Patent Abstract:
An accessory to an exhaust system is disclosed which reduces the decibel output from the engine of a vehicle while negligibly affecting the horsepower produced by the engine. The accessory can be built directly into an exhaust system by the manufacturer or added as an after-market enhancement by the consumer. The key elements to the device include a sound-funneling housing which circumscribes a diffusing element, both of which are removably or permanently capped on one side. The uncapped end of the housing is formed to engage a portion of the actual exhaust system. The overall result of this device reduces the total amount of noise produced, without noticeably affecting engine performance, while simultaneously inhibiting harmonic sound waves that can create an annoying rattling sound for the driver or passenger.

Full Description:
FIELD OF INVENTION 
       [0001]    The present invention relates to the field of automotive engines. More specifically, the invention relates to exhaust augmentations for automotive engines. 
       BACKGROUND OF THE INVENTION 
       [0002]    As cities and streets become more populated, the number of vehicles on the road constantly increases. Streets grow closer and closer to populated areas, including business districts and residential areas with homes and schools. The pervasiveness of accumulating traffic from cars, trucks and motorcycles on these streets not only impacts the chemical makeup of our environment but also the total amount of ambient noise as well. Gasoline-powered vehicles, in particular, produce a substantial amount of noise and greatly contribute to this type of pollution. In fact, the amount of noise generated from these vehicles accounts for the number one source of noise pollution today. 
         [0003]    The noise pollution due to the expanding public and increased number of vehicles interferes with our daily lives and slowly impinges upon our privacy and personal freedoms. But in addition to population growth, and especially in the United States, there exists a particular type of consumer of the automotive industry that demands the greatest amount of power from their ride. Motorcycle and scooter enthusiasts are no exception to this urge to command a powerful engine. In most cases, an increase in horsepower is accompanied by an increase in the decibel level that is produced from an engine. This means that population growth not only affects the total number of vehicles on the road, but also increases the quantity of noise from each vehicle to create a multiplicity effect on the environment and our personal space. 
         [0004]    Currently, cars are equipped with mufflers and motorcycles are equipped with exhaust pipes that are regulated by law. For example, many states such as California began requiring each municipality and county to have a Noise Element of the General Plan. But for the most part, noise regulation is enforced by city ordinances, meaning fines. Smog checks are required to be performed to renew any vehicle registration but the level of noise output from a vehicle is not and can not be regularly checked. Testing and enforcement of noise level only occurs in the form of random spot checks and citations from police officers, who in the course of normal business do not carry sound meters. 
         [0005]    A few previous solutions have been suggested to alleviate this problem. However, most sound reducing equipment on the market today uses some sort of dampening material in order to muffle sound. For example, U.S. Patent Application No. 20070227811 discloses a vehicle exhaust system containing a sound absorbing material on the outer surface of a side wall of an inner core. Other solutions have involved using devices that actually reduce the amount of horsepower from an engine in order to dampen the sound. Unlike these applications, the presently disclosed device actually obstructs sound in a blocking fashion based on the particular shape and construction of the baffle. It should be noted however that the exact shape of the presently disclosed device varies as it is uniquely created to fit certain size engines and specific model exhaust pipes. 
       SUMMARY OF THE INVENTION 
       [0006]    An accessory to an exhaust system is disclosed which reduces the decibel output from the engine of a vehicle without noticeably affecting the horsepower produced by the engine. The accessory can be built directly into an exhaust system by the manufacturer or added as an after-market enhancement by the consumer. The key elements to the device include a sound-funneling housing which circumscribes a diffusing element, both of which are removably or permanently capped on one side. The uncapped end of the housing is formed to engage a portion of the actual exhaust system. The overall result of this device reduces the total amount of noise produced, without noticeably affecting engine performance, while simultaneously inhibiting harmonic sound waves that can create an annoying rattling sound for the driver and passenger. 
         [0007]    These and other objectives of the claimed invention will no doubt become obvious to those of ordinary skill in the art after reading the following detailed description of the preferred embodiment that is illustrated in the various figures and drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS  
         [0008]      FIG. 1  illustrates an exploded view of the preferred embodiment of the present invention. 
           [0009]      FIG. 2  illustrates a side view of the preferred embodiment of the present invention. 
           [0010]      FIG. 3  illustrates a rear three-quarter view of the preferred embodiment of the present invention. 
           [0011]      FIG. 4  illustrates a front three-quarter view of the preferred embodiment of the present invention. 
           [0012]      FIG. 5  illustrates a rear view of the preferred embodiment of the present invention, showing a diffusing element within the core. 
           [0013]      FIG. 6  illustrates a front three-quarter view of the preferred embodiment of the present invention inserted into a typical exhaust pipe with the use of a nut and screw. 
           [0014]      FIG. 7  illustrates a front view of one embodiment of the present invention inserted into a typical exhaust pipe with an additional flange directed inward from the proximal end of the core. 
           [0015]      FIG. 8  illustrates a front view of one embodiment of the present invention engaged with just the final section of a typical exhaust pipe. 
