Vehicle exhaust assembly

Abstract

The present disclosure relates to a vehicle exhaust assembly (1) for an internal combustion engine. The vehicle exhaust assembly (1) comprises an exhaust system (3) and an exhaust mounting assembly (4) for mounting the exhaust system (3) to a vehicle (2). The exhaust system (3) comprises an inlet section (5) for connection to the internal combustion engine; an intermediate section (6) connected to the inlet section (5); an outlet section (7) for exhausting gases from the internal combustion engine; and one or more exhaust decoupler (8) for decoupling the intermediate section (6) from the inlet section (5). The exhaust mounting assembly (4) comprises one or more first isolator device (20-1, 20-2) for resiliently constraining movement of the intermediate section (6) of the exhaust system (3) in a longitudinal direction; and one or more second isolator device (20-3, 20-4) for resiliently constraining movement of the outlet section (7) of the vehicle (2) exhaust in a transverse direction. The present disclosure also relates to a vehicle (2) including a vehicle exhaust assembly (1).

Claims

1. A vehicle exhaust assembly for an internal combustion engine, the vehicle exhaust assembly comprising; an exhaust system; and an exhaust mounting assembly for mounting the exhaust system, wherein the exhaust system comprises: an inlet section for connection to the internal combustion engine; an intermediate section connected to the inlet section; an outlet section for exhausting gases from the internal combustion engine; and at least one exhaust decoupler for decoupling the intermediate section from the inlet section, and wherein the exhaust mounting assembly comprises: at least one first isolator device for resiliently constraining movement of the intermediate section of the exhaust system in a longitudinal direction and for inhibiting movement of the intermediate section of the exhaust system in a transverse direction; and at least one second isolator device for resiliently constraining movement of the outlet section of the vehicle exhaust in the transverse direction and for inhibiting movement of the outlet section of the exhaust system in the longitudinal direction.

2. The vehicle exhaust assembly as claimed in claim 1, wherein the at least one first isolator device has an axial dynamic stiffness in the longitudinal direction of less than or equal to 60 N/mm up to an excitation frequency of 180 Hz.

3. The vehicle exhaust assembly as claimed in claim 1, wherein the at least one second isolator device has an axial dynamic stiffness in the transverse direction of less than or equal to 60 N/mm up to an excitation frequency of 180 Hz.

4. The vehicle exhaust assembly as claimed in claim 1, wherein the at least one first isolator device comprises a first resilient isolator element moulded from an elastomeric material and/or wherein the at least one second isolator device comprises a second resilient isolator element moulded from an elastomeric material.

5. The vehicle exhaust assembly as claimed in claim 4, wherein the at least one first isolator device comprises a first rigid housing, wherein the first resilient isolator element is moulded into the first rigid housing, and/or wherein the at least one second isolator device comprises a second rigid housing, wherein the second resilient isolator element is moulded into the second rigid housing.

6. The vehicle exhaust assembly as claimed in claim 1, wherein the at least one first isolator device provides greater resilient constraint for the intermediate section in the longitudinal direction than in a vertical direction and/or wherein the at least one second isolator device provides greater resilient constraint for the outlet section in the transverse direction than in the vertical direction.

7. The vehicle exhaust assembly as claimed in claim 6, wherein the at least one first isolator device is configured to support the intermediate section in the vertical direction substantially without resiliently constraining movement in the vertical direction and/or wherein the at least one second isolator device is configured to support the outlet section in the vertical direction substantially without resiliently constraining movement in the vertical direction.

8. The vehicle exhaust assembly as claimed in claim 1, wherein the at least one first isolator device is a single first isolator device.

9. The vehicle exhaust assembly as claimed in claim 1, wherein the at least one second isolator device is a single second isolator device.

10. The vehicle exhaust assembly as claimed in claim 1, wherein the at least one second isolator device comprises two second isolator devices only.

11. The vehicle exhaust assembly as claimed in claim 1, wherein the at least one exhaust decoupler has a length greater than or equal to 180 mm.

