JP2005036722A - Muffler device for vehicle, and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a muffler device and a method of manufacturing the muffler device mounted with a sound absorbing/silencing cylinder body improving silencing performance and reducing the scatter of glass wool fiber by eliminating a clearance of the sound absorbing/silencing cylinder body while reducing the manufacturing cost of the sound absorbing/silencing cylinder body. <P>SOLUTION: This muffler device MO for a vehicle has the sound absorbing/silencing cylinder body formed of a silencing material and mounted in an annular space S of a muffler body M formed of an outer layer pipe P1 and an inner layer pipe P2 provided with a large number of pores h. The sound absorbing/silencing cylinder body 10 is formed in four-layer structure comprising from the inner layer side a polymeric material fiber nonwoven fabric or glass cloth 13, wire gauze (such as stainless mesh) 15, stainless wool 17 and a sound absorbing/silencing material 19 in an outer layer. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  The present invention relates to a muffler device for a vehicle and a method for manufacturing the same, and more particularly to an improved muffler performance and productivity of a sound absorbing / muffling cylinder.

  2. Description of the Related Art Conventionally, automobile exhaust silencers (muffler devices) have been provided with glass wool protected against higher temperatures and pressures of exhaust and having improved durability. The configuration is shown in FIG.

  Hereinafter, the configuration of the muffler device will be described. As shown in FIG. 13, the exhaust muffler 30 is filled with glass wool 33 between an inner tube 32 having a large number of small holes on the side surface and an outer tube 31 covering the outer periphery of the inner tube. A three-layer structure is formed by winding a suspension mesh 34 on the outside of the inner tube, winding a suspension wool 35 on the outside of the suspension mesh, and winding a suspension mesh 36 on the outside of the suspension wool. The outside is filled with the glass wool 33. This three-layer structure improves the durability of the glass wool because the suspension wool does not act directly on the glass wool even when the exhaust gas is heated to a higher temperature and pressure (see, for example, Patent Document 1). .)

JP 2003-41923 A

  The conventional configuration has the following problems. That is, it has been recognized that the exhaust silencer (muffler device) of the automobile realizes the prevention of glass fiber scattering and the effective sound absorption and silencing performance. However, in the winding operation of the three-layer structure, the inner suspension mesh is directly wound around the metal core, the suspension wool and the suspension mesh are wound around the outer periphery, and the winding ends are spot-welded and fixed in a cylindrical shape. Subsequently, glass wool is wound around the surface of the cylindrical three-layer structure in a double or triple manner and laminated. For this reason, when the suspension mesh is directly wound around the metal core, there is almost no friction and it takes time to form the three-layer structure into a cylindrical body.・ Space is created. This leads to poor productivity and increased manufacturing costs. Furthermore, according to the exhaust silencer that employs such a three-layered sound absorbing and silencing cylinder, the exhaust gas circulates into the gaps / spaces of the sound absorbing and silencing cylinder glass wool to increase the temperature and pressure, thereby reducing the noise. , And induces scattering of glass wool fibers. This further promotes the problem of shortening the life of the sound absorbing and silencing cylinder in a short time.

  The present invention has been made on the basis of the above points, and an object thereof is to simplify the manufacturing process of the sound absorbing and silencing cylinder to reduce the manufacturing cost and eliminate the gap between the sound absorbing and silencing cylinder. Another object of the present invention is to provide a muffler device equipped with a sound absorbing and silencing cylinder with improved sound deadening performance and reduced scattering of glass wool fibers, and a method for manufacturing the same.

  In order to achieve the above object, a muffler device for a vehicle according to claim 1 of the present invention is a muffler device for a vehicle in which a sound-absorbing / silencer cylinder made of a sound-absorbing and silencing material is inserted between an outer layer pipe and an inner layer perforated pipe. The sound absorbing and silencing cylinder is characterized in that it is formed from the inner layer side to at least a four-layer structure comprising a polymeric fiber nonwoven fabric or glass cloth, a wire mesh, stainless wool, and an outer sound absorbing and silencing material.

