Universal heat shield

A universal heat shield which may be varied in length and shape to fit a variety of mufflers, catalytic converters, and the like, is disclosed. A pair of metal sheets, each of which includes a pair of planar members intersecting at a crease line, a pair of slots and a pair of tabs, are fastened to each other with screws which extend through the slots. The shield is fastened to the muffler by strapping the tabs to opposite ends of the muffler body.

BACKGROUND OF THE INVENTION 
The present invention is directed to the field of engine exhaust systems, 
and more particularly to a heat shield adapted for specific use with a 
part of an exhaust system, such as a muffler, catalytic converter, or the 
like. 
It has become a widely used practice in the automotive and heavy equipment 
industry to employ heat shields in proximity to various components of an 
exhaust system. Many times, especially in vehicles and heavy equipment 
employed for agricultural purposes, heat shields are employed on exhaust 
system components such as mufflers, since such components are many times 
in direct contact with combustible material. Additionally, heat shields 
have become popular on ordinary passenger vehicles due to the wide use of 
catalytic converters which tend to become very hot under certain 
circumstances. 
Heretofore, such heat shields have been designed for specific applications, 
a specific heat shield being designed for a particular muffler or 
converter. This can be troublesome when it is necessary to replace a 
muffler or converter, since the heat shield is typically provided 
separately. Thus, a supplier of exhaust system parts must stock a very 
large variety of different shields to accommodate an associated variety of 
replacement mufflers and converters. 
OBJECTS AND SUMMARY OF THE INVENTION 
It is therefore an object of the present invention to overcome the 
difficulties associated with prior art heat shields. 
It is a further object to provide a universal heat shield which can be 
adjusted to fit a very wide variety of mufflers, converters, and the like, 
thus reducing inventory requirements. 
In accordance with the invention, a shield adapted to be attached to a part 
of an exhaust system, such as a muffler, catalytic converter, or the like, 
comprises at least first and second sheets of metal, each having at least 
two generally planar members intersecting along crease lines and disposed 
such that the crease lines are substantially parallel. At least one slot 
is disposed in each planar member generally parallel to the associated 
creases. Each sheet of metal is provided with at least one mounting 
support. Preferably, the mounting supports define tabs disposed at the 
ends of the respective planar members generally parallel thereto but 
separated therefrom in directions normal to the respective planar 
surfaces. The first sheet of metal is adapted to overlie the second sheet 
of metal such that the respective creases are aligned and adjacent, and 
such that at least one slot in each of the overlapping planar members is 
at least partly in register with a slot in the corresponding planar member 
of the adjacent sheet of metal. The sheets of metal preferably are fixed 
to each other by screws which extend through the partly registered slots 
in the overlapping sheets of metal. The sheets may be secured to the 
exhaust system by strapping the planar tabs to opposite ends of the 
exhaust system part. Preferably the straps are adjustable to enable 
mounting of the sheets on exhaust systems of various size. 
The length of the shield may be adjusted by loosening or removing the 
screws, sliding the sheets of metal relative to each other, and tightening 
or repositioning the screws, thereby accommodating exhaust system parts of 
varying lengths. Further, the contour of the shield may be adjusted by 
bending the sheets of metal along the crease lines to change the angle 
between the members, and thereby accommodate exhaust system parts of 
varying contours.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
As illustrated in FIGS. 1-3, the universal heat shield of the subject 
invention is indicated generally by the numeral 12 and is mounted on a 
muffler, indicated generally by the numeral 10. The universal heat shield 
12 is comprised of a first sheet of metal 14 and a second sheet of metal 
16. The first sheet of metal 14 has generally planar members 18 and 20, 
respectively, which intersect along crease line 22 at angle .alpha., as 
shown most clearly in FIG. 3. It has been found that if heat shield 12 is 
manufactured such that angle .alpha. equals approximately 15.degree., the 
subject heat shield 12 can be used with many automobile mufflers with 
little or no adjustment to angle .alpha.. Similarly, the second sheet of 
metal 16 is provided with planar members 24 and 26 respectively which 
intersect to define crease line 28 at substantially the same angle 
".alpha.". 
