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Modular Rear Exhaust Muffler For A Vehicle

Abstract: MODULAR REAR EXHAUST MUFFLER FOR A VEHICLE The disclosure herein generally relate to an exhaust system for an internal combustion (IC) engine and more particularly, to a modular rear exhaust muffler for tuning tail pipe noise for various configurations of engines on a vehicle platform. The internal configurations of the modular rear exhaust muffler can be rearranged in accordance to the engine variant on the vehicle within less time and with minimal investment. The modular rear exhaust muffler reduces investment cost, engineering development, component development and testing time for various configurations of engine on a vehicle platform. The modular rear exhaust muffler has better noise attenuation characteristics and reduced backpressure thereof. The modular rear exhaust muffler assists in achieving better balance among order noise, flow noise and back pressure on a vehicle. Fig. 2

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Notices, Deadlines & Correspondence

Patent Information

Application #
Filing Date
10 August 2021
Publication Number
06/2023
Publication Type
INA
Invention Field
MECHANICAL ENGINEERING
Status
Email
patent@bananaip.com
Parent Application

Applicants

Mahindra & Mahindra Limited
Mahindra Research Valley, Mahindra World City, Plot No:41/1, Anjur P.O., Chengalpattu

Inventors

1. Abhinav Prasad
Mahindra & Mahindra Limited., Mahindra Research Valley. Mahindra World City, Plot No.41/1, Anjur P.O., Chengalpattu, Tamilnadu – 603004
2. Vivek Lingala
Mahindra & Mahindra Limited., Mahindra Research Valley. Mahindra World City, Plot No.41/1, Anjur P.O., Chengalpattu, Tamilnadu – 603004
3. Megavannan J
Mahindra & Mahindra Limited., Mahindra Research Valley. Mahindra World City, Plot No.41/1, Anjur P.O., Chengalpattu, Tamilnadu – 603004
4. Prasath R
Mahindra & Mahindra Limited., Mahindra Research Valley. Mahindra World City, Plot No.41/1, Anjur P.O., Chengalpattu, Tamilnadu – 603004
5. Perumal Janakiraman
Mahindra & Mahindra Limited., Mahindra Research Valley. Mahindra World City, Plot No.41/1, Anjur P.O., Chengalpattu, Tamilnadu – 603004

Specification

DESC:CROSS REFERENCE TO RELATED APPLICATION
This Application is based on and derives the benefit of Indian Provisional Application 202141036189 filed on 10th August 2021, the contents of which are incorporated herein by reference

TECHNICAL FIELD
[001] The embodiments herein generally relate to an engine exhaust system and more particularly, to a modular rear exhaust muffler for tuning tailpipe noise for multiple configurations of engines being used on a vehicle platform.

BACKGROUND
[002] Generally, an exhaust system in a vehicle is used to emit the exhaust gases from an engine to the atmosphere in a controlled manner. An exhaust muffler is a device which is used for reducing noise of exhaust gas emitted by the engine. Noise attenuation across exhaust muffler is defined by the internal construction of the exhaust muffler consisting of primarily baffle plates, internal tubing, perforations on baffle and tubes, end caps, exhaust valves and use of absorptive materials. Exhaust muffler provides restriction to exhaust gas flow which increases overall exhaust back pressure. Engine performance and fuel efficiency are directly related to the back pressure at the engine exhaust system. Lower the exhaust backpressure, higher is the fuel efficiency and better is engine performance. Different engine variants have different exhaust gas flow rates, different power and torque deliveries and hence, different source noise characteristics. To attenuate exhaust tail pipe noise for different engine variants while maintaining exhaust back pressure within specified limit, different exhaust mufflers are required to be developed. Most of modern vehicle platform use multiple engine variants each powered by different fuel and also engines are offered at different performance levels. This demands for design and development of completely new exhaust muffler for each engine variants of single vehicle platform. This increases the engineering development, investment and development time. Providing a modular rear exhaust muffler for tuning tail pipe noise for various configurations of engines on a vehicle platform is difficult and is one of the challenges posed to the original equipment manufacturers (OEM).
[003] Therefore, there exists a need for a modular rear exhaust muffler for an exhaust system of an engine, in which internal configurations can be rearranged for various configurations of engines for same vehicle platform within less time and with minimal investments. Further, there exists a need for the modular rear exhaust muffler, which obviates the aforementioned drawbacks.

