Nested Muffler Chamber with Filter Monolith for Compact Exhaust Systems

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Solution Overview

Problem

The existing exhaust system mufflers for motor vehicles are not compact enough, leading to inefficiencies in space usage and increased weight, while also requiring more assembly effort and material.

Innovation Solution

A muffler design with a nested structure that includes a filter monolith surrounded by a muffler chamber, subdivided by perforated radial partitions, allowing for flexible sound muffling properties and reduced space requirements, featuring a multi-part outer housing with segments that can be easily assembled and adapted to different filter sizes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of stationary object

If a separate muffler and filter monolith are used, then exhaust gas treatment function is ensured, but installation space and weight increase

Engineering Contradiction:

Improveinstallation spaceVSAvoidexhaust gas treatment function

Core Design Contradiction:

Volume of stationary objectVSReliability

Solution Approach 1:

The patent combines the muffler and filter monolith into a single integrated component. The filter monolith is positioned inside the muffler housing, allowing both exhaust gas filtration and noise reduction functions to be performed by one assembly rather than requiring separate components, thereby reducing installation space while maintaining both functions

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The filter monolith is nested within the muffler housing structure. The exhaust gas flows through the filter monolith first, then the filtered gas passes through the muffler chamber where noise reduction occurs. This nested arrangement allows the smaller filter component to be housed within the larger muffler structure, optimizing space utilization

Inventive Principle:

Principle #7Nested doll (Nesting)

2Volume of stationary object

If a compact muffler design is used, then installation space is reduced, but assembly effort and complexity increase

Engineering Contradiction:

Improveinstallation spaceVSAvoidassembly effort

Core Design Contradiction:

Volume of stationary objectVSEase of manufacture

Solution Approach 1:

The muffler housing is divided into multiple segments or sections that can be manufactured separately and then assembled together. The filter monolith is installed as a separate component within the housing structure. This segmentation allows for simpler manufacturing of individual parts and easier assembly compared to a monolithic compact design

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The muffler housing serves multiple functions: it provides the structural container for the filter monolith, acts as a noise reduction chamber, and facilitates exhaust gas flow distribution. This multi-functionality reduces the need for additional separate components, simplifying both manufacturing and assembly while achieving compact dimensions

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Object-affected harmful factors

If traditional muffler design is used, then noise reduction is achieved, but space efficiency and weight are suboptimal

Engineering Contradiction:

Improvenoise emissionsVSAvoidmuffler weight

Core Design Contradiction:

Object-affected harmful factorsVSWeight of stationary object

Solution Approach 1:

By merging the muffler and filter monolith into a single integrated assembly, the total weight of the exhaust system is reduced compared to having separate muffler and filter components. The combined structure eliminates redundant materials and fasteners while maintaining both noise reduction and filtration functions

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent optimizes the spatial arrangement by utilizing the internal volume of the muffler housing to accommodate the filter monolith in a three-dimensional configuration. Rather than extending the muffler lengthwise, the design uses radial and axial space efficiently within the housing, reducing overall dimensions and weight while maintaining noise reduction performance

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

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

This design results in a more compact and lightweight exhaust system with reduced assembly effort, effective noise reduction, and efficient use of installation space, while ensuring the filter monolith is fully utilized for exhaust gas treatment.

Implementation Method 1

a filter monolith through which exhaust gas flows, in particular a catalytic converter or particle filter (DPF, GPF)

Methodology Applied

Scientific EffectFiltration: Filter (physical)

Implementation Method 2

The muffler chamber is subdivided into muffler sub-chambers by at least one perforated radial partition wall

Methodology Applied

Scientific EffectAcoustic resonance: Resonance

Data Source

PatentEP3623593B1Silencer for an exhaust line of a motor vehicle and motor vehicle comprising a silencer

Publication Date: 2021.06.16 FAURECIA EMISSIONS CONTROL TECHNOLOGIES GERMANY GMBH

Figure 1~2
Figure 3~4
Figure 5~6

AI summary

A silencer (10) for an exhaust system of a motor vehicle has an outer housing (12) which has at least one inlet opening (22) and at least one outlet opening (26) for exhaust gas (32), a silencer chamber (16), and an exhaust gas-flowed filter monolith (38) which is circumferentially surrounded by the silencer chamber (16). The invention further relates to a motor vehicle with at least one silencer (10).