Exhaust system resonator pipe for reducing standing waves

Abstract

A muffler assembly for an exhaust system is in fluid communication with a collector via an exhaust conduit. The muffler assembly includes a first pipe, a valve, a second pipe, a tuner pipe, and a discharge port. The first pipe extends through a closed volume of the muffler. The valve is operable to restrict flow through the first pipe. A resonance section is defined by a section of the exhaust system extending from the collector to the valve when a standing wave is present. The tuner pipe includes an open tuner pipe end in fluid communication with the first pipe, and a closed tuner pipe end. A tuner pipe section of the tuner pipe is substantially a quarter of the resonance section. The discharge port is formed in the first pipe, allows fluid communication with the closed volume, and is positioned downstream of the open tuner pipe end.

Description

TECHNICAL FIELD

[0001] The present disclosure relates to an exhaust system for vehicle engine exhaust emissions, and in particular, to an exhaust system having a resonator pipe for reducing standing waves. BACKGROUND

[0002] This section provides background information for the present disclosure which is not necessarily prior art.

[0003] Internal combustion engines can generate a significant amount of combustion noise that propagates through the exhaust system and sounds like the noise of the exhaust pipe. A muffler is used within the exhaust system to reduce this noise and / or tune the exhaust sound characteristics to a desired sound quality. An electronic exhaust valve can be installed within the exhaust system to control the flow through a first pipe of the muffler. When the electronic exhaust valve is closed, the exhaust system can emit a humming or standing wave in the exhaust system, but when the electronic exhaust valve is open, the standing wave is not produced. The present disclosure provides a resonator pipe connected to the first pipe to attenuate the standing wave. SUMMARY

[0004] This section provides a general summary of the disclosure, and is not a comprehensive disclosure of its full scope or all of its features.

[0005] According to one aspect of the present disclosure, a muffler assembly for an exhaust system of a vehicle engine is provided. The exhaust system includes a collector and an exhaust conduit that provides exhaust emissions to the muffler assembly. The muffler assembly includes a housing, a first pipe, a valve, a resonance section, a second pipe, a resonator pipe, and a discharge port. The housing defines an enclosed volume. The first pipe includes a first pipe inlet and a first pipe outlet. The first pipe extends through the enclosed volume of the muffler. The valve is operable to restrict flow through the first pipe. The resonance section is defined by a section of the exhaust system extending from the collector of the vehicle engine to the valve. The second pipe includes a second pipe inlet and a second pipe outlet. The second pipe inlet is positioned in fluid communication with the enclosed volume. The second pipe outlet is positioned outside of the enclosed volume. The resonator pipe includes an open resonator pipe end and a closed resonator pipe end. The open resonator pipe end is in fluid communication with the first pipe. The closed resonator pipe end is opposite the open resonator pipe end. A resonator pipe section of the resonator pipe is substantially one quarter of the resonance section. The discharge port is formed in the first pipe and is in fluid communication with the enclosed volume. The discharge port is positioned downstream of the open resonator pipe end.

[0006] In some aspects of the muffler assembly of any one or more of the above paragraphs, the muffler assembly includes a first baffle and a second baffle. The first baffle cooperates with the housing to define a first compartment. The second baffle cooperates with the housing to define a third compartment. The second compartment is positioned between the first baffle and the second baffle. Each of the first baffle and the second baffle includes at least one perforation that allows the second compartment to be in fluid communication with the first compartment and the third compartment.

[0007] In some aspects of the muffler assembly of any one or more of the above paragraphs, the tuner tube is positioned within the first compartment and the second compartment.

[0008] In some aspects of the muffler assembly of any one or more of the above paragraphs, the discharge port is positioned within the first compartment.

[0009] In some aspects of the muffler assembly of any one or more of the above paragraphs, the second conduit inlet is positioned within the third compartment.

[0010] In some aspects of the muffler assembly of any one or more of the above paragraphs, the at least one baffle is disposed within the housing and cooperates with the housing to define a plurality of compartments within the housing. The at least one baffle includes at least one perforation that allows fluid communication between adjacent compartments.

[0011] In some aspects of the muffler assembly of any one or more of the above paragraphs, the open tuner tube end is spaced apart from the collector by a distance that is about 0% to about 10% of the resonant section.

[0012] In some aspects of the muffler assembly of any one or more of the above paragraphs, the open tuner tube end is spaced apart from the valve by a distance that is about 0% to about 10% of the resonant section.

[0013] In some aspects of the muffler assembly of any one or more of the above paragraphs, the muffler assembly includes a discharge tube. The discharge tube includes a first discharge tube end that is in fluid communication with the first conduit, and a second discharge tube end. The discharge port is disposed at the second discharge tube end.

[0014] In some aspects of the muffler assembly of any one or more of the above paragraphs, the discharge port is at least one perforation.

