High temperature noise and vibration enabler for composite resonators

Abstract

A composite resonator, such as for use in a vehicle intake system, includes a fiber-reinforced composite in contact with a semi-crystalline polymer substrate. The fiber-reinforced composite includes a plurality of fibers within a polymer matrix. The composite resonator also includes a granular coating in contact with the fiber-reinforced composite. The granular coating includes a plurality of granules deposited on the fiber-reinforced composite. In the vehicle intake system, the composite resonator is connected to an intake passage. The vehicle intake system also includes a turbocharger compressor connected to the intake passage.

Description

Technical Field

[0001] This invention relates to the field of vehicle intake and exhaust systems, and particularly to a high-temperature noise and vibration enabler for composite resonators. Background Technology

[0002] Resonators are used in vehicles to modulate the sound of gases (such as intake or exhaust gases) as they pass through an engine system. Resonators can be located in the intake or exhaust system. For example, an intake system resonator can be located between the supercharger or turbocharger and the intercooler in the intake system. Alternatively, or additionally, a resonator can be positioned between the exhaust manifold and the muffler. Resonators can be connected in series with the intake or exhaust lines or on side branches.

[0003] Intake or exhaust gas enters the resonator in pulses, producing sounds at various frequencies. The sound bounces within the resonator, altering the sound waves generated by the pulses. In addition to changing the sound, the exhaust resonator can also modulate the exhaust gas pulses to aid in the removal of exhaust gases from the combustion system.

[0004] Resonators are typically made of metal or composite materials. At higher operating temperatures, such as above 200°C, the structural resonant response may interfere with some micro-vibrations from the reinforcing filler. If thermal stability at the operating temperature is lacking, the resonator may provide lower damping, thus reducing its performance.

[0005] Therefore, although current resonators have achieved their intended purpose, there is still a need for new and improved resonator composite materials and methods for forming these composite materials. Summary of the Invention

[0006] According to several aspects, this disclosure relates to a composite resonator. The composite resonator includes a fiber-reinforced composite material in contact with a semi-crystalline polymer substrate. The fiber-reinforced composite material includes a plurality of fibers within the polymer matrix. The composite resonator also includes a particulate coating in contact with the fiber-reinforced composite material. The particulate coating includes a plurality of particles deposited on the fiber-reinforced composite material.

[0007] In the above aspects, the composite resonator also includes a metal housing, wherein a semi-crystalline polymer substrate is attached to the metal housing.

[0008] In any of the above aspects, the semi-crystalline polymer substrate has a continuous service temperature of at least 200°C.

[0009] In any of the above aspects, the semi-crystalline polymer substrate has a continuous service temperature of at least 200°C and at most 250°C.

[0010] In any of the foregoing aspects, the semi-crystalline polymer substrate comprises at least one of the following polymers: crystalline polyurea, polyurethane, polyarylate, polybutylene terephthalate, polyethylene terephthalate, polyethylene, epoxy resin, liquid crystal polymer, polyoxymethylene, polythalidomide, polyamide, polyphenylene sulfide, polyetheretherketone, polyetherketone, and copolymers and blends thereof.

[0011] In any of the foregoing aspects, the semi-crystalline polymer substrate comprises a semi-crystalline polymer, wherein the crystallinity percentage of the semi-crystalline polymer ranges from 50 wt% to 90 wt% of the semi-crystalline polymer on the surface of the semi-crystalline polymer substrate.

[0012] In any of the foregoing aspects, the fiber-reinforced composite material comprises a plurality of fibers, the plurality of fibers being in the range of 10 wt% to 60 wt% of the total weight of the fiber-reinforced composite material.

[0013] In any of the above aspects, at least 50% of the plurality of fibers are aligned along a first axis in the polymer matrix.

[0014] In any of the above aspects, the plurality of fibers comprises a plurality of short fibers having an average length in the range of 1 mm to 15 mm and an average diameter in the range of 2 μm to 25 μm.