12. The vehicle exhaust assembly as claimed in claim 1, wherein the at least one exhaust decoupler is configured to reduce excitation of the intermediate section to less than 0.18 mm at frequencies less than or equal to 500 Hz.

13. The vehicle exhaust assembly as claimed in claim 1, wherein the at least one exhaust decoupler has an axial dynamic stiffness of less than or equal to 50 N/mm up to an excitation frequency of 160 Hz.

14. The vehicle exhaust assembly as claimed in claim 1, wherein the at least one exhaust decoupler has a lateral dynamic stiffness of less than or equal to 60 N/mm up to an excitation frequency of 180 Hz.

15. The vehicle exhaust assembly as claimed in claim 1, wherein the at least one exhaust decoupler comprises one or more of the following: a flexible conduit, a convoluted tube, and a metal braided conduit.

16. The vehicle exhaust assembly as claimed in claim 1, wherein the intermediate section comprises at least one second exhaust decoupler.

17. The vehicle exhaust assembly as claimed in claim 1, wherein the at least one exhaust decoupler is a single exhaust decoupler.

18. The vehicle exhaust assembly as claimed in claim 1, wherein the exhaust system is made of metal sheet having a gauge thickness of between 0.4 mm and 0.7 mm.

19. The vehicle exhaust assembly as claimed in claim 1, wherein the intermediate section of the exhaust system comprises an after-treatment device.

20. A vehicle comprising the vehicle exhaust assembly of claim 1.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) One or more embodiments of the present invention will now be described, by way of example only, with reference to the accompanying figures, in which:

(2) FIG. 1 shows a vehicle incorporating a vehicle exhaust assembly in accordance with an embodiment of the present invention;

(3) FIGS. 2A-D show perspective views of the vehicle exhaust assembly shown in FIG. 1;

(4) FIG. 3 shows a schematic representation of the vehicle exhaust assembly shown in FIG. 1;

(5) FIG. 4A shows first and second graphs showing the axial dynamic stiffness of an exhaust decoupler in the vehicle exhaust assembly shown in FIG. 1;

(6) FIG. 4B shows third and fourth graphs showing the lateral and radial dynamic stiffness of an exhaust decoupler in a variant of the vehicle exhaust assembly shown in FIG. 1;

(7) FIG. 5A shows a resilient isolator element for an isolator device of the vehicle exhaust assembly; and

(8) FIG. 5B shows a fifth graph showing the stiffness of the resilient isolator element shown in FIG. 5A.

DETAILED DESCRIPTION

(9) A vehicle exhaust assembly 1 in accordance with an embodiment of the present invention will now be described with reference to the accompanying figures. The vehicle exhaust assembly 1 in the present embodiment is for use in a vehicle 2 to expel exhaust gases from an internal combustion engine (not shown). The internal combustion engine is front-mounted in the vehicle 2 and the vehicle exhaust assembly 1 extends under the body of the vehicle 2, as shown schematically in FIG. 1. The vehicle 2 is an automobile in the present embodiment, but the techniques and apparatus described herein can be applied to other types of vehicles.

(10) A vehicle reference frame comprises a longitudinal axis X, a transverse axis Y and a vertical axis Z. The vehicle exhaust assembly 1 is described herein using the vehicle reference frame. The terms longitudinal, transverse and vertical (and derivatives thereof) used herein correspond to the vehicle reference frame.

