Composite resonator, vehicle air intake system with composite resonator and method for manufacturing a composite resonator

Abstract

Composite resonator (126) comprising: a semi-crystalline polymer substrate (144); a fiber-reinforced composite material (148) in contact with the semi-crystalline polymer substrate (144), the fiber-reinforced composite material (148) containing a plurality of fibers (170) in a polymer matrix (172); and a particle coating (152) contacting the fiber-reinforced composite (148), the particle coating (152) comprising a plurality of particles (154) deposited on the fiber-reinforced composite (148).

Description

[0001] Resonators are used in vehicles to modulate the sound of gases such as intake air or exhaust gases as they flow through the engine system. Resonators can be installed in the intake or exhaust system. For example, an intake system resonator can be located between a supercharger or turbocharger and the intercooler in the intake system. Alternatively or additionally, a resonator can also be located between the exhaust manifold and the muffler. The resonators can be connected in series with the air intake or exhaust lines or in a side arm.

[0002] The intake air or exhaust gases enter the resonator in pulses, generating tones of various frequencies. The tones bounce off the resonator and alter the sound waves generated by the pulses. An exhaust resonator can not only alter the tones but also tune the exhaust gas pulses to better remove the exhaust gases from the combustion system.

[0003] Resonators are typically made of metal or composite materials. At relatively high operating temperatures, such as temperatures above 200 degrees Celsius, structural resonance responses can interfere with some microvibrations of reinforced fillers. If thermal stability is lacking at operating temperatures, the resonator may provide less damping, reducing its performance.

[0004] DE 10 2021 111 884 A1 describes a polymer sandwich structure with increased thermal conductivity, comprising a first layer formed from a first polymer matrix and containing a first fiber reinforcement layer embedded in the first polymer matrix, a second layer formed from a second polymer matrix and containing a second fiber reinforcement layer embedded in the second polymer matrix, and a third layer arranged between the first and the second layer, wherein the third layer is formed from a third polymer matrix in which graphene nanoplatelets are interspersed.Each of the first and second fiber reinforcement layers is made of reinforcing fibers and includes a respective set of staggered discontinuous perforations formed therein, each respective set of staggered discontinuous perforations defining a respective first plurality of reinforcing fibers having a respective first length and a respective second plurality of reinforcing fibers having a respective second length longer than the respective first length.

[0005] US 2018 / 0 290 401 A1 describes a method for producing finished parts from at least one multi-layer, fiber-reinforced, flat semi-finished product structure by the following steps: a) Heating the at least one multi-layer, fiber-reinforced, flat semi-finished product structure at ambient pressure to a first temperature T a, wherein the at least one multi-layer, fiber-reinforced, flat semi-finished structure consists of at least two superimposed polymer layers and the individual polymer layers are each fiber-reinforced and are not or only partially coherently bonded to one another, and in the event that at least one of the polymer layers contains a semi-crystalline polymer, the first temperature T a higher than a melting point T m of the crystalline polymer according to DIN EN ISO 11357-3:2013-04, and in the event that the at least two polymer layers do not comprise a semi-crystalline polymer, the first temperature T a higher than a glass transition temperature T g according to DIN EN ISO 11357-2:2013-09 of a polymer contained in at least one of the at least two polymer layers, and b) pressing the heated at least one multi-layer fiber-reinforced, flat semi-finished structure into a finished part at a second temperature Tb and at a pressure p b of at least 3 bar.

[0006] While current resonators serve their purpose, there is a need for new and improved resonator composites and processes for manufacturing the composites.

[0007] Accordingly, it is the object of the invention to provide resonator composite materials and methods for producing them that offer better damping performance.

[0008] The problem is solved by the subject matter of the independent claims.

[0009] According to the invention, the present disclosure is directed to a composite resonator. The composite resonator comprises a fiber-reinforced composite contacting a semi-crystalline polymer substrate. The fiber-reinforced composite contains a plurality of fibers in a polymer matrix. The composite resonator further includes a particulate coating contacting the fiber-reinforced composite. The particulate coating comprises a plurality of particles applied to the fiber-reinforced composite.

[0010] In the above embodiment, the composite resonator further comprises a metal housing, wherein the semi-crystalline polymer substrate is bonded to the metal housing.

