SYSTEMS FOR AND METHODS OF FILLING MUFFLERS WITH FIBROUS MATERIAL

Abstract

Systems for and methods of evacuating air from a muffler while it is being filled with a fibrous material are disclosed.

Claims

1. A system for filling a cavity of a muffler with a fibrous material, the system comprising: a muffler body having a first open end and a second open end; a perforated insert; a texturizing nozzle; and a vacuum source; wherein the muffler body includes a baffle that divides at least a portion of the cavity of the muffler into a first chamber and a second chamber; wherein a pipe extends between the first chamber and the second chamber, the portion of the pipe in the first chamber lacking perforations; wherein the texturizing nozzle is operable to introduce compressed air and the fibrous material into the first chamber; wherein the perforated insert is operable to interface with the first open end of the muffler body to fit over a portion of the pipe in the first chamber; and wherein the vacuum source is operable to interface with the second open end of the muffler body to draw the compressed air from the first chamber, through the perforated insert, and into the pipe.

2. The system of claim 1, further comprising: a first member for interfacing with the first open end of the muffler body; and a second member for interfacing with the second open end of the muffler body; wherein the first member and the second member are operable to hold the muffler body in place therebetween.

3. The system of claim 1, wherein an outlet opening of the texturizing nozzle extends past the perforated insert and into the first chamber.

4. The system of claim 1, wherein an outlet opening of the texturizing nozzle extends through the perforated insert and into the first chamber.

5. The system of claim 1, wherein a first open end of the pipe is located in the first chamber; wherein a second open end of the pipe is located in the second chamber; wherein the perforated insert allows the compressed air in the first chamber to pass therethrough and into the first open end of the pipe; and wherein the perforated insert prevents the fibrous material in the first chamber from passing therethrough and into the first open end of the pipe.

6. The system of claim 1, wherein the vacuum source is operable to draw the compressed air through the pipe and out of the muffler body.

7. The system of claim 1, wherein at least a portion of the perforated insert fits into the first chamber of the muffler body.

8. The system of claim 1, wherein the perforated member is positioned at the same location in the cavity of the muffler when filling the first chamber with the fibrous material as when filling the second chamber with the fibrous material.

9. The system of claim 1, wherein the perforated member is positioned at a first location in the cavity of the muffler when filling the first chamber with the fibrous material; and wherein the perforated member is positioned at a second location in the cavity of the muffler when filling the second chamber with the fibrous material.

10. The system of claim 1, wherein the fibrous material is texturized fiberglass.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0045] The general inventive concepts as well as embodiments and advantages thereof are described below in greater detail, by way of example, with reference to the drawings in which:

[0046] FIG. 1 is a diagram of a conventional filling system for filling a muffler having internal perforations with texturized fibrous material.

[0047] FIG. 2 is a diagram of the filling system of FIG. 1 attempting to fill a muffler lacking internal perforations with texturized fibrous material.

[0048] FIG. 3 is a diagram of a filling system, according to one exemplary embodiment, for filling a muffler lacking internal perforations with texturized fibrous material.

[0049] FIGS. 4A-4C illustrate a perforated insert, according to one exemplary embodiment. FIG. 4A is a diagram showing a perspective view of the perforated insert. FIG. 4B is a diagram showing a bottom plan view of the perforated insert. FIG. 4C is a diagram showing a perspective view of the perforated insert being positioned within a muffler.

[0050] FIG. 5 is a flowchart of a filling method, according to one exemplary embodiment, for filling a muffler lacking internal perforations with texturized fibrous material.

DETAILED DESCRIPTION

[0051] While the general inventive concepts are susceptible of embodiment in many different forms, there are shown in the drawings, and will be described herein in detail, specific embodiments thereof with the understanding that the present disclosure is to be considered as an exemplification of the principles of the general inventive concepts. Accordingly, the general inventive concepts are not intended to be limited to the specific embodiments illustrated herein.

[0052] Referring now to the drawings, there is shown in FIG. 3 a diagram to illustrate various aspects of the general inventive concepts. In FIG. 3, a filling system 300 allows for suitable evacuation of air being introduced into a muffler during a filling operation, even in the absence of perforations (or suitable perforations) in the pipes or baffles therein.

[0053] As shown in FIG. 3, the filling system 300 introduces texturized fibrous material 102 into a muffler cavity 204 via an opening 206 on a first end 208 of a muffler 210, while a partial vacuum (ΔP) is created at an opening 212 on a second end 214 of the muffler 210 (opposite the first end 208) by a vacuum source 120.