[0015] In any of the above aspects, the thickness of the particulate coating is in the range of 2 nanometers to 200 micrometers.

[0016] In any of the above aspects, the multiple particles include one or more carbon-based materials, metals, and ceramics.

[0017] According to several aspects, this disclosure relates to a vehicle air intake system. The vehicle air intake system includes an air intake passage, a turbocharger compressor connected to the air intake passage, and a composite resonator connected to the air intake passage according to any one of the foregoing aspects. The composite resonator includes a semi-crystalline polymer substrate, a fiber-reinforced composite material comprising a plurality of fibers in a polymer matrix in contact with the semi-crystalline polymer substrate, and a particulate coating, wherein the plurality of fibers are present in an amount ranging from 10 wt% to 60 wt% of the total weight of the fiber-reinforced composite material, the particulate coating is formed by depositing a plurality of particles on the fiber-reinforced composite material, and the thickness of the particulate coating is in the range of 2 nanometers to 200 micrometers.

[0018] In the above aspects, the composite resonator includes a metal housing, wherein a semi-crystalline polymer substrate is attached to the metal housing.

[0019] In any of the above aspects, the semi-crystalline polymer has a continuous use temperature of at least 200°C and at most 250°C.

[0020] In any of the foregoing aspects, the semi-crystalline polymer includes at least one of the following polymers: crystalline polyurea, polyurethane, epoxy resin, liquid crystal polymer, polyamide, polybutylene terephthalate, polyethylene terephthalate, polyetheretherketone, polyphthalamide, polyarylate, polyphenylene sulfide, polyoxymethylene, and copolymers and blends thereof.

[0021] In any of the foregoing aspects, the semi-crystalline polymer substrate comprises a semi-crystalline polymer having a crystallinity percentage ranging from 50 wt% to 90 wt% of the semi-crystalline polymer on the surface of the semi-crystalline substrate.

[0022] In any of the above aspects, at least 50% of the plurality of fibers are aligned along a first axis in the polymer matrix.

[0023] In any of the above aspects, the plurality of fibers comprises a plurality of short fibers having an average length in the range of 1 mm to 15 mm and an average diameter in the range of 2 μm to 25 μm.

[0024] In any of the above aspects, the multiple particles include one or more carbon-based materials, metals, and ceramics.

[0025] According to several aspects, this disclosure relates to a method of forming a composite resonator. The method includes molding a semi-crystalline polymer substrate. The method further includes forming a fiber-reinforced composite material on a first surface of the semi-crystalline polymer substrate. The fiber-reinforced composite material includes a plurality of fibers within a polymer matrix. The method further includes depositing a particulate coating comprising a plurality of particles on the fiber-reinforced composite material. Attached Figure Description

[0026] The accompanying drawings described herein are for illustrative purposes only and are not intended to limit the scope of this disclosure in any way.

[0027] Figure 1 A schematic diagram of an intake system and an exhaust system in a vehicle according to an embodiment of the present disclosure is shown.

[0028] Figure 2A A composite resonator according to an embodiment of the present disclosure is shown.

[0029] Figure 2B A composite resonator according to an embodiment of the present disclosure is shown.

[0030] Figure 3A The noise and vibration composite of a composite resonator according to an embodiment of the present disclosure is shown.

[0031] Figure 3B A noise and vibration composite element arranged on a component of a composite resonator according to an embodiment of the present disclosure is shown.

[0032] Figure 4 This is a close-up schematic diagram of a composite resonator according to an embodiment of the present disclosure.

[0033] Figure 5A A semi-crystalline polymer substrate according to an embodiment of the present disclosure is shown.

[0034] Figure 5B This is a diagram showing the effect of the semi-crystalline polymer substrate on damping.

[0035] Figure 6A A schematic diagram of a fiber composite substrate according to an embodiment of the present disclosure is shown.

[0036] Figure 6B A schematic diagram of a fiber composite substrate according to an embodiment of the present disclosure is shown.