[0011] In each of the above embodiments, the semi-crystalline polymer substrate has a continuous use temperature of at least 200 degrees Celsius.

[0012] In each of the above embodiments, the semi-crystalline polymer substrate has a continuous use temperature of at least 200 degrees Celsius and up to 250 degrees Celsius.

[0013] In each of the above embodiments, the semi-crystalline polymer substrate comprises at least one of the following polymers: crystalline polyurea, polyurethane, polyarylate, polybutylene terephthalate, polyethylene terephthalate, polyethylene, epoxy, liquid crystalline polymer, polyoxymethylene, polythalidamide, polyamide, polyphenylene sulfide, polyetheretherketone, polyetherketone, copolymers thereof, and mixtures thereof.

[0014] In each of the above embodiments, the semi-crystalline polymer substrate comprises a semi-crystalline polymer having a percentage of crystallinity in a range of 50 weight percent to 90 weight percent of the semi-crystalline polymer at a surface of the semi-crystalline polymer substrate.

[0015] In any of the above embodiments, the fiber-reinforced composite contains the plurality of fibers in a range of 10 to 60 weight percent of the total weight of the fiber-reinforced composite.

[0016] In any of the above embodiments, at least 50 percent of the plurality of fibers are aligned in a first axis in the polymer matrix.

[0017] In any of the above embodiments, the plurality of fibers comprises a plurality of chopped fibers having an average length in the range of 1 millimeter to 15 millimeters and an average diameter in the range of 2 micrometers to 25 micrometers.

[0018] In the above-mentioned embodiments, the particle coating has a thickness in the range of 2 nanometers to 200 micrometers.

[0019] In one of the above embodiments, the plurality of particles consists of one or more carbon-based materials, metals and a ceramic.

[0020] Furthermore, the present disclosure is directed to a vehicle air intake system according to the invention. The air intake system of a vehicle includes an air intake duct, a turbocharger compressor connected to the air intake duct, and a composite resonator connected to the air intake duct according to any one of the above embodiments.The composite resonator comprises a semi-crystalline polymer substrate, a fiber-reinforced composite in contact with the semi-crystalline polymer substrate and containing a plurality of fibers in a polymer matrix, the plurality of fibers being present in a range of 10 to 60 weight percent of the total weight of the fiber-reinforced composite, and a particle coating in contact with the fiber-reinforced composite, the particle coating being formed from a plurality of particles deposited on the fiber-reinforced composite, and the particle coating having a thickness in a range of 2 nanometers to 200 micrometers.

[0021] In some of the above embodiments, the composite resonator comprises a metal housing, wherein the semi-crystalline polymer substrate is bonded to the metal housing.

[0022] In each of the above-mentioned embodiments, the semi-crystalline polymer has a continuous service temperature of at least 200 degrees Celsius and up to 250 degrees Celsius.

[0023] In each of the above embodiments, the semi-crystalline polymer comprises at least one of the following polymers: crystalline polyurea, polyurethane, epoxy, liquid crystalline polymer, polyamide, polybutylene terephthalate, polyethylene terephthalate, polyetheretherketone, polyphthalamide, polyarylate, polyphenylene sulfide, polyoxymethylene, copolymers thereof, and mixtures thereof.

[0024] In each of the above embodiments, the semi-crystalline polymer substrate comprises a semi-crystalline polymer having a percentage of crystallinity in a range of 50 weight percent to 90 weight percent of the semi-crystalline polymer at a surface of the semi-crystalline polymer substrate.

[0025] In each of the above embodiments, at least 50 percent of the plurality of fibers are aligned in a first axis in the polymer matrix.

[0026] In each of the above embodiments, the plurality of fibers comprises a plurality of chopped fibers having an average length in the range of 1 millimeter to 15 millimeters and an average diameter in the range of 2 micrometers to 25 micrometers.

[0027] In each of the above embodiments, the plurality of particles consists of one or more carbon-based materials, metals, and a ceramic.

[0028] Furthermore, the present disclosure relates to a method according to the invention for producing a composite resonator according to the invention. The method comprises forming a semi-crystalline polymer substrate. The method also comprises forming a fiber-reinforced composite on a first surface of the semi-crystalline polymer substrate. The fiber-reinforced composite contains a plurality of fibers in a polymer matrix. The method further comprises applying a particulate coating containing a plurality of particles to the fiber-reinforced composite.

