Abstract
A two-piece, stamped muffler having an integrally-attached aerodynamic shield having a flat bottom shape is disclosed. The muffler may be formed with a substantially flat lower surface. The aerodynamically-improved muffler set forth herein is provided as an aerodynamic shield that is incorporated into an extended flange provided in the shell blank, as a deflector that is attached to a muffler lower shell body and the clamshell flange such as by welding, that is separately attached to the clamshell flange only such as by welding, or that is separately attached to the lower shell only, again possibly by welding. For dual stamped mufflers, the shield may be used jointly with an incremental shield separate from, or integrated into, the spare tire well to connect the twin dual muffler shields to achieve vehicle aerodynamic requirements. A muffler having the aerodynamic shield deflects underbody air flow outside of the rear fascia cavity.
Claims
1. An aerodynamic muffler comprising: an upper stamped shell portion; a lower stamped shell portion attached to said upper stamped shell portion, said lower stamped shell portion having a back end; an air deflecting shield integrally mated with said back end of said lower stamped shell portion and extending therefrom.
2. The aerodynamic muffler of claim 1 wherein said lower stamped shell portion is a substantially flat portion, said air deflecting shield being integral with and extending therefrom.
3. The aerodynamic muffler of claim 1 wherein said upper stamped shell portion has two opposed sides and said lower stamped shell portion has two opposed sides, said shells being joined at a peripheral flange, said flange extending from said sides of said portions, said air deflecting shield being integral with said peripheral flange.
4. The aerodynamic muffler of claim 3 wherein said flange has a top side and an underside and wherein said air deflecting shield is attached to said bottom side.
5. The aerodynamic muffler of claim 1 wherein said air deflecting shield has a shape selected from a flat shape, a triangular shape, a J-shape and a V-shape.
6. The aerodynamic muffler of claim 1 wherein said air deflecting shield has a base, a front wall, a back wall and a shield extension.
7. The aerodynamic muffler of claim 1 further including a shield-supporting bracket attached to said back end of said lower stamped portion, said air deflecting shield being attached to said shield-supporting bracket.
8. The aerodynamic muffler of claim 1 wherein said lower stamped portion includes a bottom wall, said flange being attached to and being integral with said bottom wall.
9. An aerodynamic muffler comprising: an upper stamped shell portion; a lower stamped shell portion attached to said upper stamped shell portion, said lower stamped shell portion having a bottom wall, a front end and a back end; and an air deflector integrally formed as part of said lower stamped shell portion.
10. The aerodynamic muffler of claim 9 wherein said integrally formed deflector is a flange extending at a location adjacent said front end of said bottom wall.
11. The aerodynamic muffler of claim 9 wherein said integrally formed deflector is a series of ridges extending from said bottom wall.
12. The aerodynamic muffler of claim 9 wherein said integrally formed deflector is a series of dimples formed on said bottom wall.
13. The aerodynamic muffler of claim 9 wherein said integrally formed deflector is a flange extending from said bottom wall, said bottom wall further including a series of dimples formed thereon.
14. The aerodynamic muffler of claim 13 wherein said flange extends from said bottom wall at a location adjacent said front end of said bottom wall.
15. The aerodynamic muffler of claim 12 further including an exhaust inlet attached to the muffler and a deflector attached to said exhaust inlet.
16. An aerodynamic muffler comprising: an upper shell portion; a lower shell portion attached to said upper shell portion, said lower stamped shell portion having a back end; an air deflector integrally mated with said lower shell portion and extending therefrom, said deflector and said lower shell portion being stamped from a single piece.
17. The aerodynamic muffler of claim 16 wherein said deflector is a flat shield extending from said lower shell portion.
18. The aerodynamic muffler of claim 16 wherein said integrally formed deflector is a flange extending at a location adjacent said front end of said bottom wall.
19. The aerodynamic muffler of claim 16 wherein said integrally formed deflector is a series of ridges extending from said bottom wall.
