Claims:

1. An exhaust muffler (200, 300) comprising:
a muffler shell (201, 301),
at least one exhaust pipe (202, 205, 302, 309) configured to be mounted inside the muffler shell (201, 301), and
at least one muffler baffle (203, 303) configured with one end mounted on the muffler shell (201, 301) and other end mounted on the exhaust pipe (202, 205, 302, 309),
wherein the muffler baffle (203, 303) is configured to be aligned longitudinally along the direction of an exhaust gas flow (204, 304) inside the exhaust muffler (200, 300).

2. The exhaust muffler (200) as claimed in claim 1, wherein the at least one muffler baffle (203) is configured to be mounted circumferentially between the muffler shell (201) and the exhaust pipe (202, 205).

3. The exhaust muffler (200) as claimed in claim 1, wherein the at least one muffler baffle (203) is configured from a shape selected from a set of “Z”, “T”, “I”, “O”, “C”, “J”, “V” and alike to secure one end of the shape on the exhaust pipe (202, 205) and other end of the shape on the muffler shell (201) for providing stiffness and rigidity to the exhaust muffler (200).

4. The exhaust muffler (200) as claimed in claim 1, wherein the number of the muffler baffles (203) is configured to vary based on the size of the muffler shell (201) and the exhaust pipe (202, 205).

5. The exhaust muffler (200) as claimed in claim 1, wherein the length, size, thickness and shape of the muffler baffles (203) are configured to vary based on the requirement of structural stiffness of the muffler shell (201) and the exhaust pipe (202, 205).

6. The exhaust muffler (300) as claimed in claim 1, wherein the muffler baffle (303) is configured with:
an outer ring (305) configured to be mounted on an inner surface of the muffler shell (301),
an inner ring (306) configured to be mounted on an outer surface of the exhaust pipe (302, 309), and
at least one radial rib (307) configured to be mounted between the outer ring (305) and the inner ring (306),
wherein the radial rib (307) is configured to align with the exhaust gas flow (304) inside the exhaust muffler (300).

7. The exhaust muffler (300) as claimed in claim 6, wherein the outer surface of the outer ring (305) and the inner surface of the muffler shell (301) are configured with a same profile and the inner surface of the inner ring (306) and the outer surface of the exhaust pipe (302, 309) are configured with a same profile adapted for optimal fitment.

8. The exhaust muffler (300) as claimed in claim 6, wherein the length, size, thickness of the radial rib (307), the outer ring (305), and the inner ring (306) are configured to vary based on the requirement of structural stiffness for the muffler shell (301) and the exhaust pipe (302, 309).

9. The muffler baffle (303) as claimed in claim 6, wherein the outer ring (305) and the inner ring (306) are configured with a shape selected from a set of rectangular, square, oval, circular, triangular, elliptical and alike based on the cross-sectional configuration of the muffler shell (301) and the exhaust pipe (302, 309) respectively.

10. The exhaust muffler (200, 300) as claimed in claim 1, wherein the type of the muffler baffle (203, 303) to be used inside the exhaust muffler (200, 300) is configured to be selected based on the requirement of structural stiffness of the muffler shell (201, 301) and the exhaust pipe (202, 205, 302, 309).
, Description:FORM 2

THE PATENTS ACT, 1970
(39 of 1970)
&
THE PATENTS RULES, 2003

COMPLETE SPECIFICATION
(See Section 10 and Rule 13)

Title of invention:
AN EXHAUST MUFFLER

Applicant:
Tata Motors Passenger Vehicles Limited
A company Incorporated in India under the Companies Act, 1956
Having address:
Floor 3, 4, Plot-18, Nanavati Mahalaya,
Mudhana Shetty Marg, BSE, Fort, Mumbai 400001,
Maharashtra, India

The following specification particularly describes the invention and the manner in which it is to be performed.

