Muffler system that internally adjustably regulates tone, decibel level, and pressure levels

Abstract

A muffler system that adjustably regulates tone, decibel level, and pressure levels. The muffler system includes a straight inlet, a relief valve chamber, a pair of dual bypass chambers, a straight outlet, and an access cover. The muffler system results in improved performance and efficiency in comparison with other muffler types and design. The proportional relief valve is internally connected to the external main adjustable extension spring, a chatter / flutter spring, and a adjustable bumper spring all housed under a vented removable cover.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This U.S. Non-Provisional Patent Application claims the benefit of U.S. Provisional Application No. 63 / 617,970, filed on Jan. 5, 2024, which claims the benefit of U.S. Provisional Application No. 63 / 481,311, filed on Jan. 24, 2023. The above identified patent application is herein incorporated by reference in its entirety to provide continuity of disclosure.BACKGROUND OF THE INVENTIONField of the Invention

[0002] The present invention is a muffler. More specifically, the present invention is a muffler system that internally adjustably regulates tone, decibel level, and pressure levels.Description of the Related Art

[0003] Mufflers aid in dampening vehicle emissions and engine noise on a vehicle with a combustion engine. Mufflers are specifically engineered to specifically address a noise level that is desired by a driver.

[0004] What is needed is a muffler system that internally adjustably regulates tone, decibel level, and pressure levels.BRIEF SUMMARY OF THE INVENTION

[0005] The present invention is a muffler. More specifically, the present invention is a muffler system that internally adjustably regulates tone, decibel level, and pressure levels.

[0006] The muffler system includes a main muffler chamber having a first horizontal end and a second horizontal end, an inlet having a tube that extends from the first horizontal end of the main muffler chamber through which exhaust gases enter the main muffler chamber, a relief valve chamber having a first horizontal end and a second horizontal end, an outlet having a tube that extends from the second horizontal end of the main muffler chamber through which exhaust gases exit the main muffler chamber, and an access cover having a removable cover that provides access to the interior of the main muffler chamber for maintenance or inspection.

[0007] It is an object of the present invention to provide a muffler system that maximizes a vehicle's efficiency.

[0008] It is an object of the present invention to provide a muffler system that internally adjustably regulates tone, decibel level, and pressure levels that maintains optimal exhaust pressure.

[0009] It is an object of the present invention to provide a muffler system that reduces strain on the engine.

[0010] It is an object of the present invention to provide a muffler system that minimizes noise and emissions by smoothing exhaust flow variations.

[0011] It is an object of the present invention to provide a muffler that improves vehicle performance and complies with stringent noise and emission standards.

[0012] It is an object of the present invention to provide a muffler system that internally regulates tone, decibel level, and pressure levels proportionally to the amount of volume in Cubic Feet per Minute or CFM and back pressure (from a combustion engine's Revolutions Per Minute or RPM) applied to a spring and lever connected to a flap inside the muffler center chamber. This regulated flap valve is located between a flared inlet and a flared outlet of a muffler regulating flow between the flared inlet and the flared outlet.

[0013] It is an object of the present invention to provide a muffler system that at relatively low RPM produces a relatively low muffled tone proportionally increasing through the engine's RPM range.

[0014] It is an object of the present invention to provide a muffler system that allows adjustable extension style spring cam ranges from relatively low tones to relatively mild tones when the valve chamber is closed.

[0015] It is an object of the present invention to provide a muffler system that once the valve chamber opens at a predetermined desired RPM, the valve depending on setting and spring rate will open regulated and proportionally to the engine's RPM.

[0016] It is an object of the present invention to provide a muffler system that closes the regulated valve chamber proportionally to the RPM at a desired setting.

[0017] It is an object of the present invention to provide a muffler system that is relatively easy to install, weld, or clamp on, and that is also universal and includes 2 simple adjustment screws.

[0018] It is an object of the present invention to provide a muffler system that allows drivers and passengers to enjoy relatively low muffled exhaust tones in neighborhoods, parking lots, garages, or relatively highly populated areas or enjoy relatively increased performance and relatively more robust sounds during relatively heavy acceleration or racing applications and relatively high RPMs just by how the driver drives.