OBJECTS
[004] The principal object of embodiments herein is to provide a modular rear exhaust muffler for an engine exhaust system of a vehicle, in which internal configurations can be rearranged for various configurations of engines for same vehicle platform within less time.
[005] Another object of embodiments herein is to provide the modular rear exhaust muffler for tuning tail pipe noise for various configurations of engines of the vehicle.
[006] Another object of embodiments herein is to provide the modular rear exhaust muffler which reduces investment cost, development and testing time for various configurations of powertrain of the vehicle.
[007] Another object of embodiments herein is to provide the modular rear exhaust muffler which has better noise attenuation characteristics and reduced backpressure thereof.
[008] Another object of embodiments herein is to provide the modular rear exhaust muffler which is optimized for various frequency ranges thereby increasing the acoustic transmission loss in respective frequency range.
[009] Another object of embodiments herein is to provide the modular rear exhaust muffler which achieves reduced sound pressure levels (reduce boom feeling) in an occupant compartment of the vehicle by reducing back pressure and to achieve higher acoustic transmission loss.
[0010] Another object of embodiments herein is to provide the modular rear exhaust muffler wherein by minor tweaking of internal constructions and the tail pipes, both order noise and flow noise can be optimized thereby improving sound quality inside passenger compartment.
[0011] Another object of embodiments herein is to provide the modular rear exhaust muffler which assists in achieving better engine performance parameters such as lesser fuel consumption and lesser emission levels.
[0012] Another object of embodiments herein is to provide a construction of muffler casing wherein internal baffles can be located at multiple but defined locations to achieve different chamber volumes for a particular muffler configuration.
[0013] Another object of embodiments herein is to provide a design wherein to achieve desired balance between order noise and flow noise, effective flow diameter of tail pipe can be varied without affecting exterior appearance of tail pipe.
[0014] These and other objects of embodiments herein will be better appreciated and understood when considered in conjunction with following description and accompanying drawings. It should be understood, however, that the following descriptions, while indicating embodiments and numerous specific details thereof, are given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the embodiments herein without departing from the spirit thereof, and the embodiments herein include all such modifications.

BRIEF DESCRIPTION OF DRAWINGS
[0015] The embodiments are illustrated in the accompanying drawings, throughout which like reference letters indicate corresponding parts in various figures. The embodiments herein will be better understood from the following description with reference to the drawings, in which:
[0016] Fig. 1 depicts a modular rear exhaust muffler being installed in an engine exhaust line, according to embodiments as disclosed herein;
[0017] Fig. 2 depicts a modular rear exhaust muffler, according to a first embodiment as disclosed herein;
[0018] Fig. 3 depicts a modular rear exhaust muffler, according to a second embodiment as disclosed herein;
[0019] Fig. 4 depicts a modular rear exhaust muffler, according to a third embodiment as disclosed herein;
[0020] Fig. 5 depicts a cross sectional view of modular rear exhaust muffler, according to first embodiment as disclosed herein;
[0021] Fig. 6 depicts multiple embodiments of modular rear exhaust muffler, as disclosed herein;
[0022] Fig. 7 depicts colour plot and graph for showing tail pipe noise reduction achieved by minor tweaking in the modular rear exhaust muffler; and
[0023] Fig. 8 depicts colour plot and graph for showing tail pipe noise reduction achieved by three different internal construction of the modular rear exhaust muffler.

