Process for curing a porous muffler preform

1. A process for curing a porous muffler preform defined by a plurality of glass fibers and a heat-curing thermoset or thermoplastic material applied to the plurality of glass fibers, the process comprising:

retaining the muffler preform in a perforated mold;

enclosing the muffler preform and the perforated mold in a chamber having a baffle positioned therein;

introducing steam into the chamber at a temperature in the range of about 330° F. to about 390° F. and at a pressure in the range of about 90 p.s.i. to about 190 p.s.i.; and

causing the steam to impact the baffle and change directions prior to entering the muffler preform through the perforated mold.

2. The process of claim 1 wherein the steam concurrently enters the muffler preform from opposite directions after impacting the baffle.

3. A process for curing a porous muffler preform defined by a plurality of glass fibers and a heat-curing thermoset or thermoplastic material applied to the plurality of glass fibers, the process comprising:

retaining the muffler preform in a mold;

enclosing the muffler preform and the mold in a chamber at a first pressure, said chamber including at least one baffling surface;

injecting steam into the chamber through an inlet port after the enclosing step, said steam injected into the chamber at a temperature in the range of about 330° F. to about 390° F. and at a pressure in the range of about 90 p.s.i. to about 190 p.s.i.; and

wherein a direction of the steam is altered by the at least one baffling surface inside the chamber such that the steam does not directly impinge on the muffler preform.

4. The process of claim 3 wherein the at least one baffling surface causes the steam to enter the muffler preform concurrently from multiple directions.

5. The process of claim 3 wherein the at least one baffling surface bifurcates the flow of steam to opposite sides of the muffler preform.

6. The process of claim 3 wherein the steam is injected into the chamber at a second pressure at least eight times the first pressure.

7. The process of claim 3 wherein the mold is perforated and includes apertures on at least two different sides.

8. The process of claim 7 wherein the mold includes an outer surface exposed in the chamber and an inner surface surrounded by the outer surface and also exposed in the chamber, and

wherein the injecting step includes causing steam to enter the mold through both the inner and outer surfaces.

9. The process of claim 8 in which substantially 5% to substantially 50% of the outer surface of the mold is open to receive steam.

10. The process of claim 3 further comprising:

causing the steam to enter the muffler preform from multiple directions;

raising the temperature of the muffler preform to substantially the temperature of the steam by contacting the muffler preform with the steam;

raising the pressure in the chamber through the introduction of the steam to the chamber;

condensing water on the muffler preform to impart heat to the heat-curing thermoset or thermoplastic material;

maintaining the temperature and pressure of the steam in the chamber for a time required to cure the thermoset or thermoplastic material or cause the thermoset or thermoplastic material to flow sufficiently that the preform will have mechanical integrity when cooled; and

venting the chamber after the maintaining step.

11. The process of claim 10 wherein the venting step includes returning the pressure in the chamber to atmospheric in less than about 25 seconds.

12. A process for curing a porous muffler preform defined by a plurality of glass fibers and a heat-curing thermoset or thermoplastic material applied to the plurality of glass fibers, the process comprising:

retaining the muffler preform in a perforated mold;

enclosing the muffler preform and the perforated mold at a first temperature in a chamber at a first pressure, said chamber including at least one baffling surface;

introducing steam into the chamber at a second pressure greater than atmospheric and the first pressure and at a second temperature substantially at the boiling point of water at the second pressure; and

causing the steam to impact the at least one baffling surface and change directions prior to entering the muffler preform through the perforated mold within the chamber,

wherein water is condensed on the muffler preform and imparts heat to the heat-curing thermoset or thermoplastic material.

13. The process of claim 12 further comprising venting the chamber to atmosphere after the condensing step such that substantially all the condensate evaporates from the muffler preform.

14. The process of claim 13 wherein the venting step is further defined as venting the chamber in less than about 25 seconds.

15. The process of claim 12 further comprising reducing the pressure in the chamber below atmospheric after the steam is introduced into the chamber.

16. The process of claim 1 wherein the chamber is sized to accommodate a plurality of muffler preforms therein.

17. The process of claim 1 wherein the baffle is a flat disc.

18. The process of claim 3 wherein the chamber is sized to accommodate a plurality of muffler preforms therein.

19. The process of claim 3 wherein the at least one baffling surface includes a flat disc.

20. The process of claim 10 wherein the time is less than 30 seconds.

21. The process of claim 10 wherein the time is between about 30 seconds and about 150 seconds.

22. The process of claim 10 wherein the venting step includes returning the pressure in the chamber to atmospheric in a range of about 20 seconds to about 40 seconds.

23. The process of claim 12 wherein the chamber is sized to accommodate a plurality of muffler preforms therein.

24. The process of claim 12 wherein said second pressure is in the range of about 90 p.s.i. to about 190 p.s.i., and

wherein said second temperature is in the range of about 330° F. to about 390° F.

25. The process of claim 13 wherein the venting step is further defined as venting the chamber in a range of about 20 seconds to about 40 seconds.