FIELD OF THE INVENTION
[001] The present subject matter described herein generally relates to an exhaust system, and more specifically to an exhaust muffler of a vehicle.
BACKGROUND
[002] An exhaust system is used in all types of vehicles to direct exhaust gases or fumes produced in an internal combustion engine away from the engine. The exhaust system is configured to improve the performance of the engine, to remove harmful substances, to improve fuel consumption and to control noise. Typically, the exhaust system comprises many pipes and parts that work in conjunction to provide a way for exhaust gasses to escape the engine. These parts include the exhaust manifold, catalytic converter, tailpipe, resonator and muffler. A baffle is an acoustically tuned metallic object placed inside the muffler to cancel out or muffle the sound from the exhaust outlet. Conventionally, the muffler baffle is provided inside a muffler shell and provides restriction to travelling sound waves for maximizing sound attenuation through destructive interference of sound waves and also the baffle provides support and adds stiffness to the muffler shell.
[003] The existing design of the muffler baffle is such that, the muffler baffle is placed perpendicular to the direction of the exhaust gas flow, resulting in obstruction of flow restriction and drop in the exhaust gas velocity and increased flow noise for the exhaust gas. Further the muffler baffle also increases the backpressure resulting in reduction of the engine performance. The muffler baffle is configured with a plurality of cut-outs made by a stamping process wherein one of the cut-out is configured to position and mount an outlet pipe of the muffler and remaining cut-outs are configured for flowing of the exhaust gas. Because of certain limitation of the cut-outs by stamping process certain area of the muffler baffle is retained to provide stiffness to the muffler baffle. This remaining area of the muffler baffle causes unwanted obstruction to the flow thereby resulting in increased backpressure.
[004] In one of the existing muffler baffle, as illustrated in figure 1(a), 1(b) and figure 1(c), an exhaust muffler 100 is disclosed. The exhaust muffler 100 comprises a muffler shell 101, a muffler exhaust pipe 102, and a muffler baffle 103. The muffler baffle 103 comprises cut-outs (105a, 105b) for exhaust gas flow, an opening 106 for mounting of the muffler exhaust pipe 102. The muffler baffle 103 is configured to align perpendicular to the exhaust gas flow direction 104 thereby increasing the flow restriction.
[005] Hence to overcome the aforesaid objection there is a requirement to provide the muffler baffle which will provide adequate support to the exhaust outlet/inlet pipe and by providing minimum restriction to the exhaust gas flow.

OBJECTS OF THE INVENTION
[006] One object of the present disclosure is to provide a muffler baffle design which is compact, lightweight and cost effective due to ease of manufacturing.
[007] Another object of the present disclosure is to provide a muffler baffle with improved structural stiffness of the muffler resulting in reduced structure borne noise of the exhaust system.
[008] Yet another object of the present disclosure is to provide a muffler baffle which will provide minimal obstruction to the exhaust flow.
[009] Yet another object of the present disclosure is to provide a muffler baffle to reduce flow noise and backpressure.

SUMMARY
[0010] Before the present system is described, it is to be understood that this application is not limited to the particular machine or device, as there can be multiple possible embodiments that are not expressly illustrated in the present disclosures. It is also to be understood that the terminology used in the description is for the purpose of describing the particular versions or embodiments only, and is not intended to limit the scope of the present application. This summary is provided to introduce aspects related to a muffler baffle, and the aspects are further elaborated below in the detailed description. This summary is not intended to identify essential features of the proposed subject matter nor is it intended for use in determining or limiting the scope of the proposed subject matter.
[0011] The present subject matter discloses an exhaust muffler comprising a muffler shell, at least one exhaust pipe mounted inside the muffler shell and at least one muffler baffle. One end of the muffler baffle is configured to be mounted on the muffler shell and the other end of the muffler baffle is configured to be mounted on the exhaust pipe. The muffler baffles are configured to be aligned longitudinally along the direction of the exhaust gas flow inside the exhaust muffler to provide structural stiffness and rigidity to the exhaust muffler. The muffler baffles are configured to reduce the backpressure, the flow noise and increase the engine performance.

