Composite Bellows Intercooler Pipe Vibration Damping
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Solution Overview
Problem
Conventional intercooler pipes made of thermoplastic ether ester elastomer (IEEE) have low noise, vibration, and harshness (NVH) performance, which limits their application in vehicles due to inadequate vibration absorption and transfer characteristics.
Innovation Solution
The intercooler pipe features bellows with a polyester (PET) exterior and a polybutylene terephthalate (PBT) interior, providing a significant difference in storage modulus to reduce vibration transfer, with the PET occupying 95% to 98% of the cross-sectional thickness and PBT 2% to 5%, and includes bent parts for improved mounting and NVH performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a plastic intercooler pipe made of thermoplastic ether ester elastomer (IEEE) with a composite structure of rubber/aluminum is used to decrease cost and weight, then the manufacturing cost and weight are reduced, but the noise, vibration, and harshness (NVH) performance deteriorates
Solution Approach 1:
The intercooler pipe employs a composite structure consisting of an inner layer made of polybutylene terephthalate (PBT) and an outer layer made of polyester (PET). This multi-material composite design combines the advantages of different materials: PBT provides structural strength and rigidity while PET offers superior vibration damping and NVH performance. The composite structure achieves both weight reduction and improved NVH characteristics that cannot be obtained with single-material designs.
Solution Approach 2:
The patent applies different materials to different regions of the intercooler pipe based on local functional requirements. The inner layer uses PBT for areas requiring structural integrity and pressure resistance, while the outer layer uses PET for areas requiring vibration absorption and noise reduction. This localized material assignment optimizes overall performance by matching material properties to specific functional demands along the pipe structure.
2Object-affected harmful factors
If the bellows thickness is increased to reduce vibration transfer, then the vibration absorption improves, but the weight and manufacturing complexity increase
Solution Approach 1:
The bellows component utilizes a composite structure with an inner PBT layer and an outer PET layer, where each material contributes its superior properties. The PBT inner layer provides structural strength to maintain bellows integrity, while the PET outer layer offers superior vibration damping characteristics. This composite approach achieves effective vibration absorption without requiring excessive thickness, thereby controlling weight and manufacturing complexity.
Solution Approach 2:
The patent optimizes the thickness parameters of the bellows to achieve the desired vibration reduction performance. By carefully selecting and adjusting the thickness of each layer in the composite structure, the design achieves effective vibration isolation while minimizing material usage and weight. The parameter optimization balances vibration absorption effectiveness with manufacturing feasibility and weight constraints.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration effectively reduces vibration transfer and enhances NVH performance, improving the durability and quality of the intercooler pipe, particularly within the frequency range of 100 Hz to 250 Hz, thereby enhancing the overall vehicle's NVH performance and safety.
Implementation Method 1
an intercooler pipe that may include a bellows that has an interior made of a first material and an exterior made of a second material to prevent transfers of vibrations to the intercooler and a side member of a vehicle body through the intercooler pipe
Data Source
AI summary
An intercooler pipe that improves noise, vibration, and harshness (NVH) performance is provided. The intercooler pipe includes a plurality of bellowses, wherein an exterior of the bellows is made of a soft material and an inside thereof is made of a hard material to make a storage modulus of the inside of the bellows greater than that of the exterior thereof. In addition, the intercooler pipe improves the durability of an intercooler pipe.