JP2000356119A - Silencing material, muffler using it, and method of forming silencing layer thereof - Google Patents

Abstract

PROBLEM TO BE SOLVED: To enhance the acid resistance and alkali resistance and to improve the silencing property by bundling a number of basalt yarns formed by fusing basalt into long fibrous shape by use of a binder to from a bound material, bulkily releasing it, and using it as a silencing material. SOLUTION: Basalt that is a natural mineral is fused to form a continuous long fibrous basalt yarn 1a, and a binder is added to a bundle of a number of the basalt yarns 1a to provide a long bound material 1. This bound material 1 is made bulky to form a fibrous bundle-like silencing material 2, and the silencing material 2 is wound on a perforated pipe 4 for muffler to form a silencing layer 6. The resulting pipe 6 is housed in an outer pipe 13, and both the ends are closed to constitute a muffler 15. At this time, the fiber diameter of one long fibrous basalt yarn 1a is set to about 9-24 μm although it is not particularly limited, and the number of the basalt yarns 1a of the bound material 1 is set to, for example, 1000-4000.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a muffling material used for a muffler of an internal combustion engine, a muffler using the same, and a method of forming a muffling layer thereof.

[0002]

2. Description of the Related Art In an exhaust system of an internal combustion engine of a motor vehicle, a silencer for silencing exhaust gas is arranged.

[0003] The silencer uses a silencer as a measure against high frequency noise, and the main material of the silencer is glass fiber. As the arrangement of the muffler, a sub-muffler and a prima-muffler are arranged downstream of the exhaust gas purification device using a catalyst, and a main muffler is arranged at the most downstream part. Such a sub-muffler and a prima-muffler may be located in the immediate vicinity of the exhaust gas purification device. In this case, the sub-muffler and the prima-muffler are affected by a high exhaust gas temperature and a large pulsation.

For this reason, conventionally, it is general that stainless wool is wound around a porous exhaust pipe of a sub muffler or a prim muffler, and a silencing material such as glass fiber is wound around or filled inside.

[0005]

Although glass fiber used as a sound deadening material has been established to have a quality that can withstand use in various temperature ranges, it is not suitable for acidic and alkaline substances contained in exhaust gas. Since the glass fiber is insufficient, the glass fiber may deteriorate and break, and may be discharged to the atmosphere together with the exhaust gas.

SUMMARY OF THE INVENTION In view of the foregoing, it is an object of the present invention to provide a silencing material having excellent acid resistance and alkali resistance and excellent silencing properties, a silencer using the same, and a method for forming a silencing layer thereof. It is.

[0007]

According to a first aspect of the present invention, in order to solve the above-mentioned problems, a large number of basalt yarns obtained by welding basalt to form long fibers are bundled with a sizing agent. This is a sound-absorbing material characterized in that it is used as a bunching material, which is defibrated into a bulky shape.

According to a second aspect of the present invention, a large number of basalt yarns obtained by welding basalt to form long fibers are bundled with a sizing agent into a sizing material, which is defibrated into a bulky shape. A silencer characterized in that a silencer is provided on an outer peripheral portion of a perforated pipe.

According to a third aspect of the present invention, there is provided a method for forming a sound deadening layer using the above sound deadening material, wherein a large number of basalt yarns obtained by welding basalt into long fibers are bundled with a sizing agent. It is characterized in that it is used as a sizing material, and the sizing material is defibrated to form a bulky muffling material. This is a method for forming a silencing layer.

According to a fourth aspect of the present invention, in the third aspect of the present invention, the method of forming the defibrated sound deadening material includes supplying the convergence material into a nozzle and pressing compressed air into the nozzle. This is a method of forming a sound deadening layer in which a sizing material is loosened by the compressed air to form a sound deadening material continuously defibrated from a nozzle.

According to a fifth aspect of the present invention, in the third or fourth aspect, as a method of arranging the defibrated sound deadening material on an outer peripheral portion of the perforated pipe, a perforated pipe is used. And a method of forming a sound deadening layer in which the sound deadening material is supplied to the outer periphery of a perforated pipe while being rotated about its axis, and the sound deadening material is wound around the perforated pipe.

