Passive exhaust valve assembly with overlapping slip joint and method of forming and installation

1. A passive exhaust valve assembly, comprising:

an exhaust conduit having a first pipe section configured to be attached in an axial direction with a second pipe section, the first and second pipe sections each comprising a respective end portion, and the end portion of the first pipe section comprising a circumferential segment;

wherein the circumferential segment is disposed within the end portion of the second pipe section to form a sleeved region in which the circumferential segment is sleeved inside the end portion of the second pipe section;

wherein the end portions of the first and second pipe sections each include a flange protruding radially outward from the respective first and second pipe sections, wherein the flange of the first pipe section is circumferentially spaced from the circumferential segment;

wherein the flanges engage with each other to form an axle seat therebetween;

a support shaft extending laterally across an interior volume of the exhaust conduit and rotatably engaging the axle seat; and

a valve plate coupled to the support shaft within the interior volume of the exhaust conduit for moving relative to the exhaust conduit between open and closed positions;

wherein one of the first and second pipe sections includes an interior surface with a recessed pocket, and a flexible bumper element disposed at the recessed pocket in a location that contacts the valve plate and dissipates impact of the valve plate moving to the closed position; and

wherein the flexible bumper element is resiliently biased radially inward relative to the exhaust conduit, and wherein the bumper element comprises a metal mesh.

2. The passive exhaust valve assembly of claim 1 , wherein the flanges each protrude outward from and extend along a portion of a circumference of the respective first or second pipe section.

3. The passive exhaust valve assembly of claim 1 , wherein the end portions of the first and second pipe sections each include a second flange protruding radially outward and engaging with each other to form a second axle seat, and wherein the second axle seat is rotatably engaged by the support shaft across the interior volume of the exhaust conduit from the axle seat.

4. The passive exhaust valve assembly of claim 1 , comprising a lap weld disposed along the sleeved region of the first and second pipe sections.

5. The passive exhaust valve assembly of claim 1 , wherein the end portion of the first pipe section has an exterior diameter that is less than or generally equal to an interior diameter of the end portion of the second pipe section.

6. The passive exhaust valve assembly of claim 1 , further comprising:

a bushing coupled between the axle seat and the support shaft to facilitate axial rotation of the support shaft to move the valve plate between the open and closed positions.

7. A passive exhaust valve assembly, comprising:

an exhaust conduit having a first pipe section attached in axial alignment with a second pipe section, the first and second pipe sections comprising respective end portions;

wherein the end portion of the first pipe section comprises a circumferential segment disposed within the end portion of the second pipe section to form an overlapping interface;

wherein the end portions of the first and second pipe sections each comprise a flange protruding radially outward from the respective first or second pipe section;

wherein the flanges engage with each other to form an axle seat therebetween;

a support shaft extending laterally across an interior volume of the exhaust conduit and rotatably engaging the axle seat;

a valve plate coupled to the support shaft within the interior volume of the exhaust conduit for moving relative to the exhaust conduit between open and closed positions; and

a flexible bumper element positioned at an interior surface of one of the first and second pipe sections and arranged so that a portion of the valve plate moves in a radial direction into contact with the flexible bumper element when the valve plate moves to the closed position; and

wherein the end portion of the other of the first and second pipe section comprises a tab that extends into the one of the first and second pipe sections to overlap with and support the flexible bumper element at the interior surface.

8. The passive exhaust valve assembly of claim 7 , wherein the tab includes a pair of arms that extends longitudinally to support respective edge portions of the flexible bumper element in a manner that allows movement of the flexible bumper element relative to the exhaust conduit.

9. The passive exhaust valve assembly of claim 7 , wherein the flexible bumper element is resiliently biased radially inward relative to the exhaust conduit, and wherein the bumper element comprises a metal mesh.

10. A method of assembling of a passive exhaust valve assembly, said method comprising:

providing a first pipe section and a second pipe section, wherein an end portion of the first pipe section is sized to mate by fitting within an end portion of the second pipe section, each end portion defining a circumference;

forming a flange that protrudes radially outward along a portion of the circumference of each end portion of the first and second pipe sections;

wherein forming the flanges comprises:

forming a continuous flange around the circumferences of the end portions of the first and second pipe sections; and

bending a circumferential section of each of the continuous flanges back to a diameter in substantial alignment with a longitudinal extent of a main tubular shaped portion of the respective first or second pipe section;

forming a first seat portion on the flange of the first pipe section;

forming a second seat portion on the flange of the second pipe section;

engaging a support shaft in one of the first and second seat portions, wherein the support shaft includes a valve plate attached to an intermediate portion of the support shaft;

inserting the first pipe section within the second pipe section to form an overlapping interface between the end portions of the first and second pipe sections, wherein the circumferential sections of the first and second pipe sections engage to form the overlapping interface;

engaging the first seat portion with the second seat portion to form an axle seat circumferentially around the support shaft, upon inserting the first pipe section within the second pipe section; and

welding the overlapping interface to attach the first pipe section to the second pipe section and form an exhaust conduit.

11. The method of claim 10 , wherein the overlapping interface includes an exterior surface of the first pipe section abutting an interior surface of the second pipe section.

12. The method of claim 10 , further comprising:

cutting the continuous flanges on opposing sides of the first and second seat portions prior to bending the circumferential flanges back to or near the respective original first or second diameter, such that the flanges remain protruding radially outward generally orthogonal to the circumferential sections.

13. The method of claim 10 , further comprising:

forming a second flange at the end portions of the first and second pipe sections, wherein the second flanges each protrude radially outward and engage with each other to form a second axle seat, and wherein the second axle seat is rotatably engaged by an opposing end portion of the support shaft across the interior volume of the exhaust conduit from the axle seat.

14. The method of claim 10 , further comprising:

inserting a bushing between the axle seat and the support shaft to facilitate rotation of the support shaft to move the valve plate between open and closed positions in the exhaust conduit.

15. The method of claim 10 , further comprising:

forming a recessed pocket on an interior surface of the second pipe section that protrudes radially outward from an exhaust flow path that extends axially through the exhaust conduit; and

engaging a flexible bumper element in the recessed pocket in a location arranged to contact the valve plate and dissipate impact of the valve plate moving toward a closed position.

16. The method of claim 15 , further comprising:

forming a tab at the end portion of the first pipe section that extends to overlap with the recessed pocket on the interior of the second pipe section, wherein the tab supports the flexible bumper element in the recessed pocket.

17. The method of claim 16 , wherein the tab includes a pair of arms at the end portion of the first pipe that extend longitudinally to the recessed pocket to support edge portions of the flexible bumper element disposed in the recessed pocket in a manner that allows sliding movement of the flexible bumper element at the edge portions when resiliently flexing into the recessed pocket upon contact with valve plate.