Sound-absorbing fiber material filling apparatus and sound-absorbing fiber material filling method

Abstract

The present invention provides a sound-absorbing fiber material filling apparatus and a sound-absorbing fiber material filling method for filling the sound-absorbing fiber material into the space of the filter pipe and holder of a sub-muffler so as to achieve a uniform filling density. [Solution] The sound-absorbing fiber material filling apparatus comprises: 2 to 4 partition walls, each independently insertable into and removed from the filling space, which divide the filling space into 2 to 4 spaces in the circumferential direction by being inserted from the terminal opening, which is one of the axial openings of the filling space; a sound-absorbing fiber material filling machine equipped with a sound-absorbing fiber material feeding mechanism and a sound-absorbing fiber material cutting mechanism; and a nozzle connected to the sound-absorbing fiber material filling machine, which is inserted from the starting end opening, which is the other opening, into each divided space, which is the filling space divided by the partition walls, and fills the sound-absorbing fiber material from the tip.

Description

Technical Field

[0001] The present invention relates to a sound-absorbing fiber material filling device and a sound-absorbing fiber material filling method for filling a sound-absorbing fiber material into a filling space of a sound-absorbing fiber material composed of a filter pipe and a holder of a sub-muffler mounted on an automobile exhaust system.

Background Art

[0002] As a sub-muffler provided in an automobile exhaust system, a muffler filled with a sound-absorbing fiber material such as glass fiber inside is often used. As a method of filling a sound-absorbing fiber material into a space composed of a filter pipe and a holder of a sub-muffler, a method of directly filling a long fiber material has been frequently used in recent years due to the social demand for reducing particulate matter in exhaust gas. However, it has been conventionally difficult to uniformly fill a long fiber material into a narrow space composed of a filter pipe and a holder.

[0003] Conventionally, a muffler is known in which an insertion hole is formed in an end plate of an outer pipe constituting the muffler, and a sound-absorbing material is filled into a space between the outer pipe and a perforated pipe (inner pipe) from the insertion hole to form a sound-absorbing layer (see, for example, FIG. 3 of Patent Document 1).

[0004] However, in such a method of filling glass fiber, there may be a variation in the filling amount over the entire space, resulting in non-uniform filling density and a possible decrease in sound absorption performance.

[0005] In response to such problems, as a method of filling continuous fibers with a uniform density into a filling space, a method is disclosed in which a cylindrical body is used during filling and guided in the bottom direction by the smooth surface of the cylindrical body to achieve uniform filling without stagnation in part (see, for example, Patent Document 2).

[0006] However, the filling method described in Patent Document 2 aims to fill the sound-absorbing fiber material smoothly by guiding it in the bottom direction, and therefore does not take into account bias in the circumferential direction, which may still result in an uneven filling density.

[0007] Furthermore, Patent Document 3 discloses a method of forming a sound-absorbing sheet such as glass wool into a tubular sound-absorbing material and inserting it into the space. However, this method requires processes such as solidifying the long fiber material into a sheet and forming it into a tube, which increases costs. [Prior art documents] [Patent Documents]

[0008] [Patent Document 1] Japanese Patent Publication No. 2000-356119 [Patent Document 2] Japanese Patent Publication No. 2007-016764 [Patent Document 3] Japanese Patent Publication No. 2002-339742 [Overview of the Initiative] [Problems that the invention aims to solve]

[0009] The object of the present invention is to provide a fiber material filling apparatus and a fiber material filling method for uniformly filling the space formed by the filter pipe and holder of a sub-muffler with sound-absorbing fiber material in an inexpensive manner. [Means for solving the problem]

[0010] The invention of claim 1 is a sound-absorbing fiber material filling device for filling a sound-absorbing fiber material into a filling space for a sound-absorbing fiber material composed of a filter pipe and holder of a sub-muffler, comprising: 2 to 4 partition walls, each configured to be independently inserted into and removed from the filling space, which divide the filling space into 2 to 4 spaces in the circumferential direction by being inserted from an opening at one end of the filling space; a sound-absorbing fiber material filling machine equipped with a sound-absorbing fiber material feeding mechanism and a sound-absorbing fiber material cutting mechanism; and a nozzle connected to the sound-absorbing fiber material filling machine, which is inserted from an opening at the other end of the filling space divided by the partition walls and fills the sound-absorbing fiber material from the tip.

[0011] According to the configuration of claim 1, by inserting a partition wall that divides the sound-absorbing fiber material filling space, which is composed of the filter pipe and holder of the sub-muffler, into 2 to 4 spaces in the circumferential direction, the filling space can be divided into smaller spaces. Therefore, it is not necessary to diffuse the sound-absorbing fiber material over a wide area, and it can be filled evenly, thus eliminating unevenness in the sound-absorbing fiber material throughout the filling space and making it uniform.

[0012] The invention of claim 2 is characterized in that, in addition to the configuration of claim 1, the shape of at least the tip of the nozzle is such that the cross-sectional shape in a direction perpendicular to the axis of the nozzle conforms to the cross-sectional shape of each divided space.

[0013] According to the configuration of claim 2, since the sound-absorbing fiber material can be filled along the wall surface of the space, it is less likely that there will be areas that are not filled, and the sound-absorbing fiber material can be filled uniformly in the divided space.