[0015] The present disclosure also provides a muffler assembly including a housing, a first conduit, a first valve, a first resonance section, a second conduit, a third conduit, a first tuner tube, and a first discharge port. The housing defines an enclosed volume. The first conduit includes a first conduit inlet and a first conduit outlet. The first conduit extends through the enclosed volume. The first valve is operable to restrict flow through the first conduit. The first resonance section is defined by a section of the exhaust system extending from a collector of a vehicle engine to the valve. The second conduit includes a second conduit inlet and a second conduit outlet. The second conduit inlet is positioned in fluid communication with the enclosed volume. The second conduit outlet is positioned outside of the enclosed volume. The third conduit includes a third conduit inlet and a third conduit outlet. The third conduit extends through the enclosed volume. The first tuner tube includes a first open tuner tube end in fluid communication with the first conduit and a first closed tuner tube end opposite the open tuner tube end. A first tuner tube section of the first tuner tube is substantially one quarter of the first resonance section. The first discharge port is formed in the first conduit and is in fluid communication with the enclosed volume. The first discharge port is positioned downstream of the first open tuner tube end.

[0016] In some configurations of the muffler assembly of any one or more of the above paragraphs, the muffler assembly further includes a second valve, a second resonance section, a second tuner tube, and a second discharge port. The second valve is operable to restrict flow through the third conduit. The second resonance section is defined by a section of the exhaust system extending from a collector of a vehicle engine to the second valve. The second tuner tube includes a second open tuner tube end in fluid communication with the third conduit and a second closed tuner tube end opposite the second open tuner tube end. A second tuner tube section of the second tuner tube is substantially one quarter of the second resonance section. The second discharge port is formed in the third conduit and is in fluid communication with the enclosed volume. The second discharge port is positioned downstream of the second open tuner tube end.

[0017] In some configurations of the muffler assembly of any one or more of the above paragraphs, the muffler assembly further includes a fourth conduit. The fourth conduit includes a fourth conduit inlet positioned in fluid communication with the enclosed volume and a fourth conduit outlet positioned outside of the enclosed volume.

[0018] In some configurations of the muffler assembly of any one or more of the above paragraphs, a third distance between the third conduit inlet and the second discharge port is greater than a fourth distance between the third conduit inlet and the second open tuner tube end.

[0019] In some configurations of the muffler assembly of any one or more of the above paragraphs, a first distance between the first conduit inlet and the first discharge port is greater than a second distance between the first conduit inlet and the first open tuner tube end.

[0020] In some configurations of the muffler assembly of any one or more of the above paragraphs, the muffler assembly further includes a first baffle and a second baffle. The first baffle cooperates with the housing to define a first compartment. The second baffle cooperates with the housing to define a third compartment. The second compartment is positioned between the first baffle and the second baffle. Each of the first baffle and the second baffle includes at least one perforation that allows the second compartment to be in fluid communication with the first compartment and the third compartment.

[0021] The present disclosure also provides a muffler assembly including a housing, a first baffle, a second baffle, a first conduit, a valve, a resonance section, a second conduit, a tuner tube, and a discharge port. The housing defines an enclosed volume. The first baffle cooperates with the housing to define a first compartment. The second baffle cooperates with the housing to define a third compartment. The second compartment is positioned between the first baffle and the second baffle. Each of the first baffle and the second baffle includes at least one perforation that allows the second compartment to be in fluid communication with the first compartment and the third compartment. The first conduit includes a first conduit inlet and a first conduit outlet. The first conduit extends through the enclosed volume. The valve is operable to restrict flow through the first conduit. The resonance section is defined by a section of the exhaust system extending from a collector of a vehicle engine to the valve. The second conduit includes a second conduit inlet positioned in fluid communication with the enclosed volume and a second conduit outlet positioned outside of the enclosed volume. The tuner tube includes an open tuner tube end in fluid communication with the first conduit and a closed tuner tube end opposite the open tuner tube end. A tuner tube section of the tuner tube is substantially one quarter of the resonance section. The discharge port is formed in the first conduit and is in fluid communication with the enclosed volume. The discharge port is positioned downstream of the open tuner tube end.

[0022] In some configurations of the muffler assembly of any one or more of the above paragraphs, the open tuner tube end is positioned in the first compartment and the closed tuner tube end is positioned in the second compartment.

[0023] In some configurations of the muffler assembly of any one or more of the above paragraphs, the valve is positioned within the enclosed volume.

[0024] In some configurations of the muffler assembly of any one or more of the above paragraphs, the valve is positioned outside of the enclosed volume.

[0025] Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure. BRIEF DESCRIPTION OF DRAWINGS

[0026] The drawings described herein are for purposes of illustration only and are not intended to limit the scope of the present disclosure.

[0027] Figure 1 is a schematic view of a vehicle engine and exhaust system having a muffler assembly in accordance with the principles of the present disclosure.

[0028] Figure 2 is a front view of an example muffler assembly.

