JP2019044592A - Method for manufacturing muffler - Google Patents

Abstract

To provide a method for manufacturing a muffler, by which a noise reduction material can be easily and almost uniformly filled with a high bulk density in a gap portion formed between a gas flow passage forming member and an outer shell forming member.SOLUTION: A method is for manufacturing a muffler 1 which comprises a gas flow passage forming member 2 with a number of small holes 2a, and an outer shell forming member 3 provided around the outer periphery of the gas flow passage forming member 2, in which a gap portion 4 is provided between the gas flow passage forming member 2 and the outer shell forming member 3. The method comprises: in a state that one end 2b in the axial direction of the gas flow passage forming member 2 in the gap portion 7 is closed, filling a sound absorption material 5 in the gap portion 7 from the other end 2c side while exhausting air in the gap portion 7 from the one end 2b side through the small holes 2a; and then, closing the other end 2c in the axial direction in the gap portion 7 while exhausting air in the gap portion 7 through the small holes 2a.SELECTED DRAWING: Figure 6

Description

  The present invention relates to a method of manufacturing a silencer.

  Conventionally, an inner pipe 101 having a large number of small holes 101a as shown in FIG. 12 as a silencer used as a motive power source with an internal combustion engine or a fuel cell as a power source, and a gap 102 on the outer periphery of this inner pipe 101 A silencer 110 is known which comprises a housing 103 arranged to comprise and a sound absorbing material 104 filled in the gap 102.

  In recent years, development of a silencer with higher muffling performance is desired from the demand for improvement of quietness of a vehicle and space saving of the silencer. As one of the methods for improving the muffling performance, it is conceivable to fill the space 102 with the sound absorbing material 104 at a high bulk density.

  As a manufacturing method of the silencer 110 in which the sound absorbing material 104 is filled with high bulk density in the gap portion 102, as shown in FIG. 13, suction means (not shown) is connected to one end of the inner pipe 101. While suctioning air out of the silencer through small holes 101a drilled in the inner pipe 101, the sound absorbing material 104 is filled in the gap 102, and thereafter, the other end of the housing 103 is necked by any processing method A manufacturing method is known in which the diameter is reduced by processing and the other end of the inner pipe 101 is joined to make the silencer 110 (see Patent Document 1).

JP, 2006-9677, A

  Since the necking process of the other end in the housing 103 of the prior art is performed as a separate process using another machine after the process of filling the sound absorbing material 104, when performing the necking process, the gap portion by the suction means Suction exhaust of the air in 102 is not performed.

  Therefore, when the suction by suction means is stopped after the sound absorbing material 104 is filled, the volume of the sound absorbing material 104 increases due to the repulsive force of the sound absorbing material 104 itself with the passage of time after filling. There is a risk of sticking out from the side opening.

  Therefore, before the necking process is performed, a process of pushing the sound absorbing material 104 that has run off into the gap 102 is required, which may make the manufacturing process complicated. In addition, when the sound absorbing material 104 is pushed into the gap 102 from the other end side, the density of the sound absorbing material 104 in the gap 102 becomes nonuniform, which may lower the muffling performance.

  Then, this invention aims at proposing the manufacturing method of the silencer which solved said problem.

In order to solve the above-mentioned subject, the present invention is provided with the gas channel formation member provided with many small holes, and the outer shell formation member provided in the perimeter of the gas channel formation member, and the gas channel formation A method of manufacturing a silencer, wherein a gap is provided between a member and an outer shell forming member,
In a state where one end of the gas flow path forming member in the gap in the axial direction is closed, the air in the gap is exhausted from the one end through the small hole, and the sound absorbing material is inserted into the gap from the other end. Fill and
Thereafter, the other end portion in the axial direction of the gap portion is closed while exhausting air in the gap portion through the small hole.

Further, the other end of the gas flow path forming member is closed, and air in the gap is exhausted from one end side of the gas flow path forming member.
The other end in the axial direction in the gap may be closed.

Further, the inside of the gas flow path forming member is divided in the axial center direction by the dividing member, and the air in the gap is exhausted from one end side of the gas flow path forming member,
The other end in the axial direction in the gap may be closed.