[0014] The invention of claim 3 is characterized in that, in addition to the configuration of claim 1 or claim 2, the length of the nozzle is 30% or more of the length in the longitudinal direction of each divided space.

[0015] According to the configuration of claim 3, since the length of the nozzle is 30% or more of the length of each divided space in the longitudinal direction, the sound-absorbing fiber material can reach the end of the divided space, and no gaps are created between the filled sound-absorbing fiber material, and it is filled evenly.

[0016] The invention of claim 4 is characterized in that, in addition to the configuration of claim 1 or claim 2, it has a vacuum head that is inserted into the opening at the end of the filter pipe and has a plurality of holes for sucking sound-absorbing fiber material through the punching holes of the filter pipe.

[0017] According to the configuration of claim 4, the vacuum head can be inserted into the opening at the end of the filter pipe, and sound-absorbing fiber material can be filled while air is being sucked in. This allows for smooth filling of the sound-absorbing fiber material while regulating the filling direction and supporting the filling operation of the sound-absorbing fiber material.

[0018] The invention of claim 5 is a method for filling a sound-absorbing fiber material, wherein the filling space, which is composed of a filter pipe and holder of a sub-muffler, is divided into 2 to 4 spaces in the circumferential direction by 2 to 4 partition walls, and sound-absorbing fiber material is individually filled into these divided spaces with a nozzle, comprising: a filling preparation step of setting the filter pipe and holder in a sound-absorbing fiber material filling device, and inserting and fixing a stopper to prevent leakage of sound-absorbing fiber material into the terminal opening, which is one of the openings in the axial direction of the filling space; and, as necessary, independently inserting the partition walls that divide the divided spaces from the terminal opening toward the starting opening, or removing them from the filling space, and rotating the filter pipe and holder or the nozzle in the circumferential direction so that the starting opening, which is the other opening of the divided space to be filled with sound-absorbing fiber material, is filled with the nozzle The present invention is characterized by comprising: a sound-absorbing fiber material filling step, in which the filter pipe and the holder or nozzle are adjusted to be positioned for insertion, the filter pipe and the holder or nozzle are moved axially, the nozzle is inserted toward the stopper in the divided space, sound-absorbing fiber material is fed from the sound-absorbing fiber material filling machine, the sound-absorbing fiber material is filled into the divided space with the nozzle, the feeding of the sound-absorbing fiber material is stopped when a predetermined amount of filling is completed, the nozzle is removed from the filling space, and these operations are repeated until a predetermined amount of sound-absorbing fiber material has been filled into all the divided spaces; and a filling completion step, in which any partition walls inserted into the filling space are removed, the sound-absorbing fiber material is cut by the sound-absorbing fiber material cutting mechanism of the sound-absorbing fiber material filling machine, and the completed sub-muffler is removed from the sound-absorbing fiber material filling device.

[0019] According to the method of claim 5, sound-absorbing fiber material is individually filled into the divided spaces, which are divided into 2 to 4 spaces in the circumferential direction by partition walls, so that the sound-absorbing fiber material can be filled evenly into each divided space. Furthermore, since each partition wall can be inserted and removed independently as needed, the insertion and removal of partition walls can be switched depending on whether or not sound-absorbing fiber material is filled into adjacent divided spaces, thereby ensuring appropriate filling of sound-absorbing fiber material.

[0020] In addition to the configuration of claim 5, the invention of claim 6 is characterized in that when filling the divided space with the sound-absorbing fiber material, if the adjacent divided space adjacent to the divided space to be filled with the sound-absorbing fiber material is not filled with the sound-absorbing fiber material, a partition wall between the adjacent divided space is inserted to prevent the sound-absorbing fiber material from leaking into the adjacent divided space while filling the divided space with the sound-absorbing fiber material; and when the adjacent divided space adjacent to the divided space to be filled with the sound-absorbing fiber material is filled with the sound-absorbing fiber material, the partition wall between the adjacent divided space is removed, and the divided space is filled with the sound-absorbing fiber material so as to be in close contact with the sound-absorbing fiber material in the adjacent divided space.

[0021] According to the method of claim 6, when the adjacent divided space is not filled with the sound-absorbing fiber material, a partition wall between the adjacent divided space is inserted, so that the sound-absorbing fiber material can be prevented from leaking into the adjacent divided space. Also, when the adjacent divided space is filled with the sound-absorbing fiber material, the partition wall between the adjacent divided space is removed, so that the divided space can be filled with the sound-absorbing fiber material so as to be in close contact with the sound-absorbing fiber material in the adjacent divided space without generating a gap due to the partition wall.

[0022] In addition to the configuration according to claim 5 or claim 6, the invention of claim 7 is characterized in that the vacuum head is inserted into the opening at the end of the filter pipe, and in conjunction with the filling of the sound-absorbing fiber material in the sound-absorbing fiber material filling step, the sound-absorbing fiber material is sucked from the vacuum head through the punching holes of the filter pipe.

[0023] According to the method of claim 7, since the sound-absorbing fiber material is attracted near the holes in the vacuum head, the sound-absorbing fiber material is accurately guided to the target position in the filling space, so that the filling speed and filling quality can be improved.