  According to a second aspect of the present invention, there is provided a method of manufacturing a vehicle muffler device comprising: a step of superimposing a wire mesh and stainless wool on a two-layer sheet; and a polymer material fiber nonwoven fabric or glass cloth serving as a core at one end of the two-layer sheet. A step of connecting one end, a step of connecting one end of a sound absorbing and silencing material to the other end of the two-layer sheet of the metal mesh and stainless wool, and forming a sheet body, and a polymer material fiber nonwoven fabric or glass of the sheet body A process of forming a four-layer structure in which a wire mesh is wound around the inner layer perforated pipe from one end of the cloth with a wire mesh inside, and a sound absorbing / silencing material is arranged on the outer layer pipe side, And a step of adhering the end of the material to the outer surface of the sound absorbing and silencing material to form a sound absorbing and silencing cylinder, and a step of externally fitting an outer pipe to the outside of the sound absorbing and silencing cylinder. It is intended.

  According to a third aspect of the present invention, there is provided a method of manufacturing a vehicle muffler device comprising: a step of superimposing a wire mesh and stainless wool on a two-layer sheet; and a polymer material fiber nonwoven fabric or glass cloth that serves as a core at one end of the two-layer sheet. A step of connecting one end, a step of connecting one end of a sound absorbing and silencing material to the other end of the two-layer sheet of the metal mesh and stainless wool, and forming a sheet body, and a polymer material fiber nonwoven fabric or glass of the sheet body A step of forming a four-layer structure in which a wire mesh is wound around a core rod from one end of the cloth in a laver winding shape and a sound absorbing and silencing material is arranged on the outer layer pipe side, and the sound absorbing and silencing material wound in the laver winding shape A step of adhering the end to the outer surface of the sound absorbing and silencing material to form a sound absorbing and silencing cylinder, and the sound absorbing and silencing cylinder in the annular space of the muffler body formed by an outer layer pipe and an inner layer perforated pipe A step of wearing and is characterized in that it consists of.

  According to the muffler device for a vehicle according to the present invention, the sound absorbing and silencing cylinder is formed of a polymer material fiber nonwoven fabric or glass from the inner layer side in the annular space of both pipes in which the muffler body is formed by the outer layer pipe and the inner layer porous pipe. A four-layer structure comprising a cloth, a wire mesh, stainless wool, and an outer layer of a sound absorbing and silencing material is formed. As a result, the four-layer structure is closely contacted with no gaps. As a result, leakage of exhaust sound is reduced, and a high silencing and soundproofing effect can be obtained. Further, scattering of the sound absorption and silencing material in the outer layer by exhaust gas can be prevented, and high durability is ensured.

  Further, according to the method of manufacturing a sound absorbing / silencing cylinder for a muffler of a motorcycle, the sound absorbing / silencing cylinder is formed by using one end of a polymeric material fiber nonwoven fabric or glass cloth and one end of a double-layer sheet of a metal mesh and stainless wool. An inner layer in which a sheet body is formed in which the other end of the sound absorbing / silencing material is connected to the sound absorbing / silencing material, and a plurality of small holes are formed from one end of the polymer material non-woven fabric or glass cloth of the sheet body. The pipe is wound into a four-layer structure like a laver with a wire mesh inside, and the edges of the sound absorbing / sound absorbing material are bonded and fixed to form a single piece. Thus, since the polymer material non-woven fabric or glass cloth is first directly wound around the inner layer pipe or core rod, an appropriate frictional resistance is obtained and the winding is easily performed without slipping. Further, in the winding and manufacturing process of the sound absorbing / silencing cylinder, the sheet body is densely wound from one end of the sheet body around the inner porous pipe or core rod in a laver shape. And the spot welding with respect to a winding start part and a winding termination | terminus part is abbreviate | omitted, a manufacturing procedure becomes easy and manufacturing cost is also reduced.