The air supply unit supplies air to the inside from the other end side of the gas flow path forming member, and exhausts air in the gap from the one end side of the gas flow path forming member.
The other end in the axial direction in the gap may be closed.

  According to the present invention, the other end of the gap in the axial direction is closed while the air in the gap is exhausted through the small holes of the gas flow path forming member, so that the sound absorbing material leaks out from the gap. Can be suppressed, and the sound absorbing material can be filled in the gap with a substantially uniform and high bulk density.

BRIEF DESCRIPTION OF THE DRAWINGS The longitudinal cross-sectional view of the silencer based on Example 1 of this invention. BRIEF DESCRIPTION OF THE DRAWINGS The longitudinal cross-sectional view of the intermediate product which concerns on Example 1 of this invention. The longitudinal cross-sectional view explaining the method to be filled with a sound absorbing material in a clearance part from the state of FIG. The longitudinal cross-sectional view of the state which filled the sound absorbing material in the clearance gap part in the intermediate product of FIG. The longitudinal cross-sectional view of the state which attached the intermediate product of FIG. 4 to another processing apparatus. The longitudinal cross-sectional view of the state which connected the suction nozzle from the state of FIG. The longitudinal cross-sectional view of the state which gave the necking process from the state of FIG. The longitudinal cross-sectional view of the state which took out the silencer of FIG. 1 from the state of FIG. The longitudinal cross-sectional view for demonstrating the manufacturing method of the silencer which concerns on Example 2 of this invention. The longitudinal cross-sectional view for demonstrating the manufacturing method of the silencer which concerns on Example 3 of this invention. The longitudinal cross-sectional view of the silencer concerning Example 4 of the present invention. The longitudinal cross-sectional view of the silencer of a prior art. FIG. 13 is a longitudinal cross-sectional view for explaining the method for manufacturing the silencer in FIG. 12.

  A mode for carrying out the present invention will be described based on an embodiment shown in the drawings.

Example 1
FIG. 1 shows a longitudinal sectional view of a silencer 1 according to a first embodiment of the present invention.

  As shown in FIG. 1, the silencer 1 is provided on the outer periphery of the gas flow path forming member 2 and the gas flow path forming member 2 constituting a cylindrical inner pipe in which a large number of small holes 2 a are bored. It has the shell forming member 3 which comprises a housing.

  The outer shell forming member 3 has a cylindrical general portion 3a having the same axial core as the axial core XX of the gas flow passage forming member 2 and having an inner diameter larger than the inner diameter of the gas flow passage forming member 2, The reduced diameter portions 3b and 3c whose diameter is gradually reduced toward the outer side in the axial center XX direction are formed at both ends of the axial direction XX of the gas flow path forming member 2 in the portion 3a. The diameter-reduced portions 3b and 3c are respectively fitted to the outer peripheral surfaces of the both end portions 2b and 2c in the axial center XX direction of the gas flow path forming member 2.

  A gap 4 is formed between the outer shell forming member 3 and the gas flow path forming member 2, and the sound absorbing material 5 is substantially uniformly filled in the gap 4 with a high bulk density.

  Next, a method of manufacturing the silencer 1 will be described.

  First, as shown in FIG. 2, an intermediate having a gas flow path forming member 2, a quasi outer shell forming member 6, and a gap portion 7 formed between the gas flow path forming member 2 and the semi outer shell forming member 6. Form article 10 The quasi-outer shell forming member 6 has a cylindrical general portion 6a having an inner diameter larger than the outer diameter of the gas flow passage forming member 2, and in the axial center XX direction of the gas flow passage forming member 2 in the general portion 6a. A reduced diameter portion 6b is formed at one end portion so as to be gradually reduced toward the outer side in the axial center XX direction. One end of the gap 7 is closed, and the other end is open. The inside of the gas flow path forming member 2 and the gap portion 7 are in communication via small holes 2 a formed in the gas flow path forming member 2.

