Muffler for vehicle

Abstract

A muffler for a vehicle includes: a muffler housing; a baffle plate disposed in the muffler housing and having a first opening and a second opening for allowing exhaust gas to pass therethrough; and a variable valve mounted on the baffle plate. Specifically, the variable valve includes: a valve plate rotatably mounted to open and close the first opening of the baffle plate; a valve stem connected to the valve plate; and a valve actuator for moving the valve stem by a change in the pressure of the exhaust gas. The valve plate is rotatable in a plane parallel to the plane of the baffle plate.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to and the benefit of Korean Patent Application No. 10-2019-0143687, filed on November 11, 2019, which is hereby incorporated by reference in its entirety. Technical Field

[0003] The present disclosure relates to a muffler for a vehicle. Background Art

[0004] The statements in this section merely provide background information related to the present disclosure and may not constitute prior art.

[0005] A muffler for a vehicle receives exhaust gas discharged from an internal combustion engine or a diesel engine to reduce the noise generated by the exhaust gas flow. Typically, a muffler includes a muffler housing, a plurality of baffles disposed within the muffler housing, and a plurality of pipes installed between adjacent baffles. The internal space of the muffler housing may be divided into a plurality of chambers by the plurality of baffles, and a plurality of pipes may pass through adjacent baffles to connect between adjacent chambers. A plurality of micropores may be formed in the wall of each pipe to attenuate sound waves and reduce noise levels.

[0006] In order to reduce exhaust noise, a variable valve can be mounted on any one of a plurality of baffles. The variable valve includes: a valve body having an opening through which exhaust gas passes, a valve plate pivotally mounted on the valve body to open and close the opening of the valve body, and a torsion spring elastically supporting the valve plate. When the pressure of the exhaust gas is greater than the spring force of the torsion spring, the valve plate can be spaced apart from the valve body. When the pressure of the exhaust gas is less than the spring force of the torsion spring, the valve plate can contact the valve body by the elastic force of the torsion spring. When the pressure of the exhaust gas is less than the spring force of the torsion spring (when the pressure of the exhaust gas is relatively low), the torsion spring can be used as a biasing element that applies a spring force (biasing force) to bias the valve plate toward a closed position.

[0007] In a variable valve according to the prior art, as the pressure of the exhaust gas changes, the valve plate is spaced apart from or in contact with the valve body to open and close the opening of the valve body. Therefore, the valve plate moves in the same direction as the direction of the exhaust gas flow. When the valve plate opens and closes the opening of the valve body, noise due to shaking or vibration of the valve plate itself and noise due to contact or impact between the valve plate and the valve body may be generated. In order to prevent such noise, a shock-absorbing material such as a metal mesh may be inserted between the valve plate and the valve body. However, the assembly of additional components such as shock-absorbing materials increases manufacturing costs and weight.

[0008] Expensive materials such as INCONEL are applied by considering corrosion resistance, oxidation resistance, etc. of a torsion spring as a biasing element used in a variable valve in the related art. The size of the torsion spring is larger than that of a coil spring, and its manufacture is relatively difficult, and thus the manufacturing cost and weight are relatively increased.

[0009] The above information described in this Background section is provided to assist in understanding the background of the inventive concept and may include any technical concept that is not considered to be prior art known to those skilled in the art. Summary of the invention

[0010] The present disclosure has been made to solve the above-mentioned problems occurring in the prior art while completely maintaining the advantages achieved by the prior art.

[0011] An aspect of the present disclosure provides a muffler for a vehicle, which is capable of minimizing or preventing various noises generated by opening and closing of a variable valve.

[0012] According to one aspect of the present disclosure, a muffler for a vehicle may include: a muffler housing; a baffle disposed within the muffler housing and having a first opening and a second opening allowing exhaust gas to pass therethrough; and a variable valve mounted on the baffle. Specifically, the variable valve may include: a valve plate rotatably mounted to open and close the first opening of the baffle; a valve stem connected to the valve plate; and a valve actuator configured to move the valve stem by a change in the pressure of the exhaust gas. The valve plate may be rotatable in a plane parallel to the plane of the baffle.

