A muffler system and an exhaust system

Abstract

A muffler system including a primary channel; a secondary channel in fluid communication with the primary channel; and, a capping mechanism operatively connected to the primary channel and the secondary channel to open and close the primary channel and secondary channel; such that when the primary channel is in a closed position, the secondary channel is in an open position and vice versa.

Description

[0001] A Muffler System and an Exhaust System

[0002] Technical Field

[0003] The present invention relates to an exhaust pipe muffler system, and an exhaust system including the same. According to one specific example, the exhaust system further includes an adjustable resonating chamber.

[0004] Background of the Invention

[0005] The following references to and descriptions of prior proposals or products are not intended to be and are not to be construed as, statements or admissions of common general knowledge in the art. In particular, the following prior art discussion does not relate to what is commonly or well known by the person skilled in the art, but may assist in the understanding of the present invention.

[0006] Presently, exhaust systems, such as for vehicles and the like, include a high-sound volume channel for exhaust gas, which typically produces the highest volume sound as gas travels through the channel, and also include a channel for production a low-sound volume for producing reduced volume sounds.

[0007] Typically, exhaust systems include a single valve on the high-sound channel such that when this valve is closed, the exhaust gas is directed into the channel with higher resistance (that is, the low-volume channel). When the valve is fully open, the gas flows through the path with the least resistance, producing the highest sound volume. However, even when the valve is open, a portion of the exhaust gas and its associated sound wave still flows through the high-resistance, low-sound volume path, which reduces overall sound volume and increases exhaust gas back pressure.

[0008] The present invention seeks to provide a muffler system and an exhaust system which may ameliorate the foregoing shortcomings and disadvantages or which will at least provide a useful alternative.

[0009] of the Invention

[0010] According to one aspect, there is provided herein a muffler system including: a primary channel; a secondary channel in fluid communication with the primary channel; and, a capping mechanism operatively connected to the primary channel and the secondary channel to open and close the primary channel and secondary channel such that when the primary channel is in a closed position, the secondary channel is in an open position and vice versa.

[0011] According to one example, the capping mechanism includes a primary valve configured to cap the primary channel and a secondary valve configured to cap the secondary channel.

[0012] In yet a further example, the primary valve and the secondary valve are interconnected.

[0013] According to another example, the primary channel and the secondary channel are disposed at least partially parallel to each other.

[0014] In yet a further example, the secondary valve is close to or proximal to the primary channel.

[0015] In a further form, in the capping mechanism includes one or more cog gears.

[0016] In yet another form, the muffler system has an auxiliary channel in fluid communication with the primary channel.

[0017] According to another example, the muffler system includes a primary chamber and a secondary chamber being formed proximal to each other such that the primary channel is formed to extend from the inlet through the primary and secondary chambers and to the outlet, and the secondary chamber is formed extending from the primary channel and within the primary chamber.

[0018] In yet another example, the auxiliary channel being formed from the secondary chamber and connecting to the primary channel in the primary chamber.

[0019] According to another form, the primary channel and the secondary channel are configured at an angle with respect to each other.

[0020] In another example, the muffler system includes a plurality of any one or a combination of the secondary channel and the primary channel and capping mechanism.

[0021] In another form, the primary channel, secondary channel, and capping mechanism form a dual-valve mechanism, and the muffler system includes a plurality of dual-valve mechanisms. According to yet a further example, the plurality of dual-valve mechanisms include a first dual-valve mechanism and a second dual-valve mechanism, the second dual-valve mechanism cascading from the first dual-valve mechanism.

[0022] In a further example, the muffler system includes a resonating chamber.

[0023] According to another example, the resonating chamber includes a valve that is adjustable to a particular frequency.

[0024] In a further example, wherein the muffler system includes a plurality of resonating chambers.

[0025] According to another example, the muffler system includes one inlet and a plurality of outlets.

[0026] According to one example, the secondary valve is close to or proximal to the primary channel / conduit.

[0027] According to another aspect, there is provided herein an exhaust system having any one or a combination the muffler system described herein and a resonating chamber having an adjustable volume.

[0028] According to another aspect, there is provided herein a resonating chamber having an adjustable volume.

[0029] In one example, the resonating chamber has a moveable plugging mechanism being configured to move to adjust the volume of the resonating chamber.

[0030] In yet another example, the resonating chamber has an elongate body, the body having a movable plugging mechanism being configured to move along the body of the resonating chamber to adjust the volume of the chamber.

[0031] In one example, the plugging mechanism includes a push rod and a controller being configured to move an end cap or piston along the body of the resonating chamber from an open end of the resonating chamber to a closed end of the resonating chamber.

[0032] In yet a further example, a rotatable threaded shaft with threaded surfaces actuates / moves the endcap / piston. In one example, the threaded shaft passes through a threaded opening in the endcap / piston.

[0033] In a further example, a fixed guide rail or stopper extends through another or secondary opening in the endcap / piston. It will be appreciated that the stopper can provide stability and prevent unwanted rotation. This configuration can enable the endcap / piston to move linearly along the threaded shaft and guide rail during operation.

[0034] It will be appreciated by persons skilled in the art that any combination of features described herein is included within the scope of the present specification.

