Catalytic converter muffler

Abstract

A catalytic converter muffler has a tubular housing with an inlet and outlet, and a baffle chamber intermediate the length thereof, a generally cylindrical catalytic converter supported in the tubular housing adjacent the inlet and a pair of tubular baffle members are disposed in the baffle chamber. An outlet offset baffle ring closing the inlet end of one of the baffles to block flow of gas thereinto, and an inlet offset baffle element closes the outlet end of the other of the baffles to block flow of gas outwardly to the outlet end of the housing. A power bar is provided in the outlet baffle closely adjacent the outlet end thereof to interrupt the harmonic waves of the base in the outlet baffle. The exhaust gas flows from the catalytic converter into the other baffle and thence through the perforations into the outlet baffle through the perforations in the inlet baffle and through the perforations in the outlet baffle.

Description

BACKGROUND OF THE INVENTION

The present invention relates to mufflers for vehicles and, more particularly, mufflers for motorcycles and the like.

In an effort to reduce carbon emissions in the atmosphere, catalytic converters are required for most vehicles. It is also common, particularly with motorcycles and the like, to provide mufflers that reduce the noise level and/or alter the frequency of the sound. There have been efforts to combine a muffler and a catalytic converter to reduce the package size and to obtain improved results. Indicative of an early effort in this regard is Wagner U.S. Pat. No. 4,094,664 which was issued in 1978. However, there has remained a need to develop a combination muffler/catalytic converter construction which is relatively simple to assemble and relatively long lived.

It is an object of the present invention to provide a novel catalytic converter muffler with a structure which can be varied in dimension easily for different types of vehicles.

It is also an object to provide such an improved muffler to improve gas flow and performance characteristics and to improve fuel consumption and reduce unwanted noise.

SUMMARY OF THE INVENTION

It has now been found that the foregoing and related objects may be attained in a catalytic converter muffler which has a tubular housing having an inlet and outlet, and a baffle chamber intermediate the length thereof. A generally cylindrical catalytic converter is supported in the tubular housing adjacent the inlet, the converter provider flow passages therethrough. A pair of tubular baffle members is disposed in the baffle chamber, and they have perforations along the length thereof. An outlet offset baffle ring close the inlet end of one of the baffles to block flow of gas thereinto, and an inlet offset baffle element closing the outlet end of the other of the baffles to block flow of gas outwardly to the outlet end of the housing. A power bar is provided in the outlet baffle closely adjacent the outlet end thereof to interrupt the harmonic waves of the gas in the outlet baffle.

Exhaust gas flows from the catalytic converter into the other baffle and thence through the perforations into the outlet baffle through the perforations in the inlet baffle and through the perforations in the outlet baffle.

Preferably the baffle members each have an outer wall with an arcuate section and a generally linear section. At least one tie bar has its ends secured to the baffle elements to assemble the baffle members. Desirably, a pair of tie bars are diametrically spaced apart. Expanding funnel-shaped inlet members are provided prior to and after the catalytic converter.

The baffle elements are of generally ring-like configuration and the power bar extends transversely of the baffle member.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an isometric view of a catalytic converter muffler embodying the present invention;

FIG. 2 is a partially schematic sectional view thereof;

FIG. 3 is an exploded view of the components;

FIG. 4 is a partially schematic isometric view with the housing removed;

FIG. 5 is an exploded view of the baffle assembly; and

FIG. 6 is a schematic view of the gas flow in the muffler.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Turning now in detail to the attached drawings, the muffler has a cylindrical housing 10, an exhaust pipe 12 to be connected to the engine (not shown) and an intake funnel 14. At its other end, the muffler has an end cap 16. Adjacent the intake end is an expanding funnel 18.

Inserted into the housing is a cylindrical catalytic converter 20 which is conveniently fabricated from sintered metal. An expanding funnel 22 leads the gases into the baffle chamber 24.

