Muffler for internal combustion engines

Claim 2

A muffler comprising, a closed chamber having an exhaust inlet adjacent one end, an exhaust outlet adjacent the other end, a first outer wall portion with said exhaust inlet therein and at least two spaced mounting holes extending therethrough adjacent said exhaust inlet adapted to receive bolts for mounting said muffler on an engine, and a second outer wall portion axially spaced from and generally opposed to said first outer wall portion with second mounting holes therethrough coaxial with said first-mentioned mounting holes, a one-piece baffle member having two spaced perforate panel portions integrally interconnected by a bight portion, said baffle member being fixed in said chamber between said inlet and outlet and oriented therein with said panel portions spaced apart in the direction of gas flow through said chamber to divide said chamber into at least three compartments through which exhaust gases pass, and a one-piece spacer member received in said chamber immediately adjacent said exhaust inlet such that at least a portion of the exhaust gases from the inlet pass therethrough before passing through said baffle member, said one-piece spacer member having spacer tubes extending between said coaxial first and second mounting holes and a perforate portion extending between and rigidly interconnecting said spacer tubes.

Claim 3

A muffler comprising, a cloSed chamber having an exhaust inlet adjacent one end, an exhaust outlet adjacent the other end and opposed side walls each having a bend between said exhaust inlet and outlet, and a one-piece baffle member having two spaced perforate panel portions integrally interconnected by a bight portion, said baffle member being closely received between said side walls during assembly of the muffler such that said baffle member can be slidably wedged into a positive location in said chamber adjacent said bends prior to being fixed in said chamber, said baffle member being fixed in said chamber between said inlet and outlet and oriented therein with said panel portions spaced apart in the direction of gas flow through said chamber to divide said chamber into at least three compartments through which exhaust gases pass.

Claim 4

A muffler comprising, a cloSed chamber having an exhaust inlet adjacent one end, an exhaust outlet adjacent the other end and opposed side walls each having a bend between said exhaust inlet and outlet, and a one-piece baffle member having two spaced perforate panel portions integrally interconnected by a bight portion, said baffle member being closely received between said side walls during assembly of the muffler such that said baffle member can be slidably wedged into a positive location in said chamber adjacent said bends prior to being fixed in said chamber, said baffle member being fixed in said chamber between said inlet and outlet and oriented therein with said panel portions spaced apart in the direction of gas flow through said chamber to divide said chamber into at least three compartments through which exhaust gases pass.

Claim 5

The muffler of claim 2 wherein said chamber comprises a tub shaped body having a bottom wall and generally longitudinally extending side walls and a cover having a top wall parallel to said bottom wall and side walls adapted for sealing engagement with said side walls of said body.

Claim 6

The muffler of claim 2 wherein one of said panel portions of said baffle member has louver means tending to direct exhaust gases passing through said openings in said one panel member away from said exhaust outlet of said chamber.

Claim 7

The muffler of claim 2 wherein said two panel portions of said baffle member lie generally in two planes non-parallel with respect to each other with at least one of said planes being oriented at an oblique angle with respect to a side wall of said chamber.

Claim 8

The muffler of claim 2 further including a spacer member immediately adjacent said exhaust inlet through which at least a portion of the exhaust gases from the inlet pass before passing through said baffle member.

Claim 9

The muffler of claim 3 wherein said body and cover side walls have marginal mating flanges with said flanges being crimped into retaining and sealing engagement with each other.

Claim 10

A muffler for small internal combustion engines comprising a body with a bottom wall and generally longitudinally extending side walls, a matching cover sealed to said body and having side walls and a top wall in spaced relation to said botton wall of said body to provide a closed chamber, an exhaust inlet adjacent one end of said chamber and an exhaust outlet adjacent the other end of said chamber, said side walls of said chamber being generally parallel and having oppositely disposed bends between said inlet and outlet, and a one-pieced baffle member having a close fit between said side walls but obstructed from longitudinally sliding movement therealong by said bends to thereby positively locate said baffle member in said chamber adjacent said bends prior to being fixed in said chamber, said one-piece baffle member having first and second perforate panel portions disposed in said chamber at oblique angles to one another and to said side walls between said inlet and outlet and dividing said chamber into at least three compartments through which exhaust gases pass.

Claim 11

A muffler for small internal combustion engines comprising a body with a bottom wall and generally longitudinally extending side walls, a matching cover sealed to said body and having side walls and a top wall in spaced relation to said botton wall of said body to provide a closed chamber, an exhaust inlet adjacent one end of said chamber and an exhaust outlet adjacent the other end of said chamber, said side walls of said chamber being generally parallel and having oppositely disposed bends between said inlet and outlet, and a one-pieced baffle member having a close fit between said side walls but obstructed from longitudinally sliding movement therealong by said bends to thereby positively locate said baffle member in said chamber adjacent said bends prior to being fixed in said chamber, said one-piece baffle member having first and second perforate panel portions disposed in said chamber at oblique angles to one another and to said side walls between said inlet and outlet and dividing said chamber into at least three compartments through which exhaust gases pass.