[0037] Figure 7A A schematic diagram of a particulate coating according to an embodiment of the present disclosure is shown.

[0038] Figure 7B This is a graph showing the effect of particle coating thickness on damping.

[0039] Figure 8 A method for forming a composite resonator is shown. Detailed Implementation

[0040] The following description is merely exemplary in nature and is not intended to limit this disclosure, its application, or its uses. Furthermore, it is not intended to be bound by any express or implied theory set forth in the foregoing technical field, background, brief overview, or the following detailed description. It should be understood that throughout the drawings, corresponding reference numerals indicate similar or corresponding parts and components.

[0041] As used herein, the term "vehicle" is not limited to automobiles. While this article primarily describes the technology in conjunction with automobiles, the technology is not limited to automobiles. The concept can be used in a wide variety of applications, such as those relating to aircraft, watercraft, other vehicles, and consumer electronics components.

[0042] Figure 1 A vehicle 100 including an engine 102 is shown. The engine 102 includes an intake system 104 and an exhaust system 106. Various gases enter the intake system 104, pass through the engine 102, and exit through the exhaust system 106. In some aspects, the vehicle 100 includes a turbocharger 108 connected to both the intake system 104 and the exhaust system 106. In other aspects, the turbocharger 108 is driven by exhaust gas 112 and forces compressed intake air 114 through the intake system 104 into the combustion chamber 110 of the engine 102.

[0043] In various aspects, the intake system 104 includes an intake passage 120. The compressor side 122 of the turbocharger 108 is connected to the intake passage 120, drawing air from the atmosphere 118 into the intake passage 120 and compressing the intake air 114 to a pressure higher than atmospheric pressure. The compressed intake air 114 then passes through a compound resonator 126, an air filter 128, an intercooler 130, and a throttle 132. Alternatively, the compound resonator 126, air filter 128, and intercooler 130 may be arranged in different orders upstream or downstream of other components in the system. Furthermore, more than one compound resonator 126 may be present in the intake passage 120. In other aspects, a mixing valve (not shown) may be connected to the intake passage 120 to mix the compressed intake air 114 with exhaust gas 112 recirculated back into the intake passage 120. The compound resonator 126 is illustrated as being connected to the intake passage 120 via a pipeline, thereby providing a portion of the intake passage. Alternatively, the composite resonator 126 may be connected to the intake channel 120 as a branch of the intake channel 120. As described above, the compressed intake air 114 enters the composite resonator 126, and the composite resonator 126 modulates the sound of the compressed intake air 114.

[0044] The exhaust system 106 includes an exhaust passage 116. After combustion of the fuel mixture with intake air 114, exhaust gas 112 is formed. Exhaust gas 112 exits the engine 102 and passes through the drive side 124 of the turbocharger 108 to drive the compressor side 122 of the turbocharger 108. Exhaust gas 112 can then pass through a compound resonator 134, a catalytic converter 136, and a muffler 138. Again, although the compound resonator 134 is illustrated as being connected to the exhaust passage 116 via a pipeline, thus forming part of the exhaust passage 116, the compound resonator 134 can still be connected to the exhaust passage 116 as a branch. Furthermore, more than one compound resonator 126 may exist in the exhaust passage 116. Depending on the type of engine 102, other exhaust system components, such as selective catalytic reduction elements and diesel-specific filters, may be connected to the exhaust passage 116. In other respects, an exhaust gas recirculation loop may branch off from the exhaust passage 116.

[0045] Figure 2A and Figure 2B The diagram illustrates various aspects of the resonator 126, which can be connected in the intake passage 120, including... Figure 2A Branched composite resonators and Figure 2B The inline composite resonator 126. Each resonator 126 includes... Figure 3A , Figure 3B and Figure 4The noise and vibration composite element 140 is illustrated in the figure. The noise and vibration composite element 140 is disposed on the outer surface of the composite resonator 126, the inner surface of the composite resonator 126, or both the outer and inner surfaces of the composite resonator 126. In the illustrated aspect, the composite resonator 126 is enclosed in a plastic housing 142; however, in alternative aspects, the composite resonator 126 is enclosed in a metal, such as stainless steel, aluminum, plastic, or a combination thereof. In all aspects, the housing 142 is one or more of the following: a thermal shield, a shock-resistant housing, and an electrically automated housing. However, it should be understood that, depending on the application, the housing 142 may be absent, and the composite resonator 126 may only include the noise and vibration composite element 140.