[0029] The drawings described herein are for illustrative purposes only and are not intended to limit the scope of the present disclosure in any way. Fig. 1 shows a schematic diagram of an air intake system and an exhaust system in a vehicle according to an embodiment of the present disclosure. Fig. 2A shows a composite resonator according to an embodiment of the present disclosure. Fig. 2B shows a composite resonator according to an embodiment of the present disclosure. Fig. 3A shows a noise and vibration composite of a composite resonator according to an embodiment of the present disclosure. Fig. 3B shows a noise and vibration composite disposed on a component of a composite resonator according to an embodiment of the present disclosure. Fig. 4 is a schematic close-up view of a composite resonator according to an embodiment of the present disclosure. Fig. 5A shows a semi-crystalline polymer substrate according to an embodiment of the present disclosure. Fig.Figure 5B is a graph showing the effect of a semi-crystalline polymer substrate on damping. Fig. 6A shows a schematic representation of a fiber composite matrix according to an embodiment of the present disclosure. Fig. 6B shows a schematic representation of a fiber composite matrix according to an embodiment of the present disclosure. Fig. 7A shows a schematic representation of a particle coating according to an embodiment of the present disclosure. Fig. Figure 7B shows a graph illustrating the effect of particle coating thickness on damping. Fig. Figure 8 shows a method for manufacturing a composite resonator.

[0030] The term "vehicle" used herein is not limited to motor vehicles. While the present technology is primarily described in the context of motor vehicles, it is not limited to motor vehicles. The concepts may be used in a wide variety of applications, including aircraft, watercraft, other vehicles, and consumer electronic components.

[0031] Fig.1 shows a vehicle 100 with an engine 102. The engine 102 includes an air intake system 104 and an exhaust system 106. Various gases flow into the air intake system 104, 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 air intake system 104 and the exhaust system 106. In further aspects, the turbocharger 108 is driven by exhaust gas 112 and forces compressed intake air 114 through the air intake system 104 and into the combustion chambers 110 of the engine 102.

[0032] In some aspects, the air intake system 104 includes an air intake duct 120. The compressor side 122 of the turbocharger 108 is connected to the air intake duct 120 and draws air from the atmosphere 118 into the air intake duct 120 and compresses the intake air 114 to a pressure above atmospheric pressure. The compressed intake air 114 then flows through a composite resonator 126, an air filter 128, a charge air cooler 130, and through the throttle body 132. In alternative aspects, the composite resonator 126, the air filter 128, and the charge air cooler 130 may be arranged in a different order before or after the other components of the system. Additionally, more than one composite resonator 126 may be present in the air intake duct 120.In further aspects, a mixing valve (not shown) may be connected to the air intake duct 120 to mix the compressed intake air 114 with the exhaust gas 112 recirculated into the air intake duct 120. The composite resonator 126 is connected inline with the air intake duct 120 and forms a portion of the air intake duct. Alternatively, the composite resonator 126 may be connected to the air intake duct 120 as a branch of the air intake duct 120. As mentioned 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.

[0033] The exhaust system 106 includes an exhaust path 116. Following the combustion of a mixture of fuel and intake air 114, exhaust gas 112 is produced. The exhaust gas 112 exits the engine 102 and flows through the driven side 124 of the turbocharger 108 to drive the compressor side 122 of the turbocharger 108. The exhaust gas 112 may then flow through a composite resonator 134, through a catalyst 136, and through a muffler 138. Although the composite resonator 134 is connected inline with the exhaust path 116 and forms part of the exhaust path 116, the composite resonator 134 may be connected to the exhaust path 116 as a branch of the exhaust path 116. Further, more than one composite resonator 126 may be present in the exhaust path 116. Depending on the type of engine 102, additional components of the exhaust system may be connected to the exhaust passage 116, for example a selective catalytic reduction and a diesel filter.In further aspects, exhaust gas recirculation circuits may be provided that branch off from the exhaust path 116.