20. The aerodynamic muffler of claim 16 wherein said integrally formed deflector is a series of dimples formed on said bottom wall.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] For a more complete understanding of this invention, reference should now be made to the embodiments illustrated in greater detail in the accompanying drawings and described below by way of examples of the invention wherein:
[0014] FIG. 1 is a side view of an embodiment of the stamped muffler having an air deflecting shield according to the disclosed inventive concept;
[0015] FIG. 2 is a side view of another embodiment of the stamped muffler having an air deflecting shield according to the disclosed inventive concept;
[0016] FIG. 3 is a side view of another embodiment of the stamped muffler having an air deflecting shield according to the disclosed inventive concept;
[0017] FIG. 4 is a side view of another embodiment of the stamped muffler having an air deflecting shield according to the disclosed inventive concept;
[0018] FIG. 5 is a perspective view of an embodiment of the disclosed inventive concept that includes a pair of stamped mufflers with each muffler having an air deflecting shield;
[0019] FIG. 6 is a perspective view of another embodiment of the disclosed inventive that includes a pair of stamped mufflers with each muffler having an air deflecting shield;
[0020] FIG. 7 is a perspective view of another embodiment of the disclosed inventive concept that includes a pair of stamped mufflers with each muffler having an air deflecting shield;
[0021] FIG. 8 is a partially ghosted, perspective view of an embodiment of the stamped muffler having dual exhaust inputs and outputs and an air deflecting shield according to the disclosed inventive concept;
[0022] FIG. 9 is a partially ghosted, top view of the embodiment of the stamped muffler having dual exhaust inputs and outputs and an air deflecting shield of FIG. 8;
[0023] FIG. 10 is a sectional perspective view of the embodiment of the stamped muffler having dual exhaust inputs and outputs and an air deflecting shield of FIG. 8;
[0024] FIG. 11 is a side view of another embodiment of the stamped muffler having an air deflecting shield according to the disclosed inventive concept;
[0025] FIG. 12 is a side view of another embodiment of the stamped muffler having an air deflecting shield according to the disclosed inventive concept;
[0026] FIG. 13 is a side view of another embodiment of the stamped muffler having an air deflecting shield according to the disclosed inventive concept;
[0027] FIG. 14 is a side view of another embodiment of the stamped muffler having an air deflecting shield according to the disclosed inventive concept;
[0028] FIG. 15 is a side view of another embodiment of the stamped muffler having an air deflecting shield according to the disclosed inventive concept;
[0029] FIG. 16 is a side view of another embodiment of the stamped muffler having an air deflecting shield according to the disclosed inventive concept;
[0030] FIG. 17 is an underside view of the embodiment of the stamped muffler having an air deflecting shield shown in FIG. 16;
[0031] FIG. 18 is a side view of another embodiment of the stamped muffler having an air deflecting shield according to the disclosed inventive concept;
[0032] FIG. 19 is an underside view of the embodiment of the stamped muffler having an air deflecting shield shown in FIG. 18;
[0033] FIG. 20 is a side view of another embodiment of the stamped muffler having an air deflecting shield according to the disclosed inventive concept; and
[0034] FIG. 21 is a side view of another embodiment of the stamped muffler having an air deflecting shield according to the disclosed inventive concept.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0035] In the following figures, the same reference numerals will be used to refer to the same components. In the following description, various operating parameters and components are described for different constructed embodiments. These specific parameters and components are included as examples and are not meant to be limiting.
[0036] The accompanying figures show various related interpretations of the disclosed inventive concept which provides a two-piece aerodynamic muffler having a stamped upper portion attached to a stamped lower portion and an air deflecting structure associated with the stamped lower portion. The air deflecting structure may be a substantially flat flange or may be a surface feature formed on the underside of the stamped lower portion such as a series of parallel ridges or a series of dimples. It is to be understood that the concepts illustrated in the accompanying figures and discussed in relation thereto are not intended as being limiting as certain variations, such as the number and placement of the flange, the length and position of the extension, and the depth, number and placement of the dimples may be varied without deviating from the disclosed inventive concept as discussed hereafter.