[0035] Brief Description of the Drawings

[0036] The invention may be better understood from the following non-limiting description of a preferred embodiment, in which:

[0037] Figures 1A to 1D are schematics of an example of a muffler system with a capping mechanism for use with a primary and secondary channel; i

[0038] Figures 2A to 2D are schematics of another example of a muffler system with multiple dual-valves / capping mechanisms and channels;

[0039] Figures 3 is a schematic of another muffler system having a dual-valve mechanism.

[0040] Figures 4A to 4E are schematics of another example of a muffler system with multiple dual-valves / capping mechanisms and outlets, including a resonating chamber;

[0041] Figure 5 is a schematic of an example cross-section in exploded view of the preferred angle of the tube for the secondary channel joining to the tube of the primary channel;

[0042] Figures 6A to 6C and 7 are schematics of another example of a muffler system with multiple resonating chambers with multiple valves;

[0043] Figures 8 to 11 and 12B are schematics of an example of a resonating chamber / channel in fluid communication with a channel of the muffler system described herein; and Figure 12A is a are schematic diagram showing an example cross-section of the resonating chamber / channel.

[0044] Detailed Description of the Drawings

[0045] Figures 1A to 1D show an example of a of a muffler system in accordance with an aspect of the present invention.

[0046] In the example of Figures 1A to 1 D, there is shown an example of a muffler system 10, where the muffler system has a primary channel 20, and a secondary channel 25 which is typically in fluid communication with the primary channel 20. The muffler system 10 also includes a capping mechanism 30 operatively connected to the primary channel 20 and the secondary channel 25 to open and close the primary channel 20 and secondary channel 25, such that when the primary channel 20 is in a closed position, the secondary channel 25 is in an open position and vice versa. Thus, the closing and opening mechanism of the primary channel and the secondary channel in this example can be interconnected.

[0047] Figures 1A to 1D show an example of a first valve mechanism including a capping mechanism 30 configured to cap or act as a valve for a primary channel 20 and a secondary channel 25 in the muffler system 10. The valve or capping mechanism has interconnected components, such as interconnected gears or cogs, to allow for movement of the capping system to change the flow in both the primary and secondary channels.

[0048] In the example shown in Figures 1A to 1D, the primary channel 20 and secondary channel 25 (also referred to herein as a side-channel) are interconnected by cog gears, with each gear connected to the respective channel. When the main channel opens, the side channel simultaneously closes and when the main channel closes, the side channel simultaneously opens. Thus, for example, exhaust gas enters through the main inlet 15. If the main channel 20 is open and the side channel 25 is closed, the exhaust gas can travel through the main passage without any or limited leakage through the side channel. Alternatively, if the second channel is open this can lead to a flow path with multiple reflection paths and an expansion chamber, which reduces exhaust sound volume and finally out at the outlet 35 (as discussed further below).

[0049] As an example, the capping mechanism 30 can include a primary valve 40 configured to cap the primary channel 20 and a secondary valve 45 configured to cap the secondary channel 25. In one specific example, the capping mechanism includes one or more cog gears. Thus, for example, the primary valve 40 and the secondary valve 45 can include cog gears which are operatively connected together (or interconnected) and work to close and open respective channels accordingly. It will be appreciated that whilst the example of cog wheels are shown other mechanisms can be used to open / close the conduits / channels.

[0050] According to one specific example, the secondary valve 45 is installed at or near the start / opening of the secondary channel 25 which is typically the low-volume path tube. This secondary valve 45 operates in synchronization with the main valve 40, which is located in the path with generally the least resistance, as typically this means that the path is generally the one with the least amount of fluid back pressure and thus the path that typically has the loudest sound volume. The opening and closing actions of the secondary valve 45 are thus typically opposite to those of the main valve 40. That is, when the main valve 40 is fully open, the secondary valve 45 is fully closed, and when the main valve 40 is fully closed, the secondary valve 45 is fully open.

[0051] It will be appreciated that the examples show in Figures 1A to 1C can prevent / limit exhaust gas from entering the high-resistance, low-volume path when the main valve 40 is fully open, thereby eliminating any sound dampening caused by sound waves entering the secondary passage 25. This mechanism can thus maximize exhaust sound volume.

[0052] More specifically, Figure 1A shows an example of exhaust gas flow when the primary valve 40 is fully open and the secondary valve 45 is fully closed, whereas Figure 1B shows an example of the exhaust gas flow when the primary valve 40 is fully closed, and the secondary valve 45 is fully open. Figure 1C shows an example of the exhaust gas flow when both the primary valve 40 and secondary valve 45 are partially open.

[0053] Notably, the Figures show the inlet 15 of the muffler system 10, is in fluid communication with, the outlet 35 of the muffler, which is typically the exit point for exhaust gases after passing through the muffler’s internal components.

[0054] As discussed herein, Figures 1A to 1D further show the primary channel 20, which is typically the high-volume valve, configured to allow maximum exhaust gas flow, which can facilitate efficient expulsion with minimal sound attenuation. Additionally, the secondary channel 25, which is typically a low-volume valve configured to divert exhaust gas through a quieter route, reducing noise levels by limiting flow and directing fluid through sound-dampening chambers. Typically, the valves and channels are in fluid communication with chambers 42, 44. As an example, there is a primary low sound volume reflective chamber 42, which is a primary chamber in the sound reduction path, where exhaust gases are reflected and redirected toward the subsequent reflective chamber, aiding in noise attenuation, and a secondary chamber 44.

