Abstract:
An exhaust module made of a thermoplastic material which is connected to a fascia or bumper of a vehicle. In one embodiment, the hybrid fascia mounted exhaust tip assembly includes a bracket. The bracket has a bracket inlet which surrounds, but is not in contact with, an exhaust pipe. The exhaust pipe is free to move around as a result of the vehicle traveling over bumps in the road and around turns. The bracket also has a bracket outlet which is connected to the bracket inlet. A ring tip has a portion that slides onto a bezel portion of the bracket outlet.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is a Continuation-in-Part of U.S. patent application Ser. No. 14/447,096 filed Jul. 30, 2014, which is a Continuation of U.S. patent application Ser. No. 13/351,776 filed Jan. 17, 2012, which claims benefit of U.S. Provisional Patent Application Nos. 61/574,251 filed Jul. 29, 2011 and 61/574,330 filed Aug. 1, 2011. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The present invention relates to hybrid fascia mounted exhaust module made primarily of thermoplastic material resistant to corrosion, which requires minimal secondary operations during assembly. 
       BACKGROUND OF THE INVENTION 
       [0003]    Exhaust systems are used for just about every type of vehicle currently in production around the world. It is commonplace for vehicle owners to add accessories to the vehicle to change the appearance of the vehicle. Once particular type of accessory is a decorative exhaust tip typically made of steel or another type of metal which is chrome plated to provide for an aesthetically pleasing appearance. 
         [0004]    One type of design uses a slip-on type steel exhaust tip that is connected directly to the end of the exhaust pipe. This design is subject to corrosion and requires additional welding during assembly operations. 
         [0005]      FIGS. 1-2  depict a prior art design that has a metal exhaust module  100  that attaches to the rear bumper fascia  102  of the vehicle. The exhaust module  100  has metal body  104  and welded mounting flanges  106 . The welded flanges  106  are used to connect the metal body  104  a larger spacer bracket  108  that connects to the rear fascia  102 . The connection of the welded flanges  106 , spacer  108  and rear fascia  102  is made with several bolts  110  and nuts  112 . An outer surface  114  of the metal body  104  is often chrome polished or painted and can be seen when a person looks at the rear bumper fascia  102  of the vehicle. The exhaust module  100  is not connected to the exhaust pipe but has an inlet portion  103  that is positioned in close relation to the end of the exhaust gas tailpipe for receiving and passing exhaust gas through the exhaust module. Exhaust modules of this type often are formed of several welded steel parts and brackets that come into direct contact with the exhaust gas from the exhaust pipe being formed of steel or some other types of metal. 
         [0006]    The above described designs result in undesirable gap between the chrome tip of the exhaust tip or exhaust module and the rear bumper fascia of the vehicle because the design must account for thermal expansion of the metal portions exposed to the hot gasses from the exhaust pipe. The exhaust modules designs that mount to the rear fascia also add a considerable amount of weight causing undue stress on the rear fascia, which is often made of plastic. Also both the metal slip on exhaust tip and exhaust module designs described above are costly to produce because they are primarily made of metal. It is therefore desirable to design an exhaust module that is light weight, low cost, and aesthetically pleasing by having a tight fit or minimal gap to the rear fascia of the vehicle. It is also desirable to produce an exhaust gas module that has a minimal number of components for ease of assembly, which would also result in cost savings. 
       SUMMARY OF THE INVENTION 
       [0007]    The present invention is an exhaust module for a vehicle made from a thermoplastic material and is connected to a fascia or bumper of the vehicle. The exhaust module assembly includes one of a two piece bracket formed entirely of polymer and defines an exhaust flow path through the two piece bracket. The two piece bracket includes a first bracket body piece and a second bracket body piece. Between the first bracket body piece and the second bracket body piece is an alignment groove that is formed on one of the first bracket body piece or the second bracket piece and a rib is formed on the other one of the first bracket body piece or second bracket body piece, such that the rib aligns in the alignment groove and functions to connect and align the first bracket body piece and second bracket body piece together. A bracket inlet of the two piece bracket surrounds, but is not in contact with an exhaust pipe of a vehicle. This creates a clearance between the exhaust pipe and the bracket inlet. The exhaust assembly also includes a bracket outlet of the two piece bracket connected to the bracket inlet. A ring tip is connected to the bracket outlet. 