[0019] It is an object of the present invention to provide a muffler system that includes an adjustable setting to allow the muffler system to be set to an engine's capabilities and driving style and preference.

[0020] It is an object of the present invention to provide a muffler system that provides a relatively new and different sound range, tone and function to the muffler system marketplace.

[0021] It is an object of the present invention to provide a muffler system that provides a relatively wide range of universal applications designed for a dual exhaust set-up or a single exhaust set-up.

[0022] It is an object of the present invention to provide a muffler system that is sold with a plurality of different size (rated) extension style springs to be compatible with different engines sizes and set-ups.

[0023] It is an object of the present invention to provide a muffler system that benefits from relatively high back pressure at relatively low RPM and the advantages of relatively low back pressure at relatively high RPM.BRIEF DESCRIPTION OF THE DRAWINGS

[0024] The present invention will be described by way of exemplary embodiments, but not limitations, illustrated in the accompanying drawings in which like references denote similar elements, and in which:

[0025] FIG. 1 illustrates a performance graph of a back pressure proportional relief valve chamber and a pair of dual baffling chambers RPMs versus Tone, in accordance with one embodiment of the present invention.

[0026] FIG. 2 illustrates an open overhead perspective view of a muffler system and a pair of dual baffling chambers, in accordance with one embodiment of the present invention.

[0027] FIG. 3A illustrates an open overhead perspective view of a back pressure proportional relief valve chamber of a muffler system, in accordance with one embodiment of the present invention.

[0028] FIG. 3B illustrates an open side perspective view of a back pressure proportional relief valve chamber of a muffler system, in accordance with one embodiment of the present invention.

[0029] FIG. 4A illustrates a first open overhead perspective view of an access cover of a muffler system, in accordance with one embodiment of the present invention.

[0030] FIG. 4B illustrates a second open overhead perspective view of an access cover of a muffler system, in accordance with one embodiment of the present invention.

[0031] FIG. 5 illustrates an exploded side perspective view of a muffler system, in accordance with one embodiment of the present invention.DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

[0032] Various aspects of the illustrative embodiments will be described using terms commonly employed by those skilled in the art to convey the substance of their work to others skilled in the art. However, it will be apparent to those skilled in the art that the present invention may be practiced with only some of the described aspects. For purposes of explanation, specific numbers, materials and configurations are set forth in order to provide a thorough understanding of the illustrative embodiments. However, it will be apparent to one skilled in the art that the present invention may be practiced without the specific details. In other instances, well-known features are omitted or simplified in order not to obscure the illustrative embodiments.

[0033] Various operations will be described as multiple discrete operations, in turn, in a manner that is most helpful in understanding the present invention, however the order of description should not be construed as to imply that these operations are necessarily order dependent. In particular, these operations need not be performed in the order of presentation.

[0034] FIG. 1 illustrates a performance graph 100 of a relief valve chamber 110 and a pair of dual baffling chambers (FIGS. 2, 260) RPMs versus Tone, in accordance with one embodiment of the present invention.

[0035] The performance graph 100 may include an X-axis 102, a Y-axis 104, and a plurality of graphical lines 106.

[0036] The X-axis 102 may stand for tone in units of Cubic Feet per Minute or CFM / Backpressure of volume or the like. The Y-axis 104 may stand for a combustion engine's Revolutions Per Minute or RPM or the like. The graphical lines 106 may include a stock muffler CFM line 106A, a stock muffler tone line 106B, a muffler with a relief valve chamber line or a proportional CFM line 106C, and a proportional valve muffler tone line 106D.

[0037] The muffler with a relief valve chamber 110 or proportional CFM line 106A illustrates the performance improvement of the muffler with a back pressure proportional relief valve chamber 110 over other mufflers currently in use.

[0038] FIG. 2 illustrates an open overhead perspective view of a muffler system 200 and a pair of dual baffling chambers 260, in accordance with one embodiment of the present invention. FIG. 2 illustrates the muffler system 200 in an open position.

