Muffler, muffler insert, and methods and apparatus for making
IPC분류정보
국가/구분
United States(US) Patent
등록
국제특허분류(IPC7판)
F01N-001/10
F01N-001/24
B29C-053/58
B29C-065/00
출원번호
US-0803879
(2010-07-07)
등록번호
US-8336673
(2012-12-25)
발명자
/ 주소
Zanzie, Daniel
Bauer, Charles L.
출원인 / 주소
Bay Industries Inc.
대리인 / 주소
Wilhelm, Thomas D.
인용정보
피인용 횟수 :
0인용 특허 :
30
초록▼
A fiberglass-binder insert is made by fabricating a shape-constant, cured fiberglass-binder mixture, into a shape-constant insert core, and shrink-wrapping the core while leaving exposed any bore which extends into the core. The core is fabricated by mixing fiberglass and uncured binder in a mixer,
A fiberglass-binder insert is made by fabricating a shape-constant, cured fiberglass-binder mixture, into a shape-constant insert core, and shrink-wrapping the core while leaving exposed any bore which extends into the core. The core is fabricated by mixing fiberglass and uncured binder in a mixer, dropping the mixture into a conforming guide such as a funnel, and moving the mixture through the conforming guide and into a mold. A tamper can tamp the mixture to move the mixture from the conforming guide into the mold, and to distribute portions of the mixture vertically in the mold. Rotation of the mold effects circumferential distribution of the mixture in the mold. The mixture in the mold is heated to cure the binder, thus to establish a fixed shape of the resultant core product. A shrink film is shrunk about the core, providing apertures in the shrunk film at bore openings in the core.
대표청구항▼
1. A method of charging a cavity in a mold with a fiberglass-binder mixture, the method comprising: (a) making a mixture of fiberglass strand material and binder in a mixer;(b) moving a charge of the fiberglass-binder mixture from the mixer into a conforming guide, wherein the mixture in the conform
1. A method of charging a cavity in a mold with a fiberglass-binder mixture, the method comprising: (a) making a mixture of fiberglass strand material and binder in a mixer;(b) moving a charge of the fiberglass-binder mixture from the mixer into a conforming guide, wherein the mixture in the conforming guide has a relatively low density fluffy characteristic;(c) as a first consolidating operation, driving a driver and engaging the low density fiberglass-binder mixture thereby and driving the driver, and at least a portion of the low density mixture, into the mold; and(d) withdrawing the driver from the mold. 2. A method as in claim 1, further comprising, while moving the charge of the mixture from the mixer into the conforming guide, rotating the entirety of the conforming guide, and optionally rotating the mold. 3. A method as in claim 1, the consolidating operation comprising moving the driver vertically with respect to the conforming guide and thereby distributing the mixture both vertically and laterally in the mold. 4. A method as in claim 1 wherein the conforming guide is a funnel, the funnel being displaced, across open space, from the mixer. 5. A molded fiberglass product made using a method as in claim 1. 6. A muffler assembly comprising a muffler insert made according to a method as in claim 1. 7. A method of charging a cavity in a mold with a fiberglass-binder mixture, the method comprising: (a) making a mixture of fiberglass strand material and binder in a mixer;(b) moving an initial charge of the fiberglass-binder mixture from the mixer into a conforming guide; and(c) as a first consolidating operation, driving a driver and thereby engaging the fiberglass-binder mixture and driving the driver, and at least a portion of the mixture, into the mold; and(d) prior to introducing a second charge of the mixture into the mold, executing a second consolidating operation on the same initial charge of the mixture, including driving a driver against the mixture a second time. 8. A method of fabricating a glass fiber strand material molded product comprising (a) charging a mold as in claim 7;(b) curing the binder in the mold, thus binding the glass fiber strand material into a cohesive molded product having generally the shape of the mold cavity;(c) removing the molded product from the mold; and(d) after removing the molded product from the mold, enclosing the molded product in a plastic shrink film and heat shrinking the film about an outwardly-facing surface of the molded fiberglass-binder product such that the film closely surrounds substantially the entirety of the outwardly-facing surface of the molded fiberglass-binder product. 9. A method as in claim 8 wherein the combination of the molded product, surrounded by the shrunk film, comprises a muffler insert. 10. A method as in claim 8 wherein the insert core has a bore extending therethrough, the bore having first and second opposing ends, the insert core thus having an inwardly-facing surface facing across the bore, the method further comprising providing for apertures in the shrunk film at ends of the bore. 11. A method as in claim 7, the mold cavity having a height, the fiberglass-binder mixture comprising a low-density mixture, wherein the second consolidating operation, on the same initial charge of the mixture, includes driving the driver into the mold, and stopping the driving of the driver at the mid-point of the height of the cavity. 