  Next, as shown in FIG. 3, after fixing the gas flow path forming member 2 and the quasi outer shell forming member 6 by fixing means (not shown), the partition body 11 which is a dividing member inside the gas flow path forming member 2. Are slidably inserted in the axial center XX direction.

  A rod 12 protruding outward from the other end of the gas flow path forming member 2 is fixed to the partition 11, and the partition 11 is a gas by an axial core XX direction moving unit (not shown) connected to the rod 12. It can move in the axial center XX direction of the flow path forming member 2.

  Next, a suction unit (not shown) such as a fan is connected to one end 2 b of the gas flow path forming member 2. When the suction portion is driven, air in the gap portion 7 is sucked from the one end portion 2b to the outside as indicated by the arrows through the small holes 2a existing between the partition body 11 and the suction portion divided by the partition body 11 Exhausted.

  Next, the sound absorbing material 5 in which long glass fibers are converged with a binder is supplied to the blowing nozzle 13 from the other end side opening 7a of the gap 7 together with the compressed air supplied from the compressed air supply unit (not shown). As shown in FIG. 3, the sound absorbing material 5 is supplied from the other end side opening 7 a of the gap 7 into the gap 7 together with the compressed air from the blowing nozzle 13. At the time of the supply, the sound absorbing material 5 is disintegrated by the compressed air and gradually filled into the gap 7 from one end side.

  In addition to the long fibers of glass, a sound absorbing material made of an arbitrary material such as ceramics, metal, or resin can be used as the sound absorbing material 5. In addition, the length and the thickness of the fiber are set arbitrarily.

  Next, the blow-in nozzle 13 is gradually moved along the inner wall surface of the gas flow path forming member 2 from the one end side to the other end side by the axial direction moving means (not shown). Further, the sound absorbing material 5 is supplied into the gap 7, and as shown in FIG. 4, the sound absorbing material 5 is filled in the gap 7 by a predetermined amount.

  By the method of filling the sound absorbing material 5 described above, the sound absorbing material 5 can be filled in the gap 7 with a high bulk density. Although it is preferable to fill the sound absorbing material 5 while moving the partition 11, it is preferable to fill the sound absorbing material 5 in the gap 7 without moving the partition 11 or without using the partition 11. May be

  Next, the intermediate product 20 as shown in FIG. 4 filled with the sound absorbing material 5 is removed from the fixing means (not shown) and fixed to the clamp jig 22 in another processing device 21 as shown in FIG. Do.

  The processing device 21 has a suction unit 24 and a necking unit 25. The suction unit 24 has a suction nozzle 24 a and is provided near one end side of the intermediate product 20. The suction nozzle 24a can be moved in the axis XX direction (vertical direction in FIG. 5) with respect to the one end 2b side of the gas flow path forming member 2 in the intermediate product 20 by the moving unit 26 such as an air cylinder. It is supposed to be.

  Further, the necking portion 25 has a cored bar 28 and a spinning roller 29 and is provided in the vicinity of the other end side of the intermediate product 20. The cored bar 28 is in the axial center XX direction with respect to the other end 2c side of the gas flow path forming member 2 in the intermediate product 20 by moving parts such as an air cylinder (not shown) (vertical direction in FIG. 5) It can be moved. In addition, the spinning roller 29 is moved in the axial direction XX with respect to the other end 2c side of the gas flow path forming member 2 in the intermediate product 20 by a moving unit such as an air cylinder (not shown). It can move in the radial direction centering on.

  Next, as shown in FIG. 6, the suction nozzle 24 a is moved to the one end 2 b side of the gas flow path forming member 2 by the moving unit 26, and the tip end of the suction nozzle 24 a is one end of the gas flow path forming member 2. It inserts in the part 2b, it fits, and mutually connects mutually airtightly.

  Next, the suction unit 24 is driven to suck and exhaust the air in the gap 7 to the outside of the intermediate product 20 through the small holes 2a. As a result, the sound absorbing material 5 in the gap 7 is drawn to the one end side (the lower side in the drawing), and the sound absorbing material 5 can be prevented from coming out from the inside of the gap 7. There is no need to push it in.