[0029] Figure 3 is Figure 2 is a perspective view of the example muffler assembly shown in

[0030] Figure 4 is Figure 2 and Figure 3 is an exploded perspective view of the example muffler assembly shown in

[0031] Figure 5 is a schematic view of another example muffler assembly in accordance with the principles of the present disclosure, including arrows for showing a closed valve flow path, an open valve flow path, and an intermediate open valve flow path.

[0032] Figure 6 is a schematic view of yet another example muffler assembly in accordance with the principles of the present disclosure, including additional arrows for showing a closed valve flow path, an open valve flow path, an intermediate open valve flow path, a second closed valve flow path, a second open valve flow path, and a second intermediate open valve flow path.

[0033] Corresponding reference characters indicate corresponding parts throughout the several views of the drawings. DETAILED DESCRIPTION

[0034] A more complete understanding of example embodiments can be attained by reference to the following detailed description when taken in conjunction with the accompanying drawings, wherein:

[0035] The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used herein, the singular forms "a," "an," and "the" can be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms "comprises," "comprising," "including," and "having," are inclusive and therefore specify the presence of stated features, integers, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their

[0036] When an element or layer is referred to as being "on," "engaged to," "connected to," or "coupled to" another element or layer, it can be directly on, engaged, connected, or coupled to the other element or layer, or one or more intervening elements or layers can be present. In contrast, when an element is referred to as being "directly on," "directly engaged to," "directly connected to," or "directly coupled to" another element or layer, there are no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., "between" versus "directly between," "adjacent" versus "directly adjacent," etc.). As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed items.

[0037] Although the terms first, second, third, etc. can be used herein to describe various elements, components, regions, layers and / or sections, these elements, components, regions, layers and / or sections should not be limited by these terms. These terms can be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as "first," "second," and other numerical terms as used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example embodiments.

[0038] Spatially relative terms, such as "inner," "outer," "beneath," "below," "lower," "above," "upper," and the like, can be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. Spatially relative terms can be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as "below" or "beneath" other elements or features would then be oriented "above" the other elements or features. Thus, the example term "below" can encompass both an orientation of above and below. The device can be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

[0039] With reference to Figure 1 and Figure 2 A vehicle engine 10 is provided and is operable to discharge exhaust emissions into an exhaust system 12. The vehicle engine 10 can include a first bank of cylinders and a second bank of cylinders positioned opposite the first bank of cylinders. In-line cylinder configurations are also common.

[0040] The exhaust system 12 can include one or more exhaust manifolds 14, a collector 16, an exhaust conduit 18, and a muffler assembly 20. Typically, one exhaust manifold 14 is mounted to the vehicle engine 10 in fluid communication with either the first bank of cylinders or the second bank of cylinders. The exhaust manifold can extend between a mounting face 22 or mounting flange 24 and an exhaust manifold outlet end 26. The collector 16 can be integrally formed with the exhaust manifold 14 at the exhaust manifold outlet end 26 or can be a separate component provided at the exhaust manifold outlet end 26. The collector 16 is the portion of the exhaust system 12 that combines the flow of gases from each individual cylinder of the vehicle engine 10 into an exhaust passageway 28 of the exhaust conduit 18. The collector 16 can extend between a collector inlet 30 and a collector outlet 32.

[0041] More specifically, each exhaust manifold 14 can include a branch 34 associated with each cylinder. In the depicted exemplary vehicle engine 10 (a V8 engine), each exhaust manifold includes a first branch 36, a second branch 38, a third branch 40, and a fourth branch 42. The first branch 36 extends between the mounting flange 24 and the collector 16. Each of the second branch 38, the third branch 40, and the fourth branch 42 also extend from the mounting flange 24 to the collector 16. The mounting flange 24 abuts the vehicle engine 10 to place the first branch 36, the second branch 38, the third branch 40, and the fourth branch 42 of the exhaust manifold 14 in fluid communication with a cylinder bank (not shown) of the vehicle engine 10. In some configurations, the first branch 36 and the second branch 38 can join in fluid communication with one another upstream of the collector inlet 30. The third branch 40 and the fourth branch 42 can also join together in fluid communication with one another upstream of the collector inlet 30. Regardless, all of the cylinders of a representative cylinder bank are in fluid communication with one another within the collector 16. The opposite cylinder bank is equipped with another exhaust manifold 14 that is generally a mirror image of the aforementioned exhaust manifold 14.

[0042] The exhaust conduit 18 is positioned downstream of the collector 16 and receives the gases expelled from the collector 16. The exhaust conduit 18 extends between the collector outlet 32 and the muffler assembly 20. The exhaust conduit 18 can include a catalytic converter 44, one or more flexible bellows 46, and / or additional connecting piping 48. The catalytic converter 44 treats the exhaust gases and the flexible bellows 46 dampen movements that occur in the exhaust system 12, if the vehicle is so equipped. The gases expelled from the exhaust conduit 18 are provided to the muffler assembly 20.

[0043] The muffler assembly 20 can be shaped to fit within a given available space on a vehicle (not shown). For example, in some configurations, the muffler assembly 20 can be shaped to fit within a spare tire well of the vehicle and / or around other components at or near the chassis of the vehicle.

