Method of and apparatus for packing exhaust silencer casings

Description

[0001] This invention relates to a method of packing exhaust silencer casings and a silencer casing produced thereby.

[0002] Such silencer casings contain packing in order to assist in silencing exhaust gases from an engine by virtue of conversion of kinetic energy of the exhaust gases into mechanical displacements of the packing and thus heating thereof.

[0003] It is known for the fibre to be "fluffed-up" into a wool-like consistency. This material can be produced by chopping continuous strands of glass fibre.

[0004] In the past such silencer casings have been packed manually and, to assist in this process, it has been proposed to apply a vacuum to one end of the silencer casing.

[0005] In order to adapt the process for automatic operation, glass fibre material in wool-like form has been fed into a hopper, from which it passes along ducts before being metered into individual quantities, each suitable for packing one silencer casing. However the material has been prone to clog in the ducts and this has made the accurate metering of the material difficult, if the expense of weigh pans is to be avoided.

[0006] GB-A-1279 472 discloses apparatus in which discrete lengths of glass fibre are fed into one end of an exhaust silencer casing whilst air is drawn therethrough by a suction pump connected to the other end.

[0007] EP-A-91 413 discloses apparatus in which a continuous strand of glass fibre is formed into a continuous "wool sausage" by means of a nozzle, this is then blown into one end of a silencer casing with the assistance of a suction fan connected to the other end of the silencer casing.

[0008] According to a first aspect of this invention there is provided a method of packing an exhaust silencer casing, comprising the steps of: establishing gas flow into one end of the silencer casing and then out of the other end through a perforated tube passing therethrough; and allowing discrete lengths of fibres to be carried into the silencer casing in the gas flow, characterised in that the gas flow is passed through a restricted passageway before entering the silencer casing and a strand consisting of a plurality of fibres other than continuous glass fibres is chopped into discrete lengths upstream of the restricted passageway so that as the discrete lengths are formed they are carried by the gas flow through the restricted passageway and individual fibres in each discrete length separate from each other in a region of turbulence created thereby to form a wool-like material.

[0009] It should be noted that the term "strand" used in this specification refers to a plurality of fibres which may be twisted, plaited or laid parallel, A strand typically comprises 200-1600 fibres, The term "roving" refers to a bundle of strands. A roving typically comprises eight or more strands and may comprise over 500 fibres. The term "fibre" refers to an elongate object, such as a filament, from which a wool-like material can be made.

[0010] It has been found that the individual fibres of each discrete length of chopped strand separate as they are carried into the silencer casing in the gas flow so that the fibres "fluff up" in the desired manner in the silencer casing itself or as they enter the casing.

[0011] According to a second aspect of this invention there is provided apparatus for packing an exhaust silencer casing comprising: means for establishing gas flow into the casing, and means for chopping into discrete lengths a strand consisting of fibres other than continuous glass fibres, the arrangement being such that the chopped fibres are carried into the casing in the gas flow.

[0012] Preferred features of the invention will be apparent from the subsidiary claims if this specification.

[0013] This invention will now be illustrated, merely by way of example, with reference to the accompanying drawings, in which:

Figure 1 is a part sectional view of a first embodiment of apparatus according to this invention;

Figure 2 is a side view of a gun of the apparatus shown in Figure 1;

Figure 3 is a front view of the gun shown in Figure 2;

Figure 4 is a plan view of the gun shown in Figure 2; and

Figure 5 is a schematic view of a second embodiment of apparatus according to this invention.

[0014] The apparatus for packing a silencer casing 1 shown in Figure 1 comprises vacuum producing apparatus 2, sealing apparatus 3 and a gun 4.

[0015] The silencer casing 1 is circular in cross-section, and one end thereof is closed by an end piece 5 which supports a perforated tube 6 extending through the silencer casing 1. The end piece 5 also supports a stub pipe 7 which, in use, connects the silencer to the rest of the exhaust assembly. A similar end piece (not shown) bearing a stub pipe is welded to the other end of the silencer casing 1 after it has been packed.

[0016] The vacuum producing apparatus 2 has a rubber sealing member 8 which fits tightly around the stub pipe 7. A vacuum is produced in the apparatus by means of a centrifugal compressor (not shown) driven by a forty horse power (29.8 KW) motor (not shown). This produces a vacuum of around ten inches of mercury (33.9 KNm-²) in the apparatus 2.

[0017] The sealing apparatus 3 likewise has a sealing member 9 and this seals against the open end of the casing 1 and also blocks off the open end of the peforated tube 6, as the tube 6 should not be filled with any packing material. The sealing member 9 includes a circular aperture 10 whose diameter is 3/4 inch (19 mm) which provides communication between the interior of the sealing apparatus 3 and the interior of the casing 1. The aperture 10 forms a restriction in the pathway from the gun 4 to the interior of the casing 1.

[0018] Attention is drawn to the GB-A-2 127 093 which relates specifically to the use of continuous glass fibres in similar apparatus.

[0019] Figure 2 shows roving being fed into the gun 4 and discrete lengths of this being emitted from the gun 4. The roving consists of a bundle of strands each of which consists of a plurality of fibres, e.g. at least 100 or at least 1000 fibres, of a mineral such as basalt, i.e. the material from which rockwool is made. Other types of fibres which when "fluffed-up" form a wool-like material may be used, foe instance ceramic fibres. The fibres typically have a diameter in the range of 6-12 microns. The fibres in each strand may be twisted, plaited or laid parallel and the fibres may be continuous, i.e. extend the length of the strand, or may be relatively short in which case they may be spun to form a strand in much the same manner as cotton or wool is spun to form threads. Preferably, the roving fed into the gun 4 comprises eight or more strands so that each discrete chopped length thereof consists of a large number of fibres, e.g. over 2000 fibres. However, it is possible to operated the apparatus with only a single strand being fed into the gun 4. Preferably, the fibres have a diameter of less than 30 microns or less than 15 microns. The roving is fed into the gun 4 from a spool (not shown) containing a length of about two hundred meters of roving.

[0020] The gun 4 has an air-powered motor, contained in a housing 11, to which a rubber roller 12 is coaxially attached. The roving is driven through the gun 4 by means of the rubber roller 12 and a steel roller 13 which is hard in contact with the rubber roller 12. The roving is cut into discrete lengths by means of a cutter 14 mounted diametrically through a further roller 15 so that the cutter 14 extends along a generator of the roller 15. Every half revolution of roller 15, the roving is severed at the point of contact between the rollers 12 and 15. The rollers 12, 13 and 15 are contained in a housing 16 (see Figures 3 and 4) having an inlet 17 and an outlet 18. Exhaust air from the air powered motor is fed into the housing 16, and since the area of the outlet 18 is much greater than that of the inlet 17, the chopped lengths of roving are projected out of the gun 4 with the aid of a blast of this exhaust air.

[0021] In operation a silencer casing 1 to be filled with packing is fitted onto the vacuum producing apparatus 2 and the sealing apparatus 3 is brought up to the open end of the casing 1.. The centrifugal compressor is started. The gun 4 is then run and left running for a pre-determined period of time. This pre-determined period corresponds to the desired weight of fibre it is desired to pack into the particular silencer casing 1, and this can be calculated simply from the weight per unit length of the roving and the velocity at which the roving is fed through the gun 4.

[0022] The chopped lengths of roving projected from the gun 4 are all sucked through the aperture 10 in the sealing member 9 by the vacuum applied at the other end of the silencer casing 1, and the casing 1 is gradually filled with fibres. It has been found that the fibres in each chopped length of roving separate either before they enter the silencer casing 1 or while they are in the silencer casing 1 (probably the separation mainly takes place within the silencer), and this results in the production of the desired wool-like form of the fibres in the casing 1. The air flow within the casing 1 will of course be turbulent since it is being sucked through the perforated tube 6. The fibres do not pass into the tube 6 themselves.

[0023] One advantage of the apparatus and method described is that it is possible to accurately meter the quantity of fibres with which each casing is packed. Also, the ducting require for handling wool-like glass fibre is not required.

[0024] The desired method and apparatus may be used to pack any form of silencer casing including those in which exhaust gases make multiple passes of the whole or part of the length of the silencer casing.

[0025] Various modifications of the method or apparatus are of course possible. For example, tests have been carried out with an arcuate aperture 10 in the sealing member 9, the aperture 10 having length of about four times its breadth. Although the roving "fluffed-up" in a satisfactory manner, it was nevertheless found that it "fluffed-up" better with the 3/4 inch (19 mm) diameter aperture referred to earlier.

[0026] A second embodiment of fhe apparatus according to this invention is shown in Figure 5. This apparatus differs from that shown in the previous figures in that no vacuum is required to draw the chopped roving into the silencer casing. Instead, the chopped roving is carried into the casing by an air flow.

[0027] A silencer casing 20 to be filled with packing is closed at the lower end as seen in Figure 5 by a closing plate 21 which has an aperture through which a perforated tube 22 of the silencer extends. The silencer casing 20 is mounted on a platform 23 through which air can pass. At the upper end of the silencer casing 20 as seen in the Figure is a closing plate 24 which carries a plug 25 for closing the upper end of the perforated tube 22.

[0028] Chopped strands of the roving are fed into the silencer casing 20 via a tube 26 and a conical member 27, the tube 26 being sealed in an aperture in the closing plate 24. The tube 26 thus forms a restriction in the pathway from a gun 28 to the interior of the casing 20.

[0029] The gun 28 supplies chopped roving to the wide end of the conical member 27. The gun 28 is similar to the gun 4 described except that the exhaust air thereof does not assist in projecting the chopped strands of roving from the gun 28, the chopped roving being projected from the gun 28 solely by the rotation of the rollers 12, 13 and 15.

[0030] A narrow tube 29 opens into the tube 26, and compressed air is supplied through the narrow tube 29 into the tube 26. It has been found that the compressed airfed into the tube 26 draws large quantities of air into the conical member 27, through the wide end thereof and hence through the tube 26 into the silencer casing 20. The chopped roving is therefore carried by this air flow into the silencer 20. The air flow leaves the silencer casing 20 via the perforated tube 22. It has been found that the fibres of the chopped roving are "fluffed-up" in this process, and that the silencer casing 20 is filled in a very satisfactory manner.

[0031] Examples of suitable dimensions and pressures for the apparatus shown in Figure 5 will now be given.

[0032] It is believed that the narrow diameter of the tube 26 is important in "fluffing-up" the chopped roving, since only with a narrow diameter is sufficient turbulence created in the tube 26 to achieve this. Similarly, it is believed that the narrow aperture 10 in the apparatus shown in Figure 1 is responsible for creating the necessary turbulence to cause "fluffing-up". The narrower the diameter of the tube 26 or aperture 10, are smaller the compressed air pressure or vacuum needed to "fluff-up" the chopped roving. However, if the diameter is too small, the restriction is prone to clogging.

[0033] It will be apparent that any means of establishing an air flow or gas flour through the silencer casing to be packed may be used to carry the chopped roving into the casing.

[0034] This invention also relates to any exhaust silencer casing packed in accordance with the method described above and to an exhaust system comprising such a silencer casing.

Claims

1. A method of packing an automobile silencer casing (1;20) comprising the steps of: establishing gas flow into one end of the silencer casing (1;20) and then out of the other end through a perforated tube (6;22) passing therethrough; and allowing discrete lengths of fibres to be carried into the silencer casing (1;20) in the gas flow, characterised in that the gas flow is passed through a restricted passageway (10;26) before entering any silencer casing (1;20) and a strand consisting of a plurality of fibres other than continuous glass fibres is chopped into discrete lengths upstream of the restricted passageway (10;26) so that as the discrete lengths are formed they are carried by the gas flow through the restricted passageway (10;26) and individual fibres in each discrete length separate from each other in a region of turbulence created thereby to form a wool-like material..

2. A method as claimed in claim 1, in which the strand consists of at least one hundred fibres.

3. A method as claimed in claim 2, in which the strand consists of at least a thousand fibres.

4. A method as claimed in any one of claims 1 to 3, in which the diameters of the fibres are less than thirty microns.

5. A method as claimed in claim 4, in which the diameter of the fibres are less than fifteen microns.

6. A method as claimed in any preceding claim, in which the strand comprises mineral fibres, e.g. basalt fibres, or'ceramic fibres.

7. A method as claimed in any preceding claim, in which the strand is fed between two rollers (12, 13) engaging one another, one of which (12) is driven.

8. A method as claimed in claim 7, in which the strand passes between a pair of rollers (12, 15), one of which (15) has a cutter (14) mounted diametrically therethrough.

9. A method as claimed in claim 7 or claim 8, in which the discrete lengths are projected through the passageway (10; 26) with the assistance of a gas blast.

10. A method as claimed in any preceding claim, in which the diameter of the passageway (10; 26) is less than one inch (25.4 mm).

11. A method as claimed in claim 10, in which the passageway (26) is formed by the narrow end of a tapering tube (27), the wide end of which receives the discrete lengths.

12. A method as claimed in any preceding claim, in which the gas flow is established by reducing the pressure where the gas flow leaves the silencer casing (1; 20).

13. A method as claimed in any preceding claim, in which the gas flow is established by means of a jet of compressed air directed into the passageway (10; 26).

14. A method as claimed in claims 11 and 13, in which the jet is inclined with respect to the axis of the tapering tube (27).

15. An automobile exhaust silencer casing (1;20) packed in accordance with method claim 1 with discrete lengths of fibre, other than glass fibre, characterised in that the discrete lengths are fluffed-up to produce a wool-like material.

16. A silencer casing (1; 20) as claimed in claim 15 incorporated into an automobile exhaust system.

Ansprüche

1. Verfahren zum Füllen eines Kraftfahrzeug-Auspuffschalldämpfergehäuses (1; 20), das folgende Schritte umfaßt: Erzeugen einer Gasströmung in ein Ende des Auspuffschalldämpfergehäuses (1; 20) hinein und danach am anderen Ende heraus durch ein perforiertes Rohr (6; 22), das durch dieses hindurchführt; und Einragenlassen von getrennten Abschnitten von Fasern in das Auspuffschalldämpfergehäuse (1; 20) in der Gasströmung; dadurch gekennzeichnet, daß die Gasströmung durch einen verengten Durchlaß (10; 26) geleitet wird, bevor sie in das Auspuffschalldämpfergehäuse (1; 20) eintritt, und daß ein Strang, der aus einer Mehrzahl von Fasern besteht, bei denen es sich nicht um fortlaufende Glasfasern handelt, stromaufwärts von dem verengten Durchlaß (10; 26) in getrennte Abschnitte zerstückelt wird, so daß dann, wenn die getrennten Abschnitte hergestellt sind, diese von der Gasströmung durch den verengten Durchlaß (10; 26) getragen werden und einzelne Fasern jedes getrennten Abschnitts sich in einer dadurch erzeugten Turbulenzzone voneinander trennen und dadurch ein wollartiges Material bilden.

2. Verfahren nach Anspruch 1, dadurch gekennzeichnet, daß der Strang aus wenigstens 100 Fasern besteht.

3. Verfahren nach Anspruch 2, dadurch gekennzeichnet, daß der Strang aus wenigstens 1000 Fasern besteht.

4. Verfahren nach einem der Ansprüch 1 bis 3, dadurch gekennzeichnet, daß die Durchmesser der Fasern weniger als 30 pm betragen.

5. Verfahren nach Anspruch 4, dädurch gekennzeichnet, daß die Durchmesser der Fasern weniger als 15 um betragen.

6. Verfahren nach einem der vorausegehenden Ansprüche dadurch gekennzeichnet, daß der Strang mineralische Fasern, z.B. Basaltfasern, oder keramische Fasern aufweist.

7. Verfahren nach einem der vorausegehenden Ansprüche dadurch gekennzeichnet, daß der Strang zwischen zwei aneinander angreifende Walzen (12,13) geführt wird, von denen eine (12) angetrieben wird.

8. Verfahren nach Anspruch 7, dadurch gekennzeichnet, daß der Strang zwischen einem Paar von Walzen (12, 15) hindurchgeführt wird, von denen eine (15) eine diese diametral durchsetzend montierte Schneidvorrichtung (14) aufweist.

9. Verfahren nach Anspruch 7 oder Anspruch 8, dadurch gekennzeichnet, daß die getrennten Abschnitte mit Hilfe eines Gasstroms durch den Durchlaß (10; 26) geblasen werden.

10. Verfahren nach einem der vorausgehenden Ansprüche dadurch gekennzeichnet, daß der Durchmesser des Durchlasses (10; 26) kleiner als ein Inch (25,4 mm) ist.

11. Verfahren nach Anspruch 10, dadurch gekennzeichnet, daß der Durchlaß (26) durch das enge Ende einer sich verjüngenden Röhre (27) gebildet wird, deren weites Ende die getrennten Abschnitte erhält.

12. Verfahren nach einem der vorausgehenden Ansprüche dadurch gekennzeichnet, daß die Gasströmung durch Reduzierung des Drucks an der Stelle, wo die Gasströmung das Auspuffschalldämpfergehäuse (1; 20) verläßt, erzeugt wird.

13. Verfahren nach einem der vorausgehenden Ansprüche, dadurch gekennzeichnet, daß die Gasströmung durch einen Strahl komprimierter Luft erzeugt wird, der in den Durchlaß (10; 26) gerichtet wird.

14. Verfahren nach Anspruch 11 und 13, dadurch gekennzeichnet, daß der Strahl in bezug auf die Längsachse der sich verjüngenden Röhre (27) geneigt ist.

15. Kraftfahrzeug-Auspuffschalldämpfergehäuse (1; 20) das nach dem Verfahrensanspruch 1 mit getrennen Faserabschnitten, bei denen es sich nicht um Glasfasern handelt, gefüllt ist, dadurch gekennzeichnet, daß die getrennten Abschnitte zur Erzeugung eines wollartigen Materials aufgeplustert sind.

16. Auspuffschalldämpfergehäuse (1; 20) nach Anspruch 15, das in ein Kraftfahrzeug-Auspuffsystem integriert ist.

Revendications

1. Procédé de garnissage d'un boîtier (1; 20) de silencieux d'automobile, comprenant les stades de: établissement d'un courant d'air pénétrant à une première extrémité du boîtier (1; 20) de silencieux puis sortant à l'autre extrémité, et circulant dans un tube perforé (6; 22) disposé dans ce boîtier, et transport de tronçons distincts de fibres dans le boîtier (1; 20) du silencieux dans la courant de gaz, caractérisé en ce que le courant de gaz circule dans un passage (10; 26) de dimension restreinte avant de pénétrer dans le boîtier (1; 20) du silencieux, et un brin formé de plusieurs fibres autres que des fibres continues de verre est est découpé en tronçons distincts en amont du passage (10; 26) de dimension restreinte, afin que, lorsque les tronçons sont formés, ils soient transportés par le gaz dans le passage (10; 26) de dimension restreinte et que les fibres individuelles de chaque tronçon distinct se séparent les unes des autres dans une région de turbulence ainsi créée et pour former un matériau analogue à de la laine.

2. Procédé selon la revendication 1, dans lequel le brin est formé d'au moins cent fibres.

3. Procédé selon la revendication 2, dans lequel le brin est formé d'au moins mille fibres.

4. Procédé selon l'une quelconque des revendications 1 à 3, dans lequel les diamètres des fibres sont inférieurs à 30 Ilm.

5. Procédé selon la revendication 4, dans lequel les diamètres des fibres sont inférieurs à 15 Ilm.

6. Procédé selon l'une quelconque des revendications précédentes, dans lequel le brin contient des fibres minérales, par exemple des fibres de basalte, ou des fibres céramiques.

7. Procédé selon l'une quelconque des revendications précédentes, dans lequel le brin est avancé entre deux rouleaux (12, 13) qui sont en contact mutuel et dont l'un (12) est entraîné.

8. Procédé selon la revendication 7, dans lequel le brin passe entre deux rouleaux (12, 15) dont l'un (15) a un organe de coupe (14) monté diamétralement sur lui.

9. Procédé selon la revendication 7 ou la revendication 8, dans lequel les tronçons distincts sont projetés dans le passage (10, 26) avec l'assistance d'un flux de gaz soufflé.

10. Procédé selon l'une quelconque des revendications précédentes, dans lequel le diamètre du passage (10; 26) est inférieur à 25,4 mm.

11. Procédé selon la revendication 10, dans lequel le passage (26) est formé par l'extrémité étroite d'un tube (27) de forme tronconique dont l'extrémité large reçoit les tronçons distincts.

12. Procédé selon l'une quelconque des revendications précédentes, dans lequel le flux de gaz est établi par réduction de la pression à l'endroit où le flux de gaz quitte le boîtier (1; 20) du silencieux.

13. Procédé selon l'une quelconque des revendications précédentes, dans lequel le flux de gaz est établi à l'aide d'un jet d'air comprimé dirigé dans le passage (10; 26).

14. Procédé selon les revendication 11 et 13, dans lequel le jet est incliné par rapport à l'axe du tube (27) de forme tronconique.

15. Boîtier (1; 20) de silencieux d'échappement pour automobile, garni selon le procédé de la revendication 1 à l'aide de trançons distincts de fibres, autres que des fibres de verre, caractérisé en ce que les tronçons distincts bouffent afin de former une matière analogue à de la laine.

16. Boîtier (1; 20) de silencieux selon la revendication 15, incorporé à un ensemble d'échappement d'automobile.

Drawing