Patent Publication Number: US-9885267-B2

Title: Exhaust chamber for saddle-riding type vehicle

Description:
CROSS REFERENCE TO THE RELATED APPLICATION 
     This application is based on and claims Convention priority to Japanese patent application No. 2014-174378, filed Aug. 28, 2014, the entire disclosure of which is herein incorporated by reference as a part of this application. 
     BACKGROUND OF THE INVENTION 
     (Field of the Invention) 
     The present invention relates to exhaust chambers disposed in exhaust passages through which exhaust gas from engines of saddle-riding type vehicles pass. 
     (Description of Related Art) 
     It has been known that saddle-riding type vehicles such as motorcycles have exhaust chambers in exhaust passages through which exhaust gas from engines pass (for example, JP Laid-open Patent Publication No. 2009-041562). The exhaust chamber is disposed upstream of a muffler positioned at a downstream end of the exhaust passage with respect to a direction of flow of the exhaust gas. Such an exhaust chamber allows sufficient muffling effect for exhaust gas to be obtained without increasing a size of the muffler. 
     An exhaust chamber is generally formed so as to have a so-called “two-part structure” obtained by two divisional parts being joined to each other since the shape of the exhaust chamber is complicated in many cases. Further, in order to enhance silencing effect, it is advantageous that the exhaust chamber has a great capacity. However, when the capacity is increased, a planar portion of the outer shape tends to be increased, and vibration sound is more likely to be radiated due to vibration of the exhaust chamber. 
     SUMMARY OF THE INVENTION 
     An object of the present invention is to provide an exhaust chamber, for a saddle-riding type vehicle, which enables radiated vibration sound to be reduced while allowing a sufficient capacity to be assured. 
     In order to accomplish the above object, an exhaust chamber for a saddle-riding type vehicle according to the present invention is disposed in an exhaust passage through which exhaust gas from an engine of the saddle-riding type vehicle passes, and includes: an inner case having a chamber expansion region therein; and an outer case configured to cover at least a portion of the inner case. The inner case has a first inner case half and a second inner case half which are obtained by division into two parts, and is formed by the first inner case half and the second inner case half being joined to each other at an inner joining portion. The outer case has a plurality of outer case pieces that are spaced from each other. Each outer case piece is joined to a portion, on an outer surface of the inner case, which portion is different from the inner joining portion. 
     According to the above configuration, each outer case piece of the outer case is jointed to a portion, on the outer surface of the inner case, which portion is different from the inner joining portion. Thus, rigidity of the inner case is enhanced in the joining portion between the inner and outer cases. Accordingly, even if the capacity is increased in order to enhance silencing effect, by setting the joining portion in a planar portion of the outer shape, vibration due to difference in pressure of the exhaust gas is reduced, resulting in radiated vibration sound or radiated sound being reduced. Further, a plurality of outer case pieces are disposed on the outer surface of the inner case so as to be spaced from each other. Therefore, while the size of the outer case is reduced, rigidity of the inner case can be effectively enhanced in a desired portion. Moreover, the inner case to be covered by the outer case may have protrusions and recesses or the like for reducing vibration, with no regard to an outer appearance. 
     In the present invention, the outer case pieces are preferably disposed over a division surface of the first and the second inner case halves, and are preferably joined to both the inner case halves. According to this configuration, the outer case pieces are disposed over the division surface, and joined to the two inner case halves of the inner case. Thus, the inner case can be prevented from greatly expanding in a direction perpendicular to the division surface of both the inner case halves. 
     In the present invention, the outer case preferably covers the inner case from an outer lateral side of a vehicle body. According to this configuration, the inner case having a complicated shape is not exposed to the outer lateral side, thereby improving an outer appearance of the vehicle. 
     In the present invention, a portion of the inner case is preferably exposed to an outside. According to this configuration, not all the outer circumference of the inner case is covered by the outer case. Therefore, the size of the outer case can be reduced. Further, a portion of the inner case at which rigidity needs to be enhanced, or a portion of the inner case to be covered for improving the outer appearance is selected, and the outer case can be disposed according to the selection. 