DETAILED DESCRIPTION
[0024] The embodiments herein and the various features and advantageous details thereof are explained more fully with reference to the non-limiting embodiments that are illustrated in the accompanying drawings and detailed in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.
[0025] The embodiments herein achieve a modular rear exhaust muffler for an engine exhaust system of a vehicle, in which internal configurations can be rearranged for various configurations of engines for same vehicle platform within less time and with minimal investments. Further, embodiments herein achieve the modular rear exhaust muffler for tuning tail pipe noise for various configurations of engine on the vehicle. Referring now to the drawings Figs 1 through 8, where similar reference characters denote corresponding features consistently throughout the figures, there are shown embodiments.
[0026] Fig. 1 depicts a modular rear exhaust muffler (100, 200, 300) being installed in an engine exhaust line, according to embodiments as disclosed herein Exhaust line externally remains the same across the vehicle platform which uses multiple variants of engines. Each engine has its characteristic noise output; to reduce tail pipe noise, alternate muffler internal constructions are required. With this design of modular rear muffler, different internal constructions are feasible, multiple combination of outlet exhaust tubes (tail pipes) and also there is provision to add passive exhaust valve inside the muffler for further control over noise attenuation. While designing the rear muffler is made modular to have alternate internal construction for three engines on the same vehicle platform. The external shape of the muffler is customized to utilize maximum space while it aids modularity in internal construction to make the, suitable for all the three engine requirements.
[0027] Fig. 2 depicts a modular rear exhaust muffler (100), according to a first embodiment as disclosed herein. In the first embodiment, the modular rear exhaust muffler (100) includes a housing (101), an inlet exhaust tube (102), a first end cap (103), a plurality of baffles (104F, 104S), a first exhaust intermediate tube (106), a second exhaust intermediate tube (108), a third exhaust intermediate tube (110), a second end cap (111), a plurality of outlet exhaust tubes (112A, 112B), an adapter cap (113) and a glass wool (114). The housing (101) is adapted to support the components of the modular rear exhaust muffler (100). The housing (101) is a split type housing which includes a first housing section (101Y) and a second housing section (101Z). The second housing section (101Z) is connected to the first housing section (101Y). Each first and second housing sections (101Y, 101Z) defines a plurality of embossing portions (101E) adapted to secure the baffles (104F, 104S) at various locations inside the housing (101) thereby chamber volumes can be varied as required from noise tuning. For example, a volume of the first chamber (101A) is more than that of a volume of the intermediate chamber (101B) and the second chamber (101C). The inlet exhaust tube (102) is adapted to allow exhaust gas flow into a first chamber (101A) defined in the housing (101). The inlet exhaust tube (102) defines an exhaust gas inlet (102I) adapted to facilitate entry of exhaust gas into the inlet exhaust tube (102). The inlet exhaust tube (102) defines a plurality of perforations (102p) adapted to allow exhaust gas flow to the first chamber (101A) thereby reducing the noise of the exhaust gas. The first end cap (103) is adapted to be connected to the inlet exhaust tube (102). The first end cap (103) defines a plurality of fourth perforations (103p) adapted to allow exhaust gas flow from the inlet exhaust tube (102) to the first chamber (101A) thereby reducing noise of the exhaust gas. The plurality of baffles (104F, 104S) are disposed inside the housing (101). The plurality of baffles (104F, 104S) includes a first baffle (104F) and a second baffle (104S). The first baffle (104F) and one end of the housing (101) define a first chamber (101A) in the housing (101). The first baffle (104F) and the second baffle (104S) define an intermediate chamber (101B) in the housing (101). The second baffle (104S) and the other end of the housing (101) defines a second chamber (101C) in the housing (101), where the second chamber (101C) is opposite to the first chamber (101A) in the housing (101). The first baffle (104F) is used to separate the first chamber (101A) and the intermediate chamber (101B) in the housing (101). The first and second baffles (104F, 104S) are adapted to support the first exhaust intermediate tube (106). The first baffle (104F) and the second baffle (104S) are parallel and spaced away from each other. The first baffle (104F) defines a plurality of perforations (104Fp) adapted to allow the exhaust gases to flow to from the first chamber (101A) to the intermediate chamber (101B) in the housing (101) thereby reducing the exhaust noise. The second baffle (104S) defines a plurality of perforations (104Sp) adapted to allow the exhaust gases to flow to from the intermediate chamber (101B) to the second chamber (101C) in the housing (101) thereby reducing the exhaust noise. The first intermediate exhaust tube (106) is supported by the baffles (104F, 104S). The first exhaust intermediate tube (106) is adapted to allow exhaust gas flow from the intermediate chamber (101B) to corresponding outlet exhaust tube (112A) through the second exhaust intermediate tube (108). The first intermediate exhaust tube (106) defines an exhaust gas inlet (106I) adapted to facilitate entry of exhaust gas from the first chamber (101A) to said first intermediate exhaust tube (106). The first intermediate exhaust tube (106) defines an exhaust gas outlet (106P) adapted to facilitate exit of exhaust gas therefrom to the second intermediate exhaust tube (108). One end of the second intermediate exhaust tube (108) is connected to the first intermediate exhaust tube (106) and another end of the second intermediate exhaust tube (108) is connected to corresponding outlet exhaust tube (112A). The second intermediate exhaust tube (108) adapted to allow exhaust gas flow from the first intermediate exhaust tube (106) to corresponding the outlet exhaust gas tube (112B). The second exhaust intermediate tube (108) is co-axial to the first exhaust intermediate tube (106). The second intermediate exhaust tube (108) defines a plurality of seventh perforations (108p) adapted to allow exhaust gas flow therefrom to the second chamber (101C) thereby reducing noise of the exhaust gas. One end of the third intermediate exhaust tube (110) is supported by the second baffle (104S) and is positioned in the intermediate chamber (101B), and another end of the third intermediate exhaust tube (110) is coupled to corresponding another outlet exhaust tube (112B). The third intermediate exhaust tube (110) defines a plurality of sixth perforations (110p) adapted to allow exhaust gas flow therefrom to the second chamber (101C). The third exhaust intermediate tube (110) is parallel and spaced away from the second exhaust intermediate tube (108). The third intermediate exhaust tube (110) adapted to allow exhaust gas flow to corresponding another outlet exhaust gas tube (112B) through the adapter cap (113). The second end cap (111) is adapted to be connected to an exhaust gas inlet (110A) of the third intermediate exhaust tube (110). The second end cap (111) defines a plurality of fifth perforations adapted to allow exhaust gas flow from the intermediate chamber (101B) to the third intermediate exhaust tube (110). The plurality of outlet exhaust tubes (112A, 112B) are supported onto a rear end of the housing (101). The plurality of outlet exhaust tubes (112A, 112B) is adapted to facilitate exit of exhaust gas. The plurality of outlet exhaust tubes (112A, 112B) includes a first outlet exhaust tube (112A) and a second outlet exhaust tube (112B). The first outlet exhaust tube (112A) is in fluid communication with the second exhaust intermediate tube (108). The second outlet exhaust tube (112B) is in fluid communication with the third exhaust intermediate tube (110). Difference in diameters in outlet exhaust tube (112B) and the third intermediate tube (110) is bridged by using an adapter cap (113). The adapter cap (113) adapted to connect the third intermediate exhaust tube (110) to the second outlet exhaust gas tube (112B). The glass wool (114) is adapted to be disposed in the second chamber (101C) to attenuate noise of the exhaust gas.
[0028] Fig. 3 depicts a modular rear exhaust muffler (200), according to a second embodiment as disclosed herein. In the second embodiment, the modular rear exhaust muffler (200) includes a housing (201), an inlet exhaust tube (202), a plurality of baffles (204F, 204S), a plurality of intermediate exhaust tubes (206A, 206B) and a plurality of outlet exhaust tubes (207A, 207B). The housing (201) is adapted to support the components of the modular rear exhaust muffler (200). The housing (201) is a split type housing which includes a first housing section (201Y) and a second housing section (201Z), wherein the second housing section (201Z) is connected to the first housing section (201Y). Each first and second housing sections (201Y, 201Z) defines a plurality of embossing portions (201E) adapted to secure said baffles (204F, 204S) at various locations inside the housing (201) thereby chamber volumes can be varied as required from noise tuning. The inlet exhaust tube (202) includes a first portion (202A) and a second portion (202B). A diameter of the second portion (202B) of the inlet exhaust tube (202) is lesser than a diameter of the first portion (202A) of the inlet exhaust tube (202). The second portion (202B) of the inlet exhaust tube (202) is supported by the baffles (204F, 204S). The first portion (202A) of the inlet exhaust tube (202) is positioned in the first chamber (201A) and is supported by the housing (201). The inlet exhaust tube (202) defines an exhaust gas inlet (202I) on the first portion (202A), wherein the exhaust gas inlet (202I) is adapted to facilitate entry of exhaust gas into the inlet exhaust tube (102). The inlet exhaust tube (202) defines a plurality of perforations (202p) adapted to allow exhaust gas flow to the first chamber (201A) thereby reducing noise of the exhaust gas. The inlet exhaust tube (202) defines an exhaust gas outlet (202Q) on the second portion (202B), wherein the exhaust gas outlet (202P) is adapted to facilitate exit of exhaust gas from the inlet exhaust tube (202) to the second chamber (201C). The plurality of baffles (204F, 204S) are disposed inside the housing (201). The plurality of baffles (204F, 204S) includes a first baffle (204F) and a second baffle (204S). The first baffle (204F) and one end of the housing (201) define a first chamber (201A) in the housing (201). The first baffle (204F) and the second baffle (204S) define an intermediate chamber (201B) in the housing (201). The second baffle (204S) and the other end of the housing (201) defines a second chamber (201C) in the housing (201), where the second chamber (201C) is opposite to the first chamber (201A) in the housing (201). The first baffle (204F) is used to separate the first chamber (201A) and the intermediate chamber (201B) in the housing (201). A volume of the first chamber (201A) is more than that of a volume of the intermediate chamber (201B). A volume of the second chamber (201C) is more than that of a volume of the intermediate chamber (201B). The second chamber (201C) acts as a Helmholtz resonator. The baffle (204F, 204S) are adapted to support the inlet exhaust tube (202). The first baffle (204F) and the second baffle (204S) are parallel and spaced away from each other. The first baffle (204F) defines a plurality of perforations (204Fp) adapted to allow exhaust gas flow from the first chamber (201A) to the intermediate chamber (201B) thereby reducing noise of the exhaust gas. The second baffle (204S) is a solid baffle. Each intermediate exhaust tubes (206A, 206B) is adapted to allow exhaust gas flow from the intermediate chamber (201B) of the housing (201) to corresponding outlet exhaust tubes (207A, 207B). One end of each intermediate exhaust tube (206A, 206B) is supported by the second baffle (204S) and is positioned in the intermediate chamber (201B), and another end of each intermediate exhaust tube (206A, 206B) is connected to corresponding outlet exhaust tube (207A, 207B). Each intermediate exhaust tube (206A) is parallel to the other intermediate exhaust tube (206B). The plurality of outlet exhaust tubes (207A, 207B) are supported onto a rear end of the housing (201). Each outlet exhaust tubes (207A, 207B) are adapted to release exhaust gases to atmosphere.
[0029] Fig. 4 depicts a modular rear exhaust muffler (300), according to a third embodiment as disclosed herein. In the third embodiment, the modular rear exhaust muffler (300) includes a housing (301), an inlet exhaust tube (302), a plurality of baffles (304F, 304S), a first exhaust intermediate tube (306), a third intermediate exhaust tube (307), a second exhaust intermediate tube (308) and an outlet exhaust tube (310), a first end cap (not shown) and a second end cap (311). This variant of modular rear exhaust muffler (300) does not have second outlet exhaust tube (second tail pipe) and the opening in the housing (301) is closed by using the second end cap (311). The housing (301) is adapted to support the components of the modular rear exhaust muffler (300). The inlet exhaust tube (302) defines an exhaust gas inlet (302I) adapted to allow exhaust gas flow into the inlet exhaust tube (302). The inlet exhaust tube (302) includes defines an exhaust gas outlet (302P) adapted to facilitate exit of exhaust gas from the inlet exhaust tube (302) to the first chamber (301A). The plurality of baffles (304F, 304S) is disposed inside the housing (301). The plurality of baffles (304F, 304S) includes a first baffle (304F) and a second baffle (304S). The first baffle (304F) and one end of the housing (301) define a first chamber (301A) in the housing (301). The first baffle (304F) and the second baffle (304S) define an intermediate chamber (301B) in the housing (301). The second baffle (304S) and the other end of the housing (301) defines a second chamber (301C) in the housing (301), where the second chamber (301C) is opposite to the first chamber (301A) in the housing (301). The first baffle (304F) is used to separate the first chamber (301A) and the intermediate chamber (301B) in the housing (301). The baffles (304F, 304S) are adapted to support the first and second exhaust intermediate tubes (306, 308). The first baffle (304F) and the second baffle (304S) are parallel and spaced away from each other. The first baffle (304F) defines a plurality of perforations (304Fp) adapted to allow the exhaust gases to flow to from the first chamber (301A) to the intermediate chamber (301B) in the housing (301) thereby reducing the exhaust gas noise. A volume of the first chamber (301A) is more than that of a volume of the intermediate chamber (301B). A volume of the second chamber (301C) is more than that of a volume of the intermediate chamber (301B). The second baffle (304S) defines a plurality of perforations (304Sp) adapted to allow the exhaust gas flow from the intermediate chamber (301B) to the second chamber (301C) in the housing (301) thereby reducing the exhaust gas noise. The first exhaust intermediate tube (306) is adapted to allow exhaust gas flow from the second chamber (301C) to the outlet exhaust tube (310). One end of the second intermediate exhaust tube (308) which is positioned in the first chamber (301A) is closed by using the first end cap. The open end of the second intermediate exhaust tube (308) is adapted to allow exhaust gas flow from the second chamber (301C) to the second intermediate exhaust tube (308). The second exhaust intermediate tube (308) provides gas flow path among the intermediate chamber (301B) and the second chamber (301C). The second intermediate exhaust tube (308) defines a plurality of third perforations (308p) adapted to allow exhaust gas flow therefrom to the intermediate chamber (301B). The second exhaust intermediate tube (308) is adapted to accommodate a passive spring loaded exhaust valve which is tuned to tune both order and flow noises coming out of exhaust. The outlet exhaust tube (310) is adapted to facilitate exit of exhaust gas to atmosphere.
[0030] Fig. 5 shows cross sectional view of the modular rear muffler (100, 200, 300) wherein multiple embossing portions (101E, 201E, 301E) of specific width and depth are provided on the first and second housing sections (101Y, 201Y, 301Y, 101Z, 201Z, 301Z), all parallel to each other in order to secure internal baffles (104F, 104S) at different locations thereby chamber volumes can be varied as required from noise tuning. The modular muffler disclosed are three-chamber design and it can be designed up to four chambers but only limited by size of the muffler.
[0031] Fig. 6 depicts few additional internal constructions designed using modularity provided by the modular rear muffler wherein number, diameter, length and perforations for each internal tube are varied. Number, location and perforations for internal baffles are varied. Number and diameter of tail pipe are varied. To achieve required engine performance and tail pipe noise targets a specific muffler internal construction can be designed using modularity of the muffler.
[0032] Fig. 7 depicts colour plot and graph for showing tail pipe noise reduction achieved by minor tweaking in the modular rear exhaust muffler. Fig. 8 depicts colour plot and graph for showing tail pipe noise reduction achieved by three different internal construction of the modular rear exhaust muffler. It is clearly evident that from fig. 7 and fig. 8, the noise of the exhaust gas flowing through the modular rear exhaust muffler (100, 200, 300) is significantly reduced when compared to conventional rear exhaust mufflers.
[0033] The technical advantages of the modular rear exhaust mufflers (100, 200, 300) are as follows. The internal configurations can be rearranged for various configurations of engines for same vehicle platform within less time. The modular rear exhaust muffler for tuning tail pipe noise for various configurations of engines of the vehicle. Multiple internal constructions can be realized in the same modular rear exhaust muffler to optimize engine performance and tail pipe noise for different engine variants on a vehicle platform. Using modularity in design desired balance among order noise, flow noise and back pressure can be achieved. The internal configurations of the modular rear exhaust muffler can be rearranged in accordance with the configuration of engine variant on the vehicle within less time and with minimal investments. The modular rear exhaust muffler reduces investment cost, engineering development, component development and testing time for various configurations of powertrain of the vehicle platform. The modular rear exhaust muffler has better noise attenuation characteristics and reduced backpressure thereof. The modular rear exhaust muffler is optimized for various frequency bands thereby increasing the acoustic transmission loss in desired frequency range. The modular rear exhaust muffler which achieves reduced sound pressure levels (reduce boom feeling) in an occupant compartment of the vehicle by reducing back pressure and to achieve higher acoustic transmission loss. Minor tweaking of internal constructions and the tail pipes of the modular rear exhaust muffler results in both order noise and flow noise can be optimized thereby improving sound quality inside passenger compartment. The modular rear exhaust muffler improves sound quality in an occupant compartment of the vehicle while keeping back pressure within required level to ensure fuel efficiency. The modular rear exhaust muffler which assists in achieving better engine performance parameters such as lesser fuel consumption and lesser emission levels. The internal baffles can be located at multiple but defined locations to achieve different chamber volumes for a particular muffler configuration.
[0034] The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modifications within the spirit and scope of the embodiments as described herein.
,CLAIMS:We claim:
1. A modular rear exhaust muffler (100) for a vehicle, said modular rear exhaust muffler (100) comprising:
a housing (101);
a plurality of baffles (104F, 104S) disposed inside said housing (101), wherein said baffles (104F, 104S) includes a first baffle (104F) and a second baffle (104S), wherein said first baffle (104F) and one end of said housing (101) define a first chamber (101A), wherein said first and second baffles (104F, 104B) define an intermediate chamber (101B) there between, wherein said second baffle (104S) and another end of said housing (101) defines a second chamber (101C);
an inlet exhaust tube (102) adapted to allow exhaust gas flow into said first chamber (101A) of said housing (101);
a first intermediate exhaust tube (106) supported by said baffles (104F, 104S);
a plurality of outlet exhaust tubes (112A, 112B) supported onto a rear end of said housing (101);
a second intermediate exhaust tube (108), wherein one end of said second intermediate exhaust tube (108) is connected to said first intermediate exhaust tube (106) and another end of said second intermediate exhaust tube (108) is connected to corresponding said outlet exhaust tube (112A); and
a third intermediate exhaust tube (110), wherein one end of said third intermediate exhaust tube (110) is supported by said second baffle (104S) and is positioned in said intermediate chamber (101B), and another end of said third intermediate exhaust tube (110) is coupled to corresponding another said outlet exhaust tubes (112B).

