Method for winding a strand of material around a substrate and products formed thereby

Abstract

A process for applying a cushioning material around a substrate, that is a catalytic converter or a muffler, includes rotating the substrate, and winding a strand of fibers around an outer surface of the rotating substrate.

1 . A process for applying a cushioning material around a substrate that is a catalytic converter or a muffler, the process comprising: rotating the substrate, and winding one or more continuous strands of fibers around an outer surface of the rotating substrate.  
   
   
       2 . The process of  claim 1 , wherein the strand comprises a bulked up roving material.  
   
   
       3 . The process of  claim 2 , including winding the cushioning material onto the rotating substrate in successive wraps that are spaced at incremental axial distances, wherein the incremental distances are approximately equal to a width of one wrap of the cushioning material so that successive wraps continuously contact each other.  
   
   
       4 . The process of  claim 2 , wherein the cushioning material is wound around the substrate at an angle less than about  50  from a line normal to the longitudinal axis.  
   
   
       5 . The process of  claim 3 , wherein the wrap comprises more than one strand substantially simultaneously wound around the substrate.  
   
   
       6 . A process for winding a cushioning material around a substrate comprising: 
 providing an elongated substrate having a longitudinal axis and opposing first and second ends;    positioning the first end of the substrate against a drive plate, the drive plate being configured to rotate the substrate about the longitudinal axis;    positioning a press plate against the second end of the substrate, and applying with the press plate a pressure sufficient to substantially hold the substrate against the drive plate;    rotating the drive plate such that the substrate and press plate rotate about the longitudinal axis; and,    winding the cushioning material around the rotating substrate.    
   
   
       7 . The process of  claim 6 , wherein the cushioning material comprises one or more strands of fibers.  
   
   
       8 . The process of  claim 7 , wherein the strand comprises a bulked up roving material.  
   
   
       9 . The process of  claim 8 , wherein the cushioning material is wound around the substrate at an angle less than about  5  ° from a line normal to the longitudinal axis.  
   
   
       10 . The process of  claim 6 , including winding the cushioning material onto the rotating substrate in successive wraps that are spaced at incremental axial distances, wherein the incremental distances are approximately equal to a width of one wrap of the cushioning material so that successive wraps continuously contact each other.  
   
   
       11 . The process of  claim 7 , wherein the wrap comprises more than one strand substantially simultaneously wound around the substrate.  
   
   
       12 . The process of  claim 6 , wherein the drive plate and the press plate each include a resilient surface configured to engage the ends of the substrate.  
   
   
       13 . The process of  claim 6 , wherein the substrate comprises a catalytic converter substrate or a muffler insert.  
   
   
       14 . A process for forming a catalytic converter comprising: 
 providing a catalytic converter substrate;    winding one or more continuous strands of fibers around the catalytic converter substrate to form an insert; and,    positioning the insert within a catalytic converter cannister.    
   
   
       15 . The process of  claim 14 , wherein the substrate has a longitudinal axis, and wherein the winding step includes rotating the substrate about its longitudinal axis.  
   
   
       16 . The process of  claim 15 , wherein the strand comprises a bulked up roving material.  
   
   
       17 . The process of  claim 16 , wherein the cushioning material is wound around the substrate at an angle less than about  5 ° from a line normal to the longitudinal axis.  
   
   
       18 . An insert for a catalytic converter comprising a catalytic converter substrate having a strand of fibers wound around an outer surface of the catalytic converter substrate.  
   
   
       19 . The insert of  claim 16 , wherein the strand is a bulked up roving material wound on the substrate in successive wraps that are spaced at incremental axial distances, wherein the incremental distances are approximately equal to a width of one wrap of the roving material so that successive wraps continuously contact each other.  
   
   
       20 . The process of  claim 19 , wherein the wrap comprises more than one strand substantially simultaneously wound around the substrate.  
   
   
       21 . A muffler comprising a muffler insert having a strand of fibers wound around an outer surface of the muffler insert.  
   
   
       22 . The muffler of  claim 21 , wherein the strand is a bulked up roving material wound on the substrate in successive wraps that are spaced at incremental axial distances, wherein the incremental distances are approximately equal to a width of one wrap of the roving material so that successive wraps continuously contact each other.