Background of the Invention
The present invention relates to exhaust systems, in particular to an exhaust system wherein scavenging occurs, especially in combination with silencing.
In internal combustion engines it is quite common for two or more of the exhaust valves of various cylinders to be open at the same time. Normally, the exhaust gas pressure in the cylinders with exhaust valves open at the same time will not be the same. For example, for one cylinder the exhaust port may have just opened and the exhaust gasses within the cylinder are at a relatively high pressure, whereas simultaneously the exhaust valve for another cylinder may have been open for some time such that most of the gasses within the cylinder have escaped and the valve has started to close. If the gasses escaping from these various cylinders are all vented into the same exhaust manifold, it is quite possible, due to poor engineering, that the exhaust gasses from the cylinder where the valve has just opened may at least partially repressurize the cylinder where the valve is just about to close with exhaust gasses thereby substantially decreasing the efficiency of the engine.
Over the years various exhaust configurations have been designed in attempts to alleviate the above mentioned problem and thereby increase the efficiency of the engine. For instance, exhaust gasses from cylinders which would have exhaust valves open at the same time were vented into separate exhaust manifolds. However, higher efficiency has been obtained when, through proper design, the exhaust gasses escaping at high pressure from one cylinder are utilized to draw exhaust gasses from a cylinder at relatively low pressure before the exhaust valve of the latter closed. This operation and related operations are generally referred to as "scavenging".
In theory, the performance (as used herein--the relative horsepower at any given rate of revolution of the engine) can be improved by decreasing the amount of exhaust gasses remaining in a cylinder prior to intake of fresh fuel. It is desirable that the fuel-air mixture which is combusted in each succeeding fuel-air burn in a cylinder contain a minimal amount of the burnt fuel-air mixture of the preceeding combustion. When it is not possible to have only a given fuel-air mixture in the cylinder, it is preferred that fresh ambient air be included therewith, rather than exhausted gasses from a previous combustion. Therefore, the function of the present invention is to reduce the amount of residual combusted gasses in a cylinder for the succeeding burn as much as possible.
It is also important in exhaust systems of this type to limit the amount of noise produced by the escape of gasses from the end of the exhaust system into the ambient atmosphere. Various types of silencing devices have been developed over the years which use different techniques to deaden the noise escaping from the exhaust system utilizing same. It is possible to lower or dampen the amount of noise emitted by a vibrating or oscillating material by combining that material with a similar material which is vibrating 180.degree. out of phase with the first material such that the vibrations in the two materials in effect cancel each other. It is desirable that a silencing system utilizing such resonance dampening be available for use in conjunction with the above mentioned exhaust system and, in particular a silencer which does not substantially impair the increased efficiency produced by the exhaust system.
Objects of the Invention
Therefore the objects of the present invention are as follows: to provide an exhaust system for an internal combustion engine which improves the performance of the engine over conventional exhaust systems; to provide such a system which is highly effective in scavenging exhaust gasses from cylinders of the engine; to provide such a system which decreases the relative amount of exhaust gasses and increases the relative amount of fuel to fresh air in a mixture within such a cylinder prior to combustion; to provide such a system which includes a silencer device; to provide such a silencer device which utilizes resonance deadening principles to decrease the noise emitted by the system; to provide such a system which is relatively simple and easily reparable; to provide such a system which is relatively inexpensive to manufacture, easy to install, and particularly well adapted for the intended usage thereof.
Other objects and advantages of this invention will become apparent from the following description taken in conjunction with the accompanying drawings wherein are set forth, by way of illustration and example, certain embodiments of this invention.
