Vertical Muffler with Trapezoidal Covers for Generator Space
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Solution Overview
Problem
Conventional muffler devices for vehicles are not directly applicable to portable generators, which require a lightweight, compact, and space-efficient design with NOx purification capabilities.
Innovation Solution
A muffler device for portable generators featuring a vertically disposed casing with trapezoidal end covers, a vertically positioned catalyst device, and a diffuser pipe to cool high-temperature exhaust gases before they reach the catalyst, along with an arrester to maintain compactness and silencing functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If conventional vehicle muffler design is used, then noise reduction function is achieved, but the device is too heavy and large for portable generator application
Solution Approach 1:
The muffler device is segmented into distinct functional zones: a catalyst device section for NOx purification, a diffuser pipe section for exhaust gas cooling and expansion, and an arrester section for noise reduction. This segmentation allows each component to be optimized independently for portable generator applications, reducing overall weight while maintaining effectiveness.
Solution Approach 2:
The invention transitions from the conventional horizontal vehicle muffler layout to a vertical configuration suitable for portable generators. The exhaust pipe connects to the upper portion of the casing, and the tail pipe exits from the lower portion, utilizing vertical space to achieve compact dimensions while preserving the noise reduction function.
2Object-generated harmful factors
If catalyst device is added for NOx purification, then emission standards are met, but device complexity and size increase
Solution Approach 1:
The catalyst device is merged with the muffler structure, integrating NOx purification functionality into the existing exhaust system. The catalyst device is positioned within the casing, sharing the same space and structural support, which avoids adding separate components and maintains design simplicity.
Solution Approach 2:
The muffler device is designed to perform multiple functions simultaneously: noise reduction through the arrester, NOx purification through the catalyst device, and exhaust gas cooling through the diffuser pipe. This multi-functionality eliminates the need for separate devices, reducing overall system complexity.
3Speed
If high-temperature exhaust gas directly enters catalyst device, then exhaust flow is maintained, but catalyst device is damaged by heat
Solution Approach 1:
The diffuser pipe is positioned between the exhaust pipe and the catalyst device to preliminarily cool and expand the exhaust gas before it reaches the catalyst. This preliminary action reduces the temperature of the exhaust gas, protecting the catalyst device from thermal damage while maintaining effective exhaust flow.
4Quantity of substance
If casing volume is increased for sufficient inner capacity, then catalyst device fits, but overall size becomes too large
Solution Approach 1:
The catalyst device, diffuser pipe, and arrester are nested within the casing in a compact vertical arrangement. The catalyst device is positioned in the upper portion, the diffuser pipe extends downward, and the arrester is located at the lower portion, maximizing space utilization and achieving sufficient capacity without increasing overall size.
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 solution enhances the inner capacity and rigidity of the muffler device, allowing for a compact design, reduced manufacturing costs, improved maintainability, and protection of the catalyst device from high-temperature damage, while maintaining effective noise reduction.
Implementation Method 1
the diffuser pipe is disposed between the connection portion to the exhaust pipe, and the placement position of the catalyst device, and therefore, a space in which the exhaust gas flowing into the casing exists before entering the catalyst device can be secured to be wide. As a result, the high-temperature exhaust gas flowing into the casing from the exhaust pipe is cooled before flowing into the catalyst device
Implementation Method 2
a catalyst device in an inside of the casing, wherein the catalyst device is disposed in a vertical direction
Implementation Method 3
an arrester is disposed in a connection portion of the diffuser pipe to the tail pipe
Data Source
AI summary
A lightweight and compact muffler device that can be installed in a limited space in an inside of a generator. A top cover and an undercover (end cover) provided on a top and a bottom of a vertically disposed casing are each formed in substantially trapezoidal shape. Thereby, an inner capacity of the casing can be secured to be large, as a result of which, a size of the muffler device can be made compact, and no extra component is required, so that reduction in manufacturing cost and reduction in weight can be achieved. Since the casing is disposed vertically, it is possible to install the casing even when an installation space is small in an inside of a housing of a generator, and it is possible to make the generator compact.