EP3191697B1 - Procédé et machine pour la production d'un élément tubulaire afin d'isoler acoustiquement et/ou thermiquement un composant d'un véhicule motorisé - Google Patents

Procédé et machine pour la production d'un élément tubulaire afin d'isoler acoustiquement et/ou thermiquement un composant d'un véhicule motorisé Download PDF

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Publication number
EP3191697B1
EP3191697B1 EP15788190.5A EP15788190A EP3191697B1 EP 3191697 B1 EP3191697 B1 EP 3191697B1 EP 15788190 A EP15788190 A EP 15788190A EP 3191697 B1 EP3191697 B1 EP 3191697B1
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EP
European Patent Office
Prior art keywords
skein
tubular
tubular fibre
fibre skein
fibres
Prior art date
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EP15788190.5A
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German (de)
English (en)
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EP3191697A1 (fr
Inventor
Luigi ZARA
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SoLaIs - Lavorazione Isolanti - Srl Con Unico Socio Soc
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SoLaIs - Lavorazione Isolanti - Srl Con Unico Socio Soc
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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N13/00—Exhaust or silencing apparatus characterised by constructional features ; Exhaust or silencing apparatus, or parts thereof, having pertinent characteristics not provided for in, or of interest apart from, groups F01N1/00 - F01N5/00, F01N9/00, F01N11/00
    • F01N13/14—Exhaust or silencing apparatus characterised by constructional features ; Exhaust or silencing apparatus, or parts thereof, having pertinent characteristics not provided for in, or of interest apart from, groups F01N1/00 - F01N5/00, F01N9/00, F01N11/00 having thermal insulation
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N1/00—Silencing apparatus characterised by method of silencing
    • F01N1/24—Silencing apparatus characterised by method of silencing by using sound-absorbing materials
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N13/00—Exhaust or silencing apparatus characterised by constructional features ; Exhaust or silencing apparatus, or parts thereof, having pertinent characteristics not provided for in, or of interest apart from, groups F01N1/00 - F01N5/00, F01N9/00, F01N11/00
    • F01N13/18—Construction facilitating manufacture, assembly, or disassembly
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N2310/00—Selection of sound absorbing or insulating material

Definitions

  • the present invention relates to a method and to a machine for producing a tubular element structured to be inserted/fitted in a component of a vehicle provided with an internal combustion engine so as to acoustically and/or thermally insulate said component.
  • the present invention relates to a method and to a machine for producing a sound-deadening and/or thermally insulating insert or tubular element that can be installed in a component of an internal combustion engine and/or in an exhaust system of a vehicle such as a car, a motor vehicle or the like; to which the following description specifically refers but without any loss of generality.
  • silencers in exhaust systems of motor vehicles define a stretch of the exhaust path along which the noise produced by the pressure waves of the exhaust gases emitted by the engine is attenuated.
  • the silencer typically comprises an outer metal containment shell or casing, one or more ducts and/or metal diaphragms arranged within the casing and through which, in use, the exhaust gases flow, and a tubular element made of sound-deadening material, typically mineral fibres, which is generally fitted on the ducts, within the chamber, so as to attenuate the transmission of noise.
  • the tubular element generally comprises a reel or skein of wound fibres, which are resin-bonded, i.e., they are impregnated with consolidating resins and/or amalgams and then heat-set so as to be joined/compacted together to give the tubular element enough consistency to prevent the fibres from opening up when being fitted/installed on the duct to be acoustically insulated.
  • the use of consolidating resins and amalgams to stiffen the tubular element is however inconvenient in that, in use, they are broken down and fragmented due to the high temperatures of the exhaust gases in the silencer, and therefore tend to be expelled through the exhaust system with undesirable consequences in terms of environmental pollution.
  • the decomposition/fragmentation of the resins/amalgams causes, on the one hand, a gradual flaking and weakening of the fibres which reduces the sound-deadening capacity of the tubular element, and on the other, the expulsion of the fibres from the silencer.
  • WO2014017696 describes a method for producing a seamless tubular sleeve having no limitations in length, which is designed to be installed in ducts/conduits of industrial installations to repatir the latter.
  • the method comprises the step of providing a thin compact layer made of non-woven fabric material, previously carded and pressed, similar to felt, having a certain width.
  • the method further comprises the step of continuously feeding the layer to a threaded drum so as to wind it tangentially around the threaded surface thereof in such a way as to obtain, during the winding, adjacent side edges overlapping one another in a helical winding.
  • the method also envisages imparting a roto-translational motion to the tubular layer around and along the longitudinal axis of the threaded drum via a pair of driving drums which are arranged adjacent to the threaded drum, and actuating a needle support head to join the overlapping edges of the wound layer as it advances along the threaded drum.