Summary of the Invention
An exhaust system is provided for an internal combustion engine, especially a high performance motorcycle engine or the like. The exhaust system comprises a plurality of exhaust tubes or pipes each of which is connected at one end to an exhaust port of the engine. As used herein the term "exhaust pipe" refers to the part of the exhaust system nearest the engine. A second end of each exhaust pipe is connected to a collector chamber defined by structure means comprising suitable surrounding walls. Further, a discharge pipe is connected at one end thereof to the collector chamber and discharges at a second end thereof into the ambient atmosphere. Flow communication means, preferably a second discharge pipe provides for flow of gas between the chamber and the atmosphere. As used herein, the term "discharge pipe" refers to that part of the exhaust system prior to where the gas passes into the ambient atmosphere.
Preferably, each of the exhaust pipes is of substantially equal length. Also the exhaust pipes are connected to a first end of the collector chamber and the discharge pipes are connected to a second end of the collector chamber opposite the first end thereof. Further, the exhaust pipes are arranged in sets of one or more such that the pipes of each set are generally coaxially aligned with one of the discharge pipes. It is obviously impossible to exactly coaxially align multiple and generally parallel exhaust pipes when they are included in the set with a single discharge pipe and it has been found that only a relatively close alignment is required for operation of the device as described herein. Therefore, the term "generally aligned" as used herein does not mean exactly aligned but rather aligned so that the momentum of gasses flowing through one exhaust pipe generally directs the gasses into the associated discharge pipe.
In addition, preferably the generally aligned axis discussed above joining associated exhaust pipes and discharge pipes crosses within a plane similar axes associated with other exhaust pipes and discharge pipes within the collector chamber.
The collector chamber is also preferably tapered or converging from the first side thereof where same joins with the exhaust pipes to the opposite side thereof where same joins with the discharge pipes. Also, the discharge pipes diverge outwardly from their juncture with the collector to the outer end thereof preferably in a ratio of approximately 3 to 5 length units at the opposite ends thereof when the sidewalls of the discharge pipes are diverged at an angle of approximately 3.degree. with respect to the central axis of the discharge pipe. Discharge pipes are therefore shaped similar to a megaphone. In this manner the lateral or transverse cross-sectional area of the collector chamber is substantially larger than any of the exhaust pipes near the first end thereof and is substantially narrowed in cross-sectional area near the second end thereof with respect to the first end. The discharge pipes not only open into the ambient atmosphere and, therefore, allow a gas stream to diverge substantially at that point, but also diverge along the length thereof. In this manner, a venturi-like configuration is formed within the system.
A particularly effective configuration of the exhaust system has been employed with a four cylinder motorcycle engine, although it is foreseen that engines having two, three, six or other numbers of cylinders may utilize the same principles. In an exhaust system for use with four cylinders, typically pairs of the exhaust pipes are generally axially aligned with one of the discharge pipes in a crossing pattern. This has been found to be especially effective in four cylinder engines where a first cylinder has already discharged the exhaust gas thereof to the exhaust system and still has the exhaust valve thereof open when the exhaust valve of a second cylinder opens. In addition, near the end of the cycle of the first cylinder when the discharge valve is about to close the intake valve may be open such that there is an overlap wherein both valves are open at the same time.
A silencer mechanism is also provided for each of the discharge pipes. The silencer mechanism comprises an impedance tube mounted in the free or distal end of each discharge pipe and having a reduced cross-sectional area as compared to the discharge pipe at that location. The end of the discharge pipe between the impedance tube and discharge pipe is sealed. A deflection plate is mounted on the interior of the discharge pipe at a distance spaced from the end of the discharge pipe and the impedance tube. The deflector plate blocks straight-through flow from entering approximately one-half of the impedance tube. Preferably, the distance between the end of the discharge tube and the deflecting plate is such that gas deflected by the plate, especially after having impinged on the end wall of the discharge pipe and then reentered the gas stream with the remaining non-deflected gas, is approximately 180.degree. out of phase in vibration or oscillation (related resonance frequency) with such remaining gas so that vibrations in the two gas streams tend to cancel one another and reduce the noise in the combined gas stream emitted from the discharge pipes.
The drawings constitute a part of this specification 12 and include exemplary embodiments of the present invention and illustrate various objects and features thereof.