According to a sixth aspect of the present invention, in the fifth aspect, when the defibrated silencer is supplied to an outer peripheral portion of a perforated pipe, tension is applied to the silencer by a tension roller. This is a method of forming a sound absorbing layer that is supplied to a perforated pipe while being applied.

According to a seventh aspect of the present invention, a large number of basalt yarns obtained by welding basalt into long fibers are bundled with a sizing agent to form a sizing material, and the sizing material is defibrated and bulky. A method for forming a sound deadening layer, comprising: forming a sound deadening material in a shape of a letter; and inserting and filling the sound deadening material into a space between an outer pipe and a perforated pipe constituting the sound deadening device.

[0014]

BEST MODE FOR CARRYING OUT THE INVENTION The sound-absorbing material of the present invention is a continuous mineral fission basalt made by welding a basalt, which is a natural mineral, and a large number of the basalt yarns 1a as shown in FIG. 1 (a). A sizing agent is added to the sizing material to form a long sizing material 1. The sizing material 1 is bulky as shown in FIG.

The long-fiber basalt yarn 1a-1
The fiber diameter of the book is set as desired, but ideally 9 μm to 24 μm. Further, the number of basalt yarns 1a used as the sizing material 1 is set as desired.
Use 100 pieces.

As a method for converting the sizing material 1 into a bulky fiber bundle as described above, for example, the sizing material 1 is supplied into a nozzle and compressed air is blown into the nozzle. The bundled material 1 is unraveled into a single fiber and continuously sent out from a nozzle to continuously produce a silencer 2 which is bulged in a bulky shape.

Then, the silencer 2 is wound around a perforated pipe of the silencer as follows. First, the silencer 2 formed continuously and long as described above is stocked in the stocker 3 as shown in FIG. 1 (c). At this time, 1
The muffler 2 in a bundle is stocked to some extent in a defibrated state.

Next, the sound deadening material 2 stocked in the stocker 3 is pulled out of the stocker 3 and FIG.
As shown in (d), it is wound around a perforated pipe constituting the silencer, for example, the outer peripheral surface of the inner pipe 4. A small hole 5 is formed in the inner pipe 4, and the silencer 2 is wound around the area where the small hole 5 is formed. In addition, as a method of winding, the sound absorbing material 2 is reciprocated in the axial direction of the inner pipe 4 by a traverse mechanism or the like while the inner pipe 4 is appropriately rotated around its axis by a rotating means, and wound. The winding amount is set as desired, and the single or multiple winding is performed according to the reciprocating amount of the muffler 2 formed in one bundle.

As described above, the bundle may be wound with a single bundle of the muffling material 2, but a plurality of bundles such as two bundles or three bundles may be wound simultaneously in consideration of productivity. FIG. 1 (e) shows a state in which the sound is wound as described above, and the sound winding layer 6 of a basalt yarn having bulkiness is formed by the above-described winding.

As described above, as a method for supplying the muffling material 2 in the stocker 3 to the inner pipe 4, the muffling material 2 is supplied from inside the stocker 3 by supply rollers 7 and 8, as shown in FIG. The silencer 2 is drawn out, passed between the tension rollers 9 and 10, and its tip is supplied to the inner pipe 4 and wound. By providing the tension rollers 9 and 10 in this manner, the density and weight of the muffling material 2 wound around the inner pipe 4 can be adjusted by adjusting the tension of the tension rollers 9 and 10.

Incidentally, depending on the density required for the sound absorbing layer 6, the tension rollers 9 and 10 as described above may not be used. That is, only the friction between the silencing material 2 and the member supplying the same may be used.

After the sound deadening layer 6 is formed on the inner pipe 4 as shown in FIG. 1E, the inner pipe 4 on which the sound deadening layer 6 is formed is connected to one of the inner pipes as shown in FIG. The outer pipe 13 having the end plate 12 in which the insertion hole 11 is formed is inserted through the other end side opening. At this time, the outer diameter of the sound absorbing layer 6 is an outer diameter that fits into the inner surface of the outer pipe 13 at a time.

Then, as described above, the inner pipe 4 and the sound absorbing layer 6 are connected to the outer pipe 13 as shown in FIG.
After insertion into the other end plate 1 as shown in FIG.
4 is fixed to the outer pipe 13 to produce the silencer 15.