           [0016]      FIG. 9  illustrates a rear view of one embodiment of the present invention, showing a diffusing element within the core being held in place by a rod running through the center of the diffusing element. 
           [0017]      FIG. 10  illustrates a rear three-quarter view of one embodiment of the present invention, showing a short imperforated core throat and a flat end cap without any lip or additional flanges. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0018]    In the following description of the various embodiments, reference is made to the accompanying drawings, which form a part hereof, and in which is shown by way of illustration, various embodiments in which the invention may be practiced. It is to be understood that other embodiments may still be utilized and structural and functional modifications may be made without departing from the scope and spirit of the present invention. 
         [0019]    Referring to  FIG. 1 , an exploded view of the preferred embodiment of device  10  is shown. Device  10  includes insertable core  11  which is attached at one end to end cap  12 . Core  11  can be hollow or partially filled along its side walls. In the preferred embodiment of device  10 , core  11  is cylindrical in shape but core  11  does not have to maintain a perfect circle in any one plane. For example, the shape of core  11  in the plane normal to the opening of core  11  may be oval, semi oval, contain several straight edges or even be rectangular or octagonal in shape. These various shapes are envisioned in order to fit within certain existing exhaust pipes. They may be crafted so that core  11  fits flush with an exhaust pipe or contains small areas that are open or blocked from the outside air. This allows only a predetermined capacity of gas to flow through device  10 . The exact amount of gas passing through device  10 , combined with the shape of various components, eliminates harmonic vibrations that can occur from different engine systems. The end of core  11  opposite end cap  12  comprises any number of perforations  14 , which allow gases to escape from core  11 . Perforations  14  can be manufactured in any size or shape and extend along core  11  stopping short of end cap  12  to reveal the unblemished throat  15  of core  11 . These perforations  14  can also be patterned in a particular way or randomly. 
         [0020]    Still referring to  FIG. 1 , device  10  also comprises diffusing element  16 , which is usually inserted within core  11  during manufacturing. It can be held in place by being welding to the side walls of core  11  or attached to the side walls by other means that are known in the art, either continually or sporadically along its edges. In the preferred embodiment, diffusing element  16  is rectangular in shape and contains alternating folds so that it is bent in an accordion fashion. The number of folds and distance between folds vary for different systems that work in conjunction with device  10 . In other embodiments of device  10 , diffusing element  16  may not be rectangular in shape. This will depend upon the specific model of device  10 . The sheet of material that forms diffusing element  16  may have different thicknesses at different points along its length. Also, diffusing element  16  may be formed by at least two separate pieces  17  and  18  that fit together to complete the structure. 
         [0021]    Now referring to  FIG. 2 , a side view of device  10  is shown. End cap  12  can more thoroughly be seen in this illustration. End cap  12  is shown comprising locating tab  20 , which in turn comprises locating hole  21 . In the preferred embodiment, end cap  12  can be fastened around throat  15 , as depicted in  FIG. 1 , by solder. However, in various alternative embodiments, the fastening may be accomplished by other methods known in the art, including but not limited to pressure alone. Additionally, end cap  12  can be secured by adjoining diffusing element  16 . It can also be appreciated that perforations  14  may not continue entirely around core  11 , in order to leave room for at least one unblemished column  23  along core  11 , which provide additional structural support to device  10 . End cap  12  may also include a variety of motifs, such as the hollowed dip cup shown in  FIG. 2 , which incorporates a ring and one beveled lid  24 . Alternatively, end cap  12  may contain a lid  24  on both sides and remain hollow or be filled solid. Also, some embodiments will include various design features and ornamental indicia of device  10 . 
         [0022]    Now referring to  FIG. 3 , a rear three quarter view of device  10  is shown. This illustration best shows the pervasiveness that perforations  14  can take, almost completing inundating core  11  until merely thin weaves or nets of material  30  remain. In the preferred embodiment of this invention, core  11  would be inserted into an exhaust system beginning with the perforated side (shown on the top of  FIG. 3 ). The material for core  11  may be anything durable and semi heat resistant including, but not limited to, metal, metal alloy, polymer, vulcanized rubber or ceramic. Perforations  14  may end abruptly toward the front of core  11  (shown toward the bottom of  FIG. 3 ) or gradually fade before reaching core throat  15 . The effect of the multiple perforations  14  is to further disrupt the flow of gas from device  10 . Perforations  14  create surfaces on the interior wall of core  11  which preclude laminar flow. This slows the exhaust gases from jetting out all at once while reducing the total amount of escaping gas which softens the resulting sound. 
         [0023]    Now referring to  FIG. 4 , a front three quarter view of the preferred embodiment is shown. The inside of end cap  12  can more easily be viewed from this angle. The corner where end cap  12  meets core throat  15  may alternatively contain a flange (see  FIG. 7 ) that juts inward in order to block additional gases from escaping. As described infra, flanges can control the total amount of gas emitted from device  10 , in addition to reducing the amount of noise to some degree. In this particular illustration, core throat  15  extends into lid  24  to some extent along lip  40 . However, lid  24  may not always completely surround core throat  15 , or even include lip  40 . Also in this illustration, locating tab  20  is shown flush against end cap  12 , but in various embodiments, it may be separated from the ring of end cap  12 . Additionally, it may be entirely absent if locating hole  21  is found directly on end cap  12 . 