[0055] More specifically in Figure 1 D, there is shown an example of a control system which can be used to control the opening and closing of the valve. In this example, there is shown at 15 a main exhaust conduit inlet; at 43 DC motor for the capping mechanism; at 35 Main exhaust conduit exit; at (21) programmable exhaust controller; at (22) a Harness or connector for connecting the controller to the system 10; (23) a remote key fob; and a (24) mobile device. It will be appreciated that the controller, remote key and mobile device shown in Figure 1 D are examples only and the valve system described herein can be controlled by any form of controller / processing system. It will also be appreciated that the processing system that is used to control the controller can be connected by any means such as wirelessly or through a vehicle, for example.

[0056] In the examples shown in Figures 1A to 1D, the valves 45 and 40 are typically interconnected by a gear such that the motor 43 can drive the gears to turn in such a manner whereby turning one gear will turn the other respectively. In this example, the gears turn in opposing directions so that when one gear opens the cap for one conduit / channel, the other gear will move to close the cap for the other corresponding conduit / channel. Thus, the two caps of the main channel and the side or secondary channel work together in sequence and, in this example, are dependent (or codependent) on one another.

[0057] Further, the muffler system 10 shown in the examples 1A to 1 D is formed such that the system includes the primary channel 20 at proximity to the secondary channel 25 to allow the respective caps 45 and 40 of the channels to be interconnected. In this example, at least a portion of the conduits / channels are formed such that they are parallel to one another. That is, the secondary channel extends from the primary channel, such that the base 26 of the secondary channel extends perpendicularly from the primary channel and at least a portion of the body of the secondary channel, where the cap 45 of the secondary channel is located, is formed substantially parallel to a portion of the body of the primary channel. This allows gas to flow from the inlet 15 and through the primary channel 20 if the cap of the primary channel is open and out the outlet 35, and also allows gas to flow from the inlet 15 through the primary channel 20 before exiting from the secondary channel if the cap of the primary channel is closed. Thus, the primary channel and the secondary channel are in fluid communication with one another.

[0058] Typically, it will be appreciated that gas that flows through the primary channel and exits at the outlet without exiting the secondary channel (as shown in Figure 1 A) makes the loudest sound as there are the least impediments for the gas through the primary channel. Gas that enters the secondary channel 25 (as shown in Figure 1B) makes a quieter sound due to further travels through the system, as described below.

[0059] Additionally, Figures 1A to 1D show a further auxiliary channel 27 which can receive fluid from a chamber of the muffler system for entry into the primary channel 20. In these specific examples, the muffler system has two chambers - the primary chamber 42 and the secondary chamber 44, the chambers being in fluid communication with at least the secondary and auxiliary channels, and in a further example, the primary channel extends from inlet to outlet of the muffler system.

[0060] More specifically in these examples, the primary channel 20 extends across / through the primary and secondary chambers 42, 44, which are typically formed next to each other. The volume of the primary chamber 42 is typically larger than the volume of the secondary chamber 44. The inlet 15 is formed at the side nearest the secondary chamber and a plate 37 separates the primary chamber 42 from the secondary chamber 44. Given the volume of the primary chamber 42 is larger than the volume of the secondary chamber 44, it will be appreciated that in these examples the main portions of the primary, secondary and auxiliary channels are formed in the primary chamber 42.

[0061] Turning now to fluid flow for when the cap 40 of the primary channel 20 is closed, as shown in Figure 1B, fluid can enter the inlet at 15 and flow through to the secondary channel 25 and out into the primary chamber 42. From there, fluid can flow through perforations in the plate 37 to a secondary chamber 44 and into the inlet of the auxiliary channel 27, which has its inlet formed in the secondary chamber 44. Fluid will then typically flow to the primary channel 20 and out the outlet 35. In this example, the cap 40 for the primary channel 20 is formed between the connection of the primary channel 20 with the secondary channel 25 and the auxiliary channel 27 entrance into the primary channel 20. Thus, if the cap 40 is closed, fluid communication between the auxiliary channel and the secondary channel is disconnected.

[0062] Notably, the plate 37 can have one or more perforations 38 (as shown in Figure 1 C, for example) which can further impede / affect liquid flow through the chambers. It will be appreciated that this can affect the sound and can attenuate sound volume further. In this example, the perforations act like vents formed within the plate 37, but they can be of any form and as shown in Figures 3 and 4A can be of the form of perforated tubes.

[0063] Although Figures 1A and 1D show the primary channel 20 formed substantially in the middle of the muffler, with the outlet 35 being formed in the middle of the side of the muffler, and the inlet 15 being formed offset from the middle of a side of the muffler, it will be appreciated that the channels, inlet and outlets can be formed in the middle or offset from the midline of the muffler system.

[0064] According to a further example, there can be a plurality or a multi-valve system whereby the muffler system includes a plurality of capping mechanisms 30 configured to open / close a plurality of respective primary and secondary channels. The addition of multiple interconnected valves can provide more choice and adjustment for different tones and sounds. Thus, having a plurality of valves can increase the range of sound adjustability and can provide more control of the sounds made by the exhaust system.

