Abstract: A stamp formed muffler includes upper and lower internal plates and upper and lower external shells secured to the respective internal plates. The internal plates are formed to include arrays of channels that are placed in register with one another to define an array of tubes. The external shells are formed to define chambers that surround selected tubes formed by the internal plates. The upper internal plate includes at least one pair of aligned channels disposed in spaced apart end-to-end relationship and in register with a continuous channel in the lower internal plate. The chambers of the external shells are separated from one another by baffle creases. The baffle crease of the upper external shell is disposed in registration with the spaced apart aligned channels of the upper external shell. As a result, the baffle crease of the upper external shell is substantially free of pockets that conceivably could trap foreign materials.

Abstract: A muffler is provided comprising an array of tubes and a stamp formed external shell surrounding the tubes. The external shell is stamp formed to define at least one chamber surrounding at least portions of the tubes. The chamber extends away from peripheral portions of the external shell to define a three-dimensional volume. The chamber is characterized by a plurality of inwardly directed V-shaped grooves, with each groove extending continuously between opposed spaced apart locations on the periphery of each chamber. The grooves preferably define a parallel array of substantially identical grooves. The grooves strengthen the walls of the chamber and efficiently prevent shell noise.

Abstract: A stamp formed exhaust muffler for mounting on a vehicle is provided. The muffler comprises a plurality of plates secured in juxtaposed relationship and stamp formed to define an array of tubes therebetween. At least one external shell is secured to the internal plates to define at least one chamber which communicates with the array of tubes. The external shell includes at least one conformal area which permits the muffler to conform to the shape of a structure on the vehicle. The conformal area may be an area of generally arcuate concavity when viewed from the exterior of the muffler or may define an internal corner on the muffler. Thus, a plane or line connecting two locations on the conformal area of the external shell will pass through the interference zone of a structure on the vehicle. The conformal area may be disposed where peripheral edges of the formed components are joined.

Abstract: A stamp formed muffler is provided with a nonplanar array of tubes. The tubes are defined by at least one pair of nested formed members. The nested members include at least one external shell having a nonplanar portion and at least one internal plate having a nonplanar portion, with the respective nonplanar portions being configured to be placed in generally nested face-to-face relationship. The nonplanar configuration comprises an array of channels, such that an array of tubes is defined by the channels when the components are placed in nested relationship to one another. One or more chambers of the muffler are defined adjacent the nested formed members. The chambers may be defined by a single plate placed in register with the nested components or by a second pair of nested members. The nested pairs of formed members is effective in dampening shell noise attributable to vibration of the formed members.

Abstract: A stamp formed exhaust muffler for mounting on a vehicle is provided. The muffler comprises a plurality of plates secured in juxtaposed relationship and stamp formed to define an array of tubes therebetween. At least one external shell is secured to the internal plates to define at least one chamber which communicates with the array of tubes. The external shell includes a conformal area which permits the muffler to conform to the shape of a structure on the vehicle. The conformal area may be an area of generally arcuate concavity when viewed from the exterior of the muffler or may define an internal corner on the muffler. Thus, a plane or line connecting two locations on the conformal area of the external shell will pass through the interference zone of a structure on the vehicle.

Abstract: A process and an apparatus for forming an air gap pipe are provided. Inner and outer pipes are bent or deformed into comparable configurations such that the inner pipe can be mounted within the outer pipe. The outer pipe then is split longitudinally by a preprogrammed cutting apparatus. The cutting of the outer pipe terminates just short of the complete longitudinal length of the pipe to facilitate rematching later in the process. The cutter includes a follower to trace the actual configuration of the pipe and thereby to offset differences from one pipe to the next. An array of clamps are provided to align the outer pipe halves relative to one another and to facilitate the reattachment.

Abstract: A process and an apparatus for forming an air gap pipe are provided. Inner and outer pipes are bent or deformed into comparable configurations such that the inner pipe can be mounted within the outer pipe. The outer pipe then is split longitudinally by a preprogrammed cutting apparatus. The cutting of the outer pipe terminates just short of the complete longitudinal length of the pipe to facilitate rematching later in the process. The cutter includes a follower to trace the actual configuration of the pipe and thereby to offset differences from one pipe to the next. An array of clamps are provided to align the outer pipe halves relative to one another and to facilitate the reattachment.

Abstract: A method is provided for manufacturing a heat shield for an exhaust system component. The exhaust system component preferably is of tubular nonlinear configuration. The heat shield is formed from a larger pipe having an internal diameter greater than the outer diameter of the exhaust system component. Appropriately dimensioned inwardly directed supports are formed in the larger pipe. The larger pipe then is bent into a nonlinear configuration substantially identical to the configuration of the exhaust system component. The outer pipe then is cut longitudinally in half along its entire length to define a unitary nonlinear heat shield which can be mounted to the exhaust system component. A portion of the remaining half of the larger pipe can be reattached to the heat shield to provide an air gap pipe along a portion of the length of the exhaust system component.