Leaf Spring Variable Valve for Muffler High Temperature Stability

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Conventional variable valves in mufflers face issues with precise flow control due to decreased spring characteristics at high temperatures, leading to excessive valve opening and interference with surrounding components, as well as unpleasant sounds from shaking and touching between the valve cover and housing.

Innovation Solution

A leaf spring type variable valve design where a leaf spring supports the valve cover with a wide contact area, preventing excessive opening and reducing noise, and uses a hinge protrusion and housing protrusion to control the valve's closing behavior, eliminating the need for a shaft and cushioning member.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a torsion spring is used to support the valve cover, then the valve can be opened and closed, but the spring characteristic significantly decreases at high temperatures causing excessive valve opening

Engineering Contradiction:

Improvespring characteristicVSAvoidhigh temperature

Core Design Contradiction:

ReliabilityVSTemperature

Solution Approach 1:

The patent changes the spring mechanism from a torsion spring to a leaf spring, fundamentally altering the elastic parameter behavior. The leaf spring maintains consistent elastic characteristics across temperature ranges, preventing the degradation seen in torsion springs at high temperatures. This parameter change ensures reliable spring behavior in exhaust system conditions.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces the torsion spring mechanical system with a leaf spring mechanical system. The leaf spring is directly mounted to the housing and provides support to the valve cover through a different mechanical principle, eliminating the temperature-sensitive torsion spring mechanism while maintaining the opening and closing function.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Ease of operation

If a torsion spring with point contact is used to support the valve cover, then the valve can rotate, but unpleasant sounds occur due to shaking and collision

Engineering Contradiction:

Improvevalve rotationVSAvoidunpleasant sound

Core Design Contradiction:

Ease of operationVSObject-generated harmful factors

Solution Approach 1:

The patent merges the support function and the noise reduction function into a single leaf spring component. The leaf spring provides both the mechanical support for valve rotation and the damping effect to reduce shaking and collision sounds, eliminating the need for separate cushioning members and reducing overall noise.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The leaf spring is designed with inherent damping characteristics that provide beforehand cushioning against shaking and collision. The material and structure of the leaf spring are selected to absorb and dampen vibrations and impacts, preventing unpleasant sounds before they occur during valve operation.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Reliability

If a shaft and cushioning member are used to support the valve cover, then the valve can be secured, but the device complexity and manufacturing cost increase

Engineering Contradiction:

Improvevalve supportVSAvoidnumber of components

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The leaf spring serves multiple functions simultaneously: it supports the valve cover, enables rotation, provides damping against shaking, and prevents excessive opening. This multi-functionality eliminates the need for separate shafts, cushioning members, and other components, reducing device complexity while maintaining reliability.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent extracts and eliminates unnecessary components such as the shaft and separate cushioning member from the conventional valve support system. The leaf spring alone performs all necessary functions, simplifying the overall device structure and reducing manufacturing complexity.

Inventive Principle:

Principle #2Taking out (Extraction)

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 leaf spring type variable valve maintains strong spring characteristics at high temperatures, reduces unpleasant sounds, and prevents excessive opening, while saving manufacturing costs and weight by eliminating the need for additional components.

Implementation Method 1

a leaf spring which is interposed between a leaf spring support part fixedly secured to the hinge support part of the housing and the valve cover to thereby elastically pressurize the valve cover

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS9482186B2Leaf spring type variable valve

Publication Date: 2016.11.01 HYUNDAI MOTOR CO LTD

AI summary

A leaf spring type variable valve may include a housing wherein a hinge support part may be formed at a side thereof and an opening may be formed at another side thereof, a valve cover which may be rotatably secured to the hinge support part of the housing to thereby open or close the opening of the housing, and a leaf spring which may be interposed between a leaf spring support part fixedly secured to the hinge support part of the housing and the valve cover to thereby elastically pressurize the valve cover, wherein the leaf spring has an area in contact with the valve cover.