     When a portion of the inner case is exposed to the outside, it is preferable that the first inner case half and the second inner case half of the inner case are separable in a vertical or up-down direction, center portions, in a vehicle widthwise direction, of an upper surface and a lower surface of the inner case are exposed to the outside, and the outer case covers an outer side portion outward of the exposed center portion in the vehicle widthwise direction, and is joined to the exposed center portion. According to this configuration, since the inner case is divided into two parts, that is, the upper portion and lower portion, an internal space of the exhaust chamber can be easily formed into a flattened shape that has a small dimension in the vertical direction and a large dimension in the vehicle widthwise direction by a plate material being subjected to shallow drawing. Thus, by the dimension in the vertical direction being reduced, the size of the outer case for covering the inner case from the outer lateral sides, can be reduced, and, by the dimension of the inner case in the vehicle widthwise direction or left-right direction being increased, the capacity of the exhaust chamber can be increased. Further, since the outer case covers only the outer lateral portions of the inner case, the dimension of the outer case in the vehicle widthwise direction can be reduced. Therefore, the outer case can be easily formed by a plate material being subjected to shallow drawing. 
     In this case, a bracket for attachment to a vehicle body frame is preferably provided in the exposed center portion of the first inner case half on an upper side. According to this configuration, the bracket can be provided in a large space on the upper surface of the inner case. Further, when the bracket is provided, the rigidity of the upper surface of the inner case is enhanced. 
     In the present invention, a heat insulation space is preferably formed between the inner case and the outer case. According to this configuration, heat insulation in the exhaust chamber is improved. 
     In the present invention, an endless reinforcing belt member is preferably disposed on an inner surface of the inner case so as to extend in a direction that intersects a division surface of the inner case. Here, “endless” represents a continuous loop-like shape having no end. According to this configuration, rigidity of the inner case is further enhanced, and radiated vibration sound can be still further reduced. 
     Any combination of at least two constructions, disclosed in the appended claims and/or the specification and/or the accompanying drawings should be construed as included within the scope of the present invention. In particular, any combination of two or more of the appended claims should be equally construed as included within the scope of the present invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       In any event, the present invention will become more clearly understood from the following description of preferred embodiments thereof, when taken in conjunction with the accompanying drawings. However, the embodiments and the drawings are given only for the purpose of illustration and explanation, and are not to be taken as limiting the scope of the present invention in any way whatsoever, which scope is to be determined by the appended claims (What is claimed is). In the accompanying drawings, like reference numerals are used to denote like parts throughout the several views, and: 
         FIG. 1  is a side view illustrating a rear portion of a motorcycle which is one kind of a saddle-riding type vehicle having an exhaust chamber according to a preferred embodiment of the present invention; 
         FIG. 2  is a side view of the exhaust chamber; 
         FIG. 3  is a plan view of the exhaust chamber; 
         FIG. 4  is a perspective view of the exhaust chamber; 
         FIG. 5  is an exploded perspective view of the exhaust chamber; 
         FIG. 6  is a cross-sectional view taken along a line VI-VI in  FIG. 3 ; and 
         FIG. 7  is a plan view illustrating an inside of the exhaust chamber. 
     
    
    
     DESCRIPTION OF PREFERRED EMBODIMENTS 
     Hereinafter, a preferred embodiment of the present invention will be described with reference to the drawings. In the description herein, the left-right direction represents the left-right direction as viewed from a rider riding a motorcycle. 
       FIG. 1  is a side view illustrating a rear portion of a motorcycle that has an exhaust chamber for an engine according to a preferred embodiment of the present invention. The motorcycle has a vehicle body frame FR, and the vehicle body frame FR includes a main frame  1  that forms a front half of the vehicle body frame FR, and a rear frame  2  that is joined to a rear portion of the main frame  1  and forms a rear half of the vehicle body frame FR. A front wheel is supported at the front end portion of the main frame  1  through a not-illustrated front fork. 
     A swing arm bracket  4  is provided at the lower portion of the rear end of the main frame  1 , and a swing arm  6  is supported by the swing arm bracket  4  through a pivot  5  so as to be able to swing in the vertical direction. A rear wheel  8  is supported at the rear end portion of the swing arm  6 . A combustion engine E is disposed below the center portion of the main frame  1 , and the rear wheel  8  is driven by the combustion engine E through a power transmitting member  10  such as a chain. The combustion engine E is, for example, a parallel multi-cylinder four-cycle engine, but is not limited to this. 
     The combustion engine E of the present embodiment has a supercharger  12  mounted thereto. Specifically, the supercharger  12  is disposed above a rear portion of a crank case  14  of the combustion engine E, and intake air pressurized by the supercharger  12  is stored in an intake air chamber  16  disposed above the supercharger  12 , and supplied to the combustion engine E, through a throttle body  18 , from an intake port  22  formed on a rear face of a cylinder head  20  of the combustion engine E. 