[0013] In one form, the valve plate may be rotatably mounted on the baffle plate by a shaft to maintain contact with the surface of the baffle plate.

[0014] In another form, the valve actuator may include an actuator housing having an accommodation space for receiving the exhaust gas through the second opening, and the accommodation space of the actuator housing may be directly communicated with the second opening of the baffle.

[0015] In other forms, the valve plate may have a lug extending from a peripheral edge thereof, and the lug may be rotatably mounted on the baffle plate via a shaft.

[0016] In some forms of the present disclosure, the valve stem may be moved by the pressure of the exhaust gas contained in the accommodation space of the actuator housing. The lug may have a guide protrusion protruding in a direction away from the baffle, and the valve stem may have a guide recess by which the movement of the guide protrusion is guided. When the valve stem moves, the guide protrusion of the lug may be guided along the guide recess of the valve stem so that the valve plate can rotate.

[0017] In some forms of the present disclosure, the actuator housing may have a guide opening through which movement of the valve stem is guided, and an edge of the actuator housing may be coupled to the baffle by a circumferential weld.

[0018] In some forms of the present disclosure, the valve stem may include a disk located within the accommodation space of the actuator housing, and the disk may have a contact surface with which exhaust gas accommodated in the accommodation space of the actuator housing directly contacts.

[0019] In one form, the disc may have a shape and size that conforms to the receiving space of the actuator housing.

[0020] The contact surface of the disk may be perpendicular to the longitudinal axis of the valve stem.

[0021] The valve actuator may include a spring interposed between an inner surface of the actuator housing and the disk.

[0022] Further areas of applicability will become apparent from the description provided herein.It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] In order that the present disclosure may be better understood, various forms thereof given by way of example will now be described with reference to the accompanying drawings, in which:

[0024] Figure 1 A perspective view showing a muffler for a vehicle according to an exemplary form of the present disclosure;

[0025] Figure 2 Shows Figure 1 an enlarged view of a portion A of;

[0026] Figure 3 Shows from Figure 2 The state of the valve plate opening the first opening of the baffle observed in the direction indicated by arrow B;

[0027] Figure 4 It shows the state where the valve plate closes the first opening of the baffle;

[0028] Figure 5 A perspective view showing a valve plate in a muffler for a vehicle according to an exemplary form of the present disclosure; and

[0029] Figure 6 A perspective view of a valve stem in a muffler for a vehicle according to an exemplary form of the present disclosure is shown.

[0030] The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way. DETAILED DESCRIPTION

[0031] The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features.

[0032] Hereinafter, exemplary forms of the present disclosure will be described in detail with reference to the accompanying drawings. In addition, detailed descriptions of well-known technologies associated with the present disclosure will be excluded so as not to unnecessarily obscure the gist of the present disclosure.

[0033] Terms such as first, second, A, B, (a) and (b) can be used to describe the elements in the exemplary form of the present disclosure. These terms are only used to distinguish one element from another element, and the inherent characteristics, order or sequence of the corresponding elements, etc. are not limited by the terms. Unless otherwise defined, all terms used herein (including technical terms or scientific terms) have the same meaning as the meaning generally understood by those of ordinary skill in the field to which the present disclosure belongs. Terms such as those defined in commonly used dictionaries should be interpreted as having the same meaning as the contextual meaning in the relevant technical field, and should not be interpreted as having an ideal or overly formal meaning, unless clearly defined in the present application as having such meaning.

[0034] refer to Figures 1 to 6 A muffler 10 for a vehicle according to an exemplary form of the present disclosure may include: a muffler housing 11; a plurality of baffles 12, 13 and 14 disposed in the muffler housing 11; and a plurality of pipes 15, 16 and 17 installed between adjacent baffles 12, 13 and 14.