STATEMENT OF INVENTION
[0012] The present subject matter discloses an exhaust muffler comprising a muffler shell, at least one exhaust pipe configured to be mounted inside the muffler shell and at least one muffler baffle configured with one end mounted on the muffler shell and other end mounted on the exhaust pipe. The muffler baffle is configured to be aligned longitudinally along the direction of an exhaust gas flow inside the exhaust muffler.
[0013] In an embodiment, at least one muffler baffle is configured to be mounted circumferentially between the muffler shell and the exhaust pipe.
[0014] In an embodiment, at least one muffler baffle is configured from a shape selected from a set of “Z”, “T”, “I”, “O”, “C”, “J”, “V” and alike to secure one end of the shape on the exhaust pipe and other end of the shape on the muffler shell for providing stiffness and rigidity to the exhaust muffler.
[0015] In an embodiment, the number of the muffler baffles are configured to vary based on the size of the muffler shell and the exhaust pipe.
[0016] In an embodiment, the length, size, thickness and shape of the muffler baffles are configured to vary based on the requirement of structural stiffness of the muffler shell and the exhaust pipe.
[0017] In an embodiment, the muffler baffle is configured with an outer ring configured to be mounted on an inner surface of the muffler shell, an inner ring configured to be mounted on an outer surface of the exhaust pipe, and at least one radial rib configured to be mounted between the outer ring and the inner ring. The radial ribs are configured to align with the exhaust gas flow inside the exhaust muffler.
[0018] In an embodiment, the outer surface of the outer ring and the inner surface of the muffler shell are configured with a same profile and the inner surface of the inner ring and the outer surface of the exhaust pipe are configured with a same profile adapted for optimal fitment.
[0019] In an embodiment, the length, size, thickness of the plurality of the radial ribs, the outer ring, and the inner ring are configured to vary based on the requirement of structural stiffness for the muffler shell and the exhaust pipe.
[0020] In an embodiment, the plurality of radial ribs, the outer ring and the inner ring are configured with a shape selected from a set of rectangular, square, oval, circular, triangular, elliptical and alike based on the cross-sectional configuration of the muffler shell and the exhaust pipe respectively.
[0021] In an embodiment, the type of the muffler baffle to be used inside the exhaust muffler is configured to be selected based on the requirement of structural stiffness of the muffler shell and the exhaust pipe.

BRIEF DESCRIPTION OF THE DRAWINGS
[0022] The foregoing summary, as well as the following detailed description of embodiments, is better understood when read in conjunction with the appended drawings. For the purpose of illustrating the disclosure, there is shown in the present document example constructions of the disclosure, however, the disclosure is not limited to the specific methods and device disclosed in the document and the drawing. The detailed description is described with reference to the following accompanying figures.
[0023] Figure 1(a) illustrates an isometric view of an exhaust muffler with a muffler baffle, in accordance with the prior art.
[0024] Figure 1(b) illustrates an isometric view of a muffler baffle, in accordance with the prior art.
[0025] Figure 1(c) illustrates a side view of the muffler baffle, in accordance with the prior art.
[0026] Figure 2(a) illustrates an isometric view of an exhaust muffler with a muffler baffle, in accordance with an embodiment of the present subject matter.
[0027] Figure 2(b) illustrates a side view of the muffler baffle, in accordance with an embodiment of the present subject matter.
[0028] Figure 2(c) illustrates an isometric view of the muffler baffle, in accordance with an embodiment of the present subject matter.
[0029] Figure 3(a) illustrates an isometric view of the exhaust muffler with the muffler baffle, in accordance with an embodiment of the present subject matter.
[0030] Figure 3(b) illustrates a side view of the muffler baffle, in accordance with an embodiment of the present subject matter.
[0031] Figure 3(c) illustrates an isometric view of the muffler baffle, in accordance with an embodiment of the present subject matter.
[0032] The figures depict various embodiments of the present disclosure for purposes of illustration only. One skilled in the art will readily recognize from the following discussion that alternative embodiments of the structures illustrated herein may be employed without departing from the principles of the disclosure described herein.
DETAILED DESCRIPTION OF INVENTION
[0033] Some embodiments of this disclosure, illustrating all its features, will now be discussed in detail. The words "comprising", “having”, and "including," and other forms thereof, are intended to be equivalent in meaning and be open ended in that an item or items following any one of these words is not meant to be an exhaustive listing of such item or items, or meant to be limited to only the listed item or items. It must also be noted that as used herein and in the appended claims, the singular forms "a," "an," and "the" include plural references unless the context clearly dictates otherwise. Although any devices and methods similar or equivalent to those described herein can be used in the practice or testing of embodiments of the present disclosure, the exemplary, devices and methods are now described. The disclosed embodiments are merely exemplary of the disclosure, which may be embodied in various forms.
[0034] Various modifications to the embodiment will be readily apparent to those skilled in the art and the generic principles herein may be applied to other embodiments. However, one of ordinary skill in the art will readily recognize that the present disclosure is not intended to be limited to the embodiments illustrated, but is to be accorded the widest scope consistent with the principles and features described herein.
[0035] Following is a list of elements and reference numerals used to explain various embodiments of the present subject matter.
Reference Numeral Element Description
100 Muffler
101 Muffler Shell
102 Muffler Exhaust Pipe
103 Muffler Baffle
104 Exhaust Gas Flow Direction
105a, 105b Cut-Outs for Exhaust Gas Flow
106 Opening for Exhaust Pipe Mounting
200 Muffler
201 Muffler Shell
202 Outlet Exhaust Pipe
203 Muffler Baffle
204 Exhaust Gas Flow Direction
205 Inlet Exhaust Pipe
206 Open Area Between the Two Baffles
300 Muffler
301 Muffler Shell
302 Outlet Exhaust Pipe
303 Muffler Baffle
304 Exhaust Gas Flow Direction
305 Outer Ring of the Muffler Baffle
306 Inner Ring of the Muffler Baffle
307 Radial Ribs of the Muffler Baffle
308 Open Area Between the Two Rings and Adjacent Ribs for the Exhaust Gas Flow
309 Inlet Exhaust Pipe