[0065] More specifically referring to Figure 2A to 2D, the inlet of the muffler 15 is in fluid connection with a primary high-volume valve 40A, which provides an open path for maximum exhaust gas flow, and a primary low-volume valve 45A which creates a quieter path for reduced sound volume. Figures 2A to 2C further show a secondary high-volume valve 40B, which can provide an open path for maximum exhaust gas flow, and a secondary low-volume valve 45B, which can create a quieter path for reduced sound volume. The outlet of the muffler 35 is in fluid connection with the plurality of primary and secondary valves 40A, 40B, 45A, 45B.

[0066] Accordingly, Figure 2A shows an example of exhaust gas flow for a muffler system 10 with two dual-valve mechanisms 30A / 30B, where in this example, the flow is shown through the first dual-valve 30A when the primary valve 40A is fully open and the secondary valve 45A is fully closed. Figure 2B shows an example of the exhaust gas flow for muffler with two dual-valve mechanism, such that in the first dual-valve Mechanism 30A, the primary valve 40A is fully closed, and the secondary valve 45A is fully open, and in the secondary dual-valve mechanism 30B: the primary valve 40B is fully open, and the secondary valve 45B is fully closed.

[0067] Additionally, Figure 2C shows an example of the exhaust gas flow for muffler with two dual-valve mechanism 30A / 30B, where in the First Dual-Valve Mechanism 30A, the primary valve 40A is fully closed, and the secondary valve 45A is fully open, and in the secondary dual-valve mechanism 30B, the primary valve 40B is fully closed, and the secondary valve 45B is fully open.

[0068] Furthermore, it is appreciated that in Figures 2A to 2D, the example Muffler system 10 shows a secondary low sound volume reflective chamber 44 which is a second chamber in the series (similar to that shown in Figures 1 A to 1 D), where exhaust gases can be further reflected before being guided back to the main conduit for final exit through the muffler, completing the sound reduction process.

[0069] Thus, Figures 2A to 2D show examples of multiple dual-valve mechanisms. Typically, a dual-valve mechanism includes a primary channel and a secondary channel with interconnected capping mechanisms. A muffler system having multiple (or a plurality of) dual-valve mechanisms thus can include a first dual-valve mechanism and second dual-valve mechanism, a third dual-valve mechanism and so on. According to one specific example, the plurality of dual-valve mechanisms, as shown in Figures 2A to 2D can cascade from each other (i.e. they can be formed in a cascading configuration). That is, they can be operatively connected such that the secondary channel of the first dual-valve mechanism can become the first channel of the second dual-valve mechanism. The sequence can continue for as many dual-valve mechanism there are in the system, in this sequence. Thus for example, the secondary channel of the second dual valve mechanism can become the primary channel of the third dual-valve mechanism and so on.

[0070] Referring to Figure 2D, Figure 2D further shows an example of the muffler system with a control system. In this example, 2D shows the main exhaust conduit inlet 15 and the outlet (main exhaust conduit exit) 35. At 43A Figure 2D shows an example of a DC motor for the capping mechanism for the high-volume channel, at 43B there is a DC motor for the capping mechanism for the low-volume channel, at (21) an example of a Programmable exhaust controller at (22) a harness / connector, at (23) a remote key fob and at (24) an example of a mobile device which can be connected to the fob and controller to control the muffler system. Notably, it will be appreciated that other forms of system control can be used.

[0071] According to a further example, there can be multiple valve / capping systems in the muffler system 10. Further example variations in design for different types of muffler canisters and different inlet and outlet pipe layouts are shown in Figures 3 to 4D. In these examples, in order to enhance the adjustability along the low-volume path (that is typically the secondary channel 25), additional dual-valve mechanisms can be installed. Typically, this can include repeating the configuration in Figures 1A and 1C along the secondary channel 25, which is typically a path of low volume and is also the path with higher exhaust gas pressure resistance. It will be appreciated that this setup can allow users to fine-tune the sound output level and provides greater flexibility in adjusting exhaust back pressure.

[0072] Referring more specifically to Figures 3 and 4A to 4D, they show the inlet 15 of the muffler 10, where gas enters into the primary channels 20, if the main valve 40 is open, for maximum exhaust gas flow. The side or secondary valve 45 for regulating flow through secondary channel 25 is shown as being interconnected with the main valve 40 and can be used in an open configuration / position for a quieter path for less sound volume. Figures 2 and 3 also show multiple outlets. In this example, there are multiple outlets 35A and 35B which are typically the outlets for an open path with maximum gas flow and minimum back pressure (that is, when gas flows through the primary channel 20). There are also multiple secondary outlets 35C and 35D which are typically for the flow path with minimum exhaust sound and volume (that is, via the secondary channel 25).

[0073] Figures 4A to 4D further show a resonating chamber 50A for reducing resonating droning sound. This will be described in further detail below.

[0074] Accordingly, in one example, there is provided herein a synchronized dual-valve mechanism which can prevent / limit exhaust gas flow leakage into the low-volume path when the main valve is fully open, and thus maximising sound volume. In one specific example, the two valves can be driven by a single DC motor and connected by cog gears, ensuring synchronization and preventing both paths from being closed simultaneously, which would otherwise stall the vehicle's engine. In these examples, the DC Motor is shown in Figures 2 and 3, in these examples positioned directly above the valves

[0075] In another example, the muffler system can include a single shaft for both valves, allowing the DC motor to drive the valves from the side of the muffler canister rather than from the top, which is particularly useful in situations with confined clearance between the muffler body and the vehicle chassis.