Each of the planar members 18, 20, 24 and 26 is approximately 9.75 inches 
long and approximately 4.5 inches wide. Additionally, each planar member 
is provided with a pair of slots, such that planar member 18 includes 
slots 30 and 31, planar member 20 includes slots 32 and 33, planar member 
24 includes slots 34 and 35, and planar member 26 includes slots 36 and 
37. Each slot is disposed in its respective planar member generally 
parallel to the associated crease 22 and 28. Additionally, each slot is 
spaced distance "a" from the respective crease 22 or 28 to enable 
longitudinal adjustments, as explained below. Preferably, distance "a" 
equals 3.00 inches. 
Planar tabs 38, 40, 44 and 46 are disposed at the ends of the respective 
planar members 18, 20, 24 and 26. The planar tabs 38, 40, 44 and 46 are 
generally parallel to and spaced from their associated planar members. 
More particularly, each of the planar tabs 38, 40, 44 and 46 is attached 
to its respective planar member by means of the respective extensions 39, 
41, 45 and 47. The extensions 39, 41, 45 and 47 are substantially 
perpendicular to their respective planar members and extend therefrom a 
distance "b" which preferably equals approximately 0.50 inches. Each tab 
38, 40, 44 and 46 is provided with a notch 53, 55, 57 and 59 respectively 
on the side thereof nearest the associated crease 22 or 28. The notches 
53, 55, 57 and 59 are dimensioned to receive adjustable strap members for 
mounting in the manner explained below. 
As shown in FIGS. 1-3, the first sheet of metal 14 is adapted to overlie 
the second sheet of metal 16 such that the creases 22 and 28 are aligned 
and adjacent to one another. Planar members 18 and 20 on the first sheet 
of metal 14 overlap planar members 24 and 26 on the second sheet of metal 
16 respectively. As noted above, slots 30 through 37 are parallel to and 
spaced distance "a" away from the associated creases 22 and 28. As a 
result, when the first and second sheets of metal 12 and 14 are placed in 
overlapping relationship as shown in FIGS. 1 and 2, at least one slot on 
planar member 18 will be at least partly in register with a slot on planar 
member 24. Similarly, at least one slot on planar member 20 will be at 
least partly in register with a slot on planar member 26. More 
particularly, and as shown in FIG. 2, slots 30 and 34 are partly in 
register, and slots 32 and 36 are partly in register. The degree to which 
the slots are in register will vary, of course, according to the 
particular longitudinal dimensions of the exhaust system part to which 
shield 10 is attached. Additionally, in certain instances slots 30 and 35, 
slots 31 and 34, slots 32 and 37, and slots 33 and 36 will define pairs of 
slots at least partly in register. This will occur generally only on very 
small exhaust system parts which require protection from heat shield 12. 
Turning to FIGS. 4-6, adjustable mounting members 62 are provided for 
mounting the heat shield 12 on the muffler 10 or other exhaust system 
component. The mounting member 62 includes an elongated strap portion 64 
having opposed ends 66 and 67. The length of strap portion 64 as indicated 
by dimension "d" is approximately 12.25 inches. Fastening portion 68 is 
connected to and extends perpendicularly from strap portion 64 adjacent 
end 66 thereof. As illustrated in FIGS. 4 and 5, fastening portion 68 
extends distance "e" which preferably equals approximately 1.00 inches. 
Additionally, as shown in FIG. 5, fastening portion 68 is provided with 
hole 70 through which a bolt may be inserted for mounting purposes. 
Stiffening rib 72 is provided adjacent end 66 of strap portion 64 extending 
diagonally between the strap and fastening portions 64 and 68 
respectively. Stiffening rib 72 ensures that the strap and fastening 
portions 64 and 68 remain in perpendicular alignment with respect to one 
another even when forces are exerted on the respective members during 
mounting. 