         [0008]    Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0009]      FIG. 1  is an expanded perspective view of a prior art exhaust gas module and fascia; 
           [0010]      FIG. 2  is a side plan view of a mounted prior art exhaust gas module to a rear fascia of a vehicle; 
           [0011]      FIG. 2A  is an expanded perspective view of an exhaust gas module in accordance with one embodiment of the present invention; 
           [0012]      FIG. 2B  is a perspective view of an assembled exhaust gas module in accordance with one embodiment of the present invention; 
           [0013]      FIG. 3A  is a schematic side view diagram of a prior art exhaust tip connected to an exhaust pipe and positioned relative to a portion of a partially broken away portion of the rear fascia; 
           [0014]      FIG. 3B  is a side schematic view of an exhaust module relative to the rear fascia and exhaust pipe in accordance to one embodiment of the present invention; 
           [0015]      FIG. 4A  is a perspective view of an alternate embodiment of a ring tip in accordance with one embodiment of the present invention; 
           [0016]      FIG. 4B  is an expanded perspective view of an alternate embodiment of the bracket assembly and ring tip of the exhaust gas module in accordance with the present invention; 
           [0017]      FIG. 4C  is a perspective view of the assembled exhaust gas module of  FIG. 4B ; 
           [0018]      FIG. 5  is a cross-sectional plan view of the exhaust gas module assembled to the bracket taken along section line  5  in  FIG. 2B ; 
           [0019]      FIG. 6  is an expanded perspective view of an alternate embodiment of the exhaust module assembly wherein the bracket is integrated into the rear fascia; 
           [0020]      FIG. 7A  is a cross-sectional side schematic view of a mold machine for an alternate embodiment of the present invention where the ring tip is insert molded to the bracket; 
           [0021]      FIG. 7B  is a cross-sectional side schematic view of a mold machine for an alternate embodiment of the present invention where the ring tip is insert molded to the bracket; 
           [0022]      FIG. 7C  is a cross-sectional side view of an alternate embodiment of the exhaust module wherein the ring tip has been insert molded onto the bracket; 
           [0023]      FIG. 8  is a partially sectioned angled top perspective view of a two piece bracket in accordance with another embodiment of the invention; 
           [0024]      FIG. 9  is a side perspective view of a two piece bracket having the ring tip removed in accordance with the present embodiment of the invention; 
           [0025]      FIG. 10  is a rear perspective view of the two piece bracket; 
           [0026]      FIG. 11  is an expanded rear perspective view of the two piece bracket in a disassembled state; 
           [0027]      FIG. 12  is an enlarged perspective view of a portion of the disassembled two piece bracket; 
           [0028]      FIG. 13  is an enlarged plan cross-sectional view of a sleeve of the ring tip connected to the two piece bracket; 
           [0029]      FIG. 14  is a rear perspective view of the two piece bracket connected to a vehicle fascia; and 
           [0030]      FIG. 15  is a plan view of a vehicle with two piece bracket connected. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0031]    The following description of the preferred embodiment(s) is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses. 
         [0032]    Referring to the  FIGS. 2A ,  2 B,  4 A,  4 B,  4 C,  5 ,  6  and  7 C, which are the Figs. of the embodiments of the present invention generally, an exhaust module according to the present invention is shown generally at  10 . The module  10  includes a bracket, shown generally at  12 , and a ring tip, shown generally at  14 . The bracket  12  has a plurality of mounting flanges  16 , which are used for connecting the bracket  12  to the fascia or bumper of a vehicle (not shown). 
         [0033]    The bracket  12  includes a bracket inlet  18  and a bracket outlet  20 . The bracket inlet  18  surrounds the end portion of an exhaust pipe  42 , which is connected to a muffler, or other exhaust system component. The bracket inlet  18  is about four inches in diameter, and the exhaust pipe  42  is about two inches in diameter, which creates about a one-inch clearance between the exhaust pipe  42  and the bracket inlet  18  of the bracket  12 . This clearance limits the exposure of the bracket  12  to the temperatures of the exhaust pipe  42 , and allows for the exhaust pipe  42  to have some movement, or “play,” as the vehicle travels over bumps, around curves, and the like. While a diameter of four inches for the bracket inlet and a diameter of two inches for the exhaust pipe is disclosed, it is within the scope of this invention for different diameters to be used depending upon the size of the diametrical size of the exhaust pipe. 