(11) As shown in FIG. 2A, the vehicle exhaust assembly 1 comprises an exhaust system 3 and an exhaust mounting assembly 4. The exhaust system 3 routes exhaust gases from the internal combustion engine to the rear of the vehicle 2. The exhaust system 3 comprises an inlet section 5, an intermediate section 6, and an outlet section 7. The inlet section 5 comprises an exhaust decoupler 8 and an inlet conduit 9. As shown in FIG. 2B, the exhaust decoupler 8 is a flexible coupling (providing a super-soft coupling element) and comprises a decoupler inlet 10, a decoupler outlet 11 and a decoupler sidewall 12. The exhaust decoupler 8 forms a flexible conduit for reducing the transmittal of vibrations into the intermediate section 6 of the exhaust system 3. The decoupler sidewall 12 in the present embodiment is formed by a flexible metal braid. The inlet conduit 9 is a stainless steel pipe having a diameter of 65 mm and is connected to an exhaust port of the internal combustion engine. The inlet conduit 9 is substantially rigid (i.e. inflexible) and connects to the decoupler inlet 10. In use, the vibrations are the result of two primary excitations in the form of the internal combustion engine and/or the road surface. The exhaust decoupler 8 is generally cylindrical and has a length (measured along a central longitudinal axis) of 180 mm. The decoupler outlet 11 has a diameter of 60 mm and connects to the intermediate section 6 of the exhaust system 3. In certain arrangements, more than one exhaust decoupler 8 could be provided in said inlet section 5.

(12) The intermediate section 6 comprises a silencer 13, and first and second intermediate conduits 14-1, 14-2. The silencer 13 has one inlet 15, first and second outlets 16-1, 16-2, and a sidewall 17. The inlet 15 of the silencer 13 is connected to the decoupler outlet 11; and the first and second intermediate conduits 14-1, 14-2 are connected to the first and second outlets 16-1, 16-2 respectively. Optionally, an exhaust decoupler could be provided in each of said first and second intermediate conduits 14-1, 14-2. The first and second intermediate conduits 14-1, 14-2 each have a diameter of 70 mm and are made of stainless steel having a gauge thickness of 0.5 mm (or less). The first and second intermediate conduits 14-1, 14-2 are substantially rigid (i.e. inflexible).

(13) The outlet section 7 comprises first and second exhaust silencers 18-1, 18-2, and first and second tailpipes 19-1, 19-2. The first and second intermediate conduits 14-1, 14-2 are connected to the first and second exhaust silencers 18-1, 18-2 respectively. The first and second tailpipes 19-1, 19-2 are disposed at the rear of the vehicle 2 to expel exhaust gases from the exhaust system 3.

(14) The exhaust mounting assembly 4 provides a semi-rigid structure to support the exhaust system 3 under the body of the vehicle 2. The exhaust mounting assembly 4 comprises a first mounting assembly 20 for mounting the intermediate section 6 of the exhaust system 3. The first mounting assembly 20 comprises first and second opposing isolator devices 20-1, 20-2 fixedly attached to a mounting plate 21 which is fastened to the vehicle body. As shown in FIG. 2C, the first isolator device 20-1 comprises a first housing 22-1 and a first resilient isolator element 23-1. The first housing 22-1 is in the form of a rigid metal frame into which the first resilient isolator element 23-1 is over-moulded. The first resilient isolator element 23-1 has a first central aperture 24-1 for receiving a first mounting pin 25-1. The second isolator device 20-2 comprises a second housing 22-2 and a second resilient isolator element 23-2. The second housing 22-2 is in the form of a rigid metal frame into which the second resilient isolator element 23-2 is over-moulded. The second resilient isolator element 23-2 has a second central aperture (not visible) for receiving a second mounting pin (not visible). The first and second mounting pins 25-1, 25-2 are connected respectively to a first bracket 26-1 and a second bracket (not visible). The first and second brackets 26-1 are rigidly mounted to the first and second intermediate conduits 14-1, 14-2, for example by welding, brazing or mechanical fasteners. The first and second resilient isolator elements 23-1, 23-2 provide a semi-rigid mounting arrangement for the intermediate section 6 of the exhaust system 3. The first and second resilient isolator elements 23-1, 23-2 thereby form a localised body interface between the first and second brackets 26-1 and the first and second intermediate conduits 14-1, 14-2. Alternatively, or in addition, a metal retaining band or collar can be disposed around the outside of the silencer to mount the intermediate section 6. One or more additional mounting bracket can optionally be provided along the length of the first and second intermediate conduits 14-1, 14-2, for example at a mid-point, to provide additional support. The first and second mounting pins 25-1, 25-2 have a first head 27-1 and a second head (not visible) for engaging an outer surface of the first and second resilient isolator elements 23-1. The first and second isolator devices 20-1, 20-2 are disposed on opposing sides of the first and second intermediate conduits 14-1, 14-2. The first and second isolator devices 20-1, 20-2 are arranged coaxially such that the first and second central apertures 24-1 are disposed on a transverse axis parallel to the transverse axis Y of the vehicle 2.