[0044] The muffler assembly includes a housing 50, a first conduit 52 extending through at least one wall 54 of the housing 50, a second conduit 56 extending through the at least one wall 54 of the housing 50, and a valve 58. The first conduit 52 can extend through the housing 50 between a first conduit inlet 60 and a first conduit outlet 62. The first conduit inlet 60 is in fluid communication with the collector 16 via the exhaust conduit 18. In other words, the first conduit inlet 60 receives exhaust gas from the exhaust conduit 18. The valve 58 is operable to restrict the flow of exhaust gas through the first conduit 52. The valve 58 can be an electrically operated valve, and its range of operating positions is from a fully open position to a fully closed position. The precise position of the valve 58 depends on the performance characteristics desired for the muffler assembly 20. The fully open position of the valve 58 allows exhaust gas to pass freely through the first conduit 52 and exit the first conduit outlet 62. The fully closed position of the valve 58 restricts the flow of exhaust gas through the first conduit outlet 62 and redirects the flow of exhaust gas through the muffler assembly 20. In the configuration shown in the drawings, the valve 58 is positioned downstream and outside of the housing 50. Alternatively, the valve 58 can be positioned inside the housing 50.

[0045] The drawings illustrate a closed-closed system defined when the first conduit outlet 62 is closed via the valve 58. More specifically, the closed-closed system can be presented when the valve 58 is at the fully closed position at one end of the system and the exhaust manifold 14 is disposed at the opposite end of the system. A standing wave can be created in the closed-closed system when two waves move in opposite directions. The standing wave can extend from the collector outlet 32 to the valve 58. A resonance section 66 is defined as the distance along the centerline of the exhaust conduit 18 and the first conduit 52 from the collector outlet 32 to the valve 58. The standing wave can produce audible frequencies that are objectionable to customers. Therefore, it is desirable to attenuate, eliminate, or otherwise reduce and minimize the standing wave.

[0046] With reference to Figures 2 to 4 , the muffler assembly 20 is operable to reduce noise and tune the characteristics of the exhaust sound to a desired sound quality. In the configuration shown in the drawings, the housing 50 includes an inner housing surface 68, an outer housing surface 70, a first shell 72, and a second shell 74. The first shell 72 can be welded, mechanically locked, or otherwise sealingly secured to the second shell 74 to define an enclosed volume 76. Additionally, the housing 50 can include an inlet opening 78, a first outlet opening 80, and a second outlet opening 82. A one-piece housing is also contemplated.

[0047] The muffler assembly includes a tuner tube 84. A tuner tube section 86 of the tuner tube 84 is substantially one-quarter the size of the resonant section 66. In this case, "substantially one-quarter" refers to a section that need not be exactly one-quarter the size of the resonant section 66 but is within a tolerance of plus or minus 5% of the resonant section 66. The tuner tube 84 has an outer tuner tube surface 88 and a tuner tube diameter 90.

[0048] The tuner tube 84 extends between an open tuner tube end 92 and a closed tuner tube end 94. The tuner tube 84 may include one or more bends or turns. The open tuner tube end 92 opens into the first conduit 52 and allows fluid communication between the tuner tube 84 and the first conduit 52. The closed tuner tube end 94 is sealed by a tube cap 96. The tuner tube 84 is operable to attenuate standing waves. The optimal position for the open tuner tube end 92 is at a high sound pressure location within the exhaust system 12. More specifically, the position of the open tuner tube end 92 is optimal when the distance from the valve 58 is approximately 0% to approximately 10% of the resonant section 66. Alternatively, the position of the open tuner tube end 92 is optimal when the distance from the collector outlet 32 ​​is approximately 0% to approximately 10% of the resonant section 66.

[0049] The muffler assembly 20 may further include an exhaust pipe 100. The exhaust pipe 100 extends between a first exhaust pipe end 102 and a second exhaust pipe end 104. The exhaust pipe 100 may include one or more bends or bends. The exhaust pipe has an outer exhaust pipe surface 106 and an exhaust pipe diameter 108.

[0050] A first discharge pipe end 102 opens into the first conduit 52 and allows fluid communication between the first conduit 52 and the discharge pipe 100. A second discharge pipe end 104 defines a discharge port 110, placing the second discharge pipe end 104 in fluid communication with the enclosed volume 76. The first discharge pipe end 102 is positioned downstream of the open tuner pipe end 92. A first distance 112 is defined between the first conduit inlet 60 and the first discharge pipe end 102. A second distance 114 is defined between the first conduit inlet 60 and the open tuner pipe end 92. When the first distance 112 is greater than the second distance 114, the discharge pipe 100 is positioned downstream of the open tuner pipe end 92. In other words, the tuner pipe 84 is positioned upstream of the discharge pipe 100.