  In addition, the polymer-based material fiber nonwoven fabric or glass cloth used to make it easier to wind the wire mesh around the inner perforated pipe at the time of manufacture burns and disappears due to the high temperature and high pressure of the exhaust gas generated when the muffler is used. .

  Hereinafter, a first embodiment of the present invention will be described with reference to FIGS. FIG. 1 is a perspective view of a muffler device for a vehicle and a sound absorbing / silencing cylinder thereof, and FIG. 2 is a sectional view thereof. 3 to 6 are a flowchart and a process diagram showing the manufacturing process of the sound absorbing / silencing cylinder. FIG. 6 is a cross-sectional view of the muffler device and its sound absorbing / silencing cylinder.

  Hereinafter, the configuration of the muffler device MO will be described. First, with reference to FIG. 1 and FIG. 2, the configuration of the vehicle muffler device MO of the present invention and the sound absorbing and silencing cylinder 10 will be described. First, the muffler body M is formed by concentrically stacking an outer layer pipe P1 and an inner layer perforated pipe P2 provided with a large number of small holes h. In the annular space S between the pipes P1 and P2 in the muffler main body M, a muffler sound absorbing and silencing cylinder 10 is mounted. This muffler sound-absorbing / silencer cylinder 10 includes a polymer material fiber nonwoven fabric or glass cloth 13 that is directly wound around the inner porous pipe P2 from the inner layer side, a wire mesh (for example, stainless steel mesh) 15, a stainless wool 17, and an outer layer. A four-layer structure is formed of a sound absorbing and silencing material (for example, a suitable material such as glass fiber, ceramic wool, ceramic fiber, rock wool, etc.) 19.

  The vehicle muffler device MO operates as follows. First, the sound absorbing and silencing cylinder 10 mounted in the muffler device MO is constructed of a polymeric material fiber nonwoven fabric or glass cloth 13, a wire mesh (for example, stainless steel mesh) 15, a stainless wool 17 and an outer layer from the inner layer side. A four-layer structure made of the material 19 is integrally formed. The sound-absorbing / silencer cylindrical body 10 having a four-layer structure is closely and closely formed with no gaps between the layers, and can provide a high silencing effect and a soundproofing effect. Scattering can be prevented and high durability is ensured.

  Further, the high-friction material high-molecular-weight material fiber nonwoven fabric or glass cloth 13 used for facilitating winding of the wire mesh (for example, stainless steel mesh) 15 around the inner-layer porous pipe P2 at the time of manufacture is generated when the muffler main body M is used. The exhaust gas burns and disappears due to high temperature and high pressure.

  Next, with reference to FIGS. 3 to 6, a method for manufacturing the sound absorbing and silencing cylinder 10 in the muffler device MO will be described. First, in the preparation step, a process H1 of superimposing a wire mesh (for example, stainless mesh) 15 and stainless wool 17 on the two-layer sheet 20, and a high-molecular-weight material fiber nonwoven fabric having a large frictional resistance at one end 20A of the two-layer sheet 20 or A step H2 for connecting one end 13A of the glass cloth 13 and a sheet 19 by connecting one end 19A of the sound absorbing and silencing material 19 to the other end 20B of the double-layer sheet 20 of the wire mesh (for example, stainless steel mesh) 15 and stainless wool 17. Wrapped in a laver winding shape with the wire mesh (for example, stainless steel mesh) 15 inside the porous pipe P2 of the inner layer from one end 13B of the polymer-based material fiber nonwoven fabric or glass cloth 13 of the sheet body 30 and the process H3 as the body 30; Step H4 of forming a four-layer structure in which the sound absorbing and silencing material 19 is arranged in multiple turns on the outer layer pipe P1 side. A step H5 of adhering the end 19B of the sound absorbing and silencing material 19 wound in a laver winding shape to the outer surface 19C of the sound absorbing and silencing material 19 with an adhesive 60 or the like, and an outer pipe on the outside of the sound absorbing and silencing cylinder 10 Step H6 for fitting P1 externally.