2. The modular rear exhaust muffler (100) as claimed in claim 1, wherein said housing (101) is a split type housing which includes a first housing section (101Y) and a second housing section (101Z) connected to said first housing section (101Y); and
each of said first and second housing sections (101Y, 101Z) defines a plurality of embossing portions (101E) adapted to secure said baffles (104F, 104S) at various locations inside said housing (101) thereby chamber volumes can be varied as required from noise tuning.

3. The modular rear exhaust muffler (100) as claimed in claim 1, wherein said inlet exhaust tube (102) defines,
an exhaust gas inlet (102I) adapted to facilitate entry of exhaust gas into said inlet exhaust tube (102); and
a plurality of first perforations (102p) adapted to allow exhaust gas flow to said first chamber (101A) to reduce noise of the exhaust gas,
wherein
said first baffle (104F) defines a plurality of second perforations (104Fp) adapted to allow exhaust gas flow from said first chamber (101A) to said intermediate chamber (101B) thereby reducing noise of the exhaust gas;
said second baffle (104S) defines a plurality of third perforations (104Sp) adapted to allow exhaust gas flow from said intermediate chamber (101B) to said second chamber (101C) thereby reducing noise of the exhaust gas; and
a volume of said first chamber (101A) is more than that of a volume of said intermediate chamber (101B) and said second chamber (101C).