[0037] Referring to FIG. 1, a side view of an embodiment of the stamped muffler having an air deflecting shield according to the disclosed inventive concept is illustrated and is generally shown as a stamped, transverse muffler 10. The stamped, transverse muffler 10 includes an upper stamping 12 having attached thereto a stamped lower flat or substantially flat base 14. A flat air deflecting shield 16 extends vehicle rearward from the end of the flat or substantially flat base 14. The air deflecting shield 16 creates an aerodynamic shield effect when the vehicle is moving.
[0038] Referring to FIG. 2, a side view of another embodiment of the stamped muffler having an air deflecting shield according to the disclosed inventive concept is illustrated and is generally shown as a stamped, transverse muffler 20. The stamped, transverse muffler 20 includes an upper stamping 22 having attached thereto a lower shallow stamping 24. The upper stamping 22 and the lower shallow stamping 24 are joined at a peripherally extending mating flange 26. A flat air deflecting shield 28 extends vehicle rearward from the end of the mating flange 26. The air deflecting shield 28 creates an aerodynamic shield effect when the vehicle is moving as illustrated by the air flow AF.
[0039] Referring to FIG. 3, a side view of another embodiment of the stamped muffler having an air deflecting shield according to the disclosed inventive concept is illustrated and is generally shown as a stamped, transverse muffler 30. The stamped, transverse muffler 30 includes an upper stamping 32 having a substantially flat upper surface having attached thereto a deep drawn lower stamping 34 having a domed configuration. The upper stamping 32 and the deep drawn lower stamping 34 are joined at a peripherally extending mating flange 36. A flat air deflecting shield 38 extends vehicle rearward from the end of the mating flange 36.
[0040] Referring to FIG. 4, a side view of another embodiment of the stamped muffler having an air deflecting shield according to the disclosed inventive concept is illustrated and is generally shown as a stamped, transverse muffler 40. The stamped, transverse muffler 40 includes a deep drawn upper stamping 42 having a domed configuration having attached thereto a deep drawn lower stamping 44 that also has a domed configuration. The deep drawn upper stamping 42 and the deep drawn lower stamping 44 are joined at a peripherally extending mating flange 46. A flat air deflecting shield 48 is attached, such as by welding, to the end portion of the mating flange 46. The flat air deflecting shield 48 thus extends vehicle rearward from the end of the mating flange 46.
[0041] As set forth in FIGS. 1 through 4, the disclosed inventive concept has application to transverse mufflers that include an air deflecting shield. Additional transverse mufflers having alternative air deflecting configurations are possible and such configurations are discussed below. However, it is to be understood that the air deflecting shield of the disclosed inventive concept may also find utility with dual muffler exhaust systems of the types illustrated in FIGS. 5, 6 and 7.
[0042] Referring to FIG. 5, a perspective view of a dual muffler embodiment of the disclosed inventive concept is generally illustrated as a dual muffler assembly 50. The dual muffler assembly 50 includes a first muffler 52 having a first exhaust inlet pipe 54 and a first exhaust outlet 55. The first muffler 52 further includes a first upper stamping 56 and a first lower stamping 58. The first upper stamping 56 and the first lower stamping 58 are joined at a first extended flange 60. A first air deflecting shield 62 extends from and is an integral part of the rearward end of the first extended mating flange 60. The dual muffler assembly 50 further includes a second muffler 52 having a second exhaust inlet pipe 541 and a second exhaust outlet 55. The second muffler 52 further includes a second upper stamping 56 and a second lower stamping 58. The second upper stamping 56 and the second lower stamping 58 are joined at a second extended flange 60. A second air deflecting shield 62 extends from and is an integral part of the rearward end of the second extended mating flange 60.