     A plurality of exhaust pipes  26  connected to exhaust ports  24  positioned in the front portion of the cylinder head  20  of the combustion engine E are merged into a merging exhaust pipe  25  below the combustion engine E, and connected to a muffler  28  through an exhaust chamber  27  and a connecting pipe  35 . The exhaust pipes  26 , the merging exhaust pipe  25 , the exhaust chamber  27 , the connecting pipe  35  and the muffler  28  cooperate together to form an exhaust passage  30 . The muffler  28  is disposed on the outer lateral side of the rear wheel  8 , for example, to the right of the rear wheel  8  in the lateral direction, and the exhaust chamber  27  and the muffler  28  are partially covered by a cover  31  from the outer lateral side. 
     The exhaust chamber  27  is disposed upstream of the muffler  28  and downstream of the merging exhaust pipe  25  with respect to a direction of flow of exhaust gas. Further, the exhaust chamber  27  is disposed in front of the rear wheel  8  and below the combustion engine E. 
       FIGS. 2 to 4  are a side view, a plan view, and a perspective view, respectively, of the exhaust chamber  27 . As shown in  FIG. 2 , the exhaust chamber  27  includes: a chamber body  29  having a chamber expansion region or space  32  therein; a chamber inlet pipe  31  through which the exhaust gas G is introduced into the chamber expansion region  32 ; and a chamber outlet pipe  33  through which the exhaust gas G is discharged from the chamber expansion region  32 . The chamber body  29 , the chamber inlet pipe  31 , and the chamber outlet pipe  33  are integrated by welding. The chamber inlet pipe  31  and the chamber outlet pipe  33  are connected to the merging exhaust pipe  25  and the connecting pipe  35 , respectively, shown in  FIG. 1 . 
     As shown in  FIG. 3 , the chamber body  29  of the exhaust chamber  27  has an inner case  34  forming the chamber expansion region  32 , and an outer case  36  that covers a portion of the inner case  34 . The inner case  34  and the outer case  36  are made of the same kind of metal, for example, stainless steel. In order to improve outer appearance, the outer case  36  may be subjected to surface treatment, coating, or the like. 
       FIG. 5  is a perspective view illustrating a state where the inner case  34  and the outer case  36  are separated. As shown in  FIG. 5 , the inner case  34  has a two-part structure formed by the inner case  34  being divided into two parts in the vertical direction, such that the inner case  34  has a first inner case half  38  disposed on the upper side and a second inner case half  40  disposed on the lower side. The first and second inner case halves  38  and  40  are joined to each other by welding. 
     As shown in  FIG. 3 , the outer case  36  covers inner and outer lateral faces, of the inner case  34 , in the vehicle widthwise direction from the inner lateral side and the outer lateral side of the vehicle body. However, a portion of the inner case  34 , for example, a portion of the upper surface and a portion of the lower surface of the inner case  34  in the present embodiment, is exposed to the outside. A bracket  42  for attachment to the vehicle body frame as shown in  FIG. 4  is provided in the exposed portion of the upper surface of the inner case  34 . As shown in  FIG. 1 , the exhaust chamber  27  is supported at the lower end of the swing arm bracket  4  through a stay  44  joined to the bracket  42 . 
     As shown in  FIG. 3 , the outer case  36  has a first outer case piece  46  and a second outer case piece  48 , and the first and second outer case pieces  46  and  48  are spaced from each other in the vehicle widthwise direction of the inner case  34 . The first outer case piece  46  covers the right side portion (the outer side of the vehicle body) of the inner case  34 , and the second outer case piece  48  covers the left side portion (the inner side of the vehicle body) of the inner case  34 . The entirety of the opening edge of each of the first and the second outer case pieces  46  and  48  is welded to the outer surface of the inner case  34 . 
     Specifically, as shown in  FIG. 6  that is a cross-sectional view as taken along a line VI-VI in  FIG. 3 , a division surface D 1  is defined in the inner case  34  at a mid-portion, of the inner case  34 , in the vertical direction. An inner joining portion  51  is formed by flanges  45 ,  47  forming the division surface D 1 . While opposing joining surfaces  50  of both the flanges  45  and  47  are brought into contact with each other, the first inner case half  38  and the second inner case half  40  are welded to each other. 
     On the other hand, the first and the second outer case pieces  46  and  48  of the outer case  36  include: body portions  46   a  and  48   a  that cover the outer lateral sides of the inner case  34 ; and outer and inner joining portions  46   b  and  48   b  that extend from the body portions  46   a  and  48   a  toward the inner case  34  and are joined to the outer surfaces of the inner case  34 . Each of the outer case pieces  46  and  48  is disposed over the division surface D 1  of the first and the second inner case halves  38  and  40 . 
     That is, the upper joining portions  46   b  and  48   b  of the first and the second outer case pieces  46  and  48  are joined to portions P which are different from the inner joining portion  51  on the outer surface of the first inner case half  38  (the upper surface of the inner case  34 ), and the lower joining portions  46   b  and  48   b  of the first and the second outer case pieces  46  and  48  are joined to the outer surface of the second inner case half  40  (the lower surface of the inner case  34 ). 