[0034] Fig. 2A and Fig. 2B show aspects of resonators 126 that can be connected into the air intake duct 120, including a branched composite resonator in Fig. 2A and an inline composite resonator 126 in Fig. 2B. The resonators 126 each contain a noise and vibration composite material 140 which is Fig. 3A, Fig. 3B and Fig.4. The noise and vibration composite 140 is disposed on the outer surface of the composite resonator 126, inside the composite resonator 126, or on both the outer and inner surfaces of the composite resonator 126. In the illustrated aspects, the composite resonator 126 is encased in a plastic housing 142; however, in alternative aspects, the composite resonator 126 is encased in metal, such as stainless steel or aluminum, plastic, or a combination thereof. In some cases, the housing 142 is one or more of the following: heat shield, impact enclosure, and electromatic enclosure. However, depending on the application, the housing 142 may not be present, and the composite resonator 126 may consist solely of the noise and vibration composite 140.

[0035] As can be seen from the Fig.As can be seen, a first layer of the noise and vibration composite 140 consists of a semi-crystalline polymer substrate 144. The semi-crystalline polymer substrate 144 includes a polymer material formed from a semi-crystalline polymer. In some aspects, the semi-crystalline polymer substrate 144 has a thickness in the range of 0.1 millimeters to 3 millimeters, inclusive of all values and ranges therein. The semi-crystalline polymer has a relatively high percentage of crystallinity, i.e., crystalline structures by weight, at the surface 146 to a depth of two percent of the thickness of the semi-crystalline polymer substrate 144 (as shown, both surfaces 146 have a relatively high percentage of crystallinity) from the surface 146, and in aspects, throughout the entire thickness of the semi-crystalline polymer substrate 144.The percentage of crystallinity is greater than 40 percent and up to 90 percent by weight of the semi-crystalline polymer, and in further aspects from 50 percent to 90 percent. Furthermore, the semi-crystalline polymer comprising the semi-crystalline polymer substrate 144 has a minimum continuous use temperature or heat deflection temperature of at least 200 degrees Celsius and up to 250 degrees Celsius, including all values and ranges therein, as measured according to ASTM D648-18. Thermal stability at elevated temperatures prevents loss of damping properties of the material, as well as loss of structural strength and flexibility. In some aspects, the substrate 144 has a thickness in the range of 0.1 millimeters to 3 millimeters, including all values and ranges therein.The semi-crystalline polymer substrate 144 comprises, for example, one or more of the following polymers: crystalline polyurea, polyarylate, polybutylene terephthalate, polyethylene terephthalate, polyurethane, polyethylene, epoxy, liquid crystalline polymer, polyoxymethylene, polythalidamide, polyamide, polyphenylene sulfide, polyetheretherketone, polyetherketone, copolymers thereof and mixtures thereof, and copolymers or mixtures thereof. Changing the degree of crystallinity changes the attenuation behavior and transmission loss. Furthermore, the density of the crystalline structures can influence the resonance behavior and act as a polarizer to attenuate the resonance behavior. Fig. 3B shows aspects in which the semi-crystalline polymer substrate 144 is deposited on a component 160, such as the one shown in Fig. 2A and Fig.2B. Here, too, the component 160 can be made of a plastic, a ceramic, a metal, or a combination thereof.

[0036] It will be on the Fig. 5A and Fig. 5B, which show an illustrative example of the effect of using a semi-crystalline polyurea substrate 144 on a component 160. Fig. 5A shows a metal part 160 coated on one side with a semi-crystalline polyurea polymer substrate 144. Fig.Figure 5B shows the effect of the coating on the attenuation of noise at frequencies ranging from 0 Hz to 2000 Hz, as determined by finite element analysis. When the semi-crystalline polyurea substrate 144 is not present, which is illustrated by line 206, the resonant response of the component 160 is relatively higher in the middle range of approximately 800 to 1300 Hz and significantly higher in the upper range around 1750 Hz. When the semi-crystalline polyurea substrate 144 is coated on one surface of the component 160, e.g., on the inside of the component, as shown in line 204, the damped response is damped in the middle and upper ranges, demonstrating some degree of damping. When the semi-crystalline polyurea substrate 144 is coated on both sides of the component 160, e.g.,On both the inside and outside of the component 160, as shown in line 202, the damped response is damped in the middle and upper range, showing a damping level of about 30 to 40 dB from about 450 Hz to 2000 Hz.

