Abstract: Methods and systems for filling a muffler body with a fibrous material prior to completing assembly of the muffler body are disclosed.

Abstract: Methods and systems for filling a muffler body with a fibrous material prior to completing assembly of the muffler body are disclosed. The muffler body is composed of two half shells and the fibrous material is injected between the shells by a filling nozzle.

Abstract: A device for texturizing strand material into a wool-type product includes outer and inner nozzle sections. The outer and inner nozzle sections interface and define a passage through which the strand material travels. A locking device in the inner nozzle section is operable to selectively stop movement of the strand material. The locking device includes a seal holder that positions a sealing member within the inner nozzle section to prevent debris from entering the inner nozzle section, thereby promoting continued effective operation of the locking device. The outer nozzle section includes an end nozzle assembly including a hardened outlet tube. The hardened outlet tube is distinct from the outer nozzle section and, thus, can be repaired or replaced independently of the outer nozzle section.

Abstract: A method for filling a muffler with a fibrous material is disclosed. The muffler includes partitions which form a first chamber and second chamber, and a first muffler pipe having an outlet end. A filling aperture at one end of the second muffler pipe is positioned in the first muffler chamber. The second muffler pipe has a filling sleeve therein, the filling sleeve having a filling discharge opening that coordinates with the filling aperture of the second muffler pipe. The first muffler chamber is filled with fibrous material by applying a vacuum source to the first muffler pipe, which draws the fibrous material through the filling aperture. The filling aperture of the second muffler pipe is then positioned into the second muffler chamber, and the second muffler chamber is filled in the same manner as the first muffler chamber. The filling sleeve is then removed from the second muffler pipe.

Abstract: A method for filling a muffler with a fibrous material is disclosed. The muffler includes partitions which form a first chamber and second chamber, and a first muffler pipe having an outlet end. A filling aperture at one end of the second muffler pipe is positioned in the first muffler chamber. The second muffler pipe has a filling sleeve therein, the filling sleeve having a filling discharge opening that coordinates with the filling aperture of the second muffler pipe. The first muffler chamber is filled with fibrous material by applying a vacuum source to the first muffler pipe, which draws the fibrous material through the filling aperture. The filling aperture of the second muffler pipe is then positioned into the second muffler chamber, and the second muffler chamber is filled in the same manner as the first muffler chamber. The filling sleeve is then removed from the second muffler pipe.

Abstract: The present invention provides composite muffler systems formed of a long fiber thermoplastic. Long fiber thermoplastic technology allows the fibers, to maintain a length sufficient to provide structural strength at lower fiber loading. The long fiber thermoplastic material for forming composite muffler systems also provides increased impact strength and creep resistance as well as chemical and thermal resistance. Mufflers molded with long fiber thermoplastics demonstrate improved dimensional stability as compared to known short fiber based moldings. One suitable muffler structure is a multi-piece muffler assembly including at least one long fiber thermoplastic shell section. In accordance with the present invention, the long fiber thermoplastic material and moldings may also be combined with over-molding of preforms of unidirectional or woven inlays, which provide local structural performance.

Abstract: A method for filling a muffler with a fibrous material is disclosed. The muffler includes partitions which form a first chamber and second chamber, and a first muffler pipe having an outlet end. A filling aperture at one end of the second muffler pipe is positioned in the first muffler chamber. The second muffler pipe has a filling sleeve therein, the filling sleeve having a filling discharge opening that coordinates with the filling aperture of the second muffler pipe. The first muffler chamber is filled with fibrous material by applying a vacuum source to the first muffler pipe, which draws the fibrous material through the filling aperture. The filling aperture of the second muffler pipe is then positioned into the second muffler chamber, and the second muffler chamber is filled in the same manner as the first muffler chamber. The filling sleeve is then removed from the second muffler pipe.

Abstract: Methods of forming compressed preform products formed from continuous fibers substantially evenly coated with a thermoplastic sizing composition are provided. Applying a thermoplastic sizing composition to continuous fibers during the formation of the fibers enables a preform to be formed without applying any additional sizing or binder compositions at later stages of the manufacturing of the preform. The thermoplastic sizing composition includes a thermoplastic material, and, optionally a silane coupling agent. The thermoplastic material in the thermoplastic sizing composition includes chemicals and/or compounds that are thermoplastic or possess thermoplastic properties. One or more preforms may be randomly inserted to a muffler cavity. Upon the application of heat, the preforms decompress and fill the cavity with fibrous material. Due to the ability to decompress the compressed preform product, the preform product can have a shape that is independent of the shape of the muffler cavity.

Abstract: Compressed preform products formed from continuous fibers substantially evenly coated with a thermoplastic sizing composition are provided. Preferably, the continuous fibers are glass fibers. Applying a thermoplastic sizing composition to continuous fibers during the formation of the fibers enables a preform to be formed without applying any additional sizing or binder compositions at later stages of the manufacturing of the preform. The thermoplastic sizing composition includes a thermoplastic material, and, optionally a silane coupling agent. The thermoplastic material in the thermoplastic sizing composition includes chemicals and/or compounds that are thermoplastic or possess thermoplastic properties. One or more preforms may be randomly inserted to a muffler cavity. Upon the application of heat, the preforms decompress and fill the cavity with fibrous material.

Abstract: A process is provided for filling a muffler shell with fibrous material. It comprises the step of providing a muffler shell comprising one or more muffler shell outer parts which define an internal cavity and an internal structure adapted to extend at least part way through the shell internal cavity and having one or more openings adapted to communicate with the shell internal cavity. The process further comprises the step of providing a bag filled with fibrous material. The bag has a first side with one or more first perforations defining a first side total open area and a second side with either no perforations or one or more second perforations defining a second side total open area. The first open area is greater than the second open area.

Abstract: A process is provided for filling a muffler shell with fibrous material. The process involves providing a muffler shell comprising first and second muffler shell outer parts which define an internal cavity when coupled together and an internal structure adapted to extend at least part way through the shell internal cavity and having one or more openings communicating with the shell internal cavity.

Abstract: A process is provided for filling a muffler shell with fibrous material. The process involves providing a muffler shell comprising first and second muffler shell outer parts which define an internal cavity when coupled together and an internal structure adapted to extend at least part way through the shell internal cavity and having one or more openings communicating with the shell internal cavity.