  Next, as shown in FIG. 7, in a state where the suction unit 24 is driven and the air in the gap 7 is sucked and exhausted, the core metal 28 of the necking unit 25 is formed with a gas flow path by a moving unit (not shown). It is moved to the other end 2c side of the member 2 and inserted into the other end 2c of the gas flow path forming member 2, and the other end 2c is closed and spinning is performed by the spinning roller 29 The diameter of the other end 6 c of the outer shell forming member 6 is reduced toward the outer side in the axial center XX direction, and the inner surface of the outer end is the outer surface of the other end 2 c of the gas flow path forming member 2. The diameter is reduced to form a diameter-reduced portion 6 d so as to be joined, and the other end side of the gap portion 7 is closed.

  Inserting the cored bar 28 into the other end 2c of the gas flow path forming member 2 improves the necking processing accuracy, and the cored bar 28 blocks the other end 2c of the gas flow path forming member 2 Thus, the supply area of air from the outside into the gap 7 is reduced, and the suction force of the suction unit 24 is also improved.

  Next, the suction by the suction unit 24 is stopped, and the moving unit 26 separates the suction nozzle 24a from the one end 2b side of the gas flow path forming member 2, and the necking unit 25 is moved by the moving unit (not shown) The muffler 1 of the present invention is obtained by separating it from the other end 2 c side of the path forming member 2 and removing it from the clamp jig 22. After the suction by the suction unit 24 is completed, the sound absorbing material 5 spontaneously restores itself, and the entire space in the gap 4 is substantially uniform and has a high bulk density.

  As described above, the silencer 1 of the present embodiment can suppress the protrusion of the sound absorbing material at the time of necking by the above-described configuration and operation, thereby eliminating the need for the process of pushing in as in the prior art and simplifying the manufacturing process. Can be In addition, since the sound absorbing material 5 spontaneously restores itself after the end of suction, the sound absorbing material 5 can be filled substantially uniformly throughout the gap 4 with a high bulk density, and the muffling performance of the silencer 1 is improved. .

  In the above embodiment, the cored bar 28 is inserted into the other end portion 2c of the gas flow path forming member 2 in a state where the air in the gap portion 7 is sucked and exhausted by the suction portion 24. After being inserted into the other end 2 c of the flow path forming member 2, suction by the suction unit 24 may be started.

  In the above embodiment, the diameter of the other end 6c of the semi-shell forming member 6 is reduced by spinning. However, the other end of the quasi-shell forming member 6 is optionally necked by pressing other than spinning. The diameter of the portion 6c can be reduced.

  Further, when reducing the diameter of the other end 6c of the semi-shell forming member 6 by necking while suctioning by the suction portion 24, the core metal 28 blocks the other end 2c of the gas flow path forming member 2 Although it is preferable to do, it does not have to be closed.

  Further, in the above embodiment, the process of filling the sound absorbing material 5 in the gap 7 and the process of reducing the diameter of the other end 6c of the outer shell forming member 6 by necking are performed using different processing machines. However, it may be performed using one processing machine.

Example 2
In the first embodiment, the core metal 28 is used to reduce the diameter of the other end 6 c of the semi-shell forming member 6 by necking while suctioning by the suction unit 24. The other end 2c of the valve is closed to reduce the air supply area from the outside into the gap 7. However, as shown in FIG. By inserting it, the supply area of air from the outside into the gap 7 may be reduced.

  The partition 31 closes the inside of the gas flow path forming member 2 and is formed in a size and a shape that can divide the gas flow path forming member 2 into two in the axial center XX direction. Further, the partition body 31 is provided slidably in the direction of the axis XX in the gas flow path forming member 2, and as shown in FIG. It is done. The rod 32 is penetrated through the central portion of the cored bar 28A in the direction of the axis XX. The rod 32 may be fixed to the cored bar 28A, or the rod 32 and the partition 31 may be fixed to the cored bar 28A by an axial movement unit (not shown). It may be made movable in the -X direction.

  The other structure is the same as that of the first embodiment, and thus the description thereof is omitted.