[0036] The present subject matter discloses an exhaust muffler for an exhaust system. The exhaust muffler comprises a muffler shell, at least one exhaust pipe and at least one muffler baffle. The muffler baffle is configured to be aligned longitudinally along the direction of an exhaust gas flow. One end of the muffler baffle is configured to be mounted on the muffler shell and the other end of the muffler baffle is configured to be mounted on the exhaust pipe to provide structural stiffness and rigidity to the exhaust muffler. Further, the longitudinal placement of the muffler baffle reduces backpressure and flow noise due to minimum flow restriction to the exhaust gas flow. The structure and design of the muffler baffle is varied in accordance with the configuration of the exhaust muffler to achieve the desired effect.
[0037] Now referring to figure 2(a), 2(b) and 2(c), the exhaust muffler 200 is disclosed in accordance to an embodiment of the present subject matter. The exhaust muffler 200 comprises a muffler shell 201, an inlet exhaust pipe 205, an outlet exhaust pipe 202 and at least one muffler baffle 203. As per one embodiment of the present invention, the said muffler baffle 203 comprises a plurality of muffler baffles 203 configured to be mounted circumferentially between the muffler shell 201 and the outlet exhaust pipe 202. In an embodiment, the shape of the muffler baffles 203 is configured to be selected from a set of Z, T, I, C, O, J, V and alike. One end of the muffler baffles 203 is configured to be mounted circumferentially on the outlet exhaust pipe 202 and other end of the muffler baffles 203 is mounted circumferentially on the muffler shell 201 to secure and provide optimum structural stiffness and rigidity to the exhaust muffler 200. The number of the muffler baffles 203 in the exhaust muffler 200 varies based on the size of the muffler shell 201 and the outlet exhaust pipe 202 and based on the requirement of the open area 206 between any two muffler baffles 203.
[0038] In another embodiment, the length, size, shape and thickness of the muffler baffles 203 are configured to be varied based on the required stiffness and rigidity for the muffler shell 201 and the exhaust pipe (202, 205).
[0039] Now referring to figure 3(a), 3(b) and 3(c), the exhaust muffler 300 is disclosed in accordance to an embodiment of the present subject matter. The exhaust muffler 300 comprises a muffler shell 301, an inlet exhaust pipe 309, an outlet exhaust pipe 302 and at least one muffler baffle 303. Further the muffler baffle 303 comprises an outer ring 305, an inner ring 306 and at least one radial rib 307. Further, the outer ring 305 is configured to be mounted on an inner surface of the muffler shell 301. The inner ring 306 of the muffler baffle 303 is configured to be mounted on an outer surface of the outlet exhaust pipe 302. The outer surface of the outer ring 305 and the inner surface of the muffler shell 301 are configured with a same profile and the inner surface of the inner ring 306 and the outer surface of the outlet exhaust pipe 302 are configured with a same profile for firmly securing the muffler baffle 303 on a predetermined location inside the exhaust muffler 300. As per one embodiment of the present invention, the said muffler baffle 303 comprises a plurality of radial ribs 307 configured to be mounted between the outer ring 305 and the inner ring 306. The plurality of radial ribs 307 are configured to align with the exhaust gas flow 304 to provide optimum open area 308 which will provide minimal obstruction to the exhaust gas flow 304.
[0040] In another embodiment, the length, size and thickness of the radial ribs 307, the outer ring 305, the inner ring 306 tend to vary based on the length, size and shape of the muffler shell 301, the outlet exhaust pipe 302, the inlet exhaust pipe 309 and the required stiffness for the muffler shell 301, the outlet exhaust pipe 302, the inlet exhaust pipe 309. In an embodiment, the plurality of ribs 307 are configured with different shape such as rectangular, square, oval, circular, triangular, elliptical and alike based on the cross-sectional configuration of the muffler shell 301 and the exhaust pipe (302, 309) respectively. In an embodiment, the outer ring 305 and the inner ring 306 are configured with different shapes such as rectangular, square, oval, circular, triangular, elliptical and alike based on the cross-sectional configuration of the muffler shell 301 and the exhaust pipe (302, 309) respectively.