Although the above embodiment is an example in which the present invention is applied to an inner pipe, the present invention is also applicable to a case where the above-described sound deadening layer 6 is provided in a perforated portion of another perforated pipe, for example, an outlet pipe. The invention is applicable.

As shown in FIG. 3, the muffler 2 is filled into the muffler by forming an insertion hole 22 in an end plate 21 of an outer pipe 20 constituting the muffler.
The silencer 2 is inserted and filled into the space 24 between the outer pipe 20 and the perforated pipe 23 from above.
May be used to form the sound deadening layer.

Further, as shown in FIG.
After the stainless steel wool 30 is wound around the outer periphery of the above, the silencing material 6 may be wound around the outer periphery to form the silencing layer 6. This silencer 2 is made of basalt yarn 1 as described above.
This is a material obtained by bundling a large number of the bundles a into a fiber bundle, and the method of winding the silencing material 2 is the same as described above.

[0027]

As described above, the sound deadening material according to the first aspect of the present invention is made of a basalt yarn formed by welding basalt to form a long fiber, so that the sound absorbing material is made of short fiber. It is not sucked into a perforated pipe by the exhaust gas and exhausted to the atmosphere.It also becomes a sound-absorbing material with excellent acid resistance and alkali resistance, and acid and alkaline substances in the exhaust gas like conventional glass wool. It is not degraded and broken due to, and is not discharged into the atmosphere. Furthermore, since the basalt yarn is bundled and the bunched material is defibrated into a bulky shape, the silencing property is enhanced.

According to the second aspect of the present invention, it is possible to provide a muffler having the above-described effects. According to the third aspect of the present invention, a sound-absorbing layer exhibiting the effect of the basalt yarn can be formed, and a sound-absorbing material formed of a bulky fiber bundle of a large number of basalt yarns as described above is perforated. Since the silencing layer is formed around the pipe, the density of the entire silencing layer can be equalized and the silencing performance can be improved, as compared with a conventional type in which short fibers are filled into the silencer.

According to the fourth aspect of the present invention, the defibration can be performed easily and continuously. According to the fifth aspect of the present invention, the muffler can be easily wound around the perforated pipe.

According to the sixth aspect of the present invention, the density of the formed silencing layer can be easily adjusted by adjusting the tension when the silencing material is supplied. Further, even when the silencer is inserted and filled into the silencer as in the invention according to the seventh aspect, the third aspect is also described.
The same effect can be obtained.

[Brief description of the drawings]

FIG. 1 shows a sound deadening material of the present invention and a method of forming the same.
(A)-(g) show each process.

FIG. 2 shows an example of a process of supplying a silencing material to a perforated pipe in the process of forming the silencing material of the present invention.

FIG. 3 is a diagram showing an example of another formation method in the method for forming a sound absorbing layer of the present invention.

FIG. 4 is a sectional view showing another example of the sound deadening layer according to the present invention.

[Explanation of symbols]

 REFERENCE SIGNS LIST 1 focusing material 1a basalt yarn 2 sound deadening material 4 stocker 5 hole 6 perforated pipe 9,10 tension roller 20 outer pipe 23 perforated pipe 24 space

[Procedure amendment]

[Submission Date] June 27, 2000 (2006.2
7)

[Procedure amendment 1]

[Document name to be amended] Statement

[Correction target item name] Claims

[Correction method] Change

[Correction contents]

[Claims]

[Procedure amendment 2]

[Document name to be amended] Statement

[Correction target item name] 0007

[Correction method] Change

[Correction contents]

[0007]

To SUMMARY OF THE INVENTION To solve the above problems, the first invention of the first aspect, this basalt and dissolve in many present sizing agent basalt yarn was filamentous This is a sound deadening material characterized by being bundled into a bundle and then defibrated into a bulky shape.

[Procedure amendment 3]

[Document name to be amended] Statement

[Correction target item name] 0008

[Correction method] Change

[Correction contents]

In a second aspect of the present invention, basalt is melted.
A large number of basalt yarns made into long fibers were bundled with this sizing agent to form a sizing material, and a bulky sound-absorbing material was defibrated and provided on the outer periphery of the perforated pipe. It is a characteristic silencer.

