Combination muffler and catalytic converter

Abstract: A combination muffler and catalytic converter for an exhaust system of a small internal combustion engine (1). The catalytic converter (15) is mounted within a chamber (29) formed inside the muffler (2) which functions not only to contain the catalytic converter (15) but also to provide sound attenuation. The combination muffler/catalytic converter also includes an assembly (17) for introducing secondary air into the interior of the muffler body containing the catalytic converter (15) so that harmful uncombusted components such as hydrocarbons, carbon monoxide and nitrous oxides contained in the exhaust gases are further combusted prior to exiting the muffler (2). The secondary air supply assembly includes an opening (18,19) formed in the muffler body which communicates between the interior of the muffler body and atmosphere, and a reed valve (20) mounted directly on the muffler body adjacent this opening (18,19). The reed valve (20) is operable in response to exhaust gas pressure pulsations within the muffler (2) between a normally closed position which seals the opening and an open position which unseals the opening to permit atmospheric air to flow into the interior of the muffler body.

Description: The present invention relates to an exhaust system for an internal combustion engine, and more particularly to a combination muffler and catalytic converter for two or four cycle engines of the type having one or two cylinders. In order to reduce the amounts of harmful hydrocarbons and carbon monoxide components in exhaust gas, it is known to utilize a catalytic converter containing an oxidizing catalyzer disposed in the exhaust system of the engine upstream of a muffler. It is also known to feed secondary air into the exhaust system upstream of the catalytic converter for promoting oxidation of unburned hydrocarbons and carbon monoxide components in the exhaust gas to thereby reduce the expelling of such harmful hydrocarbon and carbon monoxide components into the atmosphere. In US-A-4209493, there is described a muffler having a hollow body in which there is a sound attenuation chamber formed from a plurality of perforated plates, a catalytic converter being contained within said chamber. This muffler is of complex construction and so is relatively expensive to manufacture. The present invention aims at providing a muffler including a catalytic converter, which muffler is relatively simple to manufacture, and so is economic. According to the present invention, there is provided a muffler for an exhaust system of a one or two cylinder internal combustion engine, comprising: a hollow muffler body having an exhaust gas inlet for connection to the exhaust system of the engine, and an exhaust gas outlet, said muffler body including a cup-shaped body and cover; partition means disposed transversely within said muffler body for dividing said muffler body into a first chamber communicating with said exhaust gas inlet and a second chamber communicating with said exhaust gas outlet, said partition means defining a third chamber having an upstream end opening to said first chamber and a downstream end opening to said second chamber, said upstream end including a perforated wall portion for uniformly distributing exhaust gases from said first chamber into said third chamber; a catalytic converter including a catalyzer disposed within said third chamber for oxidizing and reducing unburned exhaust gas components prior to said components discharge into said second chamber and from said exhaust gas outlet; said partition means comprising a first wall and a second wall, said first wall and second walls each defining a peripheral mounting flange; and said muffler body and cover each include a mounting flange, and the peripheral mounting flanges of said first and second partition walls are sandwiched therebetween. The present invention thus provides a simple and economical combination muffler/catalytic converter for an internal combustion engine. Preferably, the partition means comprises a first wall disposed back-to-back with a second wall, said first and second walls defining a peripheral mounting flange. In this case, there may be mounting means for securing said cup-shaped body and cover together, said mounting means further securing said partition means such that said body, cover and partition means are all rigidly secured together by said same mounting means. Such mounting means is defined by a crimp formed by one of the mounting flanges of the body and cover. Brief Description of the Drawings The drawings illustrate the best mode presently contemplated of carrying out the invention. In the drawings: Fig. 1 is a side view in elevation of an internal combustion engine incorporating a muffler assembly constructed in accordance with the principles of the present invention; Fig. 2 is a top view of the muffler assembly; Fig. 3 is a cross sectional view taken along the plane of the line 3-3 in Fig. 2; Fig. 4 is a plan view illustrating the interior of the muffler body; Fig. 5 is a side view of the muffler body of Fig. 4; and Fig. 6 is a graph of muffler pressure over time as shown by the angle of the crankshaft of the engine. Detailed Description of the Invention Referring now to the drawings, Fig. 1 illustrates an internal combustion engine generally designated by the numeral 1 incorporating a muffler 2 in accordance with the present invention. As illustrated, engine 1 is of a relatively low horse power type, i.e. less than 20 horsepower having one or two cylinders, which might typically be utilized in connection with lawn and garden equipment such as lawnmowers and rotor tillers, or to power generators, pumps and the like. Engine 1 includes a crankshaft 3 conventionally powered by a piston and cylinder arrangement (not shown) and whose speed is controlled by a throttle mechanism generally designated by the numeral 4. The throttle mechanism includes a control cable 5 which could lead, depending upon the equipment being powered, to a bale and handle assembly (not shown) utilized by an operator to control the speed of the engine and the operation of the device. As illustrated, a guard 6 encloses muffler 2 to aid in preventing an operator from touching the hot metal muffler body during operation. Referring now to Figs. 2 and 3, there is illustrated in more detail muffler assembly 2. Muffler assembly 2 includes an exhaust tube 7 connected at one end by means of an integral flange 8 to the exhaust outlet from the cylinder head (not shown) of engine 1. The opposite end of tube 7 is connected to a muffler 9 which is comprised of a two-piece hollow housing including a cup-shaped body 10 and cover 11 which are secured together by means of a circumferential clinch or crimp 12. A bracket 13 is utilized to mount muffler 9 to the engine block. Muffler 9 includes a series of perforated metal walls 14a, 14b and 14c and a solid wall 14d opposite wall 14c that form two separate chambers 29 and 30 for sound attenuation purposes. As shown best in Fig. 3, a collar 28 projecting into the interior of body 10 is employed for guiding and attaching tube 7 to muffler 9. As shown best in Figs. 2 and 3, a catalytic converter 15 is mounted in chamber 29 within muffler 9 downstream of the inlet of tube 7 into the interior of muffler 9 but upstream from the outlet 16 of muffler 9. Converter 15 is surrounded by a packing material 31 which functions as a temperature insulating and vibration isolating means. All exhaust gas entering the interior of muffler 9 first passes downwardly through wall 14a into the first chamber 29 containing converter 15 in order to minimise components such as hydrocarbons and carbon monoxide. In order to accomplish this, catalytic converter 15 is in the form of a honeycombed ceramic structure. The structure is appropriately sized for the engine displacement and emission reduction desired, and as illustrated in Fig. 2 is dimensioned approximately 3 inches by 1 inch by 1 inch for the 5 horsepower engine 1 illustrated in Fig. 1. The ceramic structure is coated with an oxidizing catalyzer of any known composition. Preferably, a combination of platinum, palladium and rhodium is utilized. However, any combination of known oxidizing catalyzer material may be employed. After passing through converter 15, the exhaust gas exits the first chamber 29 through wall 14b, then enters the second chamber 30 through wall 14c, and finally exits muffler 9 through outlet 16. As is well known in the art, in order to further minimise unburned exhaust gas components such as hydrocarbons and carbon monoxide in a catalytic converter, there must be supplied additional air to the catalytic converter. In order to accomplish this, Figs. 4-5 illustrate a reed valve assembly generally designated by the numeral 17. Reed valve assembly 17 includes a pair of feed openings 18 and 19 formed through body 10 of muffler 9 so that the interior of muffler 9 communicates with atmosphere. As shown best in Fig. 4, openings 18 and 19 are substantially oblong in shape and disposed parallel and adjacent to one another. However, other specific arrangements may be employed such as a single opening as opposed to two openings, and the specific locations and dimensions for these openings may be modified from that which is illustrated in Fig. 4. Reed valve assembly 17 also includes a reed valve 20 