JP6781479B2 - Manufacturing method of glass fiber sound deadening material - Google Patents

Description

The present invention provides a muffler that constitutes the flow path of the exhaust gas by the inner pipe provided in the case relates to the production how muffling material fiberglass fill the interior space between the casing and the inner pipe.

The muffler provided in the exhaust pipe of an automobile often has a structure in which the internal space between the metal case and the inner pipe is filled with sound-absorbing glass fiber. Exhaust sound is emitted into the case through a large number of holes in the inner pipe and absorbed by the glass fiber. As the glass fiber, glass wool (short fiber) or glass fiber (long fiber) is used. The glass wool is hardened with a binder and stored in the internal space. This glass wool has a problem of polluting the environment by radiating to the outside of the case when the binder burns and disappears due to the exhaust heat. For this reason, in recent years, a method of filling the internal space with glass fiber has been widely adopted (Patent Document 1).

As seen in Patent Document 1, for example, the glass fiber is filled directly into the internal space from the nozzle of the glass fiber feeder (Patent Document 1 [Claim 1]). However, it is difficult to directly fill the internal space of the silencer with glass fiber if the inner pipe is divided or curved to have a complicated structure. In Patent Document 2, a bag portion sewn with a thread-like member is filled with glass fiber in advance, and a portion that interferes with an inner pipe or the like (structure) of a silencer (inside the silencer) is sewn to create an internal space (space portion). A method of producing a sound absorbing material obtained by folding back a portion having a insufficient thickness for filling and filling the internal space is disclosed (Patent Document 2, [Claim 1], [Claim 4], and [Claim 5]).

JP 2009-281369 JP-A-2016-160818

The sound deadening material disclosed in Patent Document 2 is used when the internal space having a complicated structure is filled with glass fiber. However, it is difficult for the sound deadening material to spread the glass fiber in every corner of the internal space having a complicated structure. Since the inner surface shape of the sound deadening material does not follow the internal space, a gap remains particularly between the sound deadening material and the corner portion of the inner surface of the case. Further, since the sound deadening material is sewn at a portion that interferes with the inner pipe or the like, it cannot adhere to the surface of the inner pipe and a gap remains. Further, the sound deadening material still has a gap unless the entire surface of the folded portion comes into contact due to insufficient thickness.

The sound deadening material disclosed in Patent Document 2 is excellent in that it can fill an internal space having a complicated structure in which it is difficult to directly fill the glass fiber. However, as described above, it is undeniable that a large number of gaps actually remain and the muffling performance deteriorates. Therefore, in order to fill the internal space of the complicated structure of the silencer with glass fiber, a sound deadening material that does not generate a gap when filling the internal space and a sound deadening material using the sound deadening material were examined.

As a result of the examination, it is a method of manufacturing a glass fiber sound deadening material that fills the internal space between the case and the inner pipe in the sound deadening device that constitutes the flow path of the exhaust gas by the inner pipe provided in the case, and is the same as the internal space. A shape-retaining container having an inner surface shape is formed, glass fibers are filled in the shape-retaining container, and water is adhered to at least the surface of a lump of glass fiber formed according to the inner surface shape of the shape-retaining container. A glass characterized in that the lump of glass fiber is retained in the internal space in the same outer surface shape by freezing water, and the lump of glass fiber that has been retained is taken out from the shape-retaining container and used as a sound deadening material. We have developed a method for manufacturing fiber sound deadening materials.

The shape-retaining container may have any outer surface shape as long as the inner surface shape is the same as the inner space. The shape-retaining container is preferably a closed space (excluding the nozzle connection port of the glass fiber feeder) in which all the surfaces surrounding the inner surface shape are closed. However, for example, when the internal space extends with the same cross-sectional shape, the shape-retaining container may have a surface in the extending direction as an open surface. The shape-retaining container having an open surface has an inner surface shape longer than the internal space in the extending direction so that the glass fiber to be filled does not overflow. Further, in the shape-retaining container having an open surface, if necessary, the open surface may be temporarily closed with a movable lid that moves in the extending direction.

When the water adhering to the surface of the glass fiber mass is frozen at least, the frozen portion retains the shape by binding the glass fibers to each other. The lump of glass fiber is frozen by, for example, blowing cold air with water attached to the surface or exposing the lump of glass fiber to a freezing atmosphere (atmosphere below 0 ° C.) in the above state. The glass fiber lump may allow water to penetrate not only the surface but also the inside or the center of a certain depth to increase the frozen portion. The shape retention time by the frozen portion is proportional to the depth of freezing from the surface and the freezing temperature, and becomes longer as the depth is deeper or the freezing temperature is lower.