[0024] The invention according to claim 8 is characterized in that, in addition to the configuration according to claim 5 or claim 6, in conjunction with the filling of the sound-absorbing fiber material in the sound-absorbing fiber material filling step, the filter pipe and the holder configured to move integrally, and one or both of the nozzle and the other are axially moved relative to each other, so as to fill the sound-absorbing fiber material while separating the nozzle from the filled sound-absorbing fiber material.

[0025] According to the method of claim 8, since one or both of the filter pipe or the nozzle are moved in a direction to separate the nozzle from the filled sound-absorbing fiber material, the filled sound-absorbing fiber material can be smoothly filled without hindering the discharge of the sound-absorbing fiber material from the nozzle, and the filling efficiency can be improved.

Advantages of the Invention

[0026] According to the present invention, it is possible to provide a fiber material filling device and a fiber material filling method for uniformly filling a fiber material without unevenness in a space composed of a filter pipe and a holder of a sub-muffler in a simple and inexpensive manner.

Brief Description of the Drawings

[0027] [Figure 1] A partial cross-sectional view of a sub-muffler is shown. (a) shows an intermediate product with both ends of the holder released, and (b) and (c) show products with both ends or one end closed. [Figure 2] A schematic view of a partition wall. (a) is a front view of the partition wall, and (b) is a plan view showing the positional relationship of the partition wall (when there are three partition walls). [Figure 3] A schematic view of a nozzle. (a) is a side view of the nozzle, and (b) is a front view of the nozzle. [Figure 4] (a) shows a schematic view of the filling state of glass wool at the initial stage of filling, and (b) shows a schematic view of the filling state of glass wool at the completion of filling. [Figure 5] (a) is a front view of a vacuum head, and (b) is an external view showing the hole shape of the vacuum head.​​(a) is a side view showing the initial state of glass wool filling, and (b) is a side view showing the state of glass wool filling after completion. [Figure 7] The diagrams show cross-sections of the filling spaces in each process. (a) shows the state before filling operation, with three partition walls inserted into the filling space and the nozzle inserted into the first divided space; (b) shows the state after the first divided space has been filled with sound-absorbing fiber material; (c) shows the state after the partition wall between the first divided space filled with sound-absorbing fiber material and the second divided space has been removed and the nozzle has been inserted into the second divided space; (d) shows the state after the second divided space has been filled with sound-absorbing fiber material; (e) shows the state after the two partition walls between the first and second divided spaces filled with sound-absorbing fiber material and the third divided space have been removed and the nozzle has been inserted into the third divided space; and (f) shows the state after the third divided space has been filled with sound-absorbing fiber material, and all filling spaces have been filled with sound-absorbing fiber material. [Figure 8] (a) is a schematic front view of the sound-absorbing fiber material filling apparatus in the embodiment (when the filling jig is raised), and (b) is a schematic front view of the sound-absorbing fiber material filling apparatus in the embodiment (when the filling jig is lowered). [Figure 9] A schematic diagram showing the relative positions of the nozzle and vacuum head is provided. [Figure 10] A schematic plan view of the filling jig is shown. [Figure 11] A schematic diagram of a sound-absorbing fiber filling machine viewed from the side is shown. [Figure 12] A schematic plan view of the sound-absorbing fiber material filling apparatus in the embodiment is shown. (a) shows the position where the filter pipe and holder are set in the filling jig, and (b) shows the filling position of the sound-absorbing fiber material. [Figure 13] This shows the properties of the material to be filled during mass production. [Figure 14] This shows the actual properties of the material being filled into the trial product (test sample). [Figure 15] Implementation Verification Results [Explanation of Symbols]

[0028] 1. Sub-muffler 2 filter pipes 3 holders 4 Filling space 5. End opening 6. Opening at the starting end 7 Partition wall 8 divided space 9. Sound-absorbing fiber material filling machine 10 Sound-absorbing fiber material feeding mechanism 11 nozzles 12 Sound-absorbing fiber material 13 Vacuum head 14 Suction hole 15 Vacuum tube 16 punched holes 17 Sound-absorbing fiber material filling device 18 Filling jig 19 Workers 20 Cylinder for moving filling jig 21 rails 22 Coro 23 Clamper 24 Cylinder for partition walls 25. Servo motor for vertical movement 26 Cylinder rod 27 Stopper 28 Stopper jig 29 Cylinder for vertical movement of filling jig 30 Cylinder for rotating filling jig [Modes for carrying out the invention]

[0029] The following describes in detail typical embodiments of the sound-absorbing fiber material filling apparatus and its manufacturing method according to the present invention with reference to the drawings, but the present invention is not limited to these embodiments. Modifications can be made as appropriate without departing from the scope of achieving the effects of the present invention. In the following description, the same or corresponding parts are denoted by the same reference numerals, and redundant descriptions may be omitted. Also, since the drawings are for conceptual explanation of the present invention, the dimensions of each component shown and their ratios may differ from those of the actual components.