[0051] The first conduit 52 has an outer first conduit surface 116 and a first conduit diameter 118. The first conduit 52 can include one or more elbows or bends. In the illustrated configuration, the first conduit 52 can include a first inlet conduit 120, a first connecting conduit 122, and a first outlet conduit 124. The first connecting conduit 122 can extend between a first connecting end 126 and a second connecting end 128. The first inlet conduit 120 can be positioned outside of the housing 50 and fluidly coupled to the first connecting end 126 of the first connecting conduit 122 at the inlet opening 78 of the housing 50. The first connecting conduit 122 can be disposed within the enclosed volume 76. The first outlet conduit 124 can be positioned outside of the housing 50 and fluidly coupled to the second connecting end 128 of the first connecting conduit 122 at the first outlet opening 80 of the housing 50. Gas can enter the housing 50 from the exhaust conduit 18 via the first inlet conduit 120, flow through the housing 50 via the first connecting conduit 122, and exit the housing 50 via the first outlet conduit 124. The first outlet conduit 124 can open to the ambient environment surrounding the muffler assembly 20 or can be coupled to another exhaust system component, such as an exhaust pipe (not shown), outside of the muffler assembly 20.

[0052] The second conduit 56 has an outer second conduit surface 130 and a second conduit diameter 132. The second conduit 56 can extend between a second conduit inlet 134 and a second conduit outlet 136. The second conduit inlet 134 opens to and is in fluid communication with the enclosed volume 76, and the second conduit outlet 136 is positioned outside of the housing 50. The second conduit 56 can include one or more elbows or bends. The second conduit 56 can include a second inlet conduit 138, a second communicating conduit 140, and a second outlet conduit 142. The second communicating conduit 140 can extend between a third connecting end 144 and a fourth connecting end 146. The third connecting end 144 of the second communicating conduit 140 can be fluidly coupled to the second inlet conduit 138. The fourth connecting end 146 of the second communicating conduit 140 can be fluidly coupled to the second outlet conduit 142 at the second outlet opening 82. The second outlet conduit 142 can open to the ambient environment surrounding the muffler assembly 20 or can be coupled to another exhaust system component, such as an exhaust pipe (not shown), outside of the muffler assembly 20.

[0053] The shape and diameter of the conduits can be tailored to achieve a desired sound range and desired performance characteristics over a given engine speed range. For example, Figures 2 to 41 depicts the embodiment where the tuner tube diameter 90 is larger than the exhaust tube diameter 108. Additionally, the first conduit diameter 118 is larger than the tuner tube diameter 90, the exhaust tube diameter 108, and the second conduit diameter 132. Due to the difference between the first conduit diameter 118 and the exhaust tube diameter 108, when the valve 58 is open, a greater flow rate of exhaust gas can be discharged from the first conduit outlet 62 than if it were to move through the exhaust tube 100 into the enclosed volume 76.

[0054] The muffler assembly 20 may have baffles 148 disposed within the enclosed volume 76 and cooperating with the housing 50 to define one or more compartments 150 within the enclosed volume 76. The number of baffles, the number of compartments, and / or the volume of the compartments may not affect the performance of the tuner tube 84. Rather, the number and placement of the one or more baffles 148 may depend on the desired mechanical support of the housing 50 and / or the desired performance characteristics of the muffler assembly 20. Figure 3 and Figure 4 As shown, a first baffle 152 and a second baffle 154 are disposed within the enclosed volume 76. The second baffle 154 is spaced apart from the first baffle 152. Each of the first baffle 152 and the second baffle 154 may include an outer perimeter 156 shaped to generally match the contour of the interior housing surface 68. The outer perimeter 156 may be welded, mechanically locked, or otherwise sealingly secured to the interior housing surface 68.

[0055] The first deflector 152 and the second deflector 154 can divide the enclosed volume 76 into a first compartment 158, a second compartment 160, and a third compartment 162. The first compartment 158 ​​can be defined by the first deflector 152, the first housing 72, and the second housing 74. The second compartment 160 can be defined by the first deflector 152, the second deflector 154, the first housing 72, and the second housing 74. The third compartment 162 can be defined by the second deflector 154, the first housing 72, and the second housing 74. Therefore, the second compartment 160 can be positioned between the first compartment 158 ​​and the third compartment 162.

[0056] Each of the first baffle 152 and the second baffle 154 may include one or more perforations 164 to allow fluid communication between adjacent compartments. The number and placement of the one or more perforations 164 may depend on the desired performance of the muffler assembly 20. A greater number of perforations allows for greater fluid flow of gas between adjacent compartments, while a smaller number of perforations can restrict the flow of gas between adjacent compartments. Figure 3 and Figure 4In the illustrated configuration, the first baffle 152 and the second baffle 154 contain a plurality of perforations 164. The perforations 164 in the first baffle 152 allow fluid communication between the first compartment 158 and the second compartment 160. The perforations 164 in the second baffle 154 allow fluid communication between the second compartment 160 and the third compartment 162. Additionally, each of the first baffle 152 and the second baffle 154 can include one or more baffle openings 166 for a duct to extend through the first compartment 158, the second compartment 160, and the third compartment 162. The one or more baffle openings 166 are coupled to the respective duct and can not allow fluid communication of the enclosed volume 76 between adjacent compartments. The first baffle 152 can include a first baffle opening 168 and a second baffle opening 170. The second baffle 154 can include a third baffle opening 172.