[0076] According to one example, the valve for the low-volume path is positioned in close proximity to the main exhaust flow path, minimizing exhaust gas leakage into the low-volume path and thereby reducing the maximum sound volume.

[0077] In yet a further example, the tube leading to the low-volume path can be joined perpendicularly or slightly angled against the flow direction of the main tube in the high-volume path and is proportionally smaller in size (as shown and further described below in Figure 5). It will be appreciated that this can minimize resistance in the main gas flow and reduces the likelihood of gas flow leakage into the low-volume tube when the valve in the main tube is open.

[0078] Further, the valve mechanism can be integrated inside the muffler to reduce its overall size, enabling installation across a broader range of vehicle makes and models. And additionally, to enhance the adjustability along the low-volume path, additional dualvalve mechanisms can be installed. By repeating the aforementioned configuration process along the path of the low volume (the path with higher exhaust gas pressure resistance), this setup allows users to fine-tune the sound output level and provides greater flexibility in adjusting exhaust back pressure.

[0079] Referring more specifically to the resonating chamber, it will be appreciated that when the exhaust system is adjusted for maximum sound volume, with the valve in the first passage fully open, the exhaust sound can resonate inside the vehicle cabin and can cause discomfort for passengers.

[0080] Accordingly, to provide additional adjustability for the exhaust's resonating sound effect, a third, resonating valve can be installed on a third path / channel (referred to as a resonating channel) that leads to a resonating chamber 50. When this valve is fully open, sound waves enter the resonating chamber, reducing the resonating effect inside the vehicle's cabin. It will be appreciated that the resonating chamber 50 can be integrated inside the muffler 10 with a tube that directs partial gas flow into the chamber 50. While the majority of exhaust gas flows through the main tube 20, a portion of the gas and sound enters the resonating chamber 50, where specific frequency ranges are attenuated.

[0081] Further, a resonating valve can be installed at the inlet tube to the resonating chamber 50, to allow control over the level of resonating or droning exhaust sound inside the vehicle cabin by adjusting the valve's opening degree. Notably, the valve can be operated independently.

[0082] Figures 1C and 1D show an example of a dual-valve muffler design, featuring two dualvalve configurations that can optimize exhaust flow and noise control. It will be appreciated that the muffler system 10 can include a plurality of valves and chambers. Figures 3 and 4A to 4E show an example of a more complex muffler design, incorporating three dual-valves and an additional valve dedicated to managing a resonating / reflective chamber. This configuration can enhance both flow efficiency and sound attenuation by offering greater control over exhaust gas routing through multiple channels and chambers.

[0083] Referring more specifically to Figures 4A to 4D, the example shows an inlet of the muffler 15 in fluid communication with a plurality of outlets, valves and chambers. In this example, there is:

[0084] 1. Primary High-Volume Valve: Provides an open path for maximum exhaust gas flow (20).

[0085] 2. Primary Low-Volume Valve: Creates a quieter path for reduced sound volume (25).

[0086] 3. Valve for the resonating chamber (55A)

[0087] 4. Outlet of the muffler (High sound volume channel) (35A)

[0088] 5. Outlet of the muffler (High sound volume channel) (35B)

[0089] 6. Outlet of the muffler (Low sound volume channel) (35D)

[0090] 7. Outlet of the muffler (Low sound volume channel) (35C)

[0091] 8. Secondary High-Volume Valve: Provides an open path for maximum exhaust gas flow (55E).

[0092] 9. Secondary Low-Volume Valve: Creates a quieter path for reduced sound volume (55D). 10. Secondary High-Volume Valve: Provides an open path for maximum exhaust gas flow (55B).

[0093] 11. Secondary Low-Volume Valve: Creates a quieter path for reduced sound volume (55C).

[0094] 12. Resonating and low-volume chamber (50A)

[0095] 13. Low-volume chamber (50B) and other chambers 50C, 50D

[0096] Figure 4A shows an example of the exhaust gas flow for a muffler with three dual-valve mechanisms and one resonating chamber valve mechanism, where in the First DualValve Mechanism, the primary valve is fully open, and the secondary valve is fully closed and where in the secondary dual-valve mechanism, the primary valve is fully open, and the secondary valve is fully closed.

[0097] Figure 4B shows an example of the exhaust gas flow for a muffler with three dual-valve mechanisms and one resonating chamber valve mechanism, where in the First DualValve Mechanism, the primary valve is fully open, and the secondary valve is fully closed and in the secondary dual-valve mechanism, the primary valve is fully closed, and the secondary valve is fully open.

[0098] Figure 4C shows an example of the exhaust gas flow for a muffler with three dual-valve mechanisms and one resonating chamber valve mechanism, where in the First DualValve Mechanism, the primary valve is fully closed, and the secondary valve is fully open.

[0099] Furthermore, Figure 4D shows an example of the exhaust gas flow for a muffler with three dual-valve mechanisms and one resonating chamber valve mechanism, with the valve to the resonating chamber open.

