Needle-Punched Mat Member for Muffler Fiber Detachment
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Solution Overview
Problem
Conventional mat members used in mufflers suffer from detachment of inorganic fibers due to stress caused by exhaust gases, leading to damage and reduced noise reduction effectiveness, along with inferior handling characteristics and heat-insulating properties.
Innovation Solution
A mat member with needle penetration and protrusion marks formed by needle punching, creating entangled inorganic fibers that enhance interlayer strength, reducing fiber detachment and maintaining noise reduction over time, while also improving handling characteristics by reducing friction during press-fitting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional mat member is used in a muffler, then noise reduction is achieved, but fiber detachment occurs due to wind erosion from exhaust gases
Solution Approach 1:
The patent applies preliminary action by forming needle penetration marks and needle protrusion marks with entangled inorganic fibers during the manufacturing process, before the mat member is installed in the muffler. This pre-entanglement structure prevents fiber detachment when exhaust gases flow through the muffler, resolving the contradiction between maintaining noise reduction effectiveness and preventing fiber detachment.
2Reliability
If a conventional mat member is used in a muffler, then noise reduction is achieved, but heat insulation deteriorates causing temperature rise in the outer pipe
Solution Approach 1:
The patent forms entangled inorganic fiber structures at needle protrusion marks during manufacturing, before the mat member is installed. This pre-established entanglement structure maintains heat insulation properties by preventing fiber detachment and maintaining the mat's thermal barrier function, thus resolving the contradiction between noise reduction and heat insulation.
3Ease of manufacture
If a conventional mat member is used for muffler manufacturing, then assembly is possible, but handling characteristics are inferior due to high friction during press-fitting
Solution Approach 1:
The patent changes the surface parameters of the mat member by forming needle penetration marks and needle protrusion marks, which modify the surface friction characteristics. The needle protrusion marks create a surface structure that reduces friction during press-fitting operations, improving handling characteristics while maintaining the mat's functional properties.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The enhanced interlayer strength and reduced fiber detachment maintain noise reduction and prevent temperature-related damage to the outer pipe, ensuring superior handling and safety for operators.
Implementation Method 1
a plurality of needle marks being formed in the mat member by needle punching and extending from the needle penetration mark to the needle protrusion mark, an inorganic fiber bundle including a plurality of the inorganic fibers oriented in a closed loop configuration being formed at the needle protrusion mark
Data Source
Figure 1(a)~1(b)
Figure 2(a)~2(b)
Figure 3
AI summary
An object of the present invention is to use a mat member (100) that is superior in handling characteristics, for, for example, a muffler or the like for automobiles, wherein the mat member (100) of the present invention includes: inorganic fibers; a first surface (113a) having a plurality of needle penetration marks (114a) and/or a plurality of needle protrusion marks (115b); and a second surface (113b) opposite to the first surface (113a) having a plurality of needle protrusion marks (115a) and/or a plurality of needle penetration marks (114b), a plurality of needle marks (114a, 114b, 115a, 115b) being formed in the mat member (100) by needle punching and extending from the needle penetration mark (114a, 114b) to the needle protrusion mark (115a, 115b), an inorganic fiber bundle (118a, 118b) including a plurality of the inorganic fibers oriented in a closed loop configuration being formed at the needle protrusion mark (115a, 115b).