[0030] Figure 1 is a partial cross-sectional view of the sub-muffler 1. The filling space 4 shown in Figure 1, in which sound-absorbing fiber material is filled in the present invention, is a filling space composed of a filter pipe 2 and a holder 3. As shown in Figure 1(a), the filling space has an end opening 5, which is one opening in the axial direction of the filter pipe and the holder, and an end opening 6, which is the other opening.

[0031] On the other hand, as shown in Figures 1(b) and 1(c), once the sound-absorbing fiber material has been filled, the opening is closed by shrink-wrapping to seal in the sound-absorbing fiber material.

[0032] <Sound-absorbing fiber material filling device> The main components are described below. The sound-absorbing fiber material filling device 17 of the present invention comprises at least a partition wall 7, a sound-absorbing fiber material filling machine 9 equipped with a sound-absorbing fiber material feeding mechanism 10 and a sound-absorbing fiber material cutting mechanism, and a nozzle 11 connected to the sound-absorbing fiber material filling machine.

[0033] (Partition wall) Figure 2 is an external view of the partition walls 7. Each partition wall 7 is equipped with a drive source and can be independently inserted into and removed from the filling space 4. The number of partition walls corresponds to the number of divided spaces 8, which are divided into 2 to 4 spaces in the circumferential direction by insertion from the terminal opening 5, which is one of the axial open ends of the filter pipe 2 and holder 3. For example, if the filling space is divided into 3 spaces, 3 partition walls are provided.

[0034] The number of partition walls and the number of spaces to be divided are not limited to three; they can be two or four. However, applying two reduces the uniformity of the sound-absorbing fiber material being filled, and applying four increases the time required for filling, so three is the most desirable.

[0035] Each partition wall is connected to a drive source, such as a cylinder, allowing it to be moved independently. Since the partition walls are evenly spaced circumferentially, inserting them into a filling space divides the space into equal widths. The partition walls are made of metal, but other materials such as resin are also applicable.

[0036] (Sound-absorbing fiber filling machine) Figure 11 is a schematic diagram of the sound-absorbing fiber material filling machine 9 viewed from the side. The sound-absorbing fiber material filling machine 9 includes a sound-absorbing fiber material feeding mechanism 10 and a sound-absorbing fiber material cutting mechanism (not shown). It is connected to a nozzle 11, which will be described later. The sound-absorbing fiber material 12 is, for example, glass wool. The sound-absorbing fiber material filling machine 9 may also include a sound-absorbing fiber material defibration mechanism.

[0037] (nozzle) Figure 3(a) is a side view of the nozzle, and Figure 3(b) is a front view of the nozzle. The nozzle 11 is inserted into each divided space, which is a filling space divided by a partition wall, from the opening at the starting end, which is the other open end, and fills the sound-absorbing fiber material from the tip. As shown in Figure 3, the shape of at least the tip of the nozzle is such that the cross-sectional shape perpendicular to the axis of the nozzle follows the cross-sectional shape of each divided space.

[0038] The nozzle length is 30% or more of the longitudinal length of each divided space, which allows the filling of sound-absorbing fiber material to begin from a position close to the axial end opening of the filter pipe and the holder, and enables the released sound-absorbing fiber material to reach the end of the divided space.

[0039] (Vacuum head) Figure 5(a) is a front view of the vacuum head 13. The vacuum head 13 is inserted into the opening at the end of the filter pipe 2 and has multiple suction holes 14 on its side to suck up sound-absorbing fiber material through the punching holes 16 of the filter pipe. The top end of the vacuum head 13 is closed, and suction occurs only from the multiple suction holes 14 on the side. Since the suction holes 14 are positioned below the tip of the nozzle 11, the sound-absorbing fiber material released downward from the nozzle 11 is sucked in the direction from which it was released, providing an effect that supports the filling operation.

[0040] <Sound-absorbing fiber filling method> The following describes a method for filling sound-absorbing fiber material using the sound-absorbing fiber material filling device 17.

[0041] In the filling preparation process, the filter pipe and holder are set in the sound-absorbing fiber material filling device, and a stopper 27 is inserted and fixed into the terminal opening, which is one of the openings in the axial direction of the filter pipe and holder, to prevent leakage of the sound-absorbing fiber material.

[0042] Next, in the sound-absorbing fiber material filling process, the partition walls that divide the divided spaces are inserted independently from the terminal opening toward the starting opening as needed, or removed from the filling space. The filter pipe and holder or nozzle are rotated circumferentially to adjust the starting opening, which is the other opening of the divided space to be filled with sound-absorbing fiber material, so that it is positioned for nozzle insertion. The filter pipe and holder or nozzle are moved axially to insert the nozzle toward the stopper of the divided space. Sound-absorbing fiber material is fed from the sound-absorbing fiber material filling machine, and the nozzle is used to fill the divided space with sound-absorbing fiber material. Once a predetermined amount of material has been filled, the feeding of sound-absorbing fiber material is stopped, and the nozzle is removed from the filling space. These operations are repeated until all divided spaces have been filled with a predetermined amount of sound-absorbing fiber material.

[0043] Finally, in the filling completion process, if there are any partition walls inserted into the filling space, they are removed, and the sound-absorbing fiber material is cut by the sound-absorbing fiber material cutting mechanism of the sound-absorbing fiber material filling machine.

