Slotted snap-action valve assembly for exhaust system

1. A snap-action valve assembly for an exhaust system comprising:

a first conduit extending along a central axis from a junction end to a distal end, said first conduit having a first conduit wall with an outside surface and an inner mating surface;

a second conduit extending co-axially with said central axis between an insertion end and a proximal end, said second conduit having a second conduit wall with an inner surface and an outer mating surface;

said first and second conduits cooperating to define an exhaust passageway therein that extends from said proximal end of said second conduit to said distal end of said first conduit;

a valve flap disposed within said first conduit for controlling exhaust flow through said exhaust passageway;

a shaft supporting said valve flap in said first conduit for rotation about a pivot axis between a closed position and an open position;

first and second bushings supporting said shaft on said first conduit, each of said first and second bushings including a shaft opening that receives said shaft;

said insertion end of said second conduit being received in said junction end of said first conduit such that said outer mating surface of said second conduit faces said inner mating surface of said first conduit;

said first conduit including first and second slots, each of said first and second slots extending through said first conduit wall from an open slot end positioned at said junction end of said first conduit to a closed slot end that is longitudinally spaced from said junction end of said first conduit a distance greater than said first bushing extends in a direction parallel to said central axis; and

said first and second bushings being disposed within said first and second slots respectively between said insertion end of said second conduit and said closed slot ends of said first and second slots.

2. The snap-action valve assembly of claim 1 , wherein each of said first and second slots include opposing linear edges that run parallel to one another and wherein said first and second slots extend parallel to one another in a slot plane.

3. The snap-action valve assembly of claim 2 , wherein said slot plane is parallel to and spaced from said central axis of said first conduit by an offset distance and wherein said pivot axis of said valve flap extends in said slot plane.

4. A snap-action valve assembly for an exhaust system comprising:

a first conduit extending along a central axis from a junction end to a distal end, said first conduit having a first conduit wall with an outside surface and an inner mating surface;

a second conduit extending co-axially with said central axis between an insertion end and a proximal end, said second conduit having a second conduit wall with an inner surface and an outer mating surface;

said first and second conduits cooperating to define an exhaust passageway therein that extends from said proximal end of said second conduit to said distal end of said first conduit;

a valve flap disposed within said first conduit for controlling exhaust flow through said exhaust passageway;

a shaft supporting said valve flap in said first conduit for rotation about a pivot axis between a closed position and an open position;

first and second bushings supporting said shaft on said first conduit, each of said first and second bushings including a shaft opening that receives said shaft;

said insertion end of said second conduit being received in said junction end of said first conduit such that said outer mating surface of said second conduit faces said inner mating surface of said first conduit;

said first conduit including first and second slots, each of said first and second slots extending through said first conduit wall from an open slot end positioned at said junction end of said first conduit to a closed slot end that is longitudinally spaced from said junction end of said first conduit;

said first and second bushings being disposed within said first and second slots respectively between said insertion end of said second conduit and said closed slot ends of said first and second slots; and

first and second bushing sleeves supporting said first and second bushings within said first and second slots respectively, wherein each of said first and second bushing sleeves includes a bushing cavity that receives and supports one of said first and second bushings, and wherein each of said first and second bushing sleeves is received in one of said first and second slots and is disposed between said insertion end of said second conduit and one of said closed slot ends.

5. The snap-action valve assembly of claim 4 , wherein each of said first and second bushing sleeves includes at least one flat portion that contacts one of said first and second slots to prevent rotation of said first and second bushing sleeves within said first and second slots.

6. The snap-action valve assembly of claim 5 , wherein each of said first and second bushings includes at least one flat that contacts said at least one flat portion of one of said first and second bushing sleeves to prevent rotation of said first and second bushings within said first and second bushing sleeves.

7. The snap-action valve assembly of claim 4 , wherein each of said first and second bushing sleeves includes at least one protrusion that extends therethrough into said bushing cavity, wherein each of said first and second bushings includes at least one dimple that is aligned with one of said protrusions of said first and second bushing sleeves, and wherein said protrusions of said first and second bushing sleeves extend into said dimples in said first and second bushings to prevent axial movement of said first and second bushings relative to said first and second bushing sleeves.

8. The snap-action valve assembly of claim 4 , wherein said first and second bushings are made of wire mesh.

9. A snap-action valve assembly for an exhaust system comprising:

a first conduit extending along a central axis from a junction end to a distal end, said first conduit having a first conduit wall with an outside surface and an inner mating surface;

a second conduit extending co-axially with said central axis between an insertion end and a proximal end, said second conduit having a second conduit wall with an inner surface and an outer mating surface;

said first and second conduits cooperating to define an exhaust passageway therein that extends from said proximal end of said second conduit to said distal end of said first conduit;

a valve flap disposed within said first conduit for controlling exhaust flow through said exhaust passageway;

a shaft supporting said valve flap in said first conduit for rotation about a pivot axis between a closed position and an open position;

first and second bushings supporting said shaft on said first conduit, each of said first and second bushings including a shaft opening that receives said shaft;

said insertion end of said second conduit being received in said junction end of said first conduit such that said outer mating surface of said second conduit faces said inner mating surface of said first conduit;

said first conduit including first and second slots, each of said first and second slots extending through said first conduit wall from an open slot end positioned at said junction end of said first conduit to a closed slot end that is longitudinally spaced from said junction end of said first conduit;

said first and second bushings being disposed within said first and second slots respectively between said insertion end of said second conduit and said closed slot ends of said first and second slots; and

wherein said shaft includes an axle portion, a lever arm, and a spring attachment arm, wherein at least part of said axle portion is disposed within said first conduit and said lever arm and said spring attachment arm are external to said first conduit, wherein said valve flap is carried on said axle portion such that said axle portion of said shaft rotates with said valve flap, wherein said axle portion is co-axially aligned with said pivot axis of said valve flap and said spring attachment arm defines a spring attachment arm axis that is parallel to and spaced from said pivot axis, wherein said lever arm extends transversely between said axle portion and said spring attachment arm of said shaft, and wherein said first conduit includes an anchor post extending outwardly from said outside surface of said first conduit.

