EP0953736B1 - Insert for a silencer and method for producing it - Google Patents

Abstract

The insert is of textured glass fibre yarn encased by a textile material, for exhaust silencers, which act partially or completely acc. to the absorption method. The textile part forming the jacketing (3) has seams, which are partly or completely glued.

Description

The present invention relates to a method for producing Muffler inserts for mufflers, all or part of which Absorption principle work, as well as manufactured according to the method Baffles.

Silencer inserts of the generic type are in the silencers the exhaust systems of internal combustion engines for noise reduction arranged. The silencers are usually pot-like Formations through which the exhaust pipe is guided and in which there is sound can spread and lose in the damping material.

The sound-absorbing material is preferably a so-called porous Sound absorption material, i.e. a material without structured arrangements of cavities and material flow.

Such materials must be placed in the silencer pots. It is well known, these materials like a kind of refill from one Take out the container and insert it into silencer pots. this has a number of disadvantages, because the amount to be introduced cannot be define precisely and ensure a uniformly loose mixture. Moreover the service life of such materials has been proven to be extremely short.

In DE G 89 10 785 it was proposed to use an inner and outer sieve tube cylindrical silencer insert element formed with a filled space train. This is production technology, transport and storage technology as well as complex assembly. In addition, there is no exact fit in the Silencer pot, so that the effect is not satisfactory.

From DE 36 42 714 A1 it is known to form insulation from molded fiber parts to slide a flexible pipe onto exhaust pipes. Thereby several Layers of metal foil and glass fiber tube to form one molded part composed.

DE 31 44 193 discloses a sound-absorbing body made from a Mineral fiber pipe shell. In the first place it is bound Material, i.e. a molded article bound with a binding agent, its effect unsatisfactory and the service life is short. They are also manufacturing and assembly is complex and the molded part is expensive.

From DE G 91 01 926 it is known to have a cushion shaped cushion part provide. The long sides are sewn, creating a Material loss results. This creates when arranging the pillow in one Muffler housing a cavity which is used to form heat nests leads. These lead to premature wear of the silencer insert.

Overall, those known from the prior art Silencer inserts have the disadvantage that they are either poorly damping, stiff and are solid, or in the case of construction as light accumulations in the Manufacturing, assembly and use are problematic. Overall lead the uses known from the prior art to a frequent Need for replacement and are therefore uneconomical.

Starting from the prescribed prior art, the present invention has for its object to provide a method for the manufacture of silencer inserts and novel silencer inserts, which can be adapted to the interior of the silencer housing to be filled with simple means as optimally as possible, and also economically producible and the effects are improved.

For the technical solution to this problem, the process proposes a method for producing muffler inserts for mufflers, which work in whole or in part according to the absorption principle, a predetermined amount of a loose bundle being formed from individual elements of a suitable sound absorbing material, the loose bundle of blanks from a flat Material to form an assembly form element is encased, the assembly form element is shaped and fixed in a shape corresponding to the intended shape of the muffler insert, so that the fixed form through the encapsulation without dissolution in individual elements until assembly for intended use of the muffler insert is manageable, but the fixation is at least partially removed again during intended use as a muffler insert.

According to the method according to the invention, an existing one is created Molded composite that completes the production process and in turn is easy to store, transport and assemble. In the intended use in a silencer housing, the molded composite is again partial canceled so that an optimal filling of the interior of the to be filled Muffler housing is effected. In addition, there is the sound absorbing Character of the loose container optimally to the effect.

Advantageously, the shape bond is canceled by the action high temperatures. The usual operating conditions in silencer housings are characterized by very high temperatures. These can be used Dissolve adhesive bonds, seams or the like and thus the cause at least partial dissolution of the composite.

The loose package is available in the form of a loose cluster, namely binder-free. Advantageously, it is a bunch of Fibers from textured E-glass yarn. Also mineral wool or the like Materials can be used. Mixtures of different ones Materials can be used. Forming a predetermined amount can by Weighing done.