[0044] Furthermore, the sound-absorbing fiber material filling process can be modified to include the following steps: if the adjacent divided space to be filled with sound-absorbing fiber material is not filled with sound-absorbing fiber material, a partition wall is inserted between the adjacent divided space and the sound-absorbing fiber material to prevent leakage of sound-absorbing fiber material into the adjacent divided space while filling the divided space with sound-absorbing fiber material; if the adjacent divided space to be filled with sound-absorbing fiber material is already filled with sound-absorbing fiber material, the partition wall is removed between the adjacent divided space and the sound-absorbing fiber material to be filled into the divided space so as to be in close contact with the sound-absorbing fiber material in the adjacent divided space.

[0045] Furthermore, the sound-absorbing fiber material filling process can be enhanced by inserting a vacuum head into the opening at the end of the filter pipe and, in conjunction with the filling of the sound-absorbing fiber material in the sound-absorbing fiber material filling process, sucking the sound-absorbing fiber material from the vacuum head through the punched holes in the filter pipe.

[0046] Furthermore, the sound-absorbing fiber material filling process can be enhanced by moving either or both of the filter pipe and holder, which are configured to move together in conjunction with the filling of the sound-absorbing fiber material in the sound-absorbing fiber material filling process, and the nozzle axially relative to the other, thereby filling the sound-absorbing fiber material while separating the nozzle from the filled sound-absorbing fiber material.

[0047] As described above, the partition walls can be individually inserted and removed as needed. By filling the first divided space with sound-absorbing fiber material, then removing the partition wall separating the previously filled divided space and the adjacent divided space, and then filling the adjacent divided space, the adhesion between the sound-absorbing fibers can be improved. However, if the partition wall separating the previously filled divided space and the adjacent divided space is left inserted while the sound-absorbing fiber material is filled into the adjacent divided space, removing the partition wall after filling will result in gaps where the partition wall was inserted, leading to a deterioration in sound absorption performance.

[0048] Furthermore, because the sound-absorbing fiber material is attracted to the vicinity of the holes in the vacuum head, it is accurately guided to the target position in the filling space, thereby improving both the filling speed and filling quality.

[0049] Furthermore, by positioning the nozzle relatively far away from the filled sound-absorbing fiber material, the sound-absorbing fiber material can be filled without the sound-absorbing fiber material filling nozzle interfering with the already filled sound-absorbing fiber material, thereby improving filling efficiency.

[0050] [Examples] The sound-absorbing fiber material filling apparatus 17 of the present invention has three partition walls as shown in Figure 2, a sound-absorbing fiber material filling machine 9 equipped with a sound-absorbing fiber material feeding mechanism 10 and a sound-absorbing fiber material cutting mechanism (not shown) as shown in Figure 11, and a nozzle 11 connected to the sound-absorbing fiber material filling machine 9. The sound-absorbing fiber material apparatus in the embodiment is configured as shown in Figure 12(a). A filling jig 18 having partition walls and a vacuum head is located in front of the operator 19, and the filling jig is configured to be movable in the vertical and depth directions. The position shown in Figure 12(a) is the position for setting the workpiece consisting of a filter pipe and a holder into the filling jig 18.

[0051] When the setup is complete and the sound-absorbing fiber material is to be filled, the filling jig moving cylinder 20 is activated to move the filling jig in the depth direction, and the filling jig moves along the rail 21 on the rollers 22, so that the filling jig moves away from the operator and moves below the nozzle 11 as shown in Figure 12(b). When viewed from the front after the filling jig 18 has moved below the nozzle, it looks like Figure 8.

[0052] The top end of the vacuum head is closed, and it has multiple suction holes 14 on its side to suck in the sound-absorbing fiber material through the punched holes of the filter pipe. In this embodiment, the vacuum head has two suction holes 14, and the suction holes are rectangular, as shown in Figure 5(b). As shown in Figure 6, the suction holes 14 are positioned below the tip of the nozzle 11, so that the sound-absorbing fiber material released downward from the nozzle 11 is sucked in the direction of release, providing an effect that supports the filling operation.

[0053] As shown in Figure 8, the filter pipe 2 and holder 3 are fixed inside the holder so that they move together, and the holder 3 is clamped by a clamper 23. The filter pipe and holder are moved downward in a direction away from the filled sound-absorbing fiber material by any method such as a servo motor or robot hand, in conjunction with the filling of the sound-absorbing fiber material.

[0054] The nozzle may be moved relative to the filter pipe and holder. In this embodiment, a partition wall cylinder 24 for moving each partition wall 7 (inserted into the filling space in Figure 8) up and down is fixed to the clamper 23. The clamper 23 is fixed to a vertical movement servo motor 25 that moves the clamper up and down. Therefore, the filter pipe and holder and the partition wall 7 can be lowered together in conjunction with the filling operation from the nozzle.

[0055] As shown in Figure 8, each partition wall is connected to a drive source such as a cylinder, and can be moved up and down independently. Pneumatic cylinders and hydraulic cylinders can be used as the cylinders. In addition, electric actuators can also be used. In this embodiment, the lower part of each partition wall is connected to a cylinder rod 26, and the partition walls can be inserted into or removed from the divided space by the up and down movement of the cylinder rod 26. Also, as shown in Figure 7, the partition walls are arranged to divide the filling space into equal intervals in the circumferential direction.