If the frozen portion of the sound deadening material is thawed, the unbonded glass fiber restores elasticity and adheres to the case or inner pipe, enabling sound deadening performance. The water generated by melting the frozen part appears in the silencer because it is generated with the sound deadening material fitted in the internal space. However, the amount of the water is small and evaporates by natural drying or forced drying and does not remain in the silencer. The glass fiber is filled, for example, by inserting the nozzle of the glass fiber feeder into the shape-retaining container. In this case, if an air flow is formed by sealing the shape-retaining container and sucking out air, the bulk density of the glass fiber to be filled can be increased.

The lump of glass fiber is, for example, coated or sprayed with water from the outside of a shape-retaining container composed of a mesh surface, and then frozen together with the shape-retaining container to freeze at least the water adhering to the surface. The reticulated surface has a structure in which resin or metal wire rods are crossed, and also includes punching metal and expanded metal. When the air in the shape-retaining container is sucked when filling the glass fiber, for example, the surface of the shape-retaining container, which is a mesh surface, is closed with a removable closing plate. Water is applied to the glass fiber by brushing or dipping in a water tank, or sprayed (including watering) on the glass fiber by spraying.

In the case of an internal space having a complicated structure, a plurality of sound deadening materials corresponding to the partial space are produced by filling a shape-retaining container having the same inner surface shape as the divided subspace with glass fiber, and the sound deadening material is used. By fitting the sound deadening material into the internal space in combination, the sound deadening material can be fitted into the internal space without any gap. If the frozen part melts, the plurality of sound deadening materials fitted in the internal space will adhere to the case and inner pipe, and the glass fibers constituting the adjacent sound deadening materials will adhere to each other, eliminating the gap between the adjacent sound deadening materials. ..

Mute material, a sound-deadening material of glass fiber fill the interior space between the casing and the inner pipe in the muffler constituting the flow path of the exhaust gas by the inner pipe provided in the case, the same outer contour as the internal space It is a mass of glass fiber that has a surface that is, and at least the water adhering to the surface is frozen and retained . If the internal space of the complex structure, silenced material is configured as a mass of glass fibers having the same outer contour as the divided partial space interior space.

The muffler is a muffler that constitutes an exhaust gas flow path by an inner pipe provided in the case, and is a state in which the glass fiber muffler material is held by freezing at least water adhering to the surface. The internal space is filled with glass fiber by fitting it into the internal space and melting the frozen portion. The case opened to fit the sound deadening material into the internal space can be closed by processing (for example, a case that is spinning) or closed with a pair of members (for example, a case with a middle structure) after the sound deadening material is fitted. ). After being fitted into the internal space of the sound deadening material, the frozen portion is melted and the generated water is evaporated by natural drying or forced drying.

The present invention creates a sound deadening material as a mass of glass fiber having the same outer surface shape as the internal space of the sound deadening device and having a timely shape retention until the frozen portion melts. Since the sound deadening material has the same outer surface shape as the internal space of the sound deadening device, it can be fitted into the internal space without a gap. The shape-retaining container having a reticulated surface is particularly suitable for freezing only the surface of the glass fiber mass, which can be coated or sprayed with water from the outside. As for the sound deadening material, it is preferable that only the water adhering to the surface is frozen and kept in shape because the time until the frozen portion melts is short and the amount of water generated can be small.

The sound deadening material is made as a mass of glass fiber that has the same outer surface shape as the divided subspace and has a timely shape retention until the frozen part melts, so that multiple sound deadening materials are fitted without gaps. Therefore, the internal space can be filled with glass fiber. In the case of the manufacturing method of the present invention, a plurality of sound deadening materials can be easily produced by using a shape-retaining container according to the subspace separately from the sound deadening device. Thereby, according to the present invention, it is possible to provide a silencer filled with glass fiber by simply combining a plurality of sound deadening materials and fitting them into the internal space, regardless of the complicated internal space.

It is a perspective view which shows an example of the shape-retaining container used in this invention. It is a perspective view which shows an example of the silencer which inserts the sound deadening material manufactured in the shape-retaining container of this example. It is a perspective view which shows the shape-retaining container of this example which opened the opening and closing surface. It is a perspective view which shows the shape-retaining container of this example which is fitted in a closed container. It is a partial breaking perspective view which shows the process of filling glass fiber in the shape-retaining container of this example. It is a perspective view which shows the shape-retaining container of this example which finished filling with the glass fiber. It is a perspective view which shows the state which sprayed on the shape-retaining container of this example, and water is attached to the glass fiber. It is a perspective view which shows the state which put the shape-retaining container of this example which attached water to the glass fiber in a freezing atmosphere. It is a perspective view which shows the state which takes out the lump of frozen glass fiber from the shape-retaining container of this example. It is a perspective view which shows the state which the lump of frozen glass fiber is fitted into the internal space of a silencer. It is a partially cutaway perspective view showing a silencer in which a lump of glass fiber is melted and filled.