[0100] More specifically, Figure 4E shows an example of the muffler system with a Main exhaust conduit inlet at 15; at 43C DC motor for the Main capping mechanism; at 43D DC motor for the capping mechanism for resonating chamber / channel; at 43E DC motor for the secondary capping mechanism at 43F DC motor for the secondary capping mechanism at 35C exhaust outlet for the lower volume channel; at 3D exhaust outlet for the lower volume channel ; at 35A exhaust outlet for the high-volume channel at 35B exhaust outlet for the high-volume channel; and a control system for the muffler which can include at (21) a programmable exhaust controller; at (22) a harness; at (23) remote key fob; and at (24) a mobile device. Referring further to Figures 3 to 4D, it will be appreciated that in these examples, the inlet 15 is formed substantially in the middle of the muffler system, with multiple outlets. In this example, the muffler system is shaped substantially rectangular with the inlet 15 being formed in the middle of one of the longer sides. There are four outlets, 35A-35D, two formed on each of the shorter sides. More specifically in these examples, the primary channel 20 is formed from the inlet and splits into two separate channels with outlets 35A and 35B. Thus, typically the outlets 35A and 35B generate louder sounds than outlets 35C and 35D. Notably, it will be appreciated that the rectangular shape of the muffler system is an example as the muffler system can be of any suitable shape.

[0101] Figures 3 to 4D further show perforated tubes 38 which can provide further impediments as fluid travels between channels and chambers. Furthermore, the muffler system in the examples of Figures 4A to 4D has formed therein a resonating chamber, 55A, which can reduce the droning sound of an engine. In this example, the resonating chamber 55A also includes a resonating valve which allows the resonating chamber to be open and closed selectively, thereby allowing for the amount of reduction of the droning sound to be controlled accordingly.

[0102] Notably, the resonating chamber 55A shown in Figures 3 to 4D allows the flow of fluid into another chamber of the muffler system, thereby creating a sound-dampening path. Below an adjustable resonating chamber is described which connects to the main exhaust pipe independently of the muffler system. It will be appreciated that the different types of resonating chambers can be used separately or in combination.

[0103] Thus, the muffler system of Figures 3 to 4D show an example of multiple valves 55B, 55C, 55D and 55E which allow controlling of fluid flow between a plurality of channels and chambers, and Figures 4A to 4D show that the muffler system can also include a resonating chamber for reducing / adjusting the droning sound. Accordingly, there can be the ability to adjust the volume and frequency of the sound that an exhaust system generates. Figure 4E specifically shows an example of how a user may be able to independently control the opening and closing of the plurality of valves in order to control the sound of an exhaust system and to create certain sound effects.

[0104] Notably, in the example shown in Figures 3 to 4D, multiple chambers are formed by dividing the muffler system with plates 37. The plates 37 can include end plates for the ends of the muffler system and plates disposed between the end plates to form chambers. The various multiple channels can thereby go between the plates 37. It will also be appreciated that the muffler system of Figures 4A to 4E can have multiple or a plurality of dual-valve mechanisms and can have cascading dual-valves as described previously.

[0105] Figure 5 shows an example of different fluid flow that can occur through a valve / chamber. In this particular example:

[0106] 1. Main Gas Flow Direction: The primary path along which the exhaust gases are designed to travel through the system.

[0107] 2. Preferred Reverse-angle Side-Pipe Angle: The reverse angle of the side-pipe which lead to the side-valve helps minimize exhaust gas leakage into the side pipe with high gas back-pressure and lower sound volume when the main valve is open, reducing gas back pressure and ensuring maximum sound output while the main valve is open.

[0108] 3. Preferred Perpendicular-angled Side-Pipe: The perpendicular angel of the side-pipe which lead to the side-valve helps minimize exhaust gas leakage into the side pipe with high gas back-pressure and lower sound volume when the main valve is open, reducing gas back pressure and ensuring maximum sound output while the main valve is open.

[0109] 4. Non-Preferred Angled Gas Flow Direction: An undesirable flow path at a lesser downstream angle, which may result in increased leakage into the smaller volume chamber when the main valve is open. This can increase back pressure and reduce the maximum sound output during main valve is in full opening position.

[0110] Figures 6A to 60 and 7 show a further example of an exhaust system 100 having a multiple valve system.

[0111] In these examples, it will be appreciated that in some applications, a single muffler or resonating chamber / tube installed in an exhaust system may not provide sufficient adjustment to achieve the desired sound level. Thus, to increase sound adjustability, multiple mufflers and resonating chambers with control valves can be provided in the exhaust system. In certain exhaust applications, multiple resonating chambers / pipes with adjustable valves can be used (see, for example, Figures 10 and 11). In other cases, mufflers and resonating chambers / pipes with valves can be installed together in a single exhaust system (see Figure 7) to achieve the desired result. Specifically, Figures 6A and 7 show examples of resonating chambers with multiple valves (as shown for example in any of the Figures 1 A to Figure 4D) can be integrated into a single exhaust system 100. The examples in Figures 6A and 7 further show multiple valves installed in a single resonating pipe to alter the sound characteristics and which can be fine-tuned to match the frequency of in-cabin droning sound, thereby reducing unwanted droning.

[0112] In these particular examples, the muffler system includes altering an internal volume of the resonating chamber to achieve optimal resonating effects and reduce unwanted sound frequencies or droning inside the cabin. This is further described below.

[0113] More specifically referring to the examples shown in Figures 6A, 6B, and 6C, there is shown at 60 a main exhaust conduit, adjustable resonators at 65A, 65B, and 65C, and a control system for controlling the muffler system including a programmable exhaust controller at (21), a harness at (22) and a remote key fob at (23) and mobile device at (24). Notably, Figures 6B and 6C show examples of adjustable resonators (further shown, as an example, in Figure 12B). The adjustable resonators are further described below.

