초록 ▼

A muffler assembly includes first and second muffler components that are each formed as a single piece. The first muffler component includes a first outlet pipe portion, a first bypass pipe mount portion, and a first resonator shell portion. The second muffler component includes a second output pipe

A muffler assembly includes first and second muffler components that are each formed as a single piece. The first muffler component includes a first outlet pipe portion, a first bypass pipe mount portion, and a first resonator shell portion. The second muffler component includes a second output pipe portion, a second bypass pipe mount portion, and a second resonator shell portion. The first and second muffler components are positioned in an overlapping relationship such that respective portions are aligned with each other to form an outlet pipe, a bypass pipe mount, and a resonator shell. A noise attenuation valve assembly is also installed within the first and second muffler components. The bypass pipe mount is positioned at a non-perpendicular orientation relative to the outlet pipe such that a bypass pipe having a straight end mount can be received within the bypass pipe mount to bypass the noise attenuation valve assembly.

대표청구항 ▼

What is claimed is: 1. A muffler assembly comprising: a first muffler component having a first outlet pipe portion, a first bypass pipe mount portion, and a first resonator shell portion, said first muffler component being formed as a single piece; and a second muffler component having a second out

What is claimed is: 1. A muffler assembly comprising: a first muffler component having a first outlet pipe portion, a first bypass pipe mount portion, and a first resonator shell portion, said first muffler component being formed as a single piece; and a second muffler component having a second output pipe portion, a second bypass pipe mount portion, and a second resonator shell portion, said second muffler component being formed as a single piece, wherein said first and second muffler components are positioned in an overlapping relationship such that said first and second outlet pipe portions are aligned with each other to form an outlet pipe, said first and second bypass pipe mount portions are aligned with each other to form a bypass pipe mount adapted to receive a bypass pipe, and said first and second resonator shell portions are aligned with each other to form a resonator shell that receives a resonator in an internal cavity defined between said first and said second resonator shell portions. 2. The muffler assembly according to claim 1 including a muffler outer shell wherein said first and second muffler components are fixed together to form a muffler sub-assembly that is mounted within said muffler outer shell. 3. The muffler assembly according to claim 2 wherein said first muffler component comprises a stamped horizontal baffle that is supported by said muffler outer shell and said second muffler component comprises a stamped component that is attached to said stamped horizontal baffle. 4. The muffler assembly according to claim 3 including a noise attenuation valve assembly supported by at least one of said first and second muffler components. 5. The muffler assembly according to claim 4 wherein said noise attenuation valve assembly is positioned within said outlet pipe. 6. The muffler assembly according to claim 4 wherein said noise attenuation valve assembly is positioned directly within said stamped horizontal baffle separate from said outlet pipe and said bypass pipe with said outlet pipe being positioned on one side of said stamped horizontal baffle and an inlet pipe being positioned on an opposite side of said stamped horizontal baffle from said outlet pipe. 7. The muffler assembly according to claim 4 wherein said noise attenuation valve assembly is positioned within said bypass pipe. 8. The muffler assembly according to claim 4 wherein said outlet pipe comprises a first tailpipe extending outwardly from said muffler outer shell and a second tailpipe extending outwardly from said muffler outer shell, said first tailpipe being associated with said bypass pipe and said second tailpipe separate from said first tailpipe and wherein said noise attenuation valve assembly is positioned within said second tailpipe. 9. The muffler assembly according to claim 1 wherein said bypass pipe mount is non-perpendicular to said outlet pipe and wherein said resonator shell is axially aligned with said outlet pipe. 10. The muffler assembly according to claim 9 wherein said bypass pipe includes a generally straight end mount portion that is received within said bypass pipe mount such that said generally straight end mount portion is generally parallel to said outlet pipe. 11. The muffler assembly according to claim 1 wherein said bypass pipe mount comprises a first portion that extends obliquely relative to a centerline of the outlet pipe and a second portion that extends parallel relative to the centerline of the outlet pipe, with the bypass pipe to be received within said second portion. 12. The muffler assembly according to claim 1 wherein said resonator comprises a resonator material wrapped around a resonator pipe. 13. The muffler assembly according to claim 1 wherein said resonator and said outlet pipe are coaxial. 14. The muffler assembly according to claim 1 wherein said internal cavity is defined by inwardly facing surfaces of said first and said second muffler components, and including resonator material that is positioned within said resonator shell such that said resonator material is in abutting contact with said inwardly facing surfaces. 15. A method of forming a muffler assembly comprising: (a) forming a first muffler component as a single piece, the first muffler component having a first outlet pipe portion, a first bypass pipe mount portion, and a first resonator shell portion; (b) forming a second muffler component as a single piece, the second muffler component having a second output pipe portion, a second bypass pipe mount portion, and a second resonator shell portion; and (c) overlapping the first and second muffler components relative to each other such that the first and second outlet pipe portions are aligned with each other to form an outlet pipe, the first and second bypass pipe mount portions are aligned with each other to form a bypass pipe mount adapted to receive a bypass pipe, and the first and second resonator shell portions are aligned with each other to form a resonator shell that receives a resonator within an internal cavity defined between said first and said second resonator shell portions. 16. The method according to claim 15 including the steps of attaching the first and second muffler components together to form a muffler sub-assembly and mounting the muffler sub-assembly into a muffler outer shell. 17. The method according to claim 16 wherein the outlet pipe comprises a first outlet pipe positioned in fluid communication with one end of the resonator and including the steps of wrapping a resonator material around a second outlet pipe to form a resonator sub-assembly wherein the second outlet pipe is in fluid communication with an opposite end of the resonator, placing the resonator sub-assembly in one of the first and second muffler components, subsequently placing the other of the first and second muffler components over the one of the first and second muffler components, and subsequently attaching the first and second muffler components together to form the muffler sub-assembly. 18. The method according to claim 16 including the steps of forming the bypass pipe mount at a non-perpendicular orientation relative to the outlet pipe and axially aligning the resonator shell with the outlet pipe. 19. The method according to claim 16 including the step of installing a noise attenuation valve assembly in one of the outlet pipe and bypass pipe. 20. The method according to claim 16 including the steps of stamping a horizontal baffle to form the first muffler component, and mounting the horizontal baffle within the muffler outer shell. 21. The method according to claim 20 including the steps of mounting a noise attenuation valve assembly within the horizontal baffle, positioning an inlet pipe in a first cavity formed on one side of the horizontal baffle, and positioning the outlet pipe in a second cavity formed on an opposite side of the horizontal baffle such that exhaust gases flow from the first cavity through the noise attenuation valve and into the second cavity. 22. The method according to claim 15 including forming the bypass pipe mount with a first portion that extends obliquely relative to a centerline of the outlet pipe and a second portion that extends parallel relative to the centerline of the outlet pipe, with the bypass pipe to be received within the second portion. 23. The method according to claim 15 including forming the resonator by wrapping a resonator material around a resonator pipe to form a resonator sub-assembly, and positioning the resonator sub-assembly within the internal cavity defined between the first and second resonator shell portions such that the resonator is formed when the first and second muffler components are attached to each other. 24. The method according to claim 15 wherein the resonator and outlet pipe are coaxial. 25. The method according to claim 15 wherein the internal cavity is defined by inwardly facing surfaces of the first and the second muffler components, and including installing resonator material within the resonator shell to be in abutting contact with the inwardly facing surfaces.