         [0034]    The bracket  12  in one embodiment of the invention is formed entirely of plastic or polymer such as glass filled nylon, ABS or other polymer materials such as thermoplastic olefins. Forming the bracket  12  out of entirely polymer material is a significant advantage over the prior art which is typically formed of some type of metal, such as steel. Therefore, it is within the scope of this invention for the bracket  12  and to not be formed of metal. It is also within the scope of this invention for the bracket  12  including the bracket inlet  18 , bracket outlet  20  to not be formed of metal. It is further within the scope of this invention for the bracket  12 , including the bracket inlet  18 , bracket outlet  20  and mounting flanges  16  to not be formed of metal. It is also within the scope of this invention for the bracket  12 , including the bracket inlet  18 , bracket outlet  20 , mounting flanges  16  and ring tip  14  to not be formed of metal. 
         [0035]    The connection between the ring tip  14  and bracket  12  can vary depending on the particular embodiment of the invention. Referring to  FIGS. 2A ,  2 B and  5  the ring tip  14  is connected to the bracket  12  by snap fit tabs. The ring tip  14  has resilient tabs  34  having apertures  36  that connect with protrusions  38  formed on the bracket  12 . In another embodiment of the invention shown in  FIGS. 4A and 4B  the ring tip  14  is slid over the bracket outlet  20  until the mounting features  26  of the bracket outlet  20  becomes interlocked with the mounting features  28  formed integrally with a sleeve  30  of the ring tip  14 . In this particular embodiment the mounting features  26 ,  28  are a “toy tab” or tongue in groove feature. In other embodiments, the ring tip  14  and bracket  12  are connected through other processes, such as adhesion, vibration welding, or the like. 
         [0036]    In the embodiments of the invention described herein the bracket  12  has a bracket outlet  20 . The bracket outlet  20  is connected to the bracket inlet  18  through a tapered portion or bezel portion  24 . The sleeve  30  of the ring tip  14  terminates at a groove  32  portion of the ring tip that receives at least part of the bracket outlet  20  when the module  10  is assembled together. When assembled the bezel portion of the bracket outlet  20  rests against and supports the ring tip  14 . This allows the ring tip  14  to be made thinner, which cuts cost and weight. The ring tip  14  in one embodiment is formed of thin gauge stainless steel that is less than fifty thousandths of an inch thick. In another embodiment of the invention the ring tip  14  is formed of thin gauge stainless steel that is between twenty thousandths to forty thousandths of an inch thick. In another embodiment of the invention the ring tip  14  is formed of thin gauge stainless steel that is between twenty thousandths and thirty thousandths of an inch thick. The thickness of the ring tip  14  can vary depending upon the environmental factors, including exhaust gas temperatures exposure for a particular application. It is also possible for the ring tip  14  to be formed of polymeric material and would include a chrome plated plastic that is accomplished using a Polychlorinated Biphenyls PCBs resin or ABS resin with subsequent chrome plating of the resin material. 
         [0037]    An alternate method of assembling the ring tip  14  to the bracket  12  is shown in  FIGS. 7A-7C  wherein insert molding is used to connect the ring tip  14  to the bracket  12 . This process involves pre-forming the ring tip  14 , which has flow grooves  15  formed at opposite edges of the ring tip  14 . The ring tip  14  is placed into a mold cavity of  1  a first platen  48  of a molding machine  46 . A second platen  50  is closed on to the first platen  48  and molten polymer  52  is flowed into the molding machine  46  to form the bracket  12 . The ring tip  14  becomes connected to the bracket  12  by molten polymer  52  material flowing into the flow grooves  15  of the ring tip  14  prior to solidifying and forming the completed bracket  12 . 
         [0038]    Once the ring tip  14  is connected to the bracket  12  according to either the snap fit, toy tab, or insert molded methods of assembly described above, the ring tip  14  is brushed and polished to achieve an aesthetically acceptable part. Performing the brush and polish step once assembly is completed allows for the removal of any mold release material that can be present, particularly if the insert molding method of assembly is used. The brush polishing step also removes scratches or flash material that can be present on the ring tip  14 . 
         [0039]      FIG. 6  shows another alternate embodiment of the invention wherein an exhaust module  300  is integrated into a fascia  302 . In this particular embodiment of the invention, the bracket  12  shown in the other embodiments is not present since the exhaust module  300  is molded into the rear fascia during the process of forming the rear fascia. Once the rear fascia  302  is co-formed, a bracket inlet  18  and bracket outlet  20  is present and is capable of receiving the ring tip  14 . The ring tip  14  can connect to the bracket outlet  20  in the same manner as described in all the embodiments above. This particular embodiment of the invention further eliminates components by no longer requiring a bracket  12  and fasteners for connecting to the rear fascia. Additionally, prior to assembly of the ring tip  14 , the fascia  302  can be painted or completed without any special or additional steps since the ring tip  14  will be connected to the bracket outlet  20  in a subsequent step. Therefore, there is no concern about painting or treating the exhaust module  300  during the formation of the fascia  302 . 
