Apx Group, Inc.

Ap Parts Manufacturing Company

Goerlich's Inc.

James E Gerber

Jon W Harwood

Michael W Clegg

Bruno A Rosa

Donald P Harter

Willy Herrmann

James R Hall

Clinton R Hay

Robert J Kovacs

A muffler including an internal assembly formed of a pair of identical stampings. The internal assembly includes three tubes extending longitudinally between baffles. The internal assembly received within the muffler outer shell forms central upper and lower attenuation chambers as well as chambers at each proximal end of the muffler. The stampings are provided with impressions for forming weep holes and allowing acidic condensation to exit the central chambers. The stampings are located in mirror image relation with one another and are attached to one another by a rivet pattern and using the metal of the stampings. The rivets readily allow acidic condensate to flow between the upper and lower central chambers. Louver-shaped openings are provided on the stampings providing communication between the formed tubes and the upper and lower central chambers and thereby providing attenuation. The muffler is generally universal for use on many different exhaust engines and vehicles and is generally corrosion resistant and generally long lasting.

Exhaust muffler with stamp formed internal assembly

A muffler includes a pair of internal plates that are formed to define an array of channels and at least one chamber. The internal plates are connected in face-to-face relationship such that the channels define tubes that communicate with the chamber. At least one short section of conventional tube may be disposed between the plates to achieve a selected exhaust gas flow pattern. The connected internal plates is slid longitudinally into a tubular outer shell and end caps are secured to opposed ends to substantially enclose the muffler. The internal plates can be remanufactured prior to insertion into the tubular outer shell, and can be slid into tubular external shells of different lengths for significantly altering the acoustical tuning of the muffler.

Method of manufacturing an exhaust muffler with stamp formed internal

Exhaust mufflers with stamp formed internal components and method of

A technique for securing a tube to a flange includes the steps of inserting the end of the tube into an aperture provided on the flange from the first side of the flange such that a portion of the tube extends at least to, and preferably beyond the second side of the flange opposite the first side. A ceramic plug is optionally inserted into the end of the tube to prevent weld spatter and tube burn-through. The tube is then welded to the flange about the circumference of the tube from the second side of the flange, and that portion of the tube which extends beyond the second side of the flange is removed by grinding to produce the finished product.

Welded tube and flange, e.g., for exhaust manifold

A replacement muffler which can replace original equipment mufflers with substantially no modifications thereto, and methods for producing the same are disclosed. The replacement muffler is provided with a muffler body which only approximates the body of the original equipment muffler and a pair of replacement muffler nipples secured to the muffler body, having diameters substantially equal to the corresponding nipple diameters of the original equipment muffler and having lengths adapted to produce a nipple-to-nipple length substantially equal to the corresponding length of the original equipment muffler. The replacement muffler may be produced with a six to seven fold increase in production line efficiency by customizing only the nipple portions of the replacement muffler.

Replacement muffler and process for making same

Flange weld technique

Process for making a replacement muffler

Various universal muffler assemblies are disclosed which allow one or more muffler nipples to be secured to a selected muffler body at the time of installation.

Universal muffler assembly

A technique for threadedly securing muffler nipples to a muffler body is disclosed. The muffler nipples are provided with a threaded portion which is adapted to be inserted into a bushing attached to the muffler body, threadedly secured thereto, and tightened with a predetermined torque designed to prevent the nipples from unthreading or loosening within the muffler body.

Growing community of inventors

Walbridge, OH, United States of America

James E Gerber