  • US 3,758,926 discloses a method for producing a continuous longitudinal tubular sleeve in non-woven fabric material.
  • the method comprises the steps of: providing a thin compact layer made of non-woven fabric material previously carded and pressed, substantially similar to felt, having a certain width, continuously feeding the layer to a rotary drum to wind the layer on the outer surface thereof, and axially moving the helically wound layer along the longitudinal axis of the rotary drum, so as to make the lateral edges thereof overlap in pairs.
  • the method further comprises the step of needling the layer so as to mutually attach the overlapping side edges.
  • the carded and pressed discontinuous short fibres that make up the layer quickly tend to disjoint on to the other when subjected to the high temperatures/pressures produced by the exhaust gases flowing through the silencer.
  • the disjointing of the fibres, apart from causing a gradual deterioration of the efficiency of the silencer, also cause the fibers to be discharged through the vehicle exhaust system with evident problems in terms of environmental pollution.
  • US 4,071,394 discloses a method for manufacturing a tubular filter designed to remove gel particles or unmilled paint particles thereform.
  • the tubular filter is made by non-woven web comprising very short fibers made by rayon or darcon, randomly oriented.
  • the rayon/darcon fibers of the filter made as disclosed in US 4,071,394 are completely unsuitable to be used in a silencer of motor vehicle because are higly polluting when subjected to the high temperatures of exhaust gas.
  • US 4,454,637 discloses a method for the production of a velour needlfelt unsuitable to be used in a silencer of motor vehicle.
  • the Applicant has conducted an in-depth study with the purpose to find a solution that would achieve the aim of producing, in a simple and economical manner, a sound-deadening and/or thermally insulating semi-rigid tubular element that is structured to be inserted/fitted in a component of a vehicle provided with an internal combustion engine, and that does not contain any consolidating amalgam and/or resins, and therefore does not require any heat-setting operations.
  • This aim is achieved by the present invention in that it relates to a method for producing a tubular element that can be installed in a component of a vehicle provided with an internal combustion engine to acoustically and/or thermally insulate said component, according to claim 1 and the relevant dependent claims.
  • the present invention also relates to a machine for producing a tubular element that can be installed in a component of a vehicle provided with an internal combustion engine to acoustically and/or thermally insulate said component, according to claim 11 and the relevant dependent claims.
  • the machine comprises movement means for alternately moving a needle support head along a rectilinear direction parallel to the punching needles towards and away from the tubular fibre skein so that the punching needles pass radially through said skein and needle the fibres.
  • the machine comprises a plurality of needle support heads angularly spaced about the longitudinal reference axis.
  • the machine comprises movement means which rotate the needle support heads about the longitudinal reference axis.
  • the machine comprises driving means designed to rotate the tubular fibre skein about said longitudinal reference axis.
  • the support means comprise a shaft extending parallel to said longitudinal reference axis and on which said tubular skein is mounted.
  • the shaft has a plurality of apertures through which, in use, said penetrating means can pass.
  • the driving means comprise a conveyor belt that has a surface section in contact with the outer surface of the skein on the side opposite to said shaft, and a belt driving device, which is designed to advance the belt so that the tubular skein slides/rolls on the shaft outer surface so as to rotate about said longitudinal axis.
  • the machine comprises means for rotating the shaft about said axis so as to cause the rotation of the tubular skein.
  • the machine comprises a nozzle support head provided with one or more nozzles designed to emit jets of water and/or air directed towards the tubular fibre skein, so as to pass through the fibres; the penetrating means comprising said jets of water or air.
  • the present invention also relates to a sound-deadening and/or thermally insulating tubular element structured according to claim 14.
  • the needling sections extend seamlessly between the opposite ends of the skein of continuous fibres.
  • the needling sections are angularly spaced in relation to one another about the longitudinal axis of the skein.
  • the needling sections are arranged parallel and adjacent to one another and close together around the entire skein so as to cover the entire surface thereof.
  • the needling sections are arranged parallel and adjacent to one another around the segment or portion of the skein.
  • the tubular element is used/comprised in a heat shield.
  • the tubular element is used/comprised in an exhaust system of the motor vehicle.
  • number 1 indicates as a whole a semi-rigid tubular insert or element made of continuous fibre, that is structured to acoustically and/or thermally insulate a component of a vehicle provided with an internal combustion engine.
  • tubular element to which the present invention refers although composed of continuous fibres that are wound, twisted or needled together so as to form a skein and contain no resin and/or amalgam to hold the fibres together, has, thanks to the method described below, a high level of compactness/mechanical cohesion between the fibres which makes it possible to achieve a substantially semi-rigid and self-supporting fibrous tubular structure, capable of maintaining its tubular shape without collapsing/flattening itself out.