[0046] Now for reference Figure 3A , Figure 3B and Figure 4 The first layer of the noise and vibration composite 140 is a semi-crystalline polymer substrate 144. The semi-crystalline polymer substrate 144 comprises a polymer material formed of a semi-crystalline polymer. In all respects, the thickness of the semi-crystalline polymer substrate 144 ranges from 0.1 mm to 3 mm, inclusive. The semi-crystalline polymer has a high percentage of crystallinity by weight (i.e., crystalline structure) at a depth of up to 2% of the thickness of the semi-crystalline polymer substrate 144 from the surface 146 (as illustrated, both surfaces 146 include a high percentage of crystallinity), and in all respects, extends through the thickness of the semi-crystalline polymer substrate 144. The percentage of crystallinity is greater than 40 wt% and at least 90 wt% of the semi-crystalline polymer, and in other respects, from 50 wt% to 90 wt%. Furthermore, as measured by ASTM D648-18, the semi-crystalline polymer forming the semi-crystalline polymer substrate 144 exhibits a minimum sustained service temperature or heat distortion temperature of at least 200°C and at most 250°C, inclusive. Thermal stability at high temperatures prevents loss of material damping properties as well as structural strength and flexibility. In all respects, the thickness of substrate 144 ranges from 0.1 mm to 3 mm, including all values ​​and ranges therein. The semi-crystalline polymer substrate 144 includes, for example, one or more of the following polymers: crystalline polyurea, polyarylates, polybutylene terephthalate, polyethylene terephthalate, polyurethane, polyethylene, epoxy resins, liquid crystal polymers, polyoxymethylene, polythalidomide, polyamide, polyphenylene sulfide, polyetheretherketone, polyetherketone, and copolymers and blends thereof. Changes in the percentage of crystallinity alter the damping response and transmission loss. Furthermore, crystal density can affect the resonant response and act as a polarizer to attenuate the resonant response. Figure 3B The illustration shows a semi-crystalline polymer substrate 144 formed on component 160 (e.g., Figure 2A and Figure 3BVarious aspects of the outer casing 142 shown in the diagram. Again, component 160 may be formed of plastic, ceramic, metal, or a combination thereof.

[0047] refer to Figure 5A and Figure 5B An illustrative example of the effect of using a semi-crystalline polymer substrate 144 applied to component 160 is provided. Figure 5A The illustration shows a metal component 160, one side of which is coated with a semi-crystalline polymer substrate 144. Figure 5B The effect of the coating on noise damping in the frequency range of 0 Hz to 2000 Hz, as determined by finite element analysis, is illustrated. When the polyurea semi-crystalline polymer substrate 144 is absent, illustrated by line 206, the resonant response of component 160 is relatively high in the middle range of approximately 800 Hz to 1300 Hz, and significantly higher in the upper limit range of approximately 1750 Hz. When the semi-crystalline polymer substrate 144 is coated on one surface of component 160 (e.g., the inside of the component), illustrated by line 204, the damping attenuation response in the middle and upper limits confirms the damping effect. When the semi-crystalline polymer substrate 144 is coated on both sides of component 160 (e.g., the inside and outside of component 160), illustrated by line 202, the damping attenuation response in the middle and upper limits confirms a damping effect of approximately 30 dB to 40 dB in the approximately 450 Hz to 2000 Hz range.