[0037] A second layer of the noise and vibration composite 140, which is located in the Fig. 6A and Fig. 6B, comprises a fiber-reinforced composite material 148 contacting the semi-crystalline polymer substrate 144 at the surface 146 of the semi-crystalline polymer substrate 144, as shown in the Fig. 3A and Fig. 3B. In some aspects, the fiber-reinforced composite 148 is 1 millimeter to 2 millimeters thick, including all values and ranges therein. In Fig. 6A, the fibers 170 are randomly arranged in the polymer matrix 172. In Fig.6B, the fibers 170 are aligned along a first axis, the x-axis, as shown, with the length of the fibers 170 in the x-direction perpendicular to a second axis, the y-axis, as shown, within the polymer matrix 172. While reference is made to the x-, y-, and z-axes, the fibers 170 may be longitudinally aligned along any x-, y-, or z-axis. The alignment of the fibers can be used to achieve directional response and attenuation of sound while maintaining structural integrity at continuous and elevated operating temperatures.

[0038] In some aspects, the fibers are chopped fibers having an average diameter in the range of 2 micrometers to 25 micrometers, including all values and ranges therein, and an average length in the range of 1 millimeter to 15 millimeters, including all values and ranges therein. In further aspects, the fibers 170 comprise one or more of the following materials: glass, ceramic, carbon, para-aramid fiber (KEVLAR®), meta-aramid fiber (NOMEX®), and combinations thereof.

[0039] A polymer matrix 172 is combined with the fibers 170 to form the fiber-reinforced composite 148, with the fibers 170 dispersed in the polymer matrix 172. The polymer matrix 172 comprises a polymer of either thermosetting or thermoplastic materials such as polyester, polycarbonate, polypropylene, polyamide, epoxy, polyetherimide, and polyetherketone. The fibers 170 are present in the polymer matrix 172 in the range of 10 to 60 percent, inclusive, based on the total weight of the fiber-reinforced composite 148.

[0040] As the loading of the fiber 170 in the polymer matrix 172 increases, the frequency of the sound shifts to higher frequencies over a wide frequency range from 100 Hz to 2000 Hz. As the orientation of the fibers 170 in a particular axis, e.g., the x-axis, increases, the frequency of the sound shifts to higher frequencies over a wide frequency range from 100 Hz to 2000 Hz, compared to randomly oriented fibers 170 present in the polymer matrix 172 at the same loading. In some aspects, at least 10 percent of the fibers 170 are aligned in a first axis (as shown in the x-direction in the x,y plane), including all values and ranges from 10 percent to 70 percent, including at least 50 percent. Directional resonant behavior can be achieved with the fiber content and fiber orientation.In addition, the presence of fibers 170 in the fiber-reinforced composite 148 helps maintain the structural integrity of the composite resonator 126.

[0041] Reference is made to Table 1, which provides an illustrative example of the effect of fiber loading and direction in the polymer matrix 172 on the frequency shift. The frequency shifts were determined using finite element analysis. Table 1. Effect of fiber loading and orientation on frequency Frequency mode 0% load frequency (Hz) 10% fibers random orientation frequency (Hz) 50% random fiber orientation Frequency (Hz) 50% fiber alignment in x-axis Frequency (Hz) Mode 1 100.93 124.67 202.45 267.74 Mode 2 202.14 202.14 406.03 536.99 Mode 3 210.94 210.94 425.34 562.52 Mode 4 309.85 309.85 623.32 824.36 Mode 5 360.02 360.02 725.03 958.88 Mode 6 378.14 467.57 763.32 1009.5

[0042] As can be seen in the table above, the fibers 170, which comprise 10 weight percent of the fiber-reinforced composite 148, shift the addressed frequencies upward by an average of 24 percent in each mode. Fibers 170, which comprise 50 weight percent of the fiber-reinforced composite 148 (see Fig.6A), shift the frequency upwards by an average of 101 percent in each tested mode. Fibers 170, which comprise 50 percent by weight of the fiber-reinforced composite 148 and are aligned in the x-axis (see Fig. 6B), increase the frequency in each tested mode by an average of 115 percent.

