 300 holes, with diameters between 3 mm and 5 mm.

18. Vehicle exhaust system (100), according to claim 1, characterized by providing a sporty sound signature to the vehicle, while meeting the noise emission limits established by regulatory standards.

19. Vehicle exhaust system (100), according to any of the preceding claims, characterized by being made of high-strength steel and having an external coating against corrosion.

20. Vehicle characterized by comprising a vehicle exhaust system (100) as defined by claims 1 to 19. Petition 870250015185, dated 25 / 02 / 2025, pp. 22 / 28

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