12. A method as in claim 7 wherein the second consolidating operation moves at least a portion of the mixture material being engaged into a relatively upper portion of the mold. 13. A method as in claim 5 wherein the binder is a powdered binder material. 14. A method as in claim 7, the second consolidating operation moving the fiber-binder mixture to a relatively upper portion of the mold. 15. A molded fiberglass product made using a method as in claim 7. 16. A method of charging a cavity in a mold with a fiberglass-binder mixture, the method comprising: (a) making a mixture of fiberglass strand material and binder in a mixer;(b) moving a charge of the fiberglass-binder mixture from the mixer into a conforming guide; and(c) as a first consolidating operation, driving a driver axially and thereby engaging the fiberglass-binder mixture and driving at least a portion of the mixture into the mold;(d) driving a driver into the mold, against the same charge of the fiberglass-binder mixture a second time, and(e) making a second charge of the fiberglass-binder mixture in the mixer, moving the second charge from the mixer into the conforming guide, and subsequently executing a third consolidating operation. 17. A method as in claim 16 wherein the binder is a powdered binder material. 18. A molded fiberglass product made using a method as in claim 16. 19. A method of charging a cavity in a mold with a fiberglass-binder mixture, the method comprising: (a) making a mixture of fiberglass strand material and binder in a mixer;(b) moving a charge of the fiberglass-binder mixture from the mixer into a conforming guide; and(c) as a first conforming operation, driving a driver through the conforming guide, and engaging the fiberglass-binder mixture and driving at least a portion of the mixture, into the mold, wherein the moving of the charge from the mixer into the conforming guide comprises dropping the mixture such that the mixture falls by gravity from the mixer, through open space, and into the conforming guide. 20. A molded fiberglass muffler insert made according to a method as in claim 19. 21. A muffler assembly comprising a muffler insert made according to a method as in claim 19. 22. A method of charging a cavity in a mold with a fiberglass-binder mixture, the method comprising: (a) making a mixture of fiberglass strand material and binder in a mixer;(b) moving a charge of the fiberglass-binder mixture from the mixer into a conforming guide; and(c) as a first tamping operation, driving a tamper into engagement with the fiberglass-binder mixture and driving at least a portion of the mixture, into the cavity in the mold, a plurality of teeth being disposed at the leading edge of the tamper, and wherein the teeth extend, in a direction of movement of the tamper, from the leading edge of the tamper, a distance corresponding to about 25 percent to about 75 percent of the height of the mold cavity. 23. A method as in claim 22 wherein the binder is a powdered binder material. 24. A molded fiberglass product made using a method as in claim 22. 25. A method of charging a cavity in a mold with a fiberglass-binder mixture, the method comprising: (a) making a mixture of fiberglass strand material and binder in a mixer;(b) moving a charge of the fiberglass-binder mixture from the mixer into a conforming guide, wherein the mixture in the conforming guide has a relatively low density fluffy characteristic;(c) as a first consolidating operation, driving a driver and engaging the low density fiberglass-binder mixture thereby and driving at least a portion of the low density mixture, into the mold;(d) the method further comprising mounting the mold on a jig, the jig being mounted on a rotating table, the rotating table being mounted on a turntable, the jig having a driven gear which drives rotation of the rotating table and thus rotation of the mold, the method comprising rotating the turntable so as to move the mold under the mixer and to engage the driven gear with a drive gear and thereby drive rotation of the mold. 26. A method of charging a cavity in a mold with a fiberglass-binder mixture, the method comprising: (a) making a mixture of fiberglass strand material and binder in a mixer;(b) moving a first charge of the fiberglass-binder mixture from the mixer into a conforming guide;(c) engaging the first charge of fiberglass-binder mixture and thereby driving at least a portion of the mixture into the cavity, and withdrawing the tamper,(d) further comprising determining mass of the first charge in the mold, computing a target add-on for a second charge based on the mass of the first charge, and feeding binder and fiberglass quantities to the mold according to the computed target add-on for the second charge. 27. A method as in claim 26 wherein the binder is a powdered binder material. 28. A molded fiberglass product made using a method as in claim 26. 