  • component means any substantially cylindrical or similarly shaped element/part of the vehicle on which the tubular element 1 may be fitted to thermally and/or acoustically insulate said part.
  • the component may be comprised in the silencer or in the exhaust system or in the engine, or in the engine compartment or in the fuel tank.
  • the tubular element 1 is structured to be fitted/inserted in pipes, perforated tubular walls, ducts/exhaust conduits 3 in, connected to or passing through a chamber 2a of a silencer 2 of an exhaust gas system of an internal combustion engine of a vehicle so as to attenuate the noise/heat associated with the gas passing therethrough.
  • the tubular element 1 may perform the sound-deadening/thermal insulation function independently, i.e. without the aid of additional external elements, or may cooperate with additional outer shells/casings for example to carry out the "resonator" function in the exhaust gas system.
  • tubular element 1 may be comprised in a heat shield for externally lining an exhaust system duct 3.
  • the tubular element 1 may be interposed between an outer protection plate or shell or monocoque and the outer surface of the duct to be insulated.
  • a heat shield 50 may comprise at least a protective outer monocoque 51 made of a rigid material, for example metal, shaped so as to cover/line at least an outer surface portion or section 52 of a component, preferably, but not necessarily, in the form of a duct 53 of the exhaust system, and at least one tubular element 1 that, fitted on the outer surface portion 52 of the duct 53 below the shell 51 so as to thermally and/or acoustically insulate the latter with respect to the duct 53 below.
  • the heat shield could be used to thermally insulate a component arranged for example in the engine or the engine compartment or the fuel tank or the like.
  • the tubular element 1 comprises a semi-rigid reel or skein M formed by continuous fibres F wound around a longitudinal axis A, so as to form adjacent turns which in turn form an overall tubular body, substantially corresponding to a sleeve extending along the axis A.
  • the skein M has a cross-section that is preferably, but not necessarily, circular and has a predetermined diameter, preferably, but not necessarily, constant along the axis A. It is understood that the shape/size of the skein M are not limited to those of the skein M of the tubular element 1 illustrated in the example of Figures 1 and 2 , but may be different.
  • the shape/size of the skein M may be modified according to the shape of the component, preferably the duct on which it is fitted and/or the inner shape of the chamber 2a that accommodates it.
  • the inside/outside diameter of the semi-rigid tubular skein M may vary along the axis A, for example, it may gradually decrease or increase, while the skein M may be provided with one or more truncated and/or cylindrical and/or spherical portions having different outside/inside diameters.
  • the continuous fibres F that form the semi-rigid skein M preferably comprise mineral fibres woven/needled together by means of the method that will be described in detail below.
  • continuous fibre means a fibre having a length such as to form a plurality of wound and adjacent turns of the skein M.
  • a continuous fibre may preferably have a length of more than about 30 cm.
  • the continuous fibres F may be volumized and/or textured.
  • the fibres F may comprise any type of mineral fibre that is designed to attenuate the transmission of the noise/heat produced by the exhaust gases passing through the ducts 3.
  • the continuous fibres F may comprise, for example, glass fibres, basalt fibres, silica fibres, or any other similar type of mineral fibre having sound-deadening and/or thermal insulation properties that can be installed preferably in a silencer 2.
  • the fibres F may conveniently comprise continuous fibres of synthetic material containing polystyrene and/or polypropylene and/or polyamide and/or Kevlar and/or carbon and/or aramid and/or cotton and/or any other type of similar synthetic material.
  • the fibres F may conveniently comprise continuous metal fibres, preferably steel, for example stainless steel.
  • the metal fibres may have a thickness comprised between approximately 6 and 400 micron.
  • the tubular element 1 may comprise one or more of the types of fibres described above.
  • the tubular element 1 has one or more needling/weaving line portions T extending on the surface of the reel/skein M, parallel to one another and to the longitudinal axis A.
  • each line portions T extends seamlessly between the opposite distal ends of the skein M.
  • the line portions T are angularly spaced with respect to one another about the longitudinal axis A along the entire circumference of the skein M, so that it is completely needled on its entire surface.
  • the line portions T are arranged adjacent and close to one another.
  • the method consists of providing a support element having an elongated shape, designed to support the skein M of continuous fibres F forming the tubular body.
  • the support element may comprise a shaft 10, extending along a longitudinal axis B, whereas the fibres F are wound around the shaft 10 so as to cross/overlap to form the turns of the skein M, which in turn has its longitudinal axis A coaxial to the longitudinal axis B of the shaft 10.