4. The modular rear exhaust muffler (100) as claimed in claim 3, wherein said modular rear exhaust muffler (100) includes,
a first end cap (103) adapted to be connected to said inlet exhaust tube (102); and
a second end cap (111) adapted to be connected to an exhaust gas inlet (110A) of said third intermediate exhaust tube (110),
wherein
said first end cap (103) defines a plurality of fourth perforations (103p) adapted to allow exhaust gas flow from said inlet exhaust tube (102) to said first chamber (101A) thereby reducing noise of the exhaust gas; and
said second end cap (111) defines a plurality of fifth perforations adapted to allow exhaust gas flow from said intermediate chamber (101B) to said third intermediate exhaust tube (110); and
said third intermediate exhaust tube (110) defines a plurality of sixth perforations (110p) adapted to allow exhaust gas flow therefrom to said second chamber (101C).

5. The modular rear exhaust muffler (100) as claimed in claim 4, wherein said first intermediate exhaust tube (106) defines,
an exhaust gas inlet (106I) adapted to facilitate entry of exhaust gas from said first chamber (101A) to said first intermediate exhaust tube (106); and
an exhaust gas outlet (106P) adapted to facilitate exit of exhaust gas therefrom to said second intermediate exhaust tube (108),
wherein
said second intermediate exhaust tube (108) defines a plurality of seventh perforations (108p) adapted to allow exhaust gas flow therefrom to said second chamber (101C) thereby reducing noise of the exhaust gas;
said modular rear exhaust muffler (100) includes a glass wool (114) adapted to be disposed in said second chamber (101C) to attenuate noise of the exhaust gas;
said modular rear exhaust muffler (100) includes an adapter cap (113) adapted to connect said third intermediate exhaust tube (110) to corresponding another said outlet exhaust gas tube (112B);
said second intermediate exhaust tube (108) adapted to allow exhaust gas flow from said first intermediate exhaust tube (106) to corresponding said outlet exhaust gas tube (112B); and
said third intermediate exhaust tube (110) adapted to allow exhaust gas flow to corresponding another said outlet exhaust gas tube (112B) through said adapter cap (113).

6. A modular rear exhaust muffler (200) for a vehicle, said modular rear exhaust muffler (200) comprising:
a housing (201);
a plurality of baffles (204F, 204S) disposed inside said housing (201), wherein said baffles (204F, 204S) includes a first baffle (204F) and a second baffle (204S), wherein said first baffle (204F) and one end of said housing (201) define a first chamber (201A), wherein said first and second baffles (204F, 204B) define an intermediate chamber (201B) there between, wherein said second baffle (204S) and another end of said housing (201) defines a second chamber (201C);
an inlet exhaust tube (202) adapted to allow exhaust gas flow into said first chamber (201A) of said housing (201);
a plurality of outlet exhaust tubes (207A, 207B) supported onto a rear end of said housing (201); and
a plurality of intermediate exhaust tubes (206A, 206B), wherein one end of each of said intermediate exhaust tube (206A, 206B) is supported by said second baffle (204S) and is positioned in said intermediate chamber (201B), and another end of each of said intermediate exhaust tube (206A, 206B) is connected to corresponding said outlet exhaust tube (207A, 207B).

7. The modular rear exhaust muffler (200) as claimed in claim 6, wherein said housing (201) is a split type housing which includes a first housing section (201Y) and a second housing section (201Z) connected to said first housing section (201Y); and
each of said first and second housing sections (201Y, 201Z) defines a plurality of embossing portions (201E) adapted to secure said baffles (204F, 204S) at various locations inside said housing (201) thereby chamber volumes can be varied as required from noise tuning.

8. The modular rear exhaust muffler (200) as claimed in claim 7, wherein said inlet exhaust tube (202) includes a first portion (202A) and a second portion (202B), wherein said inlet exhaust tube (202) defines,
an exhaust gas inlet (202I) on said first portion (202A), wherein said exhaust gas inlet (202I) is adapted to facilitate entry of exhaust gas into said inlet exhaust tube (102);
a plurality of first perforations (202p) adapted to allow exhaust gas flow to said first chamber (201A) thereby reducing noise of the exhaust gas; and
an exhaust gas outlet (202Q) on said second portion (202B), wherein said exhaust gas outlet (202P) adapted to facilitate exit of exhaust gas from said inlet exhaust tube (202) to said second chamber (201C),
wherein
said first baffle (204F) defines a plurality of second perforations (204Fp) adapted to allow exhaust gas flow from said first chamber (201A) to said intermediate chamber (201B) thereby reducing noise of the exhaust gas;
said second baffle (104S) is a solid baffle;
a diameter of said second portion (202B) of said inlet exhaust tube (202) is lesser than a diameter of said first portion (202A) of said inlet exhaust tube (202);
said second portion (202B) of said inlet exhaust tube (202) is supported by said baffles (204F, 204S);
said first portion (202A) of said inlet exhaust tube (202) is positioned in said first chamber (201A) and is supported by said housing (201);
a volume of said first chamber (201A) is more than that of a volume of said intermediate chamber (201B); and
a volume of said second chamber (201C) is more than that of a volume of said intermediate chamber (201B).

9. The modular rear exhaust muffler (200) as claimed in claim 7, wherein said second chamber (201C) acts as a Helmholtz resonator; and
each of said intermediate exhaust tube (206A, 206B) is adapted to allow exhaust gas flow from said intermediate chamber (201B) to corresponding said outlet exhaust tube (207A, 207B).

10. A modular rear exhaust muffler (300) for a vehicle, said modular rear exhaust muffler (300) comprising:
a housing (301);
a plurality of baffles (304F, 304S) disposed inside said housing (301), wherein said baffles (304F, 304S) includes a first baffle (304F) and a second baffle (304S), wherein said first baffle (304F) and one end of said housing (301) define a first chamber (301A), wherein said first and second baffles (304F, 304B) define an intermediate chamber (301B) there between, wherein said second baffle (304S) and another end of said housing (301) defines a second chamber (301C);
an inlet exhaust tube (302) adapted to allow exhaust gas flow into said first chamber (301A) of said housing (301);
an outlet exhaust tube (310) supported onto a rear end of said housing (301);
a first intermediate exhaust tube (306) supported by said baffles (304F, 304S), wherein one end of said first intermediate exhaust tube (306) is positioned in said second chamber (301C) and another end of said first intermediate exhaust tube (306) is coupled to said outlet exhaust tube (310); and
a second intermediate exhaust tube (308) supported by said baffles (304F, 304S), wherein one end of said second intermediate exhaust tube (308) which is positioned in said first chamber (301A) is closed and another end of said second intermediate exhaust tube (308) which is positioned in said second chamber (301C) is open.