(15) When located in said first and second central apertures 24-1, the first and second mounting pins 25-1, 25-2 extend transversely.

(16) As illustrated in FIGS. 2C and 3, the first and second resilient isolator elements 23-1, 23-2 are configured to resiliently constrain movement of the first and second mounting pins 25-1, 25-2 in a longitudinal direction (i.e. parallel to a longitudinal axis X of the vehicle 2), for example due to shunt loads resulting from dynamic acceleration/deceleration of the vehicle 2. By constraining movement in said longitudinal direction, the first and second isolator devices 20-1, 20-2 protect the exhaust decoupler 8 from over-extension and compression. The first and second resilient isolator elements 23-1, 23-2 are arranged to provide an axial dynamic stiffness in said longitudinal direction which is less than or equal to 60 N/mm up to an excitation frequency of 180 Hz. The first and second resilient isolator elements 23-1, 23-2 can also constrain or inhibit movement of the first and second mounting pins 25-1, 25-2 in a vertical direction (i.e. parallel to a vertical axis Z of the vehicle 2). The first and second resilient isolator elements 23-1, 23-2 can provide greater resilient constraint for the intermediate section 6 in the longitudinal direction than in the vertical direction. The first and second resilient isolator elements 23-1, 23-2 can at least substantially inhibit movement of the first and second mounting pins 25-1, 25-2 in a transverse direction (i.e. parallel to a transverse axis Y of the vehicle 2).

(17) The exhaust mounting assembly 4 comprises a first silencer mounting assembly 28-1 for mounting the first exhaust silencer 18-1; and a second silencer mounting assembly 28-2 for mounting the second exhaust silencer 18-2. As shown in FIG. 2D, the first silencer mounting assembly 28-1 comprises a third isolator device 20-3 fixedly attached to a first hanger 29-1 which is fastened to the vehicle body. The third isolator device 20-3 comprises a third housing 22-3 and a third resilient isolator element 23-3. The third housing 22-3 is in the form of a rigid metal frame into which the third resilient isolator element 23-3 is over-moulded. The third resilient isolator element 23-3 has a fourth central aperture 24-3 for locating a third mounting pin 25-3. The third mounting pin 25-3 is fixedly mounted to the first exhaust silencer 18-1. The third mounting pin 25-3 has a third head (not visible) for engaging an outer surface of the third resilient isolator element 23-3. As illustrated in FIGS. 2D and 3, the third resilient isolator element 23-3 is configured to constrain movement of the third mounting pin 25-3 in a transverse direction (i.e. parallel to a transverse axis Y of the vehicle 2). The third resilient isolator element 23-3 can also constrain or inhibit movement of the third mounting pin 25-3 in a vertical direction (i.e. parallel to a vertical axis Z of the vehicle 2) and/or a longitudinal direction (i.e. parallel to a longitudinal axis X of the vehicle 2). The third resilient isolator element 23-3 can improve positional control of the first tailpipe 19-1. The appearance of the first tailpipe 19-1 in relation to the surrounding bumper/trim can be improved.

(18) The second silencer mounting assembly 28-2 comprises a fourth isolator device 20-4 fixedly attached to a second hanger 29-2 which is fastened to the vehicle body. The fourth isolator device 20-4 comprises a fourth housing (not visible) and a fourth resilient isolator element 23-4. The fourth housing is in the form of a rigid metal frame into which the fourth resilient isolator element 23-4 is over-moulded. The fourth resilient isolator element 23-4 has a fourth central aperture (not visible) for locating a fourth mounting pin 25-4. The fourth mounting pin 25-4 is fixedly mounted to the first exhaust silencer 18-1. The fourth mounting pin 25-4 has a fourth head (not visible) for engaging an outer surface of the fourth resilient isolator element 23-4. The vehicle exhaust assembly 1 is shown schematically in FIG. 3, albeit with the second exhaust silencer 18-2 omitted for clarity.