29. A method of charging a cavity in a mold with a fiberglass-binder mixture, the method comprising: (a) making a mixture of fiberglass strand material and binder in a mixer;(b) moving a charge of the fiberglass-binder mixture from the mixer into a conforming guide, the charge comprising a discrete quantity of the mixture, wherein the mixture in the conforming guide has a relatively low density fluffy characteristic;(c) as a first consolidating operation, driving a driver and engaging the low density fiberglass-binder mixture thereby and driving at least a portion of the low density mixture, into the mold; and(d) moving multiple such charges of the mixture into the mold while retaining all such charges in the mold, including stopping the feeding of the fiberglass and binder to the mixer and, while such feeding to the mixer is so stopped, initiating moving a respective such charge from the mixer into the conforming guide. 30. A molded figerglass muffler insert made according to a method as in claim 29. 31. A muffler assembly comprising a muffler insert made according to a method as in claim 29. 32. A method of fabricating a fiberglass-based muffler insert, comprising; (a) chopping one or more fiberglass strand bundles and thereby obtaining chopped strand fiberglass;(b) in flowing air, advancing the chopped strand fiberglass, and powdered binder material, into a mixer and using the flowing air to mix the binder and the chopped strand fiberglass in the mixer to make a fiberglass-binder mixture;(c) shutting off air flow to the mixer and thereby causing a first charge of the mixture to drop out of the mixer;(d) after the air flow has been shut off, driving a driver to the dropped mixture and thence into a cavity in a mold and thereby advancing the mixture into the mold; and(e) curing the binder and thereby creating a generally shape-constant muffler insert. 33. A method as in claim 32, the shutting off of air flow to the mixer causing the charge of the mixture to drop into an underlying conforming guide, further comprising driving the driver through the conforming guide and thus using the driver to drive elements of the mixture from the conforming guide and into the mold. 34. A method as in claim 32, the cavity in the mold having a top and a bottom, further comprising driving the driver into the mold, to approximately the bottom of the cavity, and executing a second driving of a driver into the mold and engaging the same first charge of the mixture including, in the process, moving the fiber-binder mixture to a relatively upper portion of the mold. 35. A method as in claim 34, further comprising moving a second charge of the fiberglass-binder mixture from the mixer into a conforming guide underlying the mixer and executing a third tamping operation on such second charge of the mixture. 36. A method as in claim 35, further comprising determining mass of the first charge in the mold, computing a target add-on amount for the second charge based on the mass of the first charge, and feeding binder and fiberglass quantities to the mold according to the computed target add-on for the second charge. 37. A muffler insert made according to a method as in claim 32. 38. A method of fabricating a fiberglass-based muffler insert, comprising: (a) chopping one or more fiberglass strand bundles and thereby obtaining a discrete amount of chopped strand fiberglass;(b) advancing the discrete amount of chopped strand fiberglass, and powdered binder material, into a mixer and entraining the binder and the chopped strand fiberglass in an air flow stream in the mixer and thus mixing the binder and fiberglass to make a low density fiberglass-binder mixture;(c) dropping the charge of the mixture out of the mixer through open space without assistance of the air flow stream;(d) moving the mixture into a mold; and(e) curing the binder in the mold and thereby creating a generally shape-constant muffler insert. 39. A muffler insert made according to a method as in claim 38. 40. A muffler assembly comprising a muffler insert made according to a method as in claim 38. 41. A method of fabricating a molded fiberglass product, comprising: (a) feeding chopped fiberglass strand material and curable powdered binder into a mixer, and mixing the chopped fiberglass strand material and the binder in the mixer and thereby forming a fiberglass-binder mixture;(b) releasing a discrete charge of the fiberglass-binder mixture from the mixer such that the fiberglass-binder mixture falls by force of gravity onto a conforming guide;(c) receiving and consolidating the discrete charge of the mixture, which falls out of the mixer, onto the conforming guide;(d) after the mixture is received on the conforming guide, engaging the mixture and moving the mixture into a mold; and(e) curing the curable binder while the fiberglass-binder mixture is in the mold to produce a cured, molded fiberglass product. 42. A method as in claim 35, the product having an outwardly-facing surface of the so-molded product, including opposing outwardly-facing end surfaces, further comprising enclosing the molded product in a plastic shrink film and shrinking the film about the molded product such that the film closely overlies substantially the entirety of the outwardly-facing surface, including the opposing outwardly-facing end surfaces. 43. A method as in claim 42 wherein the molded product comprises a muffler insert core. 44. A method as in claim 43 wherein the insert core has a bore extending therethrough, the bore having first and second opposing ends, the insert core thus having an inwardly facing surface facing across the bore, the method further comprising providing for apertures in the shrink film at the opposing ends of the bore. 45. A method as in claim 41 wherein the mixture falls out the bottom of the mixer. 