  The same effects as in the first embodiment can be obtained in the second embodiment.

  In the second embodiment, when suction is further performed by the suction portion 24, the air in the gap portion 7 is positioned closer to the one end portion 2b than the partition body 31 in the gas flow path forming member 2, as shown in FIG. The suction and exhaustion can be performed through the small holes 2a, and the sound absorbing material 5 can be reliably drawn to the one end 2b side.

[Example 3]
The third embodiment is a modification of the first and second embodiments, and as shown in FIG. 10, the other end 6c of the outer shell forming member 6 is reduced in diameter by necking while suctioning by the suction portion 24. At this time, air may be forcibly supplied from the other end 2 c of the gas flow path forming member 2 into the gas flow path forming member 2 as shown by arrows by an air supply unit (not shown).

  An air flow passage 40 is penetrated in the central axis XX direction at a central portion of the cored bar 28B, and is supplied into the gas flow path forming member 2 through the air flow passage 40. .

  The other structure is the same as that of the first and second embodiments, so that the description thereof is omitted.

  Also in the third embodiment, the same effect as the first and second embodiments can be obtained.

  Further, in the third embodiment, air is forcibly supplied into the gas flow path forming member 2 from the other end 2 c of the gas flow path forming member 2 by the air supply portion, so that the gap portion 7 is formed. The position at which the internal air flows into the gas flow path forming member 2 can be moved to the one end 2b side of the gas flow path forming member 2, and the sound absorbing material 5 can be reliably drawn to the one end 2b side.

Example 4
In the silencer 1 in the first to third embodiments, the reduced diameter portions 3b and 3c are formed at both ends in the axial center XX direction of the outer shell forming member 3, and the reduced diameter portions 3b and 3c Although both sides in the axis XX direction are closed, as shown in FIG. 11, the outer shell forming member 50 is formed in a cylindrical shape with both ends open, and the openings at both ends are end plates By closing with 52, 53, both sides in the axial center XX direction of the gap portion 4 in the silencer 51 may be closed.

  Parts corresponding to the quasi-outer shell forming member 6 and the intermediate products 10 and 20 in the first to third embodiments close the one end side of the gap 7 using the end plate 52 instead of the diameter reducing portion 3b. Configure.

  Further, the end plate 52 is connected and fixed to the other end side opening 7 a of the gap 7 while sucking and evacuating the air in the gap 7 by the suction portion 24, and the other end of the gap 7 is closed.

  The other structure is the same as that of the first to third embodiments, and thus the description thereof is omitted.

  Also in the fourth embodiment, the same effect as that of the first to third embodiments can be obtained.

1 Silencer
Reference Signs List 2 gas flow path forming member 2a small hole 3, 50 outer shell forming member 4, 7 gap portion 31 division member

Claims (4)

A gas flow path forming member provided with a large number of small holes, and an outer shell forming member provided on the outer periphery of the gas flow path forming member, and a gap is formed between the gas flow path forming member and the outer shell forming member It is a manufacturing method of the silencer provided,
In a state where one end of the gas flow path forming member in the gap in the axial direction is closed, the air in the gap is exhausted from the one end through the small hole, and the sound absorbing material is inserted into the gap from the other end. Fill and
Thereafter, the other end of the gap in the axial direction is closed while exhausting air in the gap through the small hole. The other end of the gas flow path forming member is closed, and air in the gap is exhausted from the one end side of the gas flow path forming member,
The manufacturing method of the silencer according to claim 1, wherein the other end in the axial direction in the gap portion is closed. The division member divides the inside of the gas flow path forming member in the axial direction of the gas flow path forming member, and exhausts air in the gap from one end side of the gas flow path forming member,
The manufacturing method of the silencer according to claim 1, wherein the other end in the axial direction in the gap portion is closed. The air supply unit supplies air to the inside from the other end side of the gas flow path forming member and exhausts air in the gap from the one end side of the gas flow path forming member.
The manufacturing method of the silencer according to claim 1, wherein the other end in the axial direction in the gap portion is closed.

Images