[0048] The second layer of the noise and vibration composite 140, such as Figure 6A and 6B As shown, including with Figure 3A and Figure 3B The semi-crystalline polymer substrate 144 shown is in contact with a fiber-reinforced composite material 148 on its surface 146. In all aspects, the thickness of the fiber-reinforced composite material 148 is from 1 mm to 2 mm, including all values ​​and ranges therein. Figure 6A In the polymer matrix 172, fibers 170 are randomly oriented. Figure 6B In this configuration, fibers 170 are aligned along a first axis (x-axis as shown), wherein the length of fibers 170 along the x-direction is perpendicular to a second axis (y-axis as shown) within the polymer matrix 172. Although the x, y, and z axes are referenced, it should be understood that fibers 170 can be oriented along any given axis x, y, and z in their length directions. Fiber alignment can provide a directional response and dampen sound while maintaining structural integrity under sustained and high operating temperatures.

[0049] In all respects, the fiber is a short fiber with an average diameter ranging from 2 micrometers to 25 micrometers, inclusive, and an average length ranging from 1 millimeter to 15 millimeters, inclusive. In other respects, fiber 170 includes one or more of the following: glass, ceramic, carbon, para-aramid (KEVLAR®), meta-aramid (NOMEX®), and combinations thereof.

[0050] A polymer matrix 172 is combined with fibers 170 to form a fiber-reinforced composite material 148, wherein the fibers 170 are dispersed within the polymer matrix 172. The polymer matrix 172 comprises a polymer of a thermosetting or thermoplastic material, such as one of the following: polyester, polycarbonate, polypropylene, polyamide, epoxy resin, polyetherimide, and polyetheretherketone. The fibers 170 are present in the polymer matrix 172 in a range of 10 wt% to 60 wt% (inclusive) of the total weight of the fiber-reinforced composite material 148.

[0051] As the load of fiber 170 in polymer matrix 172 increases, the sound range applied over a wide frequency range of 100 Hz to 2000 Hz shifts to higher frequencies. Furthermore, compared to randomly oriented fibers 170 present in polymer matrix 172 with the same load, as the orientation of fiber 170 along a given axis (e.g., the x-axis) increases, the sound frequency applied over a wide frequency range of 100 Hz to 2000 Hz shifts to higher frequencies. In all respects, at least 10% of fiber 170 is oriented along a first axis (as illustrated, the x-direction in the x, y plane), encompassing all values ​​and ranges between 10% and 70%, including at least 50%. A directional resonant response can be obtained through fiber content and fiber alignment. Moreover, the presence of fiber 170 in fiber-reinforced composite material 148 helps maintain the structural integrity of composite resonator 126.

[0052] Referring below to Table 1, illustrative examples are provided regarding the effect of fiber load and fiber orientation in the polymer matrix 172 on the frequency shift. The frequency shift was determined using finite element analysis.

[0053] Table 1. Effects of fiber loading and orientation on frequency

[0054]

[0055] As seen in the table above, in each mode, the presence of fiber 170 at 10 wt% of fiber-reinforced composite 178 caused a 24% higher average shift in the response frequency. The weight percentage of fiber 170 in fiber-reinforced composite 178 was 50 wt% (see [reference]). Figure 6AIn each test mode, the response frequency shift was 101% higher than the average. Fiber 170 constitutes 50 wt% of the fiber-reinforced composite 178 and is oriented along the x-axis (see [link to relevant documentation]). Figure 6B In each test mode, the response frequency offset was 115% higher than the average.

[0056] The third layer of the noise and vibration composite 140 includes a particulate coating 152, which is formed by a plurality of particles arranged on the surface 150 of the fiber-reinforced composite material 148. The thickness of the particulate coating is in the range of 0.1 mm to 5 mm, inclusive. Further, the diameter of the discrete particles in the particulate coating 152 is in the range of 2 nm to 200 μm, inclusive. Further, the coating has porosity, wherein the density of the coating is in the range of 10%-50% of the density of a solid coating of the same material, inclusive. The increasing particulate coating increases damping and transmission losses. The porosity of individual particles 154 and the thermal conductivity of the material used to form the particles can provide thermal shielding and resonant response dissipation.

