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Abstract

A method of manufacturing a muffler including a pair of stamp formed laminated external shells, each of which includes inner and outer layers. The inner and outer layers are stamped simultaneously to nest with one another. However, the respective layers of each laminated shell will spring back slightly differently from one another in view of different metallurgical characteristics inherent in each sheet. The laminated external shells are then disposed around internal components of the muffler, and peripheral regions are securely clamped together. This clamping, in view of the differential spring-back creates a narrow air chamber between the layers of each laminated external shell. Peripheral regions are then laser welded together to hermetically seal the narrow air chamber between the layers of each external shell. The hermetically sealed air chamber effectively dampens vibrations of the external shells and contributes to both heat and noise insulation from interior regions of the muffler.

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First Claim