10. The snap-action valve assembly of claim 9 further comprising:

a tension spring having a helical main body disposed between first and second hook ends, said first hook end of said tension spring being retained on said spring attachment arm of said shaft and said second hook end of said tension spring being retained on said anchor post, said tension spring biasing said valve flap to said closed position.

11. The snap-action valve assembly of claim 10 , wherein said anchor post is integral with and partially cut out from said first conduit wall, said first conduit wall including an anchor post cut-out, and said anchor post extending from a bent transition adjacent said first conduit wall.

12. A snap-action valve assembly for an exhaust system comprising:

a first conduit extending along a central axis from a junction end to a distal end, said first conduit having a first conduit wall with an outside surface and an inner mating surface;

a second conduit extending co-axially with said central axis between an insertion end and a proximal end, said second conduit having a second conduit wall with an inner surface and an outer mating surface;

said first and second conduits cooperating to define an exhaust passageway therein that extends from said proximal end of said second conduit to said distal end of said first conduit;

a valve flap disposed within said first conduit for controlling exhaust flow through said exhaust passageway;

a shaft supporting said valve flap in said first conduit for rotation about a pivot axis between a closed position and an open position;

first and second bushings supporting said shaft on said first conduit, each of said first and second bushings including a shaft opening that receives said shaft;

said insertion end of said second conduit being received in said junction end of said first conduit such that said outer mating surface of said second conduit faces said inner mating surface of said first conduit;

said first conduit including first and second slots, each of said first and second slots extending through said first conduit wall from an open slot end positioned at said junction end of said first conduit to a closed slot end that is longitudinally spaced from said junction end of said first conduit;

said first and second bushings being disposed within said first and second slots respectively between said insertion end of said second conduit and said closed slot ends of said first and second slots; and

a mass damper external to said first and second conduits that is rotatably coupled to said shaft such that said mass damper rotates with said shaft, said mass damper including a linear segment extending along a primary mass damper axis between a pair of damper ends, a first transverse segment, and a second transverse segment, said first and second transverse segments extending from said pair of damper ends in opposite transverse directions relative to said primary mass damper axis.

13. A snap-action valve assembly for an exhaust system comprising:

a first conduit extending along a central axis from a junction end to a distal end, said first conduit having a first conduit wall with an outside surface and an inner mating surface;

a second conduit extending co-axially with said central axis between an insertion end and a proximal end, said second conduit having a second conduit wall with an inner surface and an outer mating surface;

said first and second conduits cooperating to define an exhaust passageway therein that extends from said proximal end of said second conduit to said distal end of said first conduit;

a valve flap disposed within said first conduit for controlling exhaust flow through said exhaust passageway;

a shaft supporting said valve flap in said first conduit for rotation about a pivot axis between a closed position and an open position;

first and second bushings supporting said shaft on said first conduit, each of said first and second bushings including a shaft opening that receives said shaft;

said insertion end of said second conduit being received in said junction end of said first conduit such that said outer mating surface of said second conduit faces said inner mating surface of said first conduit;

said first conduit including first and second slots, each of said first and second slots extending through said first conduit wall from an open slot end positioned at said junction end of said first conduit to a closed slot end that is longitudinally spaced from said junction end of said first conduit;

said first and second bushings being disposed within said first and second slots respectively between said insertion end of said second conduit and said closed slot ends of said first and second slots; and

wherein said first conduit has a tubular shape and includes a first enlarged conduit segment at said junction end and a neck portion disposed longitudinally between said first enlarged conduit segment and said distal end, wherein said neck portion of said first conduit has a first inner diameter and said first enlarged conduit segment of said first conduit has a second inner diameter that is larger than said first inner diameter of said neck portion, wherein said second conduit has a tubular shape and an outer diameter measured across said outer mating surface that is smaller than said second inner diameter of said first enlarged conduit segment of said first conduit, and wherein said insertion end of said second conduit is slidingly received within said first enlarged conduit segment of said first conduit.

14. A method of manufacturing a snap-action valve assembly for an exhaust system, the method comprising the step of:

providing a first conduit with a junction end;

providing a second conduit with an insertion end;

cutting first and second slots into the junction end of the first conduit, each of the first and second slots extending longitudinally along the first conduit from an open slot end positioned at the junction end of the first conduit to a closed slot end;

placing first and second bushing sleeves over first and second bushings to form first and second bushing subassemblies;

placing the first bushing subassembly on a shaft by sliding the shaft through the first bushing;

attaching a valve flap to the shaft;

placing the second bushing subassembly on the shaft by sliding the shaft through the second bushing to form a valve flap subassembly where the valve flap is positioned on the shaft between the first and second bushing subassemblies;

sliding the valve flap subassembly into the first conduit from the junction end such that the shaft and the first and second bushing subassemblies are slidingly received in the first and second slots until the first and second bushing sleeves abut the closed slot ends; and

sliding the insertion end of the second conduit into the junction end of the first conduit until the insertion end of the second conduit abuts the first and second bushing sleeves.

15. The method of claim 14 , further comprising the steps of:

cutting an anchor post out from the first conduit;

bending the anchor post outwardly away from the first conduit; and

connecting a tension spring between the anchor post and a spring attachment arm on the shaft to bias the valve flap to a closed position.

16. The method of claim 14 , further comprising the step of:

attaching a mass damper to the shaft to dampen vibration related harmonics and reduce valve flap flutter.