(19) As illustrated in FIG. 3, the fourth resilient isolator element 23-4 resiliently constrains movement of the fourth mounting pin 25-4 in a transverse direction (i.e. parallel to the transverse axis Y of the vehicle 2). The fourth resilient isolator element 23-4 is arranged to provide an axial dynamic stiffness in said transverse direction which is less than or equal to 60 N/mm up to an excitation frequency of 180 Hz. The fourth resilient isolator element 23-4 can also support the fourth mounting pin 25-4 in a vertical direction (i.e. parallel to the vertical axis Z of the vehicle 2). The fourth resilient isolator element 23-4 can provide greater resilient constraint in said transverse direction than in said vertical direction. The fourth resilient isolator element 23-4 can at least substantially inhibit movement of said fourth mounting pin 25-4 in a longitudinal direction (i.e. parallel to a longitudinal axis Y of the vehicle 2). The fourth resilient isolator element 23-4 can improve positional control of the second tailpipe 19-2. The appearance of the second tailpipe 19-2 in relation to the surrounding bumper/trim can be improved.

(20) The exhaust mounting assembly 4 facilitates a lightweight construction of the exhaust system 3. The mechanical properties of the exhaust mounting assembly 4 which provide this functionality will now be described. As outlined above, the exhaust decoupler 8 has a length of 180 mm to reduce transmittal of vibrations from the inlet section 5 to the intermediate section 6. The exhaust decoupler 8 could be longer, for example 200 mm. The axial mechanical properties of the exhaust decoupler 8 are illustrated in first and second graphs 100, 105 shown in FIG. 4A. The first graph 100 shows the axial dynamic stiffness (N/mm) for an excitation amplitude of 0.2 mm in relation to frequency (Hz); and the second graph 105 shows the axial dynamic stiffness (N/mm) for excitation amplitudes of 0.1 mm and 0.2 mm in relation to frequency (Hz). A first plot 106 in the second graph 105 represents the axial dynamic stiffness for an axial excitation amplitude of 0.1 mm; and a second plot 107 represents the axial dynamic stiffness for an axial excitation amplitude of 0.2 mm. As represented by the dashed lines in the first and second graphs 100, 105, the axial dynamic stiffness of the exhaust decoupler 8 is less than 50 N/mm up to an exciting frequency of 160 Hz. The exhaust decoupler 8 is configured to reduce excitation to less than 0.18 mm at exciting frequencies less than or equal to 500 Hz. The lateral and radial mechanical properties of the exhaust decoupler 8 are illustrated in third and fourth graphs 110, 115 shown in FIG. 4B. The third graph 110 shows the lateral dynamic stiffness (N/mm) for an excitation amplitude of 0.2 mm in relation to frequency (Hz); and the fourth graph 115 shows the radial dynamic stiffness (N/mm) for excitation amplitudes of 0.1 mm and 0.2 mm in relation to frequency (Hz). A first plot 116 in the fourth graph 115 represents the radial dynamic stiffness for a radial excitation amplitude of 0.1 mm; and a second plot 117 represents the radial dynamic stiffness for a radial excitation amplitude of 0.2 mm. As represented by the dashed lines in the third and fourth graphs 110, 115, the dynamic stiffness of the exhaust decoupler 8 is less than 60 N/mm for an exciting frequency less than or equal to 180 Hz.