[0043] Referring to FIG. 6, a perspective view of a dual muffler embodiment of the disclosed inventive concept is generally illustrated as a dual muffler assembly 70. The dual muffler assembly 70 includes a first muffler 72 having a first exhaust inlet pipe 74 and a first exhaust outlet 75. The first muffler 72 further includes a first upper stamping 76 and a first lower stamping 78. A first air deflecting shield 80 is fitted to the first lower stamping 78. The first air deflecting shield 80 includes a first air deflecting base wall 81, a first air deflecting shield front wall 82, a first air deflecting shield back wall 84, and a first rearward extending air deflecting flange 85. One or more of the base wall 81, the front wall 82, and the back wall 84 is attached to the first lower stamping 78 by, for example, welding.
[0044] The dual muffler assembly 70 of FIG. 6 further includes a second muffler 72 having a second exhaust inlet pipe 74 and a second exhaust outlet 75. The second muffler 72 further includes a second upper stamping 76 and a second lower stamping 78. A second air deflecting shield 80 is fitted to the second lower stamping 78. The second air deflecting shield 80 includes a second air deflecting base wall 81, a second air deflecting shield front wall 82, a second air deflecting shield back wall 84, and a second rearward extending air deflecting flange 85. One or more of the base wall 81, the front wall 82, and the back wall 84 is attached to the second lower stamping 78 by, for example, welding.
[0045] Referring to FIG. 7, a perspective view of a dual muffler embodiment of the disclosed inventive concept is generally illustrated as a dual muffler assembly 90. The dual muffler assembly 90 includes a first muffler 92 having a first exhaust inlet pipe 94 and a first tailpipe 96. The first muffler 92 further includes a first upper stamping 98 and a first lower stamping 100. A cantilevered first air deflecting shield 102 is attached to the underside of the first lower stamping 100 by, for example, welding. The dual muffler assembly 90 further includes a second muffler 92 having a second exhaust inlet pipe 94 and a second tailpipe 96. The second muffler 92 further includes a second upper stamping 98 and a second lower stamping 100. A cantilevered second air deflecting shield 102 is attached to the underside of the second lower stamping 100 also by, for example, welding.
[0046] As noted above, the disclosed inventive concept applies to a broad variety of muffler types, including both transverse and dual muffler arrangements. However, it is to be understood that the integrated air deflecting shield of the disclosed inventive concept is not to be limited by muffler type. By way of an additional example, FIGS. 8, 9 and 10 illustrated partially ghosted images of a transverse muffler assembly, generally illustrated as 110, fitted with an air deflecting shield that is consistent with the scope of the present invention. Particularly, the transverse muffler assembly 110 includes a muffler 112 having a first exhaust inlet pipe 114, a second exhaust inlet pipe 114, a first tailpipe 116, and a second tailpipe 116. The stamped muffler 112 includes an upper stamping 118 and a lower stamping 120. A cantilevered air deflecting shield 122 is attached to the underside of the lower stamping 120 by, for example, welding.
[0047] Referring to FIG. 11, a side view of another embodiment of the stamped muffler having an air deflecting shield according to the disclosed inventive concept is illustrated and is generally shown as a stamped, transverse muffler 130. The stamped, transverse muffler 130 includes an upper stamping 132 having attached thereto a lower stamping 134. The upper stamping 132 and the lower stamping 134 are joined at a peripherally extending mating flange 136. A triangular air deflecting shield 138 is attached, such as by welding, to the end portion of the mating flange 136 and to the back wall of the lower stamping 134. The triangular air deflecting shield 138 thus extends vehicle rearward from the end of the mating flange 136.
[0048] Referring to FIG. 12, a side view of another embodiment of the stamped muffler having an air deflecting shield according to the disclosed inventive concept is illustrated and is generally shown as a stamped, transverse muffler 140. The stamped, transverse muffler 140 includes an upper stamping 142 having attached thereto a lower stamping 144. The upper stamping 142 and the lower stamping 144 are joined at a peripherally extending mating flange 146. A J-shaped air deflecting shield 148 is attached, such as by welding, to the end portion of the mating flange 146 and to the back wall of the lower stamping 144. The J-shaped air deflecting shield 148 thus extends vehicle rearward from the end of the mating flange 146.
[0049] Referring to FIG. 13, a side view of another embodiment of the stamped muffler having an air deflecting shield according to the disclosed inventive concept is illustrated and is generally shown as a muffler assembly 150. The muffler assembly includes a transverse muffler 152 having an exhaust inlet pipe 154 and a tailpipe 156 attached thereto. The transverse muffler 152 includes an upper stamping 158 having attached thereto a lower stamping 160. An air deflecting shield support bracket 162 is attached to the back wall of the lower stamping 160. A V-shaped air deflecting shield 164 is attached, such as by welding, to the support bracket 162 and to the underside of the lower stamping 160. The V-shaped air deflecting shield 164 thus extends vehicle rearward from the end of the lower stamping 160.
[0050] In addition to the variations of the transverse or dual muffler assemblies and their associated aerodynamic shield arrangements illustrated in FIGS. 1 through 13, the disclosed inventive concept offers alternative aerodynamic features that are integrated with relative ease into the muffler. Specifically, and referring to FIGS. 14 through 22, various embodiments of a muffler having aerodynamic, drag-reducing design features stamped into the lower stamping are illustrated in different configurations and combinations. The common objective of the drag-reducing design features formed in the lower stamping is to have the passing air become detached from the underside of the muffler as soon as possible so as to optimize the aerodynamic count. It is to be understood that the configurations and combinations illustrated in FIGS. 14 through 22 are only suggestive and are not intended as being limiting insofar as other combinations may be possible without deviating from the spirit and scope of the disclosed inventive concepts.
[0051] Referring to FIG. 14, a side view of an embodiment of the stamped muffler having an air deflecting shield according to the disclosed inventive concept in which the lower stamping is modified so as to provide improved aerodynamics is shown. A stamped muffler assembly 170 is generally shown which includes an exhaust inlet pipe 172 and an exhaust outlet (not shown). The muffler assembly 170 includes a muffler 173 having an upper stamping 174 and a relatively shallow lower stamping 176. An extended surface 178 extends from the lower stamping 176 and functions as an air dam to detach air DA from the underside of the lower stamping 176, thereby passing it along as an air flow AF. The extended surface 178 is integrally formed with the lower stamping 176.
[0052] Referring to FIG. 15, a side view of another embodiment of the stamped muffler having an air deflecting shield according to the disclosed inventive concept in which an air deflecting plate has been added forward of the muffler so as to provide improved aerodynamics is shown. A stamped muffler assembly 180 is generally shown which includes an exhaust inlet pipe 182 and an exhaust outlet (not shown). The muffler assembly 180 includes a muffler 183 having an upper stamping 184 and a relatively shallow lower stamping 186. An air deflecting plate 188 is attached to the exhaust inlet pipe 182, such as by welding, at a point forward of the muffler 183. The air deflecting plate 188 functions as an air dam to detach air DA from the underside of the lower stamping 186 as soon as possible, thereby passing it along as an air flow AF.
[0053] Referring to FIGS. 16 and 17, a side view and an underside view of another embodiment of the stamped muffler having an air deflecting shield according to the disclosed inventive concept in which a structure has been formed on the underside of the muffler to provide improved aerodynamics are shown respectively. A stamped muffler assembly 190 is generally shown which includes an exhaust inlet pipe 192 and an exhaust outlet (not shown). The muffler assembly 190 includes a muffler 193 having an upper stamping 194 and a relatively shallow lower stamping 196. A series of parallel ridges 198 is integrally formed on the underside of the lower stamping 196. It is to be understood that a greater or lesser number of parallel ridges 198 may be provided than the number illustrated. The parallel ridges 198 may also be narrower than those illustrated. Regardless of their configuration, the parallel ridges 198 detach air DA from the underside of the lower stamping 196 as soon as possible, thereby passing it along as an air flow AF.