Depending on the desired application, i.e. silencer housing types to be filled optimal quantities will be determinable. This can be done by Weight or other measurable physical properties of the material To be defined. The loose container then becomes an assembly form element molded and fixed to a form composite. A way to form the Compound can be sewing, wrapping or the like. According to A proposal of the invention can cut from flat materials are formed, from which in turn an envelope for the loose cluster will be produced. In this way, the material can be introduced into the casing and this to be sewn. The material can also be finished after the wrapping these are stuffed. Finally, the wrapper is closed and / or molded. A shape can e.g. in the formation of a hose exist, which by forming a tube shape from the filled casing and Edge stitching is created. Pipe shape formation can be supported by that the mat formed from wrapping and wrapped sound-absorbing material a mandrel is wound. The free edges are then sewn. With A particular advantage has been found here that one on one edge sewable supernatant is formed. This supernatant can, for example smooth with the outside of the mat after wrapping be glued. This can be used to support the desired outer tube shape molded element wound around the mandrel can be introduced into a tube. This Pipe shape is preferably created by folding two pipe halves together. After the adhesive has dried, the shaped element thus formed has the desired final shape. It can thus be pulled off the mandrel and well transport and finally assemble. Due to the heat in use will at least dissolve the adhesive seam and an optimal filling of the silencer housing. There can also be others Seams are opened for example by exposure to heat, so that a even better filling and an improved damping effect can be achieved.

The wrapping can, for example, also be made of textured E-glass yarn, alternative materials or mixtures exist. Also can be different Blanks of different materials can be combined depending on the application.

The blanks are cut, embossed, punched or poured formed in the case of plastic processing. Commercially available glue Hot melt adhesive can be used.

Nets, sewings and the like can also be used to form a composite be used. Wire mesh can also be used. It is essential that the materials used are non-flammable. They should also, unless they do are to be resolved as intended, such as seams or Glue points, be heat-resistant, so do not melt. Furthermore, they should have appropriate heat insulation properties, e.g. carbon housing to protect or to protect stainless steel from discoloration. Beyond that only sound absorption or sound transmission properties relevant.

With the invention, novel silencer inserts are made using a new method provided that have improved silencing effect, in addition economical to manufacture, easy to assemble and have a long service life.

On the device side, the task is solved by a new type Muffler insert, formed from a predetermined amount of a loose Package encased in individual elements of a suitable sound absorbing material to an assembly form element with cuts from a flat material, the mounting form element corresponding to the intended shape of the Muffler insert is shaped and fixed in shape, such that that the shape through the wrapping without dissolution in individual elements up to Installation for the intended use of the silencer insert is manageable, but during the intended use as Muffler insert the fixation can be at least partially removed.

Fig. 1

eine schematische Schnittansicht eines Schalldämpfergehäuses mit eingesetztem Schalldämpfereinsatz im Montagezustand;

Fig. 2

eine alternative Ausführungsform zu Figur 1 in Überdimensionierung;

Fig. 3

ein Ausführungsbeispiel der Erfindung nach fertiger Montage;

Fig. 4

ein Ausführungsbeispiel für einen erfindungsgemäßen Schalldämpfereinsatz und

Fig. 5

eine flußdiagrammartige Darstellung des Herstellungsverfahrens.

Further advantages and features of the invention result from the following description with reference to the figures. Show:

Fig. 1

a schematic sectional view of a silencer housing with inserted silencer insert in the assembled state;

Fig. 2

an alternative embodiment to Figure 1 in oversizing;

Fig. 3

an embodiment of the invention after assembly;

Fig. 4

an embodiment of a silencer insert according to the invention and

Fig. 5

a flowchart-like representation of the manufacturing process.

If a pipe shape is made from a cushion filled with silencer material A winding is formed and edge sewing is formed. 1 is a Cross section of a silencer housing 1 shown, in which a sieve tube 4 a damping material 2 is shown in a casing 3. The wrapping is sewn and shows the seam 5. In this state of assembly thus form Cavities and thus options for heat nests resulting in a short Service life or premature wear.

Would, as indicated in Fig. 2, the silencer insert oversize, the assembly is arranged in the casing 3 Damping material 2 around the sieve tube 4 by pushing it into the Silencer housing 1 problematic.

However, if one takes a shaped element as shown in FIG. 1, in which under Heat fixation, for example the seam 5, at least partially dissolves again, the silencer insert can completely remove the housing 1 expand completely and the result is the state shown in FIG. 3.

Fig. 4 shows an embodiment for a silencer insert in one Between production status. The silencer insert 6 has a mat shape and consists of a filled area 7, in which there is a loose in the envelope Containers made of individual elements made of a suitable sound absorbing material, for example fibers of textured E-glass yarn. That results in a protrusion 8 on one of the longitudinal edges.