[0057] The first duct 52 and the drain tube 100 can be positioned within the first compartment 158. The tuner tube 84 can extend from the first compartment 158 through the first baffle 152 and into the second compartment 160 via the first baffle opening 168. Thus, the open tuner tube end 92 can be positioned within the first compartment 158, and the closed tuner tube end 94 can be positioned within the second compartment 160. Next, the drain tube 100 can be positioned within the first compartment 158. Finally, the second duct 56 can extend through the second baffle 154 between the second compartment 160 and the third compartment 162 via the third baffle opening 172, and through the first baffle 152 between the second compartment 160 and the first compartment 158 via the second baffle opening 170. Thus, the second duct inlet 134 can be open to and in fluid communication with the third compartment 162.

[0058] One or more brackets 174 can be provided within the housing 50 to provide additional support between components. In the configuration shown in the drawings, a first bracket 176, a second bracket 178, and a third bracket 180 are provided. The first bracket 176 can be provided within the first compartment 158 and extends between a first bracket end 182 and a second bracket end 184. The first bracket end 182 can be contoured to the general shape of the exterior discharge tube surface 106 and abuts the exterior discharge tube surface 106. The second bracket end 184 can be contoured to the general shape of the exterior tuner tube surface 88 and abuts the exterior tuner tube surface 88. The second bracket 178 can also be provided within the first compartment 158 and extends between a third bracket end 186 and a fourth bracket end 188. The third bracket end 186 can be contoured to the general shape of the exterior first duct surface 116. The fourth bracket end 188 can be contoured to the general shape of the exterior second duct surface 130. The third bracket end 186 abuts the exterior first duct surface 116 and the fourth bracket end 188 abuts the exterior second duct surface 130. Finally, the third bracket 180 can be provided within the second compartment 160. The third bracket 180 extends between a fifth bracket end 190 and a sixth bracket end 192. The fifth bracket end 190 abuts the first insert 194 of the first baffle 152 and the sixth bracket end 192 abuts the second insert 196 of the second baffle 154. The first bracket end 182, the second bracket end 184, the third bracket end 186, the fourth bracket end 188, the fifth bracket end 190, and the sixth bracket end 192 can be welded, mechanically locked, or otherwise sealingly secured to the respective components.

[0059] As shown in Figure 5 and Figure 6 the muffler assembly of the present disclosure can be configured in a variety of different ways. In a number of embodiments, many of the elements of the foregoing muffler assembly 20 are the same or substantially the same. More particularly, the structure, location, and function of these components can be similar or identical to the structure, location, and function of the corresponding components of the muffler assembly 20 described above. Accordingly, the common components will not be described in detail again. Equivalent elements shared between embodiments have corresponding reference numbers. For example, Figures 2 to 4 the reference number 50 in Figure 5 corresponds to the reference number 250 in Figure 6 and 450. Additionally, Figures 2 to 4 the reference number 110 in Figure 5 corresponds to the reference number 310 in Figure 6 and 510.

[0060] Reference is now made to Figure 5Another muffler assembly 220 is provided, which is similar to the muffler assembly 20 of the previous embodiments. The muffler assembly 220 includes a housing 250, a first conduit 252, a valve 258, a tuner tube 284 with a tuner tube section 286, and a second conduit 256.

[0061] The shape of the conduits can be tailored to achieve a desired sound range and desired performance characteristics over a given engine speed range. In the illustrated configuration, the first conduit outlet 262 and the second conduit outlet 336 are positioned at opposite ends of the housing 250.

[0062] An exhaust port 310 is formed in the first conduit 252 as at least one perforation 364. In the illustrated configuration, a plurality of perforations 364 are provided through the first conduit 252 and positioned circumferentially. The exhaust port 310 opens to the enclosed volume 276 and is in fluid communication therewith via the perforation 364. The exhaust port 310 is positioned downstream of the open tuner tube end 292. A first distance 312 is defined between the first conduit inlet 260 and the exhaust port 310. A second distance 314 is defined between the first conduit inlet 260 and the open tuner tube end 292. When the first distance 312 is greater than the second distance 314, the exhaust port 310 is positioned downstream of the open tuner tube end 292. In other words, the open tuner tube end 292 is positioned upstream of the exhaust port 310.

[0063] When the valve 258 is in the fully closed position, a closed valve flow path 200 is defined. In the closed valve flow path 200, gas from the exhaust conduit 18 enters the first conduit 252 of the muffler assembly 220 via the first conduit inlet 260. The gas from the first conduit inlet 260 flows to the exhaust port 310 to enter the enclosed volume 276. At the same time, sound waves can propagate to the tuner tube 284 to dampen standing waves. Gas from the enclosed volume 276 flows into the second conduit 256 via the second conduit inlet 334. The gas from the second conduit inlet 334 moves to the second conduit outlet 336 for exhaust.