  • the skein M is wound/fitted in the shaft 10 so as to remain axially fixed in relation to the shaft 10 during the rotation thereof.
  • the skein M is wound around the shaft 10 so as to remain, during the rotation of the shaft 10, in a fixed axial position along the axis B so that its turns of continuous fibre do not undergo any axial displacement, but remain compactly wound and substantially stable in the respective initial axial positions. It should be noted that the maintenance of the skein M in the fixed axial position advantageously prevents the turns from disjointing one to the other, during the process.
  • the shaft 10 may have an elongated cylindrical shape and a plurality of apertures 11 comprising, for example, radial holes, preferably blind. It is understood that the cross-section of the shaft 10 may be circular or elliptical, square, rectangular or similar, and thus modifiable according to the shape of the element 1 to be produced.
  • apertures 11 may be distributed on the body of the shaft 10 one after the other and a certain distance apart on a directrix, preferably equidistantly spaced, to form straight lines, parallel to one another and to the axis B. It is understood that the present invention is not limited to the distribution of the apertures 11 in a straight line as shown in Figures 4 and 5 .
  • the apertures 11 may be obtained in the shaft 10 so as to form a plurality of discontinuous longitudinal adjacent and angularly staggered sections.
  • the present invention is not limited to apertures in the form of blind holes, as shown in Figures 4 and 5 , and according to an alternative embodiment it may comprise one or more narrow elongated grooves (about 3 mm wide) obtained in the outer surface of the shaft 10 so as to extend along the generatrices of the cylindrical surface of said shaft 10.
  • the present invention is not limited to a solid cylindrical shaft 10, and according to an alternative embodiment (not shown) it may comprise a tubular shaft provided with through apertures 11.
  • the shaft 10 may be different from a cylindrical body and comprise a profile having a polygonal cross-section, for example star-shaped, having a plurality of longitudinal side seats extending in straight lines and parallel to the axis B.
  • the shaft 10 may be provided with a series of supporting bars/rods arranged parallel to one another and angularly spaced about the axis B, so as to delimit the longitudinal through apertures 10.
  • the method also comprises the arrangement of penetrating elements structured so that, in use, they pass radially through the continuous fibres F of the skein M so as to twist them together at the penetration/crossing points, the arrangement of the penetrating elements in a position immediately adjacent to the shaft 10 and facing the tubular skein M wound around the shaft 10 ( Figure 4 ), and the operation of the penetrating elements so that they penetrate the skein M radially and locally join/connect the fibres F along one or more longitudinal sections T, so as to stiffen/compact the tubular skein M at said line portions T.
  • the penetrating elements comprise a plurality of punching needles 12, which extend orthogonally to the axis B, parallel to one another.
  • the punching needles 12 may be arranged next to one another, preferably equally spaced, so as to form at least one row of needles lying on a plane parallel to the axis B.
  • the punching needles 12 protrude from a needle support head 14 parallel to one another and perpendicular to the axis B.
  • the method comprises the step of making the needle support head 14, and thus the punching needles 12, move alternately from and towards the shaft 10 along a direction D orthogonal to the axis A and parallel to said punching needles 12, so that the punching needles 12 pass through the tubular skein M and form needling line portions T on said skein M.
  • punching needle means a needle provided with a series of pointed and/or hooked or saw tooth-shaped side projections shaped so as to locally pull some fibres to make them penetrate into other adjacent fibres, compacting and/or weaving them together ( Figure 12 ).
  • needleling refers to a purely mechanical operation whereby the punching needles 12 are moved alternately in the direction D parallel to said punching needles 12 and substantially transverse with respect to the fibres F, during which the punching needles 12 move the fibres F by means of their projecting parts, so as to cross/twist/overlap them and form a web of compact fibres, structurally similar to a fabric.
  • the method also comprises the phase of rotating the tubular skein M around the axis B, with respect to the punching needles 12, or vice versa, keeping the tubular skein M in an axially fixed position relative to the shaft 10 along the axis B.
  • the skein M is rotated about the axis B, with respect to the punching needles 12.
  • the skein M may be mounted idle on the shaft 10 so as to slip/slide freely on the outer surface thereof, remaining in an axially fixed position along the axis B, whereas the method may envisage maintaining the shaft 10 in an angularly fixed position and making the skein M rotate about the axis B by means of advancing means 13.
  • the advancing means 13 may comprise a conveyor belt 28 with at least a superficial portion or section that is locally tangent to the skein M and in contact therewith.
  • the advancing means 13 are not limited to the conveyor belt 28 described above, but may alternatively and/or in addition comprise other means capable of performing the same function of advancing the skein M, such as one or more rollers/rotating disks placed adjacent to the shaft 10 and parallel to the axis B, so as to be at a tangent to the skein M.