46. A method as in claim 41 wherein the mixer comprises a cyclone mixer wherein the chopped fiberglass and the binder are mixed with each other by a flow of air passing through the mixer and the resultant mixture leaves the mixer as a result of the termination of the air flow. 47. A molded fiberglass product made according to a method as in claim 41. 48. A method of preparing a mixture of fiberglass strand material and curable binder, comprising: (a) feeding chopped fiberglass strand material and curable powdered binder into a mixer;(b) mixing the chopped fiberglass strand material and the curable binder in the mixer and thereby forming a fiberglass-binder mixture;(c) receiving and consolidating the mixture in a mold, the consolidating of the mixture in the mold comprising (i) driving the mixture a first time by advancing a driver, to generally the bottom of the mold,(ii) retracting the driver, and(iii) advancing a driver a second time into the mold, and thus consolidating, the same mixture material a second time. 49. A method as in claim 42, further comprising, after consolidating the same mixture in the mold the first and second times, providing a second charge of the mixture to the mold and consolidating the composite of the first and second charges a third time. 50. A method as in claim 48, the advancing of the driver the second time comprising advancing the driver to generally the mid-point of the height of the mold. 51. A method as in claim 48, the advancing of the driver the second time moving at least a portion of the fiber-binder mixture into a relatively upper portion of the mold. 52. A method of preparing a mixture of fiberglass strand material and curable binder, comprising: (a) feeding chopped fiberglass strand material and curable powdered binder into a mixer;(b) mixing the chopped fiberglass strand material and the curable binder in the mixer and thereby forming a fiberglass-binder mixture;(c) receiving and consolidating the mixture in a mold; and(d) providing multiple charges of the fiberglass-binder mixture to the mold in the process of charging the mold, and including rotating the mold between charges. 53. A method of charging a cavity in a mold with a fiberglass-binder mixture, the method comprising; (a) chopping one or more fiberglass strand bundles and thereby obtaining chopped strand fiberglass,(b) advancing the chopped strand fiberglass and binder into a mixer, and mixing the fiberglass strand material and the binder in the mixer using a flow of air through the mixer, and terminating the flow of air through the mixer, thereby dropping the so-fabricated mixture from the mixer toward the mold;(c) moving a charge of the fiberglass-binder mixture from the mixer into a conforming guide, wherein the mixture in the conforming guide has a relatively low density fluffy characteristic; and(c) driving a driver and engaging the low density fiberglass-binder mixture thereby and driving at least a portion of the low density mixture into the mold. 54. A molded fiberglass-binder product made according to a method as in claim 53. 55. A muffler assembly comprising a muffler insert made using a method as in claim 53. 56. A method of preparing a discrete charge of a mixture of fiberglass strand material and curable binder, comprising: (a) entraining fiberglass strand material in a first air stream;(b) entraining solid particulate binder in a second air stream;(c) feeding the first and second air streams, including the fiberglass and binder, together into a mixer;(d) using air flow of the first and second air streams, mixing the fiberglass strand material and the binder in the mixer and thereby forming the discrete charge of the fiberglass-binder mixture, dispersed and temporarily held in the mixer by the collective first and second air streams; and(e) shutting off air flow to the mixer, whereupon fiberglass and binder are no longer being fed to the mixer, and the discrete charge subsequently falls by gravity out of the mixer. 57. A method as in claim 56 the discrete charge falling by gravity out of the mixer into a conforming guide upon termination of the air flow, the method further comprising, after the air flow has been terminated, moving the mixture from the conforming guide into a mold. 58. A method as in claim 57, further comprising driving the charge of the mixture into the mold, and while the fiberglass-binder mixture is being driven into the mold, rotating the mold about an axis consistent with the direction in which the fiberglass mixture is being moved toward the mold. 59. A method as in claim 56, further comprising using a tamper to drive the mixture charge into an underlying mold. 60. A method as in claim 59, further comprising forming a second mixture charge in the mixer, dropping the second charge from the mixer and using a subsequent tamping operation to drive the second charge into a relatively upper portion of the mold. 61. A molded fiberglass product made using a method as in claim 56. 62. A muffler assembly comprising a muffler insert made according to a method as in claim 56.
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