[0056] In the embodiment, the sound-absorbing fiber material 12 is bundled long fiber glass wool, which is defibrated by a defibration mechanism provided in the sound-absorbing fiber material filling machine 9 and then sent to a nozzle by the sound-absorbing fiber material feeding mechanism 10. The glass wool has 24 μm fibers. In the case of glass wool, it is bundled in quantities of 5800 or 8500 fibers, which are defibrated and filled into the filling space.

[0057] In this embodiment, the longitudinal length of the filter pipe is 413 mm, the longitudinal length of the filling space is 310 mm, and the length of the nozzle is 350 mm.

[0058] Furthermore, the air flow rate of the sound-absorbing fiber material filling machine that supplies the sound-absorbing fiber material in the embodiment is 70 L / min.

[0059] Furthermore, the stopper 27 in Figure 9 is annular in shape and made of plastic, but other materials such as metal can also be used. The stopper has a hole for passing through the partition wall. The stopper is fixed to the opening at the end and serves to prevent leakage of the sound-absorbing fiber material and also to form a filled space. The stopper is placed on top of the stopper jig 28 shown in Figure 9. The stopper jig is made of metal, but it can be made of any material that can fix the stopper, such as resin. Note that the partition wall is not shown in Figure 9 for ease of viewing.

[0060] The following shows a series of steps related to filling with sound-absorbing fiber material according to the present invention. In this embodiment, an example is shown in which the filling space is divided into three sections and filled with sound-absorbing fiber material.

[0061] (1) The worker fixes the filter pipe 2 and holder 3 inside the holder so that they can move together, inserts and fixes a stopper 27 into the opening 5 at the end of the filling space 4 formed by the filter pipe 2 and holder 3 to prevent leakage of sound-absorbing fiber material, and switches on the sound-absorbing fiber material filling device 17.

[0062] A clamper 23 provided on the filling jig 18 clamps the holder 3. The filling jig 18 also moves in the direction of the sound-absorbing fiber material filling machine 9. At this time, in this embodiment, the area curtain (not shown) of the photoelectric sensor is turned on for the safety of the worker.

[0063] In this embodiment, a stopper 27 is used to prevent leakage of the sound-absorbing fiber material, but the end opening 5 may be shrink-wrapped instead of using the stopper 27.

[0064] (2) As the filling jig 18 rises, the vacuum head 13 provided on the filling jig also rises, and the vacuum head is inserted into the opening at the end of the filter pipe 2 from below the filter pipe.

[0065] At this time, as the filling jig 18 rises, the partition wall 7 provided on the filling jig 18 also rises and is inserted into the filling space 18 through the opening 5 at the end of the filling space 18, dividing the filling space 4.

[0066] At this time, as the filling jig 18 rises, the clamper 23 provided on the filling jig 18 and the holder 3 clamped to the clamper 23 also rise. This rise causes the nozzle, which is fixed at a predetermined height above the filter pipe 2 and the holder 3, to be inserted from the opening 6 at the starting end of the filling space into one of the divided spaces 8, which are divided filling spaces 4.

[0067] Furthermore, the plan views representing the filling space 4 and its surroundings at this time are shown in Figures 7 and 10. From Figures 7 and 10, it can be seen that the filling space is divided into three separate spaces by partition walls.

[0068] (3) The sound-absorbing fiber material 12 is fed out from the sound-absorbing fiber material filling machine 9 and the sound-absorbing fiber material 12 is filled into the divided space 8 from the nozzle 11. In conjunction with the filling of the sound-absorbing fiber material 12, the sound-absorbing fiber material is sucked out from the vacuum head 13 through the punched holes 16 of the filter pipe 2.

[0069] After the sound-absorbing fiber material 12 is filled from the nozzle 11, the clamper 23 lowers the holder using the servo motor 25 for vertical movement, thereby moving the filled sound-absorbing fiber material away from the nozzle 11 while filling the sound-absorbing fiber material 12.

[0070] Figure 4(a) is a schematic diagram showing the initial state of glass wool filling, and Figure 6(a) is a schematic diagram viewed from a different direction. Figure 4(b) is a schematic diagram showing the state of glass wool filling when filling is complete, and Figure 6(b) is a schematic diagram viewed from a different direction. In Figures 4 and 6, the areas where sound-absorbing fiber material has been filled are indicated by the shaded areas. As shown in Figures 4 and 6, at this point, sound-absorbing fiber material has been filled into one of the divided spaces within the filled space. Note that the partition wall is not shown in Figures 4 and 6 for ease of viewing.

[0071] Figure 7 shows schematic plan views of the cross-section of the filled space 4 at each stage. Figure 7(a) of the first stage shows that there is no divided space 8 filled with sound-absorbing fiber material 12, and the first filling of the divided space 4 with sound-absorbing fiber material 12 results in Figure 7(b). The divided space 8 filled with sound-absorbing fiber material 12 is the shaded area.