Hereinafter, embodiments for carrying out the present invention will be described with reference to the drawings. According to the present invention, for example, as shown in FIG. 1, in a silencer 1 in which an inner pipe 12 is passed through a case 11 having a middle structure in which a set of case constituent members 111 are integrated in the middle, the inner pipe is described. A pair of partition plates 121 are provided on the 12 and are used for manufacturing a glass fiber sound deadening material 5 (see FIG. 10 below) to be fitted into the internal space 13 where it is difficult to fill the glass fiber from the outside of the case 11.

The internal space 13 is a space sandwiched between partition plates 121 provided on the inner pipe 12 on the same bale-shaped plane in the cross section of the case 11, and a cylindrical space corresponding to the inner pipe 12 is located in the center of the bale-shaped plane. It penetrates. Therefore, one sound deadening material through which the cylindrical space penetrates cannot be fitted into the internal space 13. Therefore, as shown in FIG. 2, the shape-retaining container 2 of this example corresponds to a partial space in which the internal space 13 is divided in half by a dividing line that divides the internal space 13 in the longitudinal direction of the bale-shaped plane through the center of the cylindrical space. The structure is as follows. As a result, the silencer 1 of this example fits the two silencers manufactured in the two shape-retaining containers 2 (see FIG. 2) into the internal space 13 as a set.

As seen in FIG. 3, in the shape-retaining container 2 of this example, the opening / closing surface 22 is connected to the curved side surface 23 following the inner surface of the case 11 by a hinge 222, and the bottom surface 24 is closed while the upper surface 21 is opened. Consists of. The opening / closing surface 22 is configured by providing a constricted portion 221 having a semicircular arc shape in which the cylindrical space corresponding to the inner pipe 12 is divided in half on a vertical surface following a dividing line that divides the internal space 13 in half. Further, the bottom surface 24 is formed by removing the arc-shaped notch 241 in which the cylindrical space corresponding to the inner pipe 12 is divided in half from the horizontal plane in which the same bale-shaped plane is divided in half in the cross section of the case 11.

The shape-retaining container 2 of this example is a net-like surface in which an opening / closing surface 22, a side surface 23, and a bottom surface 24 are each crossed with metal wire rods. As a result, the glass fiber filled in the shape-retaining container 2 can be coated with water from the outside of the shape-retaining container 2. The pitch of the mesh can be freely set as long as the glass fiber to be filled does not protrude. The nozzle 4 of the glass fiber feeder (see FIG. 5 below) is inserted from the open upper surface 21. Therefore, in the shape-retaining container 2 of this example, the opening / closing surface 22 and the side surface 23 are made longer than the length ISL in the extending direction of the internal space 13 by an excess length EL, and the supplied glass fiber does not overflow from the upper surface 21. I am doing it.

The procedure for manufacturing the sound deadening material 5 using the shape-retaining container 2 of this example will be described. First, as shown in FIG. 4, the shape-retaining container 2 with the opening / closing surface 22 closed is fitted into the closed container 3 having an inner surface shape that imitates the outer surface of the shape-retaining container 2. The upper surface of the closed container 3 is open like the shape-retaining container 2, and two exhaust pipes 31 are connected to correspond to the bottom surface 24 of the shape-retaining container 2. As a result, when filling the glass fiber, air is sucked out from the bottom surface 24 of the shape-retaining container 2 to create an air flow from above to below, and the bulk density of the filled glass fiber is increased.

By fitting the shape-retaining container 2 into the closed container 3, as shown in FIG. 5, the opening / closing surface 22, the side surface 23, and the bottom surface 24 are closed. As described above, the glass fiber 41 reciprocates the nozzle 4 of the glass fiber feeder (not shown) inserted from the open upper surface 21 to the left and right to evenly disperse the inside of the shape-retaining container 2. Due to the flow of air sucked out from the exhaust pipe, it is filled as a mass 42 with increased bulk density. The nozzle 4 may be meandered or may be repeated a plurality of times while shifting the linear movement, as long as the glass fiber 41 is evenly dispersed.

When the shape-retaining container 2 is filled with a predetermined amount of glass fiber 41, the supply of the glass fiber is stopped and the shape-retaining container 2 is taken out from the closed container 3. The shape-retaining container 2 of this example is formed to be larger than the internal space 13 by the excess length EL (see FIG. 1). Therefore, as seen in FIG. 6, the glass fiber lump 42 formed in the shape-retaining container 2 has a length corresponding to the surplus length EL from the open upper surface 21 (depending on the filling amount of the glass fiber). It has an outer shape that follows the inner surface shape of the shape-retaining container 2 with a size up to the depth that leaves (front and back).