Brief Description of the Drawings
FIG. 1 is a side elevational view of a motorcycle having an internal combustion engine and an exhaust system according to the present invention.
FIG. 2 is an enlarged perspective view of the exhaust system showing exhaust pipes, a collector, and discharge pipes, showing internal portions of a silencer in phantom.
FIG. 3 is an enlarged front end view of the exhaust system.
FIG. 4 is an enlarged top plan view of the exhaust system.
FIG. 5 is a further enlarged and partial cross-sectional view of the exhaust system, especially detailing the collector, taken along line 5--5 of FIG. 1.
FIG. 6 is an enlarged cross-sectional view of the exhaust system taken along line 6--6 of FIG. 5, with portions broken away to show interior detail thereof.
FIG. 7 is an enlarged cross-sectional view of the exhaust system taken along line 7--7 of FIG. 5.
FIG. 8 is a partial and enlarged side elevational view of a distal end of one of the discharge pipes, with portions removed to show interior detail thereof.
Detailed Description of an Embodiment of the Invention
As required, detailed embodiments of the present 12 invention are disclosed herein, however, it is to be understood that the disclosed embodiments are merely exemplary of the invention which may be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention in virtually any appropriately detailed structure.
The reference numeral 1 generally designates an exhaust system mounted on a motorcycle 2 having an internal combustion engine 3. The exhaust system 1 comprises a plurality of exhaust pipes generally designated by the reference numeral 10, a cross-flow collector 11, a first discharge pipe 12 and a second discharge pipe 13.
In the embodiment shown, there are four exhaust pipes 10 in particular two outer exhaust pipes 15 and 16 and two inner exhaust pipes 17 and 18. Each of the exhaust pipes 10 have a similar configuration and are of substantially the same length. As an example, outer exhaust pipe 15 has an upper neck 20 having an end 21 associated therewith which opens to the interior of the pipe 15. A manifold clamp 22 surrounds and is secured by welding or the like to the neck 20 and secures the exhaust pipe 15 to the engine 3 with suitable bolts or the like passed through the clamp 22. The end 21 is received by the exhaust port of the engine 3. The interior of the exhaust pipe 15 communicates with a single exhaust port (not shown) on the engine 3 in a manner well known in the art. Continuing along the exhaust pipe 15 after the neck 20 is a bend 26 followed by a drop section 27 another bend 28 which thereafter directs the exhaust gasses therein both rearwardly and generally horizontally. Following the bend 28 is a convergent section 29 which is interiorly flow-connected to a port 35 in the collector 11. The exhaust pipe 17 has a convergent section 36 which is aligned generally parallel to convergent section 29 of exhaust pipe 15. Exhaust pipes 16 and 18 also have convergent sections 37 and 38 respectfully which are aligned generally parallel to one another but at somewhat acute angles to sections 29 and 36. Each of the sections 29, 36, 37 and 38 are also slightly angled with respect to a longitudinal axis of the collector 11, each diverging at about the same angle from the axis but with sections 37 and 38 on opposite sides of the axis from section 29 and 36.
The collector 11 defines an interior chamber 40, as seen in FIG. 5. The chamber 40 includes a top wall 41, bottom wall 42, sidewalls 43 and 44 and a front end wall 45 and a rear end wall 46. The chamber rear end wall 45 has apertures, such as collector port 35, for each of the exhaust tubes 15, 16, 17 and 18 passing therethrough. The lateral cross-sectional area of the chamber 40 near the exhaust pipes 15, 16, 17 and 18, as indicated by the letter A in FIG. 5 is substantially greater than the cross-sectional area of any one of the exhaust pipes and also the lateral cross-sectional area of the chamber 40 near an opposite end thereof associated with the discharge pipes 12 and 13 and indicated by the letter B in FIG. 5. The chamber upper wall 41 and lower wall 42 are generally trapezoidal-shaped having their bases secured to the front end wall 45. The chamber side walls 43 and 44 generally converge toward 12 one another and toward the central axis of the collector 11 from the front end wall 45 to the rear end wall 46 while maintaining a relatively constant height therealong.