having a pair of tongue members 21 and 22 co-operating with air openings 18 and 19 respectively. Reed valve 20 is comprised of thin elastic tempered metal or the like and is fastened at one end by a pair of rivets 23 to the inside surface of body 10. A stop 24 in the form of a thin metal plate is also mounted via rivets 23 to body 10 and as shown in Fig. 5 is angled slightly away from the interior wall of body 10. Stop 24 functions to prevent excessive flexing of reed valve 20, as will hereinafter be described. Fig. 6 illustrates a graph of muffler pressure over time as determined by the crankshaft angle of engine 1. Dashed line 25 in Fig. 6 is representative of atmospheric pressure, namely, 14.7 pounds per square inch. Peak 26 is representative of the opening of the exhaust valve (not shown) in engine 1. Finally, peaks such as those illustrated at 27 are representative of a negative pressure in muffler 9 since these peaks are below atmospheric pressure line 25. As a result, the areas illustrated below line 25 in Fig. 6 will cause reed valve 20 to open as they are representative of negative pressure in muffler 9 whereas areas above line 25 in Fig. 6 will result in the closing of reed valve 20 as these are representative of pressures above atmospheric. Thus, when closed, reed valve 20 prevents exhaust leaks from muffler 9. In operation, reed valve 20 is flexed or opened to unseal air openings 18 and 19 during those times when the pressure within muffler 9 is below atmospheric i.e. below line 25 in Fig. 6. During these times, secondary air from the atmosphere passes through air openings 18 and 19 into the interior of muffler 9 to aid in the oxidation of exhaust gas components such as carbon monoxide and various other hydrocarbons prior to their discharge from outlet 16. On the other hand, reed valve 20 is closed thus sealing openings 18 and 19 to prevent exhaust leaks from muffler 9 whenever the pressure within muffler 9 is above line 25 in Fig. 6. Thus, reed valve 20 is in a constant state of movement to permit secondary air into muffler 9 at various times during one complete rotation of the crankshaft of engine 1. There is thus provided a simple and economical combination muffler/catalytic converter structure and means for supplying secondary air to catalytic converter 15.

Claims: A muffler for an exhaust system of a one or two cylinder internal combustion engine, comprising: a hollow muffler body (9) having an exhaust gas inlet (7) for connection to the exhaust system of the engine, and an exhaust gas outlet (16), said muffler body including a cup-shaped body (10) and cover (11); partition means (14) disposed transversely within said muffler body (9) for dividing said muffler body into a first chamber communicating with said exhaust gas inlet and a second chamber communicating with said exhaust gas outlet, said partition means defining a third chamber (29) having an upstream end opening to said first chamber and a downstream end opening to said second chamber, said upstream end including a perforated wall portion (14a) for uniformly distributing exhaust gases from said first chamber into said third chamber (29); a catalytic converter (15) including a catalyzer disposed within said third chamber (29) for oxidizing and reducing unburned exhaust gas components prior to said components discharge into said second chamber and from said exhaust gas outlet (16); said partition means (14) comprising a first wall (14a,14d) and a second wall (14b,14c), said first and second walls each defining a peripheral mounting flange; and said muffler body (10) and cover (11) each include a mounting flange, and the peripheral mounting flanges of said first and second partition walls (14a,14b; 14c,14d) are sandwiched therebetween. A muffler as claimed in claim 1 wherein the first and second walls defining the partition means (14) are arranged in an overlying manner with the third chamber formed therebetween. A muffler as claimed in claim 1 or claim 2, wherein there is provided mounting means (12) for securing said cup-shaped body (10) and cover (11) together, said mounting means (12) further securing said partition means (14) such that said body, cover and partition means are all rigidly secured together by said same mounting means (12), said mounting means comprising a crimp (12) formed by one of the mounting flanges of said body (10) and cover (11). A muffler as claimed in any of the preceding claims, wherein said third chamber (29) comprises a sound attenuation chamber.

Inventors: WINBERG JAMES R, WINBERG, JAMES R.
Applicants: BRIGGS & STRATTON CORP, BRIGGS & STRATTON CORPORATION
Application year: 1992
Main classification: F01N3
IPC codes: F01N7, F01N3, F01N1