  • the conveyor belt 28 and the skein M may be of the same width.
  • the advancing means 13 comprise the shaft 10 which rotates, while the skein M is angularly integral with the shaft 10, so as to be made to rotate thereby.
  • the skein M and the shaft 10 may be angularly fixed/stationary relative to one another, while the punching needles 12 are mounted in one or more needle support heads 14, angularly spaced from one another with respect to the axis B, and the method may comprise the step of rotating the needle support head(s) about the axis B, i.e. around the skein M, so as to make the punching needles 12 penetrate the skein M in a series of predetermined angular positions.
  • the machine 20 comprises a plurality of needle support heads 14, which are angularly spaced with respect to one another around the axis B so that the punching needles 12 face towards the skein M.
  • the needle support heads 14 are angularly fixed with respect to the skein M and are moved in corresponding straight directions orthogonal to the axis B so as to perform a reciprocating motion towards and from the skein M, so that the punching needles 12 penetrate the skein M radially.
  • the machine 20 comprises: a support frame 21 designed to be placed on the ground, a spindle 22 arranged above the frame 21 and connected thereto by means of a vertical extension/pillar, and the shaft 10 supporting the skein M which protrudes from the spindle 22 above the frame 21 and is arranged so that the axis B is preferably horizontal.
  • the shaft 10 is an elongated cylinder (as in the example, the tubular element 1 to be obtained has a cylindrical shape), and is provided on one side with a row of through apertures 11 lying on a horizontal plane.
  • the shaft 10 may conveniently be mechanically coupled to the spindle 22 in a permanent but easily detachable manner, so that it can easily be coupled/uncoupled.
  • the shaft 10 can be conveniently removed from the spindle 22 and mounted on a rotating spindle of a winding machine (not shown) suitable for unwinding the continuous fibre from one reel and winding it on the shaft 10 to produce the wound turns forming the reel/skein M.
  • the machine 20 further comprises the needle support head 14 that is arranged above the supporting frame 21 in a position facing the side of the shaft 10 provided with the apertures 11, and a movement device 23 for moving the needle support head 14 along a direction D, from and towards the shaft 10 with a reciprocating motion, so that the punching needles 12 move repeatedly between a resting position in which the punching needles 12 are completely extracted from the skein ( Figure 7 ), and a needling position ( Figure 6 , on the right in the drawing) in which they penetrate into the skein M so as to protrude into the apertures 11 of the shaft 10, and vice versa.
  • the needle support head 14 is slidingly mounted on one or more straight guides 24 which are placed on the top plane of the frame 21, preferably below the shaft 11 and extending on said plane along a direction that is parallel to the direction D, while the movement device 23 may comprise a power unit for example, an electric motor controlled by an electronic control unit 25, and a motion transmission member 26 designed to transform the rotary motion of the electric motor shaft into linear motion and may comprise, for example, a crankshaft mechanism connected at one side to the drive shaft and at the other to the needle support head 14, so as to make it slide, in use, on the guides 24 towards and from the shaft 10 along the direction D.
  • the movement device 23 may comprise a power unit for example, an electric motor controlled by an electronic control unit 25, and a motion transmission member 26 designed to transform the rotary motion of the electric motor shaft into linear motion and may comprise, for example, a crankshaft mechanism connected at one side to the drive shaft and at the other to the needle support head 14, so as to make it slide, in use, on the guides 24 towards and from the shaft 10 along the direction
  • the machine 10 also includes a perforated sheller plate 27, which is interposed between the needle support head 14 and the shaft 10, and is structured to uncouple, in use, the fibres F held/moved by the punching needles 12 during their motion to the resting position.
  • the perforated plate 27 extends parallel to the axis B so as to face the apertures 11 in the shaft 10, and has in turn a plurality of through apertures aligned axially with both the apertures 11 in the shaft 10 and the punching needles 12 so that it can be crossed thereby.
  • the machine 10 may be provided with a movement device (not shown) designed to move the perforated plate 27, preferably along a horizontal direction, towards and from the shaft 10 between an operating position where the perforated plate 27 is substantially in contact with the skein M in correspondence with the apertures 11 ( Figure 5 ), and a resting position in which the perforated plate 27 is moved away from the shaft 10 and thus from the skein M ( Figure 4 ).
  • a movement device not shown
  • the perforated plate 27 preferably along a horizontal direction, towards and from the shaft 10 between an operating position where the perforated plate 27 is substantially in contact with the skein M in correspondence with the apertures 11 ( Figure 5 ), and a resting position in which the perforated plate 27 is moved away from the shaft 10 and thus from the skein M ( Figure 4 ).
