Vehicle muffler with integrated air deflector

Abstract

A muffler having an integrated air deflector comprised of sheet metal includes a tubular shell portion and an integrated air deflector comprised of the sheet metal is described. The integrated air deflector is formed by bending a portion of the sheet metal to project outwardly from a surface of the tubular shell portion. A muffler assembly includes a muffler having an integrated air deflector comprised of sheet metal and end caps configured to attach to tubular ends of the tubular shell portion. The muffler assembly is configured to be installed on an underbody of a motor vehicle. The muffler assembly results in improved aerodynamic efficiency of the motor vehicle and thereby increases a fuel efficiency of the motor vehicle.

What is claimed is: 
     
         1 . A muffler having an integrated air deflector comprising:
 a tubular shell portion formed from a piece of sheet metal, the sheet metal having a front portion and an end portion; and   an air deflector formed integrally with the tubular shell portion , wherein the air deflector portion is bent to project outwardly from a surface of the tubular shell portion.   
     
     
         2 . The muffler of  claim 1 , wherein the air deflector is positioned between a center portion and a rearmost portion of a lower surface of the tubular shell portion when installed on a vehicle. 
     
     
         3 . The muffler of  claim 1 , wherein the tubular shell portion comprises more than one layer of sheet metal. 
     
     
         4 . The muffler of  claim 1 , wherein the air deflector is formed from an end portion of the sheet metal. 
     
     
         5 . The muffler of  claim 4 , wherein the end portion of the sheet metal has a narrower width than a front portion of the sheet metal. 
     
     
         6 . The muffler of  claim 4 , wherein the air deflector further comprises a second bend in the end portion, the second bend causing the end portion to fold back on itself and travel back to the surface of the tubular shell portion. 
     
     
         7 . The muffler of  claim 1 , wherein the air deflector is formed from a middle portion of the sheet metal. 
     
     
         8 . The muffler of  claim 7 , wherein the middle portion of the sheet metal is bent such that the air deflector has a generally triangular cross-sectional shape. 
     
     
         9 . A muffler assembly for a motor vehicle comprising:
 a body formed having an air deflector extending therefrom, wherein the body and the air deflector are formed from a single piece of sheet metal; and   a first end cap attached to a first end of the muffler and a second end cap attached to a second end of the muffler.   
     
     
         10 . The muffler assembly of  claim 9 , wherein the air deflector portion of the muffler is configured to project lower than a rear bumper fascia of a motor vehicle in which the muffler is installed. 
     
     
         11 . The muffler assembly of  claim 9 , wherein the body is formed of multiple windings of the single piece of sheet metal. 
     
     
         12 . The muffler assembly of  claim 9 , wherein the air deflector is formed from an end portion of the piece sheet metal. 
     
     
         13 . The muffler assembly of  claim 12 , wherein the end portion has a narrower width than a front portion of the sheet metal. 
     
     
         14 . The muffler assembly of  claim 9 , wherein the air deflector has a generally triangular cross-section that includes a first portion that is bent away from the body and a second portion that is bent back toward the body. 
     
     
         15 . The muffler assembly of  claim 9 , wherein the air deflector includes a first portion that extends away from the body in a direction generally normal to a surface of the body and a second portion that is folded back adjacent to the first portion and is also in a direction that is generally normal to the surface of the body. 
     
     
         16 . A method of manufacturing a muffler assembly having an integrated air deflector, comprising the steps of:
 providing a piece of sheet metal having a first end and a second end;   shaping the piece of sheet metal into a tubular shape;   welding a first portion of the sheet metal at a set of welding points to form a tubular shell portion;   forming an integrated air deflector from the piece of sheet metal by bending a second portion of the sheet metal to project outwardly from a surface of the tubular shell portion; and   attaching a first end cap to a first end of the tubular shell portion and a second end cap to a second end of the tubular shell portion.   
     
     
         17 . The method of  claim 16 , wherein the shaping comprises rolling the sheet metal into a tubular shape. 
     
     
         18 . The method of  claim 16 , wherein the shaping comprises stamping the sheet metal into a tubular shape. 
     
     
         19 . The method of  claim 16 , further comprising welding a second portion of the piece of sheet metal at a second set of welding points on the surface of the tubular shell portion. 
     
     
         20 . The method of  claim 16 , wherein the step of attaching the first end cap and the second end cap comprises welding the first end cap to the first end and the second end cap to the second end.