Abstract: A passive exhaust valve assembly includes an exhaust conduit that has a first pipe section attached in generally axial alignment with a second pipe section. The end portion of the first pipe section includes a circumferential segment disposed within the end portion of the second pipe section to form an overlapping interface. The end portions of the first and second pipe sections each include a flange protruding radially outward from the respective first or second pipe section, whereby the flanges engage with each other to form an axle seat therebetween. A support shaft extends laterally across an interior volume of the exhaust conduit and rotatably engages the axle seat. A valve plate is coupled to the support shaft within the interior volume of the exhaust conduit for moving relative to the exhaust conduit between open and closed positions.

Abstract: A mixer assembly of a vehicle exhaust system includes a base tube or pipe section and a plurality of mixing or stirring blades that sequentially engage notches formed in an end or edge portion of the base tube section and interconnect with each other to form a static blade assembly. Each blade of the plurality of mixing blades spans across the interior volume of the base tube section and includes a tab or attachment feature at each of the opposing ends of the respective blade that engages notches on opposing sides of the base tube section. The tabs of the plurality of mixing blades may be coupled with the notches in a manner that prevents disengagement and provides no weld surfaces at an interior volume of the base tube section.

Abstract: A passive exhaust valve assembly includes an exhaust conduit or pipe section with a valve plate or vane member that can pivot within the interior section or volume of the exhaust conduit to regulate the flow of exhaust gases through the exhaust conduit. A flexible bumper element, such as a metal mesh pad, may be positioned on the interior surface of the exhaust conduit, such that an end portion of the valve plate may contact the mesh pad in the closed position. The bumper element may be disposed in a recessed pocket or depression and may be biased inward, such as with a spring, for the end portion of the valve plate to contact the bumper element as it moves toward the closed position, and thereby gradually reduce the closure speed of the valve plate to the closed position.

Abstract: A passive valve assembly for an engine exhaust system includes an exhaust conduit for transferring exhaust gases from the engine and a valve plate that is operably disposed within the exhaust conduit. A pivot rod has an internal section that is coupled with the valve plate, such that the valve plate may pivot between an open position and a closed position. The pivot rod also has an external section that protrudes from the exhaust conduit. A stop feature is disposed at or near an exterior surface of the exhaust conduit in a location arranged to contact the external section of the pivot rod and prevent the valve plate from pivoting beyond one of the open position and the closed position.

Abstract: The provided process creates a fully flanged interlocked bushing by feeding a metal strip into a stamping assembly having a plurality of tool stations. The stations blank a workpiece from the metal strip, and trim the workpiece's two opposing ends forming a triangular shaped tab and a puzzle locking feature on either end. The workpiece is then formed into an annular shape, wherein the triangular shaped tabs are overlapped as the opposing ends are abutted and interlocked. A flange is then imparted into the side wall of the workpiece relieving the tab's overlapping condition, causing the tabs to abut one another and become co-planar with the flange. This creating a fully flanged part with a tightly fitted parting line. This invention also includes products formed by the aforementioned process.

Abstract: A unique tubular work piece is disclosed along with a novel method and apparatus for manufacturing tubular work pieces from sheet metal stock lighter and stronger structures with less waste and less cost than prior methods.

Abstract: A unique tubular work piece is disclosed along with a novel method and apparatus for manufacturing tubular work pieces from sheet metal stock lighter and stronger structures with less waste and less cost than prior methods.