[Procedure amendment 4]

[Document name to be amended] Statement

[Correction target item name] 0009

[Correction method] Change

[Correction contents]

A third invention according to claim 3 relates to the method of forming the muffling layer using the silencing material, bundling basalt yarn this basalt and dissolve and the long fibers in many present sizing agent To form a bulky sound-absorbing material by defibrating the bundle-forming material, and disposing this sound-absorbing material on the outer peripheral portion of a perforated pipe constituting the silencer to form a sound-absorbing layer. This is a method for forming a characteristic silencing layer.

[Procedure amendment 5]

[Document name to be amended] Statement

[Correction target item name] 0013

[Correction method] Change

[Correction contents]

[0013] Then, the seventh aspect according to claim 7, basalt and the dissolve to focusing member which are bundled in a number present sizing agent basalt yarn in length fibers and fibrillating the focusing member A method for forming a sound deadening layer, comprising: forming a bulky sound deadening material; and inserting and filling the sound deadening material into a space of an outer pipe and a perforated pipe constituting a sound deadening device to form a sound deadening layer. .

[Procedure amendment 6]

[Document name to be amended] Statement

[Correction target item name] 0014

[Correction method] Change

[Correction contents]

[0014]

Silencing material in DETAILED DESCRIPTION OF THE INVENTION The present invention is a basalt is a natural mineral and dissolve the long-fiber basalt yarn continuous to this, the basalt yarn 1a as shown in FIG. 1 (a) A bundle agent is added to a large number of bundles to form a long bundle material 1, and this bundle material 1 is bulky as shown in FIG.

[Procedure amendment 7]

[Document name to be amended] Statement

[Correction target item name] 0027

[Correction method] Change

[Correction contents]

[0027]

It seems because the foregoing, sound-deadening material according to a first aspect of the present invention, since this basalt and dissolve is composed of basalt yarn obtained by a long-fiber, as short fibers It is not sucked into the perforated pipe by the exhaust air flow and exhausted to the atmosphere.In addition, it becomes a sound-absorbing material with excellent acid resistance and alkali resistance, and acid substances and alkalinity in the exhaust gas like conventional glass wool. It is not deteriorated and broken by substances, and is not discharged to the atmosphere. Furthermore, since the basalt yarn is bundled and the bunched material is defibrated into a bulky shape, the silencing property is enhanced.

Claims (7)

[Claims] 1. A sound-absorbing material characterized in that a large number of basalt yarns obtained by welding a basalt into a long-fiber form are bundled with a sizing agent to form a sizing material, which is defibrated into a bulky shape. 2. A basalt in contact with basalt and formed into a long fiber form, and a large number of basalt yarns are bundled with a sizing agent to form a sizing material. A silencer provided on an outer peripheral portion. 3. A large number of basalt yarns in which basalt is welded and made into long fibers is bundled with a sizing agent to form a sizing material, and the sizing material is defibrated to form a bulky sound-absorbing material. Is disposed on the outer periphery of a perforated pipe constituting a muffler to form a muffling layer. 4. As a method of forming the defibrated sound deadening material, the bundled material is supplied into a nozzle and compressed air is blown into the nozzle, and the bundled material is loosened by the compressed air to continuously form the bundle. The method for forming a sound deadening layer according to claim 3, wherein the sound deadening material that has been defibrated is formed. 5. A method of arranging the defibrated sound deadening material on an outer peripheral portion of a perforated pipe, wherein the perforated pipe is rotated around an axis thereof and the sound deadening material is placed on the perforated pipe. The method for forming a sound deadening layer according to claim 3 or 4, wherein the sound deadening material is supplied to an outer periphery and wound around a perforated pipe. 6. When the defibrated sound deadening material is supplied to an outer peripheral portion of a perforated pipe, the sound deadening material is supplied to the perforated pipe while applying tension to the perforated pipe by a tension roller. The method for forming a sound absorbing layer according to the above. 7. A large number of basalt yarns in which basalt is welded and made into a long fiber is bundled with a sizing agent to form a sizing material, and the sizing material is defibrated to form a bulky muffling material. Is inserted into the space between the outer pipe and the perforated pipe constituting the muffler to form a muffling layer.