[0035] The internal space of the muffler housing 11 can be divided into a plurality of chambers 11a, 11b, 11c and 11d by a plurality of baffles 12, 13 and 14, and a plurality of pipes 15, 16 and 17 can pass through adjacent baffles to connect between adjacent chambers. A plurality of micropores can be formed in the wall of each pipe to attenuate sound waves and reduce noise levels.

[0036] The muffler 10 for a vehicle may include a variable valve 20 installed on at least one baffle 12 of a plurality of baffles 12, 13, and 14. The baffle 12 may have a first opening 31 and a second opening 32 that allow exhaust gas to pass therethrough. The first opening 31 may be opened and closed by the variable valve 20 according to changes in the pressure of the exhaust gas.

[0037] refer to Figure 2 The variable valve 20 may include a valve plate 21 that opens and closes the first opening 31 of the damper 12 , a valve arm 22 connected to the valve plate 21 , and a valve actuator 25 that linearly moves the valve arm 22 by a change in the pressure of the exhaust gas.

[0038] The valve plate 21 may be rotatably mounted by the shaft 24 to be adjacent to the first opening 31 of the baffle 12. The diameter of the valve plate 21 may be greater than the diameter of the first opening 31, and the axis of the shaft 24 may be perpendicular to the baffle 12. When the valve plate 21 rotates about the shaft 24, the valve plate 21 may open and close the first opening 31. Specifically, the valve plate 21 may rotate in a first rotation direction R1 or a second rotation direction R2. The first rotation direction R1 refers to the rotation direction of the valve plate 21 opening the first opening 31, and the second rotation direction R2 refers to the rotation direction of the valve plate 21 closing the first opening 31.

[0039] Specifically, the valve plate 21 may be mounted on the baffle 12 by the shaft 24 to slidably rotate on the surface of the baffle 12. Specifically, the valve plate 21 may be rotatably mounted to the baffle 12 by the shaft 24 so that when the valve plate 21 rotates (i.e., the first opening 31 of the baffle 12 is opened and closed), the valve plate 21 may remain in contact with the baffle 12. In particular, the valve plate 21 may be able to rotate in a plane parallel to the plane of the baffle 12. Therefore, even when the valve plate 21 is slightly spaced apart from the baffle 12, shaking or vibration of the valve plate itself may be prevented.

[0040] The valve plate 21 may have a lug 23 extending radially outward from its outer peripheral edge, and the lug 23 may be rotatably mounted on the baffle 12 via a shaft 24. A guide protrusion 28 may protrude from a free end of the lug 23 in a direction away from the baffle 12. The axis of the guide protrusion 28 may be perpendicular to the longitudinal axis of the lug 23. For example, the axis of the guide protrusion 28 may be parallel to the axis of the shaft 24.

[0041] The valve stem 22 may be in the shape of a rod having a predetermined length. The valve stem 22 may have a first end 41 connected to the valve plate 21 and a second end 42 connected to the valve actuator 25. The valve stem 22 may be linearly moved by the valve actuator 25. Specifically, the valve stem 22 may be moved in a first direction F1 or a second direction F2. The first direction F1 refers to a direction in which the first end 41 of the valve stem 22 is away from the valve actuator 25, and the second direction F2 refers to a direction in which the first end 41 of the valve stem 22 is close to the valve actuator 25.

[0042] The valve stem 22 may have a guide recess 45 by which the movement of the guide protrusion 28 of the valve plate 21 is guided.

[0043] For example, Figures 2 to 4 and Figure 6As shown, the valve stem 22 may have two fingers 43 and 44 extending from the first end 41 toward the valve plate 21, and a guide recess 45 defined by the fingers 43 and 44. Since the guide recess 45 is defined by the two fingers 43 and 44, the guide recess 45 may be a groove with one end open (i.e., an open-end groove). Since the two fingers 43 and 44 are spaced apart from each other in the longitudinal direction of the valve stem 22, the guide recess 45 may be defined by the fingers 43 and 44.