  • the machine 10 further comprises the driving element 13 that is designed to pull the skein M around the axis B, keeping it axially fixed along said axis B, and in the example shown, comprises the belt 28 which is arranged on one side of the shaft 10, on the opposite side in relation to the needle support head 14.
  • the belt 28 is wound around a series of rollers 30 so as to form a closed ring, one section of which is tangential to the shaft 10.
  • At least one of the rollers 30 is a driving roller and is mechanically connected to a power unit, such as an electric motor shaft, so as to be made to rotate about an axis parallel to the axis B.
  • the two idle rollers 30 may be arranged above or below the shaft 10 so that the two respective axes of rotation are parallel to the axis B and surrounded by the advancing section that envelops them and at least partially comes into contact with the shaft surface 10 opposite the apertures 11.
  • the two idle rollers 30 lie on a vertical plane of the axis B, and in use keep the advancing section stretched and wound around a surface portion of the skein M.
  • the skein M is arranged on the shaft 10. It should be specified that the machine 20 might be provided with a mechanism (not shown) able to unwind a fibre reel (not shown), in a controlled way, and simultaneously rotate the spindle 22 so as to wind the fibre F around the shaft 10 and form the skein M thereupon.
  • the electronic control unit 25 controls the operation of the advancing unit 13 so as to advance the belt 28 that, since it comes into contact with the skein M, causes said skein M to rotate about the axis B keeping it axially fixed.
  • the belt 28 rotates the skein M about the axis B keeping the turns in the initial axial position so as to conveniently prevent any flaking of the reel.
  • the electronic control unit 25 also operates the movement means 23 synchronously with the advancing unit 13 so as to move the needle support head 14 and make the punching needles 12 intermittently penetrate the skein M, in order to form the needling sections T thereon.
  • the speed of rotation of the skein M and the travel speed of needle support head 14 are determined in such a way as to prevent damage to the punching needles 12 by the rotating skein M.
  • the needle support head 14 is moved at high speed compared to the speed of rotation of the skein M, so that the penetration/extraction of the punching needles 12 in the skein M is completed in a fraction of a second to allow the skein M to be rotated continuously.
  • the method can clearly perform the rotation of the skein M intermittently, that is in a stepwise manner.
  • the tubular element 1 thus obtained is removed from the shaft 10 and then fitted on the silencer duct 2.
  • the present invention achieves the aforesaid aims. It should be added that the method is extremely convenient in terms of energy saving as it does not require any heat-setting operations.
  • the embodiment shown in Figure 13 regards a machine 30, that is similar to the machine 20, the component parts of which will be identified, wherever possible, with the same reference numbers used to denote corresponding parts of the machine 20.
  • the machine 30 differs from the machine 20 in that, instead of having a needle support head 14 and punching needles 12, it is provided with a nozzle support head 31 and a plurality of nozzles 32 designed to emit, upon a command, jets of pressurized air or water 35 directed towards the shaft 10 so as to penetrate into the skein M of fibres.
  • the nozzles 32 may be connected to a pressurized air/water generating system 33, via a duct 39 structured to deliver pressurized air/water to said nozzles 32.
  • the jets of pressurized water/air 35 generated by the nozzles 32 penetrate radially into the skein M and impart on the fibres crossed radial displacements that weave/twist the fibres F together, so as compact them and stiffen the skein M.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Nonwoven Fabrics (AREA)
  • Exhaust Silencers (AREA)

Claims (13)

  1. Procédé de fabrication d'un élément tubulaire (1) (60) conçu pour être installé dans un composant d'un véhicule équipé d'un moteur à combustion interne pour isoler acoustiquement et/ou thermiquement ledit composant ; ledit procédé comprend l'étape consistant à fournir un moyen de support (10) qui s'étend le long d'un axe de référence longitudinal (B) ;
    ledit procédé étant caractérisé en ce que
    - l'on prévoit sur ledit moyen de support (10) un écheveau de fibres tubulaires (M) ayant son axe longitudinal (A) parallèle audit axe de référence longitudinal (B) et comprenant des fibres continues (F) dans un matériau conçu pour réduire la transmission du bruit/chaleur produite dans ledit composant dudit véhicule ; lesdites fibres continues (F) sont enroulées autour dudit moyen de support (10) de manière à former des spires adjacentes, qui forment un corps tubulaire ;
    - l'on dispose, dans une position adjacente au dit écheveau de fibres tubulaires (M), un moyen de pénétration (12) (35) structuré pour pénétrer à travers les fibres (F) dudit écheveau de fibres tubulaires (M) ;
    - l'on actionne des moyens d'entraînement pour faire tourner ledit écheveau de fibres tubulaires (M) autour dudit axe longitudinal (B) et pour maintenir, pendant la rotation, l'écheveau de fibres tubulaires (M) dans une position axialement fixe par rapport audit moyen de support (10) le long dudit axe de référence longitudinal (B) ;
    - l'on traverse les spires dudit écheveau de fibres tubulaires (M) au moyen dudit moyen de pénétration (12) (35) pour tisser/tordre les fibres continues (F) ensemble, de manière à les joindre/les connecter mutuellement.