As seen in FIG. 7, the glass fiber mass 42 is sprayed with water from the outside of the shape-retaining container 2 by a large number of spray nozzles 6 to adhere water to at least the surface. It is desirable that the water be applied evenly to at least the surface of the glass fiber mass 42. Therefore, a plurality of spray nozzles 6 may be arranged so as to surround the shape-retaining container 2, and for example, the shape-retaining container 2 may be rotated to change the degree of contact of water sprayed from the spray nozzle 6.

As shown in FIG. 8, the glass fiber lump 42 is exposed to a freezing atmosphere while being held in the shape-retaining container 2 with water adhering to the surface to freeze the water adhering to the surface. .. The glass fiber mass 42 can also be blown with cold air, for example, to freeze the water adhering to the surface. However, the cold air to be sprayed is often scattered and not useful for freezing water. For example, when freezing water adhering to the surface of a large number of glass fiber lumps 42 held in a large number of shape-retaining containers 2, work efficiency is achieved. Is bad. Therefore, it is preferable to provide a freezing atmosphere (for example, a constant temperature bath) capable of storing a large number of shape-retaining containers 2 and expose the holding container 2 to the freezing atmosphere as in this example.

In the glass fiber lump 42, the frozen portion due to the attached water is retained by binding the glass fibers to each other to form a sound deadening material 5. The sound deadening material 5 is a lump of glass fiber 42 that has been shape-retained by the frozen portion, and as shown in FIG. 9, the opening / closing surface 2 of the shape-retaining container 2 can be opened and taken out as it is. The shape-retaining container 2 is used in succession to the production of another sound deadening material by removing the remaining glass fiber scraps and frozen portions.

Since the sound deadening material 5 of this example has an outer shape corresponding to a partial space obtained by dividing the internal space 13 to be fitted by half, a set of two of the sound deadening material 5 fills the internal space 13. As seen in FIG. 10, the pair of sound deadening materials 5 is sandwiched between the inner pipe 12 and the case component 111, and is fitted into the internal space 13. Since the fitting operation of the sound deadening material 5 with respect to the internal space 13 is carried out at room temperature, the frozen portion gradually melts. However, the sufficiently frozen sound deadening material 5 is retained for several minutes to ten and several minutes, and its shape does not collapse during the fitting operation.

As shown in FIG. 11, the pair of sound deadening materials 5 fitted in the internal space 13 adheres to the case 111 and the inner pipe 12 when the frozen portion melts, and the sound deadening materials 5 adjacent to each other The constituent glass fibers are in close contact with each other to eliminate gaps. The amount of water generated by melting the frozen portion is very small and usually evaporates by natural drying, so that it does not remain in the case 11. Thus, according to the present invention, it becomes possible to provide a silencer 1 in which glass fibers are densely filled in the internal space 13 which could not be filled without gaps in the past.

1 silencer
11 cases
12 Inner pipe
13 Internal space 2 Shape-retaining container
21 Open top surface
22 Opening and closing surface
23 side
24 Bottom 3 Closed container
31 Exhaust pipe 4 nozzle
41 Fiberglass supplied
42 Glass fiber mass 5 Glass fiber silencer 6 Spray nozzle
Length of ISL interior space
EL surplus length

Claims (3)

A method for manufacturing a glass fiber sound deadening material that fills the internal space between the case and the inner pipe in a sound deadening device that constitutes an exhaust gas flow path by an inner pipe provided in the case.
A shape-retaining container having the same inner surface shape as the internal space is constructed,
Fill the shape-retaining container with glass fiber and
Water is attached to at least the surface of the glass fiber lump formed according to the inner surface shape of the shape-retaining container.
By freezing the water, the lump of glass fiber is kept in the internal space in the same outer surface shape.
A method for producing a glass fiber sound deadening material, which comprises taking out a shape-retaining glass fiber block from a shape-retaining container and using it as a sound deadening material. After water is applied to or sprayed on the glass fiber lump from the outside of the shape-retaining container composed of the mesh surface, the glass fiber lump is frozen together with the shape-retaining container and applied to at least the surface of the glass fiber lump. The method for producing a glass fiber sound deadening material according to claim 1, wherein the attached water is frozen. The method for producing a glass fiber sound deadening material according to claim 1 or 2, wherein the shape-retaining container having the same inner surface shape as the subspace in which the internal space is divided is filled with glass fiber.

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