[0039] The muffler system 200 may include a main muffler chamber 210, an inlet 220, a relief valve chamber 230, an outlet 240, and an access cover 250.

[0040] The main muffler chamber 210 may include a first horizontal end 210A and a second horizontal end 210B and may reduce noise. The inlet 220 may be a straight horizontal tube 222 that extends from the first horizontal end 210A of the main muffler chamber 210 through which exhaust gases enter the main muffler chamber 210. The relief valve chamber 230 may include a first horizontal end 230A and a second horizontal end 230B and may be disposed within the main muffler chamber 210 in a horizontal position within the main muffler chamber 210. The outlet 240 may be a straight horizontal tube 242 that may extend from the second horizontal end 210B of the main muffler chamber 210 through which exhaust gases exit the main muffler chamber 210. The inlet 220 may be in communication with the first horizontal end 230A of the relief valve chamber 230 and the outlet 240 may be in communication with the second horizontal end 230B of the relief valve chamber 230. The access cover 250 may be riveted closed to prevent access to the interior of the relief valve chamber 230 of the main muffler chamber 210.

[0041] The access cover 250 may include a bumper spring and chatter / flutter spring (FIGS. 3B, 262). The access cover 250 may be removable or the like.

[0042] FIG. 3A illustrates an open overhead perspective view of a relief valve chamber 230 of a muffler system 200, in accordance with one embodiment of the present invention.

[0043] The muffler system 200 may include the relief valve chamber 230 that may receive the inlet 220. The regulated flap valve 238 may be connected to an angled end of the inlet 220 that is also controlled by a hinge 224A. The hinge 224A may be a spring-loaded hinge 224B or the like. The regulated flap valve 238 may include a closed end of the inlet 220 with a valve arm lever 224 connected to a hinge 224A disposed over the regulated flap valve 238. A valve cap 298 may be attached to the valve arm lever 224 to be aligned over the valve opening (FIGS. 5, 232).

[0044] FIG. 3B illustrates an open side perspective view of a relief valve chamber 230 of a muffler system 200, in accordance with one embodiment of the present invention.

[0045] The valve lever arm 266 extends thru the valve seal plate 280 and the access cover (FIGS. 4A, 250) and connects to the adjustable main spring 264 and the bumper spring and chatter / flutter spring 262. The bumper spring and chatter / flutter spring 262 connects directly to the outer vented removable cover 200A. The adjustable main spring 264 connects to the main adjustment screw 255 that is also fixed to the outer vented removable cover 200A.

[0046] The bumper spring and chatter / flutter spring 262 may help prevent or reduce vibrations and rattling to maintain a relatively quieter and smooth valve operation. The adjustable main spring 264 may help prevent or reduce vibrations and rattling to maintain a constant lever applied forced to keep valve closed and provides the adjustable resistance for valve operation. The valve lever arm 266 may extend upward and include an aperture 267 disposed on an extended upward end. The high temperature wire (FIGS. 4B, 265) may be positioned as a closed valve bumper stop and may also be adjustable by a screw (FIGS. 4B, 295) to set low idle tone and eliminate chatter between the regulated flap valve 238 and a valve cap 298. The adjustable main spring 264 may connect to the end of the main adjustment screw 255 attached to the access cover (FIGS. 4A, 250).

[0047] FIG. 4A illustrates an overhead perspective view of an access cover 250 of a muffler system 200, in accordance with one embodiment of the present invention.

[0048] The access cover 250 may include a plurality of elongated horizontal vents 252, a main adjuster 254 on the inside of access cover 250, and a plurality of removable fasteners 256.

[0049] The elongated horizontal vents 252 may be disposed on the front surface 250A of the access cover 250. More specifically, the elongated horizontal vents 252 may be disposed across the front surface in a pair of horizontal rows 252A to provide ventilation to inside of the muffler system 200.

[0050] The main adjuster 254 may be disposed on an inside surface 250B of the access cover 250 to couple with the main adjustment screw 255 to secure a regulated flap valve (FIGS. 2, 238) which directly affects an amount of sound dampening and exhaust flow, allowing for fine-tuning of exhaust tone and performance depending on a desired level of noise reduction.