  In addition, as shown in FIGS. 4, 5, 7, 8, and 9, there is also a manufacturing method in which one end 13 </ b> B of the polymer material fiber nonwoven fabric or glass cloth 13 of the sheet body 30 is wound around the core rod 50. In this case, first, in the preparation process, a process H1 in which a metal mesh (for example, stainless mesh) 15 and stainless wool 17 are stacked on the two-layer sheet 20 and a polymer having a high frictional resistance at one end 20A of the two-layer sheet 20. One end 19A of the sound absorbing and silencing material 19 is connected to the other end 20B of the double-layer sheet 20 of the metal mesh (for example, stainless steel mesh) 15 and the stainless steel wool 17 by connecting the one end 13A of the system material fiber nonwoven fabric or glass cloth 13 together. The sheet H 30 is connected to the sheet material 30, and the polymer material fiber nonwoven fabric or the glass cloth 13 of the sheet body 30 is connected to the core rod 50 from one end 13 </ b> B with a wire mesh (for example, stainless steel mesh) 15 as an inner laver winding shape. Step H of forming a four-layer structure in which the sound absorbing and silencing material 19 is arranged in multiple turns on the outer layer pipe P1 side A step H5 of adhering the end 19B of the sound absorbing and silencing material 19 wound in a laver winding shape to the outer surface 19C of the sound absorbing and silencing material 19 with an adhesive 60 or the like, and the sound absorbing and silencing cylinder 10 as an outer pipe P1. And the step H6 of mounting in the annular space S of the muffler main body M formed by the inner layer pipe P2. In the process H6 of attaching the muffler main body M in the annular space S, the sound absorbing / muffling cylindrical body 10 may be removed from the core rod 50 and then inserted into the annular space S as it is. There is a case where a process H7 for cutting to a predetermined dimension is interposed in the middle.

  The polymer material nonwoven fabric 13 is a nonwoven fabric made of a polymer material fiber selected from polyethylene, polypropylene, nylon, polyvinyl chloride, polyester, and the like. For example, a trade name “Spunbond” manufactured by Nittobo Can be used. The glass cloth 13 is a woven fabric in which glass fibers are woven into a cloth shape. This may be a non-woven fabric. In short, a thin fabric having a high frictional resistance may be used. The glass cloth 13 burns and disappears when heated at about 400 ° C., and the polymer material fiber nonwoven fabric burns and disappears when heated at about 100 ° C. The wire mesh (for example, stainless steel mesh) 15 is made of a stainless steel wire having a diameter of about 0.1 mm and woven into a mesh or woven fabric.

  Further, the stainless steel wool 17 is produced, for example, by a manufacturing process of a “metal fiber manufacturing apparatus using a hot-soluble resin-coated coil material cutting method” shown in FIGS. In FIG. 10, in the coating apparatus 100, the coil material C is pulled out by the coating roll CR, and the surface thereof is coated with the hot-melt plastic UP, and after being dried by the drying heater KH, it is wound around the winding roller as a coating material. Subsequently, the coil material C1 wound in a cylindrical shape is cut into a thread shape by a cutting tool B in the longitudinal direction by a cutting device 110 such as a lathe. Thereafter, the substrate is washed with warm water of 75 to 90 ° C. by the washing and winding device 120 and wound up as the washed thread-like metal fiber C2. Subsequently, the filamentous metal fiber C2 is subjected to a felting process by the web manufacturing apparatus 200 shown in FIG. First, in the needle punch section 210, the metal fiber C2 is pulled out by the felt pull-out roll FR, cut by the needle section N and the web width adjusting plate WP, and then needle punched. Then, the metal fibers C3 punched by the needle in the web manufacturing unit 220 are cut by the disk mount K, cut by the head portion H and the fiber bundle mount K1, and the web pressing plate W1, the web width determining plate W2, and the head. Thomson processing is performed by the section HO and the fiber bundle gantry K2, and the final processing is carried out.