[0043] The third layer of the noise and vibration composite 140 includes a particle coating 152 consisting of a plurality of particles disposed on the surface 150 of the fiber-reinforced composite 148. The thickness of the particle coating layer ranges from 0.1 millimeters to 5 millimeters, inclusive. Furthermore, the diameter of the individual particles in the particle coating 152 ranges from 2 nanometers to 200 micrometers, inclusive. Furthermore, the coating has a degree of porosity, with the coating having a percentage density ranging from 10 to 50, inclusive, of the density of a solid coating of the same material. As the particle coating increases, the attenuation and transmission loss increases.The porosity of the individual particles 154 and the thermal conductivity of the materials from which the particles are made can contribute to heat shielding and dissipation of the resonance reactions.

[0044] The particle coating 152 consists of one or more materials: carbon-based materials, such as carbon nanotubes or graphene; metals, such as transition metals, base metals, metalloids, and their alloys; a ceramic containing a combination of metals and non-metals; and polymers, including thermally conductive polymers or electrically conductive polymers. A thermally conductive or electrically conductive polymer is a polymer that contains an additive that conducts heat or dissipates electricity, respectively. Thermally conductive polymers contain one or more of the following thermally conductive fillers: graphene, metal, and metal alloys. Electrically conductive polymers include one or more of the following electrically conductive fillers: carbon fibers, carbon nanotubes, graphene, graphite, metal, and metal alloys.

[0045] It will be on the Fig. 7A and Fig.7B, which show an illustrative example of the effect of a particle coating 152 applied to a component 160. Fig. 7A shows a particle coating 152 applied to an underlying component 160, which in this example may be made of metal, plastic, or ceramic and has a thickness in the range of 1 millimeter to 3 millimeters. Fig.Figure 7B illustrates the effect of applying the particle coating 152 to an underlying component 160 on the attenuation of noise at frequencies ranging between 0 and 2000 Hz, as determined by finite element analysis. When the particle coating 152 is absent (see line 210), the resonant response of the component 160 is relatively higher across the entire frequency range between 0 and 2000 Hz than for the samples measured with the particle coating 152. As the thickness of the particle coating 152 increases from 0.1 millimeters to 1 millimeter to 2 millimeters, the resonant response is dampened and the frequencies shift to higher frequencies in the frequency range between 0 Hz and 2000 Hz. Thirty to forty decibels less are achieved at frequencies ranging between 0 Hz and 2000 Hz.

[0046] A method 800 for manufacturing the noise and vibration composite 140 of the composite resonator 126 is described in Fig.8. In block 810, the semi-crystalline polymer substrate 144 of the noise and vibration composite 140 is formed. The semi-crystalline polymer substrate 144 is formed using one or more of a variety of polymer molding processes, including coating, injection molding, compression molding, extrusion, vacuum forming, blow molding, additive manufacturing including 3D printing, etc. When the composite resonator 126 is provided in combination with another component, e.g., a metal housing 142, the semi-crystalline polymer substrate 144 may be assembled with the other component or molded directly onto the other component using processes such as compression molding, injection molding, etc.

[0047] In block 820, the fiber-reinforced composite 148 is applied to the semi-crystalline polymer substrate 144. In some aspects, the fiber-reinforced composite 148 is formed by resin transfer molding, compression transfer molding, injection molding, additive manufacturing including 3D printing, etc., wherein the fibers 170 are disposed on the surface 146 of the semi-crystalline polymer substrate 144 and then the polymer forming the polymer matrix 172 is impregnated into the fibers 170 under pressure in a mold cavity. In other aspects, the fibers 170 are introduced with the polymer matrix 172 into a mold cavity on the semi-crystalline polymer substrate 144.

[0048] In block 830, the particle coating 152 is formed on the surface 150 of the fiber-reinforced composite. The particles 154 and the particle coating 152 may be formed by one or more of several methods, such as vapor deposition, e.g., physical vapor deposition or chemical vapor deposition, and thermal spraying, e.g., atmospheric plasma spraying, additive manufacturing, e.g., multi-jet fusion, etc.

[0049] In block 840, the composite resonator 126 may be assembled to the other component if the composite resonator 126 has not yet been molded to another component, e.g., the metal housing 142. Alternatively, the assembly of the composite resonator 126 to another component, e.g., the metal housing 142, may occur between blocks 810 and 820 or between 820 and 830, and block 840 may occur after blocks 810 and 820.