[0054] Referring to FIGS. 18 and 19, a side view and an underside view of another embodiment of the stamped muffler having an air deflecting shield according to the disclosed inventive concept in which an alternative structure has been formed on the underside of the muffler to provide improved aerodynamics are shown respectively. A stamped muffler assembly 200 is generally shown which includes an exhaust inlet pipe 202 and an exhaust outlet (not shown). The muffler assembly 200 includes a muffler 203 having an upper stamping 204 and a relatively shallow lower stamping 206. An array of dimples 208 is integrally formed on the underside of the lower stamping 206. It is to be understood that a greater or lesser number of dimples 208 may be provided than the number illustrated. The dimples 208 may be larger or smaller than those illustrated. Regardless of their configuration, the dimples 208 also detach air DA from the underside of the lower stamping 206 as soon as possible, thereby passing it along as an air flow AF.
[0055] As discussed and illustrated, FIGS. 14 through 19 illustrate different configurations of the lower stamping having integral extended surfaces in the forms of an air dam, a deflection plate, and a series of parallel ridges as well as a dimpled surface. An important feature of the disclosed inventive concept is its ability to be modified, adjusted and otherwise tuned to provide a specific amount of drag. Specific tuning may be achieved based upon a combination of two or more of the integral extended surface, the parallel ridges and the dimpled surface. Examples of such combinations are illustrated in FIGS. 20 and 21.
[0056] Referring to FIG. 20, a side view of a stamped muffler of the disclosed inventive concept representing another such combination of features is illustrated. The stamped muffler, generally illustrated as 210, includes an exhaust inlet pipe 212, an upper stamping 214, and a relatively shallow lower stamping 216. An extended surface 218 is formed adjacent the forward area of the lower stamping 216 and extends therefrom. An array of dimples 220 is formed on the underside of the lower stamping 216. The extended surface 218, working in conjunction with the array of dimples 220, functions as an air dam to detach air DA from the underside of the lower stamping 216. The detached air DA passes along in an air flow AF. The extended surface 218 and the array of dimples 220 are integrally formed with the lower stamping 216.
[0057] Referring to FIG. 21, a side view of a stamped muffler of the disclosed inventive concept representing still another such combination of features is illustrated. The stamped muffler, generally illustrated as 230, includes an exhaust inlet pipe 232, an upper stamping 234, and a relatively shallow lower stamping 236. An extended surface in the form of an air deflecting plate 238 is attached to the exhaust inlet pipe 232, such as by welding, at a point forward of the muffler 230. An array of dimples 230 is formed on the underside of the lower stamping 230. The air deflecting plate 238, working in conjunction with the array of dimples 240, functions as an air deflector to detach air DA from the underside of the lower stamping 236. The detached air DA passes along in an air flow AF.
[0058] The disclosed inventive concept in its various embodiments disclosed in FIGS. 1 through 21 and discussed in relation thereto enhances the inherent aerodynamic function of the large flat surfaces possible in stamped muffler designs. Each of the various tunable embodiments reduces vehicle drag by largely or entirely restricting under body air flow from being captured in the cavity between the rear of the stamped muffler and front of the fascia return flange. In conjunction with the substantially flat bottomed stamped mufflers, the combined function of this invention avoids significant cost through the elimination of separate body exterior rear underbody aero dynamic shields.
[0059] One skilled in the art will readily recognize from such discussion, and from the accompanying drawings and claims that various changes, modifications and variations can be made therein without departing from the true spirit and fair scope of the invention as defined by the following claims.