     The chamber expansion region  32  is formed into a flattened shape having a dimension reduced in the vertical direction, that is, formed such that a dimension in the vertical direction is less than a dimension in the vehicle widthwise direction and a dimension in the front-rear direction or longitudinal direction. Further, in the present embodiment, the dimension in the longitudinal direction is greater than the dimension in the vehicle widthwise direction. The inner case  34  is divided in the vertical direction in which the dimension is reduced for the flattened shape. The outer case  36  of the present embodiment is divided into two parts in the vehicle widthwise direction. A dimension in the vehicle widthwise direction is the lesser of dimensions in the directions perpendicular to the vertical direction, and the dimension in the vertical direction is reduced to flatten the shape. 
     The division surface D 1  of the inner case  34  and division surfaces D 2  of the outer case  36  preferably intersect each other, and are more preferably perpendicular to each other. In the present embodiment, the division surface D 1  and the division surface D 2  are substantially perpendicular to each other. Here, “substantially perpendicular” represents an intersection angle of 80° to 90°. Further, in the present embodiment, the outer case  36  does not cover the center portions, in the vehicle widthwise direction, of the upper surface and the lower surface of the inner case  34 . The exposed center portions of the upper surface and the lower surface of the inner case  34  are raised outward by an amount corresponding to the thickness of the outer case  36 . Thus, positioning of the outer case  36  is facilitated. 
     A heat-insulation space S, which is closed, is formed between the inner case  34  and the outer case  36 . In the present embodiment, a heat-insulation material  54  is interposed in the heat-insulation space S. The heat-insulation material  54  is, for example, glass wool. A plurality of spacer members may be welded to the left and the right outer side surfaces of the inner case  34 , and the inner surface of the outer case  36  may be brought into contact with the spacer members, to form the heat-insulation spaces S that have a predetermined interval. 
       FIG. 7  is a plan view illustrating an inside of the exhaust chamber  27 . As shown in  FIG. 7 , the chamber expansion region  32  in the exhaust chamber  27  is sectioned into a first expansion chamber  58  on the upstream side and a second expansion chamber  60  on the downstream side by a dividing wall  56 . The first expansion chamber  58  and the second expansion chamber  60  communicate with each other via a through pipe  62  that penetrates through the dividing wall  56 . A catalyst  64  for exhaust purification is disposed inside the through pipe  62 . 
     An endless reinforcing belt member  69  is attached to the inner surface of the inner case  34  so as to extend in a direction that intersects the division surface D 1  of the inner case  34 . The reinforcing belt member  69  has a quadrangular-loop-like shape that fits with the inner surface of the inner case  34 , and is fixed, by welding, to the inner surface of one of the first and the second inner case halves  38 ,  40 , in this embodiment, the inner surface of the first inner case half  38  in  FIG. 7 . In the present embodiment, the four reinforcing belt members  69  are aligned in the longitudinal direction. However, the number of the reinforcing belt members  69  is not limited to four. Further, the internal structure of the exhaust chamber  27  is not limited to the illustrated one. 
     In the above structure, the first and the second outer case pieces  46  and  48  of the outer case  36  shown in  FIG. 6  are jointed to the portions P, on the outer surface of the inner case  34 , which are different from the inner joining portion  51 . Thus, rigidity of the inner case  34  is enhanced in the joining portions P. Accordingly, even if the capacity of the chamber expansion region  32 , that is, the outer shape of the inner case  34  is increased in order to enhance silencing effect, by setting the joining portions P for joining to the outer case  36  in a planar portion of the outer shape, vibration due to difference in pressure of the exhaust gas G is reduced, resulting in radiated vibration sound being reduced. Further, the first and second outer case pieces  46  and  48  are disposed on the outer surface of the inner case  34  so as to be spaced from each other. Therefore, while the size of the outer case  36  is reduced, rigidity of the inner case  34  can be effectively enhanced in a desired portion. 
     Further, the first and the second outer case pieces  46  and  48  are disposed over the division surface D 1  of the first and the second inner case halves  38  and  40 , and joined to both the inner case halves  38  and  40  in the upper and lower joining portions  46   b  and  48   b . Thus, the upper surface and the lower surface of the inner case  34  can be prevented from greatly expanding in the vertical direction (directions indicated by arrows A in  FIG. 6 ) that is perpendicular to the division surface D 1 . 