11. The modular rear exhaust muffler (300) as claimed in claim 10, wherein said housing (301) is a split type housing which includes a first housing section (301Y) and a second housing section (301Z) connected to said first housing section (301Y); and
each of said first and second housing sections (301Y, 301Z) defines a plurality of embossing portions (301E) adapted to secure said baffles (304F, 304S) at various locations inside said housing (301) thereby chamber volumes can be varied as required from noise tuning;
wherein
said modular rear exhaust muffler (300) includes a third intermediate exhaust tube (307) adapted to connect said first intermediate exhaust tube (306) to said outlet exhaust tube (310); and
said second exhaust intermediate tube (308) is adapted to accommodate a passive spring loaded exhaust valve which is tuned to tune both order and flow noises coming out of exhaust.

12. The modular rear exhaust muffler (300) as claimed in claim 10, wherein said inlet exhaust tube (302) includes defines,
an exhaust gas inlet (302I) adapted to facilitate entry of exhaust gas into said inlet exhaust tube (302); and
an exhaust gas outlet (302P) adapted to facilitate exit of exhaust gas from said inlet exhaust tube (302) to said first chamber (301A),
wherein
said first baffle (304F) defines a plurality of second perforations (304Fp) adapted to allow exhaust gas flow from said first chamber (301A) to said intermediate chamber (301B) thereby reducing noise of the exhaust gas;
said second baffle (304S) defines a plurality of second perforations (304Sp) adapted to allow exhaust gas flow from said intermediate chamber (301B) to said second chamber (301C) thereby reducing noise of the exhaust gas;
said one end of said second intermediate exhaust tube (308) which is positioned in said first chamber (301A) is closed by using a first end cap;
said open end of said second intermediate exhaust tube (308) is adapted to allow exhaust gas flow from said second chamber (301C) to said second intermediate exhaust tube (308);
said second intermediate exhaust tube (308) defines a plurality of third perforations (308p) adapted to allow exhaust gas flow therefrom to said intermediate chamber (301B);
said modular rear exhaust muffler (300) does not have second tail pipe and an opening in said housing (301) is closed by using a second end cap (311).
a volume of said first chamber (301A) is more than that of a volume of said intermediate chamber (301B); and
a volume of said second chamber (301C) is more than that of a volume of said intermediate chamber (301B).

Documents

Application Documents

# Name Date
1 202141036189-STATEMENT OF UNDERTAKING (FORM 3) [10-08-2021(online)].pdf 2021-08-10
2 202141036189-PROVISIONAL SPECIFICATION [10-08-2021(online)].pdf 2021-08-10
3 202141036189-POWER OF AUTHORITY [10-08-2021(online)].pdf 2021-08-10
4 202141036189-FORM 1 [10-08-2021(online)].pdf 2021-08-10
5 202141036189-DRAWINGS [10-08-2021(online)].pdf 2021-08-10
6 202141036189-DECLARATION OF INVENTORSHIP (FORM 5) [10-08-2021(online)].pdf 2021-08-10
7 202141036189-Proof of Right [24-12-2021(online)].pdf 2021-12-24
8 202141036189-FORM 18 [10-08-2022(online)].pdf 2022-08-10
9 202141036189-DRAWING [10-08-2022(online)].pdf 2022-08-10
10 202141036189-CORRESPONDENCE-OTHERS [10-08-2022(online)].pdf 2022-08-10
11 202141036189-COMPLETE SPECIFICATION [10-08-2022(online)].pdf 2022-08-10
12 202141036189-FER.pdf 2023-02-15
13 202141036189-OTHERS [14-08-2023(online)].pdf 2023-08-14
14 202141036189-FER_SER_REPLY [14-08-2023(online)].pdf 2023-08-14
15 202141036189-DRAWING [14-08-2023(online)].pdf 2023-08-14
16 202141036189-CORRESPONDENCE [14-08-2023(online)].pdf 2023-08-14
17 202141036189-COMPLETE SPECIFICATION [14-08-2023(online)].pdf 2023-08-14
18 202141036189-CLAIMS [14-08-2023(online)].pdf 2023-08-14
19 202141036189-ABSTRACT [14-08-2023(online)].pdf 2023-08-14
20 202141036189-FORM-8 [20-08-2025(online)].pdf 2025-08-20
21 202141036189-US(14)-HearingNotice-(HearingDate-15-12-2025).pdf 2025-11-14

Search Strategy

1 202141036189E_14-02-2023.pdf