[0057] The particulate coating 152 includes one or more of the following: carbon-based materials, such as carbon nanotubes or graphene; metals, such as transition metals, alkali metals, quasi-metals, and their alloys; ceramics, including metal and non-metal compositions; and polymers, including thermally conductive polymers or electrically conductive polymers. Thermally conductive or electrically conductive polymers are understood to be polymers comprising additives that respectively conduct heat or dissipate electricity. Thermally conductive polymers include one or more of the following thermally conductive fillers: graphene, metals, and metal alloys. Electrically conductive polymers include one or more of the following conductive fillers: carbon fibers, carbon nanotubes, graphene, graphite, metals, and metal alloys.

[0058] refer to Figure 7A and Figure 7B An illustrative example of the effect of using the particulate coating 152 applied to component 160 is provided. Figure 7A The illustration shows a particulate coating 152 deposited on an underlying component 160. In this example, the particulate coating 152 may be metal, plastic, or ceramic, and exhibits a thickness ranging from 1 mm to 3 mm. Figure 7BThe illustration shows the damping effect of the particulate coating 152 added to the underlying component 160 on noise in the frequency range between 0 Hz and 2000 Hz, as determined by finite element analysis. When the particulate coating 152 is absent, as illustrated by line 210, the resonant response of component 160 is relatively high across the entire frequency range between 0 Hz and 2000 Hz compared to the sample measured with the particulate coating 152. As the thickness of the particulate coating 152 increases from 0.1 mm to 2 mm, the resonant response decays, and the frequency shifts to higher frequencies, spanning the frequency range between 0 Hz and 2000 Hz. The reduction is 30 to 40 dB in the frequency range between 0 Hz and 2000 Hz.

[0059] Figure 8 The diagram illustrates a method 800 for forming a noise and vibration composite 140 of a composite resonator 126. In block 810, a semi-crystalline polymer substrate 144 is formed of the noise and vibration composite 140. The semi-crystalline polymer substrate 144 is molded using one or more polymer forming processes, including coating, injection molding, compression molding, extrusion molding, vacuum forming, blow molding, additive manufacturing including 3D printing, etc. If the composite resonator 126 is configured to be combined with other components (such as a metal housing 142), the semi-crystalline polymer substrate 144 can be assembled with the other components or directly molded onto the other components using processes such as compression molding, injection molding, etc.

[0060] In frame 820, fiber-reinforced composite material 148 is applied to a semi-crystalline polymer substrate 144. In one aspect, the fiber-reinforced composite material 148 is formed by resin transfer molding, compression transfer molding, injection molding, additive manufacturing including 3D printing, etc., wherein fibers 170 are arranged on the surface 146 of the fiber-reinforced composite material 144, and then the polymer of the polymer matrix 172 is impregnated in the fibers 170 under pressure within a mold cavity. In other aspects, the fibers 170 are introduced into the mold cavity together with the polymer matrix 172 material and placed on the semi-crystalline polymer substrate 144.

[0061] In frame 830, particulate coating 152 is formed on surface 150 of fiber-reinforced composite material. Particles 154 and particulate coating 152 can be formed by one or more of several processes, including vapor deposition such as physical vapor deposition or chemical vapor deposition; thermal spraying such as atmospheric plasma spraying; additive manufacturing such as multi-jet melting, etc.

[0062] In block 840, if the composite resonator 126 is not molded onto another component (such as the metal housing 142), the composite resonator 126 can be assembled to other components. It should also be understood that, alternatively, the assembly of the composite resonator 126 to another component, such as the metal housing 142, can occur between blocks 810 and 820 or between blocks 820 and 830, and block 840 can occur after blocks 810 and 820.

