The high noise levels of a combustion engine in the intake and exhaust system have to be reduced to acceptable levels, not only to comply with legislative regulations but also to meet the passengers' comfort requirements. Moreover, the muffler is one of the means to tune the engine sound in such a way that e.g. a limousine or a sporty sound is created. New technologies such as exhaust systems with active valves enable us to meet the demands for maximum engine performance and minimum fuel consumption as well as for high comfort requirements.

Spun Muffler:

Spun mufflers are characterized by simple assembly, reduced consumption of material and low tooling cost. They offer the best compromise between cost and vehicle package usage . The use of the underfloor can be optimized through adjusted cross-sections, the so-called triovals. They are optimally adapted to the underfloor through variable radii. The spun muffler is the preferred muffler design and it is applied for nearly every passenger car platform.

Shell Muffler:

The shell muffler is adapted to the underfloor through its pressed housing, allowing optimum use to be made of the vehicle package. The advantage of this muffler is high acoustic efficiency thanks to the large internal volume. Shell mufflers are required if there is too little packaging space for spun or rolled mufflers.

Rolled Muffler:

The simplest shape of a muffler is a pipe, formed at its ends in such a way that a closed housing is produced. In addition to many other manufacturing processes Tenneco masters the so-called rolling process, by which even larger muffler volumes can be manufactured. Tenneco uses this forming process for the production of not only of mufflers but also catalysts and particulate filters. The rolling process permits the combination of catalysts or particulate filters and mufflers in one housing, a concept which has already been implemented in many series products.

Light-Weight Muffler:
This muffler was granted the Automotive News PACE Award for Innovation in 2006. Thanks to an FEM optimization process it has become possible to reduce the wall thickness of the muffler while maintaining the acoustics performance. The advantages of this innovative CAE process are weight reduction, lowering CO2 emissions and reducing fuel consumption, and less steel used, resulting in a cost reduction of around 8 to 10%.


Pace Award