Claim 12

The muffler of claim 8 wherein said inlet is located in one of said top and bottom walls and said outlet is located in one of said side walls.

Claim 13

The muffler of claim 9 wherein a spacer is disposed between said inlet and said panels and has tubular portions each receiving a mounting bolt therethrough, said spacer being disposed at an oblique angle relative to said panels.

Claim 14

The muffler of claim 10 wherein said body and cover have an end wall adjacent said outlet transverse to the longitudinal axis of said chamber and said bends impart a dog-leg configuration to said chamber, said panels and spacer being oriented at progressively increasing oblique angles relative to said end wall.

Claim 15

The muffler of claim 11 wherein said body and cover each have two spaced mounting holes therethrough adjacent said exhaust inlet adapted to receive said mounting bolts therethrough, said spacer tubular portions extending between said hOles in said cover and said body, said spacer having a perforate portion providing a screen extending between and rigidly interconnecting said spacer tubular portions, said spacer being positioned in said chamber such that at least a portion of the exhaust gases from the inlet pass through said perforate portion before passing through said baffle member.

Claim 16

The muffler of claim 12 wherein said mounting holes have flanged portions associated therewith adapted for telescoping engagement in assembly with said tubular portions of said spacer.

Claim 17

A muffler for small internal combustion engines comprising; an open body with a bottom wall and generally longitudinally extending side walls, a matching cover sealed to said open body in spaced relation to said bottom wall of said open body to provide a closed chamber, one of said side walls of said body having a portion thereof inclined relative to a portion of the other of said side walls of said open body, said portions of said side walls being in fixed relation to each other and said bottom wall of said open body, an exhaust inlet adjacent one end of said chamber and an exhaust outlet adjacent the other end of said chamber, a one-piece baffle member having two spaced perforate panel portions integrally interconnected by a bight portion, said one-piece baffle member having a close fit between said side walls of said open body and being obstructed from longitudinally sliding movement therealong in at least one direction by being wedged between said relatively inclined portions of said side walls of said open body to thereby positively locate said one-piece baffle member in said open body prior to being fixed in said open body and prior to sealing said cover to said open body, said bight portion of said one-piece baffle member bearing on one of said walls of said open body, and fastening means fixing said one-piece baffle member to said open body in said positive location wedged between said relatively inclined portions of said side walls of said open body, said one-piece baffle member being positioned in said chamber between said inlet and outlet and oriented therein with said panel portions spaced apart in the direction of gas flow through said chamber to divide said chamber into at least three compartments through which exhaust gases pass.

Claim 18

A muffler for small internal combustion engines comprising; an open body with a bottom wall and generally longitudinally extending side walls, a matching cover sealed to said open body in spaced relation to said bottom wall of said open body to provide a closed chamber, one of said side walls of said body having a portion thereof inclined relative to a portion of the other of said side walls of said open body, said portions of said side walls being in fixed relation to each other and said bottom wall of said open body, an exhaust inlet adjacent one end of said chamber and an exhaust outlet adjacent the other end of said chamber, a one-piece baffle member having two spaced perforate panel portions integrally interconnected by a bight portion, said one-piece baffle member having a close fit between said side walls of said open body and being obstructed from longitudinally sliding movement therealong in at least one direction by being wedged between said relatively inclined portions of said side walls of said open body to thereby positively locate said one-piece baffle member in said open body prior to being fixed in said open body and prior to sealing said cover to said open body, said bight portion of said one-piece baffle member bearing on one of said walls of said open body, and fastening means fixing said one-piece baffle member to said open body in said positive location wedged between said relatively inclined portions of said side walls of said open body, said one-piece baffle member being positioned in said chamber between said inlet and outlet and oriented therein with said panel portions spaced apart in the direction of gas flow through said chamber to divide said chamber into at least three compartments through which exhaust gases pass.

Claim 19

The muffler of claim 14 wherein one of said panel portions of said baffle member has louver means tending to direct exhaust gases passing through said openings in said one panel member away from said exhaust outlet of said chamber.

Claim 20

The muffler of claim 14 wherein said exhaust inlet is located in a portion of said bottom wall of said body with at least two spaced mounting holes extending therethrough adjacent said exhaust inlet adapted to receive bolts for mounting said muffler on an engine, said cover has a top wall portion axially spaced from and generally opposed to said portion of said bottom wall and has second mounting holes therethrough coaxial with said first-mentioned mounting holes, and also comprises a one-piece spacer member received in said chamber having spacer tubes extending between said coaxial first and second mounting holes and a perforate portion extending between and rigidly interconnecting said spacer tubes.

Claim 21

The muffler of claim 14 wherein said fastening means fixing said one-piece baffle member to said open body comprises at least one weld.

Claim 22

A muffler for small internal combustion engines comprising, an open body with a bottom wall and side walls, a matching cover sealed to said open body in spaced relation to said bottom wall of said open body to provide a closed chamber, at least one of said side walls of said open body having a portion thereof inclined relative to a portion of the other of said side walls of said open body, said portions of said side walls being in fixed relation to each other and said bottom wall of said body, an exhaust inlet adjacent one end of said chamber and an exhaust outlet adjacent the other end of said chamber, A one-piece baffle member having two spaced perforate panel portions integrally interconnected by a bight portion, said one-piece baffle member having a close fit between said side walls of said open body and being obstructed from sliding movement therealong in at least one direction by being wedged between said relatively inclined portions of said side walls of said open body to thereby positively locate said one-piece baffle member in said open body prior to being fixed in said open body and also prior to sealing said cover to said open body, said bight portion of said one-piece baffle member bearing on said bottom wall of said open body, fastening means fixing said bight portion to said bottom wall in said positive location of said one-piece baffle member with said baffle member being wedged between said relatively inclined portions of said side walls of said open body, said baffle member being positioned in said chamber between said inlet and outlet and oriented therein with said panel portions spaced apart in the direction of gas flow through said chamber to divide said chamber into at least three compartments through which exhaust gases pass.

Claim 23

A muffler for small internal combustion engines comprising, an open body with a bottom wall and side walls, a matching cover sealed to said open body in spaced relation to said bottom wall of said open body to provide a closed chamber, at least one of said side walls of said open body having a portion thereof inclined relative to a portion of the other of said side walls of said open body, said portions of said side walls being in fixed relation to each other and said bottom wall of said body, an exhaust inlet adjacent one end of said chamber and an exhaust outlet adjacent the other end of said chamber, A one-piece baffle member having two spaced perforate panel portions integrally interconnected by a bight portion, said one-piece baffle member having a close fit between said side walls of said open body and being obstructed from sliding movement therealong in at least one direction by being wedged between said relatively inclined portions of said side walls of said open body to thereby positively locate said one-piece baffle member in said open body prior to being fixed in said open body and also prior to sealing said cover to said open body, said bight portion of said one-piece baffle member bearing on said bottom wall of said open body, fastening means fixing said bight portion to said bottom wall in said positive location of said one-piece baffle member with said baffle member being wedged between said relatively inclined portions of said side walls of said open body, said baffle member being positioned in said chamber between said inlet and outlet and oriented therein with said panel portions spaced apart in the direction of gas flow through said chamber to divide said chamber into at least three compartments through which exhaust gases pass.

Claim 24

The muffler of claim 18 wherein said fastening means comprises at least one weld.

Claim 25

A muffler for small internal combustion engines comprising; an open body with a bottom wall and generally longitudinally extending side walls, a matching cover sealed to said open body in spaced relation to said bottom wall of said open body to provide a closed chamber, one of said side walls of said body having a portion thereof inclined relative to a portion of the other of said side walls of said open body, said portions of said side walls being in fixed relation to each other and said bottom wall of said open body, an exhaust inlet adjacent one end of said chamber and an exhaust outlet adjacent the other end of said chamber, a one-piece baffle member having a first perforate baffle portion and a second portion integral with and extending generally transverse to said first baffle portion, said second portion of said one-piece baffle member bearing on one of said walls of said open body, at least one of said first and second portions of said one-piece baffle member having a close fit between said side walls of said open body and being obstructed from longitudinally sliding movement therealong in at least one direction by being wedged between said relatively inclined portions of said side walls of said open body to thereby positively locate said one-piece baffle member in said open body prior to being fixed in said open body and prior to sealing said cover to said open body, and fastening means fixing said one-piece baffle member to said open body in said positive location wedged between said relatively inclined portions of said side walls of said open body, said one-piece baffle member being positioned in said chamber between said inlet and outlet and oriented therein with said panel portion dividing said chamber into at least two compartments through which exhaust gases pass.

Claim 26

A muffler for small internal combustion engines comprising; an open body with a bottom wall and generally longitudinally extending side walls, a matching cover sealed to said open body in spaced relation to said bottom wall of said open body to provide a closed chamber, one of said side walls of said body having a portion thereof inclined relative to a portion of the other of said side walls of said open body, said portions of said side walls being in fixed relation to each other and said bottom wall of said open body, an exhaust inlet adjacent one end of said chamber and an exhaust outlet adjacent the other end of said chamber, a one-piece baffle member having a first perforate baffle portion and a second portion integral with and extending generally transverse to said first baffle portion, said second portion of said one-piece baffle member bearing on one of said walls of said open body, at least one of said first and second portions of said one-piece baffle member having a close fit between said side walls of said open body and being obstructed from longitudinally sliding movement therealong in at least one direction by being wedged between said relatively inclined portions of said side walls of said open body to thereby positively locate said one-piece baffle member in said open body prior to being fixed in said open body and prior to sealing said cover to said open body, and fastening means fixing said one-piece baffle member to said open body in said positive location wedged between said relatively inclined portions of said side walls of said open body, said one-piece baffle member being positioned in said chamber between said inlet and outlet and oriented therein with said panel portion dividing said chamber into at least two compartments through which exhaust gases pass.