[0044] The length of the guide recess 45 may be greater than the diameter of the guide protrusion 28, so that the guide protrusion 28 of the valve plate 21 may be guided along the guide recess 45 of the valve stem 22. Therefore, the linear movement of the valve stem 22 may be converted into the rotational movement of the valve plate 21.

[0045] As another example, the guide recess 45 may be an arc-shaped groove with both ends closed. The guide recess 45 may be formed in the first end 41 of the valve stem 22 or in a portion of the valve stem 22 adjacent to the first end 41 .

[0046] refer to Figure 3 , Figure 4 and Figure 6 , the valve stem 22 may have a disc 46 attached to the second end portion 42, and the disc 46 may have a contact surface 46a with which the exhaust gas passing through the second opening 32 directly contacts. The disc 46 may have a predetermined area such as a circular cross-section, and the contact surface 46a of the disc 46 may be perpendicular to the longitudinal axis of the valve stem 22, so that the contact area between the contact surface 46a of the disc 46 and the exhaust gas can be ensured. Therefore, the disc 46 may be sensitive to changes in the pressure of the exhaust gas, so that the pressure of the exhaust gas can be effectively transmitted to the valve stem 22. The valve actuator 25 may drive the valve stem 22 and the valve plate 21 using the pressure of the exhaust gas.

[0047] According to an exemplary form, the valve actuator 25 may include an actuator housing 26 coupled to the baffle 12 to surround the second opening 32 of the baffle 12. The actuator housing 26 may have a space 26a for accommodating the exhaust gas that has passed through the second opening 32 of the baffle 12. The valve stem 22 may be linearly moved by a change in the pressure of the exhaust gas accommodated in the space 26a of the actuator housing 26.

[0048] The actuator housing 26 may be coupled to the baffle plate 12 by welding or the like, and the accommodation space 26a of the actuator housing 26 may be directly communicated with the second opening 32 of the baffle plate 12. The disk 46 of the valve stem 22 may be located within the accommodation space 26a of the actuator housing 26, and the contact surface 46a of the disk 46 may directly contact the exhaust gas having passed through the second opening 32 of the baffle plate 12.

[0049] According to an exemplary form, the disk 46 may have a shape and size consistent with the accommodation space 26 a of the actuator housing 26 so that the disk 46 and the valve stem 22 may be more easily moved by changes in the pressure of the exhaust gas accommodated in the space 26 a .

[0050] The actuator housing 26 may have a guide opening 26b, and the guide opening 26b of the actuator housing 26 may guide the movement of the valve stem 22. Specifically, the edge of the actuator housing 26 may be coupled to the baffle 12 by circumferential welding. Therefore, the actuator housing 26 may be tightly sealed from the outside except for the second opening 32 and the guide opening 26b.

[0051] The valve actuator 25 may include a spring 27 inserted between the inner surface of the actuator housing 26 and the disk 46. The spring 27 may be a coil spring disposed around the valve stem 22, and the axis of the spring 27 may be aligned with the axis of the valve stem 22. When the pressure of the exhaust gas is less than the spring force of the spring 27 (i.e., the pressure of the exhaust gas is relatively low), the spring 27 may function as a biasing element that applies a spring force (biasing force) to bias the valve plate 21 toward the closed position.

[0052] refer to Figure 3 When the pressure of the exhaust gas contained in the space 26a of the actuator housing 26 through the second opening 32 is greater than the spring force of the spring 27, the exhaust gas contained in the space 26a of the actuator housing 26 can push the contact surface 46a of the disk 46 of the valve stem 22 to allow the valve stem 22 to move in the first direction F1. When the guide protrusion 28 of the valve plate 21 moves along the guide recess 45 of the valve stem 22, the valve plate 21 can rotate in the first rotation direction R1, and the valve plate 21 can open the first opening 31.