         [0040]    Referring now to  FIGS. 3A and 3B , the advantages of the present invention are over prior art as shown.  FIG. 3A  is a schematic side view of a prior art steel exhaust tip assembly  200 . A steel exhaust tip  202  is connected to the end of an exhaust tail pipe  204 , usually by welding, fasteners or some other attachment mechanism. The steel exhaust tip  202  is positioned below a rear fascia  208  at a distance that provides a suitable gap  206  between the rear fascia  208  and the steel exhaust tip  202 . The gap  206  distances can vary but is usually approximately 28 mm or enough distance to account for thermal expansion of the exhaust tip  202  and movement of the assembly  200  as the vehicle moves. 
         [0041]      FIG. 3B  shows the exhaust module  10  schematically assembled to a rear fascia  40  in accordance with the present invention. A gap  44  is shown between the exhaust module  10  and rear fascia  40 . The gap  44  is less than or equal to 5 mm. Thus, the present invention is an improvement over the prior art because a more aesthetically pleasing appearance can be achieved due to the tighter fit and reduced gap  44  between the exhaust module  10  and rear fascia  40 . 
         [0042]    One reason for the present invention&#39;s improvement over prior designs is that the prior designs use a large percentage of metal parts, which requires the designs to account for thermal expansion of the exhaust tip or steel exhaust module. The exhaust module  10  of the present invention is formed entirely of polymer material and in one embodiment implements a thin gauge steel ring tip  14 . A smaller gap can be achieved since the polymer material of the exhaust module  10  will not be subject to the same level of thermal expansion that the prior modules are exposed to. Thus, forming the exhaust module  10  of polymer material represents an improvement over existing exhaust modules and exhaust tip designs. 
         [0043]    The bracket  12  is a glass-filled, nylon part, or is made from another type of thermoplastic material. The ring tip  14  is made from a polycarbonate (PC), acrylonitrile butadiene styrene (ABS), or other type of thermoplastic material which is injection molded. The ring tip  14  is also chrome plated, to provide an aesthetically pleasing appearance. 
         [0044]    Referring to  FIGS. 8-10 , a second embodiment showing an exhaust module assembly  100  is shown. The exhaust module assembly  100  has a two piece bracket  102  with a first bracket body piece  104  and a second bracket body piece  106 . The first bracket body piece  104  has a flange surface  108  with an alignment groove  110  formed on the flange surface. The flange surface  108  of the first bracket body piece  104  abuts against a flange surface  112  on the second bracket body piece  106 . The flange surface  112  on the second bracket body piece  106  has a rib  114  that is configured to be placed within the alignment groove  110  to align the first bracket body piece  104  and second bracket body piece  106  during assembly. While the alignment groove  110  and the rib  114  are shown on the first bracket body piece  104  and second bracket body piece  106  respectively, it is within the scope of this invention for the two structures to be reversed such that the alignment groove  110  is on the second bracket body piece  106  and the rib  114  is on the first bracket body piece  104 . 
         [0045]    When the first bracket body piece  104  and second bracket body piece  106  are positioned such that the rib  114  is within the alignment groove  110  and the flange surface  108  and flange surface  112  are in abutment, the first bracket body piece  104  and second bracket body piece  106  can be connected together using a number of different techniques, including but not limited to adhesives, fasteners, resistive implant welding, or other mechanical features. 
         [0046]    In particular, the first bracket body piece  104  has a number of tabs  116  that slide into a respective aperture  118  formed on the second bracket body piece  106 . This provides a mechanical connection between the first bracket body piece  104  and second bracket body piece  106  in order to hold the two piece bracket  102  together. It is within the scope of this invention for the tabs  116  and aperture  118  on the first bracket body piece  104  and the second bracket body piece  106  to be reversed or arranged in an alternating fashion between the first bracket body piece  104  and second bracket body piece  106  depending on the need of a particular application. For example, one particular application of the present embodiment of the invention might benefit from having the tabs  116  placed on the second bracket body piece  106  while the aperture  118  is formed on the first bracket body piece  104 . 