  Next, a specific embodiment for mass-producing the sound absorbing / silencing cylinder 10 of the present invention will be described with reference to FIG. A glass cloth 13, a metal mesh 15, stainless wool 17 and a sound absorbing / silencing material 19 are respectively supplied, cut into predetermined unfolded dimensions with a cutter CT, and wound around a long cylinder 10. Since this cylindrical body 10 is bonded at its end, it is placed on the carriage D and carried into the furnace KO. The cylinder body 10 after drying is cut in size by the cutter CT in accordance with the length of the muffler main body M, packed in a box, or carried out, or carried out to a mounting process on the muffler main body M.

  According to the method for manufacturing a vehicle muffler device MO of the present invention, the sound absorbing / silencing cylinder 10 is formed by attaching one end 13A of the polymer material fiber nonwoven fabric or glass cloth 13 to the two-layer sheet 20 of the wire mesh 15 and the stainless wool 17. Connected to one end 20A, the other end 20B of the two-layer sheet 20 forms a sheet body connected to the sound absorbing and silencing material 19, and the inner layer from one end 13A of the polymer material fiber nonwoven fabric or glass cloth 13 of this sheet body The porous pipe P2 or the core rod 50 is wound into a four-layer structure by winding it in a laver winding shape with the wire mesh 13 inside. Then, the end edge 19B of the sound absorbing and silencing material 19 is bonded and fixed with an adhesive and is integrally formed all at once. As a result, the polymer material non-woven fabric or glass cloth 13 having a large frictional resistance can be directly wound around the inner porous pipe P2 or the core rod, so that an appropriate frictional resistance can be obtained and dense winding can be performed without slipping. Further, in the winding and manufacturing process of the sound absorbing / silencing cylinder, the sheet body can be easily and precisely wound only by winding it around the inner layer pipe from one end of the sheet body. Thereby, spot welding for the winding start portion and the winding end portion is omitted, so that the manufacturing procedure is facilitated and the manufacturing cost is reduced.

  As described above, according to the embodiment of the present invention, the following effects can be obtained. First, in the annular space of the muffler device, a four-layered sound absorption / silencer cylinder consisting of a polymeric material non-woven fabric or glass cloth, wire mesh, stainless steel wool, outer layer sound absorption / silencer material is mounted from the inner layer side. From the above, the four-layer structure is in close contact with each other without any gaps, and the sound absorbing and silencing cylinder can exhibit a high silencing effect and a soundproofing effect, and can prevent scattering of the sound absorbing and silencing material in the outer layer and ensure high durability.

  Further, according to the method for manufacturing a muffler device for a vehicle, even if a polymer material fiber nonwoven fabric or glass cloth is directly wound around an inner layer pipe, a frictional resistance can be obtained, and it can be easily and densely wound without slipping. And the sound absorption / silencer cylinder is simply wound around the inner layer pipe or the like in a laver form with a sheet of a four-layer structure consisting of a polymeric material fiber nonwoven fabric or glass cloth, a wire mesh, stainless wool, and a sound absorption / silencer material. It is finished in detail. Spot welding for the winding start portion and the end portion is also omitted, and the manufacturing process becomes simple and the manufacturing cost can be reduced.

  The present invention is not limited to the above embodiment. For example, the material of the polymer material fiber nonwoven fabric 13, the material of the wire mesh 15, the material of the stainless wool 17, and the material of the sound absorbing / silencing material 19 can be arbitrarily changed. Moreover, what is necessary is just to form in at least 4 layer structure, and the frequency | count of winding of the sheet | seat body 30 may increase, and it may be a multilayer structure.

  The present invention has been described by taking the vehicle muffler device and the manufacturing method thereof as an example, but the present invention is not limited to this, and can be applied to muffler devices of various engines.