(21) The first, second, third and fourth resilient isolator elements 23-1, 23-2, 23-3, 23-4 are made of an elastomeric material, such as a rubber compound. The first, second, third and fourth resilient isolator elements 23-1, 23-2, 23-3, 23-4 can have the same or different mechanical properties. A resilient isolator element 23 is shown in FIG. 5A by way of example. The resilient isolator element 23 in the present embodiment is available from the applicant and has part number C2P13213. The resilient isolator element 23 is illustrated in a YZ plane and a fifth graph 120 illustrating the mechanical properties in the Z-axis is shown in FIG. 5B. In the Y direction, loading is transmitted directly by the resilient isolator element 23 to the housing 22. In the Z direction, shear loading of the resilient isolator element 23 improves isolation performance, since it is free to move within an air gap. The arrangement of the resilient isolator element 23 thereby provides different mechanical properties in the Y and Z directions. The resilient isolator element 23 is configured to negate stiffness behaviours in the X direction (i.e. out-of-plane stiffness). The resilient isolator element has an axial dynamic stiffness along the Z-axis of less than or equal to 60 N/mm up to an excitation frequency of 180 Hz. A first plot 125 in the fifth graph 120 shows the axial dynamic stiffness of the resilient isolator element with a preload of 40 N; and a second plot 130 shows the axial dynamic stiffness of the resilient isolator element with a preload of 80 N. The second plot 130 represents axial dynamic stiffness along the Z-axis which is less than or equal to 60 N/mm (up to an excitation frequency of 180 Hz), as represented by the dashed lines in the fifth graph 120. At least in certain embodiments, the local body interface stiffness should be not less than ten (10) times the dynamic stiffness in a vertical direction.

(22) The resilient isolator element 23 shown in FIG. 5A is representative of the first, second, third and fourth resilient isolator elements 23-1, 23-2, 23-3, 23-4. However, it will be understood that the relative orientation of the resilient isolator element 23 is changed depending on its application. The orientation of the isolator elements 23-1, 23-2, 23-3 affect centre of mass constraints under vehicle dynamic behaviour. When implemented as the first and second resilient isolator elements 23-1, 23-2, the resilient isolator element 23 is disposed in a XZ plane such that the axial dynamic stiffness along the X-axis is less than or equal to 60 N/mm (up to an excitation frequency of 180 Hz). When implemented as the third and fourth resilient isolator elements 23-3, 23-4, the resilient isolator element 23 is disposed in a YZ plane such that the axial dynamic stiffness along the Y-axis is less than or equal to 60 N/mm (up to an excitation frequency of 180 Hz).

(23) At least in certain embodiments of the present invention the vehicle exhaust assembly 1 can result in a mass reduction of approximately 50% (10-15 kg). Moreover, vehicle exhaust assembly 1 can remove the need for structural vibration palliatives to address noise, vibration and harshness (NVH).

(24) The exhaust system 3 has been described as being made of stainless steel. In certain embodiments, stainless steel, such as Inconel, could be used to fabricate the exhaust system 3. It will be appreciated that titanium or other metals could be used in place of stainless steel.

(25) It will be appreciated that changes and modifications can be made to the vehicle exhaust assembly 1 described herein without departing from the scope of the present application. For example, the diameters of the various conduits could be changed from the values specified herein. Likewise, the gauge thickness of the material used to form the conduits could be varied from the values specified herein. Furthermore, it will be appreciated that the geometry of the vehicle exhaust assembly 1 could be modified, for example to suit different vehicles and different powertrain configurations.

(26) The exhaust system 3 has been described as comprising one exhaust decoupler 8 disposed in the inlet section 5. In alternate arrangements, the exhaust system 3 can comprise more than one exhaust decoupler 8. The inlet section 5 could comprise more than one exhaust decoupler 8 disposed in a series arrangement in the inlet conduit 9. Alternatively, the inlet section 5 can comprise a plurality of inlet conduits 9. One or more exhaust decoupler 8 can be disposed in each of said inlet conduits 9. Alternatively, or in addition, the intermediate section 6 can comprise one or more exhaust decoupler. For example, the first and second intermediate conduits 14-1, 14-2 can each comprise one or more exhaust decoupler. An exhaust decoupler can be disposed between the silencer 13 and the first and second intermediate conduits 14-1, 14-2; and/or between the first and second intermediate conduits 14-1, 14-2 and the first and second exhaust silencers 18-1, 18-2. Alternatively, or in addition, the outlet section 7 can comprise one or more exhaust decoupler.