[0114] The example of Figure 7 shows an exhaust system 100 including at 60 an exhaust main conduit; at 65A an adjustable resonator; at 10 an adjustable muffler with multiple valve mechanism; at (21) a programmable exhaust controller; at (22) a harness; at (23) a remote key fob and at (24) a mobile device. Thus, Figure 7 shows an example of an exhaust system having an adjustable multi-valve muffler 10 and an adjustable resonator 65A.

[0115] In these examples, it will be appreciated that the programmable exhaust controller can allow manual control of each adjustable device within the system, which can also enable precise opening and closing. Additionally, the controller can be programmed through a mobile application or computer interface to automatically control all adjustable mufflers and resonators.

[0116] In the examples shown, it will be appreciated that each valve can be independently controlled by a controller, such as a touchscreen device or smartphone app. This configuration can allow users to generate different exhaust tones and provides greater control over sound characteristics. The system can accommodate a plurality of mufflers and resonating chambers for enhanced adjustability, and as shown more specifically in Figure 5, this can be three or more.

[0117] According to a further example, to reduce the droning exhaust sound within the vehicle’s cabin, a resonating chamber 65 can be introduced to absorb the resonating sound while maintaining overall sound volume outside the cabin. However, it will be appreciated that the specific frequency considered as undesired droning sound varies among different users. It will be appreciated that a resonating chamber with a fixed volume typically cannot accommodate these varying needs, as it can only generate a single, fixed sound characteristic.

[0118] Thus, to provide additional adjustability for the exhaust resonating chamber, there is further provided herein a mechanism that allows the internal volume of the resonating chamber 65 to be adjusted, thereby abating certain frequencies of droning sounds. Examples of an adjustable resonating chamber is shown in Figures 8 to 12B. Typically, the resonating chamber includes a plugging mechanism. One type of plugging mechanism is shown for example in Figures 8 and 9.

[0119] More specifically, Figure 8 illustrates an example of a mechanism including a push rod and associated controller or control components, including the motor and cog gears, which are typically positioned at an open end of the resonator chamber.

[0120] Alternatively, Figure 9 depicts a configuration where the push rod and the control components, including the motor and cog gears, are located at the closed end of the resonator chamber. The push rod is thus configured to move an endcap or piston win the resonating chamber between the open end and the closed end of the resonator chamber.

[0121] The example of Figure 9 can minimize the impact of high exhaust gas temperatures on the control mechanism. Notably, Figures 8 and 9 show as an example, the movable internal endcap for the resonating chamber 65 at a first position 70, the movable internal endcap for the Resonating Chamber has been extended to a second position 72 and the DC motor at 74.

[0122] Thus, the adjustable resonating chamber volume mechanism through movement of the endcap can allow for linear adjustment of the internal volume of the resonating chamber to match the frequency of a resonating droning sound. In one example, the mechanism can include a DC motor driving a straight push rod to push or pull the internal cap within the resonating chamber / tube and adjusting its internal length. The push rod can be positioned either on the exhaust gas inlet side or the “dead end” side of the resonating chamber.

[0123] It will be appreciated that the resonating chamber can be cylindrical or have other cross-sectional shapes such as oval, or the like, as suitable for the canister.

[0124] Example components in Figures 8 and 9 include:

[0125] 1. Movable Internal Endcap / Piston for the Resonating Chamber at Position 70:

[0126] Illustrates the internal endcap in its retracted, initial position within the resonating chamber.

[0127] 2. Movable Internal Endcap / Piston for the Resonating Chamber at Position 72:

[0128] Demonstrates the internal endcap in its extended position, thereby adjusting the internal volume of the resonating chamber.

[0129] 3. DC Motor and Gear Sets 74: Operates the push rod mechanism to drive the internal endcap / piston's movement between Position 70 and Position 72.

[0130] An alternative design to the configurations shown in Figures 8 and 9 is depicted in Figures 10 to 12B. In these examples, a rotatable threaded shaft with threaded surfaces replaces the push rod used to actuate the endcap / piston. The threaded shaft passes through a centrally threaded opening in the endcap / piston, which features internal threads that engage with the threaded shaft. Additionally, a fixed guide rail or stopper extends through another opening in the endcap / piston, which can provide stability and prevent unwanted rotation. This configuration can enable the endcap / piston to move linearly along the threaded shaft and guide rail during operation. The detailed mechanism is depicted in Figures 12A and 12B. When the DC motor rotates the threaded shaft, the rotational movement is transferred to the threaded interface between the threaded shaft and the endcap / piston. Since the endcap / piston is held stationary in terms of rotation by the guide rail / stopper, the resulting reaction force causes the endcap / piston to translate linearly along the threaded shaft and guide rail.

[0131] Figure 10: Illustrates the exhaust gas flow through the main exhaust channel and the connected adjustable resonating chamber. Figure 11: Arrows indicate an example of the piston / endcap movement direction within the adjustable resonating chamber.

[0132] Figures 10,11 and 12A further show:

[0133] 1. DC Motor and Gear Set 84 which can drives the shaft centrally positioned within the resonating chamber, enabling the movement of internal components.