[0064] When the valve 258 is in the fully open position or the partially open position, respectively, an open valve flow path 202 and an intermediate open valve flow path 204 are defined. In the open valve flow path 202 and the intermediate open valve flow path 204, exhaust gas from the exhaust conduit 18 enters the first conduit 252 via the first conduit inlet 260. The exhaust gas from the first conduit inlet 260 flows to the first conduit outlet 262 for exhaust. At the same time, the exhaust gas from the first conduit inlet 260 flows to the exhaust port 310 to enter the enclosed volume 276. Gas from the enclosed volume 276 flows into the second conduit 256 via the second conduit inlet 334. The gas from the second conduit inlet 334 flows to the second conduit outlet 336 for exhaust.

[0065] Referring now to Figure 6 Another muffler assembly 420 is provided. Like the muffler assemblies 20, 220 of the previous embodiments, the muffler assembly 420 includes a housing 450, a first conduit 452, a valve 458, a tuner pipe 484 with a tuner pipe section 486, a discharge port 510, and a second conduit 456 with a closed valve flow path 400, an open valve flow path 402, and an intermediate open valve flow path 404. Like the tuner pipes 84, 284 of the previous embodiments, the tuner pipe section 486 of the tuner pipe 484 is substantially one quarter of the resonance section 466. In this context, "substantially one quarter" means a section that is not necessarily exactly one quarter of the resonance section 466 but is within a tolerance of plus or minus 5% of the resonance section 466.

[0066] The muffler assembly 420 also includes a third conduit 598, a second valve 600, a second tuner pipe 602, a second discharge port 604, and a fourth conduit 606. The third conduit 598 can extend through the housing 450 between a third conduit inlet 608 and a third conduit outlet 610. The third conduit inlet 608 is in fluid communication with the collector 16 via the exhaust conduit 18. In other words, the third conduit inlet 608 receives gas from the exhaust conduit 18. The second valve 600 is operable to restrict flow through the third conduit 598. A fully open position of the second valve 600 allows gas to pass freely through the third conduit 598 and exit the third conduit outlet 610. A fully closed position of the second valve 600 redirects gas through the enclosed volume 476 of the housing 450 and restricts discharge of gas through the third conduit outlet 610. In the configuration shown in the figures, the second valve 600 is positioned downstream and outside of the housing 450. Alternatively, the second valve 600 can be positioned inside of the housing 450.

[0067] A closed-closed system is defined when both the third conduit outlet 610 and the collector outlet 32 are in a closed state. More specifically, a closed-closed system can be presented when the second valve 600 is in a fully closed position at one end of the system and the exhaust manifold 14 is disposed at the opposite end of the system. A standing wave can extend from the collector outlet 32 to the second valve 600 and define a second resonance section 612 measured along the centerline of the exhaust conduit 18 and the third conduit 598 from the collector outlet 32 to the second valve 600.

[0068] The second tuner tube section 614 of the second tuner tube 602 is substantially one quarter of the second resonant section 612. In this context, "substantially one quarter" means a section that does not need to be exactly one quarter of the second resonant section 612 but is within a tolerance of plus or minus 5% of the second resonant section 612. The second tuner tube 602 extends between a second open tuner tube end 616 and a second closed tuner tube end 618. The second open tuner tube end 616 allows fluid communication between the second tuner tube 602 and the third conduit 598. The second closed tuner tube end 618 is sealed by the tube cover 496. The second tuner tube 602 is operable to attenuate standing waves. The second tuner tube 602 is optimally positioned where high acoustic pressures exist within the exhaust system. More specifically, the second open tuner tube end 616 is optimally positioned when spaced another distance of about 0% to about 10% of the second resonant section 612 from the second valve 600. Alternatively, the second open tuner tube end 616 is optimally positioned when spaced another distance of about 0% to about 10% of the second resonant section 612 from the collector outlet 32 (not shown).

[0069] The second discharge port 604 can include a plurality of perforations 564 disposed through the third conduit 598 and positioned circumferentially. The second discharge port 604 opens to the enclosed volume 476 and is in fluid communication therewith via the perforations 564. The second discharge port 604 must be positioned downstream of the second open tuner tube end 616. A third distance 622 is defined between the third conduit inlet 608 and the second discharge port 604. A fourth distance 624 is defined between the third conduit inlet 608 and the second open tuner tube end 616. When the third distance 622 is greater than the fourth distance 624, the second discharge port 604 is positioned downstream of the second open tuner tube end 616. In other words, the second open tuner tube end 616 is positioned upstream of the second discharge port 604.