[0072] The sound-absorbing fiber material 12 is stopped from being fed out of the sound-absorbing fiber material filling machine 9, and the sound-absorbing fiber material 12 is cut by the sound-absorbing fiber material cutting mechanism of the sound-absorbing fiber material filling machine 9.

[0073] (4) In the filling jig 18 shown in Figure 8(a), when the filling jig 18 is lowered by the operation of the filling jig vertical movement cylinder 29 which moves the filling jig 18 up and down, the clamper 23 provided on the filling jig 18 lowers, and the nozzle 11 is separated from the filter pipe 2 and holder 3 to a position where the nozzle 11 does not interfere with the filter pipe 2 and holder 3, resulting in the state shown in Figure 8(b).

[0074] By rotating the filling jig rotation cylinder 30, the filling jig 18 (filter pipe 2 and holder 3) is rotated, moving the next division space to be filled, which is adjacent to the currently filled division space, below the nozzle 11. (See Figures 7(b) and 7(c))

[0075] Of the inserted partition walls 7, the partition wall 7 that separates the currently filled divided space from the adjacent divided space is removed from the filling space 4 using the partition wall cylinder 24. More specifically, in the partition wall 7 that separates the previously filled divided space from the divided space to be filled, the partition wall, which was mounted on the cylinder rod, descends as the cylinder rod is lowered, causing the partition wall within the filling space to descend. Figure 7(c) is a schematic plan view of the filling space 4, showing that the partition wall separating the previously filled divided space from the divided space to be filled has been removed from the filling space 4 (one partition wall has been removed), and that the nozzle 11 has been inserted into the divided space to be filled.

[0076] (5) By performing steps (2) and (3) above in the same manner, the sound-absorbing fiber material is filled into the second divided space of the filled space. Figure 7(d) is a schematic plan view of the filled space, showing that the sound-absorbing fiber material has been filled up to the second divided space.

[0077] Furthermore, as an effect of removing the partition wall separating the adjacent divided space, which has already been filled with sound-absorbing fiber material, the sound-absorbing fiber material in the divided space is filled in a close manner without any gaps between it and the sound-absorbing fiber material in the adjacent divided space, as shown in Figure 7(d). This ensures that the sound-absorbing performance is not compromised and the filling is done appropriately.

[0078] (6) Repeat the process described in (4) above until the next divided space to be filled is moved below the nozzle. (See Figures 7(d) and 7(e).)

[0079] Unlike (4), the two divided spaces have been filled in the previous steps, and the divided space to be filled this time is adjacent to both of those divided spaces, so the two remaining partition walls in the divided space are removed. All the partition walls inserted into the filled space are removed from the filled space using the partition wall cylinders 24. Figure 7(e) is a schematic plan view of the filled space, showing that all the partition walls separating the previously filled divided space and the divided space to be filled have been removed, and that the nozzles are inserted into the divided space to be filled.

[0080] (7)By performing (2) and (3) as described above, the sound-absorbing fiber material is filled into the third divided space of the filled space. Figure 7(f) is a schematic plan view of the filled space, showing that the entire filled space has been filled with sound-absorbing fiber material.

[0081] Similar to the filling process for the second divided space, by removing the partition walls on both sides separating it from the adjacent divided space, as shown in Figure 7(f), the sound-absorbing fiber material is filled into the divided space in a close manner without any gaps between it and the sound-absorbing fiber material in the adjacent divided spaces. This ensures proper filling without compromising sound absorption performance.

[0082] (8) As the filling jig 18 descends, the clamper 23 provided on the filling jig 18 descends, and the filter pipe 2 and holder 3 move away from the nozzle 11 to a position where they do not interfere with each other.

[0083] (9) The filling jig 18, which had been moved towards the filling machine, moves towards the worker (Figure 12(a)). The sound-absorbing fiber material that has been filled into the filling space is then pushed into the filling space by any method. In this embodiment, it is pushed in with a rod that has an annular end. The filter pipe 2 and holder 3, which were clamped to the clamper 23, are also unclamped.

[0084] When the worker approaches the filling device, the area curtain activates and the filling device stops. The worker removes the workpiece, consisting of the filter pipe 2 and holder 3, from the filling jig 18. At this time, the stopper 27 and stopper jig 28 are removed from the filling space. When the worker moves away from the filling device, the area curtain is cleared and the filling device becomes operational again.

[0085] (10) In preparation for filling the next filter pipe 2 and holder 3, the filling jig 18 rises and the three partition walls rise. The worker places the filter pipe 2 and holder 3, which were removed from the jig in (9), onto the measuring instrument and measures their weight.

[0086] Once it is confirmed that the specified amount of fiber has been filled, remove the filter pipe 2 and holder 3 from the measuring instrument.

[0087] (11) The filter pipe 2 and holder 3 measured in (10) are transported to the next process. In the next process, both ends of the filter pipe 2 and holder 3 are shrink-wrapped to seal the sound-absorbing fiber material, and then palletized.

[0088] Although the example shown divides the filling space into three sections and fills them with sound-absorbing fiber material, the process is the same when there are two or four partition walls. Also, in the embodiment, the filling jig and nozzle are installed vertically to fill the filling space, but they may also be installed horizontally and the filling may be done horizontally.

[0089] (Verification results) The verification results for the examples are shown below.