[0054] The muffler 210 includes a body 230 with two pipes 232 extending at least partially through the body 230. The pipes 232 can be inlet and/or outlet pipes for carrying the exhaust gases through the muffler 210. Each pipe 232 lacks any perforations (or lacks perforations suitable for sufficiently evacuating the amount of air being introduced into the muffler 210 during the filling operation). The muffler 210 also includes a baffle 234 that divides the muffler cavity 204 into a first chamber 236 and a second chamber 238. The baffle 234 lacks any perforations (or lacks perforations suitable for sufficiently evacuating the amount of air being introduced into the muffler 210 during the filling operation). In the context of the filling system 300, “sufficient evacuation” of the air being introduced into the muffler 210 during the filling operation means that the rate at which the air exits the muffler cavity 204 is greater than or equal to the rate at which the air is being introduced into the muffler cavity 204.

[0055] During the filling operation, the muffler 210 is held in place between a first member 122 that interfaces with the first end 208 and a second member 124 that interfaces with the second end 214. Because a body 230 of the muffler 210 is in a partially assembled state, i.e., end caps have yet to be joined to the body 230, the first member 122 interfaces with (e.g., fits into or otherwise covers) the open end 206 of the body 230 and the second member 124 interfaces with (e.g., fits into or otherwise covers) the open end 212 of the body 230. In particular, the first member 122 forms a substantially air-tight interface with the body 230 at the first end 208 and the second member 124 forms a substantially air-tight interface with the body 230 at the second end 214.

[0056] The first member 122 includes openings through which texturizing nozzles 150 can be inserted for delivery of the texturized fibrous material 102 into the muffler cavity 204. The first member 122 also fits around or covers any ends 252 of the pipes 232 in proximity to the first end 208 of the muffler 210, wherein the ends 252 can also be separately plugged to prevent any of the texturized fibrous material 102 from being drawn therein.

[0057] The second member 124 includes openings through which the vacuum source 120 can interface with any ends 254 of the pipes 232 in proximity to the second end 214 of the muffler 210. One of ordinary skill in the art will appreciate that the vacuum source 120 could interface with any one or more suitable openings in the muffler 210, such as the entire opening 212 at the second end 214 of the muffler 210. In conventional implementations, as described above, the vacuum source 120 is unable to effectively evacuate air from the inner cavity 204 (e.g., the first chamber 236 being filled with the texturized fibrous material 102), including air introduced by the filling nozzles 150, because the lack of perforations (or the lack of suitable perforations) means the air in the inner cavity 204 does not have a sufficient flow path through the pipes 232 and out of the muffler 210 during the filling operation.

[0058] To address this problem, the filling system 300 uses a perforated member 360. The perforated member 360 includes a body defining an inner cavity 362. At least a portion of the body, for example, a lower surface thereof, includes a plurality of perforations 364. In general, these perforations 364 are sized to allow air to pass therethrough while preventing the texturized fibrous material 102 from doing so. For example, while the fibers of the texturized fibrous material 102 have a relatively small diameter (e.g., 20 μm), there is a “bridging effect” that prevents the fibers from readily flowing through the perforations 364. Any number of perforations 364 may be used, as long as the perforations 364 allow for “sufficient evacuation” of the air being introduced into the muffler 210 during the filling operation. In some exemplary embodiments, the perforated member 360 includes at least 50 perforations.

[0059] In the filling system 300, the ends 252 of the pipes 232 are not plugged. Instead, the perforated member 360 is sized and shaped to at least partially fit into the muffler body 230 via the upper opening 206. In this manner, the ends 252 of the pipes 232 are received within the inner cavity 362 of the perforated member 360. As air is drawn out of the inner cavity 204 through the ends 254 of the pipes 232 by the vacuum source 120, the air within the chamber being filled (i.e., the first chamber 236) is likewise drawn through the perforations 364 in the perforated member 360, into the ends 252 of the pipes 232, through the pipes 252, and out the ends 254 of the pipes 232 as it exits the muffler 210. Thus, by virtue of the perforated member 360, the air being introduced into the inner cavity 204 by the texturizing nozzles 150 has a flow path out of the muffler 210. Various portions of the flow path are illustrated in FIG. 3 by dashed arrows.

[0060] By providing a sufficient flow path out of the muffler 210 for the air introduced into the inner cavity 204 by the texturizing nozzles 150, the perforated member 360 facilitates the controlled distribution of the texturized fibrous material 102 within the inner cavity 204. In other words, the perforated member 360 prevents the air being introduced into the inner cavity 204 from disrupting the gradual build up of the texturized fibrous material 102 in the chamber being filled (i.e., the first chamber 236). Thus, an even distribution of the texturized fibrous material 102 within the first chamber 236 to a desired density can be readily achieved, notwithstanding the lack of perforations (or adequate perforations) in the pipes 232 and/or the baffle 234.