[0041] In an embodiment, the muffler baffle (203, 303) is mounted on an inlet exhaust pipe (207, 309) or an outlet exhaust pipe (202, 302) of the muffler shell (201, 301) as per requirement. Further in another embodiment, the inlet exhaust pipe (207, 309) and the outlet exhaust pipe (202, 302) are configured as eccentric or concentric to the axis of the muffler shell (201, 301). In another embodiment, the inlet exhaust pipe (207, 309) is configured to be coaxial to the outlet exhaust pipe (202, 302).
[0042] In another embodiment, the shape of the exhaust muffler (200, 300) is circular, elliptical, rectangular, square or any other shape thereof.
[0043] In another embodiment, the type of the muffler baffle (203, 303) to be used inside the exhaust muffler (200, 300) is configured to be selected based on the requirement of structural stiffness of the muffler shell (201, 301) and the exhaust pipe (202, 205, 302, 309).
[0044] The present subject matter discloses an exhaust muffler (200, 300) comprising a muffler shell (201, 301), at least one exhaust pipe (202, 205, 302, 309) configured to be mounted inside the muffler shell (201, 301), and at least one muffler baffle (203, 303) configured with one end mounted on the muffler shell (201, 301) and other end mounted on the exhaust pipe (202, 205, 302, 309). The muffler baffle (203, 303) is configured to be aligned longitudinally along the direction of an exhaust gas flow (204, 304) inside the exhaust muffler (200, 300).
[0045] In an embodiment, the at least one muffler baffle 203 is configured to be mounted circumferentially between the muffler shell 201 and the exhaust pipe (202, 205). Further the at least one muffler baffle 203 is configured from a shape selected from a set of “Z”, “T”, “I”, “O”, “C”, “J”, “V” and alike to secure one end of the shape on the exhaust pipe (202, 205) and other end of the shape on the muffler shell 201 for providing stiffness and rigidity to the exhaust muffler 200. The number of the muffler baffles 203 is configured to vary based on the size of the muffler shell 201 and the exhaust pipe (202, 205). Further the length, size, thickness and shape of the muffler baffles 203 are configured to vary based on the requirement of structural stiffness of the muffler shell 201 and the exhaust pipe (202, 205).
[0046] In another embodiment, the muffler baffle 303 is configured with: an outer ring 305, an inner ring 306 and at least one radial rib 307. The outer ring 305 is configured to be mounted on an inner surface of the muffler shell 301. The inner ring 306 is configured to be mounted on an outer surface of the exhaust pipe (302, 309). The at least one radial rib 307 is configured to be mounted between the outer ring 305 and the inner ring 306 wherein the radial rib 307 is configured to align with the exhaust gas flow 304 inside the exhaust muffler 300.
[0047] The outer surface of the outer ring 305 and the inner surface of the muffler shell 301 are configured with a same profile and the inner surface of the inner ring 306 and the outer surface of the exhaust pipe (302, 309) are configured with a same profile adapted for optimal fitment. Further the length, size, thickness of the radial rib 307, the outer ring 305, and the inner ring 306 are configured to vary based on the requirement of structural stiffness for the muffler shell 301 and the exhaust pipe (302, 309).
[0048] The outer ring 305 and the inner ring 306 are configured with a shape selected from a set of rectangular, square, oval, circular, triangular, elliptical and alike based on the cross-sectional configuration of the muffler shell 301 and the exhaust pipe (302, 309) respectively.
[0049] The type of the muffler baffle (203, 303) to be used inside the exhaust muffler (200, 300) is configured to be selected based on the requirement of structural stiffness of the muffler shell (201, 301) and the exhaust pipe (202, 205, 302, 309).