[0134] 2. A Threaded Shaft 82 which can engage with the endcap via threaded surface contact. As the shaft rotates, the endcap remains non-rotating due to a rotation stopper / guide rail (85) but is driven linearly along the shaft’s axis by the action of the rotating thread.

[0135] 3. An Endcap / Piston 80 which is typically positioned centrally within the resonating chamber, the endcap (or piston) is internally threaded to engage with the external threads of the shaft. Its rotation is restricted by a guiding rail (item 6), allowing for linear movement without rotation as the shaft turns. 4. A Resonating Chamber 65 which typically operates as a sound-attenuation mechanism by allowing exhaust gases and associated sound waves to enter the chamber. Within the chamber, these sound waves induce oscillations and resonate at specific frequencies. The resonance counteracts targeted frequencies of exhaust noise, effectively reducing droning sounds and improving overall acoustic performance.

[0136] 5. An Exhaust Conduit 60 which typically serves as the primary channel for the exhaust gases to flow through the system.

[0137] 6. An Endcap / Piston guiding rail 85: A guiding rail positioned within the resonating chamber that restricts the rotation of the endcap or piston, ensuring linear movement along the shaft.

[0138] Figure 12B illustrates the components of an adjustable resonator, including:

[0139] 1. DC Motor and Gear Sets (84)

[0140] 2. Threaded Shaft (82)

[0141] 3. Movable Endcap / Piston (80)

[0142] 4. Guide Rail / Stopper 85 In this example, the thin curved arrows indicate the rotational turn of the shaft, and the straight thick arrows represent the movement direction of the endcap / piston, which can adjust the internal volume of the resonator chamber.

[0143] It is understood that all the resonators or resonating chambers described herein may encompass any suitable resonator design for exhaust systems, including but not limited to Helmholtz resonators and quarter-wave resonators.

[0144] According to further examples, the valves described herein can be controlled by a programmable device that can operate each valve independently or automatically, based on vehicle parameters such as engine RPM (revolutions per minute), throttle position, vehicle speed, other user requirements, and more. It will be appreciated that the programmable device can be configured to coordinate the operation of all valves in a specific sequence and with varying degrees of valve opening to produce various sound effects and achieve optimal sound characteristics.

[0145] It will be appreciated that any form of the word “comprising”, “comprises”, “comprised”, or the like, as used herein, is used in an inclusive manner and is not used in an excluding or limiting meaning.

[0146] Those skilled in the art will appreciate that the invention described herein is susceptible to variations and modifications other than those specifically described. All such variations and modifications are to be considered within the scope and spirit of the present invention the nature of which is to be determined from the foregoing description.

Claims

Claims1. A muffler system including:a primary channel;a secondary channel in fluid communication with the primary channel; and,a capping mechanism operatively connected to the primary channel and the secondary channel to open and close the primary channel and secondary channel;such that when the primary channel is in a closed position, the secondary channel is in an open position and vice versa.

2. The muffler system of claim 1, wherein the capping mechanism includes a primary valve configured to cap the primary channel and a secondary valve configured to cap the secondary channel.

3. The muffler system of claim 2, wherein the primary valve and the secondary valve are interconnected.

4. The muffler system of any one of claims 1 to 3 wherein the secondary valve is close to or proximal to the primary channel..

5. The muffler system of any one of claims 1 to 4, where in the capping mechanism includes one or more cog gears.

6. The muffler system of any one of claims 1 to 5, wherein the muffler system has an auxiliary channel in fluid communication with the primary channel.

7. The muffler system of any one of claims 1 to 6, wherein the muffler system includes a primary chamber and a secondary chamber being formed proximal to each other such that the primary channel is formed to extend from the inlet through the primary and secondary chambers and to the outlet, and the secondary chamber is formed extending from the primary channel and within the primary chamber.

8. The muffler system of claim 7 when dependent on claim 6, the auxiliary channel being formed from the secondary chamber and connecting to the primary channel in the primary chamber.

9. The muffler system of any one of claims 1 to 3, wherein the primary channel and the secondary channel are configured at an angle with respect to each other.

10. The muffler system of any one of claim 1 to 5, wherein the muffler system includes a plurality of any one or a combination of the secondary channel and the primary channel and capping mechanism.

11. The muffler system of any one of claims 1 to 10, wherein the primary channel, secondary channel, and capping mechanism form a dual-valve mechanism and the muffler system includes a plurality of dual-valve mechanisms.

12. The muffler system of claim 11, wherein the plurality of dual-valve mechanisms include a first dual-valve mechanism and a second dual-valve mechanism, the second dual-valve mechanism cascading from the first dual-valve mechanism.

13. The muffler system of any one of claims 1 to 12, wherein the muffler system includes a resonating chamber.

14. The muffler of claim 13, wherein the resonating chamber includes a valve that is adjustable to a particular frequency.

15. The muffler system of any one of claims 1 to 14, wherein the muffler system includes a plurality of resonating chambers.

16. The muffler system of any one of claims 1 to 15, wherein the muffler system includes one inlet and a plurality of outlets.

17. An exhaust system including the muffler system of any one of claims 1 to 16.

18. The exhaust system of claim 17, the exhaust system including a resonating chamber having an adjustable volume.

19. The exhaust system of claim 18, wherein the resonating chamber has an elongate body, the body having a movable plugging mechanism being configured to move to adjust the volume of the chamber.

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