[0090] Figure 13 shows the properties of the material to be filled in mass production, and Figure 14 shows the actual properties of the material to be filled in the trial product. The allowable weight is 56.0g ± control range for the long fiber weight, and the results of five verification tests are shown in Figure 15. As shown in Figure 15, it was confirmed that all tests met the allowable weight.

[0091] Although typical embodiments of the present invention have been described above, the present invention is not limited to these, and various design modifications are possible, all of which fall within the technical scope of the present invention.

Claims

1. A sound-absorbing fiber material filling device for filling the sound-absorbing fiber material into the space for sound-absorbing fiber material, which is composed of the filter pipe and holder of a sub-muffler, Two to four partition walls, each independently insertable into and removed from the filling space, divide the filling space into two to four spaces in the circumferential direction by being inserted from the terminal opening, which is one of the opening ends of the filling space. A sound-absorbing fiber material filling machine equipped with a sound-absorbing fiber material feeding mechanism and a sound-absorbing fiber material cutting mechanism, A nozzle connected to the sound-absorbing fiber material filling machine is inserted into each divided space, which is a filling space divided by the partition wall, from the opening at the starting end, which is the other open end, and fills the sound-absorbing fiber material from the tip, A sound-absorbing fiber material filling device equipped with the following features.

2. The shape of at least the tip of the nozzle is such that the cross-sectional shape perpendicular to the axis of the nozzle conforms to the cross-sectional shape of the divided space. The sound-absorbing fiber material filling apparatus according to claim 1.

3. The length of the nozzle is 30% or more of the length of the longitudinal portion of each divided space. The sound-absorbing fiber material filling apparatus according to claim 1 or claim 2.

4. A vacuum head is inserted into the opening at the end of the filter pipe and has multiple holes for sucking sound-absorbing fiber material through the punched holes of the filter pipe. A sound-absorbing fiber material filling apparatus according to claim 1 or claim 2.

5. A method for filling a sub-muffler with sound-absorbing fiber material, comprising dividing the filling space, which consists of the filter pipe and holder of the sub-muffler, into 2 to 4 spaces in the circumferential direction by 2 to 4 partition walls, and individually filling each divided space with sound-absorbing fiber material using a nozzle, The filter pipe and holder are set in the sound-absorbing fiber material filling device. A stopper is inserted and fixed into the terminal opening, which is one of the openings in the axial direction of the aforementioned filling space, to prevent leakage of sound-absorbing fiber material. The filling preparation process, The partition walls that divide the aforementioned divided space are inserted independently from the terminal opening toward the starting opening, or removed from the aforementioned filled space, as needed. The filter pipe and the holder or the nozzle are rotated in the circumferential direction to adjust the starting end opening, which is the other opening of the divided space filled with sound-absorbing fiber material, so that it is positioned for inserting the nozzle. Move the filter pipe and the holder or the nozzle in the axial direction to insert the nozzle toward the stopper in the divided space, The sound-absorbing fiber material is dispensed from the sound-absorbing fiber material filling machine, and the sound-absorbing fiber material is filled into the divided space with the nozzle. Once the predetermined amount of filling is complete, the dispensing of the sound-absorbing fiber material is stopped, and the nozzle is removed from the filling space. These steps are repeated until all divided spaces are filled with the predetermined amount of sound-absorbing fiber material. Sound-absorbing fiber material filling process, If there is a partition wall inserted into the aforementioned filling space, it is removed, and the sound-absorbing fiber material is cut by the sound-absorbing fiber material cutting mechanism of the sound-absorbing fiber material filling machine. The completed sub-muffler is removed from the sound-absorbing fiber material filling device. filling completion process; A method for filling with sound-absorbing fiber material.

6. If an adjacent partitioned space to be filled with sound-absorbing fiber material is not filled with sound-absorbing fiber material, a partition wall is inserted between the adjacent partitioned space and the partitioned space to prevent the sound-absorbing fiber material from leaking into the adjacent partitioned space while filling the partitioned space with sound-absorbing fiber material. If a sound-absorbing fiber material is to be filled into a divided space, and an adjacent divided space adjacent to that space is already filled with sound-absorbing fiber material, the partition wall between the adjacent divided space and the divided space is removed, and the sound-absorbing fiber material is filled into the divided space so as to be in close contact with the sound-absorbing fiber material in the adjacent divided space. The method for filling with sound-absorbing fiber material according to claim 5.

7. Insert the vacuum head into the opening at the end of the filter pipe, In conjunction with the filling of the sound-absorbing fiber material in the sound-absorbing fiber material filling process, the sound-absorbing fiber material is sucked from the vacuum head through the punched holes of the filter pipe. A method for filling with sound-absorbing fiber material according to claim 5 or claim 6.

8. The sound-absorbing fiber material is filled while the filter pipe and the holder, which are configured to move together in conjunction with the filling of the sound-absorbing fiber material in the sound-absorbing fiber material filling process, are moved axially relative to the other by moving either one or both of the filter pipe and the holder and the nozzle, respectively, thereby separating the nozzle from the filled sound-absorbing fiber material. A method for filling with sound-absorbing fiber material according to claim 5 or claim 6.

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