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US 8,887,863 B2Granted
Mat member, method for manufacturing the mat member, muffler and method for manufacturing the muffler
AssigneeIbiden Co., Ltd.
InventorsTakahiko Okabe, Daisuke Suzuki
Life of this patent
Estimating the term…
Abstract
A mat member includes inorganic fibers, a first surface and a second surface opposite to the first surface. The first surface has a plurality of needle penetration marks and/or a plurality of needle protrusion marks. The second surface has a plurality of needle protrusion marks and/or a plurality of needle penetration marks. A plurality of needle marks are formed in the mat member by needle punching and extend from the needle penetration mark to the needle protrusion mark. An inorganic fiber bundle which includes a plurality of the inorganic fibers oriented in a closed loop configuration is formed at the needle protrusion mark.
Claims23
A mat member for a muffler comprising:
- fibers consisting of inorganic fibers;
- a first surface having a plurality of needle penetration marks and/or a plurality of needle protrusion marks;
- and
- a second surface opposite to the first surface having a plurality of needle protrusion marks and/or a plurality of needle penetration marks, 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 b using a needle having a plurality of spine-shaped intrusions that protrude toward a tip direction formed substantially all over a side surface of a tip portion, an inorganic fiber bundle formed at said needle protrusion mark and including a plurality of said inorganic fibers oriented in a closed loop configuration, the plurality of said inorganic fibers oriented in the closed loop configuration being formed by punching a sheet member which includes inorganic fiber precursor with the needle to form said inorganic fiber precursor oriented in a closed loop and by firing the inorganic fiber precursor oriented in the closed loop, wherein the inorganic fiber precursor is manufactured by spinning a spinning mixture containing at least an inorganic compound and an organic polymer and wherein the inorganic fiber precursor comprises the organic polymer and inorganic compound and firing removes the organic polymer.
1 more element
A method for manufacturing a mat member for a muffler, comprising:
- spinning a spinning mixture containing at least an inorganic compound and an organic polymer to manufacture an inorganic fiber precursor;
- compressing said inorganic fiber precursor to manufacture a sheet member;
- punching said sheet member with at least one needle having a plurality of spine-shaped protrusions that protrude toward a tip direction formed substantially all over a side surface of a tip portion from at least one of a first surface of said sheet member and a second surface of said sheet member opposite to the first surface to manufacture a needle-punched body in which a bundle-shaped inorganic fiber precursor including said inorganic fiber precursor oriented in a dosed loop configuration is formed on at least one of the first surface and the second surface;
- and
- firing said needle-punched body so as to produce a mat member containing fibers consisting of inorganic fibers and haying inorganic fiber bundles including said inorganic fibers oriented in a closed loop configuration which are formed by firing said bundle-shaped inorganic fiber precursor.
2 more elements
A method for manufacturing a muffler, comprising:
- providing a mat member comprising:
- fibers consisting of inorganic fibers;
- a first surface having a plurality of needle penetration marks and/or a plurality of needle protrusion marks;
- a second surface opposite to the first surface having to plurality of needle protrusion marks and/or a plurality of needle penetration marks, 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 by using a needle having a plurality of spine-shaped protrusions that protrude toward a tip direction formed substantially all over a side surface of a tip portion, an inorganic fiber bundle formed at said needle protrusion mark and including a plurality of said inorganic fibers oriented in a closed loop configuration, the plurality of said inorganic fibers oriented in the closed loop configuration being formed by punching a sheet member which includes inorganic fiber precursor with the needle to form said inorganic fiber precursor oriented in a closes loop and by firing the inorganic fiber precursor oriented in the closed loop;
- wrapping the mat member around a side surface of an inner pipe having a plurality of small holes;
- press-fitting said inner pipe wrapped with the mat member into an outer pipe to produce a press-fitted body in it manner that said inorganic fiber bundles contact an inner surface of the outer pipe;
- disposing first and second end portion members to close first and second end openings of the outer pipe, respectively;
- and
- securing said first and second end portion members to the outer pipe.
6 more elements
A method for manufacturing a muffler, comprising:
- spinning a spinning mixture containing at least an inorganic compound and an organic polymer to manufacture an inorganic fiber precursor;
- compressing said inorganic fiber precursor to manufacture a sheet member;
- punching said sheet member with at least one needle having a plurality of spine-shaped protrusions that protrude toward a tip direction formed substantially all over a side surface of a tip portion from at least one of a first surface of said sheet member and a second surface of said sheet member apposite to the first surface to manufacture a needle-punched body in which a bundle-shaped inorganic fiber precursor including said inorganic fiber precursor oriented in a dosed loop configuration is formed on at least one of the first surface and the second surface;
- filing said needle-punched body so as to produce a mat member containing fibers consisting of inorganic fibers and hay Mg inorganic fiber bundles including said inorganic fibers oriented in a closed loop configuration which are formed by firing said bundle-shaped inorganic fiber precursor;
- wrapping the mat member around a side surface of an inner pipe having a plurality of small holes;
- press-fitting said inner pipe wrapped with the mat member into an outer pipe to produce a press-fitted body in it manner that said inorganic fiber bundles contact an inner surface of the outer pipe;
- disposing first and second end portion members to close first and second end openings of the outer pipe, respectively;
- and
- securing said first and second end portion members to the outer pipe.
6 more elements
Dependencies are inferred from the claim text.