    ledit écheveau de fibres tubulaires (M) est monté à vide sur ledit moyen de support (10), de manière à tourner autour dudit axe de référence longitudinal (B); ledit procédé comprenant l'étape de coulissement de l'écheveau de fibres tubulaires (M) sur la surface externe dudit moyen de support (10) au moyen d'un mécanisme d'avancement (28), de manière à faire tourner l'écheveau de fibres tubulaires (M) autour dudit axe longitudinal (B) et à maintenir, pendant ladite rotation, ledit écheveau de fibres tubulaires (M) dans ladite position fixe axiale le long dudit axe de référence longitudinal (B).
  2. Procédé selon la revendication 1, comprenant l'étape de faire tourner au moins partiellement ledit moyen de pénétration (12) (35) autour dudit axe longitudinal (B) de manière à le disposer dans des positions angulaires prédéterminées.
  3. Procédé selon l'une des revendications précédentes, dans lequel ledit moyen de pénétration comprend au moins une tête de support d'aiguille (14) et une pluralité d'aiguilles de poinçonnage (12) qui dépassent de ladite tête de support d'aiguille (14) vers ledit moyen de support (10), le long d'une direction qui est orthogonale audit axe longitudinal (B); ledit procédé comprenant l'étape consistant à déplacer alternativement la tête de support d'aiguille (14) dans un déplacement en ligne droite (D) parallèle auxdites aiguilles (12), depuis et vers l'écheveau de fibres tubulaires (M) pour faire passer les aiguilles de poinçonnage (12) radialement à travers les fibres continues (F) de l'écheveau de fibres tubulaires (M), de manière à assembler les fibres continues (F).
  4. Procédé selon les revendications 1 ou 2, comprenant l'étape apportant une tête de support de buse (31) munie d'une ou plusieurs buses (32) conçues pour émettre des jets d'eau et/ou d'air (35) vers ledit écheveau de fibres tubulaires (M), de manière à traverser les fibres (F) ; ledit moyen de pénétration comprenant lesdits jets d'eau ou d'air.
  5. Procédé selon l'une des revendications précédentes, dans lequel ledit moyen de support (10) comprend au moins un manchon (10) qui s'étend le long dudit axe longitudinal (B) et est pourvu d'ouvertures traversantes (11), par lesquelles, en utilisation, ledit moyen de pénétration est capable de traverser.
  6. Procédé selon les revendications 1 et 5, comprenant l'étape de fournir une bande transporteuse (28) qui comprend au moins une partie superficielle qui est localement tangente audit écheveau de fibres tubulaires (M), de manière à entrer en contact avec sa surface extérieure, et d'avancer ladite bande transporteuse (28) de sorte que ledit écheveau de fibres (M) glisse sur la surface extérieure du manchon (10), afin de tourner autour dudit axe de référence longitudinal (B).
  7. Procédé selon l'une des revendications précédentes, comprenant l'étape de traverser les spires dudit écheveau de fibres tubulaires (M) au moyen dudit moyen de pénétration (12) (35) pour tisser/entrelacer les fibres continues (F) ensemble, de manière à former des portions de ligne d'aiguilletage (T) s'étendant sans interruption entre les extrémités opposées dudit écheveau (M).
  8. Procédé selon la revendication 7, comprenant l'étape de passage à travers les spires dudit écheveau de fibres tubulaires (M) au moyen dudit moyen de pénétration (12) (35) pour former des portions de ligne d'aiguilletage (T) angulairement espacées les unes des autres autour de l'axe longitudinal dudit écheveau de fibres tubulaires (M) .