The illustrated chamber 40 has no internal baffles or other substantial internal restrictions. The chamber 40 top wall 41 and bottom wall 42 smoothly and sealably are joined with the side walls 43 and 44 of opposite sides thereof in a rounded and streamlined manner. The chamber rear end wall 46 includes ports 50 and 51 therethrough which respectfully flow communicate with interiors of the discharge pipes 12 and 13.
The discharge pipes 12 and 13 are connected at a first end 60 and 61 respectively thereof and each have a second end 62 and 63 respectively which opens into the ambient air. The discharge pipes 12 and 13 flair or diverge outwardly from each other from the collector 11 and are generally symmetrically positioned about the central axis passing longitudinally through the collector 11. The discharge pipe 12 has an axis which is generally coaxial with the axes Of exhaust pipes 16 and 18. It is noted that these axes cannot be exactly coaxial since there are two exhaust pipes which cannot be overlapped, however, the axes are generally made as coaxial as possible. Likewise, the discharge pipe 13 is generally coaxial with the exhaust pipes 15 and 17. In addition, the axes of the discharge pipes 12 and 13 cross in a generally planar fashion within the collector chamber 40. The discharge pipes 12 and 13 each diverge outwardly from their first ends 60 and 61 to their second ends 62 and 63, respectively. It has been found that when the angle of divergence with respect to the axis of each discharge tube is approximately 3.degree. a satisfactory ratio of the diameter of the first end 60 and 61 to the second ends 62 and 63 respectfully is in the nature of about 1.5 to 2.5.
Each of the discharge pipes 12 and 13 includes a silencer 70 and 71, respectfully. The silencers 70 and 71 are essentially identical and detail of silencer 70 is shown in FIG. 8. The silencer 70 comprises an impedance tube 72 mounted by end plate 73 in the discharge pipe distal end 62 and a deflection plate 74 mounted on an interior wall 75 of the discharge pipe 12. The impedance tube 72 is mounted generally coaxial with the discharge pipe 12 and the end plate 73 prevents flow from exiting the discharge pipe 12 except through the impedance tube 72. The deflector plate 74 is mounted generally perpendicular to the axis of the discharge pipe 12 so as to block from flow passing straight through the discharge pipe 12 approximately one-half of an interior opening, bore or passage 78 of the impedance tube 72. The deflector plate 74 is spaced from an end 79 of the impedance tube 72. The deflector plate 74 is also spaced from the discharge pipe end plate 73 a distance which is determined by the resonance frequency of the gasses discharged by the particular motorcycle engine. Such a distance is often emperically found for a given motorcycle engine. But it is theoretically positioned such that at least part of the gas that is deflected from passing straight through the impedance tube 72 is directed to impinge upon the end plate 73 and thereafter deflect off the deflector plate 74, or back into the gas stream, and is harmonically 180.degree. out of phase with vibrations within the gas stream. In this manner, a certain amount of the noise which would exist without the silencer 70 is dampened so as to reduce the decibel level associated with the system 1.
In use, when the motorcycle engine 3 is operating, pulses of gas at relatively high temperature and pressure are discharged from the engine into the exhaust pipes 12 and 13. The gas pulses traverse the interior of the exhaust pipes 10 and pass into the collector chamber 40 and thereafter pass into and through the discharge pipes 12 and 13 to the atmosphere surrounding the motorcycle 2. When the system 1 is installed on a motorcycle 2, only the discharge end 62 and 63 of the discharge pipes 12 and 13 are open to the ambient air with the rest of the interior of the system 1 being sealably flow interconnected.
It is to be understood that while certain forms of the present invention have been illustrated and described herein, it is not to be limited to the specific forms or arrangement of parts described and shown.