For the production of such an element and for further processing 5 initially in a first step 9 a predetermined amount of loose container 16 formed by sound absorption material. In parallel is in one Step 10 a blank 17 is formed from a wrapping material. The cut 17 is only a blank in the exemplary embodiment shown, but can be made from a There are a large number of individual cuts. Comes as wrapping material For example, a fabric made of textured E-glass gam in question.

In a process step 11, the loose container 16 is then on the blank 17 spread out and in process step 12 by folding over the envelope 17th a web with overhang 18 is formed. By sewing the edges a Element 19 formed with an overhang, method step 13, which corresponds to that in FIG element shown corresponds.

The mat 19 is then wound around a mandrel 20 and into one by two form 21 of the pipe halves are embedded. Thus a Formed assembly element formed. By gluing the supernatant 18 with the Wrapping material results in a cylindrical silencer insert 22 according to Method step 15. Alternatively, the silencer insert 22 can also be conical. This has a cylindrical or tubular shape and can be easily in an appropriate silencer housing. By Exposure to heat will adhere the supernatant 18 to the Dissolve the wrapping material and the mat spreads as desired and optimally inside in the housing.

The exemplary embodiments described serve for explanation and are not limiting. In particular, the materials, shapes and the like can be varied.

LIST OF REFERENCE NUMBERS

1

muffler housing

2

Dämpfstoff

3

wrapping

4

perforated pipe

5

seam

6

Use element

7

wrapping

8th

Got over

9

set construction

10

cut

11

application

12

warehousing

13

sealing

14

shape

15

Form element formation

16

loose batch

17

cut

18

preform

19

Mounting Formelememt

20

mandrel

21

tube housing

22

form composite

Claims (14)

1. Method for producing silencer inserts for silencers which operate entirely or partly on the absorption principle, a predetermined amount of a loose skein (16) of individual elements of a suitable sound-absorbent material being formed, the loose skein (16) being sheathed by cut-to-size pieces (10, 17) of a sheet-like material to form an installation form element (19), the installation form element (19) being shaped into a form corresponding to the intended form of the silencer insert, to give a composite form unit (22), and fixed in such a way that the fixed form can be handled, as a result of the sheathing, without breaking up into individual elements until the silencer insert is installed for the intended use but the fixing is at least partially released again during the intended use as a silencer insert.
2. Method according to Claim 1, characterized in that the release of the composite form unit (22) takes place by thermal exposure.
3. Method according to one of the preceding claims, characterized in that the composite form unit (22) is of a tubular design.
4. Method according to one of the preceding claims, characterized in that the loose skein (16) is formed without any binder.
5. Method according to one of the preceding claims, characterized in that at least partially textured low-alkali glass yarn is used as the sound-absorbent material.
6. Method according to one of the preceding claims, characterized in that the sound-absorbent material at least partially comprises mineral wool.
7. Method according to one of the preceding claims, characterized in that the loose skein (16) is weighed for the forming of a predetermined amount (9).
8. Method according to Claim 7, characterized in that sheet-like material which at least partially consists of textured low-alkali glass yarn is used.
9. Method according to one of the preceding claims, characterized in that the fixing is performed at least partially by sewing.
10. Method according to one of the preceding claims, characterized in that the fixing is performed at least partially by adhesive bonding.
11. Method according to one of the preceding claims, characterized in that the installation form element (19) is wound around a mandrel for the forming of a tubular composite form unit (22).
12. Method according to Claim 11, characterized in that the installation form element (19) is introduced into a tube.
13. Silencer insert, produced by at least one of the methods 1 to 12, formed from a predetermined amount of a loose skein (16) of individual elements of a suitable sound-absorbent material, sheathed with cut-to-size pieces (10, 17) of a sheet-like material to form an installation form element (19), the installation form element being shaped in a way corresponding to the intended form of the silencer insert, to give a composite form unit, and form-fixed in such a way that the form can be handled, as a result of the sheathing, without breaking up into individual elements until the silencer insert is installed for the intended use but the fixing can be at least partially released again during the intended use as a silencer insert.
14. Silencer insert according to Claim 13, characterized in that the composite form unit (22) forming the silencer insert is released by heat exposure.

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