[0051] The removable fasteners 256 may be extended through a plurality of corresponding apertures 258 disposed on each corner 250C of the access cover 250 to the main muffler chamber 210 to close and a valve chamber seal 270 but allow access to springs underneath.

[0052] FIG. 4B illustrates an open overhead perspective view of the access cover 250 of a muffler system 200, in accordance with one embodiment of the present invention. The access cover 250 may be riveted closed preventing access to interior valve components, also the valve chamber seal 270 and a valve seal plate 280 may be attached to this holding the high temperature wire 265 and the main adjustment screw 255.

[0053] The muffler system 200 may include the high temperature wire (FIG. 4B265), a valve chamber seal 270, located under a valve seal plate 280, and a plurality of rivets 290.

[0054] A high temperature wire 265 includes a spring-like component that rests against the valve lever arm (FIGS. 3B, 266) and the bumper spring and chatter / flutter spring (FIGS. 3B, 262) providing tension and flexibility for dampening vibrations, maintaining alignment, reducing stress, and allowing flexibility. There may also be the valve chamber seal 270 that may prevent leakage, improve efficiency, minimize noise, and ensure longevity. The valve seal plate 280 may provide alignment, vibration dampening, structural support, and position adjustability. The rivets 290 may be the removable fasteners (FIGS. 4B, 256) that are extended through a plurality of corresponding apertures 258 through the muffler system 200 closing the relief valve chamber (FIGS. 2, 230).

[0055] FIG. 5 illustrates an exploded perspective view of muffler system 200, in accordance with one embodiment of the present invention.

[0056] The muffler system 200 may include a high-temperature valve seal (FIGS. 4B, 270) the same size and shape and located under the valve seal plate (FIGS. 5, 280). The valve seal plate 280 may also hold the high temperature wire (FIGS. 4B, 265) and includes a screw (FIGS. 4B, 295) to hold the main adjustment screw (FIGS. 4B, 255).

[0057] The muffler system 200 may include 3 pieces. First, the valve cap 298 may be attached to the valve arm lever 224, which is aligned over the regulated flap valve 238 that also has the valve opening 232.

[0058] The valve lever arm 266 may also include a drilled hole 227 that extends through the valve seal plate 280 for the adjustable main spring (FIGS. 3B, 264) and the bumper spring and chatter / flutter spring (FIGS. 3B, 262) to attach. The valve seal plate 280 may be made from reinforced high temp or RHT silicone or the like.

[0059] Operation and use of the muffler system is straightforward. The muffler system has three chambers with two outer baffle chambers with approximately 4 to 6 high-flow, tri-shaped baffles on each side to produce relatively higher back pressure at low RPM which leads to relatively better fuel economy and relatively smoother engine idle that produces relatively low to relatively mild tone from approximately 750 to 3,000 RPM (adjustable). Beyond adjusted setting the proportional spring regulated valve chamber (center chamber) would open and close proportionally to the engines RPM and producing relatively higher flow, relatively low back pressure, increase performance, and more relatively robust tones at relatively higher RPM.

[0060] As pressure from the inlet increases, a screw adjustable extension style spring applies pressure to lever attached to the valve flap, opening and closing the valve proportionally to the engine RPM, CFM, and back pressure. Exhaust gases are expelled through the main outlet side of the muffler bypassing the dual baffling chambers. The inlet and outlet tubes are also drilled for baffling. The present invention may also be sold with multiple size (rated) extension style springs for different size engines and universal applications. May be sold in 2 ½, 3, 3 ½, and 4″ inlet / outlet sizes for different size engines and applications. The valve chamber section has a sealed cover under a removable cover that also may contain ceramic fiber insulation for vibration and sound deadening purposes and hi-temp sealer or gasket material around the cover perimeter. The cover will also have access hole to adjustment screw. The cover will also have recessed housing for valve to open into at full extension / opening.