[0050] Exemplary embodiments discussed above may provide certain advantages. Though not required to practice aspects of the disclosure, these advantages may include the following.
[0051] Some embodiments of the subject matter enable to provide a muffler baffle design which is compact, lightweight and cost effective due to ease of manufacturing.
[0052] Some embodiments of the subject matter enable to provide a muffler baffle with improved structural stiffness of the muffler resulting in reduced structure borne noise of the exhaust system.
[0053] Some embodiments of the subject matter enable to provide a muffler baffle which will provide minimal obstruction to the exhaust flow.
[0054] Some embodiments of the subject matter enable to provide a muffler baffle to reduce flow noise and backpressure.
Equivalents
[0055] With respect to the use of substantially any plural and/or singular terms herein, those having skill in the art can translate from the plural to the singular and/or from the singular to the plural as is appropriate to the context and/or application. The various singular/plural permutations may be expressly set forth herein for sake of clarity.
[0056] It will be understood by those within the art that, in general, terms used herein, and especially in the appended claims (e.g., bodies of the appended claims) are generally intended as "open" terms (e.g., the term "including" should be interpreted as "including but not limited to," the term "having" should be interpreted as "having at least," the term "includes" should be interpreted as "includes but is not limited to," etc.). It will be further understood by those within the art that if a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation no such intent is present. For example, as an aid to understanding, the following appended claims may contain usage of the introductory phrases "at least one" and "one or more" to introduce claim recitations. However, the use of such phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles "a" or "an" limits any particular claim containing such introduced claim recitation to inventions containing only one such recitation, even when the same claim includes the introductory phrases "one or more" or "at least one" and indefinite articles such as "a" or "an" (e.g., "a" and/or "an" should typically be interpreted to mean "at least one" or "one or more"); the same holds true for the use of definite articles used to introduce claim recitations. In addition, even if a specific number of an introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should typically be interpreted to mean at least the recited number (e.g., the bare recitation of "two recitations," without other modifiers, typically means at least two recitations, or two or more recitations). Furthermore, in those instances where a convention analogous to "at least one of A, B, and C, etc." is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., "a system having at least one of A, B, and C" would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). In those instances, where a convention analogous to "at least one of A, B, or C, etc." is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., "a system having at least one of A, B, or C" would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). It will be further understood by those within the art that virtually any disjunctive word and/or phrase presenting two or more alternative terms, whether in the description, claims, or drawings, should be understood to contemplate the possibilities of including one of the terms, either of the terms, or both terms. For example, the phrase "A or B" will be understood to include the possibilities of "A" or "B" or "A and B."
[0057] Although implementations for an exhaust muffler have been described in language specific to structural features and/or methods, it is to be understood that the appended claims are not necessarily limited to the specific features described. Rather, the specific features are disclosed as examples of implementation for the exhaust muffler.