[0061] The texturized fibrous material 102 may be any material suitable for absorbing and attenuating the sounds produced by exhaust gases, such as those produced by an internal combustion engine. In some embodiments, the texturized fibrous material 102 is fiberglass. In some embodiments, the fiberglass includes one of E-glass filaments and S-glass filaments. The texturized fibrous material 102 will generally have a particular density (e.g., between 50 g/L and 200 g/L).

[0062] The perforated member 360 may be made from any material suitable to withstand the filling operation. In one exemplary embodiment, the perforated member 360 is made of metal (e.g., steel, aluminum).

[0063] In some exemplary embodiments, the perforated member 360 is integrated with the first member 122.

[0064] In some exemplary embodiments, the filling system 300 uses multiple discrete perforated members 360 during a filling operation, for example, with a first perforated member 360 being placed around a first pipe within the chamber being filled and a second perforated member 360 being placed around a second pipe within the chamber being filled.

[0065] As noted above, muffler designs encompass a wide variety of shapes, sizes, and configurations. The general inventive concepts are applicable across various muffler designs (e.g., variations in the number, size, shape, and configuration of pipes and baffles). In some exemplary embodiments, the filling system 300 includes a plurality of different perforated members, each of the perforated members corresponding to a specific muffler design or configuration.

[0066] The general inventive concepts are also applicable across various filling systems (e.g., variations in the number, size, shape, and configuration of holding members). In some exemplary embodiments, the filling system 300 includes a plurality of different holding members, each of the holding members corresponding to a specific muffler design or configuration.

[0067] In some exemplary embodiments, the introduction of the texturized fibrous material 102 occurs on a side of the muffler opposite a side in which the vacuum source 120 is interfaced with the muffler. In some exemplary embodiments, the introduction of the texturized fibrous material 102 occurs on the same side of the muffler at which the vacuum source 120 is interfaced. In some exemplary embodiments, the introduction of the texturized fibrous material 102 occurs on a side adjacent to the side in which the vacuum source 120 is interfaced with the muffler.

[0068] Furthermore, while there may be perforations in the pipes and/or baffles within a muffler, those perforations may not be in or adjacent an area of the muffler (i.e., a specific chamber to be filled) where they avoid the aforementioned problems associated with a lack of perforations (or a lack of suitable perforations). The perforated member 360 would also be useful in such a muffler to achieve or otherwise improve an effective filling operation.

[0069] An exemplary embodiment of a perforated member 400 is shown in FIGS. 4A-4C. The perforated member 400 corresponds to the design of a specific muffler 450 (see FIG. 4C). The muffler 450 includes a muffler body 460 having an opening 462 at one end 464 thereof. The muffler 450 also includes a single baffle (not shown). The baffle divides an inner cavity of the muffler 450 into a first chamber and a second chamber. This particular muffler 450 includes three pipes (i.e., a first pipe 452, a second pipe 454, and a third pipe 456) that extend into or through a chamber to be filled with texturized fibrous material (i.e., the first chamber).

[0070] The perforated member 400 is a removable insert that includes a body 402 having a lower surface 404 and one or more side walls 406 that define an inner cavity 408 of the insert. In some exemplary embodiments, the body 402 further includes an upper surface (not shown), such as a lid or cover, that encloses the inner cavity 408. The upper surface will typically be parallel to the lower surface 404. In some exemplary embodiments, a holding member (e.g., the first member 122) interfaces with the perforated member 400 to enclose the inner cavity 408.

[0071] Three openings (i.e., a first opening 412, a second opening 414, and a third opening 416) are formed in the lower surface 404 of the body 402. Additionally, a plurality of perforations 418 are formed in the lower surface 404 of the body 402. The perforations are sized and/or shaped to allow the air being introduced by the filling process to pass therethrough while preventing the filling material (e.g., the texturized fibrous material 102) from doing so.

[0072] In some exemplary embodiments, one or more posts 420 are formed on the body 402. The posts 420 are hollow and extend from the lower surface 404 of the body 402 to the upper surface of the body 402 or, alternatively, to a height similar to the side walls 406 of the body 402. The posts 420 can be used, for example, to pass a filling nozzle (e.g., the texturizing nozzle 150) extending through a holding member (e.g., the first member 122) through the perforated member 400 and into the chamber to be filled with texturized fibrous material (i.e., the first chamber). In other exemplary embodiments, the filling nozzle can be inserted into the chamber to be filled without passing through the perforated member 400.