[0050] As illustrated, the noise and vibration composite 140 is formed on a metal housing 142 to form a composite resonator 126. In other cases, the composite resonator 126 is formed from the noise and vibration composite 140 without an additional component, such as the metal housing 142. Furthermore, the composite resonator 126 can take a variety of forms, such as a hollow body with a continuous cross-section, the shape of hollow cylinders, or variable cross-sections. While it is noted that the composite resonator 126 is intended for use in a vehicle 100, the composite resonator 126 may also be used in an appliance, aircraft, locomotive, generator, or other device capable of generating sound through the movement of gases.

[0051] Resonators incorporating noise and vibration composites of the present disclosure offer several advantages. These advantages include, for example, the ability to incorporate a composite resonator with a heat shield that exhibits thermal stability at continuous operating temperatures of up to 250 degrees Celsius, such as those found in air intake and exhaust systems. Thermal stability at elevated temperatures prevents loss of the material's damping properties, as well as loss of structural strength and flexibility. Additional advantages of the composite resonator of the present disclosure include the ability to vary the resonant frequencies of each layer—the semi-crystalline polymer substrate, the fiber-reinforced composite, and the particle coating layer—depending on the desired results, even at continuous operating temperatures.Other benefits include improved performance during design verification and production validation, enabling improved durability during global thermal cycle testing of engine development, as well as improved performance and functionality of the part in the field.

Claims

[1] Composite resonator (126) comprising: a semi-crystalline polymer substrate (144); a fiber-reinforced composite material (148) in contact with the semi-crystalline polymer substrate (144), the fiber-reinforced composite material (148) containing a plurality of fibers (170) in a polymer matrix (172); and a particle coating (152) contacting the fiber-reinforced composite (148), the particle coating (152) comprising a plurality of particles (154) deposited on the fiber-reinforced composite (148). [2] The composite resonator (126) of claim 1, further comprising a metal housing (142), wherein the semi-crystalline polymer substrate (144) is bonded to the metal housing (142). [3] The composite resonator (126) of claim 1, wherein the semi-crystalline polymer substrate (144) has a continuous use temperature of at least 200 degrees Celsius. [4] The composite resonator (126) of claim 3, wherein the semi-crystalline polymer substrate (144) has a continuous use temperature of at least 200 degrees Celsius and up to 250 degrees Celsius. [5] The composite resonator (126) of claim 4, wherein the semi-crystalline polymer substrate (144) includes a semi-crystalline polymer having a percentage of crystallinity in a range of 50 weight percent to 90 weight percent of the semi-crystalline polymer at a surface of the semi-crystalline polymer substrate (144). [6] The composite resonator (126) of claim 5, wherein the fiber-reinforced composite (148) contains the plurality of fibers (170) in a range of 10 to 60 weight percent of the total weight of the fiber-reinforced composite (148). [7] The composite resonator (126) of claim 6, wherein at least 50 percent of the plurality of fibers (170) are aligned along a first axis in the polymer matrix (172). [8] The composite resonator (126) of claim 7, wherein the particle coating (152) has a thickness in the range of 2 nanometers to 200 micrometers. [9] A vehicle air intake system (104) comprising: an air inlet duct (120); a turbocharger compressor (108) connected to the air intake duct (120); and a composite resonator (126) connected to the air inlet duct (120), the composite resonator (126) comprising: a semi-crystalline polymer substrate (144), a fiber-reinforced composite material (148) in contact with the semi-crystalline polymer substrate (144) and containing a plurality of fibers (170) in a polymer matrix (172), the plurality of fibers (170) being present in a range of 10 to 60 weight percent of the total weight of the fiber-reinforced composite material (148), and a particle coating (152) contacting the fiber-reinforced composite (148), the particle coating (152) being formed from a plurality of particles (154) deposited on the fiber-reinforced composite (148), the particle coating (152) having a thickness in the range of 2 nanometers to 200 micrometers. [10] A method of manufacturing a composite resonator (126), comprising: Forming a semi-crystalline polymer substrate (144), the semi-crystalline polymer substrate (144) having a first surface (146); Forming a fiber-reinforced composite material (148) on the first surface (146) of the semi-crystalline polymer substrate (144), the fiber-reinforced composite material (148) comprising a plurality of fibers (170) in a polymer matrix (172); and Depositing a particle coating (152) on the fiber-reinforced composite material (148), wherein the particle coating (152) contains a plurality of particles (154).

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