Integrated Exhaust Muffler Structure for Rear Impact Energy Absorption
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Solution Overview
Problem
Existing vehicle designs face challenges in minimizing mass and size while meeting safety requirements for crash structures and noise suppression, often resulting in separate components that increase vehicle weight and occupy space.
Innovation Solution
A multifunction apparatus that integrates noise suppression and energy absorption functions, featuring a muffler body with resonator cells that deform controllably during impacts, reducing vehicle mass and size while protecting passengers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate muffler and crash structure components are used, then noise suppression and energy absorption functions are fulfilled, but vehicle mass and size increase
Solution Approach 1:
The patent combines the muffler and crash structure into a single integrated component. The muffler body serves dual purposes: it functions as a noise suppression device during normal operation and as a crash structure for energy absorption during impacts. This merging eliminates the need for separate components, thereby reducing vehicle mass while maintaining both noise suppression and safety functions.
Solution Approach 2:
The muffler body is designed to perform multiple functions simultaneously. It acts as both an exhaust noise suppression device and a crash structure for energy absorption. The resonator cells are configured to suppress exhaust noise during normal operation while the same structure is designed to deform controllably during impact events to absorb crash energy, making the component universal in its functionality.
2Reliability
If separate muffler and crash structure components are used, then noise suppression and energy absorption functions are fulfilled, but available space for component placement decreases
Solution Approach 1:
The patent combines the muffler and crash structure into a single integrated component. The muffler body serves dual purposes: it functions as a noise suppression device during normal operation and as a crash structure for energy absorption during impacts. This merging eliminates the need for separate components, thereby reducing vehicle mass while maintaining both noise suppression and safety functions.
Solution Approach 2:
The muffler body is designed to perform multiple functions simultaneously. It acts as both an exhaust noise suppression device and a crash structure for energy absorption. The resonator cells are configured to suppress exhaust noise during normal operation while the same structure is designed to deform controllably during impact events to absorb crash energy, making the component universal in its functionality.
3Reliability
If traditional rigid muffler structure is used, then noise suppression function is maintained, but impact energy absorption capability is reduced
Solution Approach 1:
The patent introduces dynamic characteristics to the muffler structure. The resonator cells are designed with controllable deformation capabilities, allowing the structure to transition from a rigid noise-suppressing component to a dynamic energy-absorbing system during impact events. The walls are configured to deform in a controlled manner, enabling the structure to adapt its mechanical response based on the operational condition (normal operation vs. crash event).
Solution Approach 2:
The patent changes the mechanical parameters of the muffler body walls. The walls are designed with specific material properties and geometric configurations that allow them to maintain structural integrity for noise suppression during normal operation while enabling controlled deformation for energy absorption during impacts. This parameter optimization allows the same structure to serve both functions effectively.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The multifunction apparatus effectively reduces vehicle mass and size by combining noise suppression and energy absorption functions, enhancing passenger safety by distributing impact energy across the vehicle structure.
Implementation Method 1
a muffler including a body having a plurality of walls that bound an array of resonator cells. The resonator cells are arranged between inlet and outlet pipes to suppress exhaust noise.
Implementation Method 2
The resonator cells are arranged between inlet and outlet pipes to suppress exhaust noise.
Implementation Method 3
The walls are configured to controllably deform during an impact event.
Implementation Method 4
The internal walls are configured to absorb energy by deforming during an impact.
Data Source
AI summary
Multifunction noise suppression and crash structures are disclosed. In one aspect of the disclosure, the multifunction structure includes a body, inlet and outlet pipes, and a plurality of walls within the body that bound resonator cells and that are configured to suppress exhaust noise passing through the resonator cells from the inlet to the outlet pipes. The structure may be positioned between crash rails at the rear of the vehicle and between the engine and bumper. The walls may be generally aligned with, or near, the predicted impact direction and they may crumple in a controlled manner during an impact. In various embodiments the structure is 3D printed to enable construction of a wide diversity of geometric topologies and to minimize mass.