         [0024]    Now referring to  FIG. 5 , a rear view of the preferred embodiment of the present invention is shown with diffusing element  16  within core  11 . An especially clear view of diffusing element  16  can be gleaned from this angle. As mentioned supra, the preferred shape of diffusing element  16  is rectangular. Its folds can alternate in direction each and every bend, periodically or at random to create the optimum diffusion of gas, which is expelled from a joined exhaust pipe. Even more, the angle of each bend of diffusing element  16  may be in the range from 0-180 degrees. Alternatively, element  16  may be constructed from one or more distinct pieces  17  and  18 . In some embodiments, pieces  17  and  18  may traverse the complete width and make contact with core  11 . In other embodiments of device  10 , element  16  may include protruding members or take any form which blocks the flow of gas in a manner that reduces the decibel output of an adjoining engine (not shown). It can be appreciated that the gases flowing from a typical exhaust pipe discharge in waves as the pistons in the engine fire and compress gases. These waves have frequencies which often reach harmonics that rattle the entire vehicle, besides creating even more noise for bystanders. Thus, by changing the air patterns within core  11 , element  16  frustrates these waves so that specific harmonics can not be reached. 
         [0025]    Now referring to  FIG. 6 , a front three-quarter view of the preferred embodiment of the present invention is shown with device  10  inserted and attached to typical exhaust pipe  60  simply with the use of screw  60  and nut  61 . From this exterior vantage point, core throat  15  can be visible along with lip  40  of end cap  12 . The ring of end cap  12  is shown to be flush with exemplary exhaust pipe  60 . Alternatively, in other embodiments of the present invention, a small gap might exist between cap  12  and pipe  60 . This particular illustration does not contain any ornamental designs to device  10 , but the inventor reserves all rights to obtain various design patents to be used in conjunction with the present invention. 
         [0026]    Now referring to  FIG. 7 , a front view of one embodiment of the present invention is shown inserted into a typical exhaust pipe with additional flange  70  directed inward from the proximal end of the core. Flange  70  is made to cover a portion of the exit from core  11 . In this embodiment, flange  70  is rectangular with its broadest face parallel to the side walls of core  11 , but it is possible that flange  70  could pivot to block a greater area of the exit. In fact, one side of flange  70  could be shaped in a semicircle in order to fit evenly with the side wall of core  11 . Device  10  may also incorporate other obstructions, blockades, barriers and impediments that are known in the art. 
         [0027]    Now referring to  FIG. 8 , a front view of one embodiment of the present invention is shown engaged with just the final section of a typical exhaust pipe. In this particular embodiment, end cap  12  is filled almost completely solid. Drill hole  80  can be bored in exhaust pipe  60  as a possible connection to device  10 . Similarly, preexisting hole  81  can also be used as a possible connection to device  10 . Also, in this particular embodiment, core throat  15  is larger in diameter than insertable core  11  and a small ridge can be seen slightly partitioning the two distinct pieces. 
         [0028]    Now, referring to  FIG. 9 , a rear view of one embodiment of the present invention is shown with diffusing element  16  within core  11  being held in place by rod  90  running through the center of the diffusing element  16 . Optional rod  90  may extend through some or all of element  16  and attach at the proximal end of device  10 , preferably to end cap  12 . In addition to providing support, rod  90  can perform a stabilizing function when diffusing element  16  is cut thin in order to hinder or prevent vibration through device  10 . 
         [0029]    Finally, referring to  FIG. 10 , a rear three-quarter view of one embodiment of the present invention is shown with imperforated throat  15  and flat end cap  12 . Either of these two possibilities may exist independently or in combination with any of the other possible variances suggested in this disclosure. From this perspective, it can easily be seen that end cap  12  does not contain a lip directed either inward or outward or any additional flange which would reduce or deflect the amount of gases passing from an exhaust pipe (not shown) through device  10 . As such, this simple embodiment of the invention does not usually extend past the opening of an exhaust pipe. The diameter of end cap  12  can be sized to fit any model exhaust pipe and it can be secured in any manner previously suggested. Throat  15  may also contain an additional core structure within it or extending from the end of throat  15 . Additionally, throat  15  may be cut short so that it does not extend as far into the mouth of an exhaust pipe. Throat  15  may also be shaped in different patterns which are not necessarily cylindrical and possibly change the direction of gases flowing through throat  15 . The tip of diffusing element  16  can also be seen in this figure and be configured or constructed as suggested in this disclosure. 
         [0030]    The present invention includes any novel feature or combination of features disclosed herein either explicitly or any generalization thereof. While the invention has been described with respect to specific examples including presently preferred modes of carrying out the invention, those skilled in the art will appreciate that there are numerous variations and permutations of the above described apparatus. Thus, the spirit and scope of the invention should be construed broadly as set forth in the previous specification or appended claims.

Technology Classification (CPC): 5