[0073] As shown in FIG. 4C, the perforated member 400 is sized and shaped to at least partially fit into the first chamber through the opening 462. Once so positioned, the first pipe 452, the second pipe 454, and the third pipe 456 of the muffler 450 extend through the corresponding openings (i.e., the first opening 412, the second opening 414, and the third opening 416) in the perforated member 400 such that the ends of the pipes terminate within the inner cavity 408 of the perforated member 400. The side walls 406 of the body 402 may be of any height, but should extend above the ends of the pipes received in the inner cavity 408 so that a first air gap is created above the ends of the pipes. A second air gap should exist between the lower surface 404 of the body 402 and any structure (e.g., the baffle) situated below the perforated member 400. In some exemplary embodiments, the second air gap should have a height of at least 50 mm.

[0074] In this manner, the perforations 418 in the perforated member 400 contribute to a flow path by which air introduced into the first chamber during the filling operation can be drawn (e.g., by a vacuum source) through the perforated member 400, into the inner cavity 408, and then through the pipes on the way out of the muffler.

[0075] By providing a sufficient flow path out of the muffler 450 for the air introduced into the first chamber by the filling nozzle, the perforated member 400 facilitates the controlled distribution of the filling material within the first chamber. In other words, the perforated member 400 prevents the air being introduced into the first chamber from disrupting the gradual build up of the filling material in the first chamber. Thus, an even distribution of the filling material within the first chamber to a desired density can be readily achieved, notwithstanding the lack of perforations (or adequate perforations) in the pipes and/or the baffle. Likewise, sufficient coverage of the perforations 418 by the filling material is also readily achieved, notwithstanding the lack of perforations (or adequate perforations) in the pipes and/or the baffle.

[0076] The general inventive concepts also encompass the perforated insert (e.g., the perforated member 360, the perforated member 400) independent of any specific filling system implementation.

[0077] The general inventive concepts also encompass methods that correspond to the exemplary filling systems described above, such as the filling system 300 shown in FIG. 3.

[0078] For example, there is shown in FIG. 5 a flowchart to illustrate a filling method 500, according to one exemplary embodiment.

[0079] According to the filling method 500, a muffler to be filled is typically positioned or otherwise held in a semi-assembled state (e.g., without the attachment of one or more final pieces, such as the end caps) in step 502. Prior to commencing the filling operation, a perforated member (e.g., the perforated member 400) is inserted into the muffler in step 504.

[0080] With the perforated member held in place, the filling operation commences in step 506. The filling operation involves the introduction of a filling material (e.g., the texturized fibrous material 102) into a cavity or chamber of the muffler to be filled. In conjunction with the filling operation, air introduced by the filling operation is evacuated from the muffler in step 508. For example, a suction device (e.g., the vacuum source 120) can be used to draw air through the perforated member and out of the muffler. Typically, step 508 is initiated before step 506. In some exemplary embodiments, steps 506 and 508 are started at the same time. In some exemplary embodiments, steps 506 and 508 are started in relatively quick succession, for example, with step 508 starting at least 1 second before step 506. In general, step 508 occurs for at least as long as step 506 is being performed.

[0081] Once the cavity/chamber of the muffler has been adequately filled, the filling operation ceases and the muffler is released by the filling station in step 510. Thereafter, the perforated member can be removed from the muffler, so that the muffler can undergo final assembly in step 512. Final assembly of the muffler can include, for example, affixing (e.g., welding, crimping) the end caps onto the body of the muffler.

[0082] It will be appreciated that some aspects of the illustrated muffler assemblies are, in large measure, known in the art, and these aspects may be omitted for purposes of more readily illustrating various aspects of the general inventive concepts. Furthermore, the scope of the general inventive concepts are not intended to be limited to the particular exemplary embodiments shown and described herein. From the disclosure given, those skilled in the art will not only understand the general inventive concepts and their attendant advantages, but will also find apparent various changes and modifications to the methods and systems disclosed. It is sought, therefore, to cover all such changes and modifications as fall within the spirit and scope of the general inventive concepts, as described and claimed herein, and any equivalents thereof. For example, while the exemplary embodiments shown and described herein often reference a spun muffler design, the general inventive concepts are not so limited and instead are applicable to any muffler configuration in which at least two housing portions are mechanically joined to one another as part of the muffler assembly.