Tailor to Fit Muffler

摘要

A muffler includes a shell, baffles, and a plurality of pipes. The shell defines first and second end cavities and a central cavity. The end cavities have larger cross-sectional areas that a cross-sectional area of the central cavity. The baffles cooperate to form multiple chambers within the shell. A first inlet directs a first portion of the exhaust into a first chamber. A second inlet directs a second portion of the exhaust into a second chamber. A first pipe extends through first, third and fourth baffles and includes an inlet in the fourth chamber. The first pipe directs exhaust from the fourth chamber to a first outlet at the first end cavity. A second pipe extends through the second, third and fourth baffles and includes an inlet in the third chamber. The second pipe directs exhaust from the third chamber to a second outlet at the second end cavity.

主权项

1. A method of manufacturing a muffler for an exhaust system of an internal combustion engine, the method comprising:
providing a flat, one-piece sheet metal blank having first and second opposing edge portions; forming the blank into a tubular shell by bending the blank so that the first and second edge portions face each other and fixing the first and second edge portions in contact with each other, the tubular shell defining a central cavity and first and second end cavities, the first and second end cavities having larger cross-sectional areas than a cross-sectional area of the central cavity; inserting a first subassembly through a first axial end of the tubular shell and positioning the first subassembly in the central cavity, the first subassembly including first and second pipes and a plurality of baffles; inserting a second subassembly into the first axial end of the tubular shell and fixing the second subassembly in the first end cavity such that a first outlet pipe of the second subassembly is fluidly connected with the first pipe of the first subassembly; and inserting a third subassembly into a second axial end of the tubular shell and fixing the third subassembly in the second end cavity such that a second outlet pipe of the second subassembly is fluidly connected with the second pipe of the first subassembly.