In the baffle chamber 24 are perforated baffles 26,27 which are flattened about a portion of their circumference so that they provide generally flat surface portions 28 while the remainder of the circumference is arcuate or semicircular 30. At the ends of the baffles 26,27 are baffle elements 34,36 of generally circular cross section and with apertures 38,40 respectively to permit passage therethrough. The solid portions block passage of the gas.

The tie bars 42 extend between the baffle elements 34,36 and are secured thereto to couple the baffle members 26,27.

Adjacent the discharge end of the exhaust baffle member 27 is secured a power bar or rod 44 which extends transversely of the flow passage.

In operation, exhaust gas flowing through the pipe 12 flows through the funnel 18 and into the catalytic converter 20. The gas passing through the converter 20 then flows into the baffle member 26. Gas flowing through the baffle member 26 is blocked by the baffle element 34 and flows outwardly through the perforations and into the baffle chamber 24 and then into the exhaust baffle member 27. Adjacent the exhaust baffle end is the power rod 44 which interrupts the variable pulses in the flowing gas so that the flow is faster and smoother.

As is well known, the baffle chamber is used to reduce the amount of noise produced by the motor. To create the right amount of back pressure and retard exhaust flow at the optimum level in order to promote the best performance of the motor is done by modifying the length of the baffle pipes, expansion chamber, the size of the baffle chamber, the number of perforations in the baffles and their spacing, depth, size and length.

When the engine exhaust valve opens, it sends a pulse of exhaust out and down the header rod in rapid succession setting up harmonic waves. The power bar brakes the wave and in doing so effects a more rapid flow of exhaust, thereby improving sound and performance.

Integrating the catalytic converter and baffle into one assembled unit, provides a muffler that reduces noise and pollution while still improving performance.

Thus, it can be seen from the foregoing detailed description and attached drawings that the present invention provides a novel muffler construction incorporating a catalytic converter. The placement of the power bar or rod adjacent the end of the exhaust baffle interrupts the flow waves to improve flow and performance.

Claims

1. In a catalytic converter muffler, the combination comprising:

(a) a tubular housing having inlet and outlet end portions, and a baffle chamber intermediate the length thereof;

(b) a catalytic converter supported in said tubular housing adjacent said inlet end portion, said converter providing a flow passage therethrough;

(c) a pair of tubular baffle members disposed in said baffle chamber and extending in parallel relationship spaced from said housing, said baffle members having a substantially uniform cross section and perforations along the length thereof;

(d) an outlet offset baffle ring closing the inlet end of one of said baffle members to block flow of gas thereinto from said catalytic converter;

(e) an inlet offset baffle ring closing the outlet end of the other of said baffle members to block flow of gas outwardly therefrom to said outlet end of said housing;

(f) a power bar in said outlet end portion closely adjacent the outlet end thereof to interrupt the harmonic waves of the gas in said outlet;

(g) whereby exhaust gas flows from said catalytic converter into the open inlet end of said other baffle member, is blocked by said outlet baffle ring, said gas then flowing through said perforations into said baffle chambers into said one baffle member through the perforations in said baffle member, said gas then flowing outwardly through the outlet end of said baffle member.

2. The catalytic peripheral converter muffler in accordance with claim 1 wherein said baffle members have a peripheral wall with an arcuate section and a generally linear section, said linear sections being opposed.

3. The catalytic converter muffler in accordance with claim 1 wherein there is included at least one tie bar having its ends secured to said baffle members and baffle rings to assemble said baffle members and rings.

4. The catalytic converter muffler in accordance with claim 1 wherein there are included an expanding funnel-shaped inlet members prior to said catalytic converter, and a reducing funnel shaped outlet member directing the gases into said other baffle member.

5. The catalytic converter muffler in accordance with claim 3 wherein a pair of tie bars are diametrically spaced apart.

6. The catalytic converter muffler in accordance with claim 1 wherein said baffle rings are of generally circular ring-like said baffle rings having offset passages therethrough.

7. The catalytic converter muffler in accordance with claim 1 wherein said power bar extends transversely of said outlet end portion.