     The shape of the inner case  34  is complicated, and is formed so as to have a so-called “two-part structure”. In the above structure, the outer case  36  covers the inner case  34  from the left and right sides. Therefore, the inner case  34  having a complicated shape is not exposed on the outer lateral side of the vehicle body, thereby improving an outer appearance of the motorcycle. 
     A portion of the inner case  34 , specifically, the center portion, in the vehicle widthwise direction, of each of the upper surface and the lower surface of the inner case  34  is not covered by the outer case  36  and is exposed to the outside. However, as shown in  FIG. 1 , the combustion engine E is disposed above the exhaust chamber  27 , and the ground is below the exhaust chamber  27 . Thus, a region above the exhaust chamber  27  and a region below the exhaust chamber  27  are less likely to be seen from the outside. Accordingly, even when these regions are not covered by the outer case  36 , the outer appearance does not become bad. Thus, since not all the outer circumference of the inner case  34  is covered by the outer case  36 , the size of the outer case  36  can be reduced, and also, a portion of the inner case  34  at which rigidity needs to be enhanced, a portion of the inner case  34  to be covered for improving the outer appearance, or the like is selected, and the outer case  36  can be disposed according to the selection. 
     Since the inner case  34  shown in  FIG. 6  is divided into two parts, that is, the upper portion and lower portion, the chamber expansion region  32  in the exhaust chamber  27  can be easily formed into a flattened shape that has a small dimension in the vertical direction and a large dimension in the vehicle widthwise direction (the left-right direction) by a plate material being subjected to shallow drawing. Thus, by the dimension in the vertical direction being reduced, the size of the outer case  36  for covering the inner case  34  from the left and the right sides can be reduced, and, by the dimension of the inner case  34  in the vehicle widthwise direction being increased, the capacity of the exhaust chamber  27  can be increased. Further, since the outer case  36  covers only the outer lateral portions of the inner case  34 , the dimension of the outer case  36  in the vehicle widthwise direction can be reduced. Therefore, the outer case  36  can be easily formed by a plate material being subjected to shallow drawing. 
     As shown in  FIG. 4 , the bracket  42  for attachment to the vehicle body frame is provided in an exposed portion, of the upper surface of the inner case  34 , which is not covered by the outer case  36 . Thus, the bracket  42  can be provided in a large space on the upper surface of the inner case  34 . Further, when the bracket  42  is provided, the rigidity of the upper surface of the inner case  34  is enhanced, to prevent upward expansion. 
     The heat-insulation space S is formed between the inner case  34  and the outer case  36  as shown in  FIG. 6 . Thus, heat insulation in the exhaust chamber  27  is improved. Further, since the heat-insulation space S is filled with the heat-insulation material  54 , heat insulation in the exhaust chamber  27  is improved effectively. 
     The endless reinforcing belt member  69  is attached to the inner surface of the inner case  34  as shown in  FIG. 7 . Therefore, rigidity of the inner case  34  is further enhanced, and radiated vibration sound can be reduced effectively. 
     Although, in the above embodiment, a double structure including the inner case  34  and the outer case  36  is described as an example, a triple structure may be used. Specifically, a first inner case, a second inner case, and the outer case  36  as described above may be provided such that the first inner case forms the chamber expansion region and is provided on the inner side, the second inner case covers the entirety of the first inner case, and the outer case  36  covers a portion or the entirety of the second inner case. In this case, a heat-insulation space may be provided between both the inner cases, and the reinforcing belt member  69  may be attached to the outer surface of the first inner case provided on the inner side. 
     The present invention is not limited to the embodiment described above, and various additions, modifications, or deletions may be made without departing from the gist of the invention. For example, although, in the above embodiment, the outer case  36  has a two-part structure in which the outer case  36  is divided into two in the vehicle widthwise direction, a plurality of outer case pieces may be spaced from each other in the circumferential direction of the inner case  34 . Further, a surface of the inner case  34  other than the upper surface and the lower surface thereof may be exposed to the outside. Further, the present invention is applicable to saddle-riding type vehicles such as three-wheeled vehicles and four-wheeled buggies as well as motorcycles. Therefore, these are construed as included within the scope of the present invention. 
     REFERENCE NUMERALS 
     
         
         
           
               27  . . . exhaust chamber 
               30  . . . exhaust passage 
               32  . . . chamber expansion region 
               34  . . . inner case 
               36  . . . outer case 
               38  . . . first inner case half 
               40  . . . second inner case half 
               42  . . . bracket 
               46  . . . first outer case piece 
               48  . . . second outer case piece 
               51  . . . inner joining portion 
               69  . . . reinforcing belt member 
             E . . . combustion engine 
             G . . . exhaust gas 
             P . . . different portion 
             S . . . heat-insulation space