1 is an exploded perspective view of a muffler device for a motorcycle according to the present invention. 1 is a cross-sectional view of a muffler device for a motorcycle according to the present invention. It is a flowchart figure which shows 1st Embodiment of the manufacturing process of a muffler apparatus. It is a manufacturing-process figure which shows the manufacturing process of the sound-absorption / noise-reduction cylinder for mufflers. It is a manufacturing-process figure which shows the manufacturing process of the sound-absorption / noise-reduction cylinder for mufflers. It is a manufacturing process figure of the muffler sound-absorbing / silencer cylinder and a cross-sectional view of the muffler device. It is a flowchart figure which shows 2nd Embodiment of the manufacturing process of a muffler apparatus. It is a perspective view which shows the cutting process of the muffler sound-absorbing / silencing cylinder. It is a perspective view of the manufacturing process which mounts the muffler sound absorbing and silencing cylinder on the muffler body. It is a metal fiber manufacturing apparatus which implements the hot-soluble resin-coated coil material cutting method, and its manufacturing process diagram. It is a processing figure of the felt process by a web manufacturing apparatus. This is a specific embodiment for mass-producing a sound absorbing / silencing cylinder for a muffler. It is sectional drawing which shows a prior art example.

Explanation of symbols

MO muffler device M muffler main body P1 outer layer pipe P2 inner layer pipe S annular space H1 stacking process H2 connecting process H3 sheet forming process H4 forming to four-layer structure H5 bonding process H6 mounting process to muffler device H7 predetermined dimensions 10 Sound absorption / silencer cylinder 13 Polymer material fiber nonwoven fabric or glass cloth 15 Wire mesh (stainless steel mesh)
17 Stainless wool 19 Sound absorption / silencer (glass fiber)
20 Double-layer sheet 30 Sheet body 50 Core rod 60 Adhesive

Claims (3)

  In a vehicle muffler device in which a sound absorption / silencer cylinder made of a sound absorption / silencer material is inserted between an outer layer pipe and an inner layer perforated pipe, the sound absorption / silencer cylinder is formed from a polymer material fiber nonwoven fabric or glass cloth from the inner layer side. A muffler device for a vehicle, characterized in that the muffler device is formed in at least a four-layer structure comprising a metal mesh, stainless steel wool, and an outer layer of a sound absorbing and silencing material.   A step of superimposing a wire mesh and stainless wool on a two-layer sheet, a step of connecting one end of a polymer material non-woven fabric or a glass cloth as a core to one end of the two-layer sheet, and two steps of the wire mesh and stainless wool A process of connecting one end of a sound absorbing and silencing material to the other end of the layer sheet to form a sheet body, and winding a seaweed with a metal mesh inside from the one end of the polymer material non-woven fabric or glass cloth of the sheet body to the inner perforated pipe Forming a four-layer structure in which a sound absorbing and silencing material is disposed on the outer layer pipe side, and bonding the end of the sound absorbing and silencing material wound in a laver winding shape to the outer surface of the sound absorbing and silencing material A method for manufacturing a muffler device for a vehicle, comprising: a step of obtaining a sound absorbing / silencing cylinder; and a step of externally fitting an outer layer pipe to the outside of the sound absorbing / silencing cylinder. A step of superimposing a wire mesh and stainless wool on a two-layer sheet, a step of connecting one end of a polymer material fiber nonwoven fabric or glass cloth as a core material to one end of the two-layer sheet, and two steps of the wire mesh and stainless wool A step of connecting one end of a sound absorbing / silencing material to the other end of the layer sheet to form a sheet body, and a sheet of polymer material fiber nonwoven fabric or glass cloth of this sheet body from one end of the sheet rod to the core rod in a laver winding shape A process of forming a four-layer structure in which a sound absorbing and silencing material is arranged on the outer layer pipe side, and an end of the sound absorbing and silencing material wound in a laver winding shape is bonded to the outer surface of the sound absorbing and silencing material A muffler for a vehicle comprising: a step of making a sound-absorbing cylinder; and a step of mounting the sound-absorbing / silencer-cylinder in an annular space of a muffler body formed by an outer layer pipe and an inner layer perforated pipe. Manufacturing method of the device.

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