The strap portion 64 is provided with stamped bend lines 74, 76, 78, 80 and 
82. The stamp bend lines enable the strap portion 64 to be bent through 
approximately 180.degree. to form a generally U-shaped end portion for 
grasping the tabs of the heat shield for mounting purposes as explained 
below. As illustrated in FIG. 6, stamped bend line 74 is spaced from end 
67 of strap portion 64 by distance "f" which preferably equal 1.00 inches. 
This 1.00 inch length of distance "f" ensures that for the largest 
mufflers used with the subject heat shield 12, the strap portion 64 can 
securely grasp the tabs 38, 40, 44 or 46 of the heat shield 12. 
Additionally, as shown in FIG. 6 alpha numeric characters are disposed 
adjacent the stamped bend lines 74-82. The alpha numeric characters enable 
the subject mounting members to be used in conjunction with a chart 
provided by the manufacturer to indicate the proper adjustment to be made 
to the mounting member 62 for each of various size exhaust assembly parts. 
Returning to FIG. 1, the subject universal heat shield typically would be 
packaged and marketed as a kit including first and second sheets of metal 
14 and 16 along with associated machine screws 58 and 60, lock washers and 
nuts to be used with machine screws 58 and 60, and two pairs of mounting 
members 62 with associated bolts washers and nuts. To assemble the subject 
heat shield, the first and second sheets of metal 14 and 16 are placed 
loosely in overlapping relationship with the creases 22 and 28 thereof 
respectively being substantially adjacent to one another. The first and 
second sheets of metal 14 and 16 are slidably moved with respect to one 
another to approximate the length of the exhaust system part with which 
the heat shield 12 will be used. The machine screws 58 and 60 are then 
placed through slots 30 and 32 on the first sheet of metal 14 and extend 
through the slots 34 and 36 respectively on the second sheet of metal. 
Machine screws 58 and 60 then are loosely fastened in this position. With 
the heat shield 12 loosely assembled in this manner, the first and second 
sheets of metal 14 and 16 are slidably moved with respect to one another 
so that the heat shield 12 approximates the overall length of the muffler 
10 or other exhaust part with which the heat shield 12 is used. Each 
mounting member 62 then is bent at the appropriate stamped bend line 74 
through 82 to facilitate mounting of the heat shield 12 on the particular 
size muffler 10. The bent mounting members 62 then are positioned to 
engage the notches on the respective tabs, as illustrated most clearly in 
FIGS. 1 and 2. The strap portion 64 of each mounting member 62 then is 
bent manually around the perimeter of the muffler 10 so that the 
respective fastening portions 68 thereof are in proximity to one another 
and substantially parallel. A bolt then is inserted through the hole 70 in 
one fastening portion 68 and subsequently through the corresponding hole 
in the other fastening portion 68. A nut is then mounted on this bolt and 
tightened sufficiently to securely mount the subject heat shield 12 on the 
muffler 10. After the heat shield is mounted securely in this manner, the 
machine screws 58 and 60 are tightened to complete the mounting operation. 
If the particular muffler 10 has a cross sectional configuration which is 
incompatible with the angle .alpha. between the planar members of the 
respective first and second sheets of metal 14 and 16, the angular 
alignment between the planar members can be adjusted easily by the 
installer of the universal heat shield 12. 
In summary, a universal heat shield is provided which includes at least 
first and second sheets of metal configured to be disposed in overlapping 
slidably relationship to one another. Each sheet of metal includes at 
least two planar members which intersect in a crease line. Each planar 
member is provided with one or more slots which are disposed equidistant 
from the respective crease lines. Machine screws and bolts extend through 
the respective slots to hold the sheets of metal in their desired 
longitudinal relationship with respect to one another. Adjustable straps 
are provided to mount the heat shield on the exhaust system part. The 
angular relationship between the planar members of the respective sheets 
of metal can be adjusted to accommodate exhaust system parts of varying 
contours.