JP2002004832A - Silencing material and method for manufacturing the silencing material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a silencing material having durability against exhaust gas, and to provide its manufacturing method. SOLUTION: A large number of basalt yarns is produced, that basalt is dissolved to produce long fibers are bundled by greige goods, to form a bundled material 1. The bundled material is cut into short fibers, the cut bundled material is fibrillated and formed in a bulky state, and the bulky materials are stacked and formed in a mat-form using a needle process to produce the silencing material 3.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a silencer used for a silencer of an internal combustion engine and a method of manufacturing the silencer.

[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.

[0004] As a muffler arrangement, a sub-muffler and a prima-muffler are arranged downstream of the exhaust gas purification device using a catalyst.
The main muffler is arranged at the most downstream part. Such a sub muffler and a prim muffler may be located in the immediate vicinity of the exhaust gas purification device. In this case, the sub muffler and the prim 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.

[0006]

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 be deteriorated and broken, and may be discharged to the atmosphere together with the exhaust gas.

In view of the foregoing, an object of the present invention is to provide a silencer excellent in acid resistance and alkali resistance, and excellent in noise reduction, and a method of manufacturing the same.

[0008]

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 dissolving basalt into long fibers are bundled with a sizing agent to form a bundle. This is a muffler characterized by forming a material, defibrating the material into a bulky shape, stacking the material, and forming the material into a mat shape by needle processing.

According to a second aspect of the present invention, in the first aspect, the bundled material is defibrated into a bulky shape, arranged in one direction and overlapped with each other to perform a needle process. It is a sound deadening material.

According to a third aspect of the present invention, in the first aspect of the present invention, the bunched material is defibrated into a bulky shape, and is arranged in a vertical direction and a horizontal direction and overlapped with each other to perform needle processing. This is a sound-absorbing material.

According to a fourth aspect of the present invention, a large number of basalt yarns obtained by dissolving basalt into long fibers are bundled with a sizing agent into a sizing material, which is defibrated into a bulky shape. Are stacked to form a mat-like sound-muffling material by needle processing.

According to a fifth aspect of the present invention, in the fourth aspect of the present invention, the sound deadening material according to the fourth aspect of the present invention, in which the bundled material is defibrated into a bulky shape, arranged in one direction, overlapped, and needle-processed. It is a manufacturing method of.

According to a sixth aspect of the present invention, in the fourth aspect of the present invention, the bunched material obtained by defibrating the bundle is formed into a bulky shape, and is arranged in a vertical direction and a horizontal direction and is overlapped with a needle. This is a method for producing a sound deadening material.

[0014]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of the present invention will be described based on an embodiment shown in the drawings.

In the production of the sound deadening material of the present invention, basalt, which is a natural mineral, is first dissolved, and the basalt is drawn out of a porous bushing to obtain a filamentous long fiber basalt yarn.
Many basalt yarns of long fibers are bundled and wound around a bobbin, and at this time, a sizing agent for bundling the large number of basalt yarns is used to form a long bundle as shown in FIG. Make material 1. In FIG. 1A, 1a
Indicates a basalt yarn.

The long-fiber basalt yarn 1a-1
The fiber diameter of the book is set as desired, but ideally 9 μm to 24 μm. The number of basalt yarns 1a used in one bundle 1 is set as desired.
Use between 00 and 4000 tubes.

Next, the bundled material 1 bundled as described above is defibrated into a bulky (bulky) shape. As a method for increasing the bulk, for example, the above-mentioned sizing material 1 is supplied into a nozzle and compressed air is blown into the nozzle, and the sizing material 1 is loosened into a single fiber by the compressed air and continuously sent out from the nozzle. Thus, the bundled material 2 (see FIG. 1 (b)) which has been opened in a bulky shape is continuously manufactured.

Next, the bunched material 2 laid as described above is stacked in an aligned state. This stacking method is shown in FIG.
As shown in FIG. 1C, they may be arranged in one direction and stacked, or as shown in FIG. 1D, they may be arranged alternately in the vertical direction and the horizontal direction and stacked.

Next, as shown in FIG. 1 (e), the sound-muffling material 3 is formed into a mat shape (felt shape) as shown in FIG. As a result, a mat-like silencing material 3 having high strength as long fibers is obtained.

Then, the mat-shaped silencer 3 is wound around the perforated pipe 5 constituting the silencer 4, as shown in FIG. At this time, a stainless steel wool 6 is wound around the perimeter of the perforated pipe 5, and the stainless steel wool 6
It is preferable to wind the mat-shaped silencer 3 around the outer periphery of the muffler to further prevent the silencer 3 from scattering. Then, the outer periphery of the silencer 3 is covered with the outer shell 7 to form the silencer 4.

[0021]

As described above, since the sound deadening material of the present invention is formed of a basalt yarn made of a crystalline material made of basalt, the sound deadening material of the present invention has a higher quality than glass fiber made of a conventional amorphous material. Deterioration due to acidic or alkaline substances in the exhaust gas is small, and durability can be improved.

Further, it is possible to provide a mat-like silencing material having high strength as long fibers. Further, a desired amount of the silencing material can be obtained by stacking a desired amount of the bunched material and performing needle processing.

Further, the sound absorbing performance is improved by forming the bunching material into a bulky shape.

[Brief description of the drawings]

FIG. 1 shows an embodiment of the present invention, in which (a) to (e)
FIG. 4 is a diagram showing a manufacturing process of the noise reduction material.

FIG. 2 is a diagram showing a state in which the silencing material of the present invention manufactured in FIG. 1 is used for a silencer.

[Explanation of symbols]

 DESCRIPTION OF REFERENCE NUMERALS 1 bundled material 1a basalt yarn 2 defibrated bundled material 3 mat-shaped sound-absorbing material

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁷ Identification symbol FI Theme coat ゛ (Reference) F01N 1/04 F01N 1/04 E 7/18 7/18

Claims (6)

[Claims] 1. A large number of basalt yarns obtained by dissolving basalt into long fibers are bundled with a sizing agent to form a sizing material. A silencing material characterized by being formed in a shape. 2. The sound deadening material according to claim 1, wherein the bundled material is defibrated into a bulky shape, arranged in one direction and overlapped with each other to perform needle processing. 3. The sound deadening material according to claim 1, wherein the bundled material is defibrated into a bulky shape, and arranged in a vertical direction and a horizontal direction and overlapped and needle-processed. 4. A large number of basalt yarns obtained by dissolving basalt into filaments are bundled with a sizing agent to form a sizing material, which is defibrated into a bulky shape, which is stacked and formed into a mat shape by needle processing. A method for producing a sound deadening material, comprising: 5. The method for producing a sound deadening material according to claim 4, wherein the bundled material is defibrated into a bulky shape, arranged in one direction, overlapped, and needle-processed. 6. The method for producing a sound deadening material according to claim 4, wherein the bundled material is defibrated into a bulky shape, and arranged in a vertical direction and a horizontal direction and overlapped and needle-processed.