         [0047]    Additionally, in order to help further facilitate proper alignment between the first bracket body piece  104  and the second bracket body piece  106 , it is within the scope of this invention to alternate the placement of the tab  116  and the aperture  118  such that the first bracket body piece  104  and the second bracket body piece  106  have alternating tab  116  with aligning aperture  118  that will provide confirmation that the first bracket body piece  104  and second bracket body piece  106  are properly aligned during assembly. The tabs  116  and apertures  118  can be used in connection with other fastening means such as adhesives, resistive implant welding or fasteners. 
         [0048]    Once the two piece bracket  102  has been assembled, there is a flow cavity  120  created through the two piece bracket  102  that has a bracket inlet  124  and bracket outlet  122  located at opposing ends of the flow cavity  120 . The two piece bracket  102  is configured to be positioned such that an exhaust pipe  126  of a vehicle exhaust system is placed within the flow cavity  120 , within the area of the bracket inlet  124 . The exhaust pipe  126  is positioned within the bracket inlet  124  in such a way that there is a clearance  128  between the exhaust pipe  126  and an inside surface  130  of the two piece bracket  102  that defines the flow cavity  120 . The exhaust pipe  126  is not connected to the two piece bracket  102 . The two piece bracket  102  is instead connected to a vehicle  132  and a vehicle at a frame or vehicle fascia  134  using one or more mounting flanges  136  formed on either the first bracket body piece  104  and/or the second bracket body piece  106 . 
         [0049]    The two piece bracket  102  has a ring tip  138  that is a decorative ring tip that has mounting flanges  140  that are capable of connecting directly to the vehicle  132 , and specifically, the vehicle fascia  134 . The ring tip  138  has a front side decorative surface that is visible when viewing the vehicle fascia  134  with the ring tip  138  connected. The ring tip  138  also has a rear side surface  142  that has a generally U-shaped cross-section. The two piece bracket  102  has two or more ribs  144  extending from the outside surface  146  of the two piece bracket  102 . The ribs  144  may be formed or extending from either or both of the first bracket body piece  104  and second bracket body piece  106 . The two or more ribs  144  are configured to slide in and press fit against the ring tip  138  by frictionally engaging the U-shaped cross-sectional back side surface  142  of the ring tip  138 . 
         [0050]    Referring out to  FIG. 15  a vehicle  132  is showing having a vehicle fascia  134  with the exhaust module assembly  100  mounted to the rear side of the vehicle fascia  134 . The exhaust pipe  126  of the vehicle  132  is positioned within the exhaust module assembly  100 .  FIG. 14  shows an expanded rearview of the vehicle fascia  134  with the exhaust module assembly  100  connected. The two-piece bracket  102  has mounting flanges  136  that are formed on the second bracket body piece  106 . Mounting flanges  136  are configured to align with and connect to individual bracket mounting blocks  137  formed on the rear surface of the vehicle fascia  134 . Well a specific mounting block is shown it is within the scope of this invention for a different type of structure to be present. When the mounting flanges  136  are placed on the bracket mounting block  137 , A fastener  152  is place through the whole of the mounting flange  136  in order to connect the two piece bracket  102  to the vehicle fascia  134 . The ring tip  138  of the exhaust modules  100  has multiple ring tip brackets  140  extending from the edge of the ring tip  138 . Each of the ring tip brackets  140  are configured to rest and be connected to one corresponding ring tip block  141  formed on the rear surface of the vehicle fascia  134 . A fastener  152  is also used to secure the connection of the ring tip  138  to the vehicle fascia  134 .  FIG. 14  shows two fasteners connected to their respective mounting flange  136  and ring tip bracket  140 , while two of the fasteners  152  are shown expanded away from the respective mounting flange is  136  and bracket  142  demonstrate or show the aperture through the flange or bracket. 
         [0051]    Referring now to  FIG. 13  a partially cross-sectional view of the ring tip  138 , first bracket body piece  104  or second bracket body piece  106  are shown. As shown the ring tip  138  has a sleeve  139  that slides into the bracket outlet  122  and abuts against a flange  151  formed on the inside surface of the flow cavity  120  of the two-piece bracket  102 . The use of the sleeve  139  and flange  151  prevents be over insertion of the ring tip  138  into the first bracket body piece  104  and second bracket body piece  108 . This also helps to maintain the proper clearance between the ring tip  138  and the exhaust pipe  126 , which can cause the ring tip  138  to become discolored position to closely to the hot exhaust gasses. The flange  151  and ring sleeve  139  are additional features and are not necessary for each embodiment of the invention. For example some designs may not require the use of a sleeve  139  and flange  151 . 
         [0052]    The description of the invention is merely exemplary in nature and, thus, variations that do not depart from the essence of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention.