SOUND MUFFLING MATERIAL AND METHOD OF MAKING THEREOF

Abstract: A sound muffling material for use in combustion engine exhaust mufflers. The material includes volumised fibres (1) retained in compressed form by a material (2) of lower softening temperature than the fibres (1). When the material is heated by exhaust gases the material of lower softening temperature (2) is softened allowing the compressed fibres (1) to expand. The fibres (1) may be formed into a knitted fabric retained by a sacrificial thread (2). The material may be used to support catalyst bricks.

Description: SOUND MUFFLING MATERIAL AND METHOD OF MAKING THEREOF The present invention relates to a sound muffling material. The material is intended particularly although not exclusively for use in mufflers and silencers fitted to internal combustion engine exhausts. Exhaust mufflers generally include a sound muffling material, usually glass fibres. This material acts to attenuate sounds transmitted through the exhaust system. The fibres are usually disposed in at least a part of the muffler. The fibres generally fill a part of the muffler to a certain density to achieve an effective muffling effect. The fibres are usually in a volumised form. In one existing arrangement an exhaust muffler comprises a cylindrical steel body, usually referred to as a box, in which there is disposed coaxially a perforated steel tube. The perforated steel tube is mounted on annular end caps which are affixed to opposite ends respectively of the cylindrical body by welding or crimping. A muffling material, usually glass fibres, is disposed in the annular region between the perforated steel tube and the muffler body. In use exhaust gases are directed through one end cap, along the perforated tube, and out the opposite end cap. Mufflers of this type are assembled in one of two common ways. Generally the muffler is assembled by attaching one end cap to support the perforated tube. In one method volumised continuous filament glass fibres are injected, through the open end of the muffler body, into the annular region between the perforated tube and muffler body using specialist equipment. In another method a glass fibre needlefelt fabric is provided wrapped around a cardboard tube, or former, of a similar diameter to the perforated metal tube in the muffler. The cardboard tube is positioned above the perforated tube and the cylinder of needlefelt fabric slid off the cardboard tube and onto the perforated tube. There are a number of problems associated with both the above described methods. The equipment used to inject continuous filament fibres is expensive and therefore limits the number of mufflers that can be produced simultaneously at reasonable cost. When fibres are provided in the form of a needlefelt they are not necessarily continuous filament fibres. As such, when the muffler is used some fibres may pass through the perforated tube and into the flow of exhaust gases. This is undesirable as the effect of the muffler will be diminished and the escaping fibres may cause problems in the remainder of the exhaust system. Also, sliding a cylinder of needlefelt fabric onto a perforated tube is also inconvenient as the fabric tends to snag on the cut end of the perforated tube. Further, the cardboard tubes present a waste management problem. Often, the tubes are re-used which necessitates returning the tubes to the supplier, increasing transport costs. By far the most significant drawback with conventional methods of filling mufflers with fibres is that where the fibres are loose, especially in the case of the preferred continuous filament fibres, and the muffler is filled with the required density of fibres this presents problems when the end cap is attached to the muffler. Where fibres stray out of the muffler body they may become trapped between the muffler body and the end cap. This adversely affects the quality of the join between the end cap and muffler body both when the end cap is attached by welding and crimping. It is therefore essential that before the end cap is attached to a muffler body the fibres disposed in the body are carefully moved from the region of the join. This is tedious and time consuming. Another type of muffler is the clam shell type, which comprises two portions which are crimped or welded together to form a complete unit. Mufflers of this type are produced in a variety of shapes and sizes, in general, however, each half is relatively shallow. The clam shell type of muffler cannot be easily filled with fibres using the above described methods as the fibres easily escape. Instead, short fibres are provided packed in, or continuous filaments injected into, perforated polythene bags. A bag of fibres is placed into one half of a clam shell muffler and the second half is welded or crimped to the first half. In use, high temperature exhaust gases cause the polythene bags to disintegrate, releasing the fibres. Again, there are problems associated with this technique. Firstly, the bags tend to be bulky in order to provide the correct density of fibres to fill the muffler. This makes joining the two halves of the muffler difficult. Secondly, where the bag is filled with short filament fibres problems are experienced with the fibres escaping from the muffler in use, as described above. It is an object of the present invention to provide a convenient method of filling a muffler with fibres, particularly to enable continuous filament fibres to be easily used in clam shell type mufflers. According to a first aspect of the present invention there is provided a sound muffling material comprising volumised fibres retained in compressed form by a material of lower softening temperature than the fibres. According to a second aspect of the present invention there is provided a sound muffling material comprising volumised fibres retained in compressed form by a material which breaks down at a lower temperature than the fibres. According to a third aspect of the present invention there is provided a method of making a sound muffling material comprising the steps of providing fibres, volumising said fibres, providing a material with a lower softening temperature than the fibres, compressing said volumised fibres and retaining said volumised fibres by means of said material with a lower softening temperature. According to a fourth aspect of the present invention there is provided a method of making a sound muffling material comprising the steps of providing fibres, volumising said fibres, providing a material with a lower breakdown temperature than the fibres, compressing said volumised fibres and retaining said volumised fibres by means of said material with a lower breakdown temperature. According to a fifth aspect of the present invention there is provided a method of filling an exhaust muffler with fibres comprising the steps of placing a material comprising volumised fibres retained in compressed form by a material of lower softening temperature than the fibres into an exhaust muffler and heating the material so as to soften the retaining material to release the fibres. According to a sixth aspect of the present invention there is provided a method of filling an exhaust muffler with fibres comprising the steps of placing a material comprising volumised fibres retained in compressed form by a material of lower breakdown temperature than the fibres into an exhaust muffler and heating the material so as to cause the retaining material to breakdown to release the fibres. According to a seventh aspect of the present invention there is provided a method of mounting an exhaust catalyst brick comprising the steps of wrapping the brick in a material comprising volumised fibres retained in compressed form by a material of lower softening temperature than the fibres and heating the material so as to soften the retaining material to release the fibres. According to an eighth aspect of the present invention there is provided a method of mounting an exhaust catalyst brick comprising the steps of wrapping the brick in a material comprising volumised fibres retained in compressed form by a material of lower breakdown temperature than the fibres and heating the material so as to cause the retaining material to breakdown to release the fibres. The material is preferably adapted for insertion into an internal combustion engine exhaust muffler, including both domestic and commercial vehicles as well as industrial applications, for instance silencers used on gas turbine installations and during jet engine testing. The material may also be used for catalyst brick support in exhaust systems. The fibres are preferably heat resistant and may comprise silica, glass, mineral or basalt man made fibres. The fibres preferably comprise e-glass (electrical glass) fibres. The fibres are also preferably resistant to exhaust gases. The fibres are preferably resistant to thermal breakdown at temperatures up to 500°C, more preferably 1000°C, still more preferably 1 100°C or higher. The fibres preferably comprise continuous filament fibres. The average length of the fibres is preferably greater than 400mm. The fibres may be volumised by the process known as air texturising or voluminising. The fibres may be voluminised by using conventional compressed air operated volumising equipment to separate the filaments in multi-filament strands or yarns, for example multiple fibre roving. The volume occupied by the fibres is preferably increased by at least a factor of ten. The fibres may also be texturised, again using conventional equipment, for example air-jet texturising equipment. The volumised heat resistant fibres are preferably retained, when in compressed form, so as to minimise their volume. The volumised heat resistant fibres are preferably retained by an organic or synthetic material with a softening/melting point of lower temperature than that of exhaust gases, more preferably less than 200°C, still more preferably below 150°C. The retaining material preferably comprises a fibre, for example a nylon polypropylene, polyethylene or polyester fibre. It is to be understood, however, that natural materials and fibres which breakdown at temperatures below the softening or breakdown temperature of the heat resistant fibres could be used, for example cotton fibres. More generally the heat resistant fibres and retaining material are preferably chosen so that in use, for example in an exhaust muffler, the high temperature exhaust gases cause the retaining material to breakdown to release the heat resistant fibres. This allows mufflers and other equipment to be easily assembled with heat resistant fibres in a compressed form. As such the fibres take up a minimum of volume this overcomes the problem of stray fibres interfering with the assembly of the muffler and the difficulty associated with the insertion of bulky fibres into a muffler. When the muffler is first used the fibres are released and expand to fill the muffler in a desired manner. In one embodiment the arrangement of fibres comprise a fabric . In a preferred arrangement the heat resistant fibres are formed into a knitted fabric, for example a crochet or rochel knit fabric, retained by a lower melting point thread, for example a 'sacrificial' catch thread. The fabric may however take other forms, for example a woven fabric where the warp and weft comprise respectively heat resistant and heat softening fibres, or vice versa. Braided, twisted or netted methods of manufacture may also be used. Fabrics according to the present invention may be configured so that upon the melting/breakdown of the retaining material the fabric expands in a predetermined manner. For example a strip of fabric may be arranged so that it will expand mainly in length and thickness but less so in width. This is a useful feature where the fabric is used in a cylindrically bodied muffler. When the arrangement of fibres comprises a fabric it is preferable that that fabric has a density of at least 60kg/m 3 , more preferably 200kg/m 3 and still more preferably 400kg/m 3 , in compressed form, before softening/breakdown of the retaining threads. When the arrangement of fibres is a fabric this may be produced continuously and cut into pieces of desired length. It is preferable that the ends of the fabric are secured to prevent fraying and premature expansion, for example by taping the ends of the fabric or using a thread lock adhesive. It is preferred that any tape or adhesive has a softening/thermal breakdown temperature of a similar order to the retaining material and in any event lower than that of the heat resistant fibres. Portions of material of the present invention may be packed in plastic bags to aid handling. Such bags preferably breakdown on exposure to heat in exhaust systems. The present invention provides an improved method of and muffling material for filling exhaust mufflers. The method dispenses with the need for the use of either expensive equipment or for cardboard formers or other packaging. As the fibres are provided in compressed form they take up less volume and are therefore considerably easier to insert into muffler boxes. As the fibres are retained they are also less likely to interfere with the closing of muffler boxes by crimping or welding. Forming the fibres into a fabric provides the ability to control accurately the density of infill of muffler boxes and the like. They also allow a much higher overall fill density of fibres to be achieved than with conventional materials and methods. Where continuous filament fibres are provided this reduces the tendency of fibres to escape into an exhaust system . Fabrics of the present invention may also be used as a catalyst support mat for catalyst brick support. Catalyst bricks cannot be welded. Fabrics can be used to retain catalysts in exhaust systems by wrapping the catalyst brick in a fabric, the wrapped catalyst brick is then placed in a part of an exhaust system, often similar to a muffler box. Where fabrics according to the present invention are employed they can be arranged to expand on initial heating to firmly secure a catalyst brick in place and take account of the differential expansion of the catalyst brick and housing. This minimises any movement of the catalyst brick, caused, for example, by vibration of an exhaust system, and so prolongs catalyst life. In order that the invention may be more clearly understood there are now described embodiments thereof, by way of example and with reference to the accompanying drawings in which:- Fig.1 shows a plan view of a fabric of the present invention; Fig.2 shows a cross-section through the fabric illustrated in Fig. 1 , taken along the line ll-ll; Fig.3 shows a similar view to Fig.2 of a similar fabric in expanded form; Fig.4 shows a transverse cross-section through a cylindrically bodied exhaust muffler, containing a fabric of the present invention in compressed form; Fig.5 shows a longitudinal cross-section through a similar muffler to that of Fig.4, containing a fabric of the present invention in expanded form; Fig.6 shows an exploded perspective view of a clam shell type muffler; Fig.7 shows a transverse cross-section through an exhaust catalyst containing a catalyst brick supported by a fabric of the present invention; and Fig.8 shows a view similar to Fig.7 where the fabric has been expanded. Referring to Figs. 1 and 2 there is shown a rochel knit fabric comprising e-glass fibres 1 retained by a polyethylene catch thread 2. The e-glass fibres 1 have been volumised, but are retained in compact form by the catch thread 2. The e-glass fibres 1 are in the form of continuous filament roving. Other knit or weave styles may be used provided that they enable volumised glass fibres to be retained by a fibre of lower softening point. The fabric has been cut from a continuous length and ends 3 and 4 have been bound with a plastic tape to prevent fraying of the fibres. The fabric has a density of approximately 600kg/m 3 . In this form the portion of fabric may be wrapped in a polythene bag to reduce exposure of persons handling the material to the glass fibres which may act as a skin irritant. The density of the fabric may be increased or decreased as required by altering the number of catch threads. Fig.3 shows a similar fabric to that of Figs. 1 and 2 following heating of the fabric to a temperature sufficient to soften the catch threads sufficiently to enable the volumised glass fibres to break free from the catch threads. When the fabric is so heated, as would occur in an exhaust system, it expands and considerably increases in volume. Fig.3 shows expanded e-glass fibres 5, which have returned to their volumised form. Fig.4 shows a transverse cross-section through a cylindrical type exhaust muffler. The muffler comprises a steel outer casing or box 6 and an inner perforated steel tube 7 which is disposed coaxially within the box 6. For mufflers of this type to work effectively it is necessary that the annular region, generally indicated at 8 between the box 6 and the perforated tube 7 is filled with a relatively uniform density of heat resistant fibres. A method of filling this region according to the invention is illustrated by Figs. 4 and 5. Fig.4 shows a fabric 9, similar to that illustrated in Figs. 1 and 2, which has been placed into the annular region 8. The fabric fills only a small proportion of the volume of the annular region 8 and is therefore easy to insert. Further, as the fabric is compact and does not have fraying ends or stray fibres the fabric does not interfere with the open ends of the box 6 during its assembly. Fig.5 shows a transverse cross-section through a similar muffler to that illustrated in Fig.4. Again, the muffler comprises a box 10 and an inner perforated tube 1 1 . End caps 1 2 and 1 3 are affixed to opposite ends respectively of the box 10 and tube 1 1 . The end caps 1 2, 1 3 close the box 10 and serve to support the tube 1 1 coaxially within the box 10. The end caps 12 and 13 are secured to both the box 10 and the tube 1 1 by welding . In use, the muffler is installed into an exhaust system by connecting pipes, shown partially at 14 and 1 5 to openings in the end caps so as to direct exhaust gases through the perforated tube 1 1 . Fig.5 shows the effect of heating a fabric, similar to that indicated as 9 in Fig.4, which is disposed in the annular region between the box 10 and tube 1 1 . On heating the catch threads of the fabric have softened allowing the fabric to expand thereby filling the annular region surrounding the perforated tube 1 1 with glass fibres 16. As the fabric is only heated when the muffler is assembled the expansion of the fibres does not interfere with the assembly of the muffler and in particular with the attachment of the end caps 1 2, 1 3 to both the box 10 and perforated tube 1 1 . Fig.6 shows an alternative clam shell type of muffler, the body of which is formed from two parts, 17 and 18. Part 17 includes a perforated tube 19 connecting apertures 20 and 21 formed in part 17. During assembly of this type of muffler it is necessary to fill the body of the muffler surrounding the perforated tube with a muffling material and then join the two portions of the muffler 17 and 1 8 by, for example, crimping or welding them together. It is difficult when assembling this type of muffler to keep the bulky muffling material away from the regions of the muffler body which must be joined by welding or crimping. This problem is solved by the present invention. For example a fabric, such as that illustrated in Figs.1 and 2, may be placed into part of the muffier 17. The fabric is compact and will occupy only a small proportion of the muffler's volume and therefore will not interfere with the joining of the two portions of the muffler 17 and 18 together. When the muffler has been assembled and installed in an exhaust system and exhaust gases are fed through the muffler this will heat the fabric causing it to expand and evenly fill the muffler with fibres as required. The present invention provides a convenient and economical way of filling exhaust mufflers with fibres. Where cylindrical mufflers are concerned the invention negates the need for specialist equipment for injecting fibres or for cardboard formers used to slide pre-formed needlefelt fabrics into the muffler. In particular the present invention allows continuous filament fibres to be conveniently inserted into mufflers. Continuous filament fibres are preferred as they are less likely to escape from the muffler through perforations in the pipe conducting exhaust gas flow. Where clam shell type mufflers are concerned the present invention conveys a considerable advantage in that on insertion the muffling fibres are in compressed form and do not interfere with the assembly of the muffler. Only when the muffler has been completed and is used for the first time are the fibres distributed throughout the muffler body. Present methods do not allow the filling of clam shell type mufflers with continuous filament fibres. Referring to Figs.7 and 8 another use for fabric according to the present invention is for catalyst brick support. Figs. 7 and 8 show a transverse cross- section through a cylindrical box 22 in which a catalyst brick 23 is installed. Fig.7 shows the arrangement as assembled. The catalyst brick 23 is supported by a rochel knit glass fibre fabric 24, with a nylon catch thread. The fabric 24 is wrapped around the brick 23. Fig.8 shows the same arrangement following heating of the fabric by passing exhaust gases through the arrangement. On heating, the catch threads of the fabric are softened allowing the glass fibres, which have previously been volumised, to expand filling the region surrounding the catalyst brick 23 with fibres 26. Following expansion of the fabric the fibres 26 hold the catalyst brick 23 firmly within the box 22 preventing movement of the catalyst brick 23. The fibres 26 also serve to insulate the catalyst brick 23 from the box 22. This allows the catalyst brick 23 to rapidly achieve its working temperature. The above embodiments are described by way of example only and many variations are possible without departing from the invention.

Claims: CLAIMS 1 . A sound muffling material comprising volumised fibres retained in compressed form by a material of lower softening temperature than the fibres. 2. A sound muffling material comprising volumised fibres retained in compressed form by a material which breaks down at a lower temperature than the fibres. 3. A sound muffling material according to either claim 1 or 2 wherein the fibres comprise glass fibres. 4. A sound muffling material according to any of claims 1 to 3 wherein the fibres comprise continuous filament fibres. 5. A sound muffling material according to claim 4 wherein the average length of the fibres is greater than 400mm. 6. A sound muffling material according to any preceding claim wherein the fibres are resistant to thermal breakdown up to 1000 °C. 7. A sound muffling material according to any preceding claim wherein the fibres are retained by a material comprising any of nylon, polypropylene, polyethylene or polyester. 8. A sound muffling material according to any preceding claim wherein the fibres are retained by a material with a softening or melting temperature below 200 °C. 9. A sound muffling material according to any preceding claim wherein the material of lower softening temperature than the fibres is itself a fibre. 10. A sound muffling material according to any preceding claim wherein the fibres are formed into a fabric retained by a thread with a lower softening/breakdown temperature. 1 1 . A sound muffling material according to claim 10 wherein the fibres are formed into a knitted fabric. 1 2. A sound muffling material according to either claim 10 or 1 1 wherein the fabric has a density of at least 60kg/m 3 in compressed form. 1 3. A sound muffling material according to either claim 10 or 1 1 wherein the fabric has a density of at least 200kg/m 3 in compressed form. 14. A sound muffling material according to either claim 10 or 1 1 wherein the fabric has a density of at least 400kg/m 3 in compressed form. 15. A sound muffling material according to either claim 10 or 1 1 wherein the fabric has a density of the order of 600kg/m 3 in compressed form. 16. A method of filling an exhaust muffler with fibres comprising the steps of placing a material according to claim 1 or any of claims 3 to 1 5 when appendant, directly or indirectly, to claim 1 into an exhaust muffler and heating the material so as to soften the retaining material to release the fibres. 17. A method of filling an exhaust muffler with fibres comprising the steps of placing a material according to claim 2 or any of claims 3 to 1 5 when appendant, directly or indirectly, to claim 2 into an exhaust muffler and heating the material so as to cause the retaining material to breakdown to release the fibres. 18. A method of mounting an exhaust catalyst brick comprising the steps of wrapping the brick in a sound muffling material according to claim 1 or any of claims 3 to 1 5 when appendant, directly or indirectly, to claim 1 and heating the material so as to soften the retaining material to release the fibres. 19. A method of mounting an exhaust catalyst brick comprising the steps of wrapping the brick in a sound muffling material according to claim 2 or any of claims 3 to 1 5 when appendant, directly or indirectly, to claim 2 and heating the material so as to cause the retaining material to breakdown to release the fibres. 20. A method according to either claim 18 or 19 further comprising the step of inserting the wrapped brick into a box, before heating the material. 21 . A method of making a sound muffling material comprising the steps of providing fibres, volumising said fibres, providing a material with a lower softening temperature than the fibres, compressing said volumised fibres and retaining said volumised fibres by means of said material with a lower softening temperature. 22. A method of making a sound muffling material comprising the steps of providing fibres, volumising said fibres, providing a material with a lower breakdown temperature than the fibres, compressing said volumised fibres and retaining said volumised fibres by means of said material with a lower breakdown temperature. 23. A method according to either claim 21 or 22 wherein the fibres are provided in the form of multi-filament strands. 24. A method according to claim 23 wherein the multi-filament strands comprise multiple fibre roving. 25. A method according to any of claims 21 to 24 wherein the fibres are volumised using compressed air operated volumising equipment. 26. A method according to any of claims 21 to 25 wherein the volumising step increases the volume occupied by the fibres by at least a factor of ten. 27. A method according to any of claims 21 to 26 further comprising the step of texturising the fibres. 28. A method according to any of claims 21 to 27 wherein the steps of compressing and retaining said fibres comprises forming the fibres into a fabric retained by a thread of lower softening temperature than the fibres. 29. A method according to claim 28 wherein the fabric is formed by knitting .

Inventors: SHAUGHNESSY STEVE, SHAUGHNESSY, STEVE
Applicants: EUROTEX THERMAL ENGINEERING LT, SHAUGHNESSY STEVE, EUROTEX THERMAL ENGINEERING LTD., SHAUGHNESSY, STEVE
Application year: 1998
Main classification: F01N1
IPC codes: F01N1, F01N3, F01N7