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

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.

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.