[0061] The phrase “in one embodiment” is used repeatedly. The phrase generally does not refer to the same embodiment, however, it may. The terms “comprising”, “having” and “including” are synonymous, unless the context dictates otherwise.

[0062] While the present invention has been related in terms of the foregoing embodiments, those skilled in the art will recognize that the invention is not limited to the embodiments described. The present invention may be practiced with modification and alteration within the spirit and scope of the appended claims. Thus, the description is to be regarded as illustrative instead of restrictive on the present invention.

Claims

1. A muffler system, comprising:a main muffler chamber having a first horizontal end and a second horizontal end;an inlet having a straight horizontal tube that extends from the first horizontal end of the main muffler chamber through which exhaust gases enter the main muffler chamber;a relief valve chamber having a first horizontal end and a second horizontal end;an outlet having a straight horizontal tube extending from the second horizontal end of the main muffler chamber through which exhaust gases exit the main muffler chamber; andan access cover having a removable cover that provides access to the interior of the main muffler chamber for maintenance or inspection.

2. The muffler system, according to claim 1, wherein the inlet is in communication with the first horizontal end of the relief valve chamber and the outlet is in communication with the second horizontal end of the relief valve chamber.

3. The muffler system, according to claim 1, wherein the relief valve chamber is disposed within the main muffler chamber in a horizontal position within the main muffler chamber.

4. The muffler system, according to claim 1, wherein the relief valve chamber has an extension styled main spring, a regulated flap valve, a bumper spring, and a chatter flutter spring disposed over the relief valve chamber.

5. The muffler system, according to claim 4, wherein the relief valve chamber has a valve seal plate that is positioned under the valve seal plate.

6. The muffler system, according to claim 5, wherein the valve seal plate is made from reinforced high temp silicone.

7. The muffler system, according to claim 5, wherein the regulated flap valve is positioned in front of the inlet tube that is also controlled by tension from an adjustable main spring fixed on a hinge within the interior of a valve chamber seal.

8. The muffler system, according to claim 7, wherein the hinge is a spring-loaded hinge.

9. The muffler system, according to claim 7, wherein the relief valve chamber includes the bumper spring and the chatter flutter spring with a curved portion disposed over the hinge.

10. The muffler system, according to claim 1, further comprising a bumper spring wire, a valve seal, and a bumper adjustment plate.

11. The muffler system, according to claim 10, wherein the bumper spring wire includes a spring-like component that connects the regulated flap valve and the bumper spring and a chatter flutter spring to provide tension and flexibility for dampening vibrations, maintaining alignment, reducing stress, and allowing flexibility.

12. The muffler system, according to claim 10, wherein the valve seal prevents leakage, improves efficiency, minimizes noise, and ensures longevity.

13. The muffler system, According to claim 10, wherein the bumper adjustment plate provides alignment, vibration dampening, structural support, and position adjustability.

14. The muffler system, according to claim 1, wherein the access cover includes a plurality of elongated horizontal vents, a main screw adjuster, a secondary chatter spring.

15. The muffler system, according to claim 1, wherein the access cover conceals and protects the bumper spring and adjustment attached to the valve seal plate and seal.

16. The muffler system, according to claim 1, wherein the access cover is removable for service to the seal and the springs and the spring changes and provide a plurality of different size springs of the springs for different applications.

17. The muffler system, according to claim 16, wherein the elongated horizontal vents are disposed across the front surface of the access cover in a pair of horizontal rows to provide ventilation inside of the springs and a plurality of adjustments system.

18. The muffler system, according to claim 16, wherein the main screw adjuster is disposed on an inside surface of the access cover to couple with an adjustment screw to secure the regulated flap valve which directly affects an amount of sound dampening and exhaust flow, allowing for fine-tuning of exhaust tone and performance depending on a desired level of noise reduction.

19. The muffler system, according to claim 16, wherein the fasteners are extended through a plurality of corresponding apertures disposed of each corner of the access cover to couple the access covers to the main muffler chamber.

20. The muffler system, According to claim 19, wherein the fasteners are a plurality of rivets extending through the corresponding apertures disposed of each corner of the access cover to couple the access cover to the main muffler chamber.

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