[0063] As shown in the figure, a noise and vibration composite 140 is formed on a metal housing 142 to provide a composite resonator 126. In other respects, the composite resonator 126 is formed by the noise and vibration composite 140 without additional components such as the metal housing 142. Furthermore, the composite resonator 126 can be assumed to have various shapes, such as a hollow body with a continuous cross-section (assumed to be a hollow cylinder shape) or a hollow body with a variable cross-section. Further, while this document notes that the composite resonator 126 is intended for use within a vehicle 100, the composite resonator 126 can also be deployed within machinery, aircraft, locomotives, generators, or other devices that can generate sound through gas movement.

[0064] The resonator incorporating the noise and vibration composite of this disclosure offers several advantages. These advantages may include, for example, providing a thermal shield for the composite resonator that exhibits thermal stability at continuous operating temperatures up to 250°C, as found in, for example, intake and exhaust systems. This thermal stability at high temperatures prevents loss of material damping properties and structural strength and flexibility. Other advantages of the composite resonator of this disclosure include the ability to vary the resonant response frequency of each layer (i.e., the semi-crystalline polymer substrate, fiber-reinforced composite, and particulate coating) even at continuous operating temperatures, based on desired response results. Further advantages include improved performance during design and production validation, enhanced durability in global engine development thermal cycling experiments, and improved component performance and field functionality.

[0065] The descriptions in this disclosure are merely exemplary in nature, and changes that do not depart from the essential points of this disclosure are intended to be included within its scope. These changes are not considered to be departing from the spirit and scope of this disclosure.

Claims

1. A composite resonator, comprising: Semi-crystalline polymer substrate; A fiber-reinforced composite material in contact with the semi-crystalline polymer substrate, wherein the fiber-reinforced composite material comprises a plurality of fibers in a polymer matrix; as well as A particulate coating is applied to the fiber-reinforced composite material, wherein the particulate coating comprises a plurality of particles deposited on the fiber-reinforced composite material.

2. The composite resonator according to claim 1 further includes a metal housing, wherein, The semi-crystalline polymer substrate is connected to the metal casing.

3. The composite resonator according to claim 1, wherein, The semi-crystalline polymer substrate has a continuous operating temperature of at least 200°C.

4. The composite resonator according to claim 3, wherein, The semi-crystalline polymer substrate has a continuous operating temperature of at least 200°C to up to 250°C.

5. The composite resonator according to claim 4, wherein, The semi-crystalline polymer substrate comprises a semi-crystalline polymer having a crystallinity percentage in the range of 50% to 90% of the weight of the semi-crystalline polymer on the surface of the semi-crystalline polymer substrate.

6. The composite resonator according to claim 5, wherein, The fiber-reinforced composite material includes the plurality of fibers comprising a weight percentage ranging from 10% to 60% of the total weight of the fiber-reinforced composite material.

7. The composite resonator according to claim 6, wherein, At least 50% of the plurality of fibers are oriented in the same direction in the polymer matrix.

8. The composite resonator according to claim 7, wherein, The thickness of the particulate coating ranges from 2 nanometers to 200 micrometers.

9. A vehicle air intake system, comprising: Air intake passage; A turbocharger compressor is connected to the intake passage; as well as A composite resonator, connected to the intake channel, wherein the composite resonator comprises: Semi-crystalline polymer substrate; A fiber-reinforced composite material in contact with the semi-crystalline polymer matrix, comprising a plurality of fibers in the polymer matrix, wherein the plurality of fibers constitute from 10 wt% to 60 wt% of the total weight of the fiber-reinforced composite material; and A particulate coating is applied to the fiber-reinforced composite material, wherein the particulate coating is formed by depositing a plurality of particles on the fiber-reinforced composite material, and the thickness of the particulate coating is in the range of 2 nanometers to 200 micrometers.

10. A method for forming a composite resonator, comprising: A molded semi-crystalline polymer substrate, wherein the semi-crystalline polymer substrate includes a first surface; A fiber-reinforced composite material is formed on a first surface of the semi-crystalline polymer substrate, wherein the fiber-reinforced composite material comprises a plurality of fibers in a polymer matrix; as well as A particulate coating is deposited on the fiber-reinforced composite material, wherein the particulate coating comprises a plurality of particles.

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