  9. Une machine pour produire un élément tubulaire (1) conçu pour être installé dans un composant d'un véhicule équipé d'un moteur à combustion interne pour isoler acoustiquement et/ou thermiquement ledit composant ; ladite machine étant caractérisée en ce qu'elle comprend:
    - un moyen de support (10) s'étendant le long d'un axe de référence longitudinal (B) et structuré de manière à supporter un écheveau de fibres tubulaires (M) ayant son axe longitudinal (B) parallèle audit axe de référence longitudinal (B) et comprenant des fibres continues (F) en un matériau conçu pour atténuer la transmission du bruit/de la chaleur généré dans ledit composant dudit véhicule et qui sont enroulés autour de l'axe longitudinal (A) de manière à former des spires adjacentes, qui forment un corps tubulaire;
    - un mécanisme d'entraînement (28) pour faire tourner ledit écheveau de fibres tubulaires (M), lorsqu'il est supporté par ledit moyen de support (10) autour dudit axe longitudinal (B) et maintenir, pendant ladite rotation, ledit écheveau de fibres tubulaires (M) dans une position axialement fixe par rapport audit moyen de support (10) le long dudit axe de référence longitudinal (B) ;
    - un moyen de pénétration (12) (35) conçu pour pénétrer les spires dudit écheveau de fibres tubulaires (M), lorsqu'il est supporté par ledit moyen de support (10), pour tisser/entremêler les fibres continues (F) ensemble de manière à les rejoindre/les connecter réciproquement.
  10. La machine selon la revendication 9, dans laquelle ledit moyen de pénétration comprend au moins une tête de support d'aiguille (14) et une pluralité d'aiguilles de poinçonnage (12) qui dépassent de ladite tête de support d'aiguille (14) vers ledit moyen de support (10) le long d'une direction qui est orthogonale audit axe de référence longitudinal (B); un moyen pour déplacer alternativement la tête de support d'aiguille (14) dans un déplacement en ligne droite (D) parallèle auxdites aiguilles (12), depuis et vers l'écheveau de fibres tubulaires (M) pour amener les aiguilles de poinçonnage (12) à passer radialement à travers les fibres continues (F) de l'écheveau de fibres tubulaires (M) de manière à assembler les fibres continues (F).
  11. La machine selon la revendication 9, dans laquelle ledit moyen de support (10) comprend au moins un manchon (10) s'étendant le long dudit axe longitudinal (B), et pourvu d'ouvertures traversantes (11) conçues pour être utilisées pour être traversées par ledit moyen de pénétration; ledit mécanisme d'entraînement comprenant une bande transporteuse (28) ayant au moins une partie superficielle qui est localement tangente audit écheveau de fibres (M) de manière à entrer en contact avec, et qui est conçue pour tirer ledit écheveau de fibres (M) sur la surface extérieure du manchon (10) afin de le faire tourner autour dudit axe de référence longitudinal (B).
  12. Un élément tubulaire d'insonorisation et/ou d'isolation thermique (1) structuré de manière à être installé dans un composant d'un véhicule automobile ; ledit élément étant produit avec le procédé selon l'une des revendications 1 à 8.
  13. Un système d'échappement de gaz d'échappement d'un moteur à combustion interne d'un véhicule comprenant un élément tubulaire (1) produit selon la revendication 12.
EP15788190.5A 2014-09-12 2015-09-11 Procédé et machine pour la production d'un élément tubulaire afin d'isoler acoustiquement et/ou thermiquement un composant d'un véhicule motorisé Active EP3191697B1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
ITTV20140128 2014-09-12
PCT/IB2015/056985 WO2016038580A1 (fr) 2014-09-12 2015-09-11 Procédé et machine pour la production d'un élément tubulaire afin d'isoler acoustiquement et/ou thermiquement un composant d'un véhicule motorisé

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EP3191697A1 EP3191697A1 (fr) 2017-07-19
EP3191697B1 true EP3191697B1 (fr) 2020-03-18

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EP15788190.5A Active EP3191697B1 (fr) 2014-09-12 2015-09-11 Procédé et machine pour la production d'un élément tubulaire afin d'isoler acoustiquement et/ou thermiquement un composant d'un véhicule motorisé

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EP (1) EP3191697B1 (fr)
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Family Cites Families (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3758926A (en) 1969-07-01 1973-09-18 R Dilo Method of making a tubular needled web
US4071394A (en) * 1977-03-18 1978-01-31 Olympic Engineering Co. Apparatus for manufacturing non-woven fabric tubular filter
DE2900935C2 (de) * 1979-01-11 1986-10-16 Oskar Dilo Maschinenfabrik Kg, 6930 Eberbach Verfahren und Vorrichtung zum Herstellen von Velour-Nadelvliesstoffbahnen
KR101232500B1 (ko) 2012-07-25 2013-02-12 안태영 이음매가 없고 직경 및 길이의 제한이 없는 튜브형 부직포 및 그 제조장치
KR101232462B1 (ko) * 2012-07-25 2013-02-12 안태영 이음매 없는 튜브형 부직포 제조장치 및 그 제조장치에 의해 제조된 튜브형 부직포

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EP3191697A1 (fr) 2017-07-19
WO2016038580A1 (fr) 2016-03-17

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