[0070] The fourth conduit 606 extends between a fourth conduit inlet 626 and a fourth conduit outlet 628. The fourth conduit inlet 626 opens to and is in fluid communication with the enclosed volume 476, and the fourth conduit outlet 628 is positioned outside of the housing 450. The fourth conduit outlet 628 can open to the ambient environment surrounding the muffler assembly 420 or can be coupled to another exhaust system component, such as an exhaust pipe (not shown), that is external to the muffler assembly 420.

[0071] The shape of the ducts can be customized to achieve a desired sound range and desired performance characteristics over a given engine speed range. In the illustrated configuration, the third duct outlet 610 and the second duct outlet 536 are positioned on the same end of the housing 450. The first duct outlet 462 and the fourth duct outlet 628 are positioned on the same end of the housing 450. The first duct outlet 462 and the third duct outlet 610 are positioned on opposite ends of the housing 450. Similarly, the second duct outlet 536 and the fourth duct outlet 628 are positioned on opposite ends of the housing 450.

[0072] When the second valve 600 is in the fully closed position, a second closed valve flow path 630 is defined. In the second closed valve flow path 630, gas from the exhaust conduit 18 enters the third duct 598 via the third duct inlet 608. The gas from the third duct inlet 608 flows to the second discharge port 604 to enter the enclosed volume 476. At the same time, sound waves can propagate to the second tuner duct 602 to dampen standing waves. Gas from the enclosed volume 476 flows into the second duct 456 via the second duct inlet 534 and into the fourth duct 606 via the fourth duct inlet 626. The gas from the second duct inlet 534 flows to the second duct outlet 536 for discharge and the gas from the fourth duct inlet 626 flows to the fourth duct outlet 628 for discharge.

[0073] When the second valve 600 is in the fully open position or the partially open position, respectively, a second open valve flow path 632 and a second intermediate open valve flow path 634 are defined. In the second open valve flow path 632 and the second intermediate open valve flow path 634, gas from the exhaust conduit 18 enters the third duct 598 via the third duct inlet 608. The gas from the third duct inlet 608 flows to the third duct outlet 610 for discharge. The gas from the third duct inlet 608 also flows to the second discharge port 604 to enter the enclosed volume 476. Gas from the enclosed volume 476 flows into the second duct 456 via the second duct inlet 534 and into the fourth duct 606 via the fourth duct inlet 626. The gas from the second duct inlet 534 flows to the second duct outlet 536 for discharge and the gas from the fourth duct inlet 626 flows to the fourth duct outlet 628 for discharge.

[0074] The foregoing description of implementations has been presented for the purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure to the precise forms disclosed. Individual elements or features of a specific implementation are generally not limited to that specific implementation, but, where applicable, are interchangeable and can be used in selected implementations even if not specifically shown or described. The same can hold true for described manufacturing and implementation methods as well as devices based thereon. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.

Claims

1. A muffler assembly for an exhaust system for a vehicle engine emitting exhaust gas, wherein the exhaust system comprises a collector and an exhaust conduit, wherein the exhaust conduit provides exhaust gas to the muffler assembly, and wherein the muffler assembly comprises: a housing defining an enclosed volume; a first conduit, the first conduit comprising a first conduit inlet and a first conduit outlet, the first conduit extending through the enclosed volume; a valve operable to restrict flow through the first conduit; a resonance section configured to be defined by a section of the exhaust system extending from the collector to the valve; a second conduit including a second conduit inlet positioned in fluid communication with the enclosed volume and a second conduit outlet positioned outside of the enclosed volume; a tuner tube comprising an open tuner tube end in fluid communication with the first conduit and a closed tuner tube end opposite the open tuner tube end, a tuner tube section of the tuner tube being substantially one-quarter the size of the resonant section; a drain port formed in the first conduit and in fluid communication with the enclosed volume, the drain port being positioned downstream of the open tuner tube end; a first deflector, the first deflector cooperating with the housing to define a first compartment; a second deflector, the second deflector cooperating with the housing to define a third compartment; a second compartment positioned between the first baffle and the second baffle; and Each of the first and second baffles includes at least one perforation that allows the second compartment to be in fluid communication with the first and third compartments.

2. The muffler assembly according to claim 1, wherein: The tuner tube is positioned within the first compartment and the second compartment.

3. The muffler assembly according to claim 1, wherein: The discharge port is positioned within the first compartment.

4. The muffler assembly according to claim 1, wherein: The second conduit inlet is positioned within the third compartment.

5. The muffler assembly of claim 1 , further comprising: A discharge pipe includes a first discharge pipe end in fluid communication with the first conduit, and a second discharge pipe end, wherein the discharge port is disposed at the second discharge pipe end.

6. The muffler assembly according to claim 1, wherein: The discharge port is at least one perforation.

7. The muffler assembly according to claim 1, wherein: The open tuner tube end is positioned inside the first compartment, and the closed tuner tube end is positioned inside the second compartment.

8. The muffler assembly of claim 1, wherein: The valve is positioned inside the enclosed volume.

9. The muffler assembly of claim 1, wherein: The valve is positioned outside of the enclosed volume.

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