[0053] refer to Figure 4 When the pressure of the exhaust gas contained in the space 26a of the actuator housing 26 passing through the second opening 32 is less than the elastic force of the spring 27, the elastic force of the spring 27 can overcome the pressure of the exhaust gas to allow the valve stem 22 to move in the second direction F2. When the guide protrusion 28 of the valve plate 21 moves along the guide recess 45 of the valve stem 22, the valve plate 21 can rotate in the second rotation direction R2, and the valve plate 21 can close the first opening 31.

[0054] As described above, according to an exemplary form of the present disclosure, the valve plate 21 can be slidably rotated around the first opening 31 of the baffle 12 of the muffler 10, thereby opening and closing the first opening 31 of the baffle 12. Since the valve plate 21 and the baffle 12 are not spaced apart from each other, noise caused by shaking or vibration of the valve plate itself and noise caused by impact between the valve plate and the valve body can be prevented or minimized.

[0055] According to an exemplary form of the present disclosure, when the valve plate 21 opens and closes the first opening 31 of the baffle 12 , the valve plate 21 may maintain contact with the baffle 12 without a shock absorbing material, and thus weight and manufacturing costs may be reduced.

[0056] According to an exemplary form of the present disclosure, the spring 27 can be used as a biasing element for biasing the valve plate 21 under low pressure conditions of the exhaust gas, and thus the axial elasticity of the spring 27 can be used as a whole, so that the driving stability and driving performance of the valve plate 21 can be ensured. At the same time, according to the prior art, a torsion spring can be used as a biasing element. On the other hand, according to an exemplary form of the present disclosure, the spring 27 can be used as a biasing element. Since the size of the spring is significantly reduced, the consumption of materials (e.g., INCONEL) can be reduced, and thus the manufacturing cost and weight can be reduced.

[0057] Hereinabove, although the present disclosure has been described with reference to exemplary forms and drawings, the present disclosure is not limited thereto but may be variously modified and changed by those skilled in the art to which the present disclosure pertains without departing from the spirit and scope of the present disclosure.

Claims

1. A muffler for a vehicle, the muffler comprising: Muffler housing; a baffle disposed within the muffler housing and having a first opening and a second opening for allowing exhaust gas to pass therethrough; as well as A variable valve, mounted on the baffle, in: The variable valve comprises: a valve plate rotatably mounted to open and close the first opening of the baffle, a valve stem connected to the valve plate, and a valve actuator configured to move the valve stem by a change in the pressure of the exhaust gas, The valve plate is rotatable in a plane parallel to the baffle, and The valve plate is rotatably mounted on the baffle plate via a shaft so as to maintain contact with the surface of the baffle plate; wherein the valve actuator comprises an actuator housing, the actuator housing having an accommodation space for receiving the exhaust gas passing through the second opening, and the accommodation space of the actuator housing is directly connected to the second opening of the baffle; wherein the valve plate has a lug extending from its outer peripheral edge, and the lug is rotatably mounted on the baffle plate via the shaft; wherein the valve stem is moved by the pressure of the exhaust gas contained in the accommodating space of the actuator housing, the lug has a guide protrusion protruding in a direction away from the baffle, the valve stem has a guide recess through which the movement of the guide protrusion is guided, and When the valve stem moves, the guide protrusion of the lug is guided along the guide recess of the valve stem, so that the valve plate rotates.

2. The muffler according to claim 1, wherein: The actuator housing has a guide opening through which movement of the valve stem is guided, and The edge of the actuator housing is coupled to the baffle by circumferential welding.

3. The muffler according to claim 1, wherein: The valve stem includes a disk located within the receiving space of the actuator housing, and The disk has a contact surface with which the exhaust gas accommodated in the accommodation space of the actuator housing directly contacts.

4. The muffler according to claim 3, wherein: The disk has a shape and size that conform to the accommodation space of the actuator housing.

5. The muffler according to claim 3, wherein: The contact surface of the disk is perpendicular to the longitudinal axis of the valve stem.

6. The muffler according to claim 3